Maintenance Solutions


Schedule

13–15 September 2022 • Embassy Suites by Hilton Louisville Downtown • Louisville, KY, USA

Tuesday 13 September 2022

8 a.m.

Welcome and Conference Overview
John Accurso, Quaker Houghton

8:25 a.m.

Reliability Achievement Award Overview
Jeff Kusnier, Titan Bearings

8:30 a.m.

What Is Industry 4.0 and Data Analytics? Are You Ready for It?
Randy Heisler, Life Cycle Engineering
The buzz around Industry 4.0 and data analytics is reaching a fever pitch. With it comes the growing assumption that asset-intensive organizations understand it, want it and its success is assured. The reality, however, is that many companies do not fully understand Industry 4.0 and data analytics and are not ready for the benefits it brings to the workplace. What is Industry 4.0 and data analytics, and what does it mean to your organization? How can you prepare to take full advantage of it? This presentation will explore answers to these questions.

9 a.m. 

Mounting and Handling of Ball and Roller Bearings
Jennifer Wagoner, NTN Bearing Corporation of America
This topic will review the correct preparations and practices for installation a variety of ball and roller bearings. This will include inspections and measurements prior to install, as well as a variety of methods to install straight and tapered bore bearings.

9:30 a.m. 

Break

9:45 a.m.

Vibration Analysis Report Interpretations
Brad Kintner, ITR
Explanations of common machine fault issues that are identified in vibration analysis reports, what the data means, and how severity of these problems can change.

10:15 a.m.

Air Oil Delivery Systems
Walter Siegmund and Brian Wilson, HASTEC Group
This presentation will cover friction, lubrication, wear. It will focus on lubricants and systems, system components and functions, and system operating principles.

10:45 a.m.

Break

11 a.m.

When the Caboose Can’t Keep Up With the Locomotive
Rachel Schmidt​, Hydro Inc.
Treating the symptoms of an equipment failure does not always resolve the problem. This presentation will review a case study involving a steel mill’s lake water pumping system. A rash of catastrophic pump failures were the symptoms, but the real, underlying problem was that the plantwide demand on the service water system exceeded the capacity of the original service water pumps as designed. The presentation will also highlight the reliability and efficiency improvements made to the lake water pumping system resulting in 2-3 times the MTBR (meantime between repairs) while saving over $90K per pump in annual energy costs, improving efficiency and reliability.

11:30 a.m.

Optimizing and Digitizing Asset Reliability Strategies to Minimize Cost and Maximize Performance
Chris Harrington, ARMS Reliability 
Balancing risk, cost and performance is challenging in any asset-intensive, dynamic operation. With cost constraints and challenges in justifying maintenance activities, the pressure of managing risk and responding to any unplanned equipment outages is very real. This session will introduce Asset Strategy Management (ASM), a fundamental pillar of asset management enabled by people, technology and data, that delivers consistent, justified and effective asset maintenance strategies to an organization’s entire asset base.

Noon

Lunch

1 p.m.

Choosing the Right Grease
John Accurso, Quaker Houghton

1:45 p.m.

Drive Control Systems
Marcelo Lara, TMEIC
The presentation will address the induction motor AC drives control loops, power bridge topologies, and the interaction of the AC drives with the power system and the motor.

2:15 p.m. 

Break

2:30 p.m. 

Augmented Reality (AR) Technology for Steel Plants
Eric Almquist, Star Tool & Die Works Inc.
Augmented reality (AR) is a technology that will eventually become commonplace at work, at home and in between. AR is transforming the jobs of "frontline"/"deskless" workers by connecting them with digital information projected and mixed within the context of reality. 
Information about tasks appears within the context of the real equipment, similar to what one sees in science fiction movies. The impact of AR has been measured to dramatically reduce errors and enhance worker effectiveness because the workers have access to any form of information within the context of each procedural step. The details permanently recorded into the system by the job expert can be of such granularity as to enable workers with the most basic skills to successfully execute complex tasks without error. This non-commercial presentation provides an overview of AR systems and details of how one particular system is being used within the steel industry.

3 p.m.

Various Methods of Oil Sample Collection From Book to Real World
Eddie Emch, Lubrication Engineers
This presentation provides an overview of how oil samples are taken and various examples and instruction on how they should be taken.

3:30 p.m.

Break

3:45 p.m.

How to Better Implement Motion Amplification Camera Testing
Trent Martz, IVC Technologies
This presentation will focus on both the benefits and limitations of motion amplification (MA) camera testing. The advantages of using the MA camera will be discussed, as well as some of the pitfalls and how to avoid them.

4:15 p.m.

On-Line Condition Monitoring: Acquire, Archive, Analyze and Act
David Kober, Iba America
Leveraging already available sensors, along with other programmable logic controller values, signals can be automatically compared to learned process behavior using the method of time synchronous averaging. By this method, both slowly emerging deviations due to wear and tear as well as sporadic anomalies can be detected at an early stage. As a result of the close relationship to the measurement data, impacts on product quality and machine condition can be reliably predicted. This results in significantly reduced machine downtimes, reduced repair and maintenance costs, increased productivity, and better overall quality. Such an auto-adapting system for on-line anomaly detection can be implemented and applied to monitor a wide variety of cyclical or recurring processes such as saw blades, overhead cranes, robot handling systems, and many more. This will be demonstrated by a real-world example from within the steel industry.

5 p.m.

Reception

Wednesday, 14 September 2022

7 a.m. 

Breakfast

8 a.m.

Grease Delivery Options for The Steel Industry
Wayne Gaskill, DropsA USA Inc.
This presentation will cover the different options available for grease delivery, from manual to sophisticated automatic systems. It also will cover the operation of the components in the different types of system.

8:45 a.m.

2021 Reliability Achievement Award Silver — Scrap Pre-Heater Duct Conversion
Eric Novicki, Charter Steel    
This presentation will discuss process reliability and safety improvements to the hoods over the scrap pre-heat conveyor at the Charter Steel – Saukville, Wisconsin meltshop.

9:15 a.m. 

Break

9:30 a.m.

Gearbox Maintenance and Reliability
Doug Sackett, TotalEnergies Marketing USA Inc.
Understanding the inner structure and working of gears and gearboxes will aid in the proper selection of lubricant, maintain reliability and analysis of any type of failures.

10 a.m. 

Interpreting Oil Analysis Reports
Matt McMahon, Eurofins TestOil
The keys to interpreting oil analysis data into meaningful action are data trends and context picture. Learn what story your oil analysis data is trying to tell you in this informative presentation.

10:30 a.m.

Break

10:45 a.m. 

Why Are My Valves and Cylinders Failing Again?
Scott Maher, Mi Fluid Power Solutions
This presentation will briefly touch on the obvious reasons why valves and cylinders fail and then hopefully open eyes to those not-so-obvious reasons as well.

11:15 a.m. 

Leveraging Time Series Data for Proactive Maintenance Management
Everett Vazzana and Max Risinger, North American Stainless, and Crick Waters, Falkonry
Getting ahead of breakdowns is the holy grail of maintenance. Though preventive maintenance can extend the intervals between breakdowns, breakdowns are inevitable. The good news is that advances in artificial intelligence and machine learning (AI/ML) for automated anomaly detection and event diagnosis are making data-driven maintenance a reality. This presentation will present an approach to using AI/ML to influence maintenance actions and to facilitate root-cause analyses. The machines are crying — are you listening?

Noon

Lunch

1 p.m.

Assessing the Skills Gap
Ian McKinnon, Reliability Solutions LLC
This session takes a brief look at a skills assessment with sample results as an opportunity to fill missing gaps and gain manufacturing advantage. It shall consider the average results and the catalysts that create them. The presentation considers a few of the myths and barriers that have stood in the way and the need to prove returned value in skill set investments. Participants will be invited to take part in a micro skill set assessment upon returning home with results presented to them and the group as to where current skill sets lie. The challenge will include: “Once you know where you are, what is your responsibility and path to improve?”

2 p.m.

Break

3:15 p.m.

Maintaining Your Area: How Housekeeping Can Save You Time, Money and Aggravation
Landon Woody, Nucor-Steel Yamato Co.

3:35 p.m.

Critical Spare Inventory Management
Bill Bennett and Jeff Blankenship, Titan Bearings - MRSI

3:50 p.m.

Break

4 p.m.

Bearing Failure Analysis: Hands-On Demonstration
Mike Allega, Timken Corp.
Hands-on review of bearing damage with correlation to the operating condition that led to the damage seen.

5 p.m. 

Ask the Experts and Reception

Thursday, 15 September 2022

7 a.m. 

Breakfast

8 a.m. 

Plant Tour of Nucor Steel Gallatin OR McAlpine Lock & Dam-U.S. Army Corps of Engineers

Noon

Conference Adjourn