Maintenance Solutions


21–23 September 2021 • Embassy Suites San Antonio Riverwalk • San Antonio, TX, USA

►Download Schedule (PDF)
►Room Set-Socially Distanced

Tuesday, 21 September 2021

7–8 a.m.


8 a.m.

Jeff Kusnier, Titan Bearing

8:15 a.m.

Safety: It’s All About Maintenance and Reliability
Ricky Rollins, Ricky Rollins Safety Speeches, LLC

9 a.m.


9:15 a.m.

Reliability Achievement Award Overview
Carl Garringer, Steel Dynamics Inc. – Structural and Rail Division
The Reliability Achievement Award is given by the Maintenance & Reliability Technology Committee to an organization and the individuals involved in improving plant reliability through the implementation of a project or procedural change.

9:30 a.m.

2020 Reliability Achievement Award Gold: Using Pyrometers Instead of Thermocouples for the Ladle Pre-Heat Burner Control
Richard Thomas, Steel Dynamics Inc. – Flat Roll Group Sinton Division
The use of a pyrometer has decreased the maintenance on the application from approximately 100 times a year to almost never. It has also decreased the amount of natural gas used per year by millions of cubic feet.

10:15 a.m.

High School Training Program
Don McDaniel, Worthington Industries

10:45 a.m.

Journeyman Training

11:15 a.m.

What Good Looks Like
Randy Heisler, Life Cycle Engineering
An overview of maintenance and reliability best practices will be presented. This presentation covers what organizations should focus on and how to get started on the right track. It includes real-world examples and a road map that many companies have followed to improve reliability in their operations.



1 p.m.

Improving Manufacturing Reliability with Precise Maintenance Activities
Ian McKinnon, Reliability Solutions LLC

4 p.m.

Autonomous Maintenance at Work
George Miconi, Worthington Industries, and Will Zell, Nikola Labs
This presentation will discuss autonomous maintenance, a self-governing state of maintenance work made easy. Reduction of menial tasks for skilled labor.

4:30 p.m.

Industrial Augmented Reality for Maintenance, Training, Inspection and Management
Eric Almquist, Star Tool & Die
Augmented reality (AR) is a technology that “mixes” digital information within reality for the user. When AR is done well, the user experiences the digital information as if it were real. The user can interact with the technology intuitively, conveniently giving and taking information with the system. AR is the human-machine interface (HMI) of Industry 4.0, the industrial digitalization revolution, and will become the standard digital life HMI for all over the coming decade, eventually replacing phone and computer displays with lightweight glasses. AR will revolutionize the “blue-collar” workplace just as the office PC has revolutionized the “white-collar” workplace since the late 1980s. Recently AR technology, particularly hardware, has become viable for frontline industrial workers. An overview of AR technology will be provided, including a live demonstration of a state-of-the-art industrial AR system.

5 p.m.

Ask the Experts Roundtable Discussion and Reception

Wednesday, 22 September 2021

7 a.m.


8 a.m. 

2020 Reliability Achievement Award Silver
David Aguirre, California Steel Industries
This presentation will discuss improving the longevity and safety of the pond crane cables in an unusual design.

8:30 a.m.  

Vibration Analysis and Monitoring
Brad Kintner, ITR
Information will be presented explaining the most effective condition monitoring practices and technologies available as well as a look towards the future of PdM in the steel industry.

9 a.m.

Condition Monitoring
Bob Miller, IVC Technologies
This presentation provides straightforward and practical explanations of advances in condition monitoring, as well as real-world examples of properly applying predictive technologies to maximize the takeaway value for attendees.

9:30 a.m.


9:45 a.m.

Roller Bearing Lubrication Basics
Mike Allega, The Timken Co.
This presentation introduces lubrication fundamentals for rolling elements bearings. The target audience is people new to industry or anyone wanting to refresh their knowledge on lubrication basics. Topics covered will include the main functions of a lubricant, how lubrication impacts bearing performance and guidance on how to select the proper lubricant for general industrial applications. The key characteristics of a lubricant will first be established, covering both oil and grease. Then suggestions will be provided on the proper lubricant selection and the best means for lubricant delivery to rolling element bearings with an emphasis on grease.

10:15 a.m.

Digital Transformation of Maintenance and Reliability
Greg Savernik, Quaker Houghton
Looking at the recent shelter-in-place and conditions with a surprise pandemic that occurred, this presentation will discuss how the Industrial Internet of Things and remote interactions help advance maintenance procedures and effectiveness of the essential line personnel that are left to keep a facility running. Discussion includes the common tools that are used as well as the preparation needed by the end user for success.

10:45 a.m.

Automatic Lubrication Systems in the Steel Industry
Jason Craft, DropsA USA
This course will go over the usage, design and troubleshooting of the standard lubrication systems in our industry.  This includes the series progressive and dual-line systems.

1130 a.m.

Level 1/Level 0 – An Overview of PLCs, Networks, Drives and I/O
Reg Snyder, TMEIC
This discussion covers the workhorses of the distributed control system. Controller basics, communication network types and function, and the role and functionality of drives and I/O are explained.



1 p.m.

2020 Reliability Achievement Award Bronze
Jason Vicari, ArcelorMittal Indiana Harbor
Reliability improvements and energy savings have been achieved in a 55-year-old high-pressure water descaling system through restoration of pump performance, upgrades to pump materials and improvements in descale nozzle technology.

1:30 p.m.

Discounting Your Product… the Unintended Consequence of Contaminated Hydraulic Fluid, Denis Poirier, Eaton Hydraulics Business
This session explains how to quantify hydraulic fluid cleanliness, addresses failures commonly associated with contaminated fluid and explains the most common changes required in hydraulic system when using an alternative hydraulic fluid.     

2 p.m.

Laser Deposit Welding Averts a Costly Repair and Mill Shutdown
Bob Jennings, HydroAire Inc.

2:30 p.m.


2:45 p.m.

Introduction to Level 2 – What Is It?
Paul Jackson, TMEIC
This presentation will introduce the purpose of level 2 control systems in a metals control system. This will include a basic introduction to the functions of metals supervisory control systems as well as a discussion of some of the challenges faced by level 2 systems. This introduction is intended to be useful both to those who have no knowledge of the subject as well as those who have some basic knowledge

3:30 p.m. 

Hydraulic Troubleshooting Solutions for Millennials
Brad Jensen, Alloy Technology Solutions             
Finding and applying new applications that utilize growing technologies to maintain complex hydraulic systems have a valuable outcome. They bridge the gap for today’s millennials who want immediate results in system and device understanding. This presentation will use currently available technologies to troubleshoot four common failures in a complex hydraulic system used in roll bending.

4 p.m.

The Five Things a Hydraulic Troubleshooter Needs to Know
Jack Weeks, Fluid Power Learning
Many excellent hydraulic parts changers have worked on or around specific machines for so long that when a certain symptom shows, they know to change a specific part to alleviate the problem. Yet, their understanding of what actually failed and why it failed is limited. Hence, the number of actual hydraulic troubleshooters is small. This presentation will explore the five common gaps of knowledge to help parts changers become hydraulic troubleshooters.

4:30 p.m.


Thursday, 23 September 2021

7 a.m.


8 a.m.

Depart for Tour of CMC Steel

11:30 a.m.

Return from Plant Tour to Hotel & Conference Adjourns