Achieving Operational Efficiency Through Program Improvement

Achieving maintenance operational efficiency requires focus, smart thinking and innovation. Mammoet, a heavy-lifting and transport company, was able to identify areas and opportunities for program improvement – this included leveraging teamwork, maximizing data management, implementing shipping enhancements and taking advantage of program management solutions available.

The improvements Mammoet implemented in their program opened up the opportunity for the company to move from preventive maintenance to predictive maintenance and significantly extending their oil drain intervals. Learn more by reading the case study.

Identify Issues Early

It is important to identify maintenance issues early. Mammoet, a specialist in lifting, transporting, installing and decommissioning large and heavy structures, experienced this firsthand when it noticed issues with a large crane during operation.

The company, focused on equipment uptime, preventive maintenance and sustainability, have made reliability a critical component of the business. With this pivotal focus on operational efficiency, the company turned to fluid analysis to help diagnose the problem with the crane and ensure the essential piece of equipment operated efficiently.

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Published April 11, 2017

Extend Drains with Management Reports

Management reports matter. A POLARIS Laboratories® Technical Business Consultant (TBC) used his knowledge on customized reports to help a major oil company’s customer, VCNA Prairie Material, extend its drain intervals. The goal was to determine the optimum service interval for VCNA Prairie Material’s ready-mix fleet of trucks. These efforts exemplify the idea, “It’s not just data, it’s what we (you) do with it!”

Building a Championship Organization

At the root of every successful fluid analysis program is a program champion committed to success. From creating a project plan to assembling a sampling team, there are a number of actions maintenance professionals can take to maximize the value sampling provides.

A global leader in providing temperature control, temporary power generation and compressed air systems already had a robust maintenance program, but they decided to explore fluid analysis as a way to reduce downtime and costs.

With the leadership of their program champion, they developed into a reliability program saving between $750,000 to $2 million each year using fluid analysis. By documenting their process and program success, the team proved their value to their leadership team ten times over.

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Measuring Success

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The success of a fluid analysis program is usually measured by the amount of money or number of assets saved. However, program success can also be measured through an organization’s compliance.

A global lubricant manufacturer partnered with POLARIS Laboratories® to provide oil analysis to their customers with the goal of ensuring product quality. Determined to prove their commitment to their customer’s success, the manufacturer hired business consultants to help showcase the value of their product and extend drain intervals using oil analysis. Providing this free service helped the company build long-term relationships with their customers based on mutual trust.

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New Equipment Needs Oil Analysis Protection

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An industrial building service company makes sure to regularly test the oil in all of their heavy-duty trucks, including new trucks. Their maintenance staff knows all equipment experiences a period of break-in wear, and removing those particles can extend component life.

However, the first sample results from a 2015 model engine showed 255 ppm of aluminum and 198 ppm of iron. These metals are typical for early life-cycle engine break-in, but our data analyst found those quantities excessive and recommended a maintenance investigation.

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Responding to Severity Reports

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No equipment is safe from the wear and tear that comes from operating in the harsh conditions of a mining site. The challenging environment, along with the extreme load variations and the high costs involved in equipment replacement, makes avoiding catastrophic failure exceedingly important.

Many mining companies turn towards fluid analysis as a means of avoiding the high replacement costs associated with these extreme conditions. In fact, routine testing helps maintenance professionals identify problems in their equipment before full scale failures occur. Utilizing fluid analysis allows managers to take control of their reliability programs.

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Tracking Sources of Contamination

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It’s no secret contamination has a negative impact on machinery. The trouble is, potential sources of contamination can be found in a number of common locations. The key is knowing how to track down the source and drive action to limit the impact it has on equipment.

A leading manufacturer of engines, filtration, and power generation products, established diesel fuel quality, oil drains, engine oil, hydraulic and transmission, engine failure and cooling systems were hot button topics for their company as well as their customers. After identifying these pain points, they determined contamination was an issue they wanted to actively help their customers address and alleviate.

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Optimizing Program Management

The backbone of every oil analysis program is the efficiency of the program’s management system. Managing equipment in an organized manner is a vital step towards saving time, reducing errors and accurately tracking the return on investment (ROI).

A leading company in the oil and fuel industry uses POLARIS Laboratories® program management software, HORIZON®, as the centerpiece of their maintenance management system. Focused on improving their program organization, they found that using this system helped increase their overall productivity

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Extending Component and Equipment Life

In the same way early detection is used in human health to spot damage to the body, early detection is an important part of maintaining equipment health. Embracing predictive maintenance technology is an essential part of maintaining healthy equipment, lowering the time spent performing maintenance and reducing costs.

Utilizing the reliability model and concepts associated with this method helps maintenance teams extend their component and equipment lifecycles. A leading pharmaceutical company utilizes the predictive maintenance methodology and the four major predictive technologies to improve the reliability of their maintenance program. Using the method, the team tests compressors, hydraulic systems, bearings, gears and other components

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