An SKF Integrated Maintenance Solution (IMS) optimises asset efficiency by identifying key processes, technologies and cultural changes needed within a plant and providing the means to improve them.
Manufacturing companies rely on increasing machine uptime to improve profitability. An Integrated Maintenance Solution (IMS) contract agreement offers industry an alternative to current maintenance practices. Within the IMS contract, SKF Reliability Systems improves asset efficiency by providing technical expertise in the maintenance of rotating plant. This is based on SKF core competences in machine design and diagnostic engineering, to provide plant predictability and reliability. Asset utilisation is improved and maximum efficiency gained from the plant.
Each IMS contract is different and is based on an in-depth evaluation of the processes in a particular site.
The following steps are used to create a comprehensive plan, using an initial IMS assessment to develop ongoing, measurable improvement goals.
Step 1: Assessment
The process begins with a detailed assessment of the plant efficiency, including component supply costs and maintenance practices. The audit identifies key problems in the plant, enabling the creation of a sound performance improvement plan. Upon agreement of the plan, SKF Reliability Systems personnel are selected and assigned to work at the customer’s site, to strengthen existing maintenance and technical skills and to provide easy access to other SKF technical resources. A Proactive Reliability Maintenance (PRM™) process is then established to drive the improvement plan.
Step 2: Trouble-free supply
Reducing all costs associated with purchasing, supply and inventory management is an integral part of an IMS contract. Working in close partnership with our Authorised Distributor network, SKF will reduce transaction costs release capital tied up in inventories, and guarantee that spares are available and delivered when needed.
Step 3: Maintenance strategy
Analysis of the maintenance strategy applied across the plant and to each machinery asset will allow effort to be re-focussed on critical tasks, to ensure that maintenance activity adds value to the business result. SKF Reliability Systems can also provide a full capability to integrate all aspects of maintenance into EAM/CMMS systems, and can implement effective planned and predictive maintenance processes.
Step 4: Proactive Reliability Maintenance (PRM)
Through a defined process including best practice condition monitoring activities, the root causes of problems are diagnosed and corrective actions taken to eliminate recurrence. The PRM process also sets improvement objectives, known as Key Performance Indicators (KPIs) to gradually reduce problems and move toward world’s best practice within the industry segment.
Step 5: Technology upgrades
Part of the ongoing activities of an IMS contract is to adopt new technology developments to improve machine performance whenever possible.
These might include:
- Plant re-engineering using the latest component design solutions.
- Oil cleanliness systems to prolong lubrication life and minimise effects of contamination.
- Use of the latest condition monitoring technology to reduce the cost of data collection and ensure better machine diagnostics.
- Decision support software
Step 6: Machine maintenance
Precision maintenance tasks can be supervised or performed by skilled SKF engineers to ensure effective machine overhaul. This includes techniques such as laser alignment, rotor balancing and critical bearing installation and lubrication tasks.
Step 7: Training
Keeping staff maintenance skills up to date with today’s technology is an important step in achieving IMS performance goals. SKF Reliability Systems provide detailed training courses to cover the technology and practical aspects of precision maintenance that directly impact the overall return on assets, including:
- Precision maintenance skills
- Bearing maintenance and service
- Condition monitoring skills
- Management of maintenance
An IMS contract agreement is a partnership that typically runs for three to five years, and includes a defined cost structure and payback period. It also incorporates a performance-based payment structure. The IMS contract agreement guarantees that SKF will per-form to a specified level of performance.
The annual contract fee may include bearing and seal consumption, upgraded condition monitoring equipment, software tools and support, and the SKF technical resources to determine, correct and eliminate repetitive machinery problems. |
