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is functioning and that critical operations, such as coremaking, are receiving the quality of air needed to make a good core. Precision maintenance depends on achiev- ing accurate shaft and coupling alignments to prevent premature wear of components. Proper align- ment with lasers has been proven to reduce energy costs as well. Root cause failure analy-


ing facility does not have to purchase everything all at once. It makes sense to put the technology in place only as fast as the team can digest it. Using route-based data


Fig. 1. Each dot on the pass-fail curve (blue arrow) represents an opportunity to detect a failure using predictive maintenance.


sis and continuous process improvement is performed whenever a predefined alarm level is reached or a compo- nent failure is detected. Te predic- tive maintenance process is not used to simply find a problem and replace the component. Te goal is to extend equipment life by providing prompt restoration of function. Often, this means the corrective action taken can eliminate the root cause of the failure mechanism. For example, if a loose electrical


connection is found during a thermal scan, it can be tightened before a cata-


collectors will save time and quickly provide the big data you crave. A good data collector is worth the salary of two technicians. See Table 1 for estimates on costs for various data collecting investments. By using vibration analy- sis, ultrasonic analysis, infra-


red and motor conditioning monitoring, metalcasters can


strophic failure event that costs loss of function and an expensive repair. Te investigative process of root cause failure analysis and application of continuous improvement often leads to re-engineering the part or process, resulting in improved reliability and extended life cycle.


Maintenance Economics


When first starting a predictive maintenance program, the metalcast-


develop a strategic maintenance plan using reliable, accurate and repeat- able measurements to assess machine health and identify opportunities to optimize machine processes and performance (alignment, balancing, precision installation or repairs). It also can reduce premature mortality on repairs and new installations. In one study, Aarrowcast wanted


to investigate whether its successes in reducing vibration were sustainable


Fig. 2. This chart shows the impact of reducing vibration has on energy costs and bearing life.


28 | MODERN CASTING October 2016


Fig. 3. The cost of bearing and motor replacements decreased due to data collection and predictive maintenance.


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