ULTRASOUND IS MORE THAN A LEAK DETECTOR. By Deborah Hays Dmax Ltd.

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1 ULTRASOUND IS MORE THAN A LEAK DETECTOR By Deborah Hays Dmax Ltd.

2 Dmax Ltd. We machine and assemble the Duramax Diesel Engine for General Motors Heavy Duty Trucks.

3 Machining Side of the Plant Cylinder Block Cylinder Head Crank Shaft FLIR Systems 97.0 F

4 Assembly Side of the Plant Short Block Head Sub-Assembly Main Test Dress

5 Dmax Predictive Maintenance Team 1 Mechanical Service Tech (Me) 16 years maintenance 6 years predictive 1 Electrical Service Tech 15 years maintenance 1 year predictive

6 Infrared-Flir P65 Predictive Tools Vibration Analysis-Emerson/CSI 2130 Motor Circuit Analysis-All Test Pro On and Off line testers Ultrasonic-UE Systems Ultraprobe 10,000

7 ULTRASOUND & BALLSCREWS WITH THE UE 10,000 PROBE

8 Block Line Transfer Machines CB-10 ST12 X-axis BALLSCREW FLIR Systems Sp F CB-20 ST15 X-axis BALLSCREW FLIR Systems Sp F

9 Problem 90.3 F 90 Ballscrews Failing Yearly Sp3 Sp1 Sp Gearboxes Failing 6 months FLIR Systems Quality Issues Machine not holding tolerances

10 COSTS CB-10 ST12 Ballscrew-$13, Gearbox-$5, Quality- Priceless CB-20 ST15 Ballscrew-$17, Gearbox-$7, Quality- Priceless Too Expensive

11 SOLUTION Use Ultrasound to Trend Ballscrews

12 CB-10 & CB-20 BALL SCREW TRENDS CB-10 ST12L BALL SCREW TREND CB-20 ST15 BALLSCREW TREND CHART DB'S /23/2008 6/23/ /30/2008 2/4/2009 9/3/ /3/ /11/2009 6/9/2010 DB'S /8/ /28/2008 1/13/2009 1/14/2009 1/15/2009 7/29/ /22/ W-AXIS POSITION Z-AXIS 0 X-AXIS BALLSCREW

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14 CB-10 & CB-20 BALL SCREW TRENDS AFTER REPAIRS CB-10 ST12L BALL SCREW TRENDS 4/6/11 After Ball Screw Replacement CB-20 ST15 BALLSCREW TREND CHART DB'S W-AXIS AXIS Z-AXIS /23/2008 6/23/ /30/2008 2/4/2009 9/3/ /3/ /11/2009 6/9/ /22/ /25/2010 4/6/2011 DB'S X-AXIS BALLSCREW /8/ /28/2008 1/13/2009 1/14/2009 1/15/2009 7/29/2009 8/5/2009 6/1/2010 1/5/2011

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16 ULTRASOUND & GEARBOXES

17 WHY ULTRASOUND? WHY NOT VIBRATION ANALYSIS? ULTRASOUND IS MORE THAN A LEAK FINDER 10 COMPONENTS ON VIBRATION ROUTES VS. 2 TECHS = 1 CHECK P/YEAR ULTRA + VIBE = 3 CHECKS P/YEAR VIBRATION FOLLOW-UP IS A MUST

18 GEARBOX ULTRASONIC TRENDS CB-120 SPINDLE GEARBOX ULTRASONIC TREND DB'S CB L CB R CB L CB-120 3R CB-120 3L WARNING LIMIT FAULT LIMIT 10 0 Jun-07 Dec-07 Jun-08 Dec-08 DATE

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20 VIBRATION DATA

21 CB-120 ULTRASONIC CURRENT TREND CB-120 SPINDLE GEARBOX ULTRASONIC TREND DB'S CB-120 3R CB-120 3L CB L CB R CB L CB R WARNING LIMIT FAULT LIMIT 10 0 Oct-07 Jun-08 Oct-08 Apr-09 Nov-09 Feb-10 Nov-10 Feb-11 DATE

22 ULTRASOUND & TRANSFERS

23 TRANSFER BEARING TRENDS CB-120 TRANSFER BEARINGS CB-130 TRANSFER BEARINGS DB'S CB-120 BEARING TRANSFER DB READINGS DB'S CB-130 BEARING TRANSFER DB READING STATION #1 STATION #2 STATION #4 STATION #6 STATION #8 STATION #9 STATION #11 STATION #12 STATION #14 STATIONS 46 STATION #1 STATION #3 STATION #4 STATION #6 STATION #7 STATION #10 STATIONS STATION #11 STATION #13 CB-140'S TRANSFER PILLOW BLOCK BEARINGS DB'S CB-140 TRANSFER PILLOW BLOCK BEARINGS FRT CB-140 TRANSFER PILLOW BLOCK BEARINGS REAR STATION #2 STATION #5-#6 STATION #9 STATION #12 STATIONS

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25 TRANSFER GEARBOX TRENDS CB-120, CB-130, CB-90 & CB-20 TRANSFER ADVANCE & RETURN GEARBOX CB-120, CB-130, CB-20, & CB-90 TRANSFER LOWER & RAISE HYDRAULIC CYLINDER DB'S CB-120 TRANSFER ADVANCE AND RETURN GEARBOX DB READING CB-130 TRANSFER ADVANCE AND RETURN GEARBOX DB READING CB-20 TRANSFER ADVANCE AND RETURN GEARBOX DB READING CB-90 TRANSFER ADVANCE AND RETURN GEARBOX DB READING DB'S CB-120 TRANSFER RAISE AND LOWER HYDRAULIC CYLINDER DB READING CB-130 TRANSFER RAISE AND LOWER HYDRAULIC CYLINDER DB READING CB-20 TRANSFER RAISE AND LOWER HYDRAULIC CYLINDER DB READING CB-90 TRANSFER RAISE AND LOWER HYDRAULIC CYLINDER DB READING 0 CB-120 CB-130 CB-20 CB-90 BLOCK OPERATION 0 CB-120 CB-130 CB-20 CB-90 BLOCK OPERATION CB-120 TRANSFER ADVANCE & RETURN GEARBOX 7/18/08-7/29/ CB-140 TRANSFER DRIVES DB'S CB-120 TRANSFER ADVANCE AND RETURN GEARBOX DB READING CB-120 TRANSFER ADVANCE AND RETURN GEARBOX DB READING DB'S CB-140 TRANSFER LOWER & RAISE MTR/GEARBOX CB-140 TRANSFER ADV & RETURN MTR/GEARBOX /18/08 7/29/ CB-140 TRANSFER LOWER & RAISE MTR/GEARBOX MOTOR/GEARBOX CB-140 TRANSFER ADV & RETURN MTR/GEARBOX

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27 TRANSFER GEARBOX FOLLOW- UP CB-140 TRANSFER DRIVES FOLLOW-UP DB'S CB-140 TRANSFER LOWER & RAISE MTR/GEARBOX CB-140 TRANSFER LOWER & RAISE MTR/GEARBOX CB-140 TRANSFER ADV & RETURN MTR/GEARBOX CB-140 TRANSFER ADV & RETURN MTR/GEARBOX Raise & Low Adv & Ret TRANSFER GEARBOX

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29 Ultrasonic Benefits Non-intrusive PM Most Ballscrew Servo Drives are accessible while machine is running, if not check can be completed within 5 min. 0 like components make trending a snap. When problems are found follow-up work is done on 3 rd shift with no production downtime! With 10 hundred spindles, gearboxes, pumps, and motors Ultrasound is a must.

30 RESULTS TOTAL PDM COST SAVINGS TOTAL PDM COST SAVINGS 2008 $30,000, $30,000, $25,536,000 $25,000, $25,000, $20,151,000 COST SAVINGS $20,000, $15,000, $10,000, $5,000, $- $15,800,000 $6,000,000 $3,700,000 $36,000 Technology ULTRASONIC COST SAVINGS MCA COST SAVINGS IR COST SAVINGS VIBRATION COST SAVINGS TOTAL COST SAVINGS YTD COST SAVINGS $20,000, $15,000, $13,400,000 $10,000, $5,900,000 $5,000, $336,000 $515,000 $- Technology ULTRASONIC COST SAVINGS MCA COST SAVINGS IR COST SAVINGS VIBRATION COST SAVINGS TOTAL COST SAVINGS YTD TOTAL PDM COST SAVINGS 2009 TOTAL PDM COST SAVINGS 2010 $30,000, ,000,000 $9,196,000 $25,000, ,000,000 8,000,000 COST SAVINGS $20,000, $17,000,000 $15,000, $10,620,000 $10,000, $5,000, $5,000,000 $180,000 $1,200,000 $- Technology ULTRASONIC COST SAVINGS MCA COST SAVINGS IR COST SAVINGS VIBRATION COST SAVINGS TOTAL COST SAVINGS YTD COST SAVINGS 7,000,000 6,000,000 5,000,000 4,000,000 3,000,000 2,000,000 1,000,000 0 $4,200,000 $3,600,000 $1,200,000 $196,000 Technology ULTRASONIC COST SAVINGS MCA COST SAVINGS IR COST SAVINGS VIBRATION COST SAVINGS TOTAL COST SAVINGS YTD

31 Summary Non-intrusive PM s are the key to keeping production running without excessive downtime and still maintaining the machinery s integrity. Trending is the key ingredient to using ultrasound effectively. Trending specific components enables maintenance to replace only those components nearing failure. By finding failures before they are critical, companies not only save money by not having collateral damage, the job is planned so downtime is a minimal. Parts are ordered well in advance and no special shipping charges apply. Parts are ordered when they are needed. Inventory is kept to a minimum.

32 Lessons Learned 0 Ballscrews is a lot of trending! Have an open mind! We aren t always going to be right! Try all your PDM tools on all components See what fits best! PDM technologies work best when they are used together to identify problems and their solutions!

33 Achievements 2009 Published in May 2009 Issue of Hydraulics & Pneumatics Magazine: Reducing Hydraulic System Temperatures Published in Inframation 2009 proceedings: IR Trending and 1HP Motors 2009 S ULTRASONIC PROGRAM OF YEAR BY UPTIME MAGAZINE Published in Solutions proceedings: Ultrasonic Inspections on Ball Screws, Gearboxes, and Transfers 2010 MCA Plant-wide Published in Solutions proceedings: How Dmax Ltd. became an awarding Predictive Maintenance Organization 2011 Steve James Keynote Speech Solutions : From Surviving to Thriving How Dmax survived the economic downturn to thrive today. Published in Solutions proceedings: PDM and Production Partnership, Dmax teamwork at it s best.

34 THANKS DMAX, Ltd. Maintenance & Production DMAX, Ltd. Leadership for allowing us to think outside of the box Dwight Richardson, Larry Stevens, & BJ Thornbury (Past and Present Predictive Techs)

35 QUESTIONS