What will you learn at MARCON 2019?

MARCON 2019

Join us at the 23rd annual Maintenance and Reliability Conference hosted by The University of Tennessee Reliability and Maintainability Center. MARCON 2019 will be held March 4 – 7, 2019 in Knoxville, Tennessee. We are excited to announce that we will be back at the Knoxville Convention Center!

This conference is unlike any other you will attend this year. You won’t just learn by sitting in workshops and presentations. MARCON is organized to allow the opportunity to collaborate one-on-one with the presenters, exhibitors and other attendees. Join us as companies share their best practices, and information on new and emerging technologies, methods and techniques in the area of Reliability and Maintenance Engineering and Management. This conference is a forum for all — practitioners, specialists, managers, educators, students, and even the new and uninitiated.

Bring Your Team
Maximize growth by bringing your entire team to MARCON. Individuals can tailor their experience by selecting workshops and paper presentations to attend, and the team benefits by discussing what you are learning on the spot. You can also save money by attending as a team…for every 3 paid registrations from your company, you receive a 4th free!! This discount applies to the formal portion of the conference only, but workshops can be added for a reasonable fee.

Take your experience a step farther by letting us help you host a meeting at MARCON. Why travel twice? Learn from industry experts and knock out some business while you are here. The RMC staff can assist you in coordinating a space to hold a private meeting at either the Knoxville Convention Center or the Holiday Inn Downtown World’s Fair park. Whether you need to meet for two hours or two days, we can help. Please contact Kim Kallstrom (kkallstr@utk.edu / 865-974-9627) for more information.

Get the most out of your conference registration...

Plan to spend the full four days with us! Hear best practices and lessons learned from our 3 keynote speakers. Customize your registration package by deciding what combination of our 13 pre-conference workshops and 3 tracks of paper presentations best meet your needs (you may move from track to track as desired). And of course you will want to take full-advantage of the exhibit area and social events for unlimited networking.

  • MARCON 2019 will include a full schedule of events, to include workshops and presentations by leaders in the field of R&M, networking receptions, and exhibit area.
  • Refer to the speaker abstracts to choose which paper presentations to attend. Presentations will focus on best practices, case studies, asset management, and new research and technology.

Topics Include

  • Organization, Strategy, and Culture
  • Facilities Reliability
  • R&M Technology and Tools
  • Workforce Effectiveness
  • Asset Care Execution
  • Machinery and Equipment Maintenance
  • Process Reliability
  • Business and Management
  • MRO Spare Parts
  • Facilities Reliability
  • Technology and Data Implementation / Applications
  • Shutdowns, Turnarounds, and Outages
  • Optimization and Implementation
  • Aligning with Operations
  • R&M in the Power Industry
  • Work Management
What does MARCON offer?

Now in its 23rd year, MARCON has become known as a high quality, excellence driven conference – large enough to deliver value, small enough to allow interaction with the presenters and attendees. The exhibit cost for 2019 remains low and includes pipe and drape this year. And we are again offering FREE web advertisement for exhibitors and sponsors.

  • Want to hit 2019 running with an exhibit at one of the year’s first conferences?
  • Want to showcase your products and services?
  • Want to closely interact with conference attendees?
  • Want FREEadvertising on the RMC website for up to a year?

If your answer was “YES” to any of the questions, then MARCON is the conference for you!

  • We have an ideal set-up for exhibitors along the pathway of conference attendees.
  • We are not a mega-conference/trade show! Exhibitors and attendees have the time to share needs and solutions.
  • Sponsors are highlighted and recognized for their contributions, both on the RMC and MARCON websites and throughout the conference.

The exhibit area will be located in close proximity to the conference meeting rooms and the meal and break area for maximum traffic flow by conference attendees. Each exhibiting company has a 10’ x 10’ space and may have a 6-foot draped table or similar sized free-standing exhibit. Booths for 2019 will also include pipe and drape (provided by All Convention and Expo Services), as well as electricity.

Exhibiting companies receive 2 complimentary conference registrations, 6 months of advertising on the RMC website, and can include a brochure and/or a promotional item in the attendee welcome bags (a $300 value).

Sponsorships

Sponsorships are available at many different levels. All sponsors will be recognized on the conference website, in conference materials, and also receive 6-12 months of advertising on the website, depending on the level of sponsorship. They may also include a brochure or promotional item in the welcome bags for no additional charge.

University Level – $5,000 
Sponsorship comes with 12 months on RMC web advertisement, In addition, company logo will be included on conference program and signs, and conference website advertisement. A company promo item may be included in conference welcome bag free of charge.

Orange Level – $3,000 
Sponsorship comes with 6 months RMC web advertisement, In addition, company logo will be included on conference program and signs, and conference website advertisement. A company promo item may be included in conference welcome bag free of charge.

White Level – $1,500 
Sponsorship guarantees company logo will be included on conference program and signs, and conference website advertisement. A company promo item may be included in conference welcome bag free of charge.

Reception Bar Sponsor (March 4, 2019) – At cost, up to $2,500
Two drinks per person with a max obligation of listed sponsorship amount ($2,500). Bill will be paid directly to Convention Center. Sponsorship guarantees company logo will be included on conference program and signs, and conference website advertisement. A company promo item may be included in conference welcome bag free of charge.

If you would like to donate a different amount please contact the RMC.

SPEAKERS

DAYS

WORKSHOPS

OF SUCCESS STORIES

Keynote Speakers

Meet our Keynote speakers

Armin Schwab

Vice President Manufacturing

Bosch Thermotechnology

James Nord

Reliability Specialist

Detour Gold Corporation.
(Winners of Emerson’s 2018 Reliability Program of the Year)

Danielle Ouellet-Lemieux

Reliability Engineer-in-Training

Detour Gold

Schedule

Schedule is subject to change

7:00 AM - 8:00 AM
Breakfast

The course is ideal for anyone who wishes to gain a solid understanding of reliability improvement and condition-based maintenance. You will understand why you should improve reliability, what is involved in implementing a program, and what all the roadblocks will be.  You will have a clear understanding of the strategies, philosophies, and terminology associated with the very important process of improving reliability and performance. The course is perfect for managers, engineers, maintenance & operations managers, and condition monitoring leaders.

The two day workshop will cover the following:

  • A big picture overview
  • The benefits of reliability improvement
  • How to assess the benefits for your organization
  • How to develop a reliability culture
  • Selling the program to senior management
  • Developing the program strategy
  • Understanding failure and failure modes
  • Defect elimination
  • Developing an asset reliability strategy
  • Work management (planning and scheduling)
  • Spares and material management
  • Precision and proactive maintenance
  • Condition monitoring
  • How to break out of the reactive maintenance cycle of doom
  • Continuous improvement
  • A summary of the implementation strategy

If you complete the two day workshop you will be eligible to take the two-hour, 60-question, multiple-choice ARP-CAT I exam on Tuesday, March 5, from 6:00 – 8:00 pm, in the same classroom as the workshop.  The cost of the exam will be: $275 per student. You must register for the exam separately, here: https://bit.ly/2BSZZIl

Paul Dufresne Bio

Paul Dufresne is a Reliability Advisor and instructor for Mobius Institute. Paul has over 25 years of experience in the military and various industries with a primary focus on improving operations, maintenance, and reliability functions. Paul serves as chairman of the Society of Maintenance and Reliability Professionals Best Practices Committee. He is a member of the Society of Tribologist and Lubrication Engineers and the Industry Council for Machinery Lubrication. He holds credentials through STLE as Certified Lubrication Specialist (CLS); through SMRP as Certified Maintenance and Reliability Professional (CMRP) and Technician (CMRT); through the Association for Facilities Engineering as Certified Plant Maintenance Manager (CPMM). Paul is certified in predictive maintenance technologies such as vibration analysis and thermography. He has written several articles and technical white papers, and is a frequent presenter at industry conferences. Paul is a Distinguished Military Graduate from the University of Central Florida.

Paul Dufresne

How do you know which metrics truly matter? The Society for Maintenance & Reliability Professionals (SMRP) Body of Knowledge and Best Practices, 5th Edition, are the basis for this workshop. In this workshop, you’ll gain insights into the latest thinking on maintenance and reliability (M&R) metrics. Attendees will learn how to use the metric hierarchy for linking M&R activities to an organization’s strategy. Using this proven process, M&R practitioners will be able to make the business case for reliability to operations and leadership. M&R best practices will be discussed, along with how the metrics align with SMRP’s five pillars in the Body of Knowledge. This hands-on workshop reviews the standard definitions and application of common metrics developed by the SMRP Best Practices Committee. Attendees will understand how to measure performance consistently, make valid comparisons and provide guidance to their organization on how to use SMRP metrics. The workshop is interactive; attendees will participate in activities using specific examples to apply and calculate metrics.

After completing this workshop, participants will be able to:

  • Examine the process for determining the right set of metrics for yourbusiness
  • Understand the process (metric hierarchy) for linking M&R metrics to the organization’sstrategy
  • Identify metrics that measure efficiency, effectiveness and strategicexecution
  • Practice calculating M&R metrics using formulas and sample datasets
  • Discuss the value of dashboards/scorecards as a tool to track strategicexecution
  • Discuss effective techniques of data reporting so that management can use the information to make better decisions

Rick Clonan’s & Paul Casto’s Bio’s

Rick started his 27-year career in maintenance on board the submarine USS Baltimore SSN-704 in 1991. He discovered an ability to repair equipment and had a knack for figuring out why things were broken. After his time in the Navy was over, he began a career in Industrial Maintenance where he grew his skill set even more. After being promoted to Maintenance Technologist and attending RMC Bootcamp at the University of Tennessee, Rick obtained his CMRP certification. He has since held positions as Planner, Scheduler, and Maintenance Supervisor. Rick has also been a CMMS Administrator and was the lead consultant on the development of that project. He earned his RMIC certification from UT based upon quantifiable improvements made at his facility due to the successful implementation of that system. He has served or is currently serving on several committees within SMRP, including the SMRP Conference committee, the Best Practices Committee where he now serves as Chair, and the Maintenance and Reliability Knowledge Committee. He currently serves as the chapter Treasurer for the SMRP Middle Tennessee Chapter. Rick has been married for 23 years to his wife Chandra. In his spare time, he enjoys cooking, mountain biking, and golfing with his daughter.

Paul Casto is the Intelligent Assets Practice Leader at Gray Matter Systems with a focus on Asset Performance Management (APM). He is a leading practitioner in reliability and maintenance(R&M) improvement methodologies and has hands-on experiencein reliability, maintenance, operations and engineering in the chemical, steel, aluminum, automotive, oil and gas, aerospace, consumer goods and construction industries. His current areas of focus include: value creation through Asset Performance Management (APM), the development of asset health models, the applicationof

advanced reliability and maintenance tools/strategies, data analytics, prognostics, machine learning, business case development and risk analysis, and R&M leadership.

Paul holds a Bachelor’s degree in Electrical Engineering from West Virginia University, a Master’s degree in Engineering Management from Marshall University Graduate College,an MBA from Clemson University and a Masters in Maintenance Management and Reliability Engineering from the Monash University. He has done PhD work in Industrial Engineering (ABD) at the University of Tennessee. Paul holds ASQ certification in Reliability Engineering, Quality Engineering and as a Six Sigma Black Belt. He has a certificate in Strategic Decision and Risk Management from Stanford University and is pursuing an Asset Management Professional Certification (AMPC) from Humber College/PEMAC. Paul is a SMRP Certified Maintenance and Reliability Professional (CMRP) and serves on the SMRP board as the Director of SMRP’s Body of Knowledge. He has served on the University of Tennessee’s Maintenance and Reliability Center Board of Advisors, the SMRPCO Advisory Council, Chair of the SMRP Best Practices Committee, the SMRP Education Committee and the API-691 Risk Based Management for Machinery subcommittee. He is an active member of ASQ andIEEE.

Rick Clonan

This interactive workshop is designed to guide you in establishing a practical and an effective Asset Management (AM) process, which when implemented right, will minimize business risks and maximize the return on your assets. In addition, your asset management process should meet ISO’s AM standard (ISO 55000) compliance requirements.

Do your assets deliver the best value? Do they perform as designed and meet your expectations? Do you know the health of your assets or when they need to be replaced or modified? Do you know how much they cost you to operate and maintain?  Are they comparable to industry benchmarks? Do you have a process established to reduce the total cost of ownership?

This workshop is based on our experiences of managing assets “from cradle to grave” and is centered on the book ‘Ten Rights of Asset Management’ by Ramesh Gulati & Terrence O’Hanlon.

This workshop covers the following topics:

  • Introduction – What is Asset Management and Why?
  • Organization’s Goals / Expectations
  • Asset’s Role in Delivering Value
  • Asset Performance Factors
  • 10 Rights of Asset Management – Best Practices
  • Application of Asset Management Standards
  • Establishing an Asset Management Process
  • Asset Management Policies, Plans, Procedures etc.
  • Lessons Learned and Challenges

Learning Objectives:

  • Asset’s role in delivering value
  • Asset Lifecycle phases
  • Why the design, procure, build and install phases are important?
  • Understanding of all 10 Rights and their importance
  • Applicable ISO standards

Ramesh Gulati’s Bio

Asset Management & Reliability Specialist at Jacobs – Asset Management Group, Tullahoma, TN

A world-renowned leader in the maintenance, reliability, and asset management field and the author of more than four books, including the award-winning Maintenance & Reliability Best Practices. His new book, 10 Rights of Asset Managementwas released in 2017.  He is also known as “Reliability Sherpa” in reliability- asset management arena.

Ramesh has worked at Aerospace Testing Alliance / Jacobs, Arnold Engineering Development Complex -TN, Carrier A/C, True Temper Corp., Bethlehem Steel, Foundry Forge plant etc.

He is an active member of ASQ, IIE, IAM, SMRP and has authored numerous papers in maintenance – reliability, asset management, productivity improvements, application of standards and workforce development.

Ramesh holds BSME, MSIE, and an Executive MBA.

Ramesh Gulati

Lubrication Programs hinge on how well they are managed and the focus on the early detection and elimination of failure root-causes.  Few managers are able to transform their lubrication programs into world-class because they fall victim to the same school of thought as their predecessors.  By changing how we view lubrication work and evolving our practices, we can tap into the incredible potential of lubrication excellence.  The industry has realized only a fraction of the opportunities that are achievable through lubrication-enabled reliability.  This workshop takes abstract thoughts and turns them into concrete tasks that must be done to enhance your program and your way of thinking.

Learning Objectives:

  • What world-class lubrication looks like
  • How maintenance decisions control machine life expectancy
  • The differences between lubricants and lubrication
  • Five core attributes of a world-class lubrication program
  • The power of observation
  • How people and work culture affect the state of lubrication and reliability

Wes Cash’s  Bio:

Wesley (Wes) Cash is the director of technical services for Noria Corporation. He serves as a senior technical consultant for Lubrication Program Development projects and as a senior instructor for Noria’s training courses. Wes is an enthusiastic, relatable speaker who connects effortlessly with his audience. His style and easy-to-understand approach to the curriculum creates an interactive forum for learning. With his background as a former construction worker and heating, ventilation, air conditioning and refrigeration (HVAC-R) technician, Wes brings practical knowledge to which students can relate. With Noria, he has helped numerous companies transform their current lubrication practices into world-class programs. Wes is also a regular contributor of technical articles for Machinery Lubrication magazine. He holds Machine Lubricant Analyst (MLA) Level III and Machine Lubrication Technician (MLT) Level II certifications through the International Council for Machinery Lubrication (ICML) and is a Certified Lubrication Specialist through the Society for Tribologists and Lubrication Engineers (STLE).

Wes Cash

Industrial production is rapidly transforming. The Industrial Internet of Things (IIoT)–the concept of interconnected applications, equipment, and technology–is more than a buzz phrase. It’s driving real plant-wide change and enhanced asset operation and maintenance management.

Plant owners and managers must trust that their equipment will operate reliably. Being able to monitor assets and assess their health is of paramount concern. Owners, managers, and engineers need data to ensure that problems are detected before a catastrophic failure.

The clear benefits of actionable asset data have emerged: Smarter decisions–guided by fast, accurate measurements—before maintenance, repair or replacement can mean sizable cost savings on expensive equipment, improved equipment operation, and reduced safety risks. In best practice facilities, reliability inspections and condition monitoring will optimize efficiency by significantly reducing the percentage of corrective (unplanned) maintenance hours while also reducing regularly scheduled maintenance, in favor of planned maintenance triggered by changes in performance data.

In an ideal situation, owners, and managers will be able to:

  • Collect, store, and group data
  • Track trend lines and see faults
  • The readings to assets and work orders
  • Provide history
  • Receive alarms and see meters

Still, the growing adoption of connected maintenance technologies also exposes a need to equip millions of unmonitored machines in industrial plants and facilities. This unserved need provides increase potential for decision makers at these organizations. SaaS software solution and wireless technology enable maintenance managers to build and sustain successful maintenance programs. Whether you are looking to establish preventive or condition-based practices or simply maximize uptime, you can now do it with minimal investment and setup time. You can view equipment data and make informed decisions from anywhere, anytime. Improve your ability to prevent or predict failures by easily comparing all measurement types—whether electrical, mechanical or thermal— from one location. Trend data and compare current state to baselines. Confidently make decisions based on data you can trust and trace by automatically creating measurement records for your equipment, from the largest portfolio of wireless test tools.

This workshop will discuss and provide hands-on on how selecting combined technologies will give you a complete solution for your preventive maintenance and reliability program while maintaining your facility budget within limit and team resources intact to collect/review more data to make key decisions. Learn more…

Instructors Bio’s

Alex Desselle is a Product Application Specialist for Fluke Corporation focusing on the Fluke Digital Systems Tools & wireless sensors. He is a CRL (Certified Reliability Leader) with 30 years of Industry experience as a Field Engineer working in Oil & Gas and Manufacturing Business Verticals. He has held various positions as Lead Field Engineer, Project Manager & SME/Product Specialist. Desselle is often a presenter at various trade shows and conferences, has written technical articles and case studies for global trade publications. He is also a Thermal/Infrared Thermography Level I certified. Desselle holds technical degrees in digital electronics from ITI in Baton Rouge, LA. For more information, email alex.desselle@fluke.com or visit www.accelix.com.

Frederic Baudart, CMRP, is a lead product application specialist for Fluke Accelix™, a suite of solutions from Fluke Corp. (www.fluke.com), focusing on the company’s process, electrical, thermal, mechanical and condition monitoring product lines. He has 20 years’ experience in field service engineering work and preventive maintenance industry. He has held various field services and technical positions with responsibility for installation & commissioning as well as services management roles. Baudart is often a presenter at many trade shows and conferences and has written many technical articles and case studies for global trade publications. He is also a Thermal/Infrared Thermography Level I certified and recently obtained his Certified Maintenance & Reliability Professional (CMRP) certification. Baudart holds technical degrees in electrical and instrumentation engineering from technical college in Brussels, Belgium.

 

Alex Desselle & Frederic Baudart

“Reliability in capital projects begins with design.  Find out how you can achieve true competitive advantage by designing reliability and life cycle cost principles into your capital projects.”

DISCOVER HOW:

  • How the best companies include reliability in the design phase of their projects to minimize costs and maximize performance.
  • How to determine the investment required for applying life cycle principles
  • How to balance payback and return on investment
  • How to develop a policy for life cycle cost

Ron Moore presents a one-day Reliability-based Design Master Class for those implementing new capital projects in their operations.

Reliability doesn’t revolve around maintenance; it begins long before this, in the initial design and installation processes.  This master class will explain the fundamentals behind reliability practices, and describe how procurement, operations and maintenance need to work together during new capital projects to make sure the right practices are applied to reduce lifecycle costs and increase reliability.

By designing processes and equipment with operations and maintenance in mind, you can prevent ‘defects’, avoiding unnecessary costs and optimizing plant performance.

The class will review different reliability practices, and provide invaluable advice on how you can apply them in your own organization to not only lower lifecycle costs, but improve performance, increase safety, reduce environmental risks and ultimately enhance your long-term competitive position.

WHO SHOULD ATTEND?

The Master Class is for leaders in capital projects, including Directors, Project Managers & Engineers, Procurement Managers, Site Managers, Change Managers, Operations & Maintenance Managers, First-Line Supervisors, Reliability Leaders & influential frontline Operators & Maintainers.

WHAT WILL YOU LEARN:

  • An understanding of how to incorporate reliability and life cycle principles into the design of capital projects.
  • To what extent your current design and project practices incorporate reliability principles.
  • How to incorporate the requirements of operating, maintenance, installation and startup, stores/parts, and procurement into capital projects for better long term outcomes.
  • A model for determining the up-front costs of incorporating life cycle and reliability principles into your design and capital projects.
  • How to determine whether to use a payback or a discounted cash flow model in assessing the viability of a given project.
  • How to draft a corporate policy statement for assuring that life cycle and reliability principles are incorporated into your future projects.

course description

Ron Moore’s Bio

Ron Moore is the Managing Partner of The RM Group, Inc., Knoxville, TN.  He is an authority on strategies and practices for operational excellence and works with manufacturing and industrial companies in North and South America, Europe, Australia, Asia, Africa, & the Middle East.

 

Ron is the author of :

  • Making Common Sense Common Practice: Models for Operational Excellence
  • What Tool? When? A Management Guide for Selecting the Right Improvement Tools
  • Business Fables & Foibles
  • Where Do We Start Our Improvement Program?
  • Our Transplant Journey: A Caregiver’s Story;
  • And over 60 papers and journal articles.

Prior to starting The RM Group, Ron served for five years as President of Computational Systems, Inc. (CSI). Ron also served for eight years as chairman of the Industry Advisory Board at the University of Dayton’s Center for Competitive Change.  He holds a BSME, MSME, MBA, PE, and CMRP.

 

Ron Moore

Expanded content!  At the request of last year’s attendees, this course has been expanded to a full-day. In addition to more time spent at each failure analysis station, content regarding lubrication of electric motors and case studies have been added. 

We are going to help answer the question: What can a reliability engineer expect from a motor repair facility?

Well, it is pretty basic, how you treat your motor determines the life of it. When it is time to repair it, do you send it out with minimum standards in place for its performance upon return?

This workshop will cover the infrastructure (teardown, core loss testing before and after burnout, rewinding, shaft balancing, re-assembly) of a motor shop, including the integration of a motor shop’s work practices and the motor autopsy results method of communication back into your reliability program using Reliability Data Management.

For most motor repairs, any craftsmanship problems will show up in the first 30 days of an installation of a new or repaired motor. If properly installed by field services performing precision balancing and hot alignment, thermography on the electrical connections and mechanical condition evaluated through vibration monitoring, the returned and installed unit may have higher quality and even better efficiency than when the motor arrived at the shop.

The extended field services most shops offer include periodic (monthly or quarterly) vibration testing, yearly infrared, alignment and electrical testing performed on the motor, and a good lubrication program. If you have these technologies and programs deployed, motor repair facilities should be able to offer an extended warranty on the motor. Does your motor shop offer the standard one-year warranty, or an extended warranty? That would be good to know!

This workshop will be held at Tekwell Services in downtown Knoxville. Tekwell is a SKF-Certified Repair Shop, one of about 50 in the entire United States. The workshop will include activities at four of the major repair stations in the Tekwell facility, led by shop floor personnel. This is a great opportunity to ask questions and learn about best practices in the motor repair process.

 

Buddy Lee, Emerson and the Tekwell Staff’s Bio

Buddy Lee, CMRP, MBA, CRL holds a BSEE and MBA from the University of Tennessee, and is A co-holder of US Patent #6,276,213 “Signal Conditioner for a Vibration Sensor”. In 1989 he joined CSI as an Applications Engineer, and was subsequently promoted to sales, where he was Salesman of the Year in 1992.

Buddy has been active in the field of machinery monitoring for 24 years, publishing several papers, including Vibrations Magazine “Motor Current Analysis Using a PC-Based System” Technical Article, September 1992. Buddy is an active speaker at Conferences and Seminars, including Process Reliability, PPM, SMRP, PdM and various chapter meetings of the Vibration Institute.

Buddy’s interest turned to Industrial Reliability in 2004, and he became a CMRP in 2007. He co-organized and led the development of the Greater East Tennessee Chapter of the SMRP in 2010, and was elected Immediate Past Chair, and currently serves on the GET SMRP Chapter Board of Directors. In 2012 he was confirmed as the Chairman of the Membership Committee for the National SMRP. He became a Certified Reliability Leader (CRL) in May of 2015.

Buddy has a passion for teaching adult learners and has conducted many PdM and Reliability Seminars and training sessions in his career. He joined Emerson as an instructor in April of 2018.

Buddy Lee
7:00 AM - 8:00 AM
Breakfast

The course is ideal for anyone who wishes to gain a solid understanding of reliability improvement and condition-based maintenance. You will understand why you should improve reliability, what is involved in implementing a program, and what all the roadblocks will be.  You will have a clear understanding of the strategies, philosophies, and terminology associated with the very important process of improving reliability and performance. The course is perfect for managers, engineers, maintenance & operations managers, and condition monitoring leaders.

The two day workshop will cover the following:

  • A big picture overview
  • The benefits of reliability improvement
  • How to assess the benefits for your organization
  • How to develop a reliability culture
  • Selling the program to senior management
  • Developing the program strategy
  • Understanding failure and failure modes
  • Defect elimination
  • Developing an asset reliability strategy
  • Work management (planning and scheduling)
  • Spares and material management
  • Precision and proactive maintenance
  • Condition monitoring
  • How to break out of the reactive maintenance cycle of doom
  • Continuous improvement
  • A summary of the implementation strategy

If you complete the two day workshop you will be eligible to take the two-hour, 60-question, multiple-choice ARP-CAT I exam on Tuesday, March 5, from 6:00 – 8:00 pm, in the same classroom as the workshop.  The cost of the exam will be: $275 per student. You must register for the exam separately, here: https://bit.ly/2BSZZIl

Paul Dufresne Bio

Paul Dufresne is a Reliability Advisor and instructor for Mobius Institute. Paul has over 25 years of experience in the military and various industries with a primary focus on improving operations, maintenance, and reliability functions. Paul serves as chairman of the Society of Maintenance and Reliability Professionals Best Practices Committee. He is a member of the Society of Tribologist and Lubrication Engineers and the Industry Council for Machinery Lubrication. He holds credentials through STLE as Certified Lubrication Specialist (CLS); through SMRP as Certified Maintenance and Reliability Professional (CMRP) and Technician (CMRT); through the Association for Facilities Engineering as Certified Plant Maintenance Manager (CPMM). Paul is certified in predictive maintenance technologies such as vibration analysis and thermography. He has written several articles and technical white papers, and is a frequent presenter at industry conferences. Paul is a Distinguished Military Graduate from the University of Central Florida.

Paul Dufresne

This course focuses on the purpose of maintenance and performance improvement strategies to break out of the current status quo. Techniques to tap into the knowledge of your craft workers and technicians, organizational issues, gap analysis and closure plans, culture change, and development of key work processes critical for effective maintenance are discussed. Methods to break the cycle of repeating the same mistakes over and over again will provide the student with new insight on improvement possibilities. Approaches to integrating operations, maintenance, reliability and engineering to deliver a reliability focus operations and maintenance program will guide the students to a new paradigm in performance improvement. The course contains real-life applications which provide the basis to improve the future of your maintenance organization.

Learning Objectives:

  • Evaluating maintenanceperformance
  • Recognize where to focus and what todo
  • Identifying and using key performancemetrics
  • The effective maintenanceteam
  • The basics ofplanning
  • The basics ofscheduling
  • Focusing on culture change and leveraging theworkforce
  • Integrating maintenance, reliability andengineering
  • Developing a vision, mission and strategy formaintenance

Who should attend

The course is designed for all levels and departments of the organization that are interested in improving overall performance such as; maintenance and operation leaders, reliability and maintenance engineers, maintenance and operations team leaders, area managers, planners, technicians and craft

workers wanting to improve the status quo of today’s workplace.

Paul Casto’s Bio

Paul Casto is the Intelligent Assets Practice Leader at Gray Matter Systems with a focus on Asset Performance Management (APM). He is a leading practitioner in reliability and maintenance(R&M) improvement methodologies and has hands-on experiencein reliability, maintenance, operations and engineering in the chemical, steel, aluminum, automotive, oil and gas, aerospace, consumer goods and construction industries. His current areas of focus include: value creation through Asset Performance Management (APM), the development of asset health models, the applicationof

advanced reliability and maintenance tools/strategies, data analytics, prognostics, machine learning, business case development and risk analysis, and R&M leadership.

Paul holds a Bachelor’s degree in Electrical Engineering from West Virginia University, a Master’s degree in Engineering Management from Marshall University Graduate College,an MBA from Clemson University and a Masters in Maintenance Management and Reliability Engineering from the Monash University. He has done PhD work in Industrial Engineering (ABD) at the University of Tennessee. Paul holds ASQ certification in Reliability Engineering, Quality Engineering and as a Six Sigma Black Belt. He has a certificate in Strategic Decision and Risk Management from Stanford University and is pursuing an Asset Management Professional Certification (AMPC) from Humber College/PEMAC. Paul is a SMRP Certified Maintenance and Reliability Professional (CMRP) and serves on the SMRP board as the Director of SMRP’s Body of Knowledge. He has served on the University of Tennessee’s Maintenance and Reliability Center Board of Advisors, the SMRPCO Advisory Council, Chair of the SMRP Best Practices Committee, the SMRP Education Committee and the API-691 Risk Based Management for Machinery subcommittee. He is an active member of ASQ andIEEE.

Paul Casto

Detecting bearing failure with vibration data?

Don’t repeat the same mistakes. Learn what to do next.

Many plants use condition monitoring programs to detect impending bearing failure. The vibration data collected can indicate that a bearing is failing. But detection is only the first step.  Without understanding the true root cause of the failure, you run the risk of repeating the same mistakes. If that’s the case, the replacement bearing you install will likely meet the same fate.

SKF invites you to a one-day technical seminar to discuss real-world case studies of detected bearing failures. Presentations will highlight everything from the initial data reports to the final damage analysis. The damaged/failed bearings – right out of the machines – are available for hands-on inspection.

Morning session:

  • Welcome & Introductions
  • Case studies linking historical vibration data to damaged bearings
  • Hands-on exercises to begin the damage analysis process

Afternoon session:

  • Continue Case studies
  • Connecting the disciplines: Vibration & Bearing Damage Analysis
  • Compare suspected faults vs. initial damage analysis and the final fault determination
  • Aligning corrective actions to the true root cause
  • Next steps
  • Q&A/Wrap up

Who should attend?

This seminar is recommended for all plant/facility personnel involved with rotating equipment, machine reliability, and predictive maintenance.

Joe Conyer’s Bio

Joe Conyers is senior consulting engineer, training and development with SKF Training Solutions. He has held many positions with SKF in his almost 30 years with the company, and currently develops and delivers training in Mechanical skills related to rolling element bearing installation, maintenance, lubrication, and failure analysis. Joe has performed more than 100 shop audits to certify electric motor repair shops while at SKF.

Joe earned his BS in Aerospace Engineering from the U.S. Naval Academy, and served as a Navy pilot on active duty, prior to joining SKF.

Joe Conyers

World-Class organizations recognize that success is achieved through leadership however they also realize that results are only delivered through engagement and empowerment of everyone in the workforce.  Leadership does not come from one person it comes from everyone.  This is especially true for reliability.

The Certified Reliability Leader is designed to deliver value to what we call the triple bottom line of:

  • Economic Prosperity
  • Environmental Sustainability
  • Social Responsibility

The Certified Reliability Leader workshop focuses on whole life asset reliability decisions and whole life value delivery through leadership.  The system provides guidance and is a map of theory, to engage and empower every stakeholder in your organization as a Reliability Leader.

Topics include:

  • Reliability Engineering for Maintenance
  • Asset Condition Management
  • Work Execution Management
  • Leadership for Reliability
  • Asset Management

The Reliability Leader Certification is based on the holistic system of

Uptime Elements and the Certified Reliability Leader Body of Knowledge (BoK).  For more information visit:  https://www.maintenance.org/pages/crl.

This workshop will end at 4:00 pm. If you wish to take the CRL Exam, it will be offered from 6:00 – 8:00 pm in the same room. You must register for the exam separately at: https://reliabilityweb.com/crl-exam-at-marcon-2019.

Jeff Smith’s Bio

Jeff Smith writes articles for multiple Magazines. He was also the senior advisor for the Association for Maintenance Professionals (AMP) and served on the USA tag for ISO 55000.

His work has spanned substantial cross section of industries including Potash, Oil Sands, mining, pulp and paper, packaging, petrochemical, marine, brewing, transportation, synfuels and others.

Jeff has a history of successfully developing world class maintenance and reliability programs utilizing a multitude of strategies. He has effectively transitioned corporations engaging all levels from the floor to the C suite. Jeff Smith has published multiple reliability papers and has spoken at numerous conferences globally.

 

Jeff Smith

Intended audience:
Maintenance and Reliability engineers, managers and leaders; industrial process control, automation, MES and operational excellence professionals.

The workshop will serve as a primer for those who have little to no knowledge of data science, AI, and IIoT; and provide a concise, structured learning and reinforcement of topics for those with some basic understanding and knowledge.

PART I – FUNDAMENTALS

The basics

  • Data vs. insights – how do we extract insights from data
  • What is artificial intelligence; the type of problems it is solving.
  • What is machine learning and data science, how does it work and how is it different from traditional logic and rule based systems
  • Learning methods: How does an algorithm learn:
    • Supervised Learning
    • Unsupervised Learning
    • Reinforcement learning

    Algorithms

  • Different algorithm types and their application:
    • Regression
    • Classification
    • Clustering
    • Gausian models
    • Neural networks and deep learning
  • Patterns in data: pattern recognition, anomaly detection
  • Machine Learning implementation process

  • Data types, basic exploration of data with statistical methods
  • Co-relation and causation
  • What are features, feature selection, extraction and importance
  • Algorithm selection
  • Model training, validation and optimization
  • Model performance evaluation and tuning
  • Feedback mechanisms
  • Quiz: Fundamentals reinforcement

    PART II: IMPLEMENTATION

    Deployment of Models:

  • Data processing basics – batch and streaming data processing
  • Cloud, Fog and edge
  • Data pipeline and IIoT architectures
  • Security
  • Hands-on demonstration and exercise:

  • Using a modern industrial IIoT system, a step-by-step demonstration of building machine learning applications for anomaly detection and health prediction by an industrial user with no data science or programming experience.
  • Model Building Exercise:

  • Limited number of users will be able to build machine learning models for a prediction of faults and performance of a hydraulics system using a problem set and data set provided for the workshop
  • Rajiv Anand

    The recognition of a business need to include operators in reliability efforts usually involves the application of some type of Operator Basic Care training, the results of which can sometimes be short lived and difficult to measure. In order to integrate operators into reliability we have found that it can be helpful to layout a roadmap at the strategic, tactical and application levels in order to ensure that the investment in operator skills brings value back to the site immediately after training.  In this seminar we will propose some potential paths that can be taken and review some of the strategies to help ensure successful implementation of an operator care process.

    Gaining alignment across a facility on the positive impact that an operator care process can have, is invaluable to its success. Implementing and integrating operators into the reliability process is a cultural shift for a lot of sites and as such the need for frequent and varied communication about the process is helpful before, during and after implementation.

    Learning Objectives:

    • Participants will recognize that effective implementation of operator basic care training involves much more than holding a training class.
    • Participants will be able to identify and avoid some of the common pitfalls before implementing operator training.
    • Participants will come away with an awareness of the skills available to operators and how they can leverage this knowledge.
    • Participants will be aware of the necessary pre and post work for successful implementation of operator training.

    Course description

    Chris Endruhn’s Bio

    Chris has over 15 years of field experience in both the production and the mechanical maintenance areas.  He has been a mechanical maintenance supervisor, operations front line leader, process engineer, and field technical sales & service engineer ; roles that support the goal of reliable and predictable manufacturing.

    Chris earned a Bachelor of Science degree in Chemical Engineering from the University of Alberta and has worked in the paper industry, and the oil and natural gas production industry.  He has run production and process improvement trials, devised and implemented down hole and pipeline corrosion inhibition programs, oil and natural gas production specialty chemical programs and paper machine wet end specialty chemical programs.  He has been involved in the design and implementation of operator basic care rounds, roll out of maintenance work systems, precision maintenance programs, and the day to day running of crews of mechanics and operators on lean budgets.

    Chris is a Lead Instructor in Reliable Manufacturing and has worked for Baker Hughes, Nalco, Domtar and International Paper.  His extensive operations background gives him insight into what makes operators tick and how to motivate them to change.

    Chris Endruhn

    Poor maintenance processes drive higher storeroom values. It’s not uncommon to find maintenance planners spending five or more hours per day addressing parts and materials issues for hopefully, future work.  And it’s not uncommonto find storeroom personnel consuming some of their day duplicating the efforts of the maintenance planner.  At the same time, the MRO storeroom personnel struggle to balance inventory levels with “customer” service and cost. Merelyreducing inventory values without a coordinated process causes the MRO storeroom to cut maintenance efficiency and plant capacity. Often, management misses the connections between the two functions.

    Two other items, apple pie andvanilla ice cream,are favorites on their own too butalmost everyone knows that combining them creates a winning combination. Maintenance planning and scheduling along with the MRO storeroom often exist as independent silos. Yet,combining the two separate functions into a seamless flow creates a winning combination for everyone.

    In this half-day workshop, join Jeff Shiver as he shares how maintenance planning and scheduling can partner with the MRO storeroom to create an unbeatable combination where the organization wins. In this workshop, you will learn how to:

    • Design the business processes that build the partnership and create a win-win for the two groups and the organization.
    • Define the roles and responsibilities to eliminate the overlapping efforts and to ensure that we are headed in the best direction together.
    • Select performance indicators to drive the right behaviors with the partnership.
    • Leverage the CMMS/EAM system to drive efficiencies and obtain the right information for better decisions.
    • Use the PM/ CBM processes to reduce inventory values and increase storeroom turns

    Jeff Shiver’s Bio

    Jeff Shiver, CMRP, CPMM, RCM2 / RCM3 Practitioner guides people and organizations to overcome their reliability and operational challenges. Working together in partnership, we move beyond the status quo inculture, business results, and most importantly, people.

    Jeff has over 25+ years of practitioner experience. Within Mars North America, he worked at four plant locations and held two corporate roles.  Job functions included Engineering, Maintenance, and Operations management. BeforeMars, he held contract engineering positions at Proctor and Gamble, and IBM.

    Founding People and Processes, Inc. in 2006, Jeff is a trusted advisor for the Maintenance and Reliability community. He is a book author, conference speaker, thought leader, and published in domestic and international trade journals. Jeff is also the Membership Services Director for the Society of Maintenance and Reliability Professionals (SMRP).

    Jeff Shiver
    4:00 – 6:00 PM
    Welcome Reception in Exhibit Area (Exhibit Area Open)

    The Certified Maintenance & Reliability Professional (CMRP) Program (300C)

    The ANSI-accredited Certified Maintenance & Reliability Professional (CMRP) program is the #1 credentialing program for the knowledge, skills and abilities of M&R professionals. Assessing more than just textbook knowledge, the exam tests and validates the skills and abilities of maintenance and reliability professionals according to the objective of Body of Knowledge (BoK).

    Earning one of these qualifications means earning a coveted credential recognized across all industries in the manufacturing world. Get CMRP certified today – in English, Spanish or Portuguese – and join the ranks of more than 3,200 CMRPs!

    The Certified Maintenance & Reliability Technician (CMRT) Program (300C)

    The Certified Maintenance & Reliability Technician (CMRT) program is the #1 credentialing program for the knowledge, skills and abilities of maintenance and reliability technicians. Assessing more than just textbook knowledge, the exam tests and validates the skills and abilities of maintenance and reliability professionals according to the objective of Body of Knowledge (BoK).

    Earning one of these qualifications means earning a coveted credential recognized across all industries in the manufacturing world. A passing score indicates that you have achieved a level of ability consistent with requirements for competence on the job as a multi-skilled maintenance and reliability technician.

    Certified Reliability Leader (200B)

    The Association of Asset Management Professionals (AMP) has developed an exam based on the Uptime Elements and its Reliability Leadership system. Designed to create leaders who focus on delivering value to the triple bottom line of: Economic Prosperity, Environmental Sustainability, and Social Responsibility.

    ICMLInternational Council for Machinery Lubrication (300D)

    ICML is a global non-profit organization dedicated to helping lubrication practitioners succeed in their professional careers. ICML certification exams are in accordance with ISO 18436 and are available worldwide, in multiple languages.

    MobiusAsset Reliability Practitioner Category I (200A)

    If you complete the two day Asset Reliability Practitioner (ARP) workshop you will be eligible to take the two-hour, 60-question, multiple-choice ARP-CAT I exam on Tuesday, March 5, from 6:00 – 8:00 pm, in the same classroom as the workshop. The cost of the exam will be: $275 per student.

    In 2012 the Bosch production plant in Wernau, Germany, which had approximately 450 associates, was “sentenced” to be shut down. Now, six years later, the plant has:

    • Reduced finished goods stock by >50%
    • Increased productivity by 37%
    • Reduced the number of white collar associates by 35%

    Today the plant is one of the leading plants for Industry 4.0 within Bosch, and was recognized as one of the 3 best “Value Streams” within the Bosch group, out of approximately 320 plants worldwide and more than 1,500 value streams. This presentation will show the steps through this journey, including the methods, the training needed and the change of the leadership style at the facility.

    Armin Schwab, Vice President of Manufacturing, Bosch Thermotechnology
    12:45 – 1:45
    KEYNOTE ADDRESS – “TBA”
    Track 1 - POWER SYSTEM RELIABILITY

    Authors:
    Alan Ross, Vice President of Reliability at SD Myers, Inc
    Larry Bryant, Director of Reliability at Domtar Corporation

    The authors will present the unique barriers that must be overcome in order to change the culture from an unreliable power system to a reliable power system in both industrial and commercial applications. Utilizing case examples from metals processing, mining, paper, plastic and pipelines to medical and data centers, we will reveal the common barriers we face that are unique to power system reliability.

    The main barriers to overcome have been identified as:
    • Lack of organizational recognition of the risks associated with unreliability
    • Lack of common standards for testing and data management
    • Inconsistent maintenance practices
    • Poor use of contractors
    • Reliance on “fix” versus prevent cultures
    • From Boomers to Millennials: A changing workforce
    • “TITWWHADI” culture (That is The Way We Have Always Done It)
    • Data chaos from the IIot versus UIot (Useful Internet of Things) unique to the power system

    Once a power system is viewed through the lens of these barriers to reliability, it is clear that we need more than a program of the day but a complete culture change. The authors will present a proven process for creating a reliable power system, with one author’s current experience implementing this process at Domtar paper company over a multiple plant system.

    Bio:

    Alan M Ross CRL
    Vice President of Reliability

    Alan Ross is the Vice President of Reliability at SD Myers, Inc. in Tallmadge, Ohio. He is responsible for developing and executing long-term reliability strategies and next generation leadership for all operating units, both domestically and internationally. He often presents at industry conferences and has authored several trade publication articles on transformer maintenance and reliability, including articles featured in Solutions and Uptime magazines and has written two books: Unconditional Excellence and Beyond World Class. He completed his undergraduate work in Mechanical Engineering at Georgia Institute of Technology and MBA in Marketing from Georgia State University, graduating Magna Cum Laude. Alan is a Certified Reliability Leader, Chairman of the SMRP Smart Grid Working Group, SMRP designee to the DOE’s Strategic Transformer Reserve task force and member of the IEEE Reliability Society

    Larry Bryant, Domtar / Alan Ross, SD Meyers, Inc.
    10:45 –11:00
    Break (Exhibit Area)

    Electric cooperatives serve more than 80% of counties across the USA. In fact, over 42% of all USA distribution lines are owned and managed by electric cooperatives. In participating with state and national electric cooperative organizations, On Now Digital recognized that there was a lack of recent quantitative data or formal research on asset management and/or equipment lifecycle optimization specific to electric cooperatives.

    Thus, On Now Digital conducted research among cooperative executives, operations managers, and engineers on asset management current state, technology use, and needs for the future. Research activities are concluding in September 2018.

    The paper and infographic (being finalized in OCT 2018) are non-commercial and for the benefit of the not-for-profit cooperatives. A descriptive overview of the research approach, participants, and resulting trends and insights related to asset management, as reported among electric cooperatives, will be presented and discussed.

    Takeaways: Utility-related reliability professionals will be keen to these insights. Reliability professionals from other industries will gain notes to compare where their particular organization or industry is more advanced or lagging compared to the strong but diverse cooperatives across the country.

    Bio:

    Jeff Rockwood
    Managing Director

    Jeff Rockwood leads On Now Digital, and brings nearly 20 years of experience into his role. Jeff is in constant pursuit of the needs of the customer. He identifies customer experience as the driving force for developing game-changing software and data solutions. His professional career began as a software developer and database programmer for the telecom utility, Alltel. Prior to On Now Digital, Rockwood led teams in intuitive technology, analytics, and business intelligence, most recently as a Sr. Program Consultant serving Progressive Insurance (Cleveland, OH), and as Director of China Sales and Operations at Alen Corporation (Austin, TX; Yinchuan, CN).

    Jeff earned an M.B.A. from Case Western Reserve University, Weatherhead School of Management and as well as a bachelor’s in Information Systems from Cedarville College. He is a certified Scrum product owner (CSPO) with extensive training in the IBM Rational Unified Process (RUP) and the Project Management Book of Knowledge (PMBOK). In his free time, Jeff enjoys his wife and two young children, faith, soccer, hiking, and traveling, as he has visited more than 20 countries across five continents.

    Jeff Rockwood, On Now Digital
    11:45 – 12:45
    Lunch (Ballrooms E & F)
    1:45 – 2:00
    Break (Exhibit Area)
    Track 1 - WORKFORCE DEVELOPMENT

    Almost all organizations recognize that times in the maintenance community are changing. Technology is changing at a pace we can barely keep up with and simultaneously, the work force continues to age. The Y-12 National Security Complex’s Infrastructure team recognized this challenge and decided to take a proactive approach. With the cooperation of Vector Solutions we launched the Maintenance Continuing Education Program (MCEP) in 2017.

    Research into the MCEP began in 2016 as we began to focus on the complexity of managing legacy facilities in conjunction with new facilities added to our footprint and future state facilities currently in project development. We have new technology through capital projects and old technology with existing facilities; and an aging maintenance work force. Management researched and decided we would partner with Vector Solutions as our vehicle for continuing education for current workers and benchmark training for our new employees. E-learning cannot replace all training but is a very important tool to have at our disposal and something which can be utilized to understand the learning gaps between current and on-boarded maintenance personnel.

    We decided to include the craft personnel that were instrumental to our Reliability and Maintainability program in the MCEP. The courses to be utilized were chosen by the Chief and Shop Stewards, with my assistance, for each particular craft and put into 40 hour E-learning blocks. The Stewards also chose 40 hours of Safety courses that all program participants would have access to. We also had the opportunity to find a cost savings by replacing a program that had previously used a lecture format with E-learning provided by Vector Solutions.

    The MCEP will be going into its second year in 2019 and interest is growing. We decided to let our current personnel volunteer for the program and require our new hires to participate. We have had two craft personnel complete 120 hours of training and advance to the next stage of training to compete for RMIC Certification through the University of Tennessee. Interest in the program has trickled over to Management and we have opened up the library and created some specific Professional Development blocks.

    We look forward to continuing the program into 2019, benchmarking, and possible implementation into our current Learning Management System (LMS). The benefits of a program like this are hard to measure in dollars and cents; but we are convinced that skilled workers will benefit our overall maintenance program with special emphasis on Reliability and Maintainability. The MCEP plays a vital role on our path to becoming a World Class Maintenance Organization.

    John A. Evans, CNS Y-12 / Jim McLeod, RedVector
    2:45 – 3:15
    Refreshment Break (Exhibit Area)

    How far-fetched is it to think that industry competitors could work together to develop a training solution that goes beyond the limitation of state lines and company interests? That is exactly how the Advanced Manufacturing Technical Education Collaborative (AMTEC), was developed. Employees from major companies such as Ford, GM, Nissan, and Toyota, to name a few, actually sat down together in the same room and developed a consensus around the skill standards needed by their technicians.

    Today, AMTEC is a multi-state collaboration of more than 70 industry and educational partners seeking to prepare highly-skilled technicians for work in the advanced manufacturing and automobile manufacturing industries. AMTEC is a “turnkey” solution that offers a full array of services including:

    • Industry-designed maintenance certification assessments;
    • Diagnostic assessments;
    • Industry-certified, nationally validated online competency-based curriculum;
    • Hands-on training resource guide;
    • AMTEC manufacturing system simulator training equipment.

    This session will provide case studies and actual examples of companies using AMTEC to advance their workforce, improve operational efficiency, and increase revenue. Learn how collaborative partnerships with industry and education produce workers with the technical and critical-thinking skills to analyze issues, solve difficult or complex problems, and manage output.

    AMTEC offers the opportunity to develop multi-skilled workers who make a significant difference in your operations and profitability. AMTEC – the industry collaboration solution to the skills gap!

    Sheri Plain & Jason Simon, Advanced Manufacturing Technical Collaborative (AMTEC)
    4:15 – 5:00
    Break (Exhibit Area)

    Robotics is changing the way manufacturers operate, how they support their plant environments and the skillsets they need. Human-operated assembly lines are being replaced by automated machinery and robots, which are increasingly the key to global competitiveness. With increasing automation, uniquely skilled workers are needed to handle maintenance, repair and overhaul (MRO) activities.
    In the past, MRO team members had specialized knowledge of how to keep conveyor belt systems operating, and focused skillsets. Now, it’s much more complex as conveyance systems are integrated with robots having six-pivot arms that are controlled by PLCs, interfaced to other electronic systems and powered by hydraulics.

    Highly automated plants require a combination of electric power, electronic communications and computing, hydraulics and mechanics. Each system speaks its own language, and they must talk and work together. It’s essential to keep the plant producing maximum revenue at the lowest cost, which means robot-based equipment has to be regularly maintained, and if it goes down, it must be rapidly brought back online. The MRO technician now needs to know how to maintain and repair across all disciplines with skills in mechanical engineering, computer engineering, and PLC controls.

    Factories, as they’ve automated, have cross-trained experienced people who were grounded in distinct specialized skills such as electronics, instrumentation, mechanical or power systems. But those knowledgeable people are leaving, whether through retirement or being poached by other high-tech factories. This leaves a distinct skills gap that is difficult to navigate through now and is only going to get worse. Mechatronics helps close this gap.
    Mechatronics technicians have emerged more prevalently in the last few years. They are well-equipped to meet the challenges mentioned above and are being trained by schools now offering mechatronics degrees at both associate and bachelor levels. Mechatronics technicians can do ongoing multi-discipline maintenance, recognize spare parts needs, and deconstruct and rebuild equipment when necessary.

    This paper key topics will cover:

    1. The skills of mechatronically trained resources.
    2. Systems/Tools that support mechatronics success.
    3. Where to find mechatronics technicians.
    4. How adopting the mechatronics approach benefits companies.

    Dan Roessler, Maintenance Connection an Accruent Company
    5:00 – 6:30
    Networking Reception (Exhibit Area)
    Track 2 - PREPARING FOR INDUSTRY 4.0

    Is your organization caught in a constant chase after the next new thing. Do you find your team wanting to buy more technology because, let’s be honest, “it’s cool?” Do you find your projects are not getting the returns you or your team expected?

    “You cannot effectively use new technology if you have not first implemented the basics.”
    In this presentation, we will talk about some of the flashy new tech that is entering manufacturing and what is required to get real results and a solid ROI. During this interactive session you can expect to hear more about things like additive manufacturing, Augmented Reality, Industry 4.0, Internet of Things and a whole glitter bomb of other new shiny stuff. In response to this technology we will talk about the web of reliability, the importance of process, the importance of a plan, the criticality of master data and other less sparkly but absolutely critical steps to success. Bring your biggest “glitter slingers” and let’s have a talk about the real root causes of success.

    Bio:

    Shon specializes in Adult Learning, Leadership, Asset Management and Reliability Engineering and has lead improvement initiatives for industries such as pharmaceuticals, metals, petrochemical, automotive, paper, and power generation, among others. Shon has spoken at numerous professional conferences on these topics in the US as well as Europe, South America, and the Middle East.

    Shon is an engineering graduate of North Carolina State University and has become an expert in the implementation of holistic reliability solutions using tools such as Total Productive Maintenance (TPM), Reliability Centered Maintenance (RCM) and Root Cause Analysis (RCA), as well as Six Sigma and Lean to drive significant bottom line results.

    Shon is a Past Chairman of the National Board and past Director of Education for the Society of Maintenance and Reliability Professionals and is a past committee vice chairman in the area of benchmarking. Shon also serves on the boards of other global asset management and education organizations including the Global Forum on Maintenance and Asset Management (GFMAM), Association for Talent Development (ATD), and World Partners in Asset Management (WPiAM). Shon is a Certified Maintenance and Reliability Professional (CMRP), Certified Asset Management Assessor (CAMA) and has been certified by Prosci and Colorado State University as a Change Management Professional (CMP).

    Shon is a Plant Engineering Future 30 honoree and a USA Science and Engineering Festival Nifty 50 Speaker as well as being the recipient of the Solutions Magazine Best Article Award.

    Shon currently writes and manages one of the most visited industry specific blogs: www.ReliabilityNow.com. The blog is viewed monthly by over 6,000 visitors and contains over 200 posts on topics ranging from manufacturing to leadership, reliability, and education.

    When away from the asset management world Shon lives reliability as a helicopter and airplane pilot and an avid fisherman. Nobody likes to be stranded in the air or on the water.
    For a full job history including skills and recommendation please see my LinkedIn page at http://www.linkedin.com/in/shonisenhour

    Shon Isenhour, Eruditio
    10:45 –11:00
    Break (Exhibit Area)
    12:45 – 1:45
    Lunch (Ballrooms E & F)
    1:45 – 2:00
    Break (Exhibit Area)
    2:00 – 2:45
    Paper 8 - TBA
    2:45 – 3:15
    Refreshment Break (Exhibit Area)
    3:15 – 4:00
    Paper 11 - TBA
    4:00 – 4:15
    Break (Exhibit Area)

    The United States Coast Guard does not adequately perform a Level of Repair Analysis and Business Case Analysis to align vessel maintenance requirements with available resources during the development of an Integrated Logistics Life Cycle Plan (ILSP) which leads to increased vessel sustainment costs and reduced workforce proficiency. The ILSP’s maintenance philosophy dictates the designed supportability and maintainability of a vessel throughout its life cycle yet existing ILSPs fail to prescribe the required balance of Coast Guard (internal employees) and non-Coast Guard (contracted) technicians for the execution of hull, mechanical, and electrical depot maintenance. This research develops a standard model to enhance the balance of maintenance resources using a Business Case Analysis (BCA) extension of a Level of Repair Analysis (LORA) informed by Activity-Based Costing Management (ABC/M) theory. These analyses are integral to a complete Life Cycle Cost Analysis (LCCA) and will contain a simplified LORA framework that provides an analysis of alternatives, a decision analysis, and a sensitivity analysis for the development of a maintenance philosophy. This repeatable analysis can be used by engineering managers to develop and sustain cost-effective maintenance plans through all phases of a vessel’s life cycle (acquisition, sustainment, and disposal).

    Keywords: Engineering logistics, maintenance analysis, level of repair analysis

    Bio:

    Lucas Marino is a successful engineering manager, military officer, and educator. He specializes in reliability engineering, engineering logistics, project management, and training systems development. He is experienced at every level of the shipboard maintenance chain from propulsion mechanic to Chief Engineer. Dr. Marino is both an active duty Coast Guard naval engineer officer and Principal Consultant at Marino Consulting Services, LLC.

    He currently serves as Deputy Branch Chief of the Coast Guard’s Engineering and Weapons School located in Yorktown, VA. He served afloat in Coast Guard cutters LEGARE and GALLATIN prior to serving as Engineer Officer (Chief Engineer) on CGC TAMPA. He served ashore as a Machinery Technician School Instructor, Port Engineer, and Naval Engineering Workforce and Policy Manager at Coast Guard Headquarters. He holds a Bachelor of Science degree in Industrial Management, a Master of Science degree in Systems Engineering, and a Doctor of Engineering degree in Engineering Management from George Washington University.

    Lucas C. Marino, U.S. Coast Guard / Marino Consulting Services, LLC
    5:00 – 6:30
    Networking Reception (Exhibit Area)
    Track 3 - CONDITION MONITORING

    New technologies are allowing technologies like vibration analysis to be offered with off the shelf hardware. These new solutions offer affordable and powerful solutions for predictive maintenance. In this presentation, John Branan of Armstrong World and Paul Berberian of GTI Predictive Technologies, will illustrate how these new technologies are being used together to detect, diagnose and correct mechanical faults. The presentation will include case studies detailing the process of going from detection to diagnosis, using tablet-based and on-line vibration tools to diagnose and monitor machine condition.

    Bios:

    John Branan
    Vibration Analyst 3
    Armstrong World Industries

    John Branan has been with Armstrong World Industries for 15 years. He is a certified Level III vibration analyst with a degree in Business Administration. John launched the Armstrong vibration program 10 years ago and built their current databases. He has been in charge of maintaining the entire vibration program for the past 4 years.

    Paul Berberian
    Condition Monitoring Specialist
    GTI Predictive Technology

    Paul Berberian is a reliability maintenance professional, speaker and author. Paul has been working in this community for 15 years and has experience and training in vibration, balancing, ultrasound and shaft alignment. Paul currently manages GTI Predictive Technology and is instrumental in the development of new solutions for predictive maintenance.

    John Branan, Armstrong World / Paul Berberian, GTI Predictive Technologies
    10:45 –11:00
    Break (Exhibit Area)

    Imagine, instead of measuring or feeling even the most minuet vibration, you can see it. It is now possible with Motion Amplification. Motion Amplification is a video-processing product package that detects subtle motion and amplifies that motion to a level visible with the naked eye. Every pixel becomes a displacement sensor creating millions of data points in an instant. This technology creates multiple benefits for the Wood Products / Lumber industry and therefore expands the number of machine troubleshooting applications that can be tackled. Several of these case histories will be presented from Weyerhaeuser along with explanation of Motion Amplification technology.

    Bio:

    Keith Staton
    Weyerhaeuser

    Keith Staton is a Reliability Director for Weyerhaeuser Wood Products. He has over 25 years of experience in automotive die casting, wood products, and related manufacturing. Keith possesses a solid background in automation, process controls, and working in multi-plant operations at all levels. Keith is a graduate of University of Kentucky, a CMRP, CRL, Level II Vibration Analyst, MLT I and MLA II.

    Keith Staton, Weyerhaeuser / Dan Nower, RDI Technologies
    11:45 – 12:45
    Lunch (Ballrooms E & F)
    1:45 – 2:00
    Break (Exhibit Area)

    At the Oak Ridge National Laboratory (ORNL), ground breaking research goes on every day. ORNL’s High Flux Isotope Reactor (HFIR) currently has a 99.4% reliability rate. One reason that the reliability/availably rate is so high is because of our mature Predictive Maintenance Technologies program at the facility. We utilize vibration analysis, ultrasound analysis, infrared thermography, oil analysis, static and dynamic motor testing and motion amplification technologies to monitor, analyze, diagnose, and schedule the repair of equipment before it becomes a problem that could shut down the reactor. HFIR has specialized equipment from our Cold Source refrigerators that cool helium to 15o Kelvin to servo-controlled fuel rod drives to pony motors. We use Pdm Technologies in specialized ways on this specialized equipment. From utilizing infrared thermography on pony motor battery banks, doing ultrasonic lubrication, using advanced vibration analysis techniques like phase analysis and ODS/Modal studies and using motion amplification to confirm a resonance condition are just a few examples of how we have infused PdM technologies into our everyday maintenance strategies and operations at HFIR. In addition to condition monitoring technologies, we also utilize precision maintenance technologies such as laser alignment and precision balancing. Another aspect of our program is reliability techniques such as forensic analysis and root cause analysis.

    Operations, maintenance, safety, and engineering work together to keep our availability at 99.4%. The human factor is another focus of this presentation. Management encourages an engaged workforce. When operations do daily rounds, if they see or hear something that they think needs further investigation, they will contact engineering and maintenance. Engineering and Maintenance collaborate to investigate and evaluate the problem to come up with a path forward to resolve the issue. That path forward is communicated with everyone from the operator who did the rounds to the plant manager.

    With the combination of an engaged workforce, an integrated application of PdM technology and an active feedback loop help keep HFIR at 99.4% current availability.

    Bio:

    Michelle E. Foster
    ORNL HFIR Maintenance Reliability Engineer

    Michelle Foster is currently the Condition Monitoring and Analysis Lead in the Neutron Sciences Directorate, Research Reactors Division at Oak Ridge National Laboratory’s High Flux Isotope Reactor.

    In her 27 years of experience, Michelle has worked in the predictive maintenance, precision maintenance and reliability fields that include 19 years as a Mechanical Maintenance Engineer/Vibration Analyst at the Y-12 National Security Complex, 3 years as a Reliability Engineer at the Ascend Materials Chocolate Bayou Plant located outside of Houston, Texas, and 5 years at Oak Ridge National Laboratory High Flux Isotope Reactor.

    Michelle holds a Bachelor of Science degree from the University of Tennessee in Mechanical Engineering. She is a certified Level 3 vibration analyst, Level 2 thermographer, Level 1 Ultrasound, Level 1 Machinery Lubrication, and Level 1 Static and Dynamic Motor Testing. She also received the Martin Marietta Award of Excellence, the Y-12 Award of Excellence, two Special Recognition Awards for significant improvements in the Vibration Analysis Program.

    Michelle Foster, ORNL
    2:45 – 3:15
    Refreshment Break (Exhibit Area)

    In many organizations, it is challenging to switch to a proactive maintenance and reliability focus when a “fix it when it breaks” mentality has prevailed for many years. We often talk about it but seldom achieve success. One of the consistent tools to help drive that transition is reliability centered maintenance, in this case, RCM2. In this presentation, we will seek to provide an overview of RCM2 and share insights on what it looks like when implemented in an industrial setting. The presentation will be delivered by a currently practicing RCM2 Facilitator and an Aladon Network Member Certified Practitioner. The Aladon Network is a global network of Practitioners delivering consulting and education on RCM2 and RCM3.

    Abstract:

    The only operating cement plant in Georgia had its start in 1925 and is in Clinchfield. The plant is operated by CEMEX with 900,000 tons of capacity annually. As one can imagine, the site has seen many changes over its long history. The nature of the process and operating environment are not kind to the equipment from a reliability perspective. Keeping the plant’s kiln, roller mill, and finish mills running requires dedication and due diligence on the part of the plant’s maintenance and reliability personnel. Ensuring the asset availability requires that the maintenance function take steps to proactively ensure the assets are running efficiently with little margin for error from a maintenance perspective.

    Historically at many industrial facilities, the approach to maintenance has been reactive, “fix it when it breaks.” In contrast, organizations seeking world-class manufacturing implementation apply condition-based monitoring and other maintenance strategies in a holistic approach. The goal becomes to predict the potential for failure and proactively seek to repair assets before they functionally fail or degrade to the point the asset can no longer meet the production requirements. Reliability centered maintenance (RCM2) is utilized as a tool to drive asset performance. John Moubray developed RCM2 with the assistance of Stanley Nowlan for industrial assets around 1984. Nowland and Heap are credited with developing reliability centered maintenance for aviation use earlier, around 1978. RCM2 is an excellent tool to help transition an organization from reactive to proactive, ensuring the right maintenance at the right time in the right manner.

    Attendees will gain an overview of RCM2 to include the seven questions as a basis for the improvement methodology. Also, attendees will also gain insights in what worked and just as important, what did not when implementing RCM2 to extend the performance of the assets at the CEMEX Clinchfield cement plant.

    Bio’s:

    James Kordsmeier, CMRP, RCM2 Facilitator
    jamesp.kordsmeier@CEMEX.com

    James Kordsmeier is a Reliability Engineer with CEMEX USA currently positioned at the cement manufacturing plant in Clinchfield, GA, with his daily focus being on Reliability Centered Maintenance. He is a Certified Maintenance & Reliability Professional (CMRP) through the Society of Maintenance and Reliability Professionals (SMRP). James holds a BSME with a minor in Entrepreneurship from Louisiana Tech University. James has led teams on various reliability improvement projects. He started his journey on becoming a reliability professional in 2013 when joining SMRP. Since then he has obtained several certifications and countless hours training and practicing reliability activities. These certifications include but are not limited to two Six Sigma Green Belt certifications, Machinery Lubrication Technician Level 1 (MLT1), Ultrasonic Testing Level 1 (UT1), and Vibration Analyst Level 2.

    Jeff Shiver, CMRP, CPMM, RCM2 / RCM3 Practitioner
    jshiver@peopleandprocesses.com

    Jeff Shiver, CMRP, CPMM, CM2 / RCM3 Practitioner guides people and organizations to overcome their reliability and operational challenges. Working together in partnership, we move beyond the status quo in culture, business results, and most importantly, people.
    Jeff has over 25+ years of practitioner experience. Within Mars North America, he worked at four plant locations and held two corporate roles. Job functions included Engineering, Maintenance, and Operations management. Before Mars, he held contract engineering positions at Proctor and Gamble, and IBM.

    Founding People and Processes, Inc. in 2006, Jeff is a trusted advisor for the Maintenance and Reliability community. He is a book author, conference speaker, thought leader, and published in domestic and international trade journals. Jeff is also the Membership Services Director for the Society of Maintenance and Reliability Professionals (SMRP).

    James Kordsmeier, CEMEX USA / Jeff Shiver, People and Processes, Inc.
    4:00 – 4:15
    Break (Exhibit Area)

    Traditional methods of maintaining equipment (Maintenance PM) are time based and typically include schedule driven inspections that often create excessive labor burden on the maintenance workforce. In most cases, the workforce may lack the necessary training and equipment needed to perform the task without injecting human error.

    The use of non-running PMs can be excessive in nature and typically do not address critical components or mitigate risk of sudden failure. The use of Failure Modes & Effects Analysis (FMEA) as a tool to prioritize and mitigate risk is a prominent method utilized within asset management. However, FMEA’s alone are not the solution for maintenance optimization.

    Effective asset management plans should be methodical in design and designed to use the latest tools available and minimize human interaction. Plans should maximize uptime and reliability and minimize Total Cost of ownership. This paper reviews a system for using risk priority numbers (RPN) as a guide for developing an asset management plan. It involves prioritizing RPNs and then utilizing an evaluation process that factors in downtime, safety risk, member skill requirements and technology availability to reduce labor by identifying what level of preventive maintenance is needed, and defining an action plan to support the asset management plan.

    The method presented in this paper will also consider the results of case study applications and illustrate how future asset management practices can provide a clear picture of the tasks required to mitigate risk, reduce skill development cost, implement multiple PdM methods and improve equipment reliability. Remote monitoring, equipment self-diagnostic and TPM all reduce Total Cost of Ownership and increase output by improving Equipment Operational Availability while reducing labor costs by as much as 30%. However, the challenge remains on defining what systems require certain levels of maintenance optimization and how to balance this with internal company metrics and workforce skills. The methodology explained within this paper was developed by Toyota Motor Manufacturing and supported by Mississippi State University (MSU).

    Bio:

    Mike Burgett
    Toyota

    Mike Burgett, (Cross Functional Lead for Maintenance) at Toyota Motor Manufacturing Blue Springs MS.

    Mike has 21 years in experience in machine tool industry and 23 years in automotive manufacturing with Toyota. He has provided support for two plant start-ups while at Toyota and currently is focusing on Reliability at the Blue Springs Plant. His management style is driven by data, identifying gaps in the metrics and using visual control to tell the story. He is passionate about developing teams and self-sustaining processes. Mike finished his studies in Industrial Maintenance and Project Management while at General Electric in Evendale OH., before coming to Toyota. Mike has combined experience of performing maintenance and maintenance management, he considers himself a practitioner, not just a manager. Mike is currently an CMRP and Education Director for Southern Chapter of SMRP. He is working on RMC-Leader certification through UT.

    Mike Burgett, Toyota
    5:00 – 6:30
    Networking Reception (Exhibit Area)
    Track 4 - ENGAGE SESSIONS

    Today’s organizations tend to emphasize “efficiency” above all else. Efficiency – per the usual interpretation – has a human cost which is overridden by the emphasis on production targets and customer satisfaction. The results in a disengaged and stressed workforce in which turnover rates continue to rise. This workshop presents an operational excellence model which posits that productivity and employee quality of life can go hand in hand.

    The model has been developed at the Center for Advanced Systems Research and Education (CASRE) at the University of Tennessee. Prof. Rupy Sawhney, who has led the development of the model, will guide the participants through an interactive, two-session workshop.

    Session 1 will introduce participants to the fundamental principles of the model:
    • The conflict between ideal people systems and ideal operational systems, and how this leads to turnover
    • Overview of the four modules which comprise the model
    • Module 1: How to identify a single project which improves performance
    • Module 2: How to characterize the project and build leading and lagging indicators to assess it
    • Module 3: How to solve system issues and reduce human effort: A reliability-based approach
    • Module 4: How to sustain and achieve employee buy-in based on organizational and societal culture

    Dr. Rupy Sawhney, University of Tennessee, Center for Advanced Systems Research and Education
    10:45 –11:00
    Break (Exhibit Area)

    Today’s organizations tend to emphasize “efficiency” above all else. Efficiency – per the usual interpretation – has a human cost which is overridden by the emphasis on production targets and customer satisfaction. The results in a disengaged and stressed workforce in which turnover rates continue to rise. This workshop presents an operational excellence model which posits that productivity and employee quality of life can go hand in hand.

    The model has been developed at the Center for Advanced Systems Research and Education (CASRE) at the University of Tennessee. Prof. Rupy Sawhney, who has led the development of the model, will guide the participants through an interactive, two-session workshop.

    Session 2 will showcase the model at work, by way of a case study conducted in collaboration with an industry partner. The partnering company has several production facilities in the US. We tested our model at one facility and were able to show that a significant jump in throughput was possible. This improvement was concurrent with lower employee effort and therefore experienced no resistance to change from the workforce. In this session, we will share a step-by-step narrative of the experience, coupled with group participation in illustrative activities.

    By: Dr. Rupy Sawhney, University of Tennessee, Center for Advanced Systems Research and Education
    11:45 – 12:45
    Lunch (Ballrooms E & F)
    1:45 – 2:00
    Break (Exhibit Area)
    2:00 – 2:45
    Technology Demonstration 1
    2:45 – 3:15
    Refreshment Break (Exhibit Area)
    3:15 – 4:00
    Technology Demonstration 2
    4:00 – 4:15
    Break (Exhibit Area)
    4:15 – 5:00
    Round Table 1
    5:00 – 6:30
    Networking Reception (Exhibit Area)
    8:00 – 8:20
    Plenary Session “R&M Competitive Excellence – Enablers to Win” Klaus Blache, Director, University of Tennessee Reliability & Maintainability Center --- Recognition of New RMC Member Companies and RMIC Graduates

    Due to Detour Gold’s low grade ore, the demand to increase production is continuously increasing and maintenance costs are high. As a result, the reliability department has and continues to implement several upgrades to improve throughput and lower maintenance costs, while maintaining a safe working environment.

    This presentation will give a brief overview of the overall operation of the process plant and discuss some of the improvements made. This session will also include the quality control methods used for plant shut downs and off site rebuild programs with business partners. Furthermore, it will cover the ongoing inhouse maintenance strategy optimization activities.
    Please join us as the 2018 Emerson Reliability Program of the Year winner, Detour Gold, shares how they increased throughput by 30%, in their 24/7/365 operation.

    James Nord, Reliability Specialist & Danielle Ouellet-Lemieux, Reliability Engineer-in-Training, Detour Gold
    3:00 – 3:45
    PANEL DISCUSSION
    3:45 – 4:15
    MARCON Closing / Prizes / Giveaways
    9:30 – 10:00
    Refreshment Break (Exhibit Area)
    Track 1 - LUBRICATION STRATEGY

    Plain common sense says that lubrication programs need support from plant and corporate-level managers to succeed. Is a lack of support from management restraining your lubrication initiatives? In this session, you’ll learn how to confidently cost-justify, explain and defend your lubrication project. You’ll also learn how to calculate lubrication program ROI, stop lubrication program budgets from getting slashed, and help management understand the impact of an effective lubrication program on maintenance and reliability.

    Bio:

    Thomas Kurtz
    Noria Corporation

    Thomas Kurtz has been with Noria Corporation since 1998 and is the Director of Business Development in charge of customer relations and provides significant input into technical services development. Thomas holds Machinery Lubrication Technician Level II and Machinery Lubricant Analyst Level II certifications from the International Council for Machinery Lubrication.

    Thomas Kurtz, Director of Business Development, Noria Corporation
    10:45 – 11:15
    Break (Exhibit Area)

    In 2013, Jacobs Engineering Group became the primary contractor for management and maintenance of ground systems, flight hardware, and launch operations on the Test & Operations Support Contract (TOSC) at Kennedy Space Center. By 2017, Jacobs had earned the International Council for Machinery Lubrication’s (ICML) Augustus H. Gill Award for Oil Analysis Excellence. What took place between those years is an impressive display of resourcefulness: Jacobs developed a centralized oil analysis program entirely on its own, without hiring professional consultants, choosing instead to capitalize on independent training and ICML certifications. The resulting program and facility are jointly known as the TOSC Oil Pharmacy, and its story reflects a DIY approach to excellence.

    Paul Hiller, International Council for Machinery Lubrication
    12:00 – 1:00
    Lunch (Ballrooms E & F)
    Track 1 - RELIABILITY OF ROTATING EQUIPMENT

    Machinery repairs can measurably improve machine uptime, if critical control points are observed to ensure proper shaft and housing repairs for machines with rolling element bearings. Starting with a typical industrial machine, the electric motor, the repair process will be examined, focusing on shaft and housing conformance.

    Joe Conyers, SKF
    1:45 – 2:00
    Refreshment Break (Henley Concourse)

    Elastomeric couplings are generally used in applications where misalignment or vibration are present. Their advantage is how these couplings efficiently dampen or isolate the energy transfer between the driver and driven shafts. In some rare cases their radial stiffness is not symmetric and a new and unique vibration issue is created. This is such a case. A newly installed elastomeric coupling design caused high motor shaft vibration as the motor speed (load) increased. The vibration exceeded the motor shaft trip set point before full speed and limited power output of the 500 MW unit. Numerous potential causes were investigated including unbalance, misalignment, thermal growth and coupling concentricity while suppliers argued if there was a problem and if so who was responsible. The elastomeric coupling inserts were found to be the actual cause and improved quality control of the elastomer eliminated this vibration problem.In maintenance and reliability, buzzwords and “new” methods arise frequently. Many companies look for a quick fix to what must be a team-wide culture shift. Information about what data really matters and how to execute maintenance and reliability strategies has often been missing. Many teams feel pressure to implement condition-based techniques when they may just be getting scheduled maintenance off the ground, or they do not begin because they cannot use condition monitoring on all assets. How can teams in various states of reactive, preventive and predictive strategies move forward on their reliability journey? One way is to focus on asset capacity assurance.

    This presentation will discuss how capacity assurance provides a framework of connected reliability and the industrial internet of things (IIoT) can help maintenance and reliability (M&R) teams drive value and support them on the journey of maintaining inherent availability.

    Talmadge Ward, Duke Energy
    3:00 – 3:45
    Refreshment Break (Henley Concourse)
    9:30 - 10:00
    Refreshment Break (Exhibit Area)
    Track 2 - IMPLEMENTATION & OPTIMIZATION
    10:45 – 11:15
    Break (Exhibit Area)
    12:00 – 1:00
    Lunch (Ballrooms E & F)
    1:00 – 1:45
    Paper 23 - Essential Reliable Manufacturing Skills (ERMS) Case Study - TBA
    1:45 – 2:00
    Refreshment Break (Henley Concourse)
    2:00 – 2:45
    Paper 26 - Preventive Maintenance Optimization - TBA
    2:45 – 3:00
    Refreshment Break (Henley Concourse)
    9:30 – 10:00
    Refreshment Break (Exhibit Area)
    Track 3 - WORK MANAGEMENT

    In maintenance and reliability, buzzwords and “new” methods arise frequently. Many companies look for a quick fix to what must be a team-wide culture shift. Information about what data really matters and how to execute maintenance and reliability strategies has often been missing. Many teams feel pressure to implement condition-based techniques when they may just be getting scheduled maintenance off the ground, or they do not begin because they cannot use condition monitoring on all assets. How can teams in various states of reactive, preventive and predictive strategies move forward on their reliability journey? One way is to focus on asset capacity assurance.

    This presentation will discuss how capacity assurance provides a framework of connected reliability and the industrial internet of things (IIoT) can help maintenance and reliability (M&R) teams drive value and support them on the journey of maintaining inherent availability.

    Frederic Baudart & Greg Perry, Fluke Corporation
    10:45 – 11:15
    Break (Exhibit Area)

    Many plants rely on their work order system to schedule mechanical/electrical equipment inspections, operator rounds, and lube routes, with the actual inspection details being kept in a separate system such as spreadsheet-based forms. When the work order is generated, the operators or technicians print the appropriate inspection forms and record the point by point information as they walk the route, including notes about potential problems. Unfortunately, this valuable equipment condition information is now trapped on the paper form and not easily communicated to those in a position to make maintenance execution decisions.

    “The paper reports seem to go into a stack of papers on a supervisor’s desk and sometimes they are not reviewed the way they should be.” – Reliability Engineer, South Carolina Paper Mill
    To remedy this problem reliability engineers at a plastics plant and a paper mill moved their existing inspection details to a web-hosted database system, using Android, IOS, or Windows tablets for field collection. This resulted in the collected information being distributed via automated emails and web browser – a broad audience involved in maintenance decisions could see problems found during inspections on a dashboard alongside issues being reported by higher tech condition monitoring such as vibration analysis, thermography, or oil analysis. Walk-around equipment inspections became just as important as their higher tech systems in driving reliability decisions.

    In addition to driving condition-based maintenance action, the reliability engineers also found the web-hosted database inspection information to be invaluable during insurance or internal audits:
    “The biggest thing was being able to pull stuff out while they’re (auditors) standing there, live, and showing them on the screen. Everything was right out in the open. We could say, “pick one” and go in and see when it was inspected. During the report out, we would usually be called “best of class” or “best within the company” by just having our data organized in one place.”
    -Reliability Engineer, Illinois Plastics Plant

    Proposed Topic Areas:
    Asset Care Execution
    Technology and Data Implementation / Applications

    Bio’s

    Forrest Pardue: After earning a BSEE at North Carolina State and then an MBA, Forrest has worked in the field of vibration analysis and predictive maintenance for more than 30 years. As one of the founding members of Computational Systems, Inc (CSI), he was actively involved in the technical and market development of modern condition monitoring technologies. Following Emerson Electric’s acquisition of CSI in 1998, Forrest co-founded 24/7 Systems. He recognized that the greatest challenge facing industrial maintenance had shifted to the measurement, management, and improvement of plant asset reliability. 24/7 Systems is focused on the development and delivery of Reliability Information Management software and services.

    Dick Hancock: A 1972 graduate of the University of Georgia, Dick has over 35 years’ experience in the operation and maintenance of industrial machinery. In the 1980’s he worked for a Caterpillar dealership in Texas and Louisiana, providing large horsepower gas compressor packages for oilfield service. In the 1990’s he helped Computational Systems, Inc (CSI) grow into the leading provider of predictive maintenance systems. Following Emerson Electric’s acquisition of CSI, he served as VP of Marketing. Currently Dick is a sales and marketing consultant working with 24/7 Systems, Inc. to provide web-based Reliability Information Management services to manufacturing plants and their condition monitoring contractors.

    Forrest Pardue & Dick Hancock, 24/7 Systems
    12:00 – 1:00
    Lunch (Ballrooms E & F)

    Over the past few months, it has been a focus to improve Y-12’s maintenance history tracking. Currently, there are numerous gaps and inconsistencies in the data gathered within the Computerized Maintenance Management System (CMMS). CMMS cause and damage codes are being reformatted and created to fill in the gaps and create an efficient, accurate, and reliable database.

    Phase I: Cause and Damage Codes

    Failure is a part of asset life, knowing exactly how and why an asset failed can allow for measures to be taken to prevent or reduce failure occurrences. This is form of tracking requires a standard method to remain usable and consistent across the site. Causal and damage codes are an excellent way to establish this standard. These codes denote a specific part of a system, how it has failed, and why it has failed. This level of detail is necessary as it provides an accurate, clear picture of what is going on throughout the site, as well as allowing for very specific searches of common failure modes and causes. This presentation provides a background on the development of a causal and damage code system and how to develop a personalized system for your facility that will allow you to further increase the facilities system reliability as well as keep a clear record of asset performance and failures.

    Phase II: Consistent Data

    Maintenance history tracking allows one to see common causes that can lead to an assets failure. For history tracking to be utilized, there must be a system in place that identifies the repeated causes and damages. In the past, reliability data was not a primary focus, which led to gaps and inconsistency in the data. Our work has focused on creating detailed cause and damage codes for specific equipment that could be utilized for history tracking. History tracking has proved to provide insight on equipment failure and has the potential to contribute in the extension of an assets life. If the common failures of a specific asset are known, steps can be taken to avoid these failures and extend the assets life.

    Phase III: Utilization

    The causal and damage codes will be a living database able to be used for Corrective Maintenance (PM Follow up and Reactive). The process has been defined to the point that a specific piece of equipment can be selected, and the next required box to fill will be limited to object parts contained within that piece of equipment. This will then limit the list to only the relevant failure modes, which will further limit the causes to events that could cause the specific chosen damage. These will all be available in drilldowns within a future state mobile worker device, which could potentially even limit available equipment drilldowns based on the assigned location of the device. The database is dynamic or “living” because these drilldowns will contain an “other” option. This option is available in each the object type, damage, and cause codes. However, it cannot stop there or the “other” option will be unusable. The “other” option then goes on to open a required text box that can be filled in with a new code that was either missed or operating condition specific that was not included in the original database construction. This allows the database to continue to expand as one’s processes develop, thus keeping up to date with the current systems and not needing large overhauls whenever additional failures and new equipment need to be added.

    Evalynn Borrego & Andrew Walters, CNS Y-12 Reliability Interns, University of Tennessee
    1:45 – 2:00
    Refreshment Break (Henley Concourse)
    2:00 – 2:45
    Paper 27 - TBA
    2:45 – 3:00
    Refreshment Break (Henley Concourse)
    9:30 – 10:00
    Refreshment Break (Exhibit Area)
    Track 4 - ENGAGE SESSIONS
    10:00 – 10:45
    Technology Demonstration 3
    10:45 – 11:15
    Break (Exhibit Area)
    11:15 – 12:00
    Technology Demonstration 4
    12:00 – 1:00
    Lunch (Ballrooms E & F)

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    • 701 Henley St, Knoxville, TN 37902
    • rmc@utk.utk
    • (865) 974-9625
    • 8:00am - 5:00pm