Why reliability-centered maintenance

should be a top priority

70%
Assets and Investments Chronic
Failures
that Impact You
Industry Facts and Figures

Production (Uptime) Losses

$11,000 70% 50%

PER HOUR of maintenance costs are on HIGHER
of downtime costs for a large valves, pumps, compressors, failed assets repair costs
natural gas power plant exchangers, piping, vessels when not addressed early
and fired equipment
Source: Improve Reliability with Source: Improve Reliability with Essential
Source: KCF Technologies Blog, Asset Monitoring, Nikki Bishop, InTech,
Essential Asset Monitoring, Nikki
March 2013 June 2012
Bishop, InTech, June 2012

70% 25% 8-12%

of uptime failures unplanned outages are due of product costs
are chronic to equipment failure are maintenance costs
in a plant
Source: Improve Reliability with
Essential Asset Monitoring, Nikki Bishop, Source: Constance E. Dyer,
Source: Doug Martin, E.I. Dupont
InTech, June 2012 Quality Digest
de Nemours and Company.

Top 9 Preventable Downtime Causes

Hydraulic Leaks

1 Fastener Loosening
#1 Cause Of Catastrophic Failure 6 1 drop per second @ $5 per gallon =
$2025 per year per leak

Air Leaks

2 Keyway Wallow
Downtime + Replacement Parts 7 1/16” 100 psi @ $0.065 per kWh =
$842 per year per leak

3 Spun Bearings
Downtime + Replacement Parts 8 Gasket Leakage
Downtime + Replacement Parts

4 Fretting Corrosion
Downtime + Replacement Parts 9 Delayed Repairs
Downtime

5 Tape Fouled Valves

Downtime + System Flush

Reliability-centered maintenance
as a top priority
PREVENTATIVE PROACTIVE
“Protect from Neglect” “Prevent the Unpredictable”

WORLD CLASS
MANUFACTURING

REACTIVE PREDICTIVE
“Fix after failure” “Replace prior to failure”

Advantages of Predictive Maintenance

 Mining Industry

IMPACT OF $8M annually Hydraulic power and belt drive

UNPLANNED Productivity improvement failures cause up to 47%

DOWNTIME spending per concentrator
downtime cause in mining industry

Source: The Power of GE PredictivityTM, No Unplanned Downtime 2014

PREDICTIVE
MAINTENANCE
Increased Stability Poorly maintained concentrator Lost production
increases energy and
Increased Profitability maintenance costs
= lower energy and maintenance costs

 Power Generation Turbine Engine

For a utility, with average spark spread of

IMPACT OF
UNPLANNED
$1M per day $13.15/mwhr, the lost profit opportunity is

DOWNTIME
Lost revenue per power plant $45k per day
Source: The Power of GE PredictivityTM, No Unplanned Downtime 2014

PREDICTIVE
MAINTENANCE
Identifying parts that are starting to Lost production Addition maintenance
cycles
degrade

Lower maintenance cost and improved

availability and utilization

 Refinery Processing Technologies

IMPACT OF
UNPLANNED
$800k per day
In lost profit for a refinery processing 200,000 barrels per day of crude
DOWNTIME
Source: The Power of GE PredictivityTM, No Unplanned Downtime 2014

PREDICTIVE
MAINTENANCE
Cost of repairs for Interrupted Capital asset
unplanned events
Extended production runs = 10 x planned production replacement
maintenance costs
Minimized cost for cleaning and repairs

 Railway Industry

IMPACT OF $400M per year

UNPLANNED In reliability costs due to mainline
Network congestion and failures
DOWNTIME failures

Source: The Power of GE PredictivityTM, No Unplanned Downtime 2014

PREDICTIVE
MAINTENANCE
Lost train Loss per train Customer order
Improved network velocity and capacity availability per year fulfillment misses
& crew costs
Lower maintenance costs and improved
availability and utilization

 Food Manufacturing

Ten minutes per day

$35 per minute = $87,500 annually
IMPACT OF Costs once a packaging line,
UNPLANNED in profit loss
running a product contributing
DOWNTIME 10c each at 350PPM, is stopped
= 40 hours annually
in production loss

Source: The Power of GE PredictivityTM, No Unplanned Downtime 2014

PREDICTIVE
MAINTENANCE
Reduced Energy cost per unit Breakdown in Increased inventory Lost production
packaging line and labor costs
Reduced Maintenance cost

Reduced Labor cost

15% Inventory reduction

30% Improved overall equipment effectiveness

Henkel General Industry Maintenance, Repair and

Overhaul (MRO)

 Repair, rebuild, maintain and protect your assets with

LOCTITE revolutionary solutions, reaching far
beyond a single application.

MAINTAIN REPAIR
MACHINERY BONDING
ADHESIVES & SEALING

REBUILD PROTECT
COATINGS, LUBRICANTS
REBUILD & WEAR COMPOSITES & CLEANERS

 Our solutions reduce cost,

increase efficiency, improve safety
and increase reliability.

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