Tire Manufacturing – Predictive Maintenance Program

Business Challenge

Apply a proactive equipment maintenance strategy that utilizes the proper combination of preventive maintenanceTime or cycle-based actions performed to prevent system functional failure. This proactive maintenance type generally includes scheduled restoration and scheduled discard tasks. Learn more: What is Preventive Maintenance? (PMPreventive Maintenance) and Predictive MaintenanceThe use of instruments and analysis to determine equipment condition in order to predict failure before it takes place so corrective maintenance can be done in a planned and scheduled fashion. Examples include vibration analysis, oil analysis, thermography, airborne ultrasonic’s, NDT, motor current signature analysis, trending of process parameters, etc. (PdMPredictive Maintenance) to identify equipment defects as early as possible.

Solution: Approach

Route-based Predictive Maintenance (PdM) was applied to >90% of the tire manufacturing equipment. Vibration, infrared, ultrasoundSimilar to vibration analysis, ultrasound is a sound wave or frequency generated by the release of energy. As a predictive maintenance technology, ultrasonic testing can be both passive, listening, or active by emitting an ultrasonic pulse and analyzing the echo return. Ultrasound is often used to find compressed air or steam leaks, or to identify structural defects within a material., motor circuit analysis, and oil analysis technologies are all deployed according to criticality ranking and failure modes. Equipment defects identified by the Allied-led PdM program are automatically pushed into the client’s CMMSComputerized Maintenance Management System as work notifications to be planned and scheduled by the client’s planners.

• Outsourced condition-based maintenance (CBMCondition Based Maintenance) personnel: Allied Reliability currently provides 14+ CBM professionals to four US locations to conduct all necessary data collection, analysis, and reporting. Allied personnel are located on-site and execute work to the established standards.
• Integrated Asset Health Reporting: Client has adopted Allied standards, tools, and processes for reporting asset health as a strategic key performance indicatorHistorical data that provides current status and trend information regarding the effectiveness of work processes, e.g. productivity/operating costs, maintenance labor and material costs, and performance/availability data. (KPI).
• Advanced Technology & Processes: Vibration data collection with permanent-mount sensors for 731 critical mixing assets. Sensors include temperature readings and collect data once per day. Additional sensors for temperature only applied to monitor critical assetAssets identified as critical by reliability engineering that, when unable to perform, cause severe consequences for the plant or facility and lead to a shutdown of production. and process health characteristics.
• Continuous Improvement Assessment / Audit Process.
• Immediate notification of anomalies and PMs issued upon occurrence.

Solution: Enabling Tools & Technologies

• Allied Reliability’s SmartCBM® Suite:
  • Wireless sensor vibration and temperature data capture with first pass analysis by software algorithm and advanced analysis by Allied SMESubject Matter Expert.
  • Asset health management cloud-based platform enterprise.
• Allied Reliability monitoring and analysis of all PdM data.
• Condition monitoring technologies: Route-based vibration, infrared, ultrasound, motor circuit analysis, and oil analysis.