Financial Analysis of Condition Monitoring Programme
Outline of Condition Monitoring Programme & Savings
Site description:
15 years old Pharmaceutical plant based in Ireland
- High levels of unexpected downtime
- Two-week Summer shutdown period in place
- Regular PM schedules being carried out.
Condition Monitoring Programme:
- Monthly vibration analysis - Covering 270 assets
- Quarterly mechanical thermography - Covering 120 assets
- Bi-annual electrical thermography - Covering 180 panels
Total Annual costs
€45,500
Potential Cost Savings* from Condition Monitoring Programme:
€236,500
Unforeseen downtime savings: €205,000
Maintenance cost savings: €31,500
Savings from reduction in requirement for time-based overhauls: €€€€€€€
Fault Number 1
Machine type: Air Intake Fan
Inspection method: Vibration analysis
Frequency of inspection: Monthly
Fault detected: Motor Drive Bearing Wear
Timeline:
- First signs of wear reported in May 2015
- Monitored monthly for a further 2 months
- Motor drive bearing replaced in July 2015
Repair savings based on planned versus emergency repair:
€9,000, comprised of:
- Inventory cost savings: No secondary damage to the motor or fan
- Labour cost savings: No emergency repair crews required
Downtime saved: 10 hours unexpected downtime
Downtime cost per hour: €5,000 per hour
Downtime savings: €50,000
Total potential savings: €59,000
Fault number 2
Machine type: Refrigeration compressor
Inspection method: Vibration analysis
Frequency of inspection: Monthly
Fault detected: Compressor Drive Bearing Wear
Timeline:
- First signs of wear reported in Aug 2015
- Monitored monthly for a further 3 months
- Compressor overhauled and bearing replaced in Dec 2015
Repair savings based on planned versus emergency repair:
€12,000, comprised of:
- Inventory cost savings: No secondary damage to the compressor or motor
- Labour cost savings: No emergency repair crews required
Downtime saved: 16 hours unexpected downtime
Downtime cost per hour: €5,000 per hour
Downtime savings: €80,000
Total potential savings: €92,000
Fault Number 3
Machine type: Electrical Control Panel for Filtration Unit
Inspection method: Thermography
Frequency of inspection: Bi-annual
Fault detected: Overheating contactor connections (>100°C)
Timeline:
- Excessive heat detected in April 2015
- Contactor and cables replaced in May 2015
Repair savings based on planned versus emergency repair:
€2,000, comprised of:
- Inventory cost savings: No secondary damage to any other components in the panel
- Labour cost savings: No overtime labour required
Downtime saved: 3 hours unexpected downtime
Downtime cost per hour: €5,000 per hour
Downtime savings: €15,000
Total potential savings: €17,000
Fault number 4
Machine type: Motor Belts for Cooling Tower Fan
Inspection method: Thermography
Frequency of inspection: Quarterly
Fault detected: Misaligned belts / pulleys
Timeline:
- Excessive heat detected in Feb 2015
- Belts replaced and pulleys aligned in Mar 2015
Repair savings based on planned versus emergency repair:
€1,500, comprised of:
- Inventory cost savings: No secondary damage to any other machine components
- Labour cost savings: No overtime labour required
Downtime saved: 3 hours unexpected downtime
Downtime cost per hour: €5,000 per hour
Downtime savings: €15,000
Total potential savings: €16,500
Fault number 5
Machine type: Jacket cooling pump
Inspection method: Vibration analysis
Frequency of inspection: Monthly
Fault detected: Coupling Wear
Timeline:
- First signs of wear reported in Feb 2015
- Monitored monthly for a further 5 months
- Coupling replaced in July 2015
Repair savings based on planned versus emergency repair:
€2,000, comprised of:
- Inventory cost savings: No secondary damage to the pump or motor
- Labour cost savings: No emergency repair crews required
Downtime saved: 4 hours unexpected downtime
Downtime cost per hour: €5,000 per hour
Downtime savings: €20,000
Total potential savings: €22,000
Fault number 6
Machine type: MCC Panel for Reactor
Inspection method: Thermography
Frequency of inspection: Bi-annual
Fault detected: ‘T’ phase connection overheating on contactor
Timeline:
- Excessive heat detected in Nov 2015 (Burn marks evident)
- Contactor and cables replaced in Dec 2015
Repair savings based on planned versus emergency repair:
€5,000, comprised of:
- Inventory cost savings: No secondary damage to any other components in the panel
- Labour cost savings: No overtime labour required
Downtime saved:
- 5 hours unexpected downtime
- Potential fire averted
Downtime cost per hour: €5,000 per hour
Downtime savings: €25,000
Total potential savings: €30,000