What are the most effective maintenance benchmarks for reducing energy consumption?

Energy Audits: Conduct regular energy audits to identify areas of energy waste and prioritize maintenance efforts. These audits can reveal opportunities for upgrades or retrofits. Data Analysis: Use data from energy meters and sensors to track energy consumption patterns. Analyze this data to identify anomalies and areas where energy-saving maintenance is needed. Lighting: Optimize lighting systems with energy-efficient bulbs and controls, such as occupancy sensors and dimmers. HVAC Systems: Maintain heating, ventilation, and air conditioning systems to prevent leaks, optimize airflow, and replace air filters regularly. Insulation and Sealing: Maintain building insulation and seal gaps to reduce heating and cooling energy losses.

Energy reconciliation and having regular audits on energy leakages like to have checks for accounting .For efficiency improvement ,new age technologies like VFD,Pump Destaging , LEDs.

Most important benchmarking for maintenance w.r.t energy consumption is to eliminate / reduce the process / steam leakages especially in large size Fertilizer (Ammonia / Urea) complex.

First and foremost all your machines or energy users must be metered. Even better each machine must have their own energy meter. This will tell you how much energy each machine is consuming.This makes it very easy to analyze and deploy energy loss areas and trending energy pattern for a machine or system to check how well it has performed. Secondly, understanding the process and all the systems that is linked to to the machine is also an important prerequisite. It gives you a clear picture of machines duty. Without understanding and quantifying the energy consumers, one can't successfully implement a energy reduction strategy.

Revise the preventive maintenance based on time plan,upon the inspection as found report, Historical data of failure report’s, breakthrough test reports like cartridge filters replacements, desiccant replacements, applying run to fail program for low risk equipment priorities which is not related to safety or production losses applying RBI programs Reliability based inspection

Energy audits should be performed at leat twice a year. An action plan must be created including all finding during assessment.

First Implement and fix area wise or department wise metering is good for energy monitoring and control. Benchmarking based on national or international standards or fixing own standards will help.

The most effective maintenance benchmarks for reducing energy consumption are those that focus on optimizing the performance and reliability of equipment and systems. This can be achieved by implementing a preventive or predictive maintenance plan that ensures that equipment is well-maintained, lubricated, calibrated, and aligned.

Regularly servicing HVAC systems, optimizing insulation, and upgrading to energy-efficient appliances are key maintenance benchmarks for reducing energy consumption

Internal energy audit culture for various equipment can be beneficial.It needs to be integrated with regular maintenance,inspection checks.

Los principios del mantenimiento de precisión pueden ser de gran valor en el ahorro de energía. Una máquina debe estar bien FIJA. Bien LUBRICADA, bien ALINEADA y bien BALANCEADA. Esto se conoce con el acrónimo FLAB que es la base del mantenimiento de precisión. Además de permitir que la máquina logre su Máxima vida, reduce las pérdidas por fricción y por ello el consumo de energía

Using this as a springboard, and especially when discussing energy, performing heat audits on motors and switch gear can prevent failures but potentially also disastrous fires. A robust program that not only checks but relates historical data will provide trends and insights to potential environmental impacts.

El mantenimiento preventivo dentro de una estrategia de mantenimiento enfocada en la optimización de los diferentes recursos nos va a permitir identificar actividades/equipos/procesos con un uso ineficiente de la energía. Mantener los equipos operando en algunos casos mejor que cuando se instalaron.

A Preventive maintenance schedule reflecting the OEMs maintenance instructions is the foremost requirement for any successful maintenance program. This will ensure that the intended intervention as per OEM is performed to sustain the desired performance.

TPM principle of Autonomous maintenance (Jishu Hozen) can be implemented to ensure basic maintenance by the operation team rather than the maintenance team. The maintenance team would conduct predictive maintenance activities as per schedule. Apart from that the operations team could implement JH to check basic operational conditions by performing CLIT( Cleaning, Lubrication, Inspection & Tightness) checking so as to eradicate the cause of predictive failure at the root itself. It’s something called technically as maintaining the ‘Basic Condition’ of an equipment, i.e. as if it were new. This enables fault identification and rectification in an easier way, since the basic causes are already eliminated through CLIT

I successfully implemented a predictive program for a truck component. It took research of 4 years of data over two maintenance systems but I found the opportunity. I’m the end I was able to perform 10 trucks for the price of one breakdown, and avoid the pain of lost time for over the road repairs. Data research on reliable records can yield amazing insights.

El análisis de lubricantes es una extraordinaria manera de monitorizar condición de fricción anormal. La contaminación del Lubricante, pérdida de la viscosidad, degradación por oxidación, alta temperatura y condiciones de desalineamiento, desbalance o falta de soporte adecuado provocan un incremento en la fricción y el consumo anormal de energía. Todos estos modos de falla son identificados por un programa de análisis de lubricantes bien diseñado.

Carry out strategy steps according to PF curve rules so that the FMEA carried out becomes RCA (solving until the root of the problem is found).

5s,Kaizen,TPM, Lean manufacturing , will help you to uptime and improve Business bottom line, Employee Trainings, and Celebrate the employees efforts.

To enhance Electrical Efficiency Index (EEI) in motors, consider these steps: 1) Replace old motors with modern, energy-efficient models for substantial energy savings. 2) Implement routine maintenance for optimal performance. 3) Operate motors at the right load to maximize efficiency, avoiding overloading. 4) Adopt efficient operational practices, like turning off motors when not in use, reducing energy consumption. These measures result in reduced energy use and improved sustainability.

Optimal maintenance benchmarks, including proactive equipment upkeep, real-time monitoring, & and swift issue resolution stand as the most effective strategies for curtailing energy consumption in industrial operations. Elevate efficiency, minimize downtime, and contribute to sustainable practices by integrating these benchmarks into your maintenance protocols.

Continuous Improvement is required in both the maintenance philosophy and hardware upgradation of equipments to reflect the latest technological innovation to sustain or to improve upon the desired performance. When the equipments were installed originally, the technology available at that time might be already a decade old. Subsequently, the technology keeps on evolving and the maintenance team should look into this to improve the original performance.

Continuous improvement is a crucial part for every activity in a process. Everyone in a team has their own view and some can share a beautiful idea. Likewise,bproduction or process team can highlight the lags in the system. Which could be later overcome by the maintenance team. 🙂

Kaizen has been one of the world's best concepts since its conception/application within the Toyota company in the mid 1900's. Living with the "Ain't broke, don't fix it" mentality is a recipe for disaster. Things can ALWAYS be improved on. People, processes, tech, initiatives. You name it, it can be improved somehow. When conducting Kaizen, metrics are the most important. What improved? How much? Price? Worth the investment? So many great questions to ask. And as always "the only dumb question is the question not asked"

In my experience rewarding the achievements is an absolutely key point here. Without positive moral, especially in the manufacturing space, we see a lot of turnover and low productivity. We find ourselves doing an excellent job of giving negative feedback because we are pushing towards goals, but we rarely pause to celebrate what we do well and uplift folks who are working hard every day to help the company move forward. Giving kudos helps uplift everyone's spirits and therefore the company!

Reduce the amount of maintenance work altogether- especially reactive maintenance. Implement chronic failure analysis. Establish a defect elimination program. Perform RCM/PMO analysis. Determine best maintenance strategies. Analyze existing PM program to make sure it is defendable, i.e., link back to failure mode.

Reducing energy consumption through effective maintenance requires the establishment of specific benchmarks and strategies, include measuring energy efficiency ratios, implementing preventive maintenance schedules, minimizing downtime, detecting and repairing leaks, improving lighting efficiency, maintaining the building envelope, utilizing energy management software, tracking key performance indicators, benchmarking against industry standards, employee training, energy audits, & considering the life cycle of equipment. Regularly monitoring and adjusting these benchmarks are crucial for achieving energy reduction goals. Effective maintenance practices can lead to significant energy savings, cost reduction, and a more sustainable operation.

Alineación y Balanceo de precisión, basados en estándares y herramientas apropiadas. Con personal capacitado y motivado. Son actividades de gran impacto para el desempeño de los equipos, sencillas y controlables desde el montaje de maquinaria. Menos precargas, menor intensidad de fuerzas, menos carga...ahorro de energía y otros recursos.

1. In the case of a just commissioned project, archive the energy consumption at various throughputs in the Historian as benchmark for comparison. 2. Build a digital twin of the project and compare with the running plant on real time basis 3. Implement energy efficiency endeavours on ongoing basis by replacements or upgrades of obsolete equipment to update bench marks

Carry out good alignment between SAMP and AMP by referring to the agreed KPIs (lagging and leading) and using the Matrics tool as a guide, not as a hammer.