Do you know what equipment you have in your plant? The unfortunate truth is that if you are like many others, you don't!
Consider these real examples of what a facility told us about how many electric motors were in their plant, versus what they really had:
- Power plant: Told us they had 6,000, Reality: 9,000 (+50%)
- Power plant: Told us they had 5,000, Reality: 11,000 (+120%)
- Paper mill: Told us they had 300, Reality: 800 (+166%)
- Steel mill: Told us they had 15,000, Reality: 27,000 (+80%) and had 3000 spare motors with no matching applications
So, let us ask again ... are you really sure you know what you have on hand in the way of equipment?
Performing an Equipment Survey
Here at HECO, we perform equipment surveys so that you know exactly what you have on hand. We will help you establish your minimum and maximum stock levels based on technical data, not a stock number. You will be able to identify areas of excess or insufficient coverage so you can make sure your critical application needs are met. And the results of our equipment surveys contain much more information than a list of electric motors in a spreadsheet -- these surveys include both the driver of the equipment and the driven equipment.
As part of this asset survey, we will record all nameplate and critical data for all your plant locations along with application information. Each asset is tagged with a unique identifying number to allow it to be tracked throughout the remainder of its life. This information is then entered into the TracRat Repairable Asset Management Software.
Once everything has been entered into TracRat, an Inventory Analysis Report is generated that includes information on in-service to spares comparisons, obsolete inventory, in-service reports sorted by equipment type or application, and custom reports that can be sorted by nameplate data.
Our team can also help you standardize your equipment where possible, as well as reduce your inventory to get rid of obsolete assets. HECO will help you deal with those obsolete assets through scrapping them or selling them through consignment or attrition.
Why Equipment Surveys are Important
Knowing what equipment you have on hand is important for several reasons. For example, suppose one of your key electric motors goes down. Do you have a drop-in replacement for it on hand? Do you know where it is? Is it ready to install or does it need some maintenance first? How quickly can you get to it? Do you know what motors go with what equipment?
If you already have this information on hand, you can minimize the resulting downtime and reduce overall M&O costs. In fact, proper management of spares is an excellent way to improve the overall reliability of your plant.
By having up-to-date, accurate information about the equipment you have on hand, your team will also be able to make informed decisions about issues related to replacement, repair, and rebuilds. This, in turn, also contributes to plant reliability as well as reduced maintenance costs and far less downtime.
Equipment surveys can also help you to reduce your equipment inventory by up to 60% -- and do that without negatively impacting either the speed or quality of overall production. There is no reason to keep storing (and possibly maintaining) equipment that you no longer have a need for.
Finally, an equipment survey can help you identify risk areas and take definite action to mitigate those risks. If you realize from the resulting audit reports that you have no spares on hand for a certain key power train, then you can remedy that issue and be better prepared for a worst-case scenario.
Good motor management includes knowing what equipment you have (and that means not just your electric motors), where it is located, and what condition it is in. Taking the time to obtain a detailed asset survey of your plant can prove invaluable when something goes wrong or when you need to make some tough decisions about repair, rebuild, or replace.
Author: Samantha Lane - firstname.lastname@example.org