info@Hendrixpm.com (888) 233-9777 Do it Once, Do it Right! Hands-On Precision Maintenance Skills Training and Reliability Consulting CREATING RELIABLE OPERATIONS
www.HendrixPrecisionMaintenance.com 2 FROM THE DESK OF PHIL HENDRIX Co-Founder of Hendrix Precision Maintenance After doing the work ourselves and resurrecting failed maintenance efforts for 40 + years in our own careers, all of us agree most bearing & equipment failures are the result of mechanics and supervision taking shortcuts and not paying attention to the little details to eliminate com-mon assembly errors. Adopting Precision Maintenance as a Process was the most important change we ever made to double and triple equipment life OR as we say, Do it Once - Do it Right! ABOUT HENDRIX Hendrix Precision Maintenance is proud to be a leader in the world of Precision Maintenance Train-ing. Our team of expert, real-world experienced instructors take pride in being the best at what they do. With decades of experience behind each instructor, attendees can be assured they are learning real-world applications and problem solving that will be of immense value within their industry. Our small class size, content rich curriculum, hands-on simulators and dual instructor classes, ensures that everyone experiences individualized attention in an environment where class participation, col-laboration and questions are encouraged and fostered. We have trained thousands of mechanics in over 200 companies and/or plants. Each time our trainings have demonstrated measurable results providing a vast return on investment. Our hands-on simulators and static de-monstrators that replicate real-world operating equip-ment are specifically engineered to enable instructors to impart assembly errors and many common mistakes. Participants are then systematically taught to identify and eliminate each one, resulting in the conversion of a poor, high risk failure machine into an improved, reliable ma-chine – operating as intended. What makes Hendrix Unique? - Our training curriculum, courses, simulators and instructors are unique in many ways and provide immense value to all involved in the Industrial Maintenance field. There is no other Precision Maintenance Skills Development company with a two-instructor strategy and proprietary rotating equipment simulators (Running & Static Machines) to train Crafts-men, Supervisors, Engineers and Leaders about Precision Maintenance. No other company pro-vides the level of detail and amount of hands-on practical exercises.
info@Hendrixpm.com (888) 233-9777 3 Hands-On Precision Maintenance Skills Training & Reliability Consulting CREATING RELIABLE OPERATIONS PRECISION CONSULTING PRECISION SKILLS TRAINING PRECISION STANDARDS • Precision Consulting • Precision Assessment Program, Processes, Da-ta, Equipment & Skills • Equipment Condition Assessment High Critical-ly, Bad Actors • Equipment Remediation Support Workplan Devel-opment & Supervision • Coaching/Mentoring • Skills 1-Assembly Rebuild, Installation • Skills 2-Precision Bearing Installation & Maintenance • Skills 3-Pump, Hydraulics & Mechanical Seals - Trou-bleshooting & Installation • Fasteners & High Pres-sure Bolt Ups • Operator Basic Care Ob-servation , Adjustment, Lu-brication, Basic Tools, Cus-tom Tailored Training • Precision Lubrication Skills Leading to Lube Certification • Boot Camp-Accelerated Precision Knowledge & Skills • Custom Classes Precision Training Tailored to Needs • Digital Skills Training • Policies & Processes De-sign, Purchase & Commis-sioning • Job Plans & Procedures Maintenance Job Plans, Rebuilds • Precision Worksheets & Checklists • Packaged Upload-able Content Available
www.HendrixPrecisionMaintenance.com 4 Our Instructors, Our Simulators, Our Curriculum! Your site, Your Workforce, Your Private Training! WE BRING REAL WORLD, HANDS-ON SKILLS TRAINING & IMPLEMENTATION TO YOUR SITE We bring to your site, our simulators, either running, static or dynamic pieces of rotating equip-ment built to mimic the exact problems that mechanics will face in the field. In essence, we bring your plant floor machinery right into your facility! They arrive in a failed state, and we train your workforce to master the skill sets to put them back the right way. Using their new Hands-On skill sets, participants prove to themselves that what we teach can greatly extend Mean Time Between Failure (MTBF) on all rotating machines, which drastically reduces costs while improving uptime and producing reliable operations. We hold Precision Maintenance Skills Classes all over the country! Visit our Website for our Public Class Schedule www.HendrixPrecisionMaintenance.com Don’t see a class in your area, call or email us today! Suggestions of new class locations are always welcome! PUBLIC CLASSES ON-SITE CLASSES
info@Hendrixpm.com (888) 233-9777 5 COURSE DESCRIPTION Learn How to Easily Double or Triple Rotating Equipment Life by making vibration much lower through the elimination of common assembly errors and adherence to rigid precision installation, rebuild, and maintenance standards which we will show you how to achieve with little or no extra downtime. Participants will dis-assemble, re-assemble, correct defects, perform precision alignment for both in-line coupled & v-belt driven machines, and measure the noticeable improvements as common field & shop assembly errors are eliminated from our running and static simulators. RECOMMENDED AUDIENCE: maintenance and construction crafts-men, apprentices, front-line supervisors, project & reliability engineers, maintenance managers & superintendents, operations personnel and significant others implementing plant reliability improvement. COURSE OBJECTIVES • Understand what Precision Maintenance is & how to achieve w/o extra downtime • How to identify and avoid common assembly errors • Understand and correct common fit & tolerance problems • Learn basic bearing installation problems and corrections • Learn what is good, fair, and bad vibration & how it affects equip-ment life • How to lower vibration & exponentially improve Bearing life (MTBF) • How to significantly improve and retain balance • How to improve upon “status-quo” alignment standards & achieve precision alignment • How to create smooth running belt drives • How to reduce energy consumption 5%, 10%, or more on most Equipment • Learn Common Lubrication Errors & How to Avoid 40 Hours (five 8-hour days or four 10-hour days) * No prerequisites required REDUCING COMMON ASSEMBLY ERRORS IN EQUIPMENT TO EXPONENTIALLY EXTEND MTBF PRECISION MAINTENANCE SKILLS 1 PRECISION SKILLS TRAINING
www.HendrixPrecisionMaintenance.com 6 COURSE DESCRIPTION Our precision OEM trained and real-world plant experienced instructors will show participants How to easily Double or Triple Bearing Life. Using re-al plant size bearings, shafts, housings, participants will learn how to use the proper tools to eliminate the pain of common bearing installation errors and mount with proper clearances, pre-loads, critical fit & tolerances that most craft don’t know. They will practice Hands-On using the most common types of bearings seen in 95% of plant equipment in chemical, power, steel, alumi-num, paper, auto, food, and other industrial manufacturing plants. Participants will learn simple bearing failure analysis that doesn’t require a metallurgist and all the correct mounting methods used by Bearing OEM’s including: turning angle, pressure w/ hydraulic nut, how to make a “poor man’s hydraulic nut” in your shop, how to find & interpret vital bearing no-menclature and how to avoid common lube mistakes made every day that kill most bearings prematurely. RECOMMENDED AUDIENCE Maintenance and Construction Craftspeople, Front-line Supervisors, Maintenance Managers and Superintendents, Relia-bility and Maintenance Engineers supervising contractors doing machinery installation, repairs and reliability improvement. 32 Hours (4 Days) *No prerequisites required COURSE OBJECTIVES Proper bearing removal, installation and adjustment of: •Ball bearings •Cylindrical Roller Bearings including Cooper Split Bearings •Tapered Bore Spherical Roller Bearings, Journal Condition Assessment •Angular Contact Thrust Ball Bearings in Duplex, Triplex, & New Quadplex •Pillow Block Bearings “Do’s & Don’ts,” and the New Concentra Bearing •Paper Machine, Steel and Aluminum Mill Large Roll Journals, Sine Bar Use •Tapered Roller Bearings (Timken Cup and Cone Bearings) •Straight Bore Spherical Roller Bearings •Needle Bearing specifics •Timken TDO and TDI bearing specifics •Explain misunderstood bearing nomenclature •Understand Precision Bearing Installation criteria & how to achieve critical “Fit & Tolerance” PRECISION MAINTENANCE SKILLS 2 PRECISION BEARING INSTALLATION & MAINTENANCE FOR LONGER EQUIPMENT LIFE PRECISION SKILLS TRAINING
info@Hendrixpm.com (888) 233-9777 7 COURSE DESCRIPTION Our nationally renowned pump & seal instructor, with years of field expertise, field troubleshooting (for some of the largest pump and seal companies in the world) will reveal essential maintenance and troubleshooting techniques that have either been overlooked or never taught in the first place. In our years of applying precision maintenance techniques, we have learned to EXPECT pumps and seals to run trouble free without the replacement of expensive mechanical seals or bearings, until such time as the impeller, casing, or wear rings wear out and “pump won’t pump.” This is a direct result of improved pump performance and extended MTBF brought about by craft mechanics that have learned how to – “Do it Once, Do it Right!” Our course is aided greatly using a large (6 ft. tall) portable pump/hydraulic training simulator, com-plete with clear tanks, valves, piping, and a running Goulds pump with a clear casing for dynamic demonstration. It has as many gauges as a small aircraft and even has “shaft movement” visibility (using a strobe light) at different operating conditions. Students will “see” the effects of improper pump operation and learn how to avoid inducing parasitic defects back into the system only to cause increased down-time and rework. Upon completion of this course, participants will know how to operate & troubleshoot pumps. Even more importantly, they will understand how pumps should run trouble free for 100,000 hours instead of the 10,000 to 30,000 hrs. and driv-ing up repetitive maintenance costs. TOPICS COVERED plus much more. • Opening and closing various valves to create real life in field and plant conditions • Troubleshooting & corrections to operate pumps on their pump curve • “De-mystifying” Pump Curves so the average mechanic/supervisor can troubleshoot • Proper starting and stopping proce-dures with proper flows • Troubleshoot and correct common field problems that most people “guess wrong” • Packing, sealing, and gland water issues corrected • Vibration issues understood and solved • Water hammer issues PUMP HYDRAULICS / MECHANICAL SEALS TROULESHOOTING OPERATIONS/INSTALLATION 24 Hours (3 Days) *No prerequisites required PRECISION SKILLS TRAINING
www.HendrixPrecisionMaintenance.com 8 FASTENERS / HIGH PRESSURE BOLT-UPS COURSE DESCRIPTION Hendrix Precision Maintenance Instructors are now providing courses that will help you to keep things from coming apart...Literally! Fastener Integrity takes a back seat until a failure occurs! Hendrix Precision Maintenance Training has a course dedicated to the integrity of fasteners. For many years, fastener integrity has taken a back seat to more visible and what some consider more important issues, such as pumping efficiency, pro-duction maximization, or minimizing time to repair to name a few. Fastener Integrity has long been con-sidered a labor-intensive task that can be assigned to the less experienced mechanic or laborer. How-ever, Fastener Integrity is kind of like an “atta boys”. It only takes one failure to wipe out the advantage of the many that were done correctly. Lack of fastener integrity can cause disruptions in production and safety hazards at a minimum. One fastener failure has the potential to put operations out of business. The training curriculum that has been developed by Hendrix professionals is comprehensive, covering fasteners for rotating equipment, piping and vessel flanges, and structural steel. THE “CONNECTION” TO SAFE AND RELIABLE PRODUCTION 16 Hours (2 Days) *No Prerequisites required TOPICS COVERED (and more…) • Understanding Fastener Terminology & Specifications • Use of PCC-1 Standards to Ensure Prop-er Piping Alignment and Proper Sealing Surfaces • Fastener Charts and How to Use Them • Safe Disassembly of Bolted Connections – Precautions that are too often over-looked • Bolting/Fastener Reliability – Importance of correct Thread Engagement, Proper Tensioning, Adverse Effect of Stress Ris-ers • The Stress Strain Curve of a Threaded Fastener and how to stay within the Mar-gin of Error (Elastic Range) • Torque Relationship to Bolt Tension • Working with assemblies that have Multi-ple Fasteners – Flanges, Heads, etc. PRECISION SKILLS TRAINING
info@Hendrixpm.com (888) 233-9777 9 PRECISION MAINTENANCE LUBRICATION DESIGNED TO EDUCATE AND PREPARE PLANT PERSONNEL TO TAKE MLT & MLA CERTIFICATION COURSE COURSE DESCRIPTION Our Precision Lubrication Courses can be from 1-day classroom over-view to 4-day courses designed to educate and prepare plant person-nel wanting to take MLT and MLA Certification Test. We also offer on-site lube consulting, plant lube program design, and implementation, including lube routes and lube specifications. Our Lube experts with years of plant experience can also do Hands-On In-Plant Training of your personnel. Please note that onsite classes will take some of your equipment and or spare equipment and we will actually lubricate them with your personnel. OUR 3 MOST POPULAR LUBRICATION CLASSES 1. Mechanical Lube Analysis/Mechanical Lubrication Technician - Level 1 (combined 4-day class) This MLT Certification Training Level I course is a 4-day class that covers both the MLTI and MLAI Body of Knowledge in accordance to ISO 18436-4 and meets all of the instructional hours required to sit for the exam. It pro-vides the foundational training for reliability-centered machine lubrication work practices AND oil-sample based condition assessment. This class will help you understand the positive impact that high quality lubri-cation practices can have on your machine’s health and your plant’s productivity. Participants will learn how to transform an existing lubrication process from modest and reactive to thorough, accu-rate and proactive. 2. Mechanical Lubrication Technician – Level 2 (4-day class) This advanced level MLT certification class was developed to help program managers, machine lu-brication engineers and first line technicians develop their ability to articulate machine specifications and technically accurate lubrication practices. This MLT II course covers the ICML Body of Knowledge including lubrication theory and formulations; testing and analysis; lubricant selection and application; maintenance strategy; lubricant condition control and storage. This course includes practical case studies and problem-solving activities to help students retain and recall methods that tackle real world challenges. 3. Mechanical Lubrication Analysis - Level 2 (3-day class) This new 3-day MLAII course is in accordance with the ISO 18436-4 Body of Knowledge that in-cludes oil sampling, lubricant health, contamination measurement and control and wear debris mon-itoring analysis. Personnel attending this course will gain a high level of knowledge around evalua-tion of used oil samples. PRECISION SKILLS TRAINING
www.HendrixPrecisionMaintenance.com 10 PRECISION MAINTENANCE ALIGNMENT HANDS-ON PRECISION LASER ALIGNMENT TRAINING COURSE DESCRIPTION Using our Running Simulators participants can immediately see their own Results in Lower Vibra-tion and Amps. Our “best in class” experienced Alignment Millwrights (not engrs. or teachers w/no real field experience) teach hands-on in this 2-day class, which includes real life equipment prob-lems most frequently encountered in the field. Half-day instruction and 1 ½ days of hands-on prac-tice, with mentor coaching and setting units up with different built-in problems. • Included is our Written Step-by-Step Alignment Procedure and showing mechanics, engineers and supervisors the steps skipped by most mechanics and constructors that causes them to fall short of precision on new construction and maintenance alignments. • We introduce the running impact of The Most Com-mon Assembly Errors made when changing and aligning equipment and how to quickly correct it. • We furnish management with key alignment and vi-bration metrics that we (in our plant maintenance ca-reers) and our customers have used to exponentially improve rotating equipment life. • Customizable to your plant’s alignment laser. Notes: Schedule of Training: typically, two 2-day classes (conducted back-to-back in the same week) Class size of up to 8 (3-4 simulator training stations) Hendrix will use your lasers (no additional cost), or can supply lasers (additional charge) Contact us today to discuss your specific needs. PRECISION SKILLS TRAINING
info@Hendrixpm.com (888) 233-9777 11 OPERATOR BASIC CARE Tailored 2-5 day class COURSE DESCRIPTION Targeting your current operations and equipment; participants will understand the roles and respon-sibilities in improving reliability asset operations within their own plant. Our “best in class” experi-enced Maintenance and Engineering leaders teach hands-on in this 2-5 day class, which includes real life equipment problems most frequently encountered in the field. Precision maintenance relia-bility leaders will specifically design, develop, and execute tailored hands-on training to improve the skill set of the craftsman, supervisors, operators, planners, superintendents, and engineers. • We introduced breaking down silos between maintenance opera-tion and engineering functions and places more ownership on the operator. The operator of any asset is in a position two cents if there is something out of the ordinary or abnormal with a piece of equipment before a failure occurs. • We assist with developing a Plan, Procedures, and Checklists for the longevity of the operator care training program. Participants will learn how to write and revise standard inspection PM's, one-point lessons, the importance of operator care boards. • We introduce the running impact of The Most Common Errors made when changing over a piece of equipment and operating equipment and how to quickly correct it. Physical inspection points: fasteners, lubrication, pneumatics, belt wear, torque spec requirements, proper fitting and clevis-es, and general alignment. • We furnish management with key performance indicators (KPI’s) that we (in our plant mainte-nance careers) and our customers have used to exponentially improve operational efficiencies. PRECISION SKILLS TRAINING
www.HendrixPrecisionMaintenance.com 12 PRECISION SKILLS TRAINING PRECISION LEADERSHIP WORKSHOP PRECISION MAINTENANCE BOOT CAMP For Reliability Engineers, Supervisors, Planners, Vibration Analysts, & other roles that lead the work process. The Precision Maintenance Boot Camp is designed to accelerate the essential knowledge and skills necessary for reliability engineers and other essential roles that are expected to lead to reliability im-provement. In many cases, these individuals have never been formally introduced to these strate-gies, processes, and tactics, yet they are expected to be the “go to” source for solving difficult prob-lems and achieving improvements. Armed with these vital skills, craftsmen and front-line leadership can begin eliminating unscheduled downtime, recapture lost opportunities, and drive the production and profits in the right direction, up. Management overview for CEO's, VP's, Plant Managers, and other levels of supervision. This tailored seminar will provide an overview of the basic steps and share real results when adding a precision maintenance approach for reliability. Utilizing real operating and static simulators to show actual results sites have achieved, detail-ing how they did it, and the all-important critical steps for implementation. These exclusive custom sessions can be organized for one, two, or four hours in dura-tion. Awareness of Business Issues & Trends Precision Maintenance Skills Assessment Sr. Management Sponsorship Roles, Responsibilities & Processes Training Implementation Application of Skills Measuring Results - KPI’s Progress Review & Mentorship New Hires Achieving Sustainability BOOT CAMP TOPICS 10 - STEPS TO PRECISION MAINTENANCE: STRATEGIES, PROCESSES & TACTICS
info@Hendrixpm.com (888) 233-9777 13 PRECISION SKILLS TRAINING PRECISION MAINTENANCE SKILLS 1– VIDEO “The Essentials” Learn How to Easily Double or Triple Rotating Equipment Life! Hendrix has digitized our most popular hands-on, Precision Maintenance Skills 1 course…and now it’s available online! Nothing substitutes for Hendrix’s instructor led, face-to-face, hands-on training…BUT, this is as close as it gets! Your Time, Your Pace, Our Training! PRECISION MAINTENANCE SKILLS 1 - COURSE OBJECTIVES • Understand what Precision Maintenance Is & how to achieve w/o extra downtime • How to identify and avoid common assembly errors • Understand and correct common fit & tolerance problems • Learn basic bearing installation problems and corrections • Learn what is good, fair, and bad vibration & how it affects equipment life • How to lower vibration & exponentially improve Bearing life (MTBF) • How to significantly improve and retain balance • How to improve upon “status-quo” alignment stand-ards & achieve precision alignment • How to create smooth running belt drives • How to reduce energy consumption 5%, 10%, or more on most Equipment • Learn Common Lubrication Errors & How to Avoid IDEAL FOR Millwrights, Mechanics, Supervisors, Opera-tors, Planners, Reliability Engineers Any size workforce, any size company! International customers! Remote plants, mills and personnel! Human Resources Skills Development Training Programs! On-boarding New Hires! Refresher training! HIGHLIGHTS Our most popular Skills course in its entirety! Recorded in High Definition with close-up camera angles for detail! Accessible via a web-based Learning Management System (LMS) Self-paced Precision Maintenance Skills Training! Your time, Your pace, Our training! Low cost, flexible, sustainable, long-term solution for training the workforce! No travel required! Mobile Ready! Viewable on your iPad or any mobile device. Certified for Continuing Education Units (CEU) and Professional Development Hours (PDH)!
www.HendrixPrecisionMaintenance.com 14 PRECISION SKILLS TRAINING Industrial Maintenance Modularized Training “THE FUNDAMENTALS” Hendrix has developed 20 content-rich eLearning Modules designed to give craftspeople the foun-dational Industrial Maintenance knowledge needed for career advancement. Accessed via our Learning Management System (or yours), the eModules (mostly .ppt files) can be self-paced, or can be taught by your in-house instructor, or our experienced instructors. The courses are intended for Apprentices, Multi-Craft personnel, Engineers, Operators, New Hires and refresher training! Below is a list of eModules: (duration includes recommended hands-on activities) • VALVE MAINTENANCE I & II (32 hours) • PUMPS I &II (32 hours) • HEAT EXCHANGERS (8 hours) • DIESELS (8 hours) • INTRO to ELECTRICITY (8 hours) • MACHINE ALIGNMENT (32 hours) • PRINCIPLES of MACHINING (32 hours) • BEARINGS (8 hours) • PIPE, FITTINGS, and AUXILIARIES I & 11 (12 hours) • CONTROL VALVES and ACTUATORS (12 hours) • LATHE OPERATIONS (40 hours) • MEASUREMENT and TESTING EQUIPMENT (12 hours) • SAFETY & RELIEF VALVES (12 hours) • TURBINES (12 hours) • HYDRAULICS & PNEUMATICS (24 hours) • DRIVE COMPONENTS (12 hours) • LUBRICATION - PART 1 - HYDRAULIC FLUIDS (6 hours) • LUBRICATION - PART 2 - INDUSTRIAL LUBRICANTS (6 hours) • PRINT READING (12 hours) • MILLING MACHINES (24 hours) PART 1 - VERTICAL SPINDLE • MILLING MACHINES - PART 2 - HORIZONTAL SPINDLE
info@Hendrixpm.com (888) 233-9777 15 PRECISION CONSULTING Hendrix Precision Maintenance offers a low-cost skills assessment tool which is available in both hard copy and online electronic format which allows customers to conduct a rapid assessment of their maintenance workforce related to precision maintenance experience, fundamentals and skills. The skills assessment is valuable in order to establish upfront needs analysis by individual and group. The assessment can also be used to help tailor our training offerings to focus on are-as of weakness by individual or group as well as conduct post training effectiveness evaluation. • Several hundred multiple choice questions • Written or online test • Graded by our Instructors • Individual & Group results (Results delivered in written & electronic for-mat) • Individual & Group Heat Maps identifying areas of strength & weakness The Skills Assessment is an invaluable tool to help justify and measure the effectiveness of PRECISION training. SKILLS ASSESSMENT EQUIPMENT SUPPORT In order to implement Precision Maintenance, you have to actually correct installation, balance, alignment and lubri-cation deficiencies with your rotating equipment. You will need a list of all your rotating equipment ranked by criticali-ty and a plan to put the equipment into a precision state. We can help customers put their plan together and then also provide either remote or onsite support during remedi-ation efforts. This support includes providing supervision and technical support, working with customer planners to ensure the remediation procedures are effective and helping track and manage the remediation project. Our personnel have all successfully implemented and sustained precision maintenance. Be-yond our training having experienced PRECISION experts working with your people to put your equipment in a precision state is one of the fastest ways to success.
www.HendrixPrecisionMaintenance.com 16 PRECISION CONSULTING PRECISION ASSESSMENT PROGRAM For many the first step in any journey is figuring out where you are. Our Precision Assessment Program is a rapid evaluation con-ducted on-site at customer plants or facilities which helps establish the level of need and readiness for a customer. Our assessment fo-cuses on three major areas: SKILL ASSESSMENT BENCHMARK We administer and proctor our Skills Assessment evaluation to a cross section of customer maintenance personnel (normal 10-15 personnel) in order to establish the current technical knowledge, precision experience and skill level of the workforce. EQUIPMENT CONDITION ASSESSMENT We will spend hours in your plant evaluating the condition and status of rotating equipment in or-der to establish technical findings related to the level of precision evident in the installed asset base. Evaluation includes visual inspection, vibration checks and photographic data collec-tion. In a standard assessment we will normally be able to evaluate a cross-section of several hundred equipment MAINTENANCE PROGRAM ASSESSMENT We will also evaluate and assess several key maintenance program areas necessary for suc-cessful implementation and sustainment of a successful precision program. Key program areas include; lubrication program, MRO Stores and Inventory, Vibration monitoring and analysis, oper-ator care, preventive maintenance and reliability engineering. Our program assessment is ac-complished using small group interviews, CMMS data reviews and documentation analysis. Our program assessment is normally conducted by 2-3 of our personnel over the course of 3-4 days onsite. Approximately 2-weeks later the customer receives a written and electronic report which includes findings and recommendations for program implementation as well as a return-on-investment analysis for potential payback and benefits evaluation. An onsite management de-brief is also included as part of the assessment.
info@Hendrixpm.com (888) 233-9777 17 STADARDS | SPECIFICATIONS | PROCEDURES PRECISION CONSULTING Hendrix Precision Maintenance can provide standards and other tools necessary to help expe-dite your implementation of Precision Maintenance. These tools include implementation guidelines, checklists and worksheets to assist with your implementation as well as Key Per-formance Indicators to help track your journey to achieving PRECISION One of the first steps in Precision Maintenance is making sure your equipment vendors are complying with PRECISION. Hendrix has formatted equipment purchasing and repair specifica-tions which can be issued to your vendors to ensure that equipment that is either purchased or repaired comply with the necessary technical specifications to ensure the equipment can be maintained in a PRECISION state. PRECISION procedures are the key to ensuring your program is sustained long after training has been accomplished. Hendrix Precision Maintenance provides electronic formatted preci-sion maintenance PM’s which can be rapidly applied via the customer CMMS (Computerized Maintenance Management System) to specific assets to reinforce precision maintenance funda-mentals necessary to keep these assets in a precise state. Additionally, we also provide over 200 high fidelity electronically formatted rebuild and repair job plans for common equipment types which include operational steps, labor, tools, and parts for common repair activities con-forming to precision maintenance standards. STANDARDS SPECIFICATIONS PROCEDURES
www.HendrixPrecisionMaintenance.com 18 PRECISION MAINTENANCE Why Choose Hendrix? Thousands of craftspeople & supervisors who have attended different preci-sion maintenance classes agree our is 2X BETTER with more hands-on, more intensity and 2 rather than 1 instructor. At Hendrix keeping a low stu-dent/instructor ratio is paramount. We have now trained thousands of mechanics in over 300+ customer compa-nies and/or plants. Demonstrate measurable results and return $...EVERYTIME. Simply the BEST Precision Maintenance training available, delivered by Exceptional Instructors with decades of training and real world practical in-dustry craft & leadership experience. More Hands-On simulators and static demonstrators that replicate real-world, operating equipment. Specifically engineered to enable instructors to impart assembly errors and many common mistakes. Participants are then systematically taught to identify and eliminate each one, resulting in the con-version of poor, high risk of failure machine into an improved, reliable ma-chine - operating as intended. Integrated content and implementation capabilities with on-site mentor-ship, coaching and reliability engineering services. Do it Once, Do it Right!
info@Hendrixpm.com (888) 233-9777 19 Background Return On Investment ACTUAL RESULTS PETRO-CHEMICAL PLANT 2200 Pumps. Not happy with 2-year rotating as-sembly and mechanical seal life. PUMP & SEAL LIFE EXTENDED TO OVER 5 YEARS MINERAL OPERATIONS 400 3600rpm 300-400HP blowers across 49 plants worldwide. 2-year life expectancy on blowers resulting in a $50K rebuilds. DOUBLED BLOWER LIFE TO 4 YEARS WORLD’S LARGEST PULP & PAPER MILL Maintenance COST REDUCED 25% IN 4 YEARS while achieving & sustaining industry leading 98% UPTIME/AVAILABILITY MANUFACTURING PLANT On track to be shut down due to 75-85% average uptime. Precision Maintenance implementation YIELED 94-96% UPTIME & 4 YEARS OF PRODUCTION RECORDS PROCESS MANUFACTURING PLANT Chiefly interested in energy savings. 7.5% TOTAL ENERGY SAVINGS IN THE FIRST YEAR OF IMPLEMENTA-TION from putting equipment in a “Precise State”
www.HendrixPrecisionMaintenance.com 20 References Available Upon Request
info@Hendrixpm.com (888) 233-9777 21 TESTIMONIALS “The only way to truly breakthrough with exponential improvement in as-set management and maintenance improvement.” Maintenance Mgr. Pharmaceutical Industry “Every maintenance mechanic, supv, engr needs to go thru this training. I wouldn’t touch any equipment until this is complete.” Director of Reliability Petro Chemical Industry “I learned way more than I thought I would, even after reading the book a little over the last year and a half. It’s not often I dish out praise for a job well done, but after spending the last 15 years traveling around to our sites and training mechanics on our product specific equipment, I know it takes a special, dedicated person to deliver that training and keep the process lively, what I call “trick them into learning”. Mike and Wynn did a phenomenal job of keeping the class engag-ing and fun. Hats off to them for their hard work and you are lucky to have them on your team. Thanks again for putting such a comprehensive and easy to understand training opportunity out there!” Lifelong Mechanic & Technical Development Specialist Food & Beverage Industry “What Hendrix teaches is what’s missing from new generations in maintenance - hands on practical application that you just can’t get from a book or YouTube.” Senior Manufacturing Consultant Pulp and Paper Industry “All through the week of class I had numerous “ah-ha” moments, during which I realized that I had room for improvement. I wish this training was available earlier in my career as I know it would have helped to make me a better mechanic. I learned some great skills that are easy to implement in the area of equipment alignment and lubrication. The very skilled and knowledgeable instructors taught us that with a small investment in tools and a little extra time, we as mechanics can greatly improve equipment life and in doing so decrease downtime. I would highly rec-ommend this training to anyone in the field of Equipment Maintenance.” PSM/Utility Systems Specialist Food and Beverage Industry “Some of the best training I have ever received.” Vibration Analyst/ Reliability Wood Products Industry
www.HendrixPrecisionMaintenance.com 22 ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ _____________________________________________________ Do it Once, Do it Right! Notes:
info@Hendrixpm.com (888) 233-9777 23 Effect of Mis-Alignment on Vibration on a 1800 rpm piece of Rotating Equipment
www.HendrixPrecisionMaintenance.com 24 To understand what precision maintenance really is you have to (a.) know something about vibration of machines or (b.) accept one simple premise. Bearing engineers and manufacturers around the world, genuine NASA rocket scientists, and thousands now of Precision Maintenance Practitioners, will tell you…. “Lower the overall vibration of any machine with bearings in it, and you will exponentially increase the bearings and thus the machine’s life expectancy” -Dr. Wernher von Braun (Accomplished with Precision Machine - Assembly Error Reduction) The work above was done in the mid 1960’s by NASA’s Dr. Wernher von Braun and his own Rocket Team at the Redstone Arsenal in Huntsville, Alabama. Working with machinist and engineers they ran thousands of tests to determine the likeli-hood of bearings making the trip to the moon without failure. As you can see on the graph, small and usually inexpensive amounts of vibration reduction, easily achieved on most rotation equipment will yield much larger results in improved bearing life. Per NASA Running Tests