October - Library - Central Queensland University

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14 Do you have at least one trained person per shift to maintain & troubleshoot your plant PLCs? Is your maintenance staff trained on the PLC? Silly to squander over a couple of thousand in maintenance training when the lack of PLC knowledge could cost you 10 thousand an hour. I can give you a couple of good reasons why you should have at least one trained person per shift, to work reliably with PLCs. You do not want to see greater downtime on off shifts because the knowledge base is on day shift only. Also with all the baby boomers (our core knowledge base in the industry) about to retire, it is not smart management to place all your eggs in one basket. Then the question should be asked, what should we look for in training? Well I have been training individuals for over a decade and could easily write another article on just PLC training alone. I can tell you here, that you should seek training with two primary objectives:- 1. The training you decide on, should stress working with PLCs in a Safe and Reliable way. (not just textbook knowledge or self learned knowledge) 2. Secondly, the training should be actually centered around the PLC products you are using or plan to use in your facility. I feel the two criteria above are the most important. Some other good ideas to get more out of your PLC training investment would be to get hands on training using the actual PLC programs and software the maintenance technician will be working with in the f a c i l i t y. Ensure your personnel have the software, equipment and encouragement to continue with self education. PLC Training CBT (Computer Based Training) CDs are a great way for employees to follow up 6 months after the initial training. Some other ideas you could do is to provide them with simulation software and/or a spare PLC off the shelf to practice with. Do your maintenance personnel work with PLCs following written company or corporate policy and procedures? It seems that in our industrial culture, if policy and procedures are not written and enforced, we eventually stray back to the old u n reliable ways. I have reviewed many policy and pro c e d u res as well as books on the topic matter and hardly ever see maintenance management of the PLCs included. It amazes me how an organization can write guidelines for what they believe is the health of the entire organization’s body, and leave out the brain (the PLC ). Once again, a complete PLC policy and procedure manual is out of the scope of this article. However, I will donate a few random items below to get you started:- 1. Write PLC policies and procedures into your existing maintenance policy and procedures. (SOP) 2. All personnel working with PLCs will be trained on that PLC equipment. 3. Backup copies of the PLC programs will be made every 6 months regardless of change status. 4. If a PLC program has been changed ... • It will be documented in the software copy, in the printed copy and in the CMMS program. • Copies of the PLC program will be stored on a media more reliable than floppy disk (CD, USB, etc.). • Multiple copies will be stored on laptop, maintenance manager’s office and off site (corporate). • If available, EEPROM will be updated with new changed program. - If outside vendor changes, a-d will be performed by maintenance personnel 5. Future equipment purchases ... • A common PLC brand in all equipment will be sought out (Standardization of PLC types) • OEM will be required to provide a descriptor copy of PLC programs in the customer’s native language. • All PLC 110v control voltage will have a line filter on it. • All PLCs will have the backup EEPROM option for zero downtime in some failure modes. 6. Forcing inputs and outputs on or off shall be treated as a Safety issue. (See safety SOP) 7. Inputs and outputs shall not be forced on or off with out a clear understanding of complete effect on PLC program and a second opinion. • If forces are installed, they shall be removed within 24 hours and a more permanent solution found. • All forces should be documented in software and a written log before being enabled. 8. Online programming is somewhat of a safety risk, normal procedure is to change offline and download to the PLC. Hope this helps, if you have a specific question you can find me in our PLC discussion area at the www.idcon.com/toastforum6503/toast/toast.asp?sub=show&action=topics&fid=10 Business Industrial Network www.bin95.com
THE LATEST INFRARED CM/PM PACKAGE FROM NEC • FULL 320 X 240 UNCOOLED FPA DETECTOR • IN-BUILT VISIBLE CAMERA & LASER POINTER • STORES OVER 1000 IMAGES INTERNALLY • LIGHT-WEIGHT AND SMALL PACKAGE • STRONG & ROBUST TO IP54 • “FLIP-UP” 3.5 INCH LCD SCREEN • NEC QUALITY AND RELIABILITY “ALL FOR UNDER AU$ 25,000” Infratherm Pty. Limited Infratherm Pty Ltd PO Box 117, NORTH RICHMOND, NSW 2756 AUSTRALIA Te l :+ 61 2 4579 7334 or +61 2 4322 2100 Fax: +61 2 4579 6333 or +61 2 4323 7439 E-mail: jrobinson@infratherm.com.au - mratne@infratherm.com.au web: www.infratherm.com.au
Page 2 and 3: The Entek product family - complete
Page 5: A journal for all those interested
Page 8 and 9: 8 Maintenance In Iraq When it comes
Page 10: 10 A Asset Management John Wilson (
Page 13: How many PLCs is your bottom line d
Page 17 and 18: The metric is calculated as follows
Page 20 and 21: 20 Backlog Backlog is one of the ke
Page 22 and 23: 22 Proactive Maintenance Metrics PM
Page 24 and 25: 24 Vendor Stocked Maintenance Inven
Page 26 and 27: 26 Performance Rate Percentage P e
Page 28 and 29: 28 T Reliability Solutions, Inc., (
Page 30 and 31: 30 project or some major maintenanc
Page 32 and 33: 32 Survey 2005 Special Maintenance
Page 47 and 48: 48 Generating Failure Codes Using F
Page 49 and 50: 50 Figure 4: Equipment Failure Mode
Page 51 and 52: 52 Figure 6: Weibull Curve Generate
Page 53 and 54: 54 The Business End Of Maintenance
Page 55 and 56: 56 Managerial Performance Financial
Page 57 and 58: 58 Analyse Equipment Failures Impro
Page 59 and 60: 60 Moving From Reactive To Proactiv
Page 61 and 62: 62 The foundation of the maintenanc
Page 63 and 64: 64 CONDITION MONITORING TECHNIQUES
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66 The information data base reside
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68 A key objective in being success
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70 m a i n t e n a n news c e Asset
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72 CSI 4500 Online Vibration Monito
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74 According to Product Manager Jim
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Strategic Aim Create and justify fi
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Maintenance Publications The follow
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MAINTENANCE PUBLICATIONS S e rvice
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October - Library - Central Queensland University

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