Armstrong World Industries, Inc. Pensacola, Florida ... - UE Systems

Armstrong World Industries, Inc.
Pensacola, Florida
Ceiling Plant
Presented by:
Denver Osthoff

Armstrong World Industries Information
Armstrong World Industries, Inc., is a global leader in the design
and manufacture of floors, ceilings, and cabinets.
Founded in 1860, and based in Lancaster, PA,
Armstrong has plants in 12 countries
The Pensacola, Florida plant has been in operation for over 75
years and manufactures residential and commercial ceiling tiles.

UE Systems Implementation at the Pensacola Plant
UE System’s Ultrasound, technology was introduced at
the Plant in 2003 as part of a corporate initiative to
enhance PdM technologies
Began using the UE Systems in 2004
First system introduced was the UE 9000
Currently use the UE 10000 System

From our humble start in 2004
To a global initiative in 2009

UE System’s technology was
introduced at the Plant in
2003
At that time there was no one that
Wanted the job
In 2004 we started a pm program at
the Board mill that incorporated the
UE 9000

• This was a long and slow start for us, no one knew
how the UE Systems worked
• After some time and many calls to UE, which has
the best customer services I have ever used, I
became proficient with the system and now I have a
level ll in ultrasound
• Armstrong Pensacola has had many savings from
the U E systems, here are some examples

How did you find it (PdM Route,
Work Order, Daily Excellence, OBC,
DUMB LUCK)?
What did the initial data tell you?
That we had a problem with the drive
end of this motor
Who did you share the data with and
how was it used to decide how to best
address the issue?
We have a Boardmill group that I send
my info out to when we have issues and
they decide what step to take

This is the end result of trending and repairing
Corrective action taken
Motor replaced

Couch roll drive motor
Blow is a new rebuild motor that was a spare we had just installed and if we had not seen
the problem with the motor in our UE checks we would have lost it .
We had the rebuilder come and look at the report and he was able to see the information
we had. He said that the motor needed a grounding brush to stop the arcing in the
bearing . Note there was a grounding brush on the old one and we had to have one
added to this one as we had it rebuild

This was a new installation of our couch roll motor
1 2 3
This was
taken on
4/3/9
This was
taken on
4/27/9
This is today
5/7/9
What we have are 3 check R = 4/3/9 G =4/27/9
and W = today's

What we have here is the replaced motor with the new
grounding brush installed notice the sound wave

Repair before failure
Pump Replacement of
Bearings.
Cost $1707
If this had been a catastrophic failure,
the cost would be:
• New shaft $5195.
• Bearings $1095.
• Labor $612.
• Plant down $80000.
• Total cost $86902.
• Saving = $85195.

How precision maintenance can give your equipment longer life
This is the IB bearing for our fan Pump
and this is the first reading after it was
installed on 1/9/08 .You can hear and
see the impacting of the bearing after
seeing this we when back and did a
complete precision installation on the
pump and motor. See the slide on the
right and what a big change it made

ABP Predictive
Maintenance Network
Learning Library
Plant:
Armstrong Pensacola
Technician/Operator: Denver Osthoff
Sharing Learning
This is the board mill vacuum pump, Below you
will see what you can do with the UE 10,000. We
thought we had a cavitation problem, so we
checked the pump with a load and with out a load
and found out we still had a problem with the
pump. Then Bobby had the bearing checked and
found that the shaft was worn under the race, and
had the pump replaced…NO down time!!
Date: 3/26/10
Date of Conference Call
Equipment:
Vacuum pump
PdM Technology:
Primary Technology Used
(Acoustics )

This was taken on 2/12/10 with a load on the pump. We thought we had a cavitation
problem, so as you will see on the next slide, we checked the pump with no load .

This is without a load on 3/5/10 and we found we still had a problem with the pump.
On 3/22/10 Bobby had the bearing on the OB side checked and found that the shaft
was worn under the race and replaced the pump .

This is the replacement pump

Conveyor Bearing Example
Bearing noise on baseline
measurement
Bearing noise in early stages
of failure.

Airborne Measurement Example
Conveyor - Broken Collar

Airborne Measurement Example
UE gun in Airborne mode found a broken collar
Broken collar noise
on conveyor

The weld has broken on the west side, and on the next slide you
can hear what I heard when I was doing an airborne check at the
dry saw

Here we have a conveyor drive chain at the dry saw where I was doing an
airborne check. In the slide you have a before lubrication on the chain
and an after lubrication. This shows that the chains need to be lubricated
to save chain and sprocket wear

In august of 2009, due to the good report we have had at the Pensacola plant
with the UE System , Armstrong Building Products (ABP) went Global .
I have had the opportunity go to 2 of our plants in Europe and 2 plants here in
the states to share what we are doing in Pensacola with the UE Systems .
Armstrong Pensacola now has a reliability network out side of Armstrong
plants were we share the different technologies used . I have been invited to
share the UE Systems technology there.

These kind of finds helped bring our plant
in as the top plant of the year .We also use
Infrared and Vibration technology.
We have run for 4 years without a
catastrophic failure. We had 1 failure that
we knew about that ran to failure .

I must say that I know this is about U E
Systems, but in this story there was a lot
help from the maintenance and
production department to get our plant
where it is today. As I said we use all of
the technologies we can.
What I have show you here today was all
U E. With that said, I think that the U E
Systems has had a big part in our
improvement .

Questions????