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Miscon Assoc Mannheim Siemens Vibration Analysis

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Siemens Solar Industries and Shell Solar Industries used vibration analysis to improve the productivity of their wire saws. They introduced predictive maintenance practices by applying vibration sensors to high risk equipment and analyzing the data to prevent breakdowns. This increased overall equipment effectiveness, reduced costs by 15% per year, and improved uptime from 60% to an average of 96%. Condition monitoring through vibration analysis helped lower photovoltaic manufacturing costs and contributed to making solar power more commercially viable.

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Siemens Solar Industries and Shell Solar Industries Wire Saws Improved Productivity Through Vibration Analysis A Case Study M Miskus Director FM&E (2001- 2004) Siemens SI and Shell SI
Siemens Solar Industries Wire Saws Improved Productivity Through Vibration Analysis A Case Study M Miskus Director FM&E (2001-2004) Site Background on SSI The increasing demand for renewable forms of energy is making photovoltaic (PV) products an important part of the energy supply future. The costs of producing photovoltaic modules have been significantly reduced during the last 15 years as manufacturing costs per watt have dropped from over $6 per peak watt to less than half of that value now. Condition monitoring (vibration analysis) used in PV manufacturing has contributed to this reduction.
Siemens Solar Industries Wire Saws Improved Productivity Through Vibration Analysis A Case Study M Miskus Director FM&E (2001-2004) Crystal growth improvements, both in yield and machine design, have reduced the PV manufacturing energy consumption by a factor of 3 and improved silicon utilization by 40%. Wafer slicing process changes have resulted in 66% more wafers being produced for a given amount of silicon. Cell production improvements in both automation and improved efficiency have reduced the labor cost contribution by over 40% per watt.
Siemens Solar Industries Wire Saws Improved Productivity Through Vibration Analysis A Case Study M Miskus Director FM&E (2001-2004) Larger modules and better materials have added another 10% reduction in the cost to produce photovoltaics. These improvements have contributed to a better energy payback time, reducing it from over 5 years to approximately 3. Reductions in cost and improvements in energy efficiency have made photovoltaic products a commercially viable alternate energy source.
Siemens Solar Industries Wire Saws Improved Productivity Through Vibration Analysis A Case Study M Miskus Director FM&E (2001-2004) Why? How?
Siemens Solar Industries Wire Saws Improved Productivity Through Vibration Analysis A Case Study M Miskus Director FM&E (2001-2004) Introduce Predictive Maintenance Practices Subject Matter Expert Miscon Associates Mannheim Identify high risk assets and failure modes Correct application of sensors Adequate data acquisition
Siemens Solar Industries Wire Saws Improved Productivity Through Vibration Analysis A Case Study M Miskus Director FM&E (2001-2004) Interpretation of data via report Action to prevent breakdown
Siemens Solar Industries Wire Saws Improved Productivity Through Vibration Analysis A Case Study M Miskus Director FM&E (2001-2004) Identify Asset/Equipment for Pdm Survey Asset/Equipment for sensor Pre survey data for baseline Install sensors, preliminary data Review Data Collection Intervals
Siemens Solar Industries Wire Saws Improved Productivity Through Vibration Analysis A Case Study M Miskus Director FM&E (2001-2004) Review Data for Abnormalities Review Baseline Data Determine Asset Pre Failure Run time to Failure
Siemens Solar Industries Wire Saws Improved Productivity Through Vibration Analysis A Case Study M Miskus Director FM&E (2001-2004) Scientific Maintenance Life Cycle Cost Reduction Increase Overall Equipment Effectivity Operational Productivity Enhancement Lean Manufacturing
Siemens Solar Industries Wire Saws Improved Productivity Through Vibration Analysis A Case Study M Miskus Director FM&E (2001-2004) Develop and manage five-year strategic plan for equipment reliability through reliability based maintenance. SOP review. Implement predictive maintenance technologies and interval based actions Manage utility energy usage for Camarillo Campus and Vancouver, WA
Siemens Solar Industries Wire Saws Improved Productivity Through Vibration Analysis A Case Study M Miskus Director FM&E (2001-2004) Manage long term utility energy use plan for equipment Manage routine review for ISO compliance on all equipment preventive maintenance procedures effectiveness
Siemens Solar Industries Wire Saws Improved Productivity Through Vibration Analysis A Case Study M Miskus Director FM&E (2001-2004) Manage performance based projects to exceed PM/Downtime ratio for all areas measured 3.5/1 Establish OEE measurement for equipment performance reviews
Siemens Solar Industries Wire Saws Improved Productivity Through Vibration Analysis A Case Study M Miskus Director FM&E (2001-2004) Develop Five-year strategic plan for equipment reliability through reliability based maintenance and introduction of sound methods and systems reduce $15MM expense budget by 15% per year for 3 year period 2001-2003.
Siemens Solar Industries Wire Saws Improved Productivity Through Vibration Analysis A Case Study M Miskus Director FM&E (2001-2004) Integrate computerization with technical staff for on line equipment status. Achieve uptime average of 96% from 60% in 2.5 years. Administer review of all equipment preventive maintenance procedures effectiveness. Manage ISO 9000 compliance for manufacturing support role. Develop talent pool optimization for technical support of production areas. Established OEE measurement for equipment performance reviews. Exceeded PM/Downtime ratio for all areas 3.5/1 from .5/1 in 2003. Reduced redundant parts in maintenance stores and establish critical spares.
Siemens Solar Industries Wire Saws Improved Productivity Through Vibration Analysis A Case Study M Miskus Director FM&E (2001-2004) Developed talent pool optimization for technical support of production areas. Established OEE measurement for equipment performance reviews. Exceeded PM/Downtime ratio for all areas 3.5/1 from .5/1 in 2003. Reduced redundant parts in maintenance stores and establish critical spares.
Siemens Solar Industries Wire Saws Improved Productivity Through Vibration Analysis Solar Power Supply Chain
Siemens Solar Industries Wire Saws Improved Productivity Through Vibration Analysis Wire Saw Technology
Siemens Solar Industries Wire Saws Improved Productivity Through Vibration Analysis (Typical Equipment)
Siemens Solar Industries Wire Saws Improved Productivity Through Vibration Analysis (Typical Equipment)
Siemens Solar Industries Wire Saws Improved Productivity Through Vibration Analysis (Typical Equipment)
Siemens Solar Industries Wire Saws Improved Productivity Through Vibration Analysis (Typical Equipment)
Siemens Solar Industries Wire Saws Improved Productivity Through Vibration Analysis (Typical Equipment)

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Miscon Assoc Mannheim Siemens Vibration Analysis

  • 1. Siemens Solar Industries and Shell Solar Industries Wire Saws Improved Productivity Through Vibration Analysis A Case Study M Miskus Director FM&E (2001- 2004) Siemens SI and Shell SI
  • 2. Siemens Solar Industries Wire Saws Improved Productivity Through Vibration Analysis A Case Study M Miskus Director FM&E (2001-2004) Site Background on SSI The increasing demand for renewable forms of energy is making photovoltaic (PV) products an important part of the energy supply future. The costs of producing photovoltaic modules have been significantly reduced during the last 15 years as manufacturing costs per watt have dropped from over $6 per peak watt to less than half of that value now. Condition monitoring (vibration analysis) used in PV manufacturing has contributed to this reduction.
  • 3. Siemens Solar Industries Wire Saws Improved Productivity Through Vibration Analysis A Case Study M Miskus Director FM&E (2001-2004) Crystal growth improvements, both in yield and machine design, have reduced the PV manufacturing energy consumption by a factor of 3 and improved silicon utilization by 40%. Wafer slicing process changes have resulted in 66% more wafers being produced for a given amount of silicon. Cell production improvements in both automation and improved efficiency have reduced the labor cost contribution by over 40% per watt.
  • 4. Siemens Solar Industries Wire Saws Improved Productivity Through Vibration Analysis A Case Study M Miskus Director FM&E (2001-2004) Larger modules and better materials have added another 10% reduction in the cost to produce photovoltaics. These improvements have contributed to a better energy payback time, reducing it from over 5 years to approximately 3. Reductions in cost and improvements in energy efficiency have made photovoltaic products a commercially viable alternate energy source.
  • 5. Siemens Solar Industries Wire Saws Improved Productivity Through Vibration Analysis A Case Study M Miskus Director FM&E (2001-2004) Why? How?
  • 6. Siemens Solar Industries Wire Saws Improved Productivity Through Vibration Analysis A Case Study M Miskus Director FM&E (2001-2004) Introduce Predictive Maintenance Practices Subject Matter Expert Miscon Associates Mannheim Identify high risk assets and failure modes Correct application of sensors Adequate data acquisition
  • 7. Siemens Solar Industries Wire Saws Improved Productivity Through Vibration Analysis A Case Study M Miskus Director FM&E (2001-2004) Interpretation of data via report Action to prevent breakdown
  • 8. Siemens Solar Industries Wire Saws Improved Productivity Through Vibration Analysis A Case Study M Miskus Director FM&E (2001-2004) Identify Asset/Equipment for Pdm Survey Asset/Equipment for sensor Pre survey data for baseline Install sensors, preliminary data Review Data Collection Intervals
  • 9. Siemens Solar Industries Wire Saws Improved Productivity Through Vibration Analysis A Case Study M Miskus Director FM&E (2001-2004) Review Data for Abnormalities Review Baseline Data Determine Asset Pre Failure Run time to Failure
  • 10. Siemens Solar Industries Wire Saws Improved Productivity Through Vibration Analysis A Case Study M Miskus Director FM&E (2001-2004) Scientific Maintenance Life Cycle Cost Reduction Increase Overall Equipment Effectivity Operational Productivity Enhancement Lean Manufacturing
  • 11. Siemens Solar Industries Wire Saws Improved Productivity Through Vibration Analysis A Case Study M Miskus Director FM&E (2001-2004) Develop and manage five-year strategic plan for equipment reliability through reliability based maintenance. SOP review. Implement predictive maintenance technologies and interval based actions Manage utility energy usage for Camarillo Campus and Vancouver, WA
  • 12. Siemens Solar Industries Wire Saws Improved Productivity Through Vibration Analysis A Case Study M Miskus Director FM&E (2001-2004) Manage long term utility energy use plan for equipment Manage routine review for ISO compliance on all equipment preventive maintenance procedures effectiveness
  • 13. Siemens Solar Industries Wire Saws Improved Productivity Through Vibration Analysis A Case Study M Miskus Director FM&E (2001-2004) Manage performance based projects to exceed PM/Downtime ratio for all areas measured 3.5/1 Establish OEE measurement for equipment performance reviews
  • 14. Siemens Solar Industries Wire Saws Improved Productivity Through Vibration Analysis A Case Study M Miskus Director FM&E (2001-2004) Develop Five-year strategic plan for equipment reliability through reliability based maintenance and introduction of sound methods and systems reduce $15MM expense budget by 15% per year for 3 year period 2001-2003.
  • 15. Siemens Solar Industries Wire Saws Improved Productivity Through Vibration Analysis A Case Study M Miskus Director FM&E (2001-2004) Integrate computerization with technical staff for on line equipment status. Achieve uptime average of 96% from 60% in 2.5 years. Administer review of all equipment preventive maintenance procedures effectiveness. Manage ISO 9000 compliance for manufacturing support role. Develop talent pool optimization for technical support of production areas. Established OEE measurement for equipment performance reviews. Exceeded PM/Downtime ratio for all areas 3.5/1 from .5/1 in 2003. Reduced redundant parts in maintenance stores and establish critical spares.
  • 16. Siemens Solar Industries Wire Saws Improved Productivity Through Vibration Analysis A Case Study M Miskus Director FM&E (2001-2004) Developed talent pool optimization for technical support of production areas. Established OEE measurement for equipment performance reviews. Exceeded PM/Downtime ratio for all areas 3.5/1 from .5/1 in 2003. Reduced redundant parts in maintenance stores and establish critical spares.
  • 17. Siemens Solar Industries Wire Saws Improved Productivity Through Vibration Analysis Solar Power Supply Chain
  • 18. Siemens Solar Industries Wire Saws Improved Productivity Through Vibration Analysis Wire Saw Technology
  • 19. Siemens Solar Industries Wire Saws Improved Productivity Through Vibration Analysis (Typical Equipment)
  • 20. Siemens Solar Industries Wire Saws Improved Productivity Through Vibration Analysis (Typical Equipment)
  • 21. Siemens Solar Industries Wire Saws Improved Productivity Through Vibration Analysis (Typical Equipment)
  • 22. Siemens Solar Industries Wire Saws Improved Productivity Through Vibration Analysis (Typical Equipment)
  • 23. Siemens Solar Industries Wire Saws Improved Productivity Through Vibration Analysis (Typical Equipment)