Recently, we once again sat down with Dr. Karl Hoffower, Founder and Executive Director of Failure Prevention Associates, LLC (FPA) (www.failureprevention.com). Failure Prevention is located in Houston, Texas. FPA is comprised of experienced staff certified in Vibration Analysis, Thermography, Ultrasound Inspection, Electric Motor Testing, Field Balancing, Laser Alignment and Reliability Centered Maintenance practices.
Paperitalo: Karl, it seems like there are always exciting issues in your business. What's new?
FPA: Thanks, Jim. A recent experience may be of interest to your audience. We had an opportunity to do some laser alignment training. We were in a steel mill. The crafts people there were having difficulties with longevity of bearings and also having high vibration issues. They were using a certain laser alignment tool and doing the best they could with it. Sounds like the right approach, but the answer was unsatisfactory. So, we did an assessment. We found the laser alignment tool they had is one not made for the alignment application they have. Someone had made a budgetary decision when buying tool. It's like I say, you could take a sedan and drive through the hills and the creeks, but probably should have bought a real 4 wheel drive off road vehicle. This is a similar situation. Again, someone made a decision based on budget instead of function and when you do that you do have a tool, but perhaps not the right one. If the tool doesn't work as well as it supposed to for your particular situation, you're going to pay for it in huge costs over a longer period of time. Spend a little extra, buy the right tool upfront. This beats paying for it over the next 10 years at crime syndicate rates
Paperitalo: I agree, but sometimes that is a tough sell. The person with the budget control today may not plan on sticking around for ten years.
FPA: True. But when we can demonstrate the savings, even the stingiest accounting wonk can get the message. One of our clients sent me an e-mail today and he said I really want to thank us for the laser alignment training and helping us prove the value of getting an industrial laser alignment tool for shaft alignment. And then there was a troublesome piece of equipment they had. In this case, we gave them classroom training, which you can get with the most vendors. But then what we do, which is different from others, is we went out into the field and said we want to align this particular machine that you have problems with--it was indicating excessive vibration. The FPA approach is to couple the classroom work with real, in field experience.
Paperitalo: Are there any other savings for the client in a situation like this?
FPA: Of course. Every time it is not properly brought within the manufacturer's specs, it must be shut down and dug into again. That involves lock out, tag out, and all the normal safety procedures. As you know, Jim, in the paper industry an hour of downtime can cost $30,000 to $60,000 each and every time. The client can buy lots of specialized tools with just one hour of that.
Paperitalo: Any other savings?
FPA: The savings never ends. A properly aligned motor pulls a fraction of the amps of a poorly aligned motor. This goes on day after day, at least until the motor experiences a premature failure! And, then--more downtime!
Paperitalo: So, in an experience like this, what is the client left with when you leave?
FPA: Just that when it comes to our approach to training and helping to turn training into long term programs we help to achieve long term results. We have the tools (both physical tools and training techniques) to prove that making the changes we advocate will deliver long term value for the client. This is one of our key metrics to assure proof of value that we deliver and we can show it instead of just a class room only approach. We are really focused on the client learning the specific steps it takes to do proper work once we leave. Simply if we don't leave you with your own program in place with your own people having the buy-in to make it work then you're not going to get the savings results in the long term
Paperitalo: Today we have been talking to Dr. Karl Hoffower of Failure Prevention Associates. Karl, thanks for your time. How do interested parties reach you?
FPA: karl@failureprevention.com is the fastest. You can also connect with me on LinkedIn or go to failureprevention.com and click on the contact us button.
