July 29th 2009

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Return to NSW Industrial Maintenance Roundtable (IMRt)

Illawarra Yacht Club IMRt Roundtable Meeting with BOC Oxygen Plant and David Brown Gears site tours

The meeting was attended by 37 people from 12 organisations. The meeting started of with attendee introductions and General Business.

General Business Presentation Download Presentation

The meeting had two Formal Presentations and four informal discussion/presentations groups and after lunch there was a Site Tour of the BOC Oxygen Plant hosted by Hamilton Wearing and then another site tour of the David Brown Gears manufacturing and overhauls workshop.

Formal Presentations

Machine Killers - Arrest and Rehabilitation by Rod Bennett from Silcar -

Rod came up from Westernport Victoria by special request to present an overview of the Best-Of Skills & Practice Flyers that they have been using at Bluescope Steel. These flyers are intended to be presented as a 5 minute teach for use at toolbox meetings and have been widely accepted as an ideal way to drive defect elimination and as an extremely valuable technical resource. Rod with present some of the topics covered by his flyers and some of the wins that have been achieved. Rod's presentation was very well received with lots of questions from the attendees.

(Download Presentation) 3.5 Meg Presentation so may take a while to view.

Rod Bennett's Reliability Walk Proforma - Download

Link to Maintenance Skills and Practices Flyers

Overhaul Standards & Repair Compliance by Richard Wishard from HVO Rio Tinto Coal Aust - This presentation was one

of the best from the recent Electrical & Safety Forum in Melbourne. Richard Wishart is the Rio Tinto Procurement Technical Inspector based at Hunter Valley Operations. They are very interested in improved management of their offsite repairs to critical equipment with a high impact on mine production for both mobile and fixed plant. He was employed to develop and implement a system of management which would bring ‘off site’ repair work under control both technically and financially. During the last three years his group has developed a suite of repair specifications and procedures in conjunction with the repair vendors and the equipment end-users to improve reliability, extend the duration between equipment overhauls and lower the overall cost of asset ownership. Significant ‘hard dollar’ savings to the business have been realised which have more than paid for the Off Site Repair team and justified it’s expansion to improve penetration and further embed the process.

(Download Presentation) 4 Meg Presentation so may take a while to view.

Informal Topics Including Group Discussions

Knowledge Management in Maintenance - This session was lead by Marie O’Brien who is the Knowledge Management Roundtable (KMRt) Facilitator for NSW. She was one of the key contributors to our Knowledge Management in Maintenance Common Interest Workgroup meeting and gave feedback the highlights from that meeting and discuss with the group various option for better managing knowledge. To view the report and details from the meeting Click on this Link.

Overhead Crane Maintenance & Reliability – This session was lead by Richard Winwood-Smith who is the Senior Mechanical Engineer Cranes at Bluescope Steel. He gave feedback from our CIWG meeting on overhead cranes and will lead discussions around what it takes to achieve reliability and extended service for cranes. Richard has expertise in determining the requirements for end of life assessments, so the report should be of great interest if you have older cranes. To view the report and details from the meeting Click on this Link.

Conveyors Maintenance & Reliability – This session gave feedback from the upcoming CIWG meeting on Conveyors and Materials Handling Maintenance & Reliability on 9th July in Parkes. This meeting was hosted by Troy Hopley from Northparkes mines and he lead this session. To view the report and details from the meeting Click on this Link.

DC Motor Reliability Improvement – Richard Wishart from Rio Tinto has done a significant amount of work with Motors reliability improvement at their site and he lead discussions for anyone interested in motors and DC drives, which there was a strong contingent from Bluescope Steel. There was positive feedback on the value of these discussions. Some information provided by Richard can be downloaded from the following links.

Pictorial Record of Improvement Work to date 3 Meg file so may take a while to view.

The Concept of Quality

BOC Port Kembla Oxygen Plant Site Tour

After lunch most of the morning group took part in a site tour of the BOC Port Kembla Oxygen Plant hosted by the NSW Operations Manager Hamilton Wearing. The tour started with a presentation by Hamilton about BOC's NSW Oxygen, Nitrogen and Carbon Dioxide plants of which the Port Kembla plant is the biggest. A very interesting fact is that all these plants plus many other across Australia and New Zealand are operated from one Central control room at North Ryde in Sydney. The Oxygen Plant is based at Port Kembla to supply the Bluescope Steel making processes. The Port Kembla plant runs with only one or two shift operator maintainers with most of the people on site being the BOC truck driver who distribute the gas.

Hamilton also gave a very detailed explanation of how the Oxygen, Nitrogen and Argon manufacturing process. The group then split up into three and had a guided tour of the plant. The tour included the turbo machinery rooms that supplies the compressed air that drives the oxygen making process.

David Brown Gears Bulli Workshop Site Tour

14 of the attendees continued on to the second site tour that was help at the David Brown Gear Industries Bulli Workshop. This workshop is David Brown's largest manufacturing and repair workshop in Australia. The meeting was organised by Peter Kilmurray the Director of Aftermarket Asia Pacific and hosted by Ian Chew their General Manager. Ian gave an initial presentation to the group on the history of David Brown and the their capability for gear manufacturing and gearbox repair. The group then were given a full tour of the workshop with a special focus on the gearbox repair area. There was a lot of interest from the group on the full load gearbox testing facility that has the capability to do a baseline condition assessment of a repaired gearbox before it leaves their facility.