November 2023 Volume 5

MAINTENANCE

Navigating Your Way Through Project Timelines for Equipment Repairs and Upgrades in the Steel Forging Industry By Jeff Fredline

Ram, Wrist Pin and Connections As with the crankshaft, main bushings rotational clearance can be measured. Rough dimensions can be gathered, which will allow for acquiring accurate costing. If you can obtain the rough dimensions, you can have new bronze castings manufactured so that they are on the shelf waiting to be machined as soon as you have the finished dimensions. Ordering castings ahead of time could save you several weeks. Driveshaft Assembly, Flywheel and Clutch Brake Assemblies Normally, you will have the necessary documentation in your files to determine what components will need to be on hand and pricing and delivery dates can be received in advance. If you plan to order new bearings and seals, verify the identification numbers, order them ahead and have them on the shelf ready when you need them. Emergency Breakdowns There are no easy answers for breakdowns. When a breakdown occurs, it is always a challenge and timing is sometimes more important than the cost of the project. When the machine goes down, the first step should be to put together an evaluation team to analyze where you are really at. Sometimes disassembly and inspection must be the first step. Ask the questions: what is damaged, what needs to be fixed and what do we need to get operational again? Once you can determine what the scope of the project needs to be, you can begin to plan the timeline and see where you might be able to improve. Prevention Work to Identify and Prevent Before It Occurs Much has been discussed over the past few years regarding the importance of Preventative Maintenance. If we apply the principles of 5S, Inspection and Benchmarking, most of the emergency breakdowns can be prevented and repairs planned more cost effectively. The establishment of accurate timelines will forever be a challenge for mechanical, electrical, and hydraulic system repairs. There will always be unknowns to be dealt with. The goal should be to manage and control what you can, and then plan for any unknowns.

Post-Pandemic, obtaining service and materials in a timely manner has become more difficult than it has been in years past. Things are improving, but we are still a long way from where we would like to be. Purchasing new machine components such as main bushings, crankshafts, bull gears, ram assemblies and other components are a challenge. There are some things you can prepare for ahead of the project that will save you money and headache. Determining the Potential Working Scope To accurately project the scope of your project, precision inspection of the condition of your machine should be the first step. Spending a day or two completing a complete machine inspection, either by your personnel or from a qualified supplier, is time and money well spent. I recommend that you add two weeks to the estimated time you believe it will take to complete the work. The following areas should be inspected: Frames Inspect frames for cracks and excessive wear. Any damage should be marked, measured, have pictures taken and recorded so that they can be discussed during the creation phase of the working scope. Repair of damaged frames and components can also be time consuming, however through inspection discovery you can get more accurate pricing estimates and a timeline before beginning the process. Crankshaft/Eccentric Shaft and Bronze Shaft Support Bearings The rotational clearance between the shaft and the main bushings can be easily checked using hydraulic jacks to lift the weight of the slide assembly and crankshaft. Check the total movement between the crankshaft and the frame of the press on both the right hand and left-hand side of the machine. If the clearance is beyond the recommended levels, you will know that the bushings will need to be replaced. No matter who is going to make the repairs, you can get the price and delivery time of the bushings. If a new crankshaft is needed, get the price and delivery estimate, and include it in the working scope. Note that it could take over a year to obtain a new crankshaft or main drive gear for a press. Tip: Bronze bushing castings, both rough cast and finished machined, can be obtained from McHenry Brass in Kentucky and Advance Bronze in Ohio. I’ve found that often their pricing and lead times are better than from OEM suppliers.

FIA MAGAZINE | NOVEMBER 2023 16