Smith & Nephew Orthopedics Reduces Unplanned Downtime by 90% With Help from IR

In early 2006 Smith & Nephew Orthopedics started a predictive maintenance program utilizing infrared, vibration, motor circuit analysis and ultrasonic testing. We began with 67 monthly, 20 quarterly, and 670 annual inspections. Along with checking for electrical issues we have utilized infrared to diagnosis a number of potential failures on machine bearings. In just one year, we reduced unplanned downtime and emergency work orders by 90%, and are planning to expand the program. Currently we have eight level II thermographers, and two with level III certification. Developing the predictive program has been both challenging and rewarding. Among the challenges: Identifying critical equipment, frequency of testing, when to take action, which technologies to use, routes, parameters, support, and how to handle the increased workload of a new PdM program. The impact of application of new PdM technologies can create some misleading initial results. Problems that have been "lived with" may now be subject to recommendations from PdM specialists in early phases of technology introduction on an asset.