If you have hydraulic equipment, there's a good chance you're tired of dealing with hydraulic-related problems like:
These things can be particularly frustrating if your personnel haven't had the basic hydraulic training needed to troubleshoot your system and identify what is causing your hydraulic problems.
"Downsizing downtime" means getting equipment back into operation faster, having equipment operate longer between breakdowns, and maybe even preventing unscheduled down time from happening at all. The things you can do to downsize your downtime include:
Hydraulics Friendly Equipment
Most equipment is designed to provide trouble-free hydraulic service for "as long as it takes to exceed the customers' expectations."
"Hydraulics Friendly" equipment helps the hydraulics provide trouble-free service "for as long as possible."
For example, the reservoir in every hydraulic system holds hydraulic fluid that is covered by a layer of air (much like a milk bottle holds milk that is covered by a layer air). A reservoir's fluid level drops and rises as the hydraulic system operates, forcing air to move in and out of the reservoir. The air can cary very small pieces of contamination that can drop into the hydraulic fluid, and then damage hydraulic components.
To prevent that, the air entering a hydraulic reservoir is filtered. Some equipment manufacturers use inexpensive air filters designed to stop particles big enough to see, and that cleans the air enough for their hydraulic systems to provide trouble-free operation for longer than their customers expect.
But contamination too small to see, including particles smaller than a white blood cell, can damage a hydraulic pump. While those small particles are rarely going to cause immediate catastrophic pump failure, they act much like sandpaper and gradually wear down a pump's internal parts. As the pump's internal parts slowly wear, performance suffers, and the pump eventually has to be replaced.
As you've probably guessed, there are air filters designed to stop particles smaller than a white blood cell. Using those air filters instead of an inexpensive air filter reduces the number of damaging particles dropping from the air into the hydraulic fluid, and makes the equipment more "hydraulics friendly."
WARNING: Before replacing an air breather, be sure the pressure drop through the new breather is the same or lower than the pressure drop through the old breather (if you are not nodding your head and thinking "that's pretty obvious," please consult a fluid power specialist, contact us, or take a Basic Hydraulics course before changing your air breather).
Companies with the fewest hydraulics headaches all have some things in common. Those things include:
The good news is that with a small amount of focused Basic Hydraulics training, your personnel and your company can be more like those companies with the fewest hydraulics headaches.
We provide on-site, non-technical, Basic Hydraulics training that focuses on downsizing your downtime:
Note: We're an independent training resource. We don't sell products and we don't promote any companies. The only thing we offer is the training and knowledge needed to help your personnel downsize your downtime.
One of the biggest problems with hydraulics is that when a hydraulic component suffers internal damage, no matter how slight, that damage creates small pieces of contamination that can damage other hydraulic components in your system. And when those other components get damaged, they send additional contamination through your hydraulic system.
To make matters worse, damage inside hydraulic components creates small pathways that allow hydraulic fluid to leak internally from areas filled with high pressure fluid to areas with low pressure fluid. In addition to reducing your system efficiency and slowing hydraulic component speeds, that internal leakage creates heat.
As heat is transferred to your hydraulic fluid, the fluid thins. And because thin hydraulic fluid doesn't protect a hydraulic component's internal parts very well, your hydraulic pumps, motors, valves, and cylinders become even more susceptible to damage from all those little pieces of contamination in your hydraulic fluid.
Bottom line? Hydraulic problems spawn additional hydraulic problems, and every day you go without fixing a problem increases the amount of time, effort, and money it takes to get your equipment back to being as productive and trouble-free as possible.
Some years ago, a brewery scheduled a production line shutdown for some routine maintenance. The brewery's equipment was "hydraulics friendly," and both maintenance personnel and machine operators consistently followed practices designed to downsize hydraulic downtime.
At the time of the shutdown, the hydraulic system had operated daily for over 9 years, often 2 and sometimes 3 shifts a day. While the hydraulic system had never caused any problems, the maintenance manager arranged to have the hydraulic pump, hydraulic motor, and hydraulic valves inspected and refurbished during the scheduled down time.
As you may have guessed, when the hydraulic components were inspected and tested, the components showed some minor wear, but the pump, motor, and valves functioned properly and were within factory specs.
A company that manufactures conveyor belts uses a total of 14 hydraulic pumps in their production equipment, and sometimes shut down as often as three times a month to change out pumps, motors, valves, and cylinders. Without including the cost of lost production, the company was spending more than $96,000 a year for new and repaired hydraulic pumps, motors, valves, and cylinders.
After a one-day "Basic Hydraulics" boot camp, the plant engineer and maintenance manager modified their hydraulic power units and maintenance procedures. They gradually made a transition to just one short, scheduled shutdown every six weeks to change out air breathers, spending less than $12,000 a year for hydraulic repairs, filter elements, and air breathers.
A company that manufactures plastic containers has a servo valve that used to lock up every 6 to 8 weeks. While the maintenance department had become pretty fast at changing out the valve, the company still had to deal with about 90 minutes of downtime every time the valve failed.
The purchasing department had been unable to find anyone who could reliably repair the servo valves, so, adding insult to injury, they were buying new servo valves every time they had a breakdown. Between the cost of downtime and new servo valves, their plant engineer figured the problem was costing "approximately" $36,574.85 a year.
The company invested a bit over $3,000 in contamination control, and the maintenance department began testing their hydraulic fluid on a regular schedule. The last time we talked, it had been 3 years since a servo valve failed. By making their equipment more "hydraulics friendly," the company's maintenance personnel eliminated a bunch of headaches and saved the company over $105,00 in servo valve costs and unscheduled downtime.
There's no way of predicting whether you'll get similar results, but these are all actual experiences. One of my mentors was involved with the brewery inspection, and our hydraulic boot camps helped maintenance personnel at the two manufacturing companies figure out the changes that downsized their downtime.
While we can't predict how much your personnel will downsize your downtime, we can guarantee that everyone who participates in our courses will:
A 1 day Basic Hydraulics Boot Camp at your facility, which focuses on downsizing your downtime while teaching your personnel all the "basics" of hydraulics, including how to read and understand hydraulic schematics, is $375 per person.
There's a minimum training fee of $1,875, a maximum training fee of $3,375, and a maximum of 12 class participants. The Boot Camp can be customized to include up to two hydraulic schematics for a one-time additional charge of $275.
A 2 day Basic Hydraulics Class at your facility, which covers the Boot Camp material in greater depth, reviews additional hydraulic circuitry, and provides your personnel with additional opportunities to practice and master the material is $685 per person.
There's a minimum training fee of $3,425, a maximum training fee of $6,165, and a maximum of 12 class participants. The Basic Hydraulics Class can be customized to include up to three hydraulic schematics for a one-time additional charge of $350.
A 3 day Basic Hydraulics Course at your facility, which expands on the 2 day Basic Hydraulics Class and integrates up to three of your hydraulic schematics is $995 per person.
There's a minimum training fee of $4,975, a maximum training fee of $8,955, and a maximum of 10 participants. The course fee include the integration of up to three of your hydraulic schematics.
If you are outside the Chicago metro area, the Columbus Ohio metro area, and the Cleveland Ohio metro area, there are additional charges for travel and lodging.
1) Start the training process in any of three ways:
2) After we all agree on the type of training, date(s), time, location, and number of participants, you'll send us any schematics or special instructions needed for the training session(s). The special instructions can include any particular issues you'd like addressed during the training.
3) We'll determine any travel and lodging costs and then send you an invoice for the deposit needed to secure the date(s) of your training.
4) In most cases, the instructor will arrive at your facility the day before the training session to meet you and view your facility.
5) We'll submit an invoice for the balance of the training fee after the training session(s).
Please let me know if you have any questions or need any information not provided here on the web site.
9520 Monroe Ave.
Brookfield IL 60513
web site: www.BasicHydraulics.com
If your personnel attended a one day "Basic Hydraulics" class that covers just the principles of hydraulics, hydraulic component functions, and basic hydraulic circuitry, that class would be worth the $375 per person we charge for our one day Hydraulic Boot Camp.
If we conducted a one day "How to Read Hydraulic Schematics" class, that schematics class alone would also be worth the $375 per person we charge for our one day Hydraulic Boot Camp.
We'll leave it up to you to determine how much it would cost to hire a consultant to visit your facility, survey your equipment, and help you develop a plan to dramatically reduce your hydraulic-related downtime.
And what would you save if you could eliminate just two hydraulic breakdowns a year, or if, like the plastic container manufacturer, your hydraulic equipment went three years without any unscheduled hydraulic downtime?
The bottom line is that almost all Basic Hydraulic training pays for itself in reduced downtime and increased productivity, an these courses are an exceptional value. Click the "Schedule a Class" button or call Rob Fish at 614-214-7261 to arrange for training and start the process of downsizing your downtime.
Customized Creations • Providing Hydraulic Instruction Since 1988 • Call 614-214-7261614-214-7261
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