Bearings - 10/09/2010
Andrey Zaluzhsky, the Chief Mechanic of “Ilim” Group in Bratsk, visited the NSK factory and training centres located in Poland and France. The purpose of the visit was to familiarise Ilim with the production processes and NSK’s training experience. This was connected to the current restructuring underway within the technical services area of the “Ilim” Group.
As previously reported, last year NSK jointly with another competitor won a bid among bearing manufacturers for centralised deliveries to “Ilim” Group plants. This was the second stage of restructuring within the maintenance and equipment repair system being held sequentially in Ilim. Under the terms of the tender the winners were to conduct training for the plant specialists in regards to bearings maintenance, mounting and dismounting, and storage.
At the beginning of the year the representatives of the Branch and “BRMZ” LLC underwent training at a competitors technical center in Moscow. Later employees from the Ilim Group – Koryazhma and Ust-Ilimsk – were shown round the NSK production sites and training centres.
"Andrey, what did the visit program include?"
"In Poland we visited the ball bearing production site in Kelce where we were shown the complete manufacturing process. I was particularly attracted by the fact that the quality is checked 100% at all stages of the process - from raw material receipt to product ready to release. The plant has different laboratories where, for instance, they use noise detectors to identify irregularities under different climate conditions, or also use vibration monitoring to control metal. There is also a chemical laboratory.
In the technical centre near Paris we participated in a seminar, where they presented new types of bearings made by NSK. Particularly we were told about TL Series rolling bearings, which could be effectively applied in driers. In April these bearings will be delivered to Bratsk.
We also discussed some current issues existing in the branches, such as the need to increase bearing life. In connection to this NSK proposed interesting solutions that could help increase bearing life and did not require a significant modernisation of bearing units.
There we also analysed in detail the possible irregularities and bearings damage cases, bearings storage and transportation conditions, and new mounting and dismounting methods. Besides that we considered the issues of equipping training classes. The partners promised to provide us with the necessary training materials such as videos, posters, instructions and technical literature in Russian."
"Why is it necessary to organise a training class directly at the production site?"
"The main reason is the territorial proximity to the production sites and the possibility for the maintenance services specialists to get quick response to arising questions, as well as theoretical and practical assistance. The class will always be open and the employees will be able to come there any time. The Responsibility service is in charge of this activity. Incidentally, it was recommended by “Ilim” Group’s Engineering Management to organise such training classes. On 5-6 April NSK specialists will conduct the first training seminar in Bratsk, where 28 mechanics and power engineers from the plants will take part. Then all trained specialists will, in turn, train the junior maintenance personnel on the basis of this training class."
"Is the training program set?"
"Yes, both companies proposed its content. Special emphasis will be given to the practical knowledge. NSK specialists who visited Bratsk confirmed that the number of pieces of equipment were quite sufficient for the start, and if necessary, they were ready to delivery more equipment for the training class."
"We speak about bearings but the area of responsibility for the maintenance personnel includes lot more."
"All equipment has bearings. And its appropriate operation (70-80 per cent) depends on the correct mounting of bearings. Therefore the basic knowledge in bearings technology shall include bearing units, mounting and dismounting methods, storage conditions and maintenance. At the same time we do not refuse from other training programs. Attendees of our Reliability service are representatives of different companies-manufacturers that visit our Bratsk sites on a regular basis. Recently for instance we have had a seminar on lubrication of units held by the senior specialists of factories. It was discussed what type of oil and for which equipment was better to use. To conduct such training we used a portable laboratory where we could check the oil quality. So in general, we do our utmost to prepare our maintenance and repair specialists to correctly operate the new equipment to be installed within the implementation of the Company’s business plan in Bratsk."
"Who else besides your mechanics will be trained in the class?"
"Contractors’ specialists, responsible for repair of our equipment. In this case special attention will be drawn to tooling, which the contractors shall obtain to ensure the appropriate fulfillment of their liabilities. Short-term training of specialists of such organisations and special tooling supplying will become obligatory conditions of work at our production site. If contracting organisations managers refuse to follow the engineering minimal courses they will have no access to the factory.
As for the nearest seminar, the specialists from Ust-Ilimsk will take part in it. Our neighbours do not have such training classes and so will come to Bratsk. NSK will conduct training on 7-8 April."
"The first seminar will be given only by NSK?"
"Yes. The matter is that our relations with NSK’s competitor are tuned. Now we have the same understanding with NSK. During their first visit to Bratsk we asked them to solve problems with two units: low-pressure feeder and “Bark Master” press. On 5 April when they come to give training we assume to get a technical solution from them and a feasibility study on these issues. Furthermore we will work with the company’s representative responsible for bottleneck eliminations. Both companies have immense experience that we can utilise."
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