So how big is your PdM program, and what all does in entail?

I'm trying to get a feel for what the general industry standard is for PdM programs/departments. I work for a large foundry in North America. We have 6 plants acrcoss the US. Our plant is currently the only one with any kind of in-house PdM program. At our facility We have about 700 employees, with 120 of them being Maintenance personnel. Our PdM program consists of vibration analysis, thermography, and some oil analysis. And right now, I am by myself when it comes to the vibration analysis and thermography (a seperate department handles the oil analysis). Currently, I am monitoring some 2500+ vibration points (at last count) on about half of our equipment. Our thermal imaging program, we cover every electrical component in the plant (disconnects, tubs/buckets, panels, everything...), but almost no mechanical applications. We do not do any kind of ultra sonic's, or motor current analysis, or acceptance testing on anything. Basically, because I'm at my limit.

My hang-up is just that, I'm by myself. I know a few other industries in our area that have extensive PdM programs/departments where they involve many people (10-12 or more), in multiple departments, across all three shifts, and all cross trained in each technology.

So what is the general concensus on PdM programs out there when it comes to size and abilities and staffing?

Bill, our group of 3 people covers 44 buildings, located mostly within 10 miles of each other. We do HVAC, power and steam, fire protection, and some R&D equipment. At present, we have about 1100 machines (roughly 10,000 points) that we perform vibration analysis on. We do alignment on our rotating equipment, most of the lubrication, including greasing and oil changes. We also replace some of the bearings, belts, gearboxes, etc. We do some in-house oil analysis, but send most of it out for now. We balance as needed. We do not do thermography on electrical switchgear, but are certified to. We do use it for roof leaks, steam leaks, and others as needed.

We are full time analysts, and part time millwrights.

We just have to be careful not to get our "cape" caught in rotating equipment, or get grease on the big "S" on our shirts