8/12/2019 2.Awareness on Equipment Criticality Assessment

http://slidepdf.com/reader/full/2awareness-on-equipment-criticality-assessment 1/13

 Equipment Criticality Assessment 

 At Vedanta Aluminium Ltd /Sterlite Energy Ltd

www.pwc.com

 Strictly Privateand Confidential 

 August 25, 2012

8/12/2019 2.Awareness on Equipment Criticality Assessment

http://slidepdf.com/reader/full/2awareness-on-equipment-criticality-assessment 2/13

25/08/2012 Presentation1

•   ECA involves calculation of Criticality Score

•   Criticality Score is the multiplication of 7 distinct factors covering the entirefunctionality of the equipment•   The 7 factors are rated on the scale of 1 to 3• The seven factors are:

The Methodology

PwC August 25, 2012

  Redundancy Factor   Downtime Factor   Cost of Replacement Factor   Severity Factor   Loading Factor   Restoration / Service Factor

Criticality Score = CF x RF x DF x CrF x SF x LF x SF

8/12/2019 2.Awareness on Equipment Criticality Assessment

http://slidepdf.com/reader/full/2awareness-on-equipment-criticality-assessment 3/13

25/08/2012 Presentation1

The Approach

1. Consequence Factor (CF)

Refers to Impact on Production (P)

& Quality (Q)

PwC August 25, 2012

 Affects neither P nor Q Affects either of them Affects both P & Q

Rating = 1 Rating = 2 Rating = 3

8/12/2019 2.Awareness on Equipment Criticality Assessment

http://slidepdf.com/reader/full/2awareness-on-equipment-criticality-assessment 4/13

25/08/2012 Presentation1

The Approach (Contd.)

2. Redundancy Factor (RF)

 Availability of Standby

PwC August 25, 2012

 Availability of dedicatedStandby

Conditional Standby No availability ofStandby

Rating = 1 Rating = 2 Rating = 3

8/12/2019 2.Awareness on Equipment Criticality Assessment

http://slidepdf.com/reader/full/2awareness-on-equipment-criticality-assessment 5/13

25/08/2012 Presentation1

The Approach (Contd.)

3. Downtime Factor1 (DF)

Equipment Downtime

PwC August 25, 2012

Less than 1% of

running time

1 – 3% of the running

time

Greater than 3% of the

running time

Rating = 1 Rating = 2 Rating = 3

1 Last 6 months data is used for calculating Downtime Factor

8/12/2019 2.Awareness on Equipment Criticality Assessment

http://slidepdf.com/reader/full/2awareness-on-equipment-criticality-assessment 6/13

25/08/2012 Presentation1

The Approach (Contd.)

4. Cost of Replacement Factor (CrF)

Cost of replacement of spare

PwC  August 25, 2012

Less than Rs1Lakh Between Rs 1Lakh to Rs 5Lakh Greater than Rs 5 Lakh

Rating = 1 Rating = 2 Rating = 3

8/12/2019 2.Awareness on Equipment Criticality Assessment

http://slidepdf.com/reader/full/2awareness-on-equipment-criticality-assessment 7/13

25/08/2012 Presentation1

The Approach (Contd.)

5. Severity Factor (SF)

Safety & Statutory Compliance

PwC  August 25, 2012

 Affect neither Safety

nor Statutory

 Affects either of the

two Affects both Safety

& Statutory

Rating = 1 Rating = 2 Rating = 3

8/12/2019 2.Awareness on Equipment Criticality Assessment

http://slidepdf.com/reader/full/2awareness-on-equipment-criticality-assessment 8/13

25/08/2012 Presentation1

The Approach (Contd.)

6. Loading Factor (LF)

Equipment Loading wrt ratedcapacity

PwC  August 25, 2012

Loading is less than 80% of

the Rated Capacity

Loading is between 80% -

100% of the Rated CapacityLoading is more than 100%

of the Rated Capacity

Rating = 1 Rating = 2 Rating = 3

8/12/2019 2.Awareness on Equipment Criticality Assessment

http://slidepdf.com/reader/full/2awareness-on-equipment-criticality-assessment 9/13

25/08/2012 Presentation1

The Approach

7. Service / Restoration Factor

Refers to Serviceability of

equipment

PwC  August 25, 2012

If spares and expertise is

available within the plant

If spares and expertise only partly available within the

 plant and external help may

be required

Rating = 1 Rating = 2 Rating = 3

Criticality Score = CF x RF x DF x FF x SF x LF x SF

If spares and /or expertise

completely dependent on

external parties only

8/12/2019 2.Awareness on Equipment Criticality Assessment

http://slidepdf.com/reader/full/2awareness-on-equipment-criticality-assessment 10/13

25/08/2012 Presentation1

The Criteria

Most Critical = Criticality Score >= 648

Critical = 64 < Criticality Score < 648Non Critical = Criticality Score =< 64

PwC  August 25, 2012

8/12/2019 2.Awareness on Equipment Criticality Assessment

http://slidepdf.com/reader/full/2awareness-on-equipment-criticality-assessment 11/13

25/08/2012 Presentation1

 Model to Develop Maintenance Strategy

CF

RF

SF

LF

DF

CrF

Non-critical(=< 64)Non Critical (=<64)

Reduce MTTR 

Breakdown

Maintenance

Non-critical(=< 64)

   P  r  o   d  u  c  t   i  o  n

   G  a  t  e

Based on

CF

  a   f  e  t  y   /   S  t  a  t  u  t  o  r  y   G  a  t  e

Based on

SF

   C  r   i  t   i  c  a   l   i  t  y   S  c  o  r  e

PwC  August 25, 2012

Critical

(64-648)Most Critical (>= 648)Critical

(64-648)

FMEA andReduction of RPNs

Proactive Maintenance,

Improve Maintainability

Critical

(64-648)

Condition isEvident

Condition ishidden

Condition Based

Maintenance

Time Based

Maintenance

 

SF

8/12/2019 2.Awareness on Equipment Criticality Assessment

http://slidepdf.com/reader/full/2awareness-on-equipment-criticality-assessment 12/13

25/08/2012 Presentation1

Plant

•   Logical equipment tree structure to be made

•   ECA would be carried out at distinct Functional level

 How We Would do at client………………………….(1/2)

PwC  August 25, 2012

Section 1

Functional Location

Super Equipment

Equipment

Section 2 Section 3

Criticality done at this

level

8/12/2019 2.Awareness on Equipment Criticality Assessment

http://slidepdf.com/reader/full/2awareness-on-equipment-criticality-assessment 13/13

Thank You

The information contained in this document is provided 'as is', for general guidance on matters of

interest only. PricewaterhouseCoopers is not herein engaged in rendering legal, accounting, tax, or

other professional advice and services. Before making any decision or taking any action, you should

consult a competent professional advisor.

© 2011 PricewaterhouseCoopers Private Limited. All rights reserved. In this document, “PwC” refers to

PricewaterhouseCoopers Private Limited (a limited liability company in India), which is a member firm

of PricewaterhouseCoopers International Limited, each member firm of which is a separate legal entity.