Mr M V S Raju

19-05-2015

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#POWEROFSEEAVAILABILITY CENTERED MAINTENANCE

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Green/sustainability??DO MORE WITH LESS

LESS RISK, LESS RESOURCES, LESS ENERGY MORE MONEY

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AVAILABLE STRATEGIES

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PREVENTIVE MAINTAINENCEfocuses on reducing failures

TPMprevents accelerated failures

RCMprevents consequences of failures

BREAKDOWN MAINTAINENCEno control on failures

CBMprevents secondary failures

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Availability Centered Maintenance


“ELIMINATING FAILURES thru extending LIFE”

=



Availability = MTBF/ (MTBF+MTBR)

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No. of Breakdowns(Avg/month)

0

10

20

30

1st Yr 2nd Yr 3rd Yr 4th Yr

Years

Nu

mb

er

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CASH FLOW 1/ NO. OF BREAKDOWNS

#POWEROFSEE

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Benefits – ACM AL Smelter May-June-

JulySeptemb

er

Total Energy Cost Saving 165719 1135

Total Outage Cost Saving 11473774

Total Maintenance & bearings cost Saving

1101018 100730

TOTAL SAVINGS 1,27,40,511 101865

Area CBM benefit till date(Rs ‘000 )GAP 2237

Bakeoven 7432Rodding 2698Cast House 77Potroom 345Utility 41


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ACM applied to 3 Cement Plants

#POWEROFSEE

on

62% equipment under critical category

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# Audit Parameters Previous After 1 Year After 2 Years

1 No. of Breakdowns /Year 57 19 3

2 % of Breakdown Hours 25 12 5

effects of

ON CEMENT PLANT

57

19

3

25

12

50

10

20

30

40

50

60

Previous After 1 Year After 2 Years

Effect of ACM

No of BreakDowns/Year % of BreakDown Hours



Audit Parameters BEFORE AFTER

KILN NON STOP <3 MONTHS >11 MONTHS

effects of

CASE I

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Audit Parameters BEFORE AFTER

KILN STOPPAGE 187 / YEAR <15 / YEAR

effects of

CASE II

Down time because of Bearing problem

36

23

34

7

45

57

1816

97

0 0 0 0 0 0 00

5

10

15

20

25

30

35

40

45

50

Apr-

02

May-

02

Jun-

02

Jul-02 Aug-

02

Sep-

02

Oct-

02

Nov-

02

Dec-

02

Jan-

03

Feb-

03

Mar-

03

Apr-

03

May-

03

Jun-

03

Jul-03 Aug-

03

Sep-

03

Dow

n T

ime (m

inu

tes /

mon

th)



effects of

benefits

BEFORE AFTER

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# Audit Parameters EFFECT

1 DOWNTIME 0 MINS

2 PRODUCTIVITY 10%



effects of

results

ACM

Effect of ACM

DOWNTIME PRODUCTIVITY

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effects of

cost

-- Reliability

-- Cost

Reliability vs. Cost

15

20

25

1 2 3 4 5 6 7 8 9 10 11 12

0

10

20

30

40



effects of

running time

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essentials

MANAGEMENT COMMITMENT

KNOWLEDGE SUPPORT

MINIMAL INTERVENTIONS




ingredients

PEOPLE

LEADERS

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development levels

LEVEL 1 – THE ART & SCIENCE OF OBSERVING REALITY

LEVEL 2 – THE ART & SCIENCE OF UNDERSTANDING COMPLEXITY

LEVEL 3 – THE ART & SCIENCE OF ANALYZING DYNAMICS

LEVEL 4 – THE ART & SCIENCE OF ELIMINATING IMPERFECTIONS

LEVEL 5 – THE ART & SCIENCE OF CREATING RELATIONSHIPS

#POWEROFSEE

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review

• MULL• EXCHANGE

• ENGAGE• NOTICE

WHAT IS HAPPENING

?

HOW AND WHY IT

HAPPENS?

WHAT TO DO?

WHEN TO DO IT?



review

“Once done the company gains permanent on-going

benefits.”

-Prof. Tim Henry, Manchester University, U.K

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Case Studies

ACME PVT LTD is the only company in the World to combine Advanced Technology, Big Data Analysis and Knowledge to deliver Manufacturing Plants with Highest Level Reliability , Availability & Sustainability

Availability Centered Maintenance Services (ACM)

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#POWEROFSEETHANK YOU

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Documents

Mr M V S Raju