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19-05-2015

#POWEROFSEE
AVAILABILITY CENTERED MAINTENANCE

© Dibyendu De

Green/sustainability??
DO MORE WITH LESS
LESS RISK, LESS RESOURCES, LESS ENERGY
MORE MONEY

© Dibyendu De

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19-05-2015 AVAILABLE STRATEGIES BREAKDOWN MAINTAINENCE no control on failures PREVENTIVE MAINTAINENCE focuses on reducing failures TPM prevents accelerated failures CBM prevents secondary failures RCM prevents consequences of failures #POWEROFSEE © Dibyendu De 2 .

19-05-2015 Availability Centered Maintenance = “ELIMINATING FAILURES thru extending LIFE” #POWEROFSEE © Dibyendu De Availability Centered Maintenance Availability = MTBF/ (MTBF+MTBR) #POWEROFSEE © Dibyendu De 3 .

of Breakdowns(Avg/month) Number 30 20 10 0 1st Yr 2nd Yr 3rd Yr 4th Yr Years CASH FLOW  1/ NO. OF BREAKDOWNS #POWEROFSEE © Dibyendu De 4 .19-05-2015 Availability Centered Maintenance No.

511 101865 CBM benefit till date(Rs ‘000 ) GAP 2237 Bakeoven Rodding Cast House Potroom Utility 7432 2698 77 345 41 Availability Centered Maintenance ACM applied to 3 Cement Plants on 62% equipment under critical category #POWEROFSEE © Dibyendu De 5 .40.27.19-05-2015 Benefits – ACM AL Smelter May-JuneJuly Septemb er Total Energy Cost Saving 165719 1135 Total Outage Cost Saving Total Maintenance & bearings cost Saving TOTAL SAVINGS 11473774 Area 1101018 100730 1.

19-05-2015 effects of Availability Centered Maintenance ON CEMENT PLANT # Audit Parameters Previous After 1 Year After 2 Years 1 No. of Breakdowns /Year 57 19 3 2 % of Breakdown Hours 25 12 5 Effect of ACM 60 57 50 40 30 20 25 19 12 10 5 3 0 Previous After 1 Year No of BreakDowns/Year After 2 Years % of BreakDown Hours #POWEROFSEE © Dibyendu De effects of Availability Centered Maintenance CASE I Audit Parameters BEFORE AFTER KILN NON STOP <3 MONTHS >11 MONTHS #POWEROFSEE © Dibyendu De 6 .

Jun.Jul-02 Aug.Jun.Apr.Nov.Jul-03 Aug.Sep.Jan.Feb.19-05-2015 effects of Availability Centered Maintenance CASE II Audit Parameters BEFORE AFTER KILN STOPPAGE 187 / YEAR <15 / YEAR #POWEROFSEE © Dibyendu De effects of Availability Centered Maintenance benefits Down time because of Bearing problem Down Time (minutes /month) BEFORE 50 45 40 35 30 25 20 15 10 5 0 AFTER 45 36 34 23 18 7 5 7 16 9 7 0 0 0 0 0 0 0 Apr.Mar.May.Sep02 02 02 02 02 02 02 02 03 03 03 03 03 03 03 03 #POWEROFSEE © Dibyendu De 7 .May.Dec.Oct.

19-05-2015 effects of Availability Centered Maintenance results # Audit Parameters EFFECT 1 DOWNTIME 0 MINS 2 PRODUCTIVITY 10% Effect of ACM ACM DOWNTIME #POWEROFSEE PRODUCTIVITY © Dibyendu De 8 .

Cost 10 15 0 1 2 3 4 5 6 7 8 9 10 11 12 #POWEROFSEE © Dibyendu De effects of Availability Centered Maintenance running time #POWEROFSEE © Dibyendu De 9 .19-05-2015 effects of Availability Centered Maintenance cost Reliability vs. Cost 25 40 30 20 20 -.Reliability -.

19-05-2015 Availability Centered Maintenance essentials MANAGEMENT COMMITMENT KNOWLEDGE SUPPORT MINIMAL INTERVENTIONS #POWEROFSEE © Dibyendu De Availability Centered Maintenance ingredients PEOPLE LEADERS #POWEROFSEE © Dibyendu De 10 .

19-05-2015 Availability Centered Maintenance development levels #POWEROFSEE LEVEL 5 – THE ART & SCIENCE OF CREATING RELATIONSHIPS LEVEL 4 – THE ART & SCIENCE OF ELIMINATING IMPERFECTIONS LEVEL 3 – THE ART & SCIENCE OF ANALYZING DYNAMICS LEVEL 2 – THE ART & SCIENCE OF UNDERSTANDING COMPLEXITY LEVEL 1 – THE ART & SCIENCE OF OBSERVING REALITY #POWEROFSEE © Dibyendu De 11 .

Manchester University.19-05-2015 Availability Centered Maintenance review • NOTICE • ENGAGE HOW AND WHAT IS HAPPENING WHY IT HAPPENS? ? WHEN TO DO IT? WHAT TO DO? • EXCHANGE • MULL #POWEROFSEE © Dibyendu De Availability Centered Maintenance review “Once done the company gains permanent on-going benefits.” -Prof. Tim Henry.K #POWEROFSEE © Dibyendu De 12 . U.

Availability & Sustainability 13 .19-05-2015 Case Studies Availability Centered Maintenance Services (ACM) 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 .

19-05-2015 #POWEROFSEE THANK YOU © Dibyendu De 14 .