Equipment Criticality

Assessment
At Vedanta Aluminium Ltd /
Sterlite Energy Ltd
www.pwc.com
Strictly Private
and Confidential
August 25, 2012
25/08/2012 Presentation1
ECA involves calculation of Criticality Score
Criticality Score is the multiplication of 7 distinct factors covering the entire
functionality of the equipment
The 7 factors are rated on the scale of 1 to 3
The seven factors are:
Consequence Factor
The Methodology
PwC
August 25, 2012
Consequence Factor
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
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
25/08/2012 Presentation1
The Approach (Contd.)
2. Redundancy Factor (RF)
Availability of Standby
PwC
August 25, 2012
Availability of dedicated
Standby
Conditional Standby
No availability of
Standby
Rating = 1 Rating = 2
Rating = 3
25/08/2012 Presentation1
The Approach (Contd.)
3. Downtime Factor
1
(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
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
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
25/08/2012 Presentation1
The Approach (Contd.)
6. Loading Factor (LF)
Equipment Loading wrt rated
capacity
PwC
August 25, 2012
Loading is less than 80% of
the Rated Capacity
Loading is between 80% -
100% of the Rated Capacity
Loading is more than 100%
of the Rated Capacity
Rating = 1
Rating = 2 Rating = 3
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
25/08/2012 Presentation1
The Criteria
Most Critical = Criticality Score >= 648
Critical = 64 < Criticality Score < 648
Non Critical = Criticality Score =< 64
PwC
August 25, 2012
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)
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Based on
CF
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G
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Based on
SF
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PwC
August 25, 2012
Critical
(64-648) Most Critical (>= 648)
Critical
(64-648)
FMEA and
Reduction of RPNs
Proactive Maintenance,
Improve Maintainability
Critical
(64-648)
Condition is
Evident
Condition is
hidden
Condition Based
Maintenance
Time Based
Maintenance
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SF
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
Thank You
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