RELIABILITY OF OVERHEAD CRANES BY PROPER

OPTIMIZATION

Project Training Report for

Post Graduate Program in Management for Working Professionals Akshay Pruthi
19pgpmwe03@iimraipur.ac.in
 
 
 
 
Under the guidance of
Prof. Gopal Kumar
Area name :Operations
Introduction
About the Company
• Bharat Aluminium Co. Ltd (BALCO) was incorporated in the year 1965 as a Public
Sector Undertaking (PSU). It is the first public sector enterprise in the country which
started producing Aluminium in 1975.Balco has its own two captive Bauxite Mines
namely “Mainpat Bauxite Mines” and “Bodai Daldail Bauxite mines”. In order to
produce the one Tonne of alumina we need about 2.75 to 2.88 Tonnes Bauxite and
for one Tonne of Aluminium metal we need two Tonnes of Alumina and therefore
for one Tonne of Aluminium metal we needs about 5.75 Tonnes of Bauxite.
• The process used in the production of Aluminium in plant 2 is HALL HEROULT
PROCESS. The technology supplier of Balco is GAMI (Gulyang Aluminium and
Magnesium Institute) .The main process of smelting is done in the Pot Room and the
anodes are produced in Green Anode Plant which are baked under controlled
condition in the Bake Oven. To make them usable anodes in the Pot room, the baked
anodes are rodded in the rodding plant.
About Pot Room

Pot line -1 works on prebaked technology. A total of 288 pots are installed
with potline current of 320KA. All 288 pots are connected in a series fashion.
The pot line has eight sections with 36 pots in each section. The name plate
capacity of potline is 2.45 lakh MT per annum.

The raw material required for Aluminium production is alumina, carbon, power,
Aluminium fluoride and cryolite.

Raw Material Alumina Carbon Cryolite Aluminium Energy

Fluoride
Theoretical 1945 415 5 23 14000KWH/t
Consumption
(kg per Ton of
Aluminium)
A pot consists of two main parts:
1.Block of carbon which has been formed by baking a mixture of coke and
pitch. This block serves as an anode ( or positive electrode)
2. Under the anode is a large rectangular steel box lined with carbon made
by baking a mixture metallurgical coke and pitch. This lining is the cathode
( or negative electrode)
Between the anode and the cathode is space filled by electrolyte. This
mixture must be heated about 980 C, at which point it melts and the refined
alumina is added. This then dissolves in the molten electrolyte.
Pot Tending Machine (PTM)

The PTM is made up, a main trolley for Long travel with two girders. A
tools trolley equipped with bath pipe, Shovel, Extracting device and a
crust breaker. Also it is equipped with two auxiliaries hoisting trolley
16MT with cross travel and one tapping trolley 16MT with cross travel.
OPERATION TOOLS USED
Extraction Device,
Anode Change
Crust Breaker & Shovel
Tapping 16 T Tapping Trolley
Auxiliary Hoist &
Beam Raising
Coiling Drum
Anode Covering Bath Pipe
Problem Statement

In order to run the operation job properly and efficiently. 96 %

available hours to operation of Pot Tending Machine is required.

Availability = 24hrs- No. of hrs. PTM under maintenance/24 *100

Last 3 Month Availability

Dec 19 = 90.26 %
Jan 19 = 91.21 %
Feb 19 = 93.41 %
Equipment Wise Availability
Month PTM-101 PTM-102 PTM-103 PTM-104 PTM-105 PTM-106 PTM-201 PTM-202 PTM-203 PTM-204 PTM-205 PTM-206

Dec 19 91.96 95.62 92.82 82.09 85.42 89.2 94.74 94.97 84.86 86.46 91.92 93.06

Jan 20 91.38 91.13 93.45 88.98 90.37 91.29 94.42 93.41 92.37 87.85 84.62 95.3

Feb 20 93.79 94.99 95.66 90.55 90 95.05 95.85 96.21 89.57 92.13 91.04 96.1
Methodology
Using Tools for Organize Data
Pareto Chart

January Month Tools Criticality Analysis

Pareto Chart
BD BD x Cumulative 30.00
Priority Tool Freq Criticality ( % )
Mins Freq Criticality 25.21
25.00 100.00
1 Breaker 2625 40 105000 25.21 25.21 94.88
89.66
2 Comm 2255 34 76670 18.41 43.62 20.00 18.41 76.28
83.36
17.48
3 Shovel 2600 28 72800 17.48 61.10 15.18

BD Mins
15.00 61.10
4 Tapping 1860 34 63240 15.18 76.28
43.62
5 Comp 1405 21 29505 7.08 83.36 10.00
7.08 6.30
6 Ext 1250 21 26250 6.30 89.66 5.00
25.21 5.22 5.12

7 Aux 1035 21 21735 5.22 94.88

0.00
8 BP 1015 21 21315 5.12 100.00 Breaker Comm Shovel Tapping Comp Ext Aux BP
Using Tools for Organize Data
Flow Diagram

Problem Checking Arrangement of

Reported Validity of resources and
by Operation Problem Spares

Acknowledgement Taking Safety

Troubleshooting
for surrender Permit for
the Problem
the Permit the Job
Using Tools for Generating Ideas
Checklist
Using Tools for Generating Ideas
Cause and Effect Diagram
Using Tools for Identifying Problems
Statistical Chart
Valve Change Statistics in PTM’s

25

20 PTM-101
PTM-102
PTM-103
PTM-104
15
PTM-105
PTM-106
PTM-201
10 PTM-202
PTM-203
PTM-204
PTM-205 PTM-205
5
PTM-203 PTM-206

PTM-201
0
Jan PTM-105
Feb Mar Apr May PTM-103
Jun Jul Aug Sep Oct PTM-101
Nov Dec
Continuous Improvement
Kaizen
Key Learning and Recommendation

• Manpower power optimization can be done, more no. manpower in

May,june,July,August and few no. of manpower in remaining months.
• More Focus and better spare availability to be ensure for Crust
breaker and Communication fault.
• More Focus needed for PTM-104, PTM-203 and PTM-204.
• Weekly technical training schedule to be fixed for technicians .
Thank You

Any queries