Ultra Tech Cement Limited Unit: Aditya Cement Works V · PDF fileour industry as heavy...
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V ision: Achieve the safe maintenance leading to zero breakdown and quality maintenance at optimal cost. Mission: To institutionalize a system of structured processes in which all employees work to improve equipment uptime,quality of maintenance, safe work culture and to reduce maintenance cost through the improved Maintenance Practices. Objectives • To strengthen the RCM implementation • To develop safe maintenance practices. • Reduction in equipment down time with proactive maintenance approach. • Enhancing equipment effectiveness with omputerized planned maintenance (PM) system. • Reduction in Maintenance cost by adopting cost control measures. • Adoption of Regular self PM audit system. Key Performance Indicators • Reduction in MTTR • Increase in MTBF and OEE • Reduction in Spares & maintenance Cost • Number of Maintenance Audits • Increase in number of equipments under Condition Based Maintenance • Development of Advanced Maintenance Management Techniques. Introduction: Our Planned Maintenance (PM) is the methodical process of building and continuously improving the maintenance system. It includes Specialized Maintenance and Self Maintenance. The Specialized maintenance involves: Preventive Maintenance, Predictive Maintenance, Reliability Centered Maintenance and Maintenance Prevention. Equipment Evaluation: Cement manufacturing process consists of handling of huge quantity of material & grinding of various materials (In million tons), as raw materials are highly abrasive, hence during process, all equipments undergo major wear & tear so reliable maintenance is important factor for maintaining availability of equipments such as Lime Stone Crusher, Mills, Kiln, Packers, Material Handling equipments, Compressors etc. Equipment logs are maintained and categorized in the SAP module to access their rank of failures. This is used in equipment wise failure analysis and spares management and maintenance notifications.Planned maintenance supports self maintenance by monitoring basic conditions through condition monitoring. Analysis of MTTR, MTBF & OEE and relevant improvement initiatives are resulting in to the downtime reduction. Equipment Performance Enhancement: We implement RCM projects on identified equipments to enhance their reliability. Equipment breakdowns are closely analyzed by using tools such as why & why, C&E analysis and is further analyzed focusing FMEA review to understand the current status of our assets. All the breakdowns are captured along with why & why analysis in SAP. Hence, we ensure no breakdown is left without analysis and repetition of breakdowns is prevented. Our maintenance teams are trained to use problem solving tools. Accelerated deterioration including ageing, wear pattern, fatigue is monitored and life is increased by proactive solutions to prolong the service life. Standardization: Routine maintenance jobs are identified and scheduled for preventive maintenance of equipments. There is a system to monitor preventive maintenance through daily evaluating PM check list in SAP and reviewed on weekly basis. Standard maintenance procedures for periodic maintenance have been prepared and Maintenance Protocols are in practice to track the deviation of the quality of the maintenance. RCM recommendations are incorporated in developing draft maintenance procedure to align with standard maintenance procedures. PM Audit is being conducted and actionable points are identified on quarterly basis to meet PM objectives. Structured system of preventive maintenance both time based as well as condition based which covers all critical equipments has been established. Our Predictive Maintenance is designed based on criticality of the equipment. Predictive Maintenance is widely used in our industry as heavy machineries need to run without any stoppage. In predictive maintenance various tools, latest instruments & techniques are used by team of engineers from maintenance specially identified for predictive maintenance. Results: Level of attainment of Planned Maintenance overall performance as per external bi-annual assessment improved from 55-60 (2009) to 75-80(2011). Ultra Tech Cement Limited Unit: Aditya Cement Works Front Row (Left to Right): Virendra Jaggi, Hitesh Makwana, Rajvir Yadav (PM Leader), Bhushan Joshi (Executive President and Unit Head), Chandra Shekhar Pandey (Senior Vice President Technical), Ashok Sahu, Vikas Garg Back Row (Left to Right): Jindas Jayaseelan, Sandeep Saxena, Ravindra Routela, Rajesh Kumar, Sanjay Gupta, Madan Maheshwari, Sunil Mishra, Jay Indoria CMMS software: • PLC & SCADA control system for plant operations from Central Control Room (CCR I). • Distributed control system (DCS) for plant operation from Central Control Room (CCR II). • PI (Process Interaction) Software for monitoring the real time plant operations. • Real Time Monitoring and analysis from PI in excel. • FUZZY Logic system for simultaneous setting and control of multiple specifications. • Optima Blending Control System for maintaining the raw meal quality and consistency. • XRF system for product quality analysis. • Cross Belt Analyzer for maintaining the raw material quality. • Kiln Shell Scanner for Temperature monitoring and control. • SAP PM, PP, QM, CMS, FICO, and MM Modules for overall asset management. • In-house developed softwares’ for Gas Cylinders Management & Fire Extinguishers Management. Predictive maintenance instruments and software: • Digital Vibration Data Collector & Analyser Two Channel with omnitrend software (Vibxpert VIB 5.300 • Pruftechnik). • Analoge Vibration Data Collector & balancer Two Channel (Vibrotest, Schenck Avery). • Easy Laser Alignment Kit. (D-279, Damalini). • Thermal Imager (Fluke Ti30). • Fast Align (Manatec, FAC 5H). • Ultrasonic Thickness Gauge (Edison-1M). • Ultrasonic Flaw detector (Einstein -II TFT, Modsonic). • Stroboscope (Nova strobe DB Plus, Monarch). • Intrigated Hardness Tester (TH 130, Time Group Inc). • Vibration Pen (SKF Vibration Pen Plus, CMVP/40/50). • Bearing Pen (SKF SEE Bearing Pen, CMPB30). • Noncontact Thermometer (Raynger ST, Raytek). • Poldy Hardness tester (Metal Spot Engineers, Navsari) • 14. AC Current Clamp (Fluke i400) • Laser Alignment ( Damalini AB) • Vibration Meter (IRD- 306) • 17. Shock Pulse Analyzer (SPM A2011) • Insulation Multimeter (Fluke 1587) • Viscosity Meter (Visage). • Electric Discharge Detector (TKED-1). • CSI-2130 & 2120 (Emerson Process Management Limited) CMMS Sofware and Predictive Maintenance Instruments/Software: Best Emerging Maintenance Reliability Program Best Maintenance Reliability Programs 2012
Transcript of Ultra Tech Cement Limited Unit: Aditya Cement Works V · PDF fileour industry as heavy...
V ision: Achieve the safe maintenance leading to zero breakdown and quality maintenance at optimal cost.Mission: To institutionalize a system of structured processes in which all employees work to improve equipment
uptime,quality of maintenance, safe work culture and to reduce maintenance cost through the improved Maintenance Practices.
Objectives
• To strengthen the RCM implementation
• To develop safe maintenance practices.
• Reduction in equipment down time with proactive maintenance approach.
• Enhancing equipment effectiveness with omputerized planned maintenance (PM) system.
• Reduction in Maintenance cost by adopting cost control measures.
• Adoption of Regular self PM audit system.
Key Performance Indicators
• Reduction in MTTR• Increase in MTBF and OEE• Reduction in Spares &
maintenance Cost• Number of Maintenance Audits• Increase in number of equipments
under Condition Based Maintenance• Development of Advanced Maintenance Management Techniques.
Introduction: Our Planned Maintenance (PM) is the methodical process of building and continuously improving the maintenance
system. It includes Specialized Maintenance and Self Maintenance.The Specialized maintenance involves: Preventive Maintenance,
Predictive Maintenance, Reliability Centered Maintenance and Maintenance Prevention.
Equipment Evaluation: Cement manufacturing process consists of handling of huge quantity of material & grinding of various materials (In million tons), as raw materials are highly abrasive, hence during process, all equipments undergo major wear & tear so reliable maintenance is important factor for maintaining availability of equipments such as Lime Stone Crusher, Mills, Kiln, Packers, Material Handling equipments, Compressors etc.
Equipment logs are maintained and categorized in the SAP module to access their rank of failures. This is used
in equipment wise failure analysis and spares management and maintenance notifications.Planned maintenance supports
self maintenance by monitoring basic conditions through condition monitoring. Analysis of MTTR, MTBF & OEE and relevant improvement initiatives are resulting in to the downtime reduction.
Equipment Performance Enhancement: We implement RCM projects on identified equipments to enhance their reliability. Equipment breakdowns are closely analyzed by using tools such as why & why, C&E analysis and is further analyzed focusing FMEA review to understand
the current status of our assets. All the breakdowns are captured along with why & why analysis in SAP. Hence, we ensure no breakdown is left without analysis and repetition of breakdowns is prevented. Our maintenance teams are trained to use problem solving tools. Accelerated deterioration including ageing, wear pattern, fatigue is monitored and life is increased by proactive solutions to prolong the service life.
Standardization: Routine maintenance jobs are identified and scheduled for preventive maintenance of equipments. There is a system to monitor preventive maintenance through daily evaluating PM check list in SAP and reviewed on weekly basis. Standard maintenance procedures for periodic maintenance have
been prepared and Maintenance Protocols are in practice to track the deviation of the quality of the maintenance. RCM recommendations are incorporated in developing draft maintenance procedure to align with standard maintenance procedures. PM Audit is being conducted and actionable points are identified on quarterly basis to meet PM objectives. Structured system of preventive maintenance both time based as well as condition based which covers all critical equipments has been established. Our Predictive Maintenance is designed based on criticality of the equipment. Predictive Maintenance is widely used in our industry as heavy machineries need to run without any stoppage. In predictive maintenance various tools, latest instruments & techniques are used by team of engineers from maintenance specially identified for predictive maintenance.
Results: Level of attainment of Planned Maintenance overall performance as per external bi-annual assessment improved from 55-60 (2009) to 75-80(2011).
Ultra Tech Cement Limited Unit: Aditya Cement Works
Front Row (Left to Right): Virendra Jaggi, Hitesh Makwana, Rajvir Yadav (PM Leader), Bhushan Joshi (Executive President and Unit Head), Chandra Shekhar Pandey (Senior
Vice President Technical), Ashok Sahu, Vikas Garg Back Row (Left to Right): Jindas Jayaseelan, Sandeep Saxena, Ravindra Routela, Rajesh Kumar, Sanjay Gupta, Madan
Maheshwari, Sunil Mishra, Jay Indoria
CMMS software:• PLC & SCADA control system for
plant operations from Central Control Room (CCR I).
• Distributed control system (DCS) for plant operation from Central Control Room (CCR II).
• PI (Process Interaction) Software for monitoring the real time plant operations.
• Real Time Monitoring and analysis from PI in excel.
• FUZZY Logic system for simultaneous setting and control of multiple specifications.
• Optima Blending Control System for maintaining the raw meal quality and consistency.
• XRF system for product quality analysis.
• Cross Belt Analyzer for maintaining the raw material quality.
• Kiln Shell Scanner for Temperature monitoring and control.
• SAP PM, PP, QM, CMS, FICO, and MM Modules for overall asset
management.• In-house developed softwares’ for
Gas Cylinders Management & Fire Extinguishers Management.
Predictive maintenance instruments and software:• Digital Vibration Data Collector
& Analyser Two Channel with omnitrend software (Vibxpert VIB 5.300
• Pruftechnik).• Analoge Vibration Data Collector &
balancer Two Channel (Vibrotest, Schenck Avery).
• Easy Laser Alignment Kit. (D-279, Damalini).
• Thermal Imager (Fluke Ti30).• Fast Align (Manatec, FAC 5H).• Ultrasonic Thickness Gauge
(Edison-1M).• Ultrasonic Flaw detector (Einstein
-II TFT, Modsonic).• Stroboscope (Nova strobe DB Plus,
Monarch).• Intrigated Hardness Tester (TH 130,
Time Group Inc).
• Vibration Pen (SKF Vibration Pen Plus, CMVP/40/50).
• Bearing Pen (SKF SEE Bearing Pen, CMPB30).
• Noncontact Thermometer (Raynger ST, Raytek).
• Poldy Hardness tester (Metal Spot Engineers, Navsari)
• 14. AC Current Clamp (Fluke i400)
• Laser Alignment ( Damalini AB)
• Vibration Meter (IRD- 306)• 17. Shock Pulse Analyzer
(SPM A2011)• Insulation Multimeter (Fluke
1587)• Viscosity Meter (Visage).• Electric Discharge Detector
(TKED-1).• CSI-2130 & 2120 (Emerson
Process Management Limited)
CMMS Sofware and Predictive Maintenance Instruments/Software:
Best Emerging
Maintenance
ReliabilityProgram
Ultra tech cement limited
Best Maintenance Reliability Programs 2012
