PM Pillar

Chapter 6

PM Pillar

6-1.2 Background

Poor Basic Condition of Machines

Before start of TPM Journey

6-1.3 Aims & Policy of PM Pillar

“We all at PM pillar are committed for retarding the natural deterioration of machines, maintaining machines with optimum cost through deployment of TBM/CBM practices, Continuous improvement & skill up gradation of maintenance personnel.”

Navneet SharmaHead Mech

S. K. PandeyMech WRM

W. Singh Utilities

Mr.Indrajit NandiGeneral ManagerShared Services &

Projects

R. Sharma Head Electrical

N MishraMech Wire Mill

S BubberMech Wire Mill

R.K.SharmaMech Jemco

S.BhattacharyaElec Jemco

Pillar head

Members

6-2.1 PM Pillar Sub-Committee

6-2.2 PM Pillar Approach

PLANNED MAINTENANCEPLANNED MAINTENANCE

ZERO FAILUREZERO FAILURE

MAINTENANCE COST REDUCTIONMAINTENANCE COST REDUCTION

JISHU HOZEN

FINDING ABNORMALITY

CORRECT ABNORMALITY

CLEANING,LUBRICATION, INSPECTION, TIGHTENING

PREVENTIVE MAINTENANCE BREAKDOWN MAINTENANCE

COST MANAGEMENT

TIME BASED MAINTENANCE &

INSPECTIONS

SHUTDOWN MAINTENANCE

EQUIPMENT FAILURE

ROOT CAUSE

ANALYSIS

CORRECTIVE ACTIONS

MAINTENANCE SKILL

UPGRADATION

SPARES MANAGEMENT

LUBRICATION MANAGEMENT

CONDITION BASED

MAINTENANCE

PLANNED MAINTENANCEPLANNED MAINTENANCE

ZERO FAILUREZERO FAILURE

MAINTENANCE COST REDUCTIONMAINTENANCE COST REDUCTION

JISHU HOZEN

FINDING ABNORMALITY

CORRECT ABNORMALITY

CLEANING,LUBRICATION, INSPECTION, TIGHTENING

PREVENTIVE MAINTENANCE BREAKDOWN MAINTENANCE

COST MANAGEMENT

TIME BASED MAINTENANCE &

INSPECTIONS

SHUTDOWN MAINTENANCE

EQUIPMENT FAILURE

ROOT CAUSE

ANALYSIS

CORRECTIVE ACTIONS

MAINTENANCE SKILL

UPGRADATION

SPARES MANAGEMENT

LUBRICATION MANAGEMENT

CONDITION BASED

MAINTENANCE

Apex KPI No.

Pillar KPI No.

Pillar KPI Pillar KAIs UOM Good KPI deployment level Supporting JH PM

kaizen No of

failures and root

cause analysis

done

Optimize lubricant

consumption

Standardize spares

MP sheet generation

Dept Section Circle Red tag

closure

training

1.1 1.1.1 Breakdown in A category equipments

Nos

1.1.2 Breakdown in B category equipments

Nos

4.2 4.2.1 Maintenance cost

Rs./MT

KAI department level Dept.

Section Circle Better ↑ ↑ ↑ ↑ ↓ ↑ ↑

Unit of measure Nos Nos Nos % Liters Nos Nos

6-2.3 PM Pillar KPI & KAI

Sl.No Activity Description FY10 FY 11 FY 12 FY 13 FY 14 FY 15 H1 H2 H1 H2 H1 H2 H1 H2 H1 H2 H1 H2

1 Carrying 1S 2S activities and establish & maintain Manager Model Machine

TP

M K

ick

Off

2 Establish PM pillar sub committee 3 Support to Jishu Hozen 4 Evaluate and

understand current equipment conditions

Data collection

Classification of equipment

5 Restore deterioration Failure analysis Weak component eradication

6 Develop maintenance management system

Build information management system

Build spare management system

Build lubrication management system

7 Build periodic maintenance system

Prepare and improve TBM calendar

8 Build predictive maintenance system

Introduce and develop equipment diagnosis technology

9 Maintenance skill education

6-2.4 PM Pillar Master Plan

6-2.5 PM Pillar KPI and KAI ( Rod Mill)

KPI No

Pillar KPI UOM Good FY10 BM FY 11 FY 12 FY 13 FY14Benchmark Targets

1.1.1 Breakdown in A category equipments

Nos ↓ 250 200 100 50 0


Nos ↓ 50 35 15 5 5

4.2.1 Maintenance cost Rs./MT ↓ 415 385 350 300 270KAI No

Pillar KAI

1 Red tag closure Cum Nos ↑ 436 2000 5000 8000 120002 PM kaizen Cum Nos ↑ 24 50 100 200 3003 No of failures Vs RCA done % ↑ 25 50 75 100 1004 Optimize lubricant consumption Liters ↓ 4550 4000 3800 3600 35005 Standardize spares Cum Nos ↑ NT NT NT 20 506 MP sheet generation Cum Nos ↑ NT NT NT 5 10

6-2.5.1 PM Pillar KPI and KAI ( Wire Mill)KPI No

Pillar KPI UOM Good FY10 BM FY 11 FY 12 FY 13 FY14

Benchmark Targets


Nos ↓ 2935 2200 1500 750 0


Nos ↓ 1467 1200 1000 500 147

4.2.1 Maintenance cost Rs./MT ↓ 811 750 650 550 450

KAI No

Pillar KAI

1 Red tag closure Cum Nos ↑ 0 500 1500 2500 4000

2 PM kaizen Cum Nos ↑ 0 25 50 100 150

3 No of failures Vs RCA done % ↑ 20 50 75 100 100

4 Optimize lubricant consumption Liters ↓ 1056 700 600 600 400

5 Standardize spares Cum Nos ↑ NT NT NT 10 20

6 MP sheet generation Cum Nos ↑ NT NT NT 2 5

6-2.6 PM Pillar KPI and KAI ( Jemco)KPI No

Pillar KPI UOM Good FY10 BM FY 11 FY 12 FY 13 FY14

Benchmark Targets


Nos ↓ 389 350 250 250 230


Nos ↓ 308 305 260 250 250

4.2.1 Maintenance cost Rs./MT ↓ 1226 35.00 28.00 50.00 50

KAI No

Pillar KAI


2 PM kaizen Cum Nos ↑ 3 10 12 15 12

3 No of failures Vs RCA done % ↑ 10 50 70 90 100


5 Standardize spares Cum Nos ↑ NT NT NT 5 20

6 MP sheet generation Cum Nos ↑ NT 10 15 25 30

6-2.7 Activities of PM Pillar

1. Support to Jishu Hozen. (Autonomous Maintenance)2. Zero Breakdown activities (Analysis and counter measure)3. Maintenance Information System4. Establishing Planned Maintenance System5. Predictive Maintenance activity6. Lubrication Management System7. Spare Parts management8. Maintenance Skill enhancement

6-4 Support to Autonomous Maintenance 6-4.1 JH Step- 0 & JH Step-1

6-4.2 JH Step – 2 : Hard to access areas located by Jishu Hozen team are rectified made easy. These Areas are further classified in to following categories.

a) Hard to Clean, b) Hard to inspect, c) Hard to Lubricate,d) Hard to re tight, e) Hard to operate, f) Hard to adjust.

Kaizens were done to remove hard to access, Hard to clean & hard to lubricate areas. Some examples are attached below :

Imparting Basic Knowledge Support in Initial Cleaning Identification of Fugais

Activity JH KK PM QMLoss No. / StepImpact on P Q C D S M

Bench Mark

Target

Kaizen Start

Kaizen Finish

Leader

Machine Target date Responsibility Status

PLANT - GF 5 MACHINE - Pay off wire separator

Theme :- To reduce the breakdown of chain in pay off basket of M/c 140.

KAIZEN IMPLEMENTATION SHEET

Kaizen Implementation sheet

ISWP/WM/K/046

Niranjan singh

Amrendra singh

Abdul sattar

To reduce the cleaning time by

1/10th

BENEFIT:-

ANALYSIS:- RESULTS:-

Scope and Plan for Horizontal deployment

01 /03/1310 /04/13

Member

Abhishek kumar

TEAM MEMBERS

S ray

Idea - Material handing sling for lifting the load..

High scale cleaning time

No tray arrangement in wire seperator stand Tray arrangement in wire seperator stand

3 Design weakness .

P = ( Before cleaning Time = 63min) (After cleaning Time =28 min) C = Rs 50000 / Year

S = No any chance of incident .

M = High moral ( No any wire breakage due to entanglement)

1) Reduction in the cleaning time by 35 min

2) In house Design Modifiction of the tray

BEFORE AFTER

1. Why scale scattering on floor ?

2. Due to no any arrangement for collect the scale

To make tray type arrangement to collect the scale

WHY

WHY

To be shown during schedule B presentation

Activity JH KK PM QMLoss No. / StepImpact on P Q C D S M

Bench Mark

Target

Kaizen StartKaizen Finish

LeaderMemberMemberMemberMemberMember

Machine Target date Res. Status

All M/cs FY 13 RKS /AK Done

Kaizen Implementation sheet

ISWP/WM/K/026

KAIZEN IMPLEMENTATION SHEET

PLANT - WIRE DRAWING MACHINE - Wire Drawing Die box unit

Theme :- To Reduce the Scattering of the burnt soap from the Die Box.

Idea - Sealed type container for the chemicals.

Consumption of the soap is 2.85 Kg / MT

Redction in consumption of the soap from 2.85 Kg / MT to 1.90 Kg/MT

Abdul Sattar

26 /05/12

Hardeep singhSc mahto

24/06/12TEAM MEMBERS

Abhishek Kumar

ANALYSIS:- RESULTS:-

Scope and Plan for Horizontal deployment

Gopal Guha

BENEFIT:-

Rakesh kr singh

1. Why scattering of soap in the working enviroment ?

2. Due to passing of wires in the die box cause the scattering of soap

4. To make arrangement of covering the die box

3. Due to No Any arrangement of Cover in the die box

1.Total Arresting of the scattering of soap

Arrangement of cover for the die box. No any arrangement of cover for the die box.

BEFORE AFTER

2. Neat & clean Work area

3. Saving about .02 kg/MT of Unburnt soap

WHY

WHY

WHY

Reduction in cleaning time.


6-4.3 JH Step-3: i) Preparation of Composite check sheet to clarify the JH and PM activitiesii) PM to helped in preparation of tentative CLITA standards.iii) Assisting JH team on making visual inspections.

Sample Sheet

Sample Sheet

VISUAL INSPECTION

6 A

XIS

TR

AIN

ING

6-4.4 JH Step- 4 :

General training imparted to JH circles on following topics :

Basics of pneumaticsElectrical basicsBasics of drives & transmissionBasics of lubricationBasics of hydraulicsBasics of fasteners

Basic M

odules Bookle

ts

Cross-section of different types of Cables

VARIOUS MODELS & CUT MODELS MADE FOR TRAINING

VARIOUS MODELS & CUT MODELS MADE FOR TRAINING

Models & cut models for better understanding of machines

6-5 Zero Breakdown Approach & Activities :3 Causes & 5 Factors Approach

Uncontrolled stress Neglected deterioration Insufficient Strength

Inadequate compliance with basic requirement

Non compliance with Usage requirement

Lack of skill Neglected deterioration Design Weaknesses

Collect the data & Investigate the Equipment/Process

Restoration By Shift-In-Charge

Breakdown Occurs

Why-Why analysis by Shift-In-Charge

Why-Why analysis by Department head with Team

Identifying Root Cause

Identify the counter measure Kaizen

Implement counter measure

Monitor the results

Results

NO

Horizontal Deployment

Documentation

Update the maintenance procedure

YES

Preparation of MP Sheet

6-5.1 Process of ZERO break-down is as shown in the figure below:

6-5.2 Example of Why-Why Analysis

Sample Sheet

Sample Sh

eet

Sample Sheet

After analysis the root cause was found as design weakness hence design modification was done & kaizen sheet was made for the same as shown below :

Sample Sheet

To be shown during schedule B

presentation

Story Line Kaizen

6-5.3 Sample summary sheet of why-why analysis done

Qty Cost

1) One time cleaning of Reservoir.

2) 3 nos 3) 1 nos

2) 30000 3) 190000

DST 10.04.11 DONE

2) Fitting suction filters in line.

3 nos 30000 AD 31.10.11 Dropped

3) fitting new high capactity heat exchanger.

1 nos 190000 AD 31.10.11 Done

APR 2011

Roller Table # 13

A 1

Gearbox jam due to coil end piece stucked in between gears.

Deliberate violation

Replace the connecting flange and key. 1 set

7000 DST 30.06.11 dONE

Inspection point to be included in check sheet

AD 01.05.11 done

MAY 2011

Coil Upender A 1UP-DOWN hyd cylinder's clevis pin sheared

Design weakness

Replace the pin with a higher diameter pin by modifying the clevis and bracker arrangement.

1 setAD + DST

15.06.2011 done

JUN 2011

Roller Table # 17

A 1Gearbox to motor gear coupling's key got damaged.

Improper Maintenance

Skill

Training to be imparted "How to fit Keys in power

transmission"AD 15.07.2011 Done

JUN 2011

Roller Table # 12

A 1

Cobble due to tail end entered in the housing gap between roll No. 5 & 6.

Inherent design weakness

Welding done of the gap.

Done

Universal spindle's connecting flange rotating free due to key failure.

Hyd P/P 5 AHydraulic pump # 2 failure

Violation of basic condition

1

1Improper

Inspection

Equipment RankNos

of Failure

APR 2011

Roller Table # 0

A

APR 2011

Target date StatusMonth Failure Detail Root Cause Action Identified Resp

Resource Required

Sample

She

et

With the aforesaid zero failure methodology & activities there is a marked reduction in equipment breakdowns. Following is the status of zero failure equipment in respective plants:

Total No. Of Equipments

Zero Breakdown

Equipments

WRM

136

69

Wire Mill 23 6

Jemco 67 13

Utilities

128

102

6-6 Establishment of PM Structure : PM structure was established at ISWPL which consists of the following :1. Preventive Maintenance2. Predictive Maintenance3. Breakdown Maintenance4. Maintenance Prevention

6-6.1 Equipment Ranking : Criticality rating of equipments done based on following criteria :

Production (P)Effect on product Quality(Q)Cost of maintenance(C)Frequency of failure & time required for repairs(D)Effect on safety & environment(S)

Rank Score (P+Q+C+D+S)

A > 28

B More than 20 less than 28

C Less than 20

Sample Sheet

The above is a sample sheet of rod mill equipments criticality rating. Similarly criticality of all machines in wire & Jemco was also established.

No. of Equipments A -Category

No. of Equipments B -Category

No. of Equipments C -Category

WRM 116 7 13

Wire Mill 19 4 0

Jemco 29 21 16

Utilities

66 2 60

6-6.2 Maintenance Management Information Structure:

MAINTENANCE MANAGEMENT INFORMATION SYSTEM

Keeping Records

Routine Inspection Check sheet & Maintenance Schedule (TBM)

Equipment diagnosis record (CBM)

To Preventdeterioration

Failure Data Record

Collection of data

From Operator

From Logbook

To measuredeterioration

Restoration

Eliminate Breakdown

Maintenance Activity

Failure Analysis

History Book

Standard maintenance/Operating procedure (SMP)

Training Manual

From KPI(Key Performance Indicator) tracking system

A maintenance management information system was evolved for streamlining all the maintenance activities. It involves collection of breakdown & abnormalities data, keeping records of TBM & CBM activities, failure analysis, equipment history, SOP’s ,training manuals. The management information system helps in keeping track of key performance indicators. An example of a typical maintenance calendar :

Sample Sheet

A Typical Equipment Service Sheet (ESS)

Sample Sheet

Example of Equipment History Register

Sample Sheet

6-7 Predictive Maintenance Activities:

Wire Rod Mill Wire Mill Jemco

Vibration analysis Oil analysis Illumination monitoring

Ultrasonic thickness checking

Bearing noise analysis

Thermography Earth resistance

monitoring

Sample Sheet

6-8 Lubrication Management Activities

Inspection of equipment to find out hard to lubricate areas.Kaizens to eliminate hard to lubricate areasLubrication schedule preparation and implementationLubrication Visual ControlSeparate cans for different oilsOperators trained on lubricantsRecording of lubrication consumptionEliminate leakage to reduce the frequency of lubricationImprovement in lubricant type to increase lubricant life

Sample Sheet

16

10

25

2220 19

35

2625

21

0

5

10

15

20

25

30

35

FY10 FY11 FY12 FY13 FY14

Identified

Arrested

Approx Rs.25 Lakh saving in lubricant cost

PROPER STORAGE OF LUBRICANTS LUBRICANT LEAKAGES IDENTIFIED VS ARRESTED

Lubrication Cost in Laks.5.67

5.234.55 4.47

3.21

0

1

2

3

4

5

6

FY-10 FY-11 FY-12 FY-13 FY-14 (Til lNov' 13)

Financial Year

Co

st i

n L

ak

s

GOOD

43% SAVING IN LUB COST PER ANNUM AT JEMCO


6-9 Spares Management: In order to achieve zero downtime, timely availability of reliable spares play a vital role. To develop spares management system the following steps were initiated which are various stages of implementation:

Equipment wise listing of sparesDeciding criticality of sparesAnalysis of consumption patternsDetermination of life cycle of critical sparesRaising of purchase requisitions as per lead time, spare parts life & criticality was initiated.Periodic stock review system was started.Disposal of obsolete & non usable spares was decided.Development of imported spares indigenously was started.

An example sheet for listing of equipment wise spares :Total

For 6 sets

Green Yellow

1 RE 45 13,15 Guide Box RE- 45 AS ( without accessories) 10316549 112507057 1 6 4 32 Roller Holder RE- 45 AS/2 Assembly 10033037 112507056 1 6 3 13 Roller Holder RE- 45 AS/2 Assembly 10033038 112507055 1 6 3 14 Roll shaft M435231A 112052061 2 12 20 125 Pivot Pin 10212782 112052066 4 24 24 12

6 Adjusting screw RH (to move the roller holder) 10032269 112052063 1 6 10 5

7 Adjusting screw LH (to move the roller holder) 10032270 112052064 1 6 10 58 Cover ( for spring assembly) M432822A 112507054 2 12 10 59 Button ( in front of Adjusting screw) 10031819 112507053 2 12 20 10

10Set screw M 24 X 3 X15 ( to move the roller holder UP/DOWN)

M432814A 112052065 4 24 30 20

11 Thrust Plate ( below the pivot pin) M432816A 112052067 4 24 30 20

12 Roller shaft spacer(in between the bearing and housing) M432819A 112052062 2 12 50 20

13 Spacer ( to tighten the nut of roll shaft) M432820AA 112507052 2 12 100 5014 Tapered roller bearing 32004X M432805B 4 24 24 18

Tapered roller bearing 32004X 102070075 4 24

15DIE DIECO Spring( for roller holder) (Same as RE- 115 & RE- 45)

M432813D 112052060 2 12 30 20

16 spring GRP 012/65 R 135008040 2 12

17 Seal Nilos Ring 10030136 112507058 4 24 100 50

18 Eye bolt with shoulder M 16 M4157168 112507051 2 12 20 10

19Socket head cap screw M 6 x 25 full thread (spring cover)

10280786 112507120 8 48 100 50

20 Socket set cup screw M16 X 25 (to tighten the insert) 10068902 112507119 2 12 100 5021 Hex Nylock nut M 16 X 2 ( for roll shaft) M437076B 112507127 2 12 100 5022 Assy.Adapter Plate (RE 45 FSA- 2) 10357771 112507059 2 1223 Rollers (for stand 13) 10087242AT 112052057 2 12 10 6

24Rollers (for stand 15)

10087242AU 112052059 2 12 10 6

25 Insert ( for stand 13) 5.5 mm [ 54.1 x 20.4 ] 10316553AC 112507116 2 12 24 1226 Insert ( for stand 13) 8 mm [ 54.5 x 23 ] 10316553Z 112052053 2 12 10 627 Insert ( for stand 15) 5.5 mm [ 41.6 x 16 ] 10316553AA 112507115 2 12 24 1228 Insert ( for stand 15) 8 mm [ 45.4 x 19.8 ] 10316553AB 112052055 2 12 10 629 Insert ( for stand 15) 5.5 mm modified [ 39.2 x 16 ] 10316553 U 112507117 2 12

Guide shop stockQty / Assembly

Material CodeMorgan Part

No./ Drawing No.S.No.

Guide Type

Stand no.

Components

Sample Sheet

Import Substitution

Water Box Nozzles Developed in India

Cost Reduction due to import substitution

75

30

0

20

40

60

80

Before After

Val

ue

in R

s.L

acs G

OOD

VISUAL UPKEEP OF SPARES

6-10 Maintenance Skill Upgradation :Listing of all maintenance activities.Preparation of SOP’s of all maintenance activities.Classroom & on the job training on maintenance SOP’s

172

84

164

76

0

50

100

150

200

Mechanical Electircal

No. of SOP Made

TrainingProvided

59

26

59

26

0

10

20

30

40

50

60

70

Mechanical Electircal

No. of SOP Made

TrainingProvided

ROD MILL WIRE MILL

CLASSROOM TRAINING ON THE JOB TRAINING

J ob : Fixing and Allignment of Hot Pusher roll

S.No Check Point/Activity Standard Status Remarks1 Take power cutting from the authorized person with help of power

cutting format,ensure

2 Fix suitable selling in the Cardon shaft and lift be EOT crane and the remove all the flange bolts of the cardon shaft at roll end , and keep on the floor.

Sling size 1/ 2"

3 loose the tension spring , lift the top roll and fix adequate packing with frame to top roll with help of selling.

Sling size 1/ 2" and hoist of 1 ton

Push the pill up bar towards qa side to remove the roll with help of bar.

5 Open the base bolts of roll , and remove the roll from its place,with help of suitable size of slings.

Bolt size 20 m.m.

6 After removal of roll, clean the surface of the plumber block. And re fixed the new/ oh roll at its place.

7 Fixed the plumber block bolts with base frame and also fixed the check nut on the same.Check the level of the bottom roll with respect of idle roll as the roll at hot pusher tray. It must be not more then + or - 2 m.m. from the consecutive roll.

8 Fixed the spindle bolts with help of EOT crane and proper size of selling.

9 Fill fresh grease in to the roll10 Check the roll for its free movement, with help of manual movement

through gear box.

WRM/Mech/fce/WI/06Issue Date :Revision No. & Date:

Sample Sheet

6-11 Maintenance Cost Control :

8. Maintenance Cost Management

a) Spare Parts By stopping forced deterioration By increasing life span By developing Import substitute By standardisationb) Lubricant consumption By arresting Leakage By reducing spillage during Handling By using correct qulity of lubricantc) Contract Labour By developing in house repair of items

Maintenance CostStatement

Priortisation ofPotential Svaing Area

Contract Labour CostCost of LubricantCost of Spares

Generation of Spareconsumption Data

Analysis of Data

Planning of CorrectiveAction & Kaizen Themes

Coorective Action &Kaizen Implementation

Kaizen Sheet

Maintenance Cost

6-12.1 Targets versus Actuals (Rod Mill)KPI No Pillar KPI UOM Good FY10 BM FY 11 FY 12 FY 13 FY14

Targets /Actual1.1.1 Breakdown in A category

equipmentsNos ↓ 250 200 100 50 0

195 120 110 781.1.2 Breakdown in B category

equipmentsNos ↓ 50 35 15 5 5

47 16 10 64.2.1 Maintenance cost Rs./MT ↓ 415 385 350 300 270

465 415 408 396

KAI No Pillar KAI


1130 4621 7566 11590

2 PM kaizen Cum Nos ↑ 24 50 100 200 300

64 102 185 215

3 No of failures Vs Root Cause Analysis done

% ↑ 25 50 75 100 100

50 80 100 100


4200 3910 3800 3550

5 Standardize spares Cum Nos ↑ NT NT NT 20 50NT NT 20 50

6 MP sheet generation Cum Nos ↑ NT NT NT 5 10NT NT 2 5

6-12.2 Targets Versus Actual Wire MillKPI No Pillar KPI UOM Good FY10 BM FY 11 FY 12 FY 13 FY14


equipmentsNos ↓ 2935

2200 1500 750 02183 1286 119 35


Nos ↓ 1467 1200 1000 500 147

1310 965 257 135

4.2.1 Maintenance cost Rs./MT ↓ 811

750 650 550 450

669 518 553 441

KAI No Pillar KAI

1 Red tag closure Cum Nos

↑ 0 500 1500 2500 4000

534 1448 3375 3879

2 PM kaizen Cum Nos

↑ 0 25 50 100 150

9 59 121 178


% ↑ 20 25 50 100 100

35 85 100 100

4 Optimize lubricant consumption

Liters ↓ 1056

700 600 600 400

634 668 668 320

5 Standardize spares Cum Nos

↑ NT NT NT 10 20NT NT 8 15

6 MP sheet generation Cum Nos

↑ NT NT NT 2 5NT NT 1 3

6-12.3 Targets Versus Actual JemcoKPI No Pillar KPI UOM Good FY10 BM FY 11 FY 12 FY 13 FY14


equipmentsNos ↓ 389 350 250 250 230

378 269 231 184


Nos ↓ 308 305 260 250 250

287 265 251 204

4.2.1 Maintenance cost Rs./MT ↓ 39.05 35.00 28.00 50.00 5029.88 49.78 49.98 24.63

KAI No Pillar KAI 1 Red tag closure Cum Nos ↑ 108 300 500 700 1100

226 435 646 845

2 PM kaizen Cum Nos ↑ 3 10 12 15 128 10 12 7


% ↑ 10 50 70 90 100

32 40 80 904 Optimize lubricant

consumptionLiters ↓ 7776 7500 7300 7100 7000

7176 6245 6136 4410

5 Standardize spares Cum Nos ↑ NT NT NT 5 20NT NT 4 12

6 MP sheet generation Cum Nos ↑ NT 10 20 25 258 16 20 28

6-13 KPI RESULTS :

Bas

e L

eve.

..

10-1

1

11-1

2

12-1

3

13-1

4

0

50

100

150

200

250

300

350

300

242

136.00120.00

84.00

Number of Breakdowns Rod MillNumbers

72% Reduction

GO

OD

Bas

e ..

.

10-1

1

11-1

2

12-1

3

13-1

4

0

1000

2000

3000

4000

5000

6000

48924367

3217.00

571.00383.00

Number of Breakdowns Wire MillNumbers

92% Reduction

Bas

e L

e...

10-1

1

11-1

2

12-1

3

13-1

4

0

100

200

300

400

500

600

700

800697 665

534482

388

Number of Breakdowns JEMCONumbers

44% Reduction

GO

OD

GO

OD

Bas

e L

...

10-1

1

11-1

2

12-1

3

13-1

4

0.0010.0020.0030.0040.0050.0060.0070.0080.0090.00

100.00

25.00

50.00

80.00

100.00 100.00

Root Cause Analysis Compliance Rod Mill%

GO

OD

Bas

e L

e...

10-1

1

11-1

2

12-1

3

13-1

4

0.00

10.00

20.00

30.00

40.00

50.00

60.00

70.00

80.00

90.00

100.00

20.00

35.00

85.00

100.00 100.00

Root Cause Analysis Compliance Wire Mill%

GO

OD

Root cause analysis of all failures.

Root cause analysis of all failures.

Bas

e L

evel

2.

..

10-1

1

11-1

2

12-1

3

13-1

4

0.00

20.00

40.00

60.00

80.00

100.00

10.00

32.0040.00

80.0090.00

Root Cause Analysis Compliance Jemco%

GO

OD

Bas

e L

...

10-1

1

11-1

2

12-1

3

13-1

4

0.00500.00

1000.001500.002000.002500.003000.003500.004000.004500.005000.00 4550.00

4200.003910.00 3800.00

3550.00

Lubricant Consumption Rod MillLitres of Lub

GO

OD

Increase in Root cause analysis of failures.

22% Reduction in Consumption

Ba

se

...

Cu

m .

..

Cu

m .

..

Cu

m .

..

Cu

m .

..

100

600

1100

1600

2100

2600

3100

3600

4100

534

1448

33753879

Red Tag Removal Wire MillCumulative Numbers

Ba

se

...

10

-11

11

-12

12

-13

13

-14

100

2100

4100

6100

8100

10100

12100

14100

4361130

4621

7566

11590

Red Tag Removal Rod MillCumulative Numbers

27 times Increase

GO

OD

Increase in red tag removals

GO

OD

Ba

se

L..

.

10

-11

11

-12

12

-13

13

-14

0

100

200

300

400

500

600

700

800

900

108226

435

646

845Red Tag Removal JEMCO

Cumulative Numbers 8 times Increase

6-14 Future PlanS.No. What Why Where How Who When

1 Implementation of computerized maintenance management system

Better compliance of maintenance activities to achieve zero failure

Across all 3 plants

SAP PM module implementation

Shared Services Deptt.

May’14

2 Commissioning of flue exhaust system

Improve work environment & comply pollution norms

JEMCO Repairing & re-commissioning of existing system

Mechanical Deptt

Mar’14

3 Automation of furnace combustion system

Reduction in fuel consumption & better heating characterstics

WRM Re-Heat Furnace

Installation of servo controlled valves & PLC

Electrical Deptt

Apr’14

PM Pillar

Documents

Transcript of PM Pillar