Approach To Zero Breakdown

YP ChawlaHd. Energy Sector

Apollo Tyres

ypchawla@gmail.comypchawla@gmail.com+91 98107 08707

How much Time it takes to Replace a Car Tyre ?

Replacing 4 Tyres ?

the sub-three second range to change a set of tyres!the sub three second range to change a set of tyres!The last time F1 had refuelling- recordedtyre change in F1 – 3.2 seconds. -1993

F1 tyre change -2009. 2.6 seconds F1 tyre. Come on.......It is near Zero Breakdown

Our Assets are our Cash Cows

AAsset Doctor

Drivers of the Today’s EconomyDrivers of the Today s Economy

• higher returns higher growth higherhigher returns, higher growth , higher productivity, with increased wage bills, fast changing technologies Capacitychanging technologies , Capacity Additions, slow down in economy

Zero breakdowns at our plantsIs it conceivable-or even desirable-to have zero breakdowns?Is it not a Political Statement only?

Zero WastageZero DefectZ B kdZero Breakdown

‘Plant Maintenance’ on a much larger Canvass as g“Asset Management” elevating the Maintenance Engineer to an “Asset Manager”to a “Business Leader”to a Business Leader

Asset reliability benefits achieved exceeds the Cost of six i li bilitsigma reliability

Inputs from other Industries

FosburyBasically a Gymnast - Not successfuly yApplied principles of Gymnastics to High Jump Result - A Quantum Jump

Inputs from Other Industries - Innovation

• Asset Management–a Business Objectiveg j• Role of Asset Manager gets enlarged in this

competitive world, ensuring that nowhere in this world, another company having the same assetsworld, another company having the same assets which produce greater capacity from those similar assets than his Assets –thus getting the most out of the assetsthe assets

• Return on Net Assets (RONA) or Return on Fixed Assets (ROFA) – the Banker’s requirements.K R lt A (KRA )• Key Result Areas (KRAs)

• Networking by the Asset Managers

3

Aligning - maintenance strategies to Breakdown curve3

Corrective maintenance reactive-based strategies

2Predictive maintenance condition-

based strategiesFailure Repair

h d l

strategies to Breakdown curve

nce X

X VibrationOilX

occurs

Failure reported

scheduled Parts, manuals

& toolslocated

erfo

rman

1Preventive maintenance time-

and usage

Oil

Noise

Heat

XX

X

Pe and usage-

based strategies X

Time

Design for Maintainability

Maintainability checks RCMMaintainability checks RCMEvaluate Prepare operational specifications and procedures, develop maintenance and

Development designDevelopment design Design & t ti

Design & t ti

PlanPlan

development optionsp , p

inspection strategies, prepare input to asset reference plan, develop facility data

p gp g constructionconstruction

ScheduleScheduleImproveImprove

Review and update maintenance strategies,

performanceD id

Ab d tAb d t

performance, estimates, reference

plan, FEMCASchedule asset related

work

Decide on remedy or

improvement (or abandonment)

AbandonmentAbandonmentAnalyzeAnalyze

ExecuteExecute Identify and define

unforeseen work

ORDM Analysis of asset

f d workperformance and maintenance

system effectiveness

T iti t Pl dTransition to Planned Maintenance Unplanned costUnplanned costMaintenance Unplanned costUnplanned cost

Planned costPlanned cost+

Total costM i t t l t th ti l id Total costMapping total cost – the practical side

Time/Usage

Y1 Y2 Y3 Y4 Y5 Y6 Y7 Y8 Y9 Y10 Y11 Y12

DesignDesign Detection of Failure SourcesDetection of Failure Sources

Reliability Assessment

Reliability Assessment

Planned ReliabilityPlanned

Reliability

Breakdown / Reliability + Design

DecisionDecision Asset ManagementBusiness ProcessesAsset ManagementBusiness Processes

Asset ManagementPlans

Asset ManagementPlans

Strategic InitiativesStrategic InitiativesInitiativesInitiatives

Annual BudgetsAnnual Budgets

Operating BudgetOperating Budget Capital BudgetsCapital Budgets

• Electronics & Instrumentation – A Boon & A Challenge

• A Caveat The Computer Connected Machines are now being challenged by Computer Virus sent for variousbeing challenged by Computer Virus sent for various Soft Ware installed in Machines to score a point over Competitors of Similar asset manufacturers, owners, and th S ft lithe Software suppliers.

• Organizational Structure• Companies’ Policies• Companies Policies• Human Asset Development for Plant Assets

Management• Outsourcing

Consumption of Inputs - More Rejunavate

Renovate

• Concluding Remarks: Successful Zero Breakdown Maintenance is built on the following Hall mark fundamentals:

• Zero breakdown equipment needs quality design, low-stress and less fatigued parts kept in good health.

• Zero breakdown maintenance - to stop human error from i l t d i t f il d t fcausing plant and equipment failures needs a team of

Talented Top Persons geting involved right from Indenting, Procurement, Selection & Design Stage, Know the Financials returns on Asset Capital Cost and canFinancials, returns on Asset Capital Cost and can undertake work in pressure conditions with a good team work with appropriate updating in knowledge for the Vital Equipment, processes, Processes, economics ofEquipment, processes, Processes, economics of outsourcing Maintenance, IT’s role, Removing operational risks of the Asset & Plant for benchmarking the Performance with integrated operational risk management

th i t lif l d th B t P ti iacross the equipment life cycle , and the Best Practices in Maintenance and Reliability.

• A Parting suggestion Organizations need to redefineA Parting suggestion Organizations need to redefine what businesses they're in and want to be in, re-evaluate processes, rationalize systems, benchmark and measure, and create new sources of revenue out of its Operations of World-Class Maintenance Management Success.

Dynamic role of an Asset Manager can help connect silos, help standardize and analyze what's going on, and build-in agility in the Organization It is a time full ofbuild in agility in the Organization. It is a time full of opportunities & Challenges for An Asset ManagerNavigating Personnel issues and Continuous knowledge updating comes down to effectively managing & getting g y g g g gthe best returns from the critical assets – a hallmark of Zero Breakdown Strategies

•PRIORITISE THE ASSEST MANAGEMENT PROJECTSPRIORITISE THE ASSEST MANAGEMENT PROJECTS• ASSIGN SPECIFIC RESPONSIBILITY TO EACH

TEAM MEMBERINTRODUCE CROSS FUNCTIONAL WORK GROUP• INTRODUCE CROSS FUNCTIONAL WORK GROUP

• IMPLEMENTATION PLAN - WITH TIME AND TARGET

• MONITOR PROJECT BY PROJECT- ACTIVITY BY ACTIVITY

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