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19-05-2015

#POWEROFSEE
AVAILABILITY CENTERED MAINTENANCE

Dibyendu De

Green/sustainability??
DO MORE WITH LESS
LESS RISK, LESS RESOURCES, LESS ENERGY
MORE MONEY

Dibyendu De

19-05-2015

AVAILABLE STRATEGIES
BREAKDOWN MAINTAINENCE
no control on failures
PREVENTIVE MAINTAINENCE
focuses on reducing failures
TPM
prevents accelerated failures
CBM
prevents secondary failures
RCM
prevents consequences of failures

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Dibyendu De

19-05-2015

Availability Centered Maintenance

=
ELIMINATING FAILURES
thru extending LIFE
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Dibyendu De

Availability Centered Maintenance

Availability = MTBF/ (MTBF+MTBR)

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Dibyendu De

19-05-2015

Availability Centered Maintenance


No. of Breakdowns(Avg/month)

Number

30
20
10
0
1st Yr

2nd Yr

3rd Yr

4th Yr

Years

CASH FLOW 1/ NO. OF BREAKDOWNS


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Dibyendu De

19-05-2015

Benefits ACM AL Smelter

May-JuneJuly

Septemb
er

Total Energy Cost Saving

165719

1135

Total Outage Cost Saving


Total Maintenance & bearings cost
Saving
TOTAL SAVINGS

11473774

Area

1101018

100730

1,27,40,511

101865

CBM benefit till date(Rs 000 )

GAP

2237

Bakeoven
Rodding
Cast House
Potroom
Utility

7432
2698
77
345
41

Availability Centered Maintenance

ACM applied to 3 Cement Plants


on
62% equipment under critical category

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Dibyendu De

19-05-2015

effects of

Availability Centered Maintenance


ON CEMENT PLANT

Audit Parameters

Previous

After 1 Year

After 2 Years

No. of Breakdowns /Year

57

19

% of Breakdown Hours

25

12

Effect of ACM
60

57

50
40
30
20

25
19
12

10

5
3

0
Previous

After 1 Year

No of BreakDowns/Year

After 2 Years

% of BreakDown Hours

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Dibyendu De

effects of

Availability Centered Maintenance


CASE I

Audit Parameters

BEFORE

AFTER

KILN NON STOP

<3 MONTHS

>11 MONTHS

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Dibyendu De

19-05-2015

effects of

Availability Centered Maintenance


CASE II

Audit Parameters

BEFORE

AFTER

KILN STOPPAGE

187 / YEAR

<15 / YEAR

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Dibyendu De

effects of

Availability Centered Maintenance


benefits

Down time because of Bearing problem


Down Time (minutes /month)

BEFORE
50
45
40
35
30
25
20
15
10
5
0

AFTER
45

36

34

23
18

16
9

7
0

Apr- May- Jun- Jul-02 Aug- Sep- Oct- Nov- Dec- Jan- Feb- Mar- Apr- May- Jun- Jul-03 Aug- Sep02
02
02
02
02
02
02
02 03
03
03
03
03
03
03
03

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Dibyendu De

19-05-2015

effects of

Availability Centered Maintenance


results

Audit Parameters

EFFECT

DOWNTIME

0 MINS

PRODUCTIVITY

10%

Effect of ACM

ACM

DOWNTIME

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PRODUCTIVITY

Dibyendu De

19-05-2015

effects of

Availability Centered Maintenance


cost

Reliability vs. Cost


25

40
30

20

20

-- Reliability
-- Cost

10
15

0
1 2 3 4 5 6 7 8 9 10 11 12

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Dibyendu De

effects of

Availability Centered Maintenance


running time

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Dibyendu De

19-05-2015

Availability Centered Maintenance


essentials

MANAGEMENT COMMITMENT
KNOWLEDGE SUPPORT

MINIMAL INTERVENTIONS

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Dibyendu De

Availability Centered Maintenance


ingredients

PEOPLE

LEADERS

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Dibyendu De

10

19-05-2015

Availability Centered Maintenance


development levels

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LEVEL 5 THE ART & SCIENCE OF CREATING RELATIONSHIPS
LEVEL 4 THE ART & SCIENCE OF ELIMINATING IMPERFECTIONS
LEVEL 3 THE ART & SCIENCE OF ANALYZING DYNAMICS
LEVEL 2 THE ART & SCIENCE OF UNDERSTANDING COMPLEXITY
LEVEL 1 THE ART & SCIENCE OF OBSERVING REALITY

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Dibyendu De

11

19-05-2015

Availability Centered Maintenance


review

NOTICE

ENGAGE

HOW AND
WHAT IS
HAPPENING WHY IT
HAPPENS?
?

WHEN TO
DO IT?

WHAT TO
DO?

EXCHANGE

MULL

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Dibyendu De

Availability Centered Maintenance


review

Once done the company gains permanent on-going


benefits.

-Prof. Tim Henry, Manchester University, U.K

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Dibyendu De

12

19-05-2015

Case Studies

Availability Centered Maintenance Services (ACM)

ACME PVT LTD is the only company in the World to


combine Advanced Technology, Big Data Analysis and
Knowledge to deliver Manufacturing Plants with Highest
Level Reliability , Availability & Sustainability

13

19-05-2015

#POWEROFSEE
THANK YOU

Dibyendu De

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