#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
=
ELIMINATING FAILURES
thru extending LIFE
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Dibyendu De
#POWEROFSEE
Dibyendu De
19-05-2015
Number
30
20
10
0
1st Yr
2nd Yr
3rd Yr
4th Yr
Years
Dibyendu De
19-05-2015
May-JuneJuly
Septemb
er
165719
1135
11473774
Area
1101018
100730
1,27,40,511
101865
GAP
2237
Bakeoven
Rodding
Cast House
Potroom
Utility
7432
2698
77
345
41
#POWEROFSEE
Dibyendu De
19-05-2015
effects of
Audit Parameters
Previous
After 1 Year
After 2 Years
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
Audit Parameters
BEFORE
AFTER
<3 MONTHS
>11 MONTHS
#POWEROFSEE
Dibyendu De
19-05-2015
effects of
Audit Parameters
BEFORE
AFTER
KILN STOPPAGE
187 / YEAR
<15 / YEAR
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Dibyendu De
effects of
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
#POWEROFSEE
Dibyendu De
19-05-2015
effects of
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
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
#POWEROFSEE
Dibyendu De
19-05-2015
MANAGEMENT COMMITMENT
KNOWLEDGE SUPPORT
MINIMAL INTERVENTIONS
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Dibyendu De
PEOPLE
LEADERS
#POWEROFSEE
Dibyendu De
10
19-05-2015
#POWEROFSEE
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
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
#POWEROFSEE
Dibyendu De
12
19-05-2015
Case Studies
13
19-05-2015
#POWEROFSEE
THANK YOU
Dibyendu De
14