#Powerof: Availability Centered Maintenance

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
#POWEROFSEE
Dibyendu De
19-05-2015
Availability Centered Maintenance
=
ELIMINATING FAILURES
thru extending LIFE
#POWEROFSEE
Dibyendu De
Availability = MTBF/ (MTBF+MTBR)
#POWEROFSEE
Dibyendu De
19-05-2015

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

#POWEROFSEE
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
ACM applied to 3 Cement Plants

on
62% equipment under critical category
#POWEROFSEE
Dibyendu De
19-05-2015
effects of

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
#POWEROFSEE
Dibyendu De
effects of

CASE I
Audit Parameters
BEFORE
AFTER
KILN NON STOP
<3 MONTHS
>11 MONTHS
#POWEROFSEE
Dibyendu De
19-05-2015
effects of

CASE II
Audit Parameters
BEFORE
AFTER
KILN STOPPAGE
187 / YEAR
<15 / YEAR
#POWEROFSEE
Dibyendu De
effects of

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
#POWEROFSEE
Dibyendu De
19-05-2015
effects of

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

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
#POWEROFSEE
Dibyendu De
effects of

running time
#POWEROFSEE
Dibyendu De
19-05-2015

essentials
MANAGEMENT COMMITMENT
KNOWLEDGE SUPPORT
MINIMAL INTERVENTIONS
#POWEROFSEE
Dibyendu De

ingredients
PEOPLE
LEADERS
#POWEROFSEE
Dibyendu De
10
19-05-2015

development levels
#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
#POWEROFSEE
Dibyendu De
11
19-05-2015

review
NOTICE
ENGAGE
HOW AND
WHAT IS
HAPPENING WHY IT
HAPPENS?
?
WHEN TO
DO IT?
WHAT TO
DO?
EXCHANGE
MULL
#POWEROFSEE
Dibyendu De

review
Once done the company gains permanent on-going

benefits.
-Prof. Tim Henry, Manchester University, U.K
#POWEROFSEE
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
14

#Powerof: Availability Centered Maintenance

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19-05-2015

Availability Centered Maintenance

Availability Centered Maintenance

Availability = MTBF/ (MTBF+MTBR)

Availability Centered Maintenance

CASH FLOW 1/ NO. OF BREAKDOWNS

Benefits ACM AL Smelter

Total Energy Cost Saving

Total Outage Cost Saving

CBM benefit till date(Rs 000 )

Availability Centered Maintenance

ACM applied to 3 Cement Plants

Availability Centered Maintenance

No. of Breakdowns /Year

Availability Centered Maintenance

KILN NON STOP

Availability Centered Maintenance

Availability Centered Maintenance

Down time because of Bearing problem

Availability Centered Maintenance

Availability Centered Maintenance

Reliability vs. Cost

Availability Centered Maintenance

Availability Centered Maintenance

Availability Centered Maintenance

Availability Centered Maintenance

Availability Centered Maintenance

Availability Centered Maintenance

Once done the company gains permanent on-going

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

Availability Centered Maintenance Services (ACM)

ACME PVT LTD is the only company in the World to

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