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2011 ARS, India: Bangalore

Track #, Session #
Begins at X:XX AM, XXXday, October Xth
Current Time:

11:32 AM

Fostering of RCM culture in Grasim, Harihar


Presenters Name and Affiliation 1. Mr. Sudarshan.S.N (Manager,Spinning Process) 2. Mr. Narayan Rao I K (Manager, Spinning Maint.)

Agenda

Applied Reliability Symposium, India 2011

Introduction Selection of equipments for RCM Details of FMEA carried out Tasks listed after FMEA SOPs prepared after RCM Benefits after RCM Training imparted Summary Questions
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5 min 5 min 5 min 10 min 5 min 10 min 5 min 5 min 10 min


Slide Number: 2

Introduction of our company

Applied Reliability Symposium, India 2011

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Slide Number: 3

Introduction of our company


GRASIM: HARIHAR

Applied Reliability Symposium, India 2011

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Slide Number: 4

Introduction of our company

Applied Reliability Symposium, India 2011

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Slide Number: 5

Introduction of our company


Flow Diagram of VSF Process

Applied Reliability Symposium, India 2011

Selected for RCM

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Slide Number: 6

Selection of equipments

Applied Reliability Symposium, India 2011

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Slide Number: 7

Training on RCM in Harihar Selection of Equipments

3 days training was conducted between 4th may 2010 6th May 2010. 6 different units from Aditya birla group participated in this training programme Cross functional teams (4 members) were formed in all units

Applied Reliability Symposium, India 2011

First half day training was on introduction to RCM and rest of the days was spent in carrying out only FMEA
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Selection of equipments
After Training

20 critical equipments were selected


Applied Reliability Symposium, India 2011

Criticality analysis of all the selected equipments are carried out

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Slide Number: 9

Selection of equipments
Criticality analysis
Criticality Analysis. Equipment 1 : Stretch Gear Box Category Factor Option X
1 - None 2 - Low Potential for Personal Injury 3 - Moderate 4 - High 5 - Very High 1 - None 2 - Low Severity of Personal Injury 3 - Moderate 4 - High 5 - Very High 1 - None 2 - Low 3 - Moderate Health Hazards 4 - Significant 5 - Extreme 1 - Not Possible 2 - Very Unlikely Fire / Explosion Event 3 - Unlikely Possible 4 - Likely 5 - Very Likely
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Downtime Impact 1 - <50 Lacs 2 - 0.5-1 Crore 3 - 1-3 Crores 4 - 3-10 Crores 5 - >10 Crores 1 - <1 Lac 2 - 1-5 Lacs 3 - 5-20 Lacs 4 - 20-50 Lacs 5 - >50 Lacs 1 - Available in House 2 - 1 to 4 weeks 3 - 1-3 Months 4 - 3 to 6 Months 5 - More than 6 months X

Repair Costs

Maintenance = 5

Spare Parts Availability

Applied Reliability Symposium, India 2011

Safety = 12

1 - None 2 - Near Equipment 3 - Local Area (Only Section) Spill/Release Haz. Material 4 - Wider Area (Near-by Sections) 5 - Whole Plant/Surrounding s 1 - No 5 - Yes 1 - None 2 Minimal 3 Moderate 4 - Significant 5 - Extreme 1 - No 5 - Yes

X
Environmental = 7 Pollution Control Device

Env. Impact Potential

X
Radiation Detection

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Slide Number: 10

Selection of equipments
Criticality analysis
1 - None 2 - Minimal (1020% Loss) 3 - Moderate (20Capacity Reduction Impact 40% Loss) 4 - Significant (4060% Loss) 5 - Extreme (Total loss) 1 - No Regulatory Requirements 5 - Yes Operations = 10 1 - No Impact on Energy 5 - Yes Consumption 1 - No Impact on Scrap 5 - Yes 1 - > 5 Years 2 - 1-5 Years 3 - Once in a year Failure Frequency Potential 4 - Once in 6 Months 5 - Once in Month
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X X

Applied Reliability Symposium, India 2011

X X

1 - None 2 - Minimal Quality Impact Potential 3 - Moderate 4 - Significant 5 - Extreme 1 - No < 2 day delay Quality Control = 3 2 - 2 to 5 day delay Missed Delivery 3 - 5 to 15 day delay 4 - 15 to 30 day delay 5 - > 30 day delay 1 - No Customer Claim Possible? 5 - Yes Overall Criticality = 37
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Slide Number: 11

Selection of equipments
Summary of criticality analysis
Score SI No 1 2 3 4 5 6 7 8 9 Equipment Stretch Gear box Cutter Gear Box Godet gear box T Gear box Machine main Drive System Machine Pump Shaft drive system Eccentric shell assembly Fixed beam assembly Squeeze roller assembly Mat opener Aftertreatment main drive system Aft Soft Finish main drive system Alluminium conveyor assembly Spike Latice assembly Dryer Drum assembly Dryer Fan Assembly Bailing Press Full Press Bailing Press Half Press Dryer Nip roller assembly Dryer Intermediate conveyor assembly Total Safety 12 12 8 10 6 6 11 9 11 11 11 7 9 15 10 10 12 11 9 10 200 Maintenance 5 4 3 3 3 3 4 4 4 4 3 3 4 4 3 3 3 4 4 4 72 Opearation 10 10 5 6 7 5 7 6 7 7 6 6 8 10 11 7 9 9 6 9 151 Envirnomental 7 6 5 5 5 6 3 6 4 5 6 5 4 6 5 4 4 5 4 4 99 Quality control 3 5 4 3 8 3 5 6 7 5 3 4 3 6 6 5 6 5 4 6 97 Total

37 37 25 27 29 23 30 31 33 32 29 25 28 41 35 29 34 34 27 33
619

Applied Reliability Symposium, India 2011

10 11 12 13 14 15 16 17 18 19 20

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Slide Number: 12

Selection of equipments
Four equipments having high scores
Sl. No. 1
Applied Reliability Symposium, India 2011

Equipments Dryer Spike lattice assembly

Scores 41

2 3
4

Stretch gear box Dryer drum assembly


Squeeze roller assembly
Track # Session #

37 35
33
Slide Number: 13

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Selection of equipments
Equipments selected for RCM
Sl. No. 3
Applied Reliability Symposium, India 2011

Equipments Dryer Spike lattice assembly

Scores 41

Dryer drum assembly

35

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Slide Number: 14

FMEA of selected equipments

Applied Reliability Symposium, India 2011

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Slide Number: 15

FMEA
Along with 4 core team members another 8 members team were formed Training imparted to them

Applied Reliability Symposium, India 2011

All 12 members together carried out FMEA of selected equipments in presence of Reliasoft personnel from 14th to 16th June of 2010.

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Slide Number: 16

FMEA
Schematic sketch of Dryer
Spike lattice
Sc1 Zv1 Hpmv1

v HP Steam line Header: Pressure: 15 Kg / cm2 Temp. : 280 deg. C

Drum assembly
v Zv6

Zv2

Zv3

v Zv4

v Zv5
Zva6

6th Zone steam inlet

Zva5 Zva4

v 5th Zone steam inlet 4th Zone steam inlet 3rd Zone steam inlet
Static Separator

2nd Zone steam inlet 1st Zone steam inlet Achordis Blower Mat opener
Fine opener

1st Int. Duct

2nd Int. Duct

Applied Reliability Symposium, India 2011

Wet rubbing drum

Al. Conveyor

Spike lattice

1st zone

2nd zone

3rd zone

4th zone

5th zone

6th zone

St1

Baling Press: Capsule Bales No. of wires : 6 Bale Weight: 235 Kgs

To desulf bath circ. tank

St2 St3 Fp1 St4 St5

Flash pot

Dryer condensate bypass line

Silencer

v v Fp2

To wash water tank

St6

Al. Conveyor Speed: 37 rpm Comber Speed Condensate tank : 160 rpm

Wet Rubbing Drum: Speed: 440 rpm

Spiked Lat. Speed : 55 rpm

1St Drive No. of drums: 12 Drum Speed: 9 sec/rev. Temperature: 1st Zone : 95 deg. C 2nd Zone : 105 deg. C

1St Intermediate opener: Speed: 330 rpm

2nd Drive No. of drums: 8 Drum Speed: 9 sec/rev. Temperature: 3rd Zone :125 deg. C 4th Zone : 100 deg. C

2nd Intermediate opener: Speed: 330 rpm

3rd Drive No. of drums: 12 Drum Speed: 9 sec/rev. Temperature: 5th Zone : 120 deg. C 6th Zone : 100 deg. C

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Slide Number: 17

Baling Press

Comber

FMEA

System Hierarchy

Applied Reliability Symposium, India 2011

Dryer Assembly is broke down into its subsystems and assemblies


Dryer Drums FMEA is done with these sub-assemblies

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Slide Number: 18

FMEA
Function Failure Modes

Effect Causes

Applied Reliability Symposium, India 2011

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Slide Number: 19

FMEA Task Selection Logic

Applied Reliability Symposium, India 2011

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Slide Number: 20

FMEA Maintenance Task Selection



Applied Reliability Symposium, India 2011

The logic is applied for all the identified causes task were defined Currently practiced maintenance as well as new tasks were proposed where ever possible as per the logic

For Currently practiced tasks the departments are assigned responsibility.


For Proposed (New) Tasks One individual of the department is assigned responsibility.

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Slide Number: 21

FMEA

FMEA of Dryer drum assembly

Applied Reliability Symposium, India 2011

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Slide Number: 22

FMEA
FMEA of Dryer spike lattice conveyor

Applied Reliability Symposium, India 2011

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Slide Number: 23

Tasks listed after FMEA

Applied Reliability Symposium, India 2011

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Slide Number: 24

Tasks listed
Tasks listed after RCM
For Dryer drum Assembly - Current Task : 20 - Proposed Task :13
Applied Reliability Symposium, India 2011

For Spike Lattice Assembly - Current Task : 15 - Proposed Task :8

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Slide Number: 25

Tasks listed
Status of proposed task (Drum assembly)
Sl. No 1 2 Task description Status Target date Mar. 11

Establish specific SOP for worm Completed gear box Inspect & ensure the static balance Completed in 8 drums of the dryer drums with External in Dryer # 2 during last Vendor preventive RCM of After treatment section To be taken up Ensure adherence to the Sticker received & to be established SOP use visuals near fixed the equipment etc. Time based replacement of the Started for 8 drums. damper seal Review the current SOP and ensure Reviewed its compliance for damper seal

3
Applied Reliability Symposium, India 2011

Mar.11 10th Mar. 11

5 6

Mar.11 -

Establish specific SOP for worm gear box


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Completed
Session #

Slide Number: 26

Track #

Tasks listed
Status of proposed task (Drum assembly)
Sl. No
8
9 10
Applied Reliability Symposium, India 2011

Task description

Status

Target date
31st Mar. 11
-

Time based replacement of the Completed in 8 drums moving ring bearing


Tack welding of washer to the fan Completed frames where ever applicable Check the temperature near bearing Being practiced. points if its >60 C lubricate the gear box Oil lubricated gear box with higher Gear box received. Will series bearings is proposed be replaced during next available stoppage. Replace the worn out fan pulley Being practiced. 8 no. during preventive replaced during last preventive Review the moving ring bearing SOP Reviewed

11

31st Mar. 11

12

13

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Slide Number: 27

Tasks listed
Status of proposed task (Spike lattice assembly)
Sl. No
1 2 3
Applied Reliability Symposium, India 2011

Task description
Sealing of the junction box Spk. lattice

Status
motor Material is on order

Target date
10th Mar. 11

Tighten the bolts using torque wrench at Being practiced 60 lb inches To follow the revised SOP regarding the Reviewed quality of chain Appropriate anti vibration pads to be Material received. provided for zone drive gear box installed. motors. Review the existing SOP of spike lattice Reviewed assembly regarding correct torque of bolts tightening Review the SOP regarding chain tightening method Reviewed To be 15th Mar.11

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Slide Number: 28

Tasks listed
Status of proposed task (Spike lattice assembly)
Sl. No
7 8

Task description
Increase the bolt shank length by 0.5 mm to ensure enough clearance Stress re leaving to be done after fabrication of spikes over latches

Status
Completed Correspondence is done to the party. Awaiting for his reply.

Target date
-

Applied Reliability Symposium, India 2011

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Slide Number: 29

SOPs prepared after RCM

Applied Reliability Symposium, India 2011

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Slide Number: 30

SOPs prepared
Sl. No. 1 2 3 4 5 6 7 8 9 10 Description

For drum assembly


DRYER DRUM INSTALLATION

Sub: Assembly of Dryer Drum as per Drg No.: 3-H-DRY-200/30 Check list for Dryer drum assembly Min (mm) 9.98 10.0 2.98 1398 1602 10 0.001 2.5 2.8 Max (mm) 10.02 10.02 3.02 1402 1605 10.1 0.001 3.0 3 Allow

Drum perforated hole size Drum perforated hole pitch Drum perforated sheet thickness Drum Diameter Drum Length Damper & Drum clearance Drum throughness Drum shaft coupling clearance Moving Ring and fixed ring clearance Drum side cover straightness

1400 1600

90o

6. Damper & Drum Clearance: How to measure Damper & Drum Clearance?

Applied Reliability Symposium, India 2011

Place 10 mm key bar at bottom & side portion of the drum damper. Adjust the damper arm downwards such that it just touches the damper. Then tighten the arm. Remove the key bar kept at bottom & side.

7. Drum Throughness How to measure the Drum throughness? Fix the assemble Drum over the stand. Then rotate it manually with side touching to the dial gauge. Take the Dial gauge reading Note down the reading Adjust the moving ring & coupling fixing bolt to get the zero reading in dial gauge through out the circumference.

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Slide Number: 31

SOPs prepared
Assembly of Dryer Drum at site: Sl. No. 1 2 3

For drum assembly

Electrically isolate the equipment. Obtain the hot & cold work safety permit. Remove the Fan assembly. Mark the Dryer panel doors. Remove all side doors. Position the gear box jack & drum jack to its position. Remove the universal joint & gear box. Dismantle the coupling & shaft. Lead the Dryer Drum outside with chain block. Description Clearance between dryer drum coupling & side panel Clearance between drum coupling & gear box coupling Clearance between moving ring & fixed ring Min 65 2.5 3 Max 68 3 3.5 Allow

Applied Reliability Symposium, India 2011

How to measure the clearance between drum coupling & drum frame? By depth gauge measure the coupling face distance end frame face. Maintain it for 70mm

How to maintain for 70mm? If the distance is less than 70mm, then slight hammer the drum shaft by 10lb hammer. If the distance is more than 70mm, then the puller over back side of the shaft. Then tighten the screw of the puller & drum shaft assembly to maintain the distance of 70mm. Clearance between Gear Box Coupling & Drum Coupling is 3mm. How to measure the clearance? Insert the feeler gauge between couplings. And measure the thickness of the feeler gauge.

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Slide Number: 32

SOPs prepared
Sub: Ref Drg No 2/H/DRY/210/10 Ref Drg No 1/H/DRY/210/27 Ref Drg No 2/H/DRY/210/19

For Spike lattice assembly

Assembly of Spike Lattice Conveyor Drive & Driven Shafts

Check list before assembly of spike lattice conveyor Sl. No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 Description Chain roller dia. Chain pitch Roller dia. clearance Chain connecting plate thickness Connecting link hole PCD No. Of links No. of teeth in drive and driven sprockets Sprocket pitch Centre distance between the sprockets Drive shaft dia. Driven shaft dia. Key way dimension Idler sprocket teeth Latch width Latch thickness Latch pin PCD Latch pin angle Latch fixing hole PCD Thoroughness of the shaft Min (mm) 30 40.0 1 4.62 28.8 24 40 1589 55 45 Max (mm) 30.01 40.01 1.001 4.65 28.9 24 40 1589.2 55.02 45.02 Allow

110

14x5x125 12 50 2 30 10o 1618 0.00 50.02 2.01 30.01 10.1o 1618 0.001

Applied Reliability Symposium, India 2011

SUB: Chain Roller Dia : Min 30mm, Max 30.01mm Once chain recd at assembly shop, proper checking of conveyor chain will be done. Any deviation in dimension will be noted and cross verified , whether is it is in acceptable condition. If found deviation is above the acceptable limit, same will be rejected.

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Slide Number: 33

SOPs prepared

For Spike lattice assembly

SUB: Chain Pitch ; Min 40 mm , Max 40.01mm Chain pitch will be checked through out the length. Any deviation in dimension will be noted and cross verified , whether is it is in acceptable condition. If found deviation is above the acceptable limit, same will be rejected.

SUB: Roller Dia clearance Min : 1mm max : 1.001 mm Chain roller dia will be checked through out the length. Any deviation in dimension will be noted and cross verified , whether is it is in acceptable condition. If found deviation is above the acceptable limit, same will be rejected.

Applied Reliability Symposium, India 2011

SUB: Chain connecting plate thickness Min : 4.62mm, Max :4.65mm Chain connecting plate thickness will be checked through out the length. Any deviation in dimension will be noted and cross verified , whether is it is in acceptable condition. If found deviation is above the acceptable limit, same will be rejected.

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Slide Number: 34

SOPs prepared

For Spike lattice assembly


Min 28.8mm, Max 28.9mm

SUB: Chain connecting link hole PCD ,

Chain connecting link PCD will be checked through out the length. Any deviation in dimension will be noted and cross verified , whether is it is in acceptable condition. If found deviation is above the acceptable limit, same will be rejected.

SUB: Through ness of the Drive and Driven shaft, Min : 0.00mm, max : 0.01mm Through ness of the shaft will be checked between center in test bench/Lathe machine. If found zero reading in dial gauge, while rotation then job will be removed. If the readings above the acceptable limit , then bend will be removed and once again readings will be taken, This exercise ill be continued ill we get the readings well within acceptable condition

Applied Reliability Symposium, India 2011

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Slide Number: 35

Benefits after RCM

Applied Reliability Symposium, India 2011

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Slide Number: 36

Benefits
Trend of Mechanical Breakdown in Fibre Dryer
1.00

RCM Implemented from Jun-10 Better


0.92
0.7 9

0.80

Dryer Downtime %

0.60

4 0.5
0.50

Applied Reliability Symposium, India 2011

0.40

0.20

0.1
0.00 FY-10 FY-11 Apr'11 May'11

Jun'11

Year and month

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Slide Number: 37

Benefits
Dryer uptime
RCM Implemented from Jun-10
735.00

7
730.00

.9 32

Uptime hours

725.00

720.00

Applied Reliability Symposium, India 2011

715.00

723.50

726.50

710.00

9.9 0 7
FY-10 FY-11

1 71

.79

705.00 Apr'11 May'11 Jun'11

Year and month

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Slide Number: 38

Better

Benefits
Dryer MTBF (Due drum assembly)
RCM Implemented from Jun-10
740.00

700.00

Hrs,

620.00

Applied Reliability Symposium, India 2011

580.00

665

660.00

552

540.00

.0 58

500.00 FY-10 FY-11 Apr'11 May'11 Jun'11

Year and month

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Slide Number: 39

Better

.00 0 72

.0 20

Benefits
Dryer MTBF (Due spike lattice)
750.00

RCM Implemented from Jun-10 Better


0 72 .00
Jun'11
Slide Number: 40

7
740.00

.0 44

Hrs,

Applied Reliability Symposium, India 2011

720

720.00

730

730.00

0.0 2 7

710.00

700.00 FY-10 FY-11 Apr'11 May'11

Year and month

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Benefits
Dryer MTTR (Due drum assembly)
1.50

Better

Hrs,

1.00

1.23

Applied Reliability Symposium, India 2011

RCM Implemented from Jun-10

0.50 FY-10 (Before RCM) FY-11 & upto date(After RCM)

Year and month

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0.67
Slide Number: 41

Benefits
Dryer MTTR (Due spike lattice)
0.60

Better

0.55

Hrs,

0.57

0.50

RCM Implemented from Jun-10

Applied Reliability Symposium, India 2011

0.40 FY-10 (Before RCM) FY-11 & upto date(After RCM)

Year and month

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0.45
Slide Number: 42

0.45

Benefits
Fiber accumulation due dryer stoppage
100.00 90.00 80.00 70.00

RCM Implemented from Jun-10


95

Better

72

70

Bales/month

60.00 50.00 40.00 30.00 20.00 10.00 0.00 FY-10 FY-11 Apr'11 May'11 Jun'11

46

Applied Reliability Symposium, India 2011

44

Year and month

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Slide Number: 43

Benefits
% of bales having moisture between 10-12%
100.00

RCM Implemented from Jun-10


.19 6 8
87

90.00

% of bales

80.00

70.00

Applied Reliability Symposium, India 2011

60.00

50.00 FY-10 FY-11 Apr'11 May'11 Jun'11

62.00

78.12

Year and month

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Slide Number: 44

Better

.9 86

.33

Benefits
HP steam consumption, T/TF
1.02

RCM Implemented from Jun-10 Better


1.00
1.00

0.9

0.98

T/TF

6 0.9
0.96
0.96

0.9

Applied Reliability Symposium, India 2011

0.94

0.92

0.90 FY-10 FY-11 Apr'11 May'11 Jun'11

Year and date

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Slide Number: 45

Benefits
Dryer stoppage incidences due fiber jamming (due process)
10

RCM Implemented from Jun-10 Better


8

No.s/month

Applied Reliability Symposium, India 2011

2
1

0 FY-10 FY-11 Apr'11 May'11 Jun'11

Year and month

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Slide Number: 46

Training imparted

Applied Reliability Symposium, India 2011

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Slide Number: 47

Training imparted
Grasilene division
Sl. No. 1
Department

Equipment selected TRP

Status Tasks generated Tasks generated Tasks generated

Completion date

Viscose

Nov-11

Applied Reliability Symposium, India 2011

Recovery

MSFE

Nov-11

CS2/H2SO4

Furnace

Nov-11

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Slide Number: 48

Training imparted
Pulp division
Sl. No. 1
Department

Equipment selected Faulgum chipper

Status Tasks generated Tasks generated

Completion date

Chipper house

Nov-11

Applied Reliability Symposium, India 2011

Pulp mill

Vacuum filter

Nov-11

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Slide Number: 49

Summary

Applied Reliability Symposium, India 2011

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Slide Number: 50

Summary
1. After training on RCM, two equipments were selected for RCM after carrying out criticality analysis of 20 critical equipments. 2. FMEA of selected equipments were carried out in presence of Reliasoft personal.

3. Tasks were listed out.


Applied Reliability Symposium, India 2011

4. Pictorial SOPs prepared after RCM.

5. Benefits after RCM are summarized.


6. Trainings are given to other departments/divisions regarding RCM.

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Slide Number: 51

Questions please

Applied Reliability Symposium, India 2011

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Slide Number: 52

Thank You

Applied Reliability Symposium, India 2011

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Slide Number: 53