Param Express. Param Sankalp December Newsletter winners. Key Activities Concluded. Watch Out For

Transcription

1 Param Express Param Sankalp December Newsletter winners Key Activities Concluded Based on RCM expert input Refinements incorporation is in progress for 1 st set of 10 equipment s. Notification generated for implementation of FMEA new action points. BOM uploaded in all sites except T&D. Comprehensive Phase B plan prepared & Shared with all sites. 160 equipment FMEAs have been customized by sites. Site immersion training conducted in Trombay, Hydro and T&D. RCM team visited TCS, Pune to evaluate potential solutions for combustion tuning, SHR FMEA integration and equipment anomaly detection. Watch Out For Roll out of Phase B planed activities. Strong push on value initiatives across all sites. Completion of Data Cleansing for balance equipment's. Uploading of BOM in SAP for T&D. Uploading of SAP. maintenance task list in Effort estimation & incorporation of RCM inputs in BTG, AHP & CHP contract across sites. Finalization of ORI tool vendor. Finalization of IT vendor.

2 RCM Immersion Programs A RCM sustainability initiative RCM Immersion Program is a capability development and sustainability initiative started under the Param Sankalp banner since October Sustainability of RCM practices and O&M culture change are critical to the Param Sankalp program. The vision is that by the time the program is over everyone in the company speaks the RCM language. So, a dedicated RCM Academy conducts training with the help of RCM partners AT Kearney. The Academy in collaboration with AT Kearney developed the training content. The first activity of the team was to identify and train a group of internal trainers and analysts from all divisions of Tata Power. The team has conducted four RCM Immersion training sessions of two days each for 50 internal trainers. Now, members from the Academy and AT Kearney travel to sites and cover other O&M personnel along with the internal trainers of the respective division. AT Kearney and RCM Core Team are handholding the internal trainers in the first few trainings. Once the academy establishes that the internal trainers are ready, the internal trainers will train the rest of the O&M personnel using the customized content for each site. The internal trainers have started training across division since December 2017 and they have covered 216 employees across all divisions of Tata Power. The academy targets to cover 100% employees by September Data Analytics is an important pillar of RCM and the Param Sankalp program. RCM Academy along with AT Kearney developed a Basic Analytics package and trained a group of identified employees across divisions. Three such training sessions were conducted across divisions. Further to this there were two Advanced Analytics sessions conducted for employees in collaboration with IIT Bombay. All the training sessions have helped our O&M personnel to see the RCM philosophy and the elements more closely. The RCM Academy has played an instrumental role in ensuring sustainability and institutionalization of RCM practices across divisions.

3 Reliability Scorecard implemented to measure reliability of stations A Reliability Scorecard has been started to track the reliability of stations on the basis of four parameters: 1. Asset Reliability 2. Performance Reliability 3. Financial Reliability and 4. RCM process adoption. The reliability score is given out of Asset Reliability is measured taking into account EFOR and Planned Outages. It has a weightage of 20% in the reliability score calculation. 2. Performance Reliability is measured taking into account Heat Rate and Aux Power Consumption. It has a weightage of 20% in the reliability score calculation. 3. Financial Reliability is measured taking into account R&M Cost, Inventory and MUs lost. It has a weightage of 20% in the reliability score calculation. 4. RCM Process Adoption score is measured taking into account FMEA creation, customization PM, CBM compliance, Data quality, Spares Mgmt. and Maintenance strategy compliance.

4 My Conversations Corner with you Mr. Shekher Mukherjee, Head - Operations & Ash Mgmt, Jojobera. Leading RCM initiatives at Jojobera. The Journey of RCM initiated at Jojobera in the early part of the year Today we are in the adolescent stage and do believe that quickly we will be matured in this passage. These maintenance strategy is an appropriate fit to our Tata Power when we are fighting in a turbulent phase for growth and sustenance. Every employee of this division someway or other is in the participation and enjoying the tour putting hand in hand with RCM core team under the keen guidance of AT Kearney troop. RCM concept originated in the aircraft industry and later with nuclear power industry, off shore oil industry gradually moving on to other industries. This methodology shows significant reduction in maintenance cost. The maintenance task considered in the RCM approach are all related to failures and functional degradation. RCM was designed to balance the costs and benefits to obtain the most cost effective PM progress. People are involved are there in FMEA preparation on various aspect from process to equipment of resource to generation at Jojobera. Multiple CFTs are also formed which are working with deep responsibility. Site management is reviewing with definite periodicity to check the progress of each CFT. The objective and target are well established and in some of the objectives we are in the stabilization phase. We all are proud today that our institute has adopted this technique right in time whose basic intent is improving MTBF and MTTR. Today our job is to align with this concept intensively so that the purpose is accomplished. In present scenario for sustenance in the business and converting threat to an opportunity, cost optimization is a basic need and to achieve it the existing maintenance practices need a significant shift and RCM is the appropriate technique in this avenue which can assure it. We believe that we will honor this effort like all past endeavors and will get the success genuinely. RCM concept originated in the aircraft industry and later got implemented in nuclear power industry and off shore oil industry gradually moving on to other industries. This methodology shows significant reduction in maintenance cost. The maintenance task considered in the RCM approach are related to failures and functional degradation. RCM was designed to balance the costs and benefits to obtain a cost effective PM progress. The people involvement are there in FMEA Preparation on various aspects from processes to equipment at Jojobera. Multiple CFTs are formed which are working with deep responsibility. Site management is reviewing with definite periodicity to check the progress of each CFT. The objective and target are established and in some of the objectives we are in the stabilization phase. We all are proud that our institute has adopted this technique right in time whose basic intent is improving MTBF and MTTR. Today our job is to align with this concept intensively so that the purpose is accomplished. In present scenario for sustenance in the business and converting threat to an opportunity, cost optimization is a basic need and to achieve it the existing maintenance practices need a significant shift and RCM is the appropriate technique in this avenue which can assure it. We believe that we will surely honour this effort like all past endeavours and will get the success genuinely.

5 Answers for quiz of the month - Crossword 1. MPL, 10-15% B 4. B 5. C 6. A December Newsletter Quiz Questions: 1. Where is the 1 st time & motion study for overhaul conducted. How much reduction in overall time identified? 2. How many RCM value workshop have been conducted till now? 3. The frequency of Condition Based Maintenance primarily depends on which of the following. a. Frequency of failure. b. Potential to Functional Failure Interval (P-F Interval) c. Mean Time to Repair. d. Hazard Rate. 4. COI in Tata Power stands for. a. Community of Instrumentation b. Community of Interest c. Common Operational Interventions d. None of the above 5. Which of the following distributions is widely used for analysis in Reliability Centred Maintenance. a. Binomial Distribution b. Normal Distribution c. Weibull Distribution d. Monte Carlo Simulation 6. Which of the following is the SAP -T code for BOM upload using Batch Data Communication? a. ZPM_BOM b. ZPMR012 c. IB03 d. MB51 Quiz of the Month Newsletter Quiz 1. Alignment of which of the following is mandatory for completion of FMEA. a. Alignment of FMEA with SAP Codification b. Alignment of FMEA with Equipment BOM c. Alignment of FMEA with SAP Existing Action Items d. None of the Above 2. SAP Catalogue are derived from which of the following a. Equipment Manual b. Equipment FMEA c. Experience d. OEM Guidelines 3. Which of the following statement is true. a. SAP Catalogues (Object code, Damage Code, Cause code) are site specific and would be different for same type of equipment across site b. SAP Catalogues (Object code, Damage Code, Cause code) are equipment specific and would be same for same type of equipment across site 4. EOQ in Spares management standards for a. Equal Ordering quantity b. Each of the Quantity c. Economical Ordered Quantity d. None of the above 5. Which of the following is not a CBM activity. a. Visual Inspection b. DCS parameters c. Operator round d. Periodic Alignment check Send your responses to paramsankalp@tatapower.com First three correct responses would be awarded.

6 Given the scale and complexity of a capital overhaul, timely execution & coordination is a challenge Can you quickly allocate the total expenditure in the outage among the equipment will be useful in analysis Detailed planning is key to ensuring desired execution while accurate data capture will be instrumental in technical and financial analysis All the different teams are working towards upcoming milestones we are on track as per our plan If you have any questions, please write to us at paramsankalp@tatapower.com