1

RELIABILITY BASED MAINTENANCE

RELIABILITY BASED MAINTENANCE IS A TECHNIQUE

THAT

UTILIZES

DETERMINE

THE

ZERO

BASE

OPTIMUM

APPROACH

TO

MAINTENANCE

REQUIREMENT OF EQUIPMENTS IN THEIR OPERATING

ENVIRONMENT.

2
NEED OF RELIABILITY BASED MAINTENANCE

TO OPTIMISE MAINTENANCE ACTIVITIES BY :A)

REDUCTION IN REPAIR TIME

B)

REDUCTION IN MAINTENANCE FREQUENCY

C)

REDUCTION IN EXCESSIVE MAINTENANCE

TO ELIMINATE ROOT CAUSE OF BREAKDOWN

RBM ORGANIZATION
PLANNED MAINTENANCE
SUB-COMMITTEE CHAIRMAN

RBM CO-ORDINATOR

RBM
CORE
GROUP

MEMBER MEMBER MEMBER MEMBER MEMBER MEMBER

(MECH.) (ELECT.) (INSTT.)
(MID.)
(PROD.)
(MID.)

REM
TEAMS

MEMBER
(MECH.)

MEMBER
(ELECT.)

MEMBER
(INSTT..)

CORE GROUP MEMBERS = 12

TOTAL MEMBERS = 65

MEMBER
(PROD.)

RBM
CONSULTANT

NO. OF REM TEAMS = 13

(FOR EVERY SECTIONS)

RBM FLOW DIAGRAM

PREPARATION OF RELIABILITY BLOCK DIAGRAM

CHOOSE CRITICAL MACHINE & TARGETS
INSERT/ADD ALL FAILURE MODES TO MACHINES & PROCESS

PHASE - I

ROOT CAUSE & WARNING

DEFINE TASKS CLEARLY TO ADDRESS ROOT CAUSE,
FREQUENCY AND TRAINING NEEDS

FOCUSSED IMPROVEMENT
LUBRICATION
BRGFAILURE STUDY

HEAT EXCHANGER STUDY

SEAL FAILURE STUDY

(FORMATION OF
- REM SHEETS
- CHECKLIST
- RELIABILITY
CALCULATION)

IMPLEMENT & MONITOR

SPARE ENGINEERING
ADD NEW M/CS

TRAINING AS PER REM

REVIEW
RESULTS

CHRONIC CASES

ASSESS EFFECTIVENESS (COST)

PROCUREMENT PROCEDURE

FAILURE
ANALYSIS

PHASE-II -

CONTINUE

5
EQUIPMENT CRITICALITY RATING CHART
LP
BAND

1
2
3
4
5
6
7
8
9

DOWN
TIME

0 - 10 min
10 - 30 min
30 - 60 min
1 - 2 hrs
2 - 4 hrs
4 - 8 hrs
8 - 16 hrs
10 - 32 hrs
> 32 hrs

RC & SEC. DAMAGE SAFETY &ENVIRONMENT

BAND

1
2
3
4
5
6
7
8
9

COST

0 - 15,000
15,000 - 25,000
25,000 - 1.0 L
1.0 - 2.0 L
2.0 - 5.0 L
5.0 - 10 L
10 - 20 L
20 - 50 L
> 50 L

BAND

1
2
3
4
5
6
7
8
9

LP = LOST PRODUCTION ; RC = REPAIR COST ; SD = SECONDARY DAMAGE

CR = FR/10 ( LP+RC+SD+S+E)
FR = FAILURE RATE ( NO OF FAILURES / YEAR)

RISK

Minimal
Significant
Serious
Potentially fatal
Disaster

CALCULATION OF CRITICALITY

UNIT :VC

SECTION: KILN (COOLER

EQPCODE

EQUIPMENT NAME

LP

RC

SD

FR

FR/YEAR CR

1CLCL01 - DR001 GRATE DRIVE 2

1CLCL01 - DR002 GRATE DRIVE 1

1CLCR01 - CR001 CLINKER CRUSHER

3.9
2.7
2.4

1CRFN02 - FN001 COOLER FAN -2A

1.8

1CLFN03 - FN001 COOLER FAN -3

1.5

1CLFN01 - FN001 COOLER FAN -1

1.2

1CLFN06 - FN001 BEARING COOLING FAN

1.0

1CLFN04 - FN001 COOLER FAN -4

1.0

1CLFN05 - FN001 COOLER FAN -5

1.0

1CLCL01 - AC112 DISCHARGE GATE 1

1.0

1CLCL01 - AC113 DISCHARGE GATE 2

1.0

1CLCL01 - AC114 DISCHARGE GATE 3

1.0

1CLCL01 - AC115 DISCHARGE GATE 4

1.0

1CLCL01 - AC116 DISCHARGE GATE 5

1.0

1CLCL01 - AC117 DISCHARGE GATE 6

1.0

1CLCL01 - AC118 DISCHARGE GATE 7

1.0

1CLCL01 - AC119 DISCHARGE GATE 8

1.0

DISCHARGE GATE 9

1.0

LUB PUMP 1

0.6

0.5

0.5

1CLFN02 - FN002 COOLER FAN -2B

LUB PUMP 2

LEGEND: LP = LOSS PRODUCTION ; RC = REPAIR COST ; SD = SECONDARY DAMAGE

FR = FAILURE RATE ; CR = CRITICALITY RATIO ; S = SAFETY ; E = ENVIRONMENT

CALCULATION OF CRITICALITY

UNIT : VC

SECTION : KILN (COOLER)

EQPCODE

EQUIPMENT NAME

LP

RC

SD

FR

FR/YEAR CR

1CLDP01 - CV001DPC 1

45

81.0

1CLDP02 - CV001DPC 2

40

68.0

1CLFN07 - LR001 C.D FAN -1

3.0

1CLFN08 - LR001 C.D FAN -2

1.5

DISCHARGEGATE 11

1.0

DISCHARGEGATE 12

1.0

DISCHARGEGATE 13

1.0

DISCHARGEGATE 14

1.0

1CLES01 - AL001 E.S.P RAL-1

0.5

1CLES01 - AL002 E.S.P RAL-2

0.5

1CLES01 - AL003 E.S.P RAL-3

0.5

1CLSC01 - SC001 E.S.P S/C 1

0.5

1CLSC02 - SC001 E.S.P S/C 2

0.5

1CLSC03 - SC001 E.S.P S/C 3

0.5

1CLSC04 - SC001 E.S.P S/C 4

0.5

1CLSC05 - SC001 E.S.P S/C 5

0.5

LEGEND: LP = LOSS PRODUCTION ; RC = REPAIR COST ; SD = SECONDARY DAMAGE

FR = FAILURE RATE ; CR = CRITICALITY RATIO ; S = SAFETY ; E = ENVIRONMENT

RBM FLOW DIAGRAM

PREPARATION OF RELIABILITY BLOCK DIAGRAM

CHOOSE CRITICAL MACHINE & TARGETS
INSERT/ADD ALL FAILURE MODES TO MACHINES & PROCESS

PHASE - I

ROOT CAUSE & WARNING

DEFINE TASKS CLEARLY TO ADDRESS ROOT CAUSE,
FREQUENCY AND TRAINING NEEDS

FOCUSSED IMPROVEMENT
LUBRICATION
BRGFAILURE STUDY

HEAT EXCHANGER STUDY

SEAL FAILURE STUDY

(FORMATION OF
- REM SHEETS
- CHECKLIST
- RELIABILITY
CALCULATION)

IMPLEMENT & MONITOR

SPARE ENGINEERING
ADD NEW M/CS

TRAINING AS PER REM

REVIEW
RESULTS

CHRONIC CASES

ASSESS EFFECTIVENESS (COST)

PROCUREMENT PROCEDURE

FAILURE
ANALYSIS

PHASE-II -

CONTINUE

EQP CODE : 1CLDP01 & 1CLDP02

EQP NAME : DPC I & II (KILN)
SUB SPARE MODE OF WARNING
ROOT
TASK
DEPT. PERIOD TIME
NAME
(FREQ) REQ .
FAILURE
EFFECT
CAUSE
DPC Roller
Brg cage
Motion
Roller brg grease Overhauling of
M
24 W 30 min
failure
detector
contaminated
rollers .
operated
due to dust
Double flap valve at
M
Once
discharge gate to be
installed
Links
Links
Abnormal
Due to aging of Checking of roller & M
1 W 1 hrs
cracked
sound
links .
chain
Chain to be replaced
M
Once 10days

REVIEW OF EQPT. MAINTENANCE

Buckets Uclits
Welding
cracked
Rail
Worn out

Guide
rail

Support
bracket
weld cracked
.

Overload of
drive

Poor welding

MAINT.
TYPE
PM

DOM

CBM
PM

Bucket taken out &

its U clit welded

Misalignment of Rail alignment to be

rails .
rectified
Higher size rail to be
installed

52 W

Once

52 W

4 hrs

1W

1/2 hrs CBM

Welding inspection
to be done.
Check the motion
sensing flag &
actuation .

3W

PM
DOM

CBM

EQP CODE : 1CLDP01 & 1CLDP02 REVIEW OF EQPT. MAINTENANCE

EQP NAME : DPC I & II (KILN)
SUB SPARE MODE OF WARNING
ROOT
TASK
DEPT. PERIOD TIME
NAME
(FREQ) REQ .
FAILURE
EFFECT
CAUSE
Gear Oil seal
Wornout
Leakage
Misalignment Output coupling
M
24 Hrs Once
Box
alignment to be
improved
Dust
Two way flap valve
M
Once
Contamination to be installed in CSP
discharge
MD
Lever Hinge failure Drive tripped Hinge locking pin locking pin to be
I
1 W 15 Min
worn out .
checked .
Probe
Broken
Transistor short To replace sensor
I
52 W 30 min
sensor short
Motor Motor Motor
Fuse blown , Underrated main Replace with 70
E
Once
winding burnt thermal
power cable
mm2 cable.
overload relay (35mm2)
operated
Insulation heated Termination
E
24 W 15 min
up
Checking .
Check motor body
E
4 W 1/2 hrs
temp(<85 deg. c)
Check vibration .
MID
4 W 15 min

10
MAINT.
TYPE
PM

DOM

PM
OFM
DOM

PM
CBM
CBM

11

RBM FLOW DIAGRAM

PREPARATION OF RELIABILITY BLOCK DIAGRAM

CHOOSE CRITICAL MACHINE & TARGETS
INSERT/ADD ALL FAILURE MODES TO MACHINES & PROCESS

PHASE - I

ROOT CAUSE & WARNING

DEFINE TASKS CLEARLY TO ADDRESS ROOT CAUSE,
FREQUENCY AND TRAINING NEEDS

FOCUSSED IMPROVEMENT
LUBRICATION
BRGFAILURE STUDY

HEAT EXCHANGER STUDY

SEAL FAILURE STUDY

(FORMATION OF
- REM SHEETS
- CHECKLIST
- RELIABILITY
CALCULATION)

IMPLEMENT & MONITOR

SPARE ENGINEERING
ADD NEW M/CS

TRAINING AS PER REM

REVIEW
RESULTS

CHRONIC CASES

ASSESS EFFECTIVENESS (COST)

PROCUREMENT PROCEDURE

FAILURE
ANALYSIS

PHASE-II -

CONTINUE

12

SEAL FAILURE STUDY OF DPC GEAR BOX

MINOR LEAKAGE FROM OIL SEAL

CHECK FOR
COUPLING
AND GEAR TRAIN
MISALIGNMENT

OUTPUT
COUPLING
MISALIGNMENT
CORRECTED

FOUNDATION
STRUCTURE OF
GEAR BOX
STRENGTHENED
TO AVOID
JERK ON
GEAR BOX

SCRATCHES ON
SHAFT SURFACE

CHECK
ABRASIVE
CONTAMINATES
IN LUBRICANT
(OIL
CENTRIFUSED)

MEASURE
SHAFT
DIMENSION
>40 RC
(FOUND 52 RC)

INADEQUATE
INTERFERENCE
FIT BETWEEN
SHAFT & SEAL

CHECK SHAFT
DIMENSION
(FOUND O.K.)

HEAT EXCHANGER - A CASE STUDY

13

EQUIPMENT:CEMENT MILL MAIN DRIVE GEAR BOX HEAT EXCHANGER - 2 NOS.

EXISTING SURFACE AREA = 2.2 + 2.2 = 4.4 M2
OBSERVATION:OIL TEMPERATURE REDUCTION = 2 DEG. C
AT INLET WATER TEMPERATURE = 34 DEG. C
AMBIENT TEMPERATURE = 28 DEG.C
IMPROVEMENT PLAN:MOTOR KW = 2250 KW
MAXIMUM POWER DRAWN = 1900 KW
HELICAL GEAR BOX EFFICIENCY = 90% (ESTIMATED)
HEAT DESSIPATION IN GEAR BOX = 1900 X 10% = 190 KW
AT INLET WATER TEMPERATURE = 38 DEC. C (IN SUMMER SEASON)
REQUIRED HEAT EXCHANGER SURFACE AREA = 22 M2 (FROM GRAPH)

HEAT EXCHANGER STUDY

14

RESULTS:- NEW PLATE TYPE HEAT EXCHANGER WITH SURFACE AREA (20 M2)
INSTALLED
- IMPROVEMENT IN OIL TEMPERATURE REDUCTION
IN NEW HEAT EXCHANGER = 8 DEG.C
- WATER TEMPERATURE RISE = 10 - 12 DEC.C
- SIGNIFICANT REDUCTION IN GEAR BOX OIL TEMPERATURE =
57 (BEFORE) - 43 (AFTER) = 14 DEG. C
- OIL SEAL LIFE AT INPUT AND OUTPUT END INCREASED BY 2.5 YEARS

SELECTION OF LUBRICANTS - A CASE STUDY

EQUIPMENT:CEMENT MILL MAIN DRIVE GEAR BOX
PINION DIA = 240mm
OIL VISCOSITY USED = 460 CSK
INPUT SPEED = 990 RPM
CALCULATION OF INPUT PIONION PERIPHERIAL SPEED:VS = PIE x D x N
60
= 3.14 x 240 x 990 = 12.5 M/Sec.
60 x 1000
FOR 10 TO 12 M/Sec. INPUT SPEED VISCOSITY SHOULD BE = 320 CSK
ACTION:OIL VISCOSITY CHANGED FROM 460 CSK TO 320 CSK
OIL TEMPERATURE AND SEAL LIFE IMPROVED

15

16

RBM FLOW DIAGRAM

PREPARATION OF RELIABILITY BLOCK DIAGRAM

CHOOSE CRITICAL MACHINE & TARGETS
INSERT/ADD ALL FAILURE MODES TO MACHINES & PROCESS

PHASE - I

ROOT CAUSE & WARNING

DEFINE TASKS CLEARLY TO ADDRESS ROOT CAUSE,
FREQUENCY AND TRAINING NEEDS

FOCUSSED IMPROVEMENT
LUBRICATION
BRGFAILURE STUDY

HEAT EXCHANGER STUDY

SEAL FAILURE STUDY

(FORMATION OF
- REM SHEETS
- CHECKLIST
- RELIABILITY
CALCULATION)

IMPLEMENT & MONITOR

SPARE ENGINEERING
ADD NEW M/CS

TRAINING AS PER REM

REVIEW
RESULTS

CHRONIC CASES

ASSESS EFFECTIVENESS (COST)

PROCUREMENT PROCEDURE

FAILURE
ANALYSIS

PHASE-II -

CONTINUE

17

IMPLEMENT & MONITOR

DEVELOP CHECKLIST FOR EACH DISCIPLINE (CONVERSION OF REM
SHEETS)
DEVELOP CBM CHECKLIST
COMPUTERIZATION OF CHECKLISTS AND SCHEDULING OF RBM MASTER
EXECUTION OF CHECKLIST (TRIAL RUN)
REVIEW AND MODIFY THE CHECKLISTS

18

RBM FLOW DIAGRAM

PREPARATION OF RELIABILITY BLOCK DIAGRAM

CHOOSE CRITICAL MACHINE & TARGETS
INSERT/ADD ALL FAILURE MODES TO MACHINES & PROCESS

PHASE - I

ROOT CAUSE & WARNING

DEFINE TASKS CLEARLY TO ADDRESS ROOT CAUSE,
FREQUENCY AND TRAINING NEEDS

FOCUSSED IMPROVEMENT
LUBRICATION
BRGFAILURE STUDY

HEAT EXCHANGER STUDY

SEAL FAILURE STUDY

(FORMATION OF
- REM SHEETS
- CHECKLIST
- RELIABILITY
CALCULATION)

IMPLEMENT & MONITOR

SPARE ENGINEERING
ADD NEW M/CS

TRAINING AS PER REM

REVIEW
RESULTS

CHRONIC CASES

ASSESS EFFECTIVENESS (COST)

PROCUREMENT PROCEDURE

FAILURE
ANALYSIS

PHASE-II -

CONTINUE

SPARE PART ENGINEERING

FOR RELIABILITY ENHANCEMENT

19

COMPONENT

LESS THAN
STANDARD LIFE

WEAR

5, 7, 8
3

RANDOM

6, 1, 2, 9

LIFE

FULL LIFE
SELECT HIGH
COST AREA FOR
IMPROVEMENT

TOO EARLY

9, 8,3

1.
2.
3.
4.
5.
6.
7.
8.
9.

OPERATION IMPROVEMENT
MAINTENANCE IMPROVEMENT
INSPECTION IMPROVEMENT
STORAGE / TRANSPORT
ENVIRONMENT IMPROVMENT
VENDOR IMPROVEMENT
LUBE / OTHER CONDTION
IMPROVEMENT
MATERIAL
DESIGN REVISION

SPARE LIFE ENHANCEMENT - A CASE STUDY

20

NAME OF THE SPARE - BUCKET ELEVATOR BOTTOM BOOT BEARINGS

OBSERVATIONS:PREVIOUS LIFE : 3 - 4 MONTHS (TOO EARLY FAILURE)
MODE OF FAILURE : BEARING CAGE WEAR DUE TO POOR LUBRICATION
CONDITION
TYPE OF BEARING : ANTIFRICTION BEARING
ENVIRONMENT
: DUST PRONE AREA
FREQUENCY OF LUBRICATION : DAILY
ACTION PERFORMED:MATERIAL CHANGE : NI HARD JOURNAL BEARING INSTALLED
ENVIRONMENT IMPROVEMENT : DUST SPILLAGE CONTROLLED
IN OPERATION
IMPROVEMENT IN FREQUENCY: FORTNIGHTLY
OF LUBRICATION
LIFE : RUNNING SINCE 1.5 YEARS

RBM FLOW DIAGRAM

21

PREPARATION OF RELIABILITY BLOCK DIAGRAM

CHOOSE CRITICAL MACHINE & TARGETS
INSERT/ADD ALL FAILURE MODES TO MACHINES & PROCESS
PHASE - I

ROOT CAUSE & WARNING

DEFINE TASKS CLEARLY TO ADDRESS ROOT CAUSE,
FREQUENCY AND TRAINING NEEDS

FOCUSSED IMPROVEMENT
LUBRICATION
BRGFAILURE STUDY

HEAT EXCHANGER STUDY

SEAL FAILURE STUDY

(FORMATION OF
- REM SHEETS
- CHECKLIST
- RELIABILITY
CALCULATION)

IMPLEMENT & MONITOR

SPARE ENGINEERING
ADD NEW M/CS

TRAINING AS PER REM

REVIEW
RESULTS

CHRONIC CASES

ASSESS EFFECTIVENESS (COST)

PROCUREMENT PROCEDURE

FAILURE
ANALYSIS

PHASE-II -

CONTINUE

22
STANDARD CHECKING PROCEDURE
OF L.T. MOTOR

CHECK INSULATION VALUE WITH 500 VOLT MEGGAR AND

RECORDS VALUE. IF VALUE LESS THAN 1 MEGAOHM,
IMPROVE THE VALUE.

CHECK INDUCTANCE AND RESISTANCE WITH MOTOR

CHECKER AND RECORD THE VALUE. DIFFERENCE OF R,Y,B
SHOULD NOT BE >5%

CHECK MOTOR TERMINATION

CHECK GLAND FOR TIGHTNESS

CHECK FOR PROPER DOUBLE EARTHING
CHECK FOR ANY HEATING OF LUGS
CHECK TERMINAL BOX SEALING

23

RBM FLOW DIAGRAM

PREPARATION OF RELIABILITY BLOCK DIAGRAM

CHOOSE CRITICAL MACHINE & TARGETS
INSERT/ADD ALL FAILURE MODES TO MACHINES & PROCESS

PHASE - I

ROOT CAUSE & WARNING

DEFINE TASKS CLEARLY TO ADDRESS ROOT CAUSE,
FREQUENCY AND TRAINING NEEDS

FOCUSSED IMPROVEMENT
LUBRICATION
BRGFAILURE STUDY

HEAT EXCHANGER STUDY

SEAL FAILURE STUDY

(FORMATION OF
- REM SHEETS
- CHECKLIST
- RELIABILITY
CALCULATION)

IMPLEMENT & MONITOR

SPARE ENGINEERING
ADD NEW M/CS

TRAINING AS PER REM

REVIEW
RESULTS

CHRONIC CASES

ASSESS EFFECTIVENESS (COST)

PROCUREMENT PROCEDURE

FAILURE
ANALYSIS

PHASE-II -

CONTINUE

CHRONIC FAILURES OF BAG HOUSE FAN

MODE OF FAILURE: INNER RACE CRACKED
BEARING HOUSING BORE DAMAGED
BEARING CLEARANCE GOT HIGH
BEARING SEATS GOT WORNOUT
FAN SHAFT BROKEN
COUPLING KEYWAY DAMAGE
WARNING EFFECT: HIGH VIBRATION
KNOCKING SOUND
HIGH BEARING TEMPERATURE

24

CHRONIC FAILURES OF BAG HOUSE FAN

ROOT CAUSE ANALYSIS: BEARING PEDESTAL FOUNDATION IS WEAK
PEDESTAL LEVELLING IS NOT PROPER SINCE ERECTION
HIGH JERK AT SHAFT BEARING SEAT DURING CHANGEOVER
FROM SPRS TO LRS AND VICE VERSA
TOLERANCE OF BEARING HOUSING BORE DIMENSION IS
NOT PROPER
ACTION PERFORMED: BEARING PEDESTAL FOUNDATION IS REGROUTED AND
PEDESTAL LEVELLING IS DONE
DRAWING DEVELOPED FOR BEARING HOUSING WITH
REQUIRED TOLERANCE
SHAFT TOLERANCE AT BEARING SEAT IS CHANGED
TRACKING SYSTEM FOR REGULATING FAN SPEED IS INSTALLED

25

26

RBM FLOW DIAGRAM

PREPARATION OF RELIABILITY BLOCK DIAGRAM

CHOOSE CRITICAL MACHINE & TARGETS
INSERT/ADD ALL FAILURE MODES TO MACHINES & PROCESS

PHASE - I

ROOT CAUSE & WARNING

DEFINE TASKS CLEARLY TO ADDRESS ROOT CAUSE,
FREQUENCY AND TRAINING NEEDS

FOCUSSED IMPROVEMENT
LUBRICATION
BRGFAILURE STUDY

HEAT EXCHANGER STUDY

SEAL FAILURE STUDY

(FORMATION OF
- REM SHEETS
- CHECKLIST
- RELIABILITY
CALCULATION)

IMPLEMENT & MONITOR

SPARE ENGINEERING
ADD NEW M/CS

TRAINING AS PER REM

REVIEW
RESULTS

CHRONIC CASES

ASSESS EFFECTIVENESS (COST)

PROCUREMENT PROCEDURE

FAILURE
ANALYSIS

PHASE-II -

CONTINUE

27
BENEFITS OF RELIABILITY BASED MAINTENANCE
NO.OF PLANTS UNDER RBM

- 3

% OF EQUIPMENTS COVERED UNDER RBM - 62

(MOST CRITICAL + CRITICAL)

RESULTS OF RBM
EQUIPMNT UNDER CBM

PREVIOUS
`
208

AFTER
322

% PM ACTIVITIES

100

58 Reduction by 42%

DESIGN OUT MAINT. CASES

28

% INCREASE IN CBM ACTIVITIES

82:18

58:42 Increase by 24%

28

VIKRAM CEMENT
12000

B/D HOURS

10000

REDUCTION OF BREAKDOWN HOURS

RBM
IMPLEMENTATION
9819.3

8000
BETTER

6000

6189
5052.8

4000

2000

4014.9
2488.8
2174.4

1554.7
999.9

1375.86

1362.47

1106.46

0
91-92 92-93 93-94 94-95 95-96 96-97 97-98 98-99 99-00 00-01 '01-02
YEAR

29

VIKRAM CEMENT
3000

REDUCTION OF BREAKDOWN FREQUENCY

RBM
IMPLEMENTATION

2688
B/D FREQUENCY

2500

2372
2171

2000

1500

1981

BETTER

1450
1263

1000

803

646

500

739

529
391

0
91-92 92-93 93-94 94-95 95-96 96-97 97-98 98-99 99-00 00-01 '01-02
YEAR

30
VIKRAM CEMENT
IMPROVEMENT IN MTTR

RBM
IMPLEMENTATION

3.65

HOURS

2.85

2.55
2.13

2.13

1.97

2.02

1.93

2.09

BETTER

1.84

1.49
1

0
91-92 92-93

93-94

94-95

95-96 96-97
YEAR

97-98

98-99

99-00

00-01 '01-02

31
VIKRAM CEMENT
IMPROVEMENT IN MTBF

130

120.8

120
110
90

HOURS

112.6

DUE TO AFFECT OF
PETCOKE ON
SPARE LIFE

100

87.02
79.8

80
70

BETTER

69.32

RBM
IMPLEMENTATION

60
50
40
30
20

28.02

27.65

35.83

39.24

43.19

20.86

10
0
91-92 92-93 93-94 94-95 95-96 96-97 97-98 98-99 99-00 00-01 '01-02

YEAR

32

VIKRAM CEMENT
IMPROVEMENT IN MAINTENANCE COST
160

157.48
148.71

COST PER TON

140
128.22

120
100

BETTER

106.4
98.27
84.11

80

61.24

65.27

60

RBM
IMPLEMENTATION

40
20
0
94-95

95-96

96-97

97-98
YEAR

98-99

99-00

00-01

'01-02

33

RBM FLOW DIAGRAM

PREPARATION OF RELIABILITY BLOCK DIAGRAM

CHOOSE CRITICAL MACHINE & TARGETS
INSERT/ADD ALL FAILURE MODES TO MACHINES & PROCESS

PHASE - I

ROOT CAUSE & WARNING

DEFINE TASKS CLEARLY TO ADDRESS ROOT CAUSE,
FREQUENCY AND TRAINING NEEDS

FOCUSSED IMPROVEMENT
LUBRICATION
BRGFAILURE STUDY

HEAT EXCHANGER STUDY

SEAL FAILURE STUDY

(FORMATION OF
- REM SHEETS
- CHECKLIST
- RELIABILITY
CALCULATION)

IMPLEMENT & MONITOR

SPARE ENGINEERING
ADD NEW M/CS

TRAINING AS PER REM

REVIEW
RESULTS

CHRONIC CASES

ASSESS EFFECTIVENESS (COST)

PROCUREMENT PROCEDURE

FAILURE
ANALYSIS

PHASE-II -

CONTINUE

34
PROCUREMENT PROCEDURE

ASSESSMENT OF CRITICALITY OF EQUIPMENT

IDENTIFY FAILURE MODES OF FAILED SPARE

DEVISE KEY RELIABILITY ASSESSMENT CRITERIA

- APPLICATION OF (PRESSURE/TEMPERATURE/IMPACT/WEAR)

DEVISE KEY RELIABILITY ACCEPTANCE CRITERIA

- PHYSICAL, METALLURGICAL, CHEMICAL, VISUAL, DIMENSIONAL

DEVISE APPROPRIATE QUALITY SAMPLING PLAN FOR

ACCEPTANCE QUALITY LEVEL

STANDARDIZE PURCHASE PROCEDURE

35
A WAY FORWARD
MAJOR CHALLENGES
CASTING LIFE GET REDUCED DUE TO PETCOKE AFFECT
INCREASED SULPHUR
INCREASED TEMPERATURE

INCREASED MATERIAL HANDLING LOAD AT BELT CONVEYOR

SYSTEM
OUTPUT INCREASED FROM 1800 TPH TO 2800 TPH
INCREASED CLINKER TEMPERATURE

CYCLONE JAMMING AND LESS REFRACTORY AND CASTABLE

LIFE IN PREHEATER

RBM TASK FORCE IS FORMED TO OVERCOME THESE PROBLEMS.