BEST MAINTENANCE PRACTICES IN PULP & PAPER MILLS TO IMPROVE PROFITABILTY BEST MAINTENANCE PRACTICES...

J K PAPER LTD…….Creating Lasting Impressions

BEST MAINTENANCE PRACTICES IN PULP & PAPER MILLS TO IMPROVE PROFITABILTY Slide No. 1

JK PAPER LTD.UNIT: CPM

IPPTA PRESENTATION

BEST MAINTENANCE PRACTICES

FOLLOWED

AT JK PAPER LTD TO IMPROVE PROFITABILITY

18 July -2014

Presented by: Sandesh Joshi



CPMPresent Capacity , 145000 TPA

Pulp & Paper Plant Packaging Board Plant

•Commenced production in 1968•Acquired by JK Group in 1992•Turn around in 1994-95 •Capacity: 55,000 TPA •Products: Cut size multi purpose office paper and security paper

•Commenced production in 2007•Capacity: 90,000 TPA •Products: Multi Layer Packaging Boards



PROFITABILTYIndia is a fast developing nation. To accelerate Economic Growth, Indian Business community has to invest into manufacturing sector, produce Qualitative as well as Quantitative products as per International standard at lowest possible manufacturing cost. Maintenance of heavy machinery is a major share in manufacturing cost. Best Maintenance Practices include powerful techniques to maximize uptime of machinery at lowest maintenance cost. This leads to profitability

Good maintenance practice is one of the keys to increasing productivity and profits

Produce qualitative as

well as quantitative products

Changing Customer Priorities

Shareholder Wealth / Profit

Migration

Best Maintenance

Practice

Maintain International Products Standard

Generates value, profit and wealth

Lowest manufacturing cost

Increase productivity



BRIEF MANUFACTURING PROCESS OF MULTI LAYER PACKAGING BOARD

Pulping Screening & cleaning Thickening Refining Blending

Dilution, centricleaning and screening

Sheet formation & consolidation Drying

Surface sizing

Calendaring 3 Stage coating

& IR Drying Reeling Rewinding

Sheeting & Packing

Storage in godown Dispatch



JK PAPER LTD – CPM UNIT – MAINTENANCAE POLICY

JK Paper Unit; CPM is committed to maintain ZERO BREAKDOWNS and ZERO REPETITIVE FAILURE through:

Deployment of combination of Time Based (TBM) and Condition Based Maintenance (CBM).

Optimization of Processes, Plant and equipment efficiency.

Identify and evolve Best maintenance solutions through Preventive Maintenance (PM),

Maintenance Prevention (MP) and Maintainability Improvement (MI) to suit individual Equipment.

Establishment of effective training mechanism and motivational policies to engage maintenance crew to achieve common Goal – Trouble free Production.

Identifying and eliminating non-value adding processes and production bottlenecks.

Cost reduction through innovative Cost Compression Schemes.

Equipment protection, security and safety with environmental and other applicable statutory compliances.

Nurturing Team work and Development of Individual skill at all levels.

Creating lively, energetic, healthy and safe work environment.



MAINTENANCE PRACTICE STEPS

STEP BY STEP - PLANNED MAINTENACE



CATAGORISATION EQUIPMENT

According to Equipment contribution in Production, equipment categorized in ABC Critical group. A. Critical EquipmentB. Sub-Critical EquipmentC. Non critical Equipment



EQUIPMENT DATA SHEETEquipment data sheet contains information regarding Specification, MOC, Drawing details, Lubrication details & Spare details.

MAKEMODELDISCHARGEHEADMOTOR KW 22 Amp 37.7 rpm 2900 frame 180M

Sr No. Location Qty1 Pump 12 Shaft 13 Shaft 24 Shaft 25 Shaft 16 Shaft 17

LubricationTypeGradeQtyRelubrication IntervalRelubrication Qty

Lithium Soap Bearing GreaseShell Alvania Water repallent - 2200gmsEvery 2500 hrs opration30 gms

SPARE DETAILS Descripation ERP codeInput shaft 7010050643Mech Seal 7010050530Bearing 6306 ZZ 1122063063V Ring 7015140060Coupling F- 70 1930450069Coupling Tyre F- 70 1930050700

PRIME MOVER Foot mounted

EQUPIMENT DATA SHEETEQUIPEMENT NAME BOTTOM LAYER RICH WATER PUMP - ABS SCAN - NL 80-160

LOCATION APPROCH PROCESS WHITE WATER TANKEQUIPMENT CATEGORY B

SPECIFICATION OF PUMP

ABS SCAN NL 80-160165 m3/hr

31 mtrs

8

27

24Motor shaft

8

27

24

Pump shaft

BEARINGHOUSING

ROTATING SHAFT

IMPELLER

STUFFING BOX

SHAFT COUPLING

MECHANICAL SEAL



BASIC OF ALL MAINTENANCE ACTIVITIES IS 5S PRACTICE



MAINTENANCE PRACTICE STEPS

STEP BY STEP - PLANNED MAINTENACE



EQUIPMENT HISTORY REGISTER

Maintaining History register in soft copy helps retrieving information related to equipment. Area wise Equipment listed in excel sheet with asset no. Each equipment hyperlinked with,

1. History of jobs carried out2. Specification with drawing details3. Spare list with ERP code4. SOP (Standard Overhauling procedure )5. Modification done if any



SOP – STANDARD OVERHAULING PROCEDURESOP sheet contains details like dismantling & assembling procedures with check point , tools used & safety measure



1. BREAKDOWN MAINTENANCE• Allow run machinery till failure.• Repair or Replace equipment when obvious problem occurs.• 7QC tools applied to study break downs. Find out root cause. Action plan prepare &

implemented. Also Horizontal application formulated.

2. TIME BASED MAINTENACE (TBM)• Schedule maintenance activities at per determined interval.• Repair or replace equipment when obvious before problem occurs.• TBM strategy followed in critical category equipment such as Pressure Screen, Rolls-

Wire, Press, MG, Calendar. • TBM jobs are planned in advance in details & clubbed with Shut down planning.• Spare sub assemblies are kept ready to minimize replacement time.

3. CONDITION BASED MAINTENANCE• Schedule maintenance activities when Mechanical or operational condition warrants.• Repair or Replace equipment when obvious problem occurs.• By continuous monitoring parameters like temperature, Vibration, Load, Noise level

etc trends are plotted. Examine deviation with standard.• Based on conclusions, Maintenance jobs are planned & clubbed with shut or

opportunity.

MAINTENANCE ACTIVITY

1. BREAK DOWN MAINTENANCE

2. TIME BASED MAINTENANCE (TBM)

3. CONDITION BASED MAINTENANCE (CBM)



BREAKDOWN ANALYSIS FORMAT

BREAK DOWN MAINTENANCEBasically it is activity of restoring equipment to make available for production. To avoid such unplanned failures following steps has been taken,1. Prepare detailed analysis using 7QC tools2. Collect details of incurred losses & cost – Direst & Indirect3. Record findings & Kaizens plans for its implementation.



CASE STUDY NO.# 1 ( REPITATIVE FAILURE)

Problem faced – Frequent Failure of Drive Motor Bearings - Drive Units 108 nosRoot Cause – Generated Eddy currents flow through Bearing.Root Cause elimination suggestion - Replace regular bearing with Insocoat type Bearing.

Fluting due to Flow of Eddy Current

Inner RaceOuter race

Action Taken – One time replacement of bearing is Practically & Commercially not viable . After brain storming session, our electric team formulated action plan to provide proper earthing mechanism to carry away Eddy currents without harming Bearing. As per action plan, team separated all drive motors & Drive Units earthing electrodes. Individual Parallel earthing provided at Drive unit & Motor. This arrangement provide less resistance path for Eddy current passage.



CASE STUDY NO.# 2 (CONDITION MAINTENACE)

Problem faced – Inaccessible Dryer Fabric roll Bearing failureRoot Cause – Condition monitoring of rolls not possible as they covered by Hood. Root Cause elimination suggestion - Provide online Temperature indication mechanism & Lubrication arrangements.

Action Taken – Bearing housing of DFR in inaccessible location fitted with RTD units. Signals carried from RTD through wires are processed & displayed at Controller cum Display unit in Operating desk. Alarm siren & Red light glow up, when Bearing housing Temperature rises than pre defined set point through DCS system. For lubrication purpose, Tubing arrangements done as accessible from floor level.

D1

D2

D5

D4

D3

1ST GROUP DRYER

DFR 1DFR 6

DFR 5DFR 3

DFR 4

DFR 2

Grease Panel

Temperature Scanner

98.3 ⁰C



CASE STUDY NO.# 3 (DESIGN WEAKNESS)

Problem faced – High Structural Vibration level in Coater unit – 6mm/sRoot Cause – Protruded DFR fitting brackets at height rattle induce high vibration in structure. Root Cause elimination suggestion - Install crosswise members in M/c structure

Action Taken – Fabricated Tie rods are installed crosswise in Coater unit Structure to dampen vibrations.

Tie Rod



CASE STUDY NO.# 4 (DESIGN WEAKNESS)

Problem faced – Frequently failure Paper roll Gear motors.Root Cause – 4 nos VFD Drive runs 16nos Paper roll Gear motor. Grouping Paper rolls in single VFD makes difficult in speed synchronizing, cause frequently Paper roll Gear motor failure.Root Cause elimination suggestion - Install separate VFD drive for each Paper roll.

Action Taken – Electric Dept install new 12nos VDF drives for drive separation. Now each paper roll can run at required speed as per its location. This arrangements eliminates any adverse effect of one Gear motor failure as previously happening in grouping system. Load shearing on electrical system improved a lot.



CASE STUDY NO.# 5 (QUALITY MAINTENANCE)

Problem faced – Physical defects like Blotches and Stamping etc are escaping to the consumer.Root Cause – At Reel speed 350 MPM, human eye can’t detect these physical defects. Root Cause elimination suggestion - Installation of On-line Web inspection system.

Action Taken – Commercially available Web Inspection system cost Rs.2.0 Caror. It was thought to have some indigenously developed solution to curb this holes problem in paper board. Web inspection system consist – • Laser Emitters & receiver system: Principle of Triangulation, detect hole >9mm.• Auto Marking system: Activated when Blotch passed & auto blue marking on web edge.• Developed page in DCS for Blotch records: Roll no., exact defect length on parent roll, trends etc.• Alarm system garb attention of near by operator.

Blue Dye markings

Alarm SystemDSC panel for record

Laser SensorBlotch

DetectedAuto Marking

system



SAFETY

Safety measurement taken to safe guard Occupants Equipments Raw & Finished product. Company's Property

CASE STUDY NO.# 6 ( SAFETY MAINTENANCE)

Problem faced – Fire occurs at IR ( Infra red ) dryer propane gas operated in coater unit during power failureRoot Cause – Power failure mode, fire fighting pump can’t start to provide water for fire extinguisher system.Root Cause elimination suggestion - Auto Fire extinguisher system which can start in power failure mode also.

Action Taken – In power failure , Board web in front of IR ( Infra red ) Dryer, Propane gas operated catches fire. Previous arrangement of Fire Extinguisher run by Fire Fighting pump fail to provide water in Power failure mode.Delay in in Fire extinguish, may damage Backing roll, Dryer screen & Broke conveyor screen.Auto fire extinguisher installed in coater unit, which pump run by UPS. Water tanks provided at 15 mtrs height provide water with positive head, for Fire extinguish shower unit at Coater unit.

IR

IR DRYERP

BACKING ROLL

SHOWER

WATER TANK



MAINTENANCE PREVENTATION

Maintenance prevention activity impart on equipment’s, Reliability , Maintainability , Economy, Operability, Safety & flexibility , Minimize Life Cycle Cost (LCC)

CASE STUDY NO.# 7 ( MAINTENANCE PREVENTATION)Problem faced – Metal pipe carrying PAC –highly corrosive chemical, corroded heavily & wastage through leak.Root Cause – PAC chemical highly reactive towards Ferrous metal. ETFE coating coated on metal pipe also deteriorated by chemical action.Root Cause elimination suggestion – Replace metal pipe with chemically inactive make .

Action Taken – PVC grade Teflon coated 3 layered pipeline replace ETFE coated metal pipe in PAC chemical supply line• ETFE coated pipeline replacement cost Rs 90,000/- per year.• One time replacement cost is Rs 60,000 /- • Life expectance 10years for 3layered Teflon coated PVC grade pipeline

PAC Storage

P

PAC Service M/L White Water

Channel

B/L White Water

Channel

T/L White Water

Channel

PPP3 Layered Teflon coated PVC grade Pipe



Import substitution is attempt to reduce foreign dependency for particular equipment and service.

Company benefited by import substitution activity in terms of,

Reduce input & Inventory cost

Shortened lead time – Procurement of spare

Development of domestic industry

Support to Indian Self –reliant policy

IMPORT SUBSTITUTION

TRAINING

HRD take initiative in conducting training & development programs for our work force.

Training impart to maintenance crew on Technical, Self management & Safety.

Both On job & Off job training conducted out by Subject Expertise either Internal or External.

Training hall equipped with Audio – Visual system with ergonomically designed seating arrangements.

Technical books along with Literature , Issues, Manuals made available for reference.

Get-Together programs arranged for sharing Knowledge across work force in conducting environment.



EFFECTIVENESS OF SHUT DOWN MAINTENANCEIncrease in effectiveness of Shut Down Maintenance depended on. Reduction in shut down numbers. - Clubbing various jobs, Equipment Life enhancement Reduction in Shut down time. – Use of Advance Tool & Tackles , Critical path methodology. Reduction in shut down cost - Spare management , Optimization in Man power deployment

FINAL RESULTS

1. BOARD PLANT MAINTENANCE COST



2. OVERALL EQUIPMENT EFFCTIVENESS (OEE)



3. BREAK DOWN CHART

End of Presentation…

BEST MAINTENANCE PRACTICES IN PULP & PAPER MILLS TO IMPROVE PROFITABILTY BEST MAINTENANCE PRACTICES...

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