This is about Winning Anywhere - the Power of See
-
Upload
dibyendu-de -
Category
Education
-
view
307 -
download
0
description
Transcript of This is about Winning Anywhere - the Power of See
![Page 1: This is about Winning Anywhere - the Power of See](https://reader035.fdocuments.in/reader035/viewer/2022081519/558394f6d8b42af07a8b4f06/html5/thumbnails/1.jpg)
R A P
© Rapidinnovation™
![Page 2: This is about Winning Anywhere - the Power of See](https://reader035.fdocuments.in/reader035/viewer/2022081519/558394f6d8b42af07a8b4f06/html5/thumbnails/2.jpg)
N E M E (Solving ‘Wicked’ Problems & Improving
Performance) Zero Breakdown through
Minimal Design Interventions
dibyendu de
See
E M EN E M E
Nemetics
N
![Page 3: This is about Winning Anywhere - the Power of See](https://reader035.fdocuments.in/reader035/viewer/2022081519/558394f6d8b42af07a8b4f06/html5/thumbnails/3.jpg)
INNOVATION
R A P I DDesign Thinking for Serious Play
© Rapidinnovation™
![Page 4: This is about Winning Anywhere - the Power of See](https://reader035.fdocuments.in/reader035/viewer/2022081519/558394f6d8b42af07a8b4f06/html5/thumbnails/4.jpg)
“In a high-growth period, productivity can be raised by anyone. But how many can attain it during more difficult circumstances induced by low-growth rate?
This is the deciding factor in the success or failure of an enterprise.
”Taiichi Ohno – Toyota
© RMCPL All rights reserved
![Page 5: This is about Winning Anywhere - the Power of See](https://reader035.fdocuments.in/reader035/viewer/2022081519/558394f6d8b42af07a8b4f06/html5/thumbnails/5.jpg)
![Page 6: This is about Winning Anywhere - the Power of See](https://reader035.fdocuments.in/reader035/viewer/2022081519/558394f6d8b42af07a8b4f06/html5/thumbnails/6.jpg)
See
E M EN E M E
Nemetics
N
![Page 7: This is about Winning Anywhere - the Power of See](https://reader035.fdocuments.in/reader035/viewer/2022081519/558394f6d8b42af07a8b4f06/html5/thumbnails/7.jpg)
![Page 8: This is about Winning Anywhere - the Power of See](https://reader035.fdocuments.in/reader035/viewer/2022081519/558394f6d8b42af07a8b4f06/html5/thumbnails/8.jpg)
INNOVATION
R A P I DDesign Thinking for Serious Play
© Rapidinnovation™
![Page 9: This is about Winning Anywhere - the Power of See](https://reader035.fdocuments.in/reader035/viewer/2022081519/558394f6d8b42af07a8b4f06/html5/thumbnails/9.jpg)
INNOVATION
R A P I DDesign Thinking for Serious Play
© Rapidinnovation™
![Page 10: This is about Winning Anywhere - the Power of See](https://reader035.fdocuments.in/reader035/viewer/2022081519/558394f6d8b42af07a8b4f06/html5/thumbnails/10.jpg)
INNOVATION
R A P I DDesign Thinking for Serious Play
© Rapidinnovation™
![Page 11: This is about Winning Anywhere - the Power of See](https://reader035.fdocuments.in/reader035/viewer/2022081519/558394f6d8b42af07a8b4f06/html5/thumbnails/11.jpg)
R A P
© Rapidinnovation™
![Page 12: This is about Winning Anywhere - the Power of See](https://reader035.fdocuments.in/reader035/viewer/2022081519/558394f6d8b42af07a8b4f06/html5/thumbnails/12.jpg)
# Audit Parameters Previous
After1.5 y After 2.5 y
1 Production (units) 200 2000 3000
2 Production (Tons) 4500 8000 10168
3 Quality rejection 20% 7% 5%
4 Capacity < 100% = 100% >100%
Effects of Strategies– Process Plant
© RMCPL All rights reserved
![Page 13: This is about Winning Anywhere - the Power of See](https://reader035.fdocuments.in/reader035/viewer/2022081519/558394f6d8b42af07a8b4f06/html5/thumbnails/13.jpg)
Case Study on System ThinkingProblem: Frequent bearing failure of ID Fan 2 in 25
MW Power Plant The bearing fails once in 3 months…
See
E M EN E M E
Nemetics
N
![Page 14: This is about Winning Anywhere - the Power of See](https://reader035.fdocuments.in/reader035/viewer/2022081519/558394f6d8b42af07a8b4f06/html5/thumbnails/14.jpg)
Fan NDE Bearing that fails often
Fan
Motor
Example – Emergence & EssenceSee
E M E
Nemetics
N
![Page 15: This is about Winning Anywhere - the Power of See](https://reader035.fdocuments.in/reader035/viewer/2022081519/558394f6d8b42af07a8b4f06/html5/thumbnails/15.jpg)
Ask questions to explore the context
• Why ID fan 2 NDE bearing is failing & not the DE bearing?
• There are 2 identical fans close to each other but the problem is with only one of the fans and not the other.
• Why outer race bearing gets affected, why not other parts?
• Why motor bearings did not fail even once?
• The expected life of the bearing is minimum 2 years but fails once in 3 months!
Similar Symptoms: Different Problems See
E M E
Nemetics
N
![Page 16: This is about Winning Anywhere - the Power of See](https://reader035.fdocuments.in/reader035/viewer/2022081519/558394f6d8b42af07a8b4f06/html5/thumbnails/16.jpg)
Outer Race damaged bearing
Nature of the Bearing Failure. Notice the fine flute marks across the outer race of the bearing.
EmergenceSee
E M E
Nemetics
N
![Page 17: This is about Winning Anywhere - the Power of See](https://reader035.fdocuments.in/reader035/viewer/2022081519/558394f6d8b42af07a8b4f06/html5/thumbnails/17.jpg)
The surface of the rollers also show fine damages
See
E M E
Nemetics
N
![Page 18: This is about Winning Anywhere - the Power of See](https://reader035.fdocuments.in/reader035/viewer/2022081519/558394f6d8b42af07a8b4f06/html5/thumbnails/18.jpg)
Vibration Data of ID Fan2 (does not improve even after bearing replacement: so the problem is not the bearing)
POINT POINT AFTER BEARING BEFORE BEARING
ID DESCRIPTION REPLACEMENT REPLACEMENT UNITS
----- ----------------------------- ------- ----- ------- ------- ---- ---
ID FAN-02 (03-Jul-10) (03-June-10)
M1H=Motor Outboard Horizontal .390 .471 mm/Sec
M1P=Motor Outboard Horz Peakvue .289 .265 G-s
M1V=Motor Outboard Vertical .748 .151 mm/Sec
M1A=Motor Outboard Axial .365 .311 mm/Sec
M2H=Motor Inboard Horizontal .418 .531 mm/Sec
M2P=Motor Inboard Horz Peakvue .375 .352 G-s
M2V=Motor Inboard Vertical .199 .231 mm/Sec
M2A=Motor Inboard Axial .607 .579 mm/Sec
F1H=Fan Inboard Horizontal 1.353 1.049 mm/Sec
F1P=Fan Inboard Horz Peakvue .602 1.115 G-s
F1V=Fan Inboard Vertical .850 .548 mm/Sec
F1A=Fan Inboard Axial 1.883 1.294 mm/Sec
F2H=Fan Outboard Horizontal .448 .932 mm/Sec
F2P=Fan Outboard Horz Peakvue .598 1.660 G-s
F2V=Fan Outboard Vertical .234 .443 mm/Sec
F2A=Fan Outboard Axial .449 .640 mm/Sec
-------------------------------------------------------------------------
Example – Emergence & EssenceSee
E M E
Nemetics
N
![Page 19: This is about Winning Anywhere - the Power of See](https://reader035.fdocuments.in/reader035/viewer/2022081519/558394f6d8b42af07a8b4f06/html5/thumbnails/19.jpg)
Challenge the assumptions: Start with a Zen mind
Assumptions we Tried, Checked & Failed were
• Bearing failed due to misalignment of shaft.
• Lubrication condition.
• Looseness of bearing.
• Over damped System.
• Level of the shaft.
• Bearing design is the problem
Challenge the assumptionsSee
E M E
Nemetics
N
![Page 20: This is about Winning Anywhere - the Power of See](https://reader035.fdocuments.in/reader035/viewer/2022081519/558394f6d8b42af07a8b4f06/html5/thumbnails/20.jpg)
(Think by observing & Zooming Out – check the
interrelationships. From Emergence to Essence). • Fault arising in outer race of Fan NDE bearing
(emergence of the system).
• Frequent failure is only in one fan not in both fan.
• Both fans are operating at same speed, load & handling the same material.
• The gas temperature is same for the both fans.
• Electric cable passing near the ID fan 2 NDE bearing (essence of system that causes the emergence)
Observe the whole – Energy Interactions See
E M E
Nemetics
N
![Page 21: This is about Winning Anywhere - the Power of See](https://reader035.fdocuments.in/reader035/viewer/2022081519/558394f6d8b42af07a8b4f06/html5/thumbnails/21.jpg)
Cable passing near the affected bearing creates Electromagnetic flux that causes the ‘mess’
Aluminium cover provided for shielding the affected Fan NDE bearing
InteractionsSee
E M E
Nemetics
N
![Page 22: This is about Winning Anywhere - the Power of See](https://reader035.fdocuments.in/reader035/viewer/2022081519/558394f6d8b42af07a8b4f06/html5/thumbnails/22.jpg)
Create & Choose responses that eliminate the set of imperfections that create the set of
problems
• The electric cable of the 220 KW motor of the adjacent fan & passing near the NDE bearing generates electromagnetic flux.
• This is the essence of the problem that causes the bearing to often fail.
• Solution Protect the affected bearing from the electromagnetic flux (shield by aluminum sheet). Simplest solution
Interactions See
E M E
Nemetics
N
![Page 23: This is about Winning Anywhere - the Power of See](https://reader035.fdocuments.in/reader035/viewer/2022081519/558394f6d8b42af07a8b4f06/html5/thumbnails/23.jpg)
Vibration Spectrum of fan NDE Horizontal Direction (The Magic Effect – Constraint removed)
PK
Velo
city
in m
m/S
ec
Frequency in CPM
FANS - ID FAN-02ID FAN-02 -F2H Fan Outboard Horizontal
0 20000 40000 60000 80000
0
0.04
0.08
0.12
0.16
0.20
0.24
0.28
0.32
Max Amp .30
09:07:5103-Jul-10
10:26:4903-Jun-10
Before Bearing Replacement without Aluminum cover
After Bearing Replacement & providing Aluminum cover
Energy Inteactions See
E M E
Nemetics
N
![Page 24: This is about Winning Anywhere - the Power of See](https://reader035.fdocuments.in/reader035/viewer/2022081519/558394f6d8b42af07a8b4f06/html5/thumbnails/24.jpg)
Vibration Spectrum of fan NDE Axial Direction (The Magic Effect – Constraint
removed)
PK
Velo
city
in m
m/S
ec
Frequency in CPM
FANS - ID FAN-02ID FAN-02 -F2A Fan Outboard Axial
0 20000 40000 60000 80000
0
0.05
0.10
0.15
0.20
0.25
Max Amp .24
09:08:4903-Jul-10
10:28:0103-Jun-10
Before Bearing Replacement without Aluminium cover
After Bearing Replacement & providing Aluminum cover
Example – Emergence & EssenceSee
E M E
Nemetics
N
![Page 25: This is about Winning Anywhere - the Power of See](https://reader035.fdocuments.in/reader035/viewer/2022081519/558394f6d8b42af07a8b4f06/html5/thumbnails/25.jpg)
Whole picture imperfection/ Insight See
E M E
Nemetics
N
![Page 26: This is about Winning Anywhere - the Power of See](https://reader035.fdocuments.in/reader035/viewer/2022081519/558394f6d8b42af07a8b4f06/html5/thumbnails/26.jpg)
Case of Diaphragm failure
1200 failures of Diaphragms/year
See
E M E
Nemetics
N
![Page 27: This is about Winning Anywhere - the Power of See](https://reader035.fdocuments.in/reader035/viewer/2022081519/558394f6d8b42af07a8b4f06/html5/thumbnails/27.jpg)
Whole picture interactions -> Insight See
E M E
Nemetics
N
![Page 28: This is about Winning Anywhere - the Power of See](https://reader035.fdocuments.in/reader035/viewer/2022081519/558394f6d8b42af07a8b4f06/html5/thumbnails/28.jpg)
Aluminum Plant - Charging CarSee
E M E
Nemetics
N
![Page 29: This is about Winning Anywhere - the Power of See](https://reader035.fdocuments.in/reader035/viewer/2022081519/558394f6d8b42af07a8b4f06/html5/thumbnails/29.jpg)
a case studyon minimalDesign intervention
Case StudySee
E M E
Nemetics
N
![Page 30: This is about Winning Anywhere - the Power of See](https://reader035.fdocuments.in/reader035/viewer/2022081519/558394f6d8b42af07a8b4f06/html5/thumbnails/30.jpg)
• production not more than 60 packet a min• vibration between 50 to 60 microns• variation of quantity in packets – 6 to 8 ml• rat tailing – wastage of material• horizontal sealing problem• vertical sealing problem• new German machine = 1Cr• workers’ problem!
The pain ….See
E M E
Nemetics
N
![Page 31: This is about Winning Anywhere - the Power of See](https://reader035.fdocuments.in/reader035/viewer/2022081519/558394f6d8b42af07a8b4f06/html5/thumbnails/31.jpg)
• Variation in fill• Horizontal
seal• Vertical seal
The sachetSee
E M E
Nemetics
N
![Page 32: This is about Winning Anywhere - the Power of See](https://reader035.fdocuments.in/reader035/viewer/2022081519/558394f6d8b42af07a8b4f06/html5/thumbnails/32.jpg)
• Observe that the machine is like a tall column pitching effect.
• The width at the base (c to c of cushy foot) = 0.7 m. Length is 1 m
• Note the sensitive directions shown by the red arrows.
0.7 m
Principles of Sensitive Direction, Proportions & Structures See
E M E
Nemetics
N
![Page 33: This is about Winning Anywhere - the Power of See](https://reader035.fdocuments.in/reader035/viewer/2022081519/558394f6d8b42af07a8b4f06/html5/thumbnails/33.jpg)
• The paper reel unit, the stair case are attached to the main unit. (Left hand side of the red line)
• It shifts the centre of mass and induces vibration which is amplified by the low stiffness of the staircase
• The yellow line more-or-less shows the centre of mass
• Note that the machine has two regions of stiffness. One the left hand side of the red line it is the region of low stiffness and on the right is the region of high stiffness.
1 M
Low Stiff region
High Stiff region
Principles of Centre of Mass & Stiffness See
E M E
Nemetics
N
![Page 34: This is about Winning Anywhere - the Power of See](https://reader035.fdocuments.in/reader035/viewer/2022081519/558394f6d8b42af07a8b4f06/html5/thumbnails/34.jpg)
• This slider mechanism is critical for the operation.
• Here the linear bearing can’t be lubricated by any means.
• Moreover, the L/D ratio of the bearing is also not ideal. This would lead to accelerated wear & misalignment
Linear Bearings
Principle of centre of friction & proportion See
E M E
Nemetics
N
![Page 35: This is about Winning Anywhere - the Power of See](https://reader035.fdocuments.in/reader035/viewer/2022081519/558394f6d8b42af07a8b4f06/html5/thumbnails/35.jpg)
• Imperfection: the temperature of the heaters are not equal. So a steady state temperature can’t be reached.
• Solution: provide more feedback to control temperature uniformly.
Principle of Centre of Temperature See
E M E
Nemetics
N
![Page 36: This is about Winning Anywhere - the Power of See](https://reader035.fdocuments.in/reader035/viewer/2022081519/558394f6d8b42af07a8b4f06/html5/thumbnails/36.jpg)
• Imperfection: variable heat distribution.
Principle of heat distributionSee
E M E
Nemetics
N
![Page 37: This is about Winning Anywhere - the Power of See](https://reader035.fdocuments.in/reader035/viewer/2022081519/558394f6d8b42af07a8b4f06/html5/thumbnails/37.jpg)
• The shampoo feed pipe is attached to the machine. Hence pipe vibrations are easily transferred to the machine.
• Solution: Detach the pipe to isolate pipe vibration. And pipe hangers should be at unequal distance
Principle of PipesSee
E M E
Nemetics
N
![Page 38: This is about Winning Anywhere - the Power of See](https://reader035.fdocuments.in/reader035/viewer/2022081519/558394f6d8b42af07a8b4f06/html5/thumbnails/38.jpg)
• Imperfection: Heat gets trapped because of enclosure
• Solution: redesign without covers no machine there – natural convection current to take away heat.
Principle of Heat DistributionSee
E M E
Nemetics
N
![Page 39: This is about Winning Anywhere - the Power of See](https://reader035.fdocuments.in/reader035/viewer/2022081519/558394f6d8b42af07a8b4f06/html5/thumbnails/39.jpg)
• Imperfection: Heat is trapped because of the stainless steel cover. This heats up other elements in the working zone and reduces life.
• Solution: replace SS cover by Aluminum to efficiently radiate heat
Stainless Steel cover
Principle of Heat TransferSee
E M E
Nemetics
N
![Page 40: This is about Winning Anywhere - the Power of See](https://reader035.fdocuments.in/reader035/viewer/2022081519/558394f6d8b42af07a8b4f06/html5/thumbnails/40.jpg)
The new machineSee
E M E
Nemetics
N
![Page 41: This is about Winning Anywhere - the Power of See](https://reader035.fdocuments.in/reader035/viewer/2022081519/558394f6d8b42af07a8b4f06/html5/thumbnails/41.jpg)
the pains……… the gains• < 60 packets a min
• 60 microns vibration
• 6 to 8 ml per packet
• rat tailing
• horiz seal problem
• vertical seal problem
• foreign mac > 1 Cr
• workers’ problem
• 80 packets a min
• < 5 microns vibration
• 8 ml per packet
• no rat tailing
• no problem
• no problem
• new machine = 7.5L
• workers’ cooperation
Pain to GainsSee
E M E
Nemetics
N
![Page 42: This is about Winning Anywhere - the Power of See](https://reader035.fdocuments.in/reader035/viewer/2022081519/558394f6d8b42af07a8b4f06/html5/thumbnails/42.jpg)
learning to live by minimal design intervention
scaling learning – the ultimate competitive advantage!
Personal Mastery – 6th PrincipleSee
E M E
Nemetics
N
![Page 43: This is about Winning Anywhere - the Power of See](https://reader035.fdocuments.in/reader035/viewer/2022081519/558394f6d8b42af07a8b4f06/html5/thumbnails/43.jpg)
Story of the Poor PIG!See
E M E
Nemetics
N
![Page 44: This is about Winning Anywhere - the Power of See](https://reader035.fdocuments.in/reader035/viewer/2022081519/558394f6d8b42af07a8b4f06/html5/thumbnails/44.jpg)
Energy flow; Interactions; SyncSee
E M E
Nemetics
N
![Page 45: This is about Winning Anywhere - the Power of See](https://reader035.fdocuments.in/reader035/viewer/2022081519/558394f6d8b42af07a8b4f06/html5/thumbnails/45.jpg)
Pain is the starting point...
1.Yield = 92% , International Benchmark = 97%
2.Weight variation, Ideal weight 9 to 11 kg, presently 7 to 14 kgs
3.% of Poor Pigs > 30%
4.Availability < 95%
5.Tried different models and techniques for 4 years without success
See
E M E
Nemetics
N
![Page 46: This is about Winning Anywhere - the Power of See](https://reader035.fdocuments.in/reader035/viewer/2022081519/558394f6d8b42af07a8b4f06/html5/thumbnails/46.jpg)
BEAS River: Insights – POV!See
E M E
Nemetics
N
![Page 47: This is about Winning Anywhere - the Power of See](https://reader035.fdocuments.in/reader035/viewer/2022081519/558394f6d8b42af07a8b4f06/html5/thumbnails/47.jpg)
Design Intervention:
1.Change the speed and synchronize
2.Change the dimensions of the molds
3.Change the height of discharge of molten metal
4.Spray less water
See
E M E
Nemetics
N
![Page 48: This is about Winning Anywhere - the Power of See](https://reader035.fdocuments.in/reader035/viewer/2022081519/558394f6d8b42af07a8b4f06/html5/thumbnails/48.jpg)
2003-04 2004-05
88
90
92
94
96
98
100
102
92
99.9
YIELD
FY
%
International BM
Results:See
E M E
Nemetics
N
![Page 49: This is about Winning Anywhere - the Power of See](https://reader035.fdocuments.in/reader035/viewer/2022081519/558394f6d8b42af07a8b4f06/html5/thumbnails/49.jpg)
2003-04 2004-05
0
5
10
15
20
25
30
35
40
10
5
25
15
30
35
21
35
13
8
WEIGHT DISTRIBUTION
A <3
B 3.1-5.0
C 5.1-7.00
D 7.1-9
E 9.1-11
FY
%
ResultsSee
E M E
Nemetics
N
![Page 50: This is about Winning Anywhere - the Power of See](https://reader035.fdocuments.in/reader035/viewer/2022081519/558394f6d8b42af07a8b4f06/html5/thumbnails/50.jpg)
2002-03 2003-04 2004-05
0
5
10
15
20
25
30
35
40
26.3
36.3
20
24.6
34.9
15.4
PPP
Target
Achieved
FY
% PPP
ResultsSee
E M E
Nemetics
N
![Page 51: This is about Winning Anywhere - the Power of See](https://reader035.fdocuments.in/reader035/viewer/2022081519/558394f6d8b42af07a8b4f06/html5/thumbnails/51.jpg)
2003-04 2004-05
92
93
94
95
96
97
98
99
100
101
95
100
AVAILABILITY
AVAILABILITY
FY
%
ResultsSee
E M E
Nemetics
N
![Page 52: This is about Winning Anywhere - the Power of See](https://reader035.fdocuments.in/reader035/viewer/2022081519/558394f6d8b42af07a8b4f06/html5/thumbnails/52.jpg)
6%
99%+
After 1 yrAfter 1 yr
World
Class-Additional Profit2
RemarksRemarksPreviouPreviouss
Audit ParametersAudit Parameters##
6 Sigma,
Internatio
nal
Benchmar
k
92%Yield1
Effects of RAPID - Process Plants See
E M E
Nemetics
N
![Page 53: This is about Winning Anywhere - the Power of See](https://reader035.fdocuments.in/reader035/viewer/2022081519/558394f6d8b42af07a8b4f06/html5/thumbnails/53.jpg)
“We broke new grounds in achieving high yield levels…. One thing which remains
hidden…is the manner in which the opportunities for improvement are
addressed. A systematic fact-based analysis followed by out-of-the box thinking to arrive
at creative solutions lead to dramatic improvements … make positive changes
irreversible & long lasting.” Harsh K. Jha, M.D. Tata Metaliks
‘Metalogue’, Vol 4, Number 2, Feb 2005 (newsletter)
This says it allSee
E M E
Nemetics
N
![Page 54: This is about Winning Anywhere - the Power of See](https://reader035.fdocuments.in/reader035/viewer/2022081519/558394f6d8b42af07a8b4f06/html5/thumbnails/54.jpg)
Right Strategy was applied to 3 process
plants
% of equipment covered: 62 (most critical +
critical)# Audit Parameters Previous After 1 yr After 2
yrs
1 No of breakdowns/year 57 19 3
2 % of breakdown hours 25 12 5
Effects of Strategies– Process Plant
© RMCPL All rights reserved
![Page 55: This is about Winning Anywhere - the Power of See](https://reader035.fdocuments.in/reader035/viewer/2022081519/558394f6d8b42af07a8b4f06/html5/thumbnails/55.jpg)
# Audit Parameters Previous After 1 yr After 2
yrs
3Design Out maintenance cases
Nil 28 Further done
4% of increase in monitoring activities
18 42
5 Capacity < 100% > 100%
6 Cost Leadership 3 1
Effects of Strategies– Process Plant
© RMCPL All rights reserved
![Page 56: This is about Winning Anywhere - the Power of See](https://reader035.fdocuments.in/reader035/viewer/2022081519/558394f6d8b42af07a8b4f06/html5/thumbnails/56.jpg)
-- Reliability -- Cost
0
10
20
30
40
15
20
25
1 2 3 4 5 6 7 8 9 10 11 12
Reliability vs. Cost
Reliability v/s COST - Cement Plant
© RMCPL All rights reserved
![Page 57: This is about Winning Anywhere - the Power of See](https://reader035.fdocuments.in/reader035/viewer/2022081519/558394f6d8b42af07a8b4f06/html5/thumbnails/57.jpg)
Cement PlantSee
E M E
Nemetics
N
![Page 58: This is about Winning Anywhere - the Power of See](https://reader035.fdocuments.in/reader035/viewer/2022081519/558394f6d8b42af07a8b4f06/html5/thumbnails/58.jpg)
Effects of Strategies– Chemical Co.
when STRATEGY was applied to 46 critical
machines in a chemical company, the
results were impressive.
05
1015202530
1st Yr 2nd Yr 3rd Yr 4th Yr
Nu
mb
er
Years
No. of Breakdowns(Avg/month)
© RMCPL All rights reserved
![Page 59: This is about Winning Anywhere - the Power of See](https://reader035.fdocuments.in/reader035/viewer/2022081519/558394f6d8b42af07a8b4f06/html5/thumbnails/59.jpg)
# Audit Parameters Before ‘98 After May ‘01
8Annual Mean Maintenance Labour Hours in a year
4675.66 hours
3108.87 hours
9 Maintenance Budget Rs 3.4 Cr Rs 1.41 Cr
10 Production rate 1.66 T/hr 1.87 T/hr
11 Quality 3.5 6
12 Leadership Position 4th 1st (sells at premium)
Effects of Strategies– Chemical Co.
© RMCPL All rights reserved
![Page 60: This is about Winning Anywhere - the Power of See](https://reader035.fdocuments.in/reader035/viewer/2022081519/558394f6d8b42af07a8b4f06/html5/thumbnails/60.jpg)
Effects of RAPID – Aluminum PlantEffects of RAPID – Aluminum Plant
## Audit Audit ParametersParameters PreviousPrevious After 6 mAfter 6 m RemarksRemarks
1 Availability 80% 90% 10 % productivity
2 Rolls/hour 20 23 15% productivity
![Page 61: This is about Winning Anywhere - the Power of See](https://reader035.fdocuments.in/reader035/viewer/2022081519/558394f6d8b42af07a8b4f06/html5/thumbnails/61.jpg)
Effects of RAPID – Aluminum PlantEffects of RAPID – Aluminum Plant
## Audit ParametersAudit Parameters PreviousPrevious EffectEffect
3 Energy 17% reduction
4 Profits 16% increase
![Page 62: This is about Winning Anywhere - the Power of See](https://reader035.fdocuments.in/reader035/viewer/2022081519/558394f6d8b42af07a8b4f06/html5/thumbnails/62.jpg)
• Leadership
• People
Ingredients of SuccessSee
E M E
Nemetics
N
![Page 63: This is about Winning Anywhere - the Power of See](https://reader035.fdocuments.in/reader035/viewer/2022081519/558394f6d8b42af07a8b4f06/html5/thumbnails/63.jpg)
![Page 64: This is about Winning Anywhere - the Power of See](https://reader035.fdocuments.in/reader035/viewer/2022081519/558394f6d8b42af07a8b4f06/html5/thumbnails/64.jpg)
Once done the company gains permanent on-going benefits.
Prof. Tim Henry, Manchester University, U.K
BenefitSee
E M E
Nemetics
N