Param Sankalp / 04
Param Express
• Completion of equipment Codificationupload in SAP across assets in July 2017.
• Completion of balance equipmentclassification & SAP upload across allsites.
• Customization boot camps for balanceFMEA.
• Completion of Spares - BOM mapping.
• Completion of SAP catalogues for selectequipment.
• Conducting APC Process FMEA bootcamp.
• Finalization of RCM bolt-on vendor.
• Launch of Maintenance planning acrosssites.
Watch Out ForKey Activities Concluded
• 46 equipment FMEAs have beencompleted out of total 66 equipmentFMEAs planned.
• Codification completed & new functionallocation uploading in SAP is in progress.
• A joint boot camp for Jojobera, MPL andHaldia was conducted in Jojobera forFMEA customization.
• FMEA customization boot campconcluded with focused effort on 7critical equipment's from 18th to 21st July2017 at Trombay.
• RCM IT tool demonstration completedwith all sites from 4th to 6th July 2017.
• Results of Culture assessment surveypublished.
Param Sankalp / 04
Operations value initiatives progressing well
Codification and classification nearing completion; changes to be uploaded in SAP
As part of operations transformation under
Param Sankalp, several cross functional teams have
been formed at all thermal assets (Jojobera, MPL,
Trombay and CGPL) for taking up value initiatives in a
focused manner. The teams consist of members from
O&M departments, CTDS and Param Sankalp core
team. Identified initiatives are tracked through well-
defined initiative charters and work plans for
monitoring progress and tracking benefit.
Good progress has been made in the combustion
tuning CFT at Jojobera. The team has conducted
various diagnostic tests to identify root causes for heat
rate losses due to LoI in fly ash and bottom ash and
gas exit temperature. Action items have been identified
based on the analysis of test results. The action items
will be implemented and tracked to ensure sustainable
benefits. The CFT has also taken up a pilot solution to
coal mill choking problem at Jojobera under which a
modification has been made in one of the coal mills.
Impact of the modification on solving the problem is
Codification and classification, the 2 pillars of
the RCM-focused Param Sankalp program, saw
massive strides in the past one month. All the sites at
Tata Power have shown great enthusiasm to expedite
the exercises, devoting multiple resources in the
process. The core team has held a number of sessions
with the various site teams and codification and
classification exercises have been wrapped up for the
common area & unit 1 for all the divisions. The initial
results of the codification and classification activities
are very encouraging. An adoption of uniform
functional location structure, identical equipment
coverage for similar functional locations, and identical
classification philosophy have led to a visible increase
in uniformity across sites. As the codification and
classification activities draw to a close, it needs to be
remembered that these activities have laid the
foundation for subsequent program activities - maintenance strategy optimization, spares
management, etc. The final closure of the codification & classification exercises will be
achieved through the SAP upload that all the sites will take up to reflect the changes made.
under assessment by the team.
Param Sankalp / 04
Spares HeadingIn the Param Sankalp program, we have kicked
off the spares management module with equipment-
spare mapping or bill of material creation being carried
out across each site. This will be followed by criticality
analysis and level optimization. It was observed that
there is wide variation in spares criticality definition
across sites currently. This may potentially lead to
missing out on some critical spares. Level setting has
been carried out for a small share of spares and inventory
levels in majority of cases may be higher than required
.
leading to steep holding costs or too low increasing risk of stock outs. A standardization in the
classification definition and linkage with inventory levels will enable a comprehensive, optimal
and reliable spare management strategy.
Spares inventory management is complex in nature and it is a known fact that legacy
systems do not optimize the inventory investment. Traditional understanding of spare parts
inventories is limited to their function of ‘need to have’ items. However, acquiring inventories
should also be understood as investments which should be evaluated by the same logical
principles as other types of investments. The approach being adopted is based on searching
for the maximum return on investment and the lowest total cost of ownership of the spares
and equipment. A comprehensive framework, including advanced statistical modeling, with
exact ways how to manage spare parts inventories will be used. This is a key element of RCM,
which ensures reliable stock levels while minimizing the costs. For a classification led spares
strategy to be effective, it is imperative that key foundational elements such as equipment-
spare mapping, consumption data and purchase data are diligently maintained.
ED Town hall on Param Sankalp
ED & COO, Mr. Ashok
Sethi, has been an ardent
evangelist of the Param
Sankalp program. During his
visit to our divisions, he takes
out dedicated time to talk to
all members on his vision of
implementing Reliability
Centered Maintenance in Tata
Power, current progress and
benefits of the program.
In the pictures he is seen
interacting with the teams at
Noida (top) and CGPL
(bottom left and right).
Param Sankalp / 04
I think RCM has really initiated structuredprocess in brain storming of various failuremodes related to particular equipment or asystem. We have even imagined failureswhich have not taken place since unit commissioning but may occur any time in future, andalso identified appropriate action plan to avoid them. While working on FMEA, I realisedthat Strong detection mechanism for timely detection of various faults in C & I system willlead to improved reliability of the overall system. (As almost all C & I systems are havingenough level of redundancy and one fault in the system may not cause any harm to thenormal running of the generating unit.)
While preparing and adopting FMEA for FSSS & DCS, I learned a lot about thesesystems and their potential failure modes and how to prevent it by implementing variousaction items identified during the course. Also proper catalogue code will help in analysingparticular defect and in turn initiate action plan to avoid or minimise such failures in future.I think the whole exercise will improve the overall availability and reliability of the systemwith our proactive approach in addressing potential failures identified in the process.
Firstly we should concentrate on implementation of key action items listed in FMEA soas to bring down the present RPN number to improve the overall availability and reliabilityof the system, secondly we should work on optimisation of PM and spares management.
My CornerConversations with you…
Mr. Mayank Garg, Lead Engineer - Comm. & Instrm. Maint., Part of FMEA team
We at Tata Power embarked on a journey to adopt
RCM with the vision to change the existing
maintenance strategy.
Development of FMEA is the core and heart of the RCM implementation along
with data quality for future analysis. Team Tata Power has started enthusiastically and we
need to maintain the same vigor and tempo to develop quality FMEAs which will be the
backbone of this implementation process.
We find FMEA development process has inculcated gelling of young and
experienced team members and creating a great bonding as a team which will enhance
capability and analytical thinking process of the entire team. We are confident that,
implementation of the RCM process will enhance safety, reliability, reduce risk & cost and
improve employee engagement with better team work. These are must for the organization
to be competitive and future ready.
Mr. Ramesh Jha, Chief-
O&M, MPL. Lead for all
RCM Initiatives at MPL
FMEA OF THE MONTH
HP Bypass
Ajay KonnurMPL
Krishna SinghMPL
Anurag SharmaCGPL
Sahil DuttaTrombay
Manoj SaahTrombay
Atanu DasTrombay
Flora RozarioTrombay
Naveen MishraEngineering
K R BairwaParam Sankalp
Param Sankalp / 04
1. Level of inventory desired at a point of time to cater for variation in lead time and demand
2. Measure used to assess risk. Helps in identifying critical failure modes.
3. State of equipment readiness for duty of immediate deployment
4. SAP Code for display of task list (Refer: SARAL Form)
5. Oil Consumed per unit power generated (Abbreviation)
6. Probabilistic Distribution curve for analyzing equipment failure distribution
7. Average of all “time taken to repair a particular equipment” (Abbreviation)
1st: Arvind Yadav
2nd: Pravin Mahadik
3rd: Vinay Jain
Winners of the Crossword are:
Quiz of the Month –Crossword
1
2
3
4
P A R A MAnswer
Send your responses to [email protected]
First three correct responses would be awarded.
5
6
7
_______ Sankalp is the initiative to implement Reliability Centered Maintenance in Tata Power.
S O C T K T Y E F S A
S T O C K S A F E T Y
P N R
R P N
Y B D A N S T
S T A N D B Y
9 A 0 I
I A 0 9
C F O S
S F O C
L L U B I W E
W E I B U L L
R T M T
M T T R
Answer the questions and unscramble the “circled” letters to identify the answer
6
1 7
2
3
4
5
Difficulty: Hard
Numbers in brackets (indicate no. of words, no. of
characters) in answer
Across:
1. Duration for which perishable materials can
be stored (2, 9)
2. ______ Mapping of boiler is a diagnostic
tool, which measures flue gas temperatures
at different boiler elevations. (1, 7)
3. SAP code for obtaining equipment
availability report. (Hint: Refer Saarthi Saral
form ) (1,7)
4. Inverse of Heat Rate gives the _____ of a
thermal generating unit (1,10)
5. A list or record of code groups (Ex: Object,
Failures, Cause, Activity) in SAP (1,9)
Down:
6. ________x Probability x Detection = RPN
number in FMEA (1, 8)
7. _______ scheme is a protection to save a
generating unit from external faults. (1, 9)
Param Sankalp / 04
If you have any questions, please write to us at [email protected]
Accurate and comprehensive data is crucial to achieve benefits from the RCM program
Accurate and comprehensive data will help us predict maintenance parameters and increase efficiency
Top Related