Param Sankalp / 04

Param Express

• Roll out of Phase B planed activities.

• Strong push on value initiatives across allsites .

• Conduct value initiative workshop acrosssites

• Revised the catalogue for 1st wave of 10critical equipment .

• Uploading of BOM in SAP across sites.

• Uploading of maintenance task list inSAP.

• Implementation of FMEA action points.

• Launch of RCM Corporate video.

• Finalization of IT vendor.

Watch Out ForKey Activities Concluded

• Maintenance Task list optimization for1st wave of 10 critical equipment is inprogress.

• Comprehensive Phase B plan prepared.

• 158 equipment FMEAs have beencustomized by sites.

• FMEA review workshop by reliabilityexpert, Mr Chris James conducted atBackbay office.

• Overhaul assessment – Time & motion

study completed for MPL unit # 1.

• Site immersion training conducted in

Trombay & Hydro.

• 2nd reliability analytics training

conducted by Prof. M Kulkarni, IIT

Bombay at Trombay.

Param Sankalp / 04

As highlighted in our last newsletter, Phase B of Param Sankalp will focus on

deriving value from the activities till now as well as identify areas for overall cost reduction. A

total of 7 workshops have been conducted till now across 4 sites with an aim to identify and

prioritize the ideas & initiatives for achieving value targets. Till now, workshops have been

conducted on SHR losses reduction, APC reduction, R&M cost optimization. Each of the

initiatives will now be driven through the site teams completely or in collaboration with the

RCM core team.

Further to these workshops, the site CFTs (cross functional teams) will be

leveraging the support of respective CoIs (Community of Interest) for inputs on areas where

expertise is needed. External experts will also be consulted wherever such a requirement is

identified.

Annual overhaul is the most critical, resource and cost intensive exercise carried

out at power plants. Any small optimization will lead to significant benefits to plants in terms

of reduced generation loss & opportunity loss.

A detailed time motion study was recently carried out at Maithon (MPL) over a

period of more than 30 days in the months of Nov-Dec 2017 with promising results. MPL has

identified 10-15% reduction against planned duration through improved resource readiness

(Ex. overhead cranes), detailed hour-wise planning schedule, parallel activity sequencing (Ex.

CRO and catenary check) and idle time reduction. This also gave an opportunity to identify

missing activities in the current plan (Ex. Insulation of HP-IP module and associated piping)

Going forward, outage management teams for each sites will be constituted to

implement recommendations. Detailed planning and resource estimation also to be carried out

by outage management teams for individual sites.

Phase B – Value Initiatives Focus

Annual Overhaul Optimization

Param Sankalp / 04

RCM Immersion Training Sessions

Tata Power started a series of RCM Immersion trainings with an objective to

impart key concepts of RCM to the entire organization. Select group of internal trainers and

analytics leads were also identified from each site to take this forward.

A series of (five) two day sessions was launched on 10th October at Jojobera

primarily for Internal trainers and analytics leads covering working details of RCM philosophy

and it’s key elements. These sessions garnered active participation from more than 120

trainers & leads across Thermal, Hydros & T&D through individual and group exercises,

quizzes, mock deliveries and feedback sessions.

One day trainings for site personnel was kick-started in Trombay on 15th

December by internal trainers emphasising on basic aspects of RCM. The Module focussed

on development of behaviour and technical traits for successful implementation of RCM and

the role of each individual in Param Sankalp. Two sessions covering 30+ personnel have been

successfully completed at Trombay and Hydros.

RCM IT Solution – Vendor evaluation completeDynamic Maintenance Plan optimization to improve equipment/ system’s

reliability in the cost optimal manner is the core of RCM philosophy. This optimization

requires advanced analytical tools to process huge amount of data available in SAP, OSI PI

and other IT/ OT systems.

Over the past few months, the core evaluation team comprising of site heads,

corporate chiefs among others have done thorough evaluation of potential RCM vendors

through extensive product demos, site visits and discussion with experts. Two vendors

namely GE and Bentley Systems have come out as potential partners for implementation.

Over the next few weeks, Tata Power commercial team will engage to finalize

the vendor for Tata Power RCM implementation

Param Sankalp / 04

Param Sankalp or Reliability Centred

Maintenance(RCM) is a good initiative

take up by organisation to transform O&M

process. It is structured program which take

care of all aspects related to O&M process. It will be great learning to all level of officers in

entire organization. Creation of FMEA is base of entire RCM tool which is key success to

achieve excellence in RCM implementation.

This shall help us to minimise the manual efforts in tracking certain process Ex: Spares

Management & Optimization, Enhance the knowledge of maintenance engineer with RCA

back up, capture history of equipment and carry out variety of analysis on equipment and

lot more. Being a part of this team, it is a great experience while creating FMEA,

Maintenance Strategy, Spares Management during boots camp. It has literally churn out

brain to identify equipment functionality, failure modes, causes and lot more.

COI is one of the forum which has brought close all the Tata Power Divisions. Now every

division can interact and share their problems and seek inputs from COI team. Key focus:

FMEA, Equipment Catalogue, New Action Items.

My CornerConversations with you…

Mr. Sachin Akhade, Group Head-CL&P-Maintenance, TrombayPart of Codification, FMEA andSpares Management teams

codification, classification, FMEA, Data Quality & Maintenance Strategy. MPL is in the

final stage of completion for all these foundational elements.

Development of FMEA is a core element for whole RCM implementation. Conducting boot

camp is an innovative way to capture the knowledge from various division and putting it in a

single document. Various technical subject experts and fresh thoughts from young

engineers have contributed in preparation of a good quality FMEA during the FMEA Boot

Camp.

Reliability Cantered Maintenance is the most advanced and mature maintenance

philosophy. Usage of advance data analysis will help in improving reliability and optimising

the cost. We must strive for improved data capture to improve our analysis.

Mr. Jagmit Singh Sidhu,

Chief - O&M (Services),

MPL. Leading RCM

initiatives at MPL.

Param Sankalp is an initiative for bringing

excellence in Operation and Maintenance in Tata

Power. The major foundation elements of RCM are

Param Sankalp / 04

Answers:

1. 320

2. Three

3. 32000

4. Time and Motion

5. 155

6. IB02

Dipak Rathod

Winner of November Newsletter are:

1. Where is the 1st 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

Send your responses to paramsankalp@tatapower.com

First three correct responses would be awarded.

Answers for quiz of the month - Crossword

Rohit K G Maharajan

1. How many supervisors were trained in the first RCM training conducted by Aakar?

2. How many RCM Immersion trainings have been conducted till now?

3. How many equipment have been covered under codification and classification?

4. _________ and __________ study was done in MPL for overhaul assessment.

5. How many FMEAs have been customized by sites?

6. New items can be added or existing items can be modified/ deleted in BOM using the _________ transaction in SAP

Param Sankalp / 04

If you have any questions, please write to us at paramsankalp@tatapower.com

Single Mean Time to Repair value (notification start time to notification closure time) portrays inaccurate and incomplete picture

Two separate KPIs for equipment time to repair & maintenance repair time show accurate and meaningful results

Updated calculation methodology (Custom Report available in SAP)

Inefficiencies removed (MJCO/ NOCO). I know for how long the equipment ran unreliably

Planning & Budgeting

AnalysisMaintenance Optimization

Notification by Operations

Maintenance acknowledgment

Prepare & apply permit

Permit approval

Work by maintenance

Trial by operations

MJCO

NOCO

WOCO

1

2

3

4

5

6

7

8

9

Equipment MTTR

Maintenance repair time

Discounting systemic inefficiencies for KPI

calculation