Param Sankalp / 04

Param Express

• Roll out of Phase B planed activities.

• Strong push on value initiatives across allsites .

• Completion of Data Cleansing for balanceequipment's .

• Uploading of BOM in SAP for T&D.

• Uploading of maintenance task list inSAP.

• Effort estimation & incorporation ofRCM inputs in BTG, AHP & CHPcontract across sites.

• Finalization of ORI tool vendor.

• Finalization of IT vendor.

Watch Out ForKey Activities Concluded

• Based on RCM expert input Refinementsincorporation is in progress for 1st set of10 equipment’s.

• Notification generated forimplementation of FMEA new actionpoints .

• BOM uploaded in all sites except T&D.

• Comprehensive Phase B plan prepared &Shared with all sites.

• 160 equipment FMEAs have beencustomized by sites.

• Site immersion training conducted in

Trombay , Hydro and T&D.

• RCM team visited TCS, Pune to evaluate

potential solutions for combustion

tuning, SHR FMEA integration and

equipment anomaly detection .

Param Sankalp December Newsletter winners

Param Sankalp / 04

RCM Immersion Programs – A RCM sustainability initiative

RCM Immersion Program is a capability

development and sustainability initiative

started under the Param Sankalp banner

since October 2017. Sustainability of RCM

practices and O&M culture change are

critical to the Param Sankalp program. The

vision is that by the time the program is over

everyone in the company speaks the RCM

language. So, a dedicated RCM Academy

conducts training with the help of RCM

partners AT Kearney. The Academy in

collaboration with AT Kearney developed the

training content. The first activity of the team

was to identify and train a group of internal

trainers and analysts from all divisions of

Tata Power. The team has conducted four

RCM Immersion training sessions of two

days each for 50 internal trainers.

Now, members from the Academy and AT

Kearney travel to sites and cover other O&M

personnel along with the internal trainers of

the respective division. AT Kearney and RCM

Core Team are handholding the internal

trainers in the first few trainings. Once the

academy establishes that the internal trainers

are ready, the internal trainers will train the

rest of the O&M personnel using the

customized content for each site. The

internal trainers have started training across

division since December 2017 and they have

covered 216 employees across all divisions of Tata Power. The academy targets to cover

100% employees by September 2018.

Data Analytics is an important pillar of RCM and the Param Sankalp program. RCM

Academy along with AT Kearney developed a Basic Analytics package and trained a

group of identified employees across divisions. Three such training sessions were

conducted across divisions. Further to this there were two “Advanced Analytics”

sessions conducted for employees in collaboration with IIT Bombay.

All the training sessions have helped our O&M personnel to see the RCM philosophy

and the elements more closely. The RCM Academy has played an instrumental role in

ensuring sustainability and institutionalization of RCM practices across divisions.

Param Sankalp / 04

Reliability Scorecard implemented to measure reliability of stations

A Reliability Scorecard has been started to track the reliability of stations on the basis of

four parameters:

1. Asset Reliability 2. Performance Reliability 3. Financial Reliability and 4. RCM process

adoption.

The reliability score is given out of 100.

1. Asset Reliability is measured taking into account EFOR and Planned Outages. It has a

weightage of 20% in the reliability score calculation.

2. Performance Reliability is measured taking into account Heat Rate and Aux Power

Consumption. It has a weightage of 20% in the reliability score calculation.

3. Financial Reliability is measured taking into account R&M Cost, Inventory and MUs lost. It

has a weightage of 20% in the reliability score calculation.

4. RCM Process Adoption score is measured taking into account FMEA creation, customization

PM, CBM compliance, Data quality, Spares Mgmt. and Maintenance strategy compliance.

Param Sankalp / 04

My CornerConversations with you…

Mr. Shekher Mukherjee,

Head - Operations & Ash

Mgmt, Jojobera. Leading

RCM initiatives at Jojobera.

The Journey of RCM initiated at Jojobera in theearly part of the year 2017. Today we are in theadolescent stage and do believe that quickly we willbe matured in this passage. These maintenancestrategy is an appropriate fit to our Tata Power when

we are fighting in a turbulent phase for growth and sustenance. Every employee of thisdivision someway or other is in the participation and enjoying the tour putting hand in handwith RCM core team under the keen guidance of AT Kearney troop.

RCM concept originated in the aircraft industry and later with nuclear power industry, off

shore oil industry gradually moving on to other industries. This methodology shows

significant reduction in maintenance cost. The maintenance task considered in the RCM

approach are all related to failures and functional degradation. RCM was designed to balance

the costs and benefits to obtain the most cost effective PM progress.

People are involved are there in FMEA preparation on various aspect from process to

equipment of resource to generation at Jojobera. Multiple CFTs are also formed which are

working with deep responsibility. Site management is reviewing with definite periodicity to

check the progress of each CFT. The objective and target are well established and in some

of the objectives we are in the stabilization phase. We all are proud today that our institute

has adopted this technique right in time whose basic intent is improving MTBF and MTTR.

Today our job is to align with this concept intensively so that the purpose is

accomplished. In present scenario for sustenance in the business and converting threat to an

opportunity, cost optimization is a basic need and to achieve it the existing maintenance

practices need a significant shift and RCM is the appropriate technique in this avenue which

can assure it.

We believe that we will honor this effort like all past endeavors and will get the success

genuinely. RCM concept originated in the aircraft industry and later got implemented in

nuclear power industry and off shore oil industry gradually moving on to other industries.

This methodology shows significant reduction in maintenance cost. The maintenance task

considered in the RCM approach are related to failures and functional degradation. RCM

was designed to balance the costs and benefits to obtain a cost effective PM progress.

The people involvement are there in FMEA Preparation on various aspects from

processes to equipment at Jojobera. Multiple CFTs are formed which are working with deep

responsibility. Site management is reviewing with definite periodicity to check the progress

of each CFT. The objective and target are established and in some of the objectives we are

in the stabilization phase. We all are proud that our institute has adopted this technique

right in time whose basic intent is improving MTBF and MTTR.

Today our job is to align with this concept intensively so that the purpose is accomplished.

In present scenario for sustenance in the business and converting threat to an opportunity,

cost optimization is a basic need and to achieve it the existing maintenance practices need a

significant shift and RCM is the appropriate technique in this avenue which can assure it.

We believe that we will surely honour this effort like all past endeavours and will get the

success genuinely.

Param Sankalp / 04

1. MPL, 10-15%

2. 7

3. B

4. B

5. C

6. A

1. Alignment of which of the following is

mandatory for completion of FMEA.

a. Alignment of FMEA with SAP

Codification

b. Alignment of FMEA with

Equipment BOM

c. Alignment of FMEA with SAP

Existing Action Items

d. None of the Above

2. SAP Catalogue are derived from which of

the following

a. Equipment Manual

b. Equipment FMEA

c. Experience

d. OEM Guidelines

3. Which of the following statement is true.

a. SAP Catalogues (Object code,

Damage Code, Cause code) are site

specific and would be different for

same type of equipment across site

b. SAP Catalogues (Object code,

Damage Code, Cause code) are

equipment specific and would be

same for same type of equipment

across site

4. EOQ in Spares management standards

for

a. Equal Ordering quantity

b. Each of the Quantity

c. Economical Ordered Quantity

d. None of the above

5. Which of the following is not a CBM

activity.

a. Visual Inspection

b. DCS parameters

c. Operator round

d. Periodic Alignment check

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

December Newsletter Quiz Questions:

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

Param Sankalp / 04

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

Given the scale and complexity of a capital overhaul, timely execution & coordination is a challenge

Detailed planning is key to ensuring desired execution while accurate data capture will be instrumental in technical and financial analysis

All the different teams are working towards upcoming

milestones – we are on track as per our plan

Can you quickly allocate the total expenditure in the outage among the equipment – will be useful in analysis