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 paramsankalp@tatapower.com

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 paramsankalp@tatapower.com

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