10-breakdown analysis, key indicators & informatic system

8/18/2019 10-Breakdown Analysis, Key Indicators & Informatic System

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PIC

Calusco 5-8 June 2006

BREAK DOWN ANALYSIS

MAINTENANCE KEY INDICATORS

2006

&

Informatic System

PIC

Calusco, 5-8 June 2006


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2PICCalusco 5-8 June 2006

INFORMATIC SYSTEM FOR MAINTENANCE

in ITC RO!"

Ita#cementi ro$% $se SA" as main informatic too# for t'e

maintenance(

ro$% r$#es are a%%#ie) in a## S$*si)iaries +e,en if -it' some

)ifferences.(

T'e ista##ations are c#assifie) at ,ario$s #e,e# accor)in/ t'e %'ysica#str$ct$res ro$% c#assification

By SA" are 'an)#e)0

"#annin/ +an) *$)/et. Notifications an) -or1 or)ers

Ins%ections Costs contro# +monitorin/ . "arts cons$ma*#e re2$isition an) stoc1

2


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INFORMATIC SYSTEM FOR MAINTENANCE

in ITC RO!"

Benc'mar1 of res$#ts0 *y %#ant year o,er year3 %#ants in 'omo/eneo$s

c#$sters in t'e S$*si)iaries an) in t'e ro$%3 *enc'mar1 at

S$*si)iaries #e,e#(

Sto%%a/es ca$ses ana#ysis(

Monitorin/ of t'e $ti#i4ation of interna# an) esterna# %ersonne# an)

cost.

Definition of 1ey in)icators for maintenance %erformances e,a#$ation(

In)ications for com%ara*#e inter,entions in ot'er %#ants of t'e ro$%(

Recor) of maintenance e2$i%ment 'istory

The data analysis allows for


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!PICCalusco 5-8 June 2006

MAIN KEY INDICATORS IN MAINTENANCE

"#$ %aintenance cost u& to clin'er (includin) )eneral ser*ices &art+

"# u "2

Cost 5t %ro)$ct $ ------ ----- ------ of the es&ensed %aintenance & C& C&

"2$ %anutenance cost u& to ce%ent (includin) )eneral ser*ices &art+

The )eneral ser*ices cost is shared /5 to clin'er e 25 to ce%ent

& $ clin'er &roduction u $ clin'er )round in the ce%ent

C& $ ce%ent &roduction

Interna# %ersonne# 'o$rs +an) costs. 1y s&ecialiation, 1y de&art%ent and 1y

%onth.

Esterna# %ersonne# 'o$rs an) costs *y contractor 1y de&art%ent and 1y

%onth.

Esterna# e6%erts costs 1y de&art%ent and 1y %onth.


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Ratio maintenance cost 5 ,a#$e insta##ations as re%#ace) *y t'e ne- ones

on study.

or 'ilns (and %ills+

MTBF refer to sto&&a)es due to %aintenance causes of the &hase.MTBY refer to sto&&a)es due to %aintenance causes of the &hase and esternal to the &hase.

MTB7 refer to sto&&a)es due to %aintenance and &roduction causes e*en esternal to the &hase.

O,era## e2$i%ment efficiency +for 1i#ns.0 net run factor t&d

Tota# in,estment for maintenance costs (accordin) 4rou& rules+ in)e6 calculated

&ro&orionally to the es&ensed %aintenance inde.

8 OEE 9 :;; 6 +net r$n factor 6 t%). act$a# 5 +net r$n factor 6 t%). tar/etT&d $ 2! h (&roduction runnin) hours+

et run factor $ runnin) hours ( total hours 7 hours lost for esternal causes and &roduction &lan+.


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7 = stoppages due to production plan

1+2 = external causes + management causes ( 2 should be monitored)

8 = stoppage due to maintenance plan (should be monitored)

RE"ORTIN OF TIME EFFICIENCYRE"ORTIN OF TIME EFFICIENCY INDE7ES & OEEINDE7ES & OEE


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/PICCalusco 5-8 June 2006


Ki#ns +an) mi##s. *rea1)o-n ana#ysis(

Pre&aration of re&orts with the indications of the %ain reasons

for sto&&a)es, nu%1ers and hours of downti%e.

nalysis of the re&orts in order to identify and re%o*e thecritical situations and recurrent &ro1le%s.

ocus on &ro9ects of i%&ro*in) %aintenance and sa*in)

e*aluation.

In*ol*e%ent of &roduction and %aintenance e%&loyees in

facin) the &ro1le%s of the &lants


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8PICCalusco, 5-8 June 2006

Stoppages & Causes

BREAK DOWN ANALYSIS


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9PIC


BREAK DOWN ANALYSIS

Brea1)o-n ana#ysis0 ro$% r$#es(

"andatory for each 'iln

:tron)ly su))ested for %ills (%ainly if runnin) in critical

condition of relia1ility

;ata in&ut u& to the &roduction de&art%ent (control roo%

o&erators or &roduction %ana)er+ e*en if other &rocedures can

1e ado&ted.


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Operating time

Up time

Disabled

timeTotal time

Required

time

Non required

time

Standby

time

Down time

Externaldisabled

time

Potentialavailabilitytime

PM! Stoppages due to produ"tion plan

Potential

unavailability

time

PM#! Stoppages due to maintenan"e plan

PM$! %auses due to line &due to maint'(

PM)! %auses due to line &due to pro"ess(

PM*! %auses outside line &due to

pro"ess(

PM+! Management "auses

PM,! External "auses

PM-! %auses outside line &due to maint'(

: < = 0 E,ents c#assification: < = 0 E,ents c#assification


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, Ele"tri"al power pea.s

+ /ull stores

- Produ"t quality

* Emission quality

$ S0ortage o1 raw materials2 et"

) Ot0er external de"isions

, Permits and aut0orisations

+ Trade Unions problems

- Transportation blo".

* Ele"tri"al power la".

$ Natural events

, O""lusion 3 obstru"tion

+ %rusts 3 rings s0ooting

- Pro"ess transition &warming(

* Produ"t "0ange

$ %ombustion system

) ot0er "auses

, 4uxiliary and general servi"es

+ Upstream p0ases

- Downstream p0ases

5oo. at next pages

5oo. at next pages

: 0 E,ents c#assification cata#o/$e: 0 E,ents c#assification cata#o/$e

Operating time

Standby

time

Down time

Externaldisabled

time

6P! Stoppages due to produ"tion plan

6P#! Stoppages due to maintenan"e plan

6P$x ! %auses inside line due to Maint'

6P* ! %auses outside line &due to pro"ess(

'(

Operating time

Standby

time

Down time

Externaldisabled

time

Potential

availabilitytime

Potential

Unavailability

time

6P)! %auses due to line &due to pro"ess(

6P+ ! Management "auses

6P, ! External "auses

6P-x ! %auses outside line due to Maint''(


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/un"t'

5o"atio

n

PPPP3+73 7,--737,895N n:7,

PPPP3,$37,,#737,Raw Mill n:,

PPPP3 +$37,*+737,%ement Mill n:,PPPP3 -$37+)7737,

%oal Mill n:,

PM-x ! %auses outside line &due to

maint'(

:6

6P-, %4USES OUTS9DE 895N 59NE

&DUE TO M49NTEN4N%E(

7, P54NT PO>ER D9STR9;' S4TER SNSTRE4M

,7 OT=ER UPSTRE4M

,, OT=ER 6ENER45 SER@9%E

6P-+ %4USES OUTS9DE M955 59NE


7, R4> M4TER945 STOR46E &"rane2 et"(

7+ TR4NSPORT TO STOR46E

7- OT=ER DO>NSTRE4M

7* OT=ER UPSTRE4M

7$ OT=ER 6ENER45 SER@9%E

Ot0ers

6P-- %4USES OUTS9DE OT=ER

59NES


7, 4uxiliary and general servi"es

7+ Upstream p0ases

7- Downstream p0ases


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!otal time

"e#uired time

$on re#uired time

%p time

&isabled time

'perating time

(running time)

tandb time

&o*n time

xternal disabled

time

!heoretical

up time

!heoretical

do*n time

2) ,anagement causes

1) xternal causes

-) .auses due to phase/maint

6) .auses due to phase/proc

3) .auses outside phase/maint

) .auses outside phase/proc

7) toppages due to production plan

8) toppages due to maintenance plan

MT;/"unning time / number o

stoppages belonging

to class -


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1-PICCalusco, 5-8 June 2006

!otal time

"e#uired time

$on re#uired time

%p time

&isabled time

'perating time

(running time)

tandb time

&o*n time

xternal disabled

time

!heoretical

up time

!heoretical

do*n time


1) xternal causes







MT;<"unning time / number o

stoppages belonging

to class 3 and -


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!otal time

"e#uired time

$on re#uired time

%p time

&isabled time

'perating time

(running time)

tandb time

&o*n time

xternal disabled

time

!heoretical

up time

!heoretical

do*n time


1) xternal causes







MT;C"unning time / number o

stoppages belonging

to class 3- and 6


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!otal time

"e#uired time

$on re#uired time

%p time

&isabled time

'perating time

(running time)

tandb time

&o*n time

xternal disabled

time

!heoretical

up time

!heoretical

do*n time


1) xternal causes







MT;M"unning time / number o

stoppages belonging

to class - and 8


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!otal time

"e#uired time

$on re#uired time

%p time

&isabled time

'perating time

(running time)

tandb time

&o*n time

xternal disabled

time

!heoretical

aailabilit time

!heoretical

unaailabilit time





( Stoppages due to produ"tion plan

#( Stoppages due to maintenan"e plan

Operation 1a"tor

!heoretical 4ctual

actual o&eration factor $ run factor

5Permits and aut0orisations5Trade Unions problems5Transportation blo".5Ele"tri"al power la".5Natural events

5Ele"tri"al power pea.s5/ull stores5Produ"t quality5Emission quality5S0ortage o1 raw materials2

et"

1) xternal causes


net run factor $ runnin) ti%e hours ( total ti%e hours - hours fro% # and / +


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!otal time

"e#uired time

$on re#uired time

%p time

&isabled time

'perating time

(running time)

tandb time

&o*n time

xternal disabled

time

!heoretical

aailabilit time

!heoretical

unaailabilit time


1) xternal causes







4vailability 1a"tor


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!otal time

"e#uired time

$on re#uired time

%p time

&isabled time

'perating time

(running time)

tandb time

&o*n time

xternal disabled

time

!heoretical

aailabilit time

!heoretical

unaailabilit time


1) xternal causes







Usage 1a"tor


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PIC


>0 List of sto%%a/es *y ca$se

;y sele"ting t0e line&s(2 you "an download data to ex"el


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DEFINITIONS +!NI ISO an) Ita#cementi STDs.DEFINITIONS +!NI ISO an) Ita#cementi STDs.

TOT45 T9ME RE/EREN%E T9ME PER9OD SET /OR T=E T9ME S%45E

NON3REU9RED T9MET=E T9ME PER9OD DUR9N6 >=9%= T=E USER DOES NOT DEM4ND T=4T T=E >OR8

%ENTER 9S 9N %OND9T9ON /OR ECE%UT9N6 4 REUESTED /UN%T9ON

POTENT945 UN4@4954;959T<T9ME

P4RT O/ NON3REU9RED T9ME DUR9N6 >=9%= T=E >OR8 %ENTER 9S NOT4@4954;5E

POTENT945 4@4954;959T< T9MEP4RT O/ NON3REU9RED T9ME DUR9N6 >=9%= T=E >OR8 %ENTER 9S 9N REST

%OND9T9ON &4@4954;5E ;UT NON3OPER4T9N6(

REU9RED T9MET=E T9ME PER9OD DUR9N6 >=9%= T=E USER DEM4NDS T=4T T=E >OR8 %ENTER 9S

9N %OND9T9ON /OR ECE%UT9N6 4 REUESTED /UN%T9ON

D9S4;5ED T9ME T=E T9ME PER9OD DUR9N6 >=9%= 4 >OR8 %ENTER 9S NOT 4;5E TO %4RR< OUTT=E REU9RED /UN%T9ONS

ECTERN45 D9S4;5ED T9ME

&or ECTERN45 5OSS T9ME(

T=E T9ME PER9OD DUR9N6 >=9%= 4 >OR8 %ENTER 9S NOT 4;5E TO %4RR< OUT

T=E REU9RED /UN%T9ONS DUE TO ECTERN45 %4USES

DO>N T9MET=E T9ME PER9OD DUR9N6 >=9%= 4 >OR8 %ENTER 9S NOT 4;5E TO %4RR< OUT

T=E REU9RED /UN%T9ONS DUE TO 9NTERN45 %4USES

UP T9ME T=E T9ME PER9OD DUR9N6 >=9%= 4 >OR8 %ENTER 9S 4;5E TO %4RR< OUT T=EREU9RED /UN%T9ONS

ST4ND;< T9ME T=E T9ME PER9OD DUR9N6 >=9%= 4 >OR8 %ENTER 9S 9N ST4ND;<

OPER4T9N6 T9MET=E T9ME PER9OD DUR9N6 >=9%= 4 >OR8 %ENTER 9S %4RR


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PIC



OPER4T9N6 T9MET=E T9ME PER9OD DUR9N6 >=9%= 4 >OR8 %ENTER 9S %4RROR8ED =OURS

S4P

T=E T9ME PER9OD DUR9N6 >=9%= 4 >OR8 %ENTER PRODU%ED 4

SPE%9/9% PRODU%T'

THE SUM TOTAL OF THE "WORKED HOURS“

FOR PRODUC! ALL THE PRODUCTS

WTH THE WORK CE!TER

S E#UAL TO THE WORK CE!TER "OPERAT! TME"

PP PRO%ESS ORDER REU9RES SEP4R4TED 9NPUT O/ T=E F>'='G

USED 9N T=E >OR8 %ENTER /OR PRODU%9N6 E4%= PRODU%T'


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PIC



MT;/ 3 ME4N T9ME ;ET>EEN

/495URES

ME4N OPER4T9N6 T9ME ;ET>EEN /495URES &NON3P54NNED STOPP46ES /OR

M49NTEN4N%E( 9NS9DE T=E >OR8 %ENTER'

MT;M 3 ME4N T9ME ;ET>EEN

M49NTEN4N%E

ME4N OPER4T9N6 T9ME ;ET>EEN P54NNED H NON3P54NNED STOPP46ES /OR

M49NTEN4N%E 9NS9DE T=E >OR8 %ENTER'

MT;C 3 ME4N T9ME ;ET>EEN

/495URES 4ND PRO%ESS

STOPP46ES &9tal"ementi STD(

ME4N OPER4T9N6 T9ME ;ET>EEN P54NNED H NON3P54NNED STOPP46ES /OR

M49NTEN4N%E 4ND PRO%ESS %4USES 9NS9DE T=E >OR8 %ENTER'

MT;< 3 ME4N T9ME ;ET>EEN

PRO%ESS STOPP46ES

&9tal"ementi STD(

ME4N OPER4T9N6 T9ME ;ET>EEN NON3P54NNED STOPP46ES /OR PRO%ESS

%4USES 9NS9DE H OUTS9DE T=E >OR8 %ENTER'

4@4954;959T< /4%TOR

T=E 4@4954;959T< O/ T=E IREU9RED T9MEI DUE TO T=E /495URES &NON3

P54NNED STOPP46ES /OR M49NTEN4N%E( 9NS9DE H OUTS9DE T=E >OR8

%ENTER'

US46E /4%TOR

T=E 4@4954;959T< O/ T=E IREU9RED T9MEI DUE TO NON3P54NNED STOPP46ES

/OR M49NTEN4N%E H PRO%ESS 9NS9DE H OUTS9DE T=E >OR8 %ENTER 4ND

M4N46EMENT 4ND ECTERN45 %4USES'

O S

+ SO i S . f


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DEFINITIONS +!NI ISO an) Ita#cementi STDs.0 referencesDEFINITIONS +!NI ISO an) Ita#cementi STDs.0 references

10-breakdown analysis, key indicators & informatic system

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