param express - tata power · launched in tata power, to analyse and integrate both the commercial...
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Param Sankalp / 02
• Equipment classification toolkit completed, trainings ongoing across sites
• 2nd FMEA boot camp concluded with focused effort on 6 critical equipment
• Technical demonstration of RCM Bolt-on software by multiple vendors
• Operations improvement CFTs formed at sites
• Ongoing data quality improvement for tracking right defect details in SAP
• In principle approval on RCM Academy from senior leadership
• Turbine FMEAs boot camp in 1st week of May
• 3rd FMEA boot camp with 5-6 critical equipment
• Ongoing site presence for FMEAs, equipment codification and data quality
• Equipment classification trainings
• Preparation of SAP catalogues for select equipment
• Finalization of RCM bolt-on vendor
• Culture assessment survey as part of Param Sankalp program
• Pilot roll out of RCM Academy
Param Express
Watch Out ForKey Activities Concluded
Accuracy of analysis – Detailed functional effect analysis, failure and maintenance cost analysis in line with guidelines
Extent of coverage – 75 components and ~300 component – failure mode & root cause combinations defined
Team commitment – Proactive completion by participation through VCs
Extent of new action items – 40 unique new action identified with applicability across multiple components
FMEA of the Month
GRP
AnanjanMukherjee
T Muralikrishna
Alok Uppal Girish Jawale M V Kini
AshfaqAhmad Ansari
Chandrasekhar Singh
Sreeram S
Param Sankalp / 02
Equipment codification going on across sites, 3-day boot camp organized for focused effort
Heat rate management process-FMEA created with participation from all sites
The Heat Rate Management Process FMEA
Bootcamp organized at Trombay between 27th and
29th March was attended by over 15 members from
CGPL, MPL, Jojobera, Trombay and CTDS. The
participants indulged in extensive brainstorming to
identify possible failure modes that could lead to
deterioration in heat rate, their root causes and
detection mechanisms. Throughout the exercise, the
participants focused on defining action items,
especially process interventions, that could help the
operations team proactively address parameter
deviations leading to deterioration in heat rate.
During the boot-camp, the team received guidance
from Mr. Anil Jain, Chief – Trombay and Mr.
Ramesh Jha, Chief – O&M, MPL. The Heat Rate
Management Process FMEA developed at the end
of the bootcamp was presented to Mr. Asim De,
Mr. Sharad Baijal and Ms. Anjali Kulkarni. The
senior leaders appreciated the team’s efforts and at
the same time urged the team to set aspirational
targets for achieving the best heat rate.
The teams were also encouraged to be torch bearers of Param Sankalp and share the knowledge
gained from brainstorming sessions with others at their respective sites.
The Equipment Codification Bootcamp was
organized at Backbay between 20th and 22nd
April and was attended by over 15 members
from CGPL, MPL, & Jojobera sites. The
purpose of the boot camp was to accelerate
codification for prioritized areas such as boiler,
turbine, generator and electrical systems.
The participants engaged in multiple cross-site discussions to ensure alignment to a common
philosophy, upholding the vision of “One Tata Power”. The teams have pledged to keep up the
momentum build during the boot camp to ensure timely completion of codification.
Param Sankalp / 02
2nd FMEA Boot Camp organized; Hydro Turbine team adjudged as Best FMEA
First FMEA boot camp was a grand
success with focused deliberations and
preparation of first set of model FMEAs
at Tata Power. On similar lines, 2nd FMEA
boot camp was planned on similar lines to
bring in cross functional teams and experts
under one roof. A 3 day FMEA boot camp
was conducted from 17th April to 19th
April. Six critical equipment wereselected – Air Pre Heater, HydroTurbine, Condenser, Circuit Breaker,CT/PT/LA&BUS and Generator forthe boot camp.
Teams had intense technical discussions to
identify new failure modes and optimize
their maintenance approach with internal
and external experts. The amount of
energy and dedication was enormous
during discussions.
The event was concluded by presentation of FMEAs to the judges comprising of senior
leadership of Tata Power. Top 2 FMEAs were selected for final round with COO & ED and
teams were evaluated comprehensively. Hydro Turbine team won the Reliability Cup. COO
&ED emphasized on the importance of Param Sankalp program and how contribution from all
employee is an imperative for its success. 3 Cheers for all the teams
Hydro Turbine
Team
Reliability Cup
Team Members: Dhiraj Kamath, Vivek Mate, Nitin Thakur, Nilesh Mahale, Sreekanth Kandi,
Debarghya Mitra
Experts: N N Nayak, S B Lakhapati
Param Sankalp / 02
"RCM is a corporate level strategic initiativeLaunched in Tata power, to analyse and integrateboth the commercial and technical part acrossvarious functions. Through various maintenanceStrategies and optimization techniques using the tools like FMEA, we are trying to analyseprocesses and make them stream lined in the most optimized way. But then we have to besure and fully aware about the strong base of the whole process, which is FMEA andcodification exercise. It was really an enriching experience of attending both FMEA andcodification boot-camp, in which we not only reinvented the whole process but alsodiscovered new depths in the present system and improvements that can come as a result ofthese exercises. But I think, to see a desired result we will have to be patient and consistentin our work."
My CornerConversations with you…
Mr. Ashish Awasthi, Lead Engineer - MMD (Team BFP FMEA and Jojobera Equipment Codification)
"RCM Program is a great intervention taken up bythe organization, which will help shape the maintenance
strategy by taking our maintenance practices to amature level. As with any initiative, the success
would depend on the rigor with which it is deployed. The 3 day FMEA Boot Camp had therequired rigor, witnessing intense discussions on all aspects of preparing FMEA. Technicalsubject experts and fresh thoughts from young engineers helped in improving the quality ofdiscussion. Defining the FMEA objective, keeping our eyes on it all the time, writing sharpaction items and giving dedicated time for preparing FMEA were key aspects that werecritical in preparing a good FMEA. I believe we need to continue with the same resolve forthese discussions and dedicate quality time for preparing FMEA as this would lay thefoundation of the way ahead for RCM."
Mr. Alok Uppal, Group Head
– EMD (Part of Team GRP
FMEA)
Photograph: Param Sankalp team at Jojobera to drive Operation Initiatives
Param Sankalp / 02
The correct answers for last month’s quiz are:
1. Most basic maintenance approach to improve equipment reliability – Preventive
2. Reactive approach to failure analysis – RCA
3. Proactive approach to failure analysis – FMEA
4. Key RCM KPI which captures decrease in time between two failures – MTBF
Overall answer for jumbled words is PARAM
Winners for first month are
Naveen K Solanki
1st 2nd 3rd
Ramkrishna Prasanna
ShamboBhattacharya
Send your responses to
paramsankalp@tatapower.com
First three correct responses would be
awarded.
Quiz of the Month
1 2 3
6 4
7
5
8
9
ACROSS
1. KPI which monitors efficiency of a Unit or a
Station. (2,4)
6. ______ FMEAs cover failure modes and
preventive actions for Heat Rate, APC etc. (1,7)
7. SAP Code: Display notification activities. (1,4)
8. Abbreviation. Clue: This FMEA team won the
best FMEA award. (1,3)
9. M4 notification is for Condition Based
Monitoring notifications. Correct/Incorrect? (1,7)
DOWN
1. IW68 gives the Equipment ____ in SAP. (1,9)
2. Governing System comes under which functional
location. (1,7)
3. Abbreviation. Gross Heat Rate minus Net Heat
Rate. (1,3)
4. Param ________ is the RCM implementation
program in Tata Power. First time in power sector
in India. (1,7)
5. Abbreviation. Temperature parameter affecting
Heat Rate. (1,4)
Winners who just missed being placed in first month quiz. Better luck for the crossword below.
Sujit Sengupta
Suranjan Chattopadhyay
Monica Pawar
SudhakarSharma
LSVKS Murthy
Pravin Mahadik
Param Sankalp / 02
If you have any questions, please write to us at paramsankalp@tatapower.com
Incorrect data capturing increases the effort to analyze failure patterns as well as limits the potential of maintenance optimization
Notifications are not mapped accurately. I can’t conclude anything
Accurate data capture helps analyze failure patterns and suggests the optimum maintenance strategy
RCM software helps me understand failure patterns and recommends maintenance strategy
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