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2011 ARS, India: Bangalore
Track #, Session #Begins at X:XX AM, XXXday, October Xth
Current Time:
11:32 AM
Fostering of RCM culture in
Grasim, HariharPresenters Name and Affiliation
1. Mr. Sudarshan.S.N (Manager,Spinning Process)
2. Mr. Narayan Rao I K (Manager, Spinning Maint.)
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Agenda
Introduction 5 min Selection of equipments for RCM 5 min
Details of FMEA carried out 5 min
Tasks listed after FMEA 10 min SOPs prepared after RCM 5 min
Benefits after RCM 10 min
Training imparted 5 min Summary 5 min
Questions 10 min
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Insert Name, Company Slide Number: 3Session #Track #Applied
ReliabilitySymposium,
India2011
Introduction of our company
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India2011
Introduction of our company
GRASIM: HARIHAR
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ReliabilitySymposium,
India2011
Introduction of our company
Flow Diagram of VSF Process
Selected for RCM
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Applied
ReliabilitySymposium,
India2011
Selection of equipments
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ReliabilitySymposium,
India2011
Trainingon RCM in HariharSelection of Equipments
3 days training was conducted between 4thmay 2010
6thMay 2010.
6 different units from Aditya birla group participated in
this training programme
Cross functional teams (4 members) were formed in allunits
First half day training was on introduction to RCM and
rest of the days was spent in carrying out only FMEA
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ReliabilitySymposium,
India2011
Selection of equipments
After Training
20 critical equipments were selected
Criticality analysis of all the selected equipments are
carried out
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ReliabilitySymposium,
India2011
Selection of equipments
Category Factor Option X1 - None
2 - Low
3 - Moderate X
4 - High
5 - Very High
1 - None2 - Low X
3 - Moderate
4 - High
5 - Very High
1 - None
2 - Low
3 - Moderate X
4 - Significant
5 - Extreme
1 - Not Possible
2 - Very Unlikely
3 - Unlikely
4 - Likely X5 - Very Likely
Criticality Analysis. Equipment 1 : Stretch Gear Box
Safety = 12
Potential for Personal Injury
Severity of Personal Injury
Health Hazards
Fire / Explosion Event
Possible
1 - 10 Crores
1 - 50 Lacs
1 - Available in
House X
2 - 1 to 4 weeks
3 - 1-3 Months4 - 3 to 6 Months
5 - More than 6
months
Maintenance = 5
Downtime Impact
Repair Costs
Spare Parts Availability
1 - None
2 - Near
Equipment X
3 - Local Area
(Only Section)
4 - Wider Area
(Near-by Sec tions)
5 - Whole
Plant/Surrounding
s
1 - No X
5 - Yes
1 - None
2 Minimal
3 Moderate X
4 - Significant
5 - Extreme1 - No X
5 - Yes
Environmental = 7
Spill/Release Haz. Material
Pollution Control Device
Env. Impact Potential
Radiation Detection
Criticality analysis
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ReliabilitySymposium,
India2011
Selection of equipments
1 - None X2 - Minimal (10-
20% Loss)
3 - Moderate (20-
40% Loss)
4 - Significant (40-
60% Loss)
5 - Extreme (Total
loss)
1 - No X
5 - Yes
1 - No X
5 - Yes
1 - No5 - Yes X
1 - > 5 Years
2 - 1-5 Years X
3 - Once in a year
4 - Once in 6
Months
5 - Once in Month
Operations = 10
Capacity Reduction Impact
Regulatory Requirements
Impact on Energy
Consumption
Impact on Scrap
Failure Frequency Potential
1 - None X
2 - Minimal
3 - Moderate
4 - Significant
5 - Extreme
1 - No < 2 day
delay X
2 - 2 to 5 day
delay
3 - 5 to 15 day
delay4 - 15 to 30 day
delay
5 - > 30 day delay
1 - No X
5 - Yes
Overall Criticality = 37
Quality Control = 3
Quality Impact Potential
Missed Delivery
Customer Claim Possible?
Criticality analysis
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ReliabilitySymposium,
India2011
Selection of equipments
Safety Maintenance Opearation Envirnomental Quality control Total
1 Stretch Gear box 12 5 10 7 3 37
2 Cutter Gear Box 12 4 10 6 5 37
3 Godet gear box 8 3 5 5 4 25
4 T Gear box 10 3 6 5 3 27
5 Machine main Drive System 6 3 7 5 8 29
6 Machine Pump Shaft drive system 6 3 5 6 3 23
7 Eccentric shell assembly 11 4 7 3 5 30
8 Fixed beam assembly 9 4 6 6 6 31
9 Squeeze roller assembly 11 4 7 4 7 33
10 Mat opener 11 4 7 5 5 32
11 Aftertreatment main drive system 11 3 6 6 3 29
12 Aft Soft Finish main drive system 7 3 6 5 4 25
13 Alluminium conveyor assembly 9 4 8 4 3 28
14 Spike Latice assembly 15 4 10 6 6 41
15 Dryer Drum assembly 10 3 11 5 6 35
16 Dryer Fan Assembly 10 3 7 4 5 29
17 Bailing Press Full Press 12 3 9 4 6 34
18 Bailing Press Half Press 11 4 9 5 5 34
19 Dryer Nip roller assembly 9 4 6 4 4 27
20 Dryer Intermediate conveyor assembly 10 4 9 4 6 33
200 72 151 99 97 619Total
Score
EquipmentSI No
Summary of criticality analysis
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ReliabilitySymposium,
India2011
Selection of equipments
Four equipments having high scores
Sl.
No.Equipments Scores
1Dryer Spike lattice
assembly41
2 Stretch gear box 37
3 Dryer drum assembly 35
4 Squeeze roller assembly 33
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ReliabilitySymposium,
India2011
Selection of equipments
Equipments selected for RCM
Sl.
No.Equipments Scores
3Dryer Spike lattice
assembly41
4 Dryer drum assembly 35
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ReliabilitySymposium,
India2011
FMEA of selected equipments
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India2011
FMEA
Along with 4 core team members another 8 membersteam were formed
Training imparted to them
All 12 members together carried out FMEA of
selected equipments in presence of Reliasoft personnel
from 14thto 16thJune of 2010.
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ReliabilitySymposium,
India2011
FMEA
Schematic sketch of Dryer
Static
Separator
Baling
Press
1St Drive
No. of drums: 12
Drum Speed: 9 sec/rev.
Temperature:
1st Zone : 95 deg. C
2nd Zone : 105 deg. C
2nd Drive
No. of drums: 8
Drum Speed: 9 sec/rev.
Temperature:
3rd Zone :125 deg. C
4th Zone : 100 deg. C
3rd Drive
No. of drums: 12
Drum Speed: 9 sec/rev.
Temperature:
5th Zone : 120 deg. C
6th Zone : 100 deg. C
1St Intermediate
opener:
Speed: 330 rpm
2nd Intermediate
opener:
Speed: 330 rpm
Al. Conveyor Speed: 37 rpm
Comber Speed : 160 rpm
Spiked Lat. Speed : 55 rpm
Al. Conveyor Spike lattice
Comber
Wet Rubbing
Drum:
Speed: 440 rpm
Wet rubbing drum
HP Steam line Header:
Pressure: 15 Kg / cm2
Temp. : 280 deg. C
1st Zone steam inlet
2nd Zone steam inlet
3rd Zone steam inlet
4th Zone steam inlet
5th Zone steam inlet
6th Zone steam inlet
1st Int. Duct 2nd Int. Duct
Baling Press:
Capsule Bales
No. of wires : 6
Bale Weight: 235 Kgs
Mat opener
Achordis
Blower
Fine
opener
1st zone 2nd zone 3rd zone 4th zone 5th zone 6th zone
Flash
pot
v
To desulf bath circ. tank
To wash
water tank
Condensate tank
SilencerDryer
condensate
bypass line
Hpmv1
Zv1 Zv2 Zv3 Zv4 Zv5 Zv6
Zva4
Zva5
Zva6
St1
St2
St3
St4
St5
St6
Fp1
Fp2
Sc1
Spike lattice Drum assembly
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Applied
ReliabilitySymposium,
India2011
FMEA System Hierarchy
Dryer Assembly
is broke down
into its sub-
systems and
assemblies
Dryer Drums FMEAis done with these
sub-assemblies
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Applied
ReliabilitySymposium,
India2011
FMEA
Failure Modes
Function
Effect
Causes
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Applied
ReliabilitySymposium,
India2011
FMEA
Task Selection Logic
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Applied
ReliabilitySymposium,
India2011
FMEA
Maintenance Task Selection
The logic is applied for all the identified
causes task were defined Currently practiced maintenance as well
as new tasks were proposed where everpossible as per the logic
For Currently practiced tasks the departments are assigned
responsibility.
For Proposed (New) Tasks One individual of the department is
assigned responsibility.
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Applied
ReliabilitySymposium,
India2011
FMEAFMEA of Dryer drum assembly
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ReliabilitySymposium,
India2011
FMEA
FMEA of Dryer spike lattice conveyor
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ReliabilitySymposium,
India2011
Tasks listed after FMEA
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Tasks listed after RCM
For Dryer drum Assembly
- Current Task : 20- Proposed Task :13
For Spike Lattice Assembly
- Current Task : 15
- Proposed Task :8
Tasks listed
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Status of proposed task (Drum assembly)
Sl.
No
Task description Status Target date
1 Establish specific SOP for worm
gear box
Completed -
2 Inspect & ensure the static balance
of the dryer drums with ExternalVendor
Completed in 8 drums
in Dryer # 2 during lastpreventive
Mar. 11
3 RCM of After treatment section To be taken up Mar.11
4 Ensure adherence to the
established SOP use visuals near
the equipment etc.
Sticker received & to be
fixed
10thMar. 11
5 Time based replacement of the
damper seal
Started for 8 drums. Mar.11
6 Review the current SOP and ensure
its compliance for damper seal
Reviewed -
7 Establish specific SOP for worm
gear box
Completed -
Tasks listed
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Status of proposed task (Drum assembly)
Tasks listed
Sl.
No
Task description Status Target date
8 Time based replacement of the
moving ring bearing
Completed in 8 drums 31stMar. 11
9 Tack welding of washer to the fanframes where ever applicable Completed -
10 Check the temperature near bearing
points if its >60 C lubricate the gear
box
Being practiced. -
11 Oil lubricated gear box with higher
series bearings is proposed
Gear box received. Will
be replaced during next
available stoppage.
31stMar. 11
12 Replace the worn out fan pulley
during preventive
Being practiced. 8 no.
replaced during last
preventive
-
13 Review the moving ring bearing SOP Reviewed -
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Status of proposed task (Spike lattice assembly)
Tasks listed
Sl.
No
Task description Status Target date
1 Sealing of the Spk. lattice motor
junction box
Material is on order 10thMar. 11
2 Tighten the bolts using torque wrench at
60 lb inches
Being practiced
3 To follow the revised SOP regarding the
quality of chain
Reviewed
4 Appropriate anti vibration pads to be
provided for zone drive gear box
motors.
Material received. To be
installed.
15thMar.11
5 Review the existing SOP of spike lattice
assembly regarding correct torque of
bolts tightening
Reviewed
6 Review the SOP regarding chain
tightening method
Reviewed -
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Status of proposed task (Spike lattice assembly)
Tasks listed
Sl.
No
Task description Status Target date
7 Increase the bolt shank length by 0.5 mm to
ensure enough clearance
Completed -
8 Stress re leaving to be done after
fabrication of spikes over latches
Correspondence is done
to the party. Awaiting forhis reply.
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SOPs prepared after RCM
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SOPs preparedFor drum assembly
DRYER DRUM INSTALLATION
Sub: Assembly of Dryer Drum as per Drg No.: 3-H-DRY-200/30
Check list for Dryer drum assembly
Sl.No.
Description Min(mm)
Max(mm)
Allow
1 Drum perforated hole size 9.98 10.02
2 Drum perforated hole pitch 10.0 10.02
3 Drum perforated sheet thickness 2.98 3.02
4 Drum Diameter 1398 1402 1400
5 Drum Length 1602 1605 1600
6 Damper & Drum clearance 10 10.1
7 Drum throughness 0.001 0.001
8 Drum shaft coupling clearance 2.5 3.0
9 Moving Ring and fixed ring clearance 2.8 3
10 Drum side cover straightness 90o
6. Damper & Drum Clearance:
How to measure Damper & Drum Clearance?
Place 10 mm key bar at bottom & side portion of the drum damper. Adjust the damper arm downwards such that it just touches the damper. Then tighten the arm. Remove the key bar kept at bottom & side.
7. Drum Throughness
How to measure the Drum throughness?
Fix the assemble Drum over the stand. Then rotate it manually with side touching to the dial gauge. Take the Dial gauge reading
Note down the reading Adjust the moving ring & coupling fixing bolt to get the zero reading in dialgauge through out the circumference.
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SOPs prepared
Assembly of Dryer Drum at site:
Electrically isolate the equipment. Obtain the hot & cold work safety permit. Remove the Fan assembly. Mark the Dryer panel doors. Remove all side doors. Position the gear box jack & drum jack to its position. Remove the universal joint & gear box. Dismantle the coupling & shaft. Lead the Dryer Drum outside with chain block.Sl.
No.
Description Min Max Allow
1 Clearance between dryer drum coupling &side panel
65 68
2 Clearance between drum coupling & gearbox coupling
2.5 3
3 Clearance between moving ring & fixed ring 3 3.5
How to measure the clearance between drum coupling & drum frame?
By depth gauge measure the coupling face distance end frame face. Maintain it for 70mmHow to maintain for 70mm?
If the distance is less than 70mm, then slight hammer the drum shaft by 10lbhammer.
If the distance is more than 70mm, then the puller over back side of the shaft. Then tighten the screw of the puller & drum shaft assembly to maintain thedistance of 70mm.
Clearance between Gear Box Coupling & Drum Coupling is 3mm.
How to measure the clearance?
Insert the feeler gauge between couplings. And measure the thickness of the feeler gauge.
For drum assembly
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SOPs preparedFor Spike lattice assembly
Assembly of Spike Lattice Conveyor Drive & Driven ShaftsSub: Ref Drg No 2/H/DRY/210/10
Ref Drg No 1/H/DRY/210/27
Ref Drg No 2/H/DRY/210/19
Check list before assembly of spike lattice conveyor
Sl.No.
Description Min(mm)
Max(mm)
Allow
1 Chain roller dia. 30 30.012 Chain pitch 40.0 40.013 Roller dia. clearance 1 1.0014 Chain connecting plate thickness 4.62 4.655 Connecting link hole PCD 28.8 28.96 No. Of links - - 1107 No. of teeth in drive and driven sprockets 24 24
8 Sprocket pitch 40 409 Centre distance between the sprockets 1589 1589.210 Drive shaft dia. 55 55.0211 Driven shaft dia. 45 45.0212 Key way dimension 14x5x12513 Idler sprocket teeth 1214 Latch width 50 50.0215 Latch thickness 2 2.0116 Latch pin PCD 30 30.0117 Latch pin angle 10o 10.1o18 Latch fixing hole PCD 1618 161819 Thoroughness of the shaft 0.00 0.001
SUB: Chain Roller Dia : Min 30mm, Max 30.01mm
Once chain recd at assembly shop, proper checking of conveyor chain will bedone. Any deviation in dimension will be noted and cross verified , whether is itis in acceptable condition. If found deviation is above the acceptable limit,same will be rejected.
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ReliabilitySymposium,
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SOPs preparedFor Spike lattice assembly
SUB: Chain Pitch ; Min 40 mm , Max 40.01mmChain pitch will be checked through out the length. Any deviation in dimensionwill be noted and cross verified , whether is it is in acceptable condition. If
found deviation is above the acceptable limit, same will be rejected.
SUB: Roller Dia clearance Min : 1mm max : 1.001 mm
Chain roller dia will be checked through out the length. Any deviation indimension will be noted and cross verified , whether is it is in acceptablecondition. If found deviation is above the acceptable limit, same will berejected.
SUB: Chain connecting plate thickness Min : 4.62mm, Max :4.65mmChain connecting plate thickness will be checked through out the length. Anydeviation in dimension will be noted and cross verified , whether is it is inacceptable condition. If found deviation is above the acceptable limit, same willbe rejected.
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ReliabilitySymposium,
India2011
SOPs preparedFor Spike lattice assembly
SUB: Chain connecting link hole PCD , Min 28.8mm, Max 28.9mm
Chain connecting link PCD will be checked through out the length. Any
deviation in dimension will be noted and cross verified , whether is it is inacceptable condition. If found deviation is above the acceptable limit, same willbe rejected.
SUB: Through ness of the Drive and Driven shaft, Min : 0.00mm, max :0.01mm
Through ness of the shaft will be checked between center in test bench/Lathemachine. If found zero reading in dial gauge, while rotation then job will beremoved. If the readings above the acceptable limit , then bend will beremoved and once again readings will be taken, This exercise ill be continued illwe get the readings well within acceptable condition
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Benefits after RCM
B fit
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Insert Name, Company Slide Number: 37Session #Track #Applied
ReliabilitySymposium,
India2011
0.5
0
0.9
2
0.54
0.79
0.18
0.00
0.20
0.40
0.60
0.80
1.00
FY-10 FY-11 Apr'11 May'11 Jun'11
Year and month
DryerDowntim
e%
Trend of Mechanical Breakdown in Fibre Dryer
Benefits
Better
RCM Implemented from Jun-10
B fit
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Insert Name, Company Slide Number: 38Session #Track #Applied
ReliabilitySymposium,
India2011
723.5
0 726
.50
711.79
732.9
4
709.9
4
705.00
710.00
715.00
720.00
725.00
730.00
735.00
FY-10 FY-11 Apr'11 May'11 Jun'11
Year and month
Uptimehou
rs
Dryer uptime
Benefits
Better
RCM Implemented from Jun-10
B fit
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Insert Name, Company Slide Number: 39Session #Track #AppliedReliabilitySymposium,
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6
65
552
720.0
0
558.00
720.0
0
500.00
540.00
580.00
620.00
660.00
700.00
740.00
FY-10 FY-11 Apr'11 May'11 Jun'11
Year and month
Hrs,
Dryer MTBF (Due drum assembly)
Benefits
Better
RCM Implemented from Jun-10
B fit
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730
720
720.0
0
744.0
0
720.0
0
700.00
710.00
720.00
730.00
740.00
750.00
FY-10 FY-11 Apr'11 May'11 Jun'11
Year and month
Hrs,
Dryer MTBF (Due spike lattice)
Benefits
Better
RCM Implemented from Jun-10
B fit
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Insert Name, Company Slide Number: 41Session #Track #AppliedReliabilitySymposium,
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0.6
7
1.2
3
0.50
1.00
1.50
FY-10 (Before RCM) FY-11 & upto date(After RCM)
Year and month
Hrs,
Dryer MTTR (Due drum assembly)
Benefits
Better
RCM Implemented from Jun-10
B fit
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Insert Name, Company Slide Number: 42Session #Track #AppliedReliabilitySymposium,
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0.4
5
0.5
7
0.40
0.45
0.50
0.55
0.60
FY-10 (Before RCM) FY-11 & upto date(After RCM)
Year and month
Hrs,
Dryer MTTR (Due spike lattice)
Benefits
Better
RCM Implemented from Jun-10
B fit
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Insert Name, Company Slide Number: 43Session #Track #AppliedReliabilitySymposium,
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44
95
72 70
46
0.00
10.00
20.00
30.00
40.00
50.00
60.00
70.00
80.00
90.00
100.00
FY-10 FY-11 Apr'11 May'11 Jun'11
Year and month
Bales/month
Benefits
Better
Fiber accumulation due dryer stoppage
RCM Implemented from Jun-10
B fit
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Insert Name, Company Slide Number: 44Session #Track #AppliedReliabilitySymposium,
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78.1
2
62.0
0
86.19 86
.97 87.33
50.00
60.00
70.00
80.00
90.00
100.00
FY-10 FY-11 Apr'11 May'11 Jun'11
Year and month
%o
fbales
% of bales having moisture between 10-12%
Benefits
Better
RCM Implemented from Jun-10
B fit
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Insert Name, Company Slide Number: 45Session #Track #AppliedReliabilitySymposium,
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0.9
6
1.0
0
0.96
0.98
0.95
0.90
0.92
0.94
0.96
0.98
1.00
1.02
FY-10 FY-11 Apr'11 May'11 Jun'11
Year and date
T/TF
HP steam consumption, T/TF
Benefits
Better
RCM Implemented from Jun-10
B fit
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3
7
2
3
1
0
2
4
6
8
10
FY-10 FY-11 Apr'11 May'11 Jun'11
Year and month
No.s
/month
Dryer stoppage incidences due fiber jamming (due process)
Benefits
Better
RCM Implemented from Jun-10
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India2011
Training imparted
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Training imparted
Sl.
No.Department
Equipment
selectedStatus Completion date
1 Viscose TRPTasks
generatedNov-11
2 Recovery MSFETasks
generatedNov-11
3 CS2/H2SO4 FurnaceTasks
generatedNov-11
Grasilene division
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India2011
Training imparted
Sl.
No.Department
Equipment
selectedStatus Completion date
1 Chipper house Faulgum chipper
Tasks
generated Nov-11
2 Pulp mill Vacuum filter
Tasks
generated Nov-11
Pulp division
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India2011
Summary
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Summary
1. After training on RCM, two equipments were selected for RCM
after carrying out criticality analysis of 20 critical equipments.
2. FMEA of selected equipments were carried out in presence of
Reliasoft personal.
3. Tasks were listed out.
4. Pictorial SOPs prepared after RCM.
5. Benefits after RCM are summarized.
6. Trainings are given to other departments/divisions regarding
RCM.
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India2011
Questions please
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edReliabilitySymposium,
India2011
Thank You