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