No Slide TitleRELIABILITY BASED MAINTENANCE
*
TO ELIMINATE ROOT CAUSE OF BREAKDOWN
*
(FOR EVERY SECTIONS)
TOTAL MEMBERS = 65
ROOT CAUSE & WARNING
FREQUENCY AND TRAINING NEEDS
FOCUSSED IMPROVEMENT
BRGFAILURE STUDY
ROOT CAUSE & WARNING
FREQUENCY AND TRAINING NEEDS
FOCUSSED IMPROVEMENT
BRGFAILURE STUDY
CR = FR/10 ( LP+RC+SD+S+E)
FR = FAILURE RATE ( NO OF FAILURES / YEAR)
Sheet2
&A
1
1
1
1
1
2
1.0
1
1
1
1
1
2
1.0
LEGEND: LP = LOSS PRODUCTION ; RC = REPAIR COST ; SD = SECONDARY DAMAGE
FR = FAILURE RATE ; CR = CRITICALITY RATIO ; S = SAFETY ; E = ENVIRONMENT
UNIT:VC/NVC COMMON
LEGEND: LP = LOSS PRODUCTION ; RC = REPAIR COST ; SD = SECONDARY DAMAGE
FR = FAILURE RATE ; CR = CRITICALITY RATIO ; S = SAFETY ; E = ENVIRONMENT
UNIT :VC
1
1
1
1
1
1
0.5
LEGEND: LP = LOSS PRODUCTION ; RC = REPAIR COST ; SD = SECONDARY DAMAGE
FR = FAILURE RATE ; CR = CRITICALITY RATIO ; S = SAFETY ; E = ENVIRONMENT
UNIT:VC
LEGEND: LP = LOSS PRODUCTION ; RC = REPAIR COST ; SD = SECONDARY DAMAGE
FR = FAILURE RATE ; CR = CRITICALITY RATIO ; S = SAFETY ; E = ENVIRONMENT
UNIT :VC
LEGEND: LP = LOSS PRODUCTION ; RC = REPAIR COST ; SD = SECONDARY DAMAGE
FR = FAILURE RATE ; CR = CRITICALITY RATIO ; S = SAFETY ; E = ENVIRONMENT
UNIT : VC/NVC
LEGEND: LP = LOSS PRODUCTION ; RC = REPAIR COST ; SD = SECONDARY DAMAGE
FR = FAILURE RATE ; CR = CRITICALITY RATIO ; S = SAFETY ; E = ENVIRONMENT
UNIT : VC
EQPCODE
LEGEND: LP = LOSS PRODUCTION ; RC = REPAIR COST ; SD = SECONDARY DAMAGE
FR = FAILURE RATE ; CR = CRITICALITY RATIO ; S = SAFETY ; E = ENVIRONMENT
UNIT :VC
EQPCODE
LEGEND: LP = LOSS PRODUCTION ; RC = REPAIR COST ; SD = SECONDARY DAMAGE
FR = FAILURE RATE ; CR = CRITICALITY RATIO ; S = SAFETY ; E = ENVIRONMENT
UNIT :VC
EQPCODE
LEGEND: LP = LOSS PRODUCTION ; RC = REPAIR COST ; SD = SECONDARY DAMAGE
FR = FAILURE RATE ; CR = CRITICALITY RATIO ; S = SAFETY ; E = ENVIRONMENT
UNIT : VC
EQPCODE
LEGEND: LP = LOSS PRODUCTION ; RC = REPAIR COST ; SD = SECONDARY DAMAGE
FR = FAILURE RATE ; CR = CRITICALITY RATIO ; S = SAFETY ; E = ENVIRONMENT
UNIT : VC
EQPCODE
LEGEND: LP = LOSS PRODUCTION ; RC = REPAIR COST ; SD = SECONDARY DAMAGE
FR = FAILURE RATE ; CR = CRITICALITY RATIO ; S = SAFETY ; E = ENVIRONMENT
&C&12VIKRAM CEMENT [RBM-II] EQUIPMENT CRITICAL RATIO
&Cpage &P
1
1
1
1
1
2
1
LEGEND: LP = LOSS PRODUCTION ; RC = REPAIR COST ; SD = SECONDARY DAMAGE
FR = FAILURE RATE ; CR = CRITICALITY RATIO ; S = SAFETY ; E = ENVIRONMENT
UNIT : VC
EQPCODE
2
2
1
1
2
4
3.2
DIVERTOR
1
1
1
1
1
2
1.0
LEGEND: LP = LOSS PRODUCTION ; RC = REPAIR COST ; SD = SECONDARY DAMAGE
FR = FAILURE RATE ; CR = CRITICALITY RATIO ; S = SAFETY ; E = ENVIRONMENT
UNIT: VC
EQPCODE
4
1
1
1
1
8
6.4
LEGEND: LP = LOSS PRODUCTION ; RC = REPAIR COST ; SD = SECONDARY DAMAGE
FR = FAILURE RATE ; CR = CRITICALITY RATIO ; S = SAFETY ; E = ENVIRONMENT
UNIT : VC
EQPCODE
4
1
1
1
2
7
6.3
1
1
1
1
1
6
1.2
LEGEND: LP = LOSS PRODUCTION ; RC = REPAIR COST ; SD = SECONDARY DAMAGE
FR = FAILURE RATE ; CR = CRITICALITY RATIO ; S = SAFETY ; E = ENVIRONMENT
UNIT:VC
EQPCODE
LEGEND: LP = LOSS PRODUCTION ; RC = REPAIR COST ; SD = SECONDARY DAMAGE
FR = FAILURE RATE ; CR = CRITICALITY RATIO ; S = SAFETY ; E = ENVIRONMENT
UNIT : KILN SECTION (VC)
1
1
1
1
1
10
5.0
1KFEX02
1
1
1
1
1
10
5.0
1KFEX03
1
1
1
1
1
10
5.0
1KFEX04
1
1
1
1
1
10
5.0
1KFEX05
1
1
1
1
1
10
5.0
1KFEX06
1
1
1
1
1
10
5.0
1KFEX07
1
1
1
1
1
10
5.0
1KFEX08
1
1
1
1
1
10
5.0
1KFEX09
1
1
1
1
1
10
5.0
1KFEX10
1
1
1
1
1
10
5.0
1KFEX11
1
1
1
1
1
10
5.0
1KFEX12
1
1
1
1
1
10
5.0
1UTBL04
1
1
1
1
1
4
2.0
1
1
1
1
1
4
2.0
1
1
1
1
1
4
2.0
LEGEND: LP = LOSS PRODUCTION ; RC = REPAIR COST ; SD = SECONDARY DAMAGE
FR = FAILURE RATE ; CR = CRITICALITY RATIO ; S = SAFETY ; E = ENVIRONMENT
UNIT :KILN SECTION (VC)
1
1
1
1
1
4
2
1
1
1
1
1
4
2
1
1
1
1
1
4
2
1
1
1
1
1
4
2
LEGEND: LP = LOSS PRODUCTION ; RC = REPAIR COST ; SD = SECONDARY DAMAGE
FR = FAILURE RATE ; CR = CRITICALITY RATIO ; S = SAFETY ; E = ENVIRONMENT
UNIT:KILN SECTION (VC)
SECTION: KILN FEED
LEGEND: LP = LOSS PRODUCTION ; RC = REPAIR COST ; SD = SECONDARY DAMAGE
FR = FAILURE RATE ; CR = CRITICALITY RATIO ; S = SAFETY ; E = ENVIRONMENT
UNIT:VC
LEGEND: LP = LOSS PRODUCTION ; RC = REPAIR COST ; SD = SECONDARY DAMAGE
FR = FAILURE RATE ; CR = CRITICALITY RATIO ; S = SAFETY ; E = ENVIRONMENT
UNIT:VC
LEGEND: LP = LOSS PRODUCTION ; RC = REPAIR COST ; SD = SECONDARY DAMAGE
FR = FAILURE RATE ; CR = CRITICALITY RATIO ; S = SAFETY ; E = ENVIRONMENT
UNIT:VC
LEGEND: LP = LOSS PRODUCTION ; RC = REPAIR COST ; SD = SECONDARY DAMAGE
FR = FAILURE RATE ; CR = CRITICALITY RATIO ; S = SAFETY ; E = ENVIRONMENT
&C&12VIKRAM CEMENT [RBM-II] EQUIPMENT CRITICAL RATIO&10
&Cpage &P
LEGEND: LP = LOSS PRODUCTION ; RC = REPAIR COST ; SD = SECONDARY DAMAGE
FR = FAILURE RATE ; CR = CRITICALITY RATIO ; S = SAFETY ; E = ENVIRONMENT
UNIT:VC
LEGEND: LP = LOSS PRODUCTION ; RC = REPAIR COST ; SD = SECONDARY DAMAGE
FR = FAILURE RATE ; CR = CRITICALITY RATIO ; S = SAFETY ; E = ENVIRONMENT
UNIT: VC
SECTION:KILN (KILN)
LEGEND: LP = LOSS PRODUCTION ; RC = REPAIR COST ; SD = SECONDARY DAMAGE
FR = FAILURE RATE ; CR = CRITICALITY RATIO ; S = SAFETY ; E = ENVIRONMENT
UNIT:VC
LEGEND: LP = LOSS PRODUCTION ; RC = REPAIR COST ; SD = SECONDARY DAMAGE
FR = FAILURE RATE ; CR = CRITICALITY RATIO ; S = SAFETY ; E = ENVIRONMENT
UNIT : VC
LEGEND: LP = LOSS PRODUCTION ; RC = REPAIR COST ; SD = SECONDARY DAMAGE
FR = FAILURE RATE ; CR = CRITICALITY RATIO ; S = SAFETY ; E = ENVIRONMENT
UNIT :VC
LEGEND: LP = LOSS PRODUCTION ; RC = REPAIR COST ; SD = SECONDARY DAMAGE
FR = FAILURE RATE ; CR = CRITICALITY RATIO ; S = SAFETY ; E = ENVIRONMENT
UNIT : VC
1
1
1
1
2
5
3.0
1
1
1
1
1
4
2.0
LEGEND: LP = LOSS PRODUCTION ; RC = REPAIR COST ; SD = SECONDARY DAMAGE
FR = FAILURE RATE ; CR = CRITICALITY RATIO ; S = SAFETY ; E = ENVIRONMENT
UNIT : VC
EQPCODE
LEGEND: LP = LOSS PRODUCTION ; RC = REPAIR COST ; SD = SECONDARY DAMAGE
FR = FAILURE RATE ; CR = CRITICALITY RATIO ; S = SAFETY ; E = ENVIRONMENT
UNIT :VC
1
1
1
1
1
5
2.5
PU002
1
1
1
1
1
5
2.5
PU003
1
1
1
1
1
5
2.5
PU004
1
1
1
1
1
5
2.5
PU008
LEGEND: LP = LOSS PRODUCTION ; RC = REPAIR COST ; SD = SECONDARY DAMAGE
FR = FAILURE RATE ; CR = CRITICALITY RATIO ; S = SAFETY ; E = ENVIRONMENT
UNIT : VC
1
1
1
1
1
5
2.5
1
1
1
1
1
5
2.5
1UTCS09
LEGEND: LP = LOSS PRODUCTION ; RC = REPAIR COST ; SD = SECONDARY DAMAGE
FR = FAILURE RATE ; CR = CRITICALITY RATIO ; S = SAFETY ; E = ENVIRONMENT
UNIT :VC
EQPCODE
LEGEND: LP = LOSS PRODUCTION ; RC = REPAIR COST ; SD = SECONDARY DAMAGE
FR = FAILURE RATE ; CR = CRITICALITY RATIO ; S = SAFETY ; E = ENVIRONMENT
&C&12VIKRAM CEMENT [RBM] EQUIPMENT CRITICAL RATIO
&Cpage &P
EQPCODE
LEGEND: LP = LOSS PRODUCTION ; RC = REPAIR COST ; SD = SECONDARY DAMAGE
FR = FAILURE RATE ; CR = CRITICALITY RATIO ; S = SAFETY ; E = ENVIRONMENT
UNIT: VC
5
1
1
1
2
5
5
4
1
1
1
2
5
4.5
1CMFN01
2
1
1
1
2
5
3.5
1CMAS08
1
1
1
1
1
4
2
1CMBF02
1
1
1
1
1
2
1
1
1
1
1
1
2
1
1
1
1
1
1
2
1
1
1
1
1
1
2
1
1
1
1
1
1
2
1
US001
LEGEND: LP = LOSS PRODUCTION ; RC = REPAIR COST ; SD = SECONDARY DAMAGE
FR = FAILURE RATE ; CR = CRITICALITY RATIO ; S = SAFETY ; E = ENVIRONMENT
UNIT:VC
EQPCODE
1
1
1
1
1
6
3.0
1
1
1
1
1
6
3.0
LEGEND: LP = LOSS PRODUCTION ; RC = REPAIR COST ; SD = SECONDARY DAMAGE
FR = FAILURE RATE ; CR = CRITICALITY RATIO ; S = SAFETY ; E = ENVIRONMENT
UNIT: VC
EQPCODE
1
1
1
1
1
6
3.0
1
1
1
1
1
6
3.0
1
1
1
1
1
6
3.0
1
1
1
1
1
6
3.0
LEGEND: LP = LOSS PRODUCTION ; RC = REPAIR COST ; SD = SECONDARY DAMAGE
FR = FAILURE RATE ; CR = CRITICALITY RATIO ; S = SAFETY ; E = ENVIRONMENT
UNIT : PACKING PLANT (VC)
EQPCODE
LEGEND: LP = LOSS PRODUCTION ; RC = REPAIR COST ; SD = SECONDARY DAMAGE
FR = FAILURE RATE ; CR = CRITICALITY RATIO ; S = SAFETY ; E = ENVIRONMENT
UNIT : PACKING PLANT (VC)
SECTION : TRUCKS WAGON LOADING
2
5
1
1
1
7
7.7
LEGEND: LP = LOSS PRODUCTION ; RC = REPAIR COST ; SD = SECONDARY DAMAGE
FR = FAILURE RATE ; CR = CRITICALITY RATIO ; S = SAFETY ; E = ENVIRONMENT
UNIT : PACING PLANT (VC)
SECTION: TRUCK & WAGON LOADING
LEGEND: LP = LOSS PRODUCTION ; RC = REPAIR COST ; SD = SECONDARY DAMAGE
FR = FAILURE RATE ; CR = CRITICALITY RATIO ; S = SAFETY ; E = ENVIRONMENT
&C&12VIKRAM CEMENT [RBM-II] EQUIPMENT CRITICAL RATIO
&Cpage &P
1
1
1
1
1
2
1.0
1
1
1
1
1
2
1.0
LEGEND: LP = LOSS PRODUCTION ; RC = REPAIR COST ; SD = SECONDARY DAMAGE
FR = FAILURE RATE ; CR = CRITICALITY RATIO ; S = SAFETY ; E = ENVIRONMENT
UNIT:VC/NVC COMMON
LEGEND: LP = LOSS PRODUCTION ; RC = REPAIR COST ; SD = SECONDARY DAMAGE
FR = FAILURE RATE ; CR = CRITICALITY RATIO ; S = SAFETY ; E = ENVIRONMENT
UNIT :VC
1
1
1
1
1
1
0.5
LEGEND: LP = LOSS PRODUCTION ; RC = REPAIR COST ; SD = SECONDARY DAMAGE
FR = FAILURE RATE ; CR = CRITICALITY RATIO ; S = SAFETY ; E = ENVIRONMENT
UNIT:VC
LEGEND: LP = LOSS PRODUCTION ; RC = REPAIR COST ; SD = SECONDARY DAMAGE
FR = FAILURE RATE ; CR = CRITICALITY RATIO ; S = SAFETY ; E = ENVIRONMENT
UNIT :VC
LEGEND: LP = LOSS PRODUCTION ; RC = REPAIR COST ; SD = SECONDARY DAMAGE
FR = FAILURE RATE ; CR = CRITICALITY RATIO ; S = SAFETY ; E = ENVIRONMENT
UNIT : VC/NVC
LEGEND: LP = LOSS PRODUCTION ; RC = REPAIR COST ; SD = SECONDARY DAMAGE
FR = FAILURE RATE ; CR = CRITICALITY RATIO ; S = SAFETY ; E = ENVIRONMENT
UNIT : VC
EQPCODE
LEGEND: LP = LOSS PRODUCTION ; RC = REPAIR COST ; SD = SECONDARY DAMAGE
FR = FAILURE RATE ; CR = CRITICALITY RATIO ; S = SAFETY ; E = ENVIRONMENT
UNIT :VC
EQPCODE
LEGEND: LP = LOSS PRODUCTION ; RC = REPAIR COST ; SD = SECONDARY DAMAGE
FR = FAILURE RATE ; CR = CRITICALITY RATIO ; S = SAFETY ; E = ENVIRONMENT
UNIT :VC
EQPCODE
LEGEND: LP = LOSS PRODUCTION ; RC = REPAIR COST ; SD = SECONDARY DAMAGE
FR = FAILURE RATE ; CR = CRITICALITY RATIO ; S = SAFETY ; E = ENVIRONMENT
UNIT : VC
EQPCODE
LEGEND: LP = LOSS PRODUCTION ; RC = REPAIR COST ; SD = SECONDARY DAMAGE
FR = FAILURE RATE ; CR = CRITICALITY RATIO ; S = SAFETY ; E = ENVIRONMENT
UNIT : VC
EQPCODE
LEGEND: LP = LOSS PRODUCTION ; RC = REPAIR COST ; SD = SECONDARY DAMAGE
FR = FAILURE RATE ; CR = CRITICALITY RATIO ; S = SAFETY ; E = ENVIRONMENT
&C&12VIKRAM CEMENT [RBM-II] EQUIPMENT CRITICAL RATIO
&Cpage &P
1
1
1
1
1
2
1
LEGEND: LP = LOSS PRODUCTION ; RC = REPAIR COST ; SD = SECONDARY DAMAGE
FR = FAILURE RATE ; CR = CRITICALITY RATIO ; S = SAFETY ; E = ENVIRONMENT
UNIT : VC
EQPCODE
2
2
1
1
2
4
3.2
DIVERTOR
1
1
1
1
1
2
1.0
LEGEND: LP = LOSS PRODUCTION ; RC = REPAIR COST ; SD = SECONDARY DAMAGE
FR = FAILURE RATE ; CR = CRITICALITY RATIO ; S = SAFETY ; E = ENVIRONMENT
UNIT: VC
EQPCODE
4
1
1
1
1
8
6.4
LEGEND: LP = LOSS PRODUCTION ; RC = REPAIR COST ; SD = SECONDARY DAMAGE
FR = FAILURE RATE ; CR = CRITICALITY RATIO ; S = SAFETY ; E = ENVIRONMENT
UNIT : VC
EQPCODE
4
1
1
1
2
7
6.3
1
1
1
1
1
6
1.2
LEGEND: LP = LOSS PRODUCTION ; RC = REPAIR COST ; SD = SECONDARY DAMAGE
FR = FAILURE RATE ; CR = CRITICALITY RATIO ; S = SAFETY ; E = ENVIRONMENT
UNIT:VC
EQPCODE
LEGEND: LP = LOSS PRODUCTION ; RC = REPAIR COST ; SD = SECONDARY DAMAGE
FR = FAILURE RATE ; CR = CRITICALITY RATIO ; S = SAFETY ; E = ENVIRONMENT
UNIT : KILN SECTION (VC)
1
1
1
1
1
10
5.0
1KFEX02
1
1
1
1
1
10
5.0
1KFEX03
1
1
1
1
1
10
5.0
1KFEX04
1
1
1
1
1
10
5.0
1KFEX05
1
1
1
1
1
10
5.0
1KFEX06
1
1
1
1
1
10
5.0
1KFEX07
1
1
1
1
1
10
5.0
1KFEX08
1
1
1
1
1
10
5.0
1KFEX09
1
1
1
1
1
10
5.0
1KFEX10
1
1
1
1
1
10
5.0
1KFEX11
1
1
1
1
1
10
5.0
1KFEX12
1
1
1
1
1
10
5.0
1UTBL04
1
1
1
1
1
4
2.0
1
1
1
1
1
4
2.0
1
1
1
1
1
4
2.0
LEGEND: LP = LOSS PRODUCTION ; RC = REPAIR COST ; SD = SECONDARY DAMAGE
FR = FAILURE RATE ; CR = CRITICALITY RATIO ; S = SAFETY ; E = ENVIRONMENT
UNIT :KILN SECTION (VC)
1
1
1
1
1
4
2
1
1
1
1
1
4
2
1
1
1
1
1
4
2
1
1
1
1
1
4
2
LEGEND: LP = LOSS PRODUCTION ; RC = REPAIR COST ; SD = SECONDARY DAMAGE
FR = FAILURE RATE ; CR = CRITICALITY RATIO ; S = SAFETY ; E = ENVIRONMENT
UNIT:KILN SECTION (VC)
SECTION: KILN FEED
LEGEND: LP = LOSS PRODUCTION ; RC = REPAIR COST ; SD = SECONDARY DAMAGE
FR = FAILURE RATE ; CR = CRITICALITY RATIO ; S = SAFETY ; E = ENVIRONMENT
UNIT:VC
LEGEND: LP = LOSS PRODUCTION ; RC = REPAIR COST ; SD = SECONDARY DAMAGE
FR = FAILURE RATE ; CR = CRITICALITY RATIO ; S = SAFETY ; E = ENVIRONMENT
UNIT:VC
LEGEND: LP = LOSS PRODUCTION ; RC = REPAIR COST ; SD = SECONDARY DAMAGE
FR = FAILURE RATE ; CR = CRITICALITY RATIO ; S = SAFETY ; E = ENVIRONMENT
UNIT:VC
LEGEND: LP = LOSS PRODUCTION ; RC = REPAIR COST ; SD = SECONDARY DAMAGE
FR = FAILURE RATE ; CR = CRITICALITY RATIO ; S = SAFETY ; E = ENVIRONMENT
&C&12VIKRAM CEMENT [RBM-II] EQUIPMENT CRITICAL RATIO&10
&Cpage &P
LEGEND: LP = LOSS PRODUCTION ; RC = REPAIR COST ; SD = SECONDARY DAMAGE
FR = FAILURE RATE ; CR = CRITICALITY RATIO ; S = SAFETY ; E = ENVIRONMENT
UNIT:VC
LEGEND: LP = LOSS PRODUCTION ; RC = REPAIR COST ; SD = SECONDARY DAMAGE
FR = FAILURE RATE ; CR = CRITICALITY RATIO ; S = SAFETY ; E = ENVIRONMENT
UNIT: VC
SECTION:KILN (KILN)
LEGEND: LP = LOSS PRODUCTION ; RC = REPAIR COST ; SD = SECONDARY DAMAGE
FR = FAILURE RATE ; CR = CRITICALITY RATIO ; S = SAFETY ; E = ENVIRONMENT
UNIT:VC
LEGEND: LP = LOSS PRODUCTION ; RC = REPAIR COST ; SD = SECONDARY DAMAGE
FR = FAILURE RATE ; CR = CRITICALITY RATIO ; S = SAFETY ; E = ENVIRONMENT
UNIT : VC
LEGEND: LP = LOSS PRODUCTION ; RC = REPAIR COST ; SD = SECONDARY DAMAGE
FR = FAILURE RATE ; CR = CRITICALITY RATIO ; S = SAFETY ; E = ENVIRONMENT
EQPCODE
LEGEND: LP = LOSS PRODUCTION ; RC = REPAIR COST ; SD = SECONDARY DAMAGE
FR = FAILURE RATE ; CR = CRITICALITY RATIO ; S = SAFETY ; E = ENVIRONMENT
UNIT : VC
1
1
1
1
2
5
3.0
1
1
1
1
1
4
2.0
LEGEND: LP = LOSS PRODUCTION ; RC = REPAIR COST ; SD = SECONDARY DAMAGE
FR = FAILURE RATE ; CR = CRITICALITY RATIO ; S = SAFETY ; E = ENVIRONMENT
UNIT : VC
EQPCODE
LEGEND: LP = LOSS PRODUCTION ; RC = REPAIR COST ; SD = SECONDARY DAMAGE
FR = FAILURE RATE ; CR = CRITICALITY RATIO ; S = SAFETY ; E = ENVIRONMENT
UNIT :VC
1
1
1
1
1
5
2.5
PU002
1
1
1
1
1
5
2.5
PU003
1
1
1
1
1
5
2.5
PU004
1
1
1
1
1
5
2.5
PU008
LEGEND: LP = LOSS PRODUCTION ; RC = REPAIR COST ; SD = SECONDARY DAMAGE
FR = FAILURE RATE ; CR = CRITICALITY RATIO ; S = SAFETY ; E = ENVIRONMENT
UNIT : VC
1
1
1
1
1
5
2.5
1
1
1
1
1
5
2.5
1UTCS09
LEGEND: LP = LOSS PRODUCTION ; RC = REPAIR COST ; SD = SECONDARY DAMAGE
FR = FAILURE RATE ; CR = CRITICALITY RATIO ; S = SAFETY ; E = ENVIRONMENT
UNIT :VC
EQPCODE
LEGEND: LP = LOSS PRODUCTION ; RC = REPAIR COST ; SD = SECONDARY DAMAGE
FR = FAILURE RATE ; CR = CRITICALITY RATIO ; S = SAFETY ; E = ENVIRONMENT
&C&12VIKRAM CEMENT [RBM] EQUIPMENT CRITICAL RATIO
&Cpage &P
EQPCODE
LEGEND: LP = LOSS PRODUCTION ; RC = REPAIR COST ; SD = SECONDARY DAMAGE
FR = FAILURE RATE ; CR = CRITICALITY RATIO ; S = SAFETY ; E = ENVIRONMENT
UNIT: VC
5
1
1
1
2
5
5
4
1
1
1
2
5
4.5
1CMFN01
2
1
1
1
2
5
3.5
1CMAS08
1
1
1
1
1
4
2
1CMBF02
1
1
1
1
1
2
1
1
1
1
1
1
2
1
1
1
1
1
1
2
1
1
1
1
1
1
2
1
1
1
1
1
1
2
1
US001
LEGEND: LP = LOSS PRODUCTION ; RC = REPAIR COST ; SD = SECONDARY DAMAGE
FR = FAILURE RATE ; CR = CRITICALITY RATIO ; S = SAFETY ; E = ENVIRONMENT
UNIT:VC
EQPCODE
1
1
1
1
1
6
3.0
1
1
1
1
1
6
3.0
LEGEND: LP = LOSS PRODUCTION ; RC = REPAIR COST ; SD = SECONDARY DAMAGE
FR = FAILURE RATE ; CR = CRITICALITY RATIO ; S = SAFETY ; E = ENVIRONMENT
UNIT: VC
EQPCODE
1
1
1
1
1
6
3.0
1
1
1
1
1
6
3.0
1
1
1
1
1
6
3.0
1
1
1
1
1
6
3.0
LEGEND: LP = LOSS PRODUCTION ; RC = REPAIR COST ; SD = SECONDARY DAMAGE
FR = FAILURE RATE ; CR = CRITICALITY RATIO ; S = SAFETY ; E = ENVIRONMENT
UNIT : PACKING PLANT (VC)
EQPCODE
LEGEND: LP = LOSS PRODUCTION ; RC = REPAIR COST ; SD = SECONDARY DAMAGE
FR = FAILURE RATE ; CR = CRITICALITY RATIO ; S = SAFETY ; E = ENVIRONMENT
UNIT : PACKING PLANT (VC)
SECTION : TRUCKS WAGON LOADING
2
5
1
1
1
7
7.7
LEGEND: LP = LOSS PRODUCTION ; RC = REPAIR COST ; SD = SECONDARY DAMAGE
FR = FAILURE RATE ; CR = CRITICALITY RATIO ; S = SAFETY ; E = ENVIRONMENT
UNIT : PACING PLANT (VC)
SECTION: TRUCK & WAGON LOADING
LEGEND: LP = LOSS PRODUCTION ; RC = REPAIR COST ; SD = SECONDARY DAMAGE
FR = FAILURE RATE ; CR = CRITICALITY RATIO ; S = SAFETY ; E = ENVIRONMENT
&C&12VIKRAM CEMENT [RBM-II] EQUIPMENT CRITICAL RATIO
&Cpage &P
ROOT CAUSE & WARNING
FREQUENCY AND TRAINING NEEDS
FOCUSSED IMPROVEMENT
BRGFAILURE STUDY
SUB
SPARE
Overhauling of rollers .
M
Once
DOM
Links
Checking of roller & chain
M
M
M
Once
DOM
Guide
M
I
SUB
SPARE
discharge
MD
Lever
I
Underrated main power cable (35mm2)
Replace with 70 mm2 cable.
E
Once
DOM
E
SUB
SPARE
Overhauling of rollers .
M
Once
DOM
Links
Checking of roller & chain
M
M
M
Once
DOM
Guide
M
I
SUB
SPARE
discharge
MD
Lever
I
Underrated main power cable (35mm2)
Replace with 70 mm2 cable.
E
Once
DOM
E
ROOT CAUSE & WARNING
FREQUENCY AND TRAINING NEEDS
FOCUSSED IMPROVEMENT
BRGFAILURE STUDY
MINOR LEAKAGE FROM OIL SEAL
CHECK FOR
EQUIPMENT:-
CEMENT MILL MAIN DRIVE GEAR BOX HEAT EXCHANGER - 2 NOS.
EXISTING SURFACE AREA = 2.2 + 2.2 = 4.4 M2
OBSERVATION:-
AT INLET WATER TEMPERATURE = 34 DEG. C
AMBIENT TEMPERATURE = 28 DEG.C
HELICAL GEAR BOX EFFICIENCY = 90% (ESTIMATED)
HEAT DESSIPATION IN GEAR BOX = 1900 X 10% = 190 KW
AT INLET WATER TEMPERATURE = 38 DEC. C (IN SUMMER SEASON)
REQUIRED HEAT EXCHANGER SURFACE AREA = 22 M2 (FROM GRAPH)
*
- NEW PLATE TYPE HEAT EXCHANGER WITH SURFACE AREA (20 M2)
INSTALLED
IN NEW HEAT EXCHANGER = 8 DEG.C
- WATER TEMPERATURE RISE = 10 - 12 DEC.C
- SIGNIFICANT REDUCTION IN GEAR BOX OIL TEMPERATURE =
57 (BEFORE) - 43 (AFTER) = 14 DEG. C
*
EQUIPMENT:-
PINION DIA = 240mm
INPUT SPEED = 990 RPM
60
60 x 1000
FOR 10 TO 12 M/Sec. INPUT SPEED VISCOSITY SHOULD BE = 320 CSK
ACTION:-
OIL TEMPERATURE AND SEAL LIFE IMPROVED
*
ROOT CAUSE & WARNING
FREQUENCY AND TRAINING NEEDS
FOCUSSED IMPROVEMENT
BRGFAILURE STUDY
DEVELOP CBM CHECKLIST
EXECUTION OF CHECKLIST (TRIAL RUN)
REVIEW AND MODIFY THE CHECKLISTS
IMPLEMENT & MONITOR
ROOT CAUSE & WARNING
FREQUENCY AND TRAINING NEEDS
FOCUSSED IMPROVEMENT
BRGFAILURE STUDY
NAME OF THE SPARE - BUCKET ELEVATOR BOTTOM BOOT BEARINGS
OBSERVATIONS:-
MODE OF FAILURE : BEARING CAGE WEAR DUE TO POOR LUBRICATION
CONDITION
ENVIRONMENT : DUST PRONE AREA
FREQUENCY OF LUBRICATION : DAILY
ENVIRONMENT IMPROVEMENT : DUST SPILLAGE CONTROLLED
IN OPERATION
*
ROOT CAUSE & WARNING
FREQUENCY AND TRAINING NEEDS
FOCUSSED IMPROVEMENT
BRGFAILURE STUDY
STANDARD CHECKING PROCEDURE
OF L.T. MOTOR
CHECK INSULATION VALUE WITH 500 VOLT MEGGAR AND RECORDS VALUE. IF VALUE LESS THAN 1 MEGAOHM, IMPROVE THE VALUE.
CHECK INDUCTANCE AND RESISTANCE WITH MOTOR CHECKER AND RECORD THE VALUE. DIFFERENCE OF R,Y,B SHOULD NOT BE >5%
CHECK MOTOR TERMINATION
CHECK FOR ANY HEATING OF LUGS
CHECK TERMINAL BOX SEALING
ROOT CAUSE & WARNING
FREQUENCY AND TRAINING NEEDS
FOCUSSED IMPROVEMENT
BRGFAILURE STUDY
MODE OF FAILURE:-
INNER RACE CRACKED
ROOT CAUSE ANALYSIS:-
PEDESTAL LEVELLING IS NOT PROPER SINCE ERECTION
HIGH JERK AT SHAFT BEARING SEAT DURING CHANGEOVER
FROM SPRS TO LRS AND VICE VERSA
TOLERANCE OF BEARING HOUSING BORE DIMENSION IS
NOT PROPER
ACTION PERFORMED:-
PEDESTAL LEVELLING IS DONE
REQUIRED TOLERANCE
TRACKING SYSTEM FOR REGULATING FAN SPEED IS INSTALLED
*
ROOT CAUSE & WARNING
FREQUENCY AND TRAINING NEEDS
FOCUSSED IMPROVEMENT
BRGFAILURE STUDY
% OF EQUIPMENTS COVERED UNDER RBM - 62
(MOST CRITICAL + CRITICAL)
- 28
RESULTS OF RBM
ROOT CAUSE & WARNING
FREQUENCY AND TRAINING NEEDS
FOCUSSED IMPROVEMENT
BRGFAILURE STUDY
IDENTIFY FAILURE MODES OF FAILED SPARE
DEVISE KEY RELIABILITY ASSESSMENT CRITERIA
- APPLICATION OF (PRESSURE/TEMPERATURE/IMPACT/WEAR)
DEVISE APPROPRIATE QUALITY SAMPLING PLAN FOR ACCEPTANCE QUALITY LEVEL
STANDARDIZE PURCHASE PROCEDURE
INCREASED SULPHUR
INCREASED TEMPERATURE
INCREASED CLINKER TEMPERATURE
CYCLONE JAMMING AND LESS REFRACTORY AND CASTABLE LIFE IN PREHEATER
A WAY FORWARD
UNIT : VC
LEGEND: LP = LOSS PRODUCTION ; RC = REPAIR COST ; SD = SECONDARY DAMAGE
FR = FAILURE RATE ; CR = CRITICALITY RATIO ; S = SAFETY ; E = ENVIRONMENT
106.4
128.22
157.48
148.71
65.27
84.11
98.27
61.24
0
20
40
60
80
100
120
140
160
94-9595-9696-9797-9898-9999-0000-01'01-02
1.0
LEGEND: LP = LOSS PRODUCTION ; RC = REPAIR COST ; SD = SECONDARY DAMAGE
FR = FAILURE RATE ; CR = CRITICALITY RATIO ; S = SAFETY ; E = ENVIRONMENT
EQUIPMENT CRITICALITY RATING CHART
BANDTIMEBANDCOSTBANDRISK
3 30 - 60 min3 25,000 - 1.0 L3Significant
4 1 - 2 hrs4 1.0 - 2.0 L4
5 2 - 4 hrs5 2.0 - 5.0 L5Serious
6 4 - 8 hrs6 5.0 - 10 L6
7 8 - 16 hrs7 10 - 20 L7Potentially fatal
8 10 - 32 hrs8 20 - 50 L8
9 > 32 hrs9 > 50 L9Disaster
LP = LOST PRODUCTION ; RC = REPAIR COST ; SD = SECONDARY DAMAGE
CR = FR/10 ( LP+RC+SD+S+E)
FR = FAILURE RATE ( NO OF FAILURES / YEAR)
9819.3
6189
5052.8
4014.9
2488.8
2174.41554.7
1106.46
999.9
1375.86
1362.47
0
2000
4000
6000
8000
10000
12000
91-9292-9393-9494-9595-9696-9797-9898-9999-0000-01'01-02
2688
2171
2372
1981
1263
1450
803
529
391
646
739
0
500
1000
1500
2000
2500
3000
91-9292-9393-9494-9595-9696-9797-9898-9999-0000-01'01-02
SUB SPAREMODE OF WARNING ROOT TASK DEPT.PERIODTIMEMAINT.
NAMEFAILUREEFFECTCAUSE(FREQ)REQ .TYPE
DPCRollerBrg cage
its U clit welded
installed
MOnceDOM
SUB SPAREMODE OF WARNING ROOT TASK DEPT.PERIODTIMEMAINT.
NAMEFAILUREEFFECTCAUSE(FREQ)REQ .TYPE
discharge
worn out .
MotorMotorMotor