CH HGRS Maintenance

Maintenance
Introduction to Cement and Concrete

HGRS / CTS / MER
August 24, 2006
Eric Lalancette
Welcome to Maintenance
Objectives for Today
Enhance understanding of:
The key success factors in the Maintenance

Process
The impact of Maintenance on Manufacturing

Performance
Holcim Group Support
Introduction to Cement Concrete & Aggregates
August 2006
Agenda
Introduction to maintenance
Inspections
Planning
Job execution
Summary & conclusion
August 2006
What are we doing?

Maintenance Team at Holcim Group Support
To be the technical expertise turntable for maintenance in

the Holcim Group
Support the plants / companies in their goals of optimizing
overall asset effectiveness
- MPRs
- Maintenance Assessment
- MAC Implementation and Sustainability
- Training in Maintenance
- Review of Quality and Design of Equipment
- Condition Monitoring
- Root Cause Failure Analysis
4
August 2006
Who are we?
Hans Burger
Eric Lalancette
Ren Burkhalter
Monia Benzoni
Eric Lanz
Risto Schmid
Tanja Meier
Hans Brtschi
Rodolfo Tiglao
Andreas Steinmann
Hoa Van Le
Stefan Jeken
Arturo de la Tejera
Ignacio Daz
Thomas Rheinegger
Daniel Reiser
Nicolae Bara
Thomas Stutz
Xavier Andries
August 2006
Definition of Maintenance
To maintain and restore the desired
condition
To define and assess the actual
condition
of technical assets.
(Equipment & Components,
Buildings, Spare Parts...)
August 2006
Evolution of Maintenance in Industry

Preventive
maintenance
Planned
maintenance
Break down
maintenance
Fix it when it
breaks
State of the art

Lubrication
Inspections
Relationship
between failure
probability and
age
Condition
monitoring
System for
planning and
controlling
Failure history of
parts and
equipment
Condition
based
maintenance
Interventions
based on
condition
Design for
reliability
Risk Assessment
Root Cause
Failure Analysis
August 2006
Weak Point Elimination

Requirement
Breakdowns eliminated
by removal of causes
Increased Availability
Optimum
Reduce # of stops / MTBF
Reduce Maintenance Cost
Requirement
Requirement
Causes of breakdowns do not

have to be continuously
repaired - elimination of weak
points
8
August 2006
Condition based
Maintenance
Maintenance
Planned
Maintenance
-B
yI
ents
Specific Measu
rem
Re
pl
ac
e
en
em
ac
W
alk
Re
pl
Corrective
Maintenance
Condition
Monitoring
ts
ns
,w
Vi
br
pe
el
at
ct
d,
io
i
o
et
Oi
nA
n
c.
lA
n
na
a
l
lys
y
We
is sis
ar
Me
a su
No
rem
n -D
ent
est
s
r
u
Mot
ctiv
or C
urre e Tes
ti
nt A
naly ng
Therm
sis
o gr a p
hy
n,
ea
cl
te
,
li b
ra
ca
at
e,
br
ic
Repair
Modification
Pareto Analysis
W
N
M
y
il i
ab nt
in poi
ta
in ak
Ma , w e etc.
y & nts on,
i
lit
bi me izat
lia ve
Re pro ptim
o
im
Lu
to
m
ite form
n
r
e a pe
or n n
st ca ctio
re i t
to ich fun
ns h d
io in w uire
ct
q
A tate re
s
a s it
et
c.
Se
rv
ic
e
Preventive
Maintenance
Root Cause Failure Analysis

Reliability Analysis
August 2006
Why do Major Equipment Breakdowns Occur?

Design and manufacturing of equipment
Inadequate quality of equipment
Operating limits
Improper operation
Maintenance
Not adequately maintained

Exceeded service life
Housekeeping
10
August 2006
Major breakdowns can be avoided
By correcting
equipment Design
(1/3)
By detecting defects during

the manufacturing phase Quality Control of Equipment
(QCE)
11
August 2006
(2/3)
By correct Operation
procedures
12
August 2006
Critical
Essential
$$$
Walk-Around
Data Collectors
and Analyzers
$$
Frequent
Cost of Lost Production
(3/3)
On-line
Surveillance
Systems
On line
Off line
Walk- Around
Inspection routines
Walk by
Years
Months
Gradual Degradation
Weeks
Days
Hours
Minutes
Seconds
Sudden Failure
Time to Failure
By establishing an appropriate Maintenance strategy

13
August 2006
Objective
Eliminate or reduce risk of major breakdowns
Pre-operation
Operation
Quality
Control of
Equipment
Condition
Monitoring
Design Review
Workshop Inspections
Baseline Determination
Installation and
Commissioning
Supervision
14
August 2006
Basis - What does QCE mean?
QCE means Quality Control of Equipment and is a

Quality assurance process applied during the design,
manufacturing, installation and commissioning of critical
components / equipment
QCE
15
August 2006
Why is QCE Necessary?

Do you want to stop your kiln
when the market is really
booming?
Have you got the time for this

repair if your silos are empty?
16
August 2006
Common Problems (QCE)

QCE-Statistics: Quality Level 2003
32%
47%
11%
Revision date:
4% 6%
Level of
complaint
without
small
medium
large
discarded
Total number inspections: 129

17
August 2006
Objective
Learn the key success factors of Condition Monitoring

to change from reactive to proactive Maintenance, because it is:
More Cost Effective

Ensures the Availability and Reliability of the equipment
to understand that condition monitoring without taking actions based on
data analysis is useless
18
August 2006
Operation - Condition Monitoring

What is Condition Monitoring?
Determine the condition of the equipment through

inspections at a given frequency
Identify and analyze deviations from required levels
Initiate actions to correct the situation
CM
19
August 2006
Walk-by inspections
Touch
Visual
Audio
Smell
20
August 2006
Walk-by inspections
21
August 2006
Off-line inspections
Misalignment
Unbalance
Lubrication
Looseness
22
August 2006
Off-line Inspections (Example: ID - Fan)
Breakdown,
Maintenance
emergency
23
August 2006
On-line Monitoring
Monitoring concept
Motor Monitoring
Reducer Monitoring
Rotation measurement
Motor Current (out of PLC System)
Temperature (out of PLC System)
Differential pressure (out of PLC System)
24
August 2006
On-line Monitoring (Example: Gear Coupling)
25
August 2006
Kiln Downtime Causes

The following is a typical breakdown of the downtime
causes for a kiln:

Frequency of shut-downs
Causes of shut-downs
80%
Brick lining failures
10%
Mechanical failures
6%
Electrical failures
4%
Others
26
August 2006
Radial Deformation and its Effect
27
August 2006
On-Line Inspections Kiln Shell Temperatures
28
August 2006
Objective
Learn key success factors for effective

Maintenance Planning
to ensure a consistent definition and understanding
of activities to optimize downtime and availability of

equipment
to ensure on time availability of resources and
preparation of work to avoid contingencies causing

additional maintenance expenses
29
August 2006
Maintenance Planning
Job Execution
Planned
Shutdowns
Three levels
Management System
Maintenance
Planning
Work Order System
of planning
Condition Monitoring
30
August 2006
The Maintenance Management System

Forecast
Plan
Report and
Data Analysis
Execution
Budget
Annual
Maint. Plan
Monthly
Prod. plan
13 week
plan
Monthly
Report
Monthly
Review
meeting
Weekly
Planning
meeting
Weekly
plan
Weekly
Report
DADA
Daily
meeting
Daily
plan
SIC
Daily
meeting
W/O
Daily
Report
Notification
31
August 2006
Master Schedule / Weekly / Daily Planning

Production plan
Maintenance
Master
Schedule
When to stop?
-Personnel
-Materials
-Tools
-Procedures
Weekly Plan
Daily Plan
Daily Work
32
August 2006
Work Order System

The Work Order is the vehicle of planning
Create
Notification
Unacceptable
condition
Root
cause
analysis
Create a
Work
Order
Plan
the
Order
Order
Confirmation
Condition
OK
Execution
Schedule
the Order
33
August 2006
Planned Shutdowns
It is a Plant event NOT a Maintenance event!!
MARKET
Shutdown
PEOPLE
EQUIPMENT
34
August 2006
The Scenarios : High Market Demand
High market demand
Focus on reducing execution time for activities

Ensure quality of work
Balance of cost vs duration of the shutdown is required
Opportunity cost for lost production
Availability and Reliability of equipment is critical

35
August 2006
The Scenarios: Low Market Demand

Low market demand
Focus on Cost reduction
Improve own labor productivity and quality of work

Optimize third party services
Optimize life of spares -higher risk vs higher cost
Time is less critical
36
August 2006
Planned Shutdown Process

A continuous cycle
Afte
r
Actio
n
Rev
iew
Definition
u
Meas
Analysis
Progress Review
es
v
i
t
Ac
vis
r
e
p
ion
Execution
ve
o
r
p
im
res to
Planning
Condition
Monitoring
Planning meetings
Cycle
Time
Comp
ressio
n
Preparation
37
August 2006
Objective
Learn key success factors for effective
Job Execution
to ensure work is done :
with the right quality in order to not having to

repeat it
within the allocated time in order to optimize
the equipment downtime
this has a direct impact on equipment
availability and maintenance expenses

38
August 2006
The Importance of Job Execution

The number of opportunities to do maintenance on the
equipment is limited
It is the time to improve the condition of the equipment
It is the most expensive phase in maintenance in terms
of time and money

It is where the quality of work must be emphasized
39
August 2006
The Pre-requisite to Job Execution

Condition Monitoring is the starting phase to job
execution and allows to prepare actions

The planning phase is the definition and preparation of
actions to ensure availability of resources
40
August 2006
The key points to good job execution

Spare parts
Tools
Measurement equipment
Competent people
Work Orders / Procedures
Short Interval Control / Execution follow up
Historical report / Knowledge sharing
41
August 2006
Short Interval Control / Execution Follow Up

Short Interval Control allows
To monitor and control losses versus a planned target
on a frequent basis by identifying problems which can

be corrected in a timely manner
To check the work status
To motivate people
42
August 2006
Short Interval Control / Execution Follow Up

Follow up of work on a frequent basis
Review meetings with comparison of plan vs. actual and
re-scheduling accordingly
Active supervision supporting and motivating workers
On-the-job-training, solving problems and giving advice
43
August 2006
Conclusions from these Maintenance Days

The first objective was:
Enhance understanding of the key success

factors in the Maintenance Process
Condition Monitoring: the basis to perform the right job!
Planning: a compulsory process to be prepared!
Job Execution: follow up to job execution is mandatory!
44
August 2006
Conclusions from these Maintenance Days

The second objective was:
Enhance understanding of the impact of

Maintenance on Manufacturing Performance
Maintenance
Production
Quality of Work
Job Execution
Duration of
Shutdowns
Planning
Major & Minor

Breakdowns
Condition Monitoring
Adequate
Equipment
Process
Parameters
Availability,
Reliability and
Maintenance
Spending
Operation
Materials/AFR
CAPEX
45
August 2006

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Maintenance

Introduction to Cement and Concrete

Objectives for Today

Enhance understanding of:

The key success factors in the Maintenance

The impact of Maintenance on Manufacturing

Holcim Group Support

Introduction to Cement Concrete & Aggregates

Holcim Group Support

Introduction to Cement Concrete & Aggregates

What are we doing?

To be the technical expertise turntable for maintenance in

Holcim Group Support

Introduction to Cement Concrete & Aggregates

Who are we?

Holcim Group Support

Introduction to Cement Concrete & Aggregates

To define and assess the actual

Holcim Group Support

Introduction to Cement Concrete & Aggregates

Evolution of Maintenance in Industry

State of the art

Holcim Group Support

Introduction to Cement Concrete & Aggregates

Weak Point Elimination

Reduce # of stops / MTBF

Reduce Maintenance Cost

Causes of breakdowns do not

Holcim Group Support

Introduction to Cement Concrete & Aggregates

Root Cause Failure Analysis

Holcim Group Support

Introduction to Cement Concrete & Aggregates

Why do Major Equipment Breakdowns Occur?

Inadequate quality of equipment

Not adequately maintained

Holcim Group Support

Introduction to Cement Concrete & Aggregates

Major breakdowns can be avoided

By detecting defects during

Holcim Group Support

Introduction to Cement Concrete & Aggregates

Major breakdowns can be avoided

Holcim Group Support

Introduction to Cement Concrete & Aggregates

Cost of Lost Production

Major breakdowns can be avoided

By establishing an appropriate Maintenance strategy

Holcim Group Support

Introduction to Cement Concrete & Aggregates

Holcim Group Support

Introduction to Cement Concrete & Aggregates

Basis - What does QCE mean?

QCE means Quality Control of Equipment and is a

Holcim Group Support

Introduction to Cement Concrete & Aggregates

Why is QCE Necessary?

Have you got the time for this

Holcim Group Support

Introduction to Cement Concrete & Aggregates

Common Problems (QCE)

Total number inspections: 129

Holcim Group Support

Introduction to Cement Concrete & Aggregates