Approach To Zero

Breakdown

YP Chawla
Hd. Energy Sector
Apollo Tyres

ypchawla@gmail.com
+91 98107 08707
 How much Time it takes to Replace a Car
Tyre ?

Replacing 4 Tyres ?

the sub-three
sub three second range to change a set of tyres!
The last time F1 had refuelling- recorded
tyre change in F1 – 3.2 seconds. -1993

F1 tyre change -2009. 2.6 seconds F1 tyre. Come on.......It is

near Zero Breakdown
Our Assets are our Cash Cows

Asset
Doctor
Drivers of the Today
Today’ss Economy
• higher returns
returns, higher growth , higher
productivity, with increased wage bills, fast
changing technologies , Capacity
Additions, slow down in economy
Zero breakdowns at our plants
Is it conceivable-or even desirable-to have zero
breakdowns?
Is it not a Political Statement only?

Zero Wastage
Zero Defect
Z
Zero Breakdown
B kd

‘Plant Maintenance’ on a much larger

g Canvass as
“Asset Management” elevating the
Maintenance Engineer to an “Asset Manager”
to a “Business
Business Leader”
Leader

Asset reliability benefits achieved exceeds the Cost of six

sigma
i reliability
li bilit
Inputs from other Industries

Fosbury
Basically
y a Gymnast
y - Not successful
Applied principles of Gymnastics to High Jump
Result - A Quantum Jump

Inputs from Other Industries - Innovation

• Asset Management–a
g Business Objective
j
• Role of Asset Manager gets enlarged in this
competitive world, ensuring that nowhere in this
world, another company having the same assets
which produce greater capacity from those similar
assets than his Assets –thus getting the most out of
the assets
• Return on Net Assets (RONA) or Return on Fixed
Assets (ROFA) – the Banker’s requirements.
• Key
K Result
R lt A
Areas (KRA
(KRAs))
• Networking by the Asset Managers
 Aligning - maintenance
strategies to Breakdown curve 2
Predictive maintenance condition-
3
Corrective maintenance
reactive-based strategies
based strategies
Failure Repair
occurs schedule
h d l
d Parts, manuals
Failure
X reporte & tools
nce

X Vibration d located
X Oil
erforman

X
Noise
1 X
Preventive maintenance time-
Heat
Pe

and usage-
usage
X
based strategies

Time
 Design for Maintainability
Prepare operational specifications and
Evaluate procedures,, develop
p p maintenance and Maintainability checks RCM
development options inspection strategies, prepare input to asset
reference plan, develop facility data

Design & Plan

Development
p design
g
construction
t ti

Review and update

maintenance
strategies,
Improve Schedule
Decide
D id on performance
performance,
remedy or estimates, reference
improvement (or plan, FEMCA
abandonment) Schedule asset related
work
Ab d
Abandonment
t
Analyze
Identify and
Execute
define
ORDM Analysis
unforeseen
of asset
work
performance
f and
d
maintenance
system
effectiveness
 Transition
T iti tto Planned
Pl d
Maintenance Unplanned cost
+
Planned cost

M
Mapping
i ttotal
t l costt – the
th practical
ti l side
id Total cost

Time/Usage

Y1 Y2 Y3 Y4 Y5 Y6 Y7 Y8 Y9 Y10 Y11 Y12

Design Detection of Failure Sources

Breakdown / Reliability + Design

Reliability Planned
Assessment Reliability

Decision Asset Management

Business Processes

Asset Management
Plans
Strategic
Initiatives

Annual Budgets

Operating Budget Capital Budgets

• Electronics & Instrumentation – A Boon & A
Challenge
• A Caveat The Computer Connected Machines are now
being challenged by Computer Virus sent for various
Soft Ware installed in Machines to score a point over
Competitors of Similar asset manufacturers, owners, and
th Software
the S ft suppliers.
li
• Organizational Structure
• Companies
Companies’ Policies
• Human Asset Development for Plant Assets
Management
• Outsourcing
Consumption of Inputs - More Rejunavate

Renovate
• Concluding Remarks: Successful Zero Breakdown
Maintenance is built on the following Hall mark
fundamentals:
• Zero breakdown equipment needs quality design, low-
stress and less fatigued parts kept in good health.
• Zero breakdown maintenance - to stop human error from
causing
i plant
l t andd equipment
i t ffailures
il needs
d a tteam off
Talented Top Persons geting involved right from Indenting,
Procurement, Selection & Design Stage, Know the
Financials returns on Asset Capital Cost and can
Financials,
undertake work in pressure conditions with a good team
work with appropriate updating in knowledge for the Vital
Equipment, processes, Processes, economics of
outsourcing Maintenance, IT’s role, Removing operational
risks of the Asset & Plant for benchmarking the
Performance with integrated operational risk management
across the
th equipment
i t life
lif cycle
l , and d th
the B
Bestt P
Practices
ti iin
Maintenance and Reliability.
• A Parting suggestion Organizations need to redefine
what businesses they're in and want to be in, re-
evaluate processes, rationalize systems, benchmark
and measure, and create new sources of revenue out
of its Operations of World-Class Maintenance
Management Success.

Dynamic role of an Asset Manager can help connect

silos, help standardize and analyze what's going on, and
build-in
build in agility in the Organization
Organization. It is a time full of
opportunities & Challenges for An Asset Manager
Navigating Personnel issues and Continuous knowledge
updating g comes down to effectively y managingg g&g getting
g
the best returns from the critical assets – a hallmark of
Zero Breakdown Strategies
•PRIORITISE
PRIORITISE THE ASSEST MANAGEMENT PROJECTS
• ASSIGN SPECIFIC RESPONSIBILITY TO EACH
TEAM MEMBER
• INTRODUCE CROSS FUNCTIONAL WORK GROUP
• IMPLEMENTATION PLAN - WITH TIME AND
TARGET
• MONITOR PROJECT BY PROJECT- ACTIVITY BY
ACTIVITY
Thanks for
associating
with Zero
Breakdown