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BEST MAINTENANCE PRACTICES IN PULP & PAPER MILLS TO IMPROVE PROFITABILTY BEST MAINTENANCE PRACTICES IN PULP & PAPER MILLS TO IMPROVE PROFITABILTY Slide.

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Presentation on theme: "BEST MAINTENANCE PRACTICES IN PULP & PAPER MILLS TO IMPROVE PROFITABILTY BEST MAINTENANCE PRACTICES IN PULP & PAPER MILLS TO IMPROVE PROFITABILTY Slide."— Presentation transcript:

1 BEST MAINTENANCE PRACTICES IN PULP & PAPER MILLS TO IMPROVE PROFITABILTY BEST MAINTENANCE PRACTICES IN PULP & PAPER MILLS TO IMPROVE PROFITABILTY Slide No. 1 JK PAPER LTD. UNIT: CPM IPPTA PRESENTATION BEST MAINTENANCE PRACTICES FOLLOWED AT JK PAPER LTD TO IMPROVE PROFITABILITY 18 July Presented by: Sandesh Joshi

2 BEST MAINTENANCE PRACTICES IN PULP & PAPER MILLS TO IMPROVE PROFITABILTY BEST MAINTENANCE PRACTICES IN PULP & PAPER MILLS TO IMPROVE PROFITABILTY Slide No. 2 CPM Present Capacity, TPA Pulp & Paper PlantPackaging Board Plant Commenced production in 1968 Acquired by JK Group in 1992 Turn around in Capacity: 55,000 TPA Products: Cut size multi purpose office paper and security paper Commenced production in 2007 Capacity: 90,000 TPA Products: Multi Layer Packaging Boards

3 BEST MAINTENANCE PRACTICES IN PULP & PAPER MILLS TO IMPROVE PROFITABILTY BEST MAINTENANCE PRACTICES IN PULP & PAPER MILLS TO IMPROVE PROFITABILTY Slide No. 3 PROFITABILTY India is a fast developing nation. To accelerate Economic Growth, Indian Business community has to invest into manufacturing sector, produce Qualitative as well as Quantitative products as per International standard at lowest possible manufacturing cost. Maintenance of heavy machinery is a major share in manufacturing cost. Best Maintenance Practices include powerful techniques to maximize uptime of machinery at lowest maintenance cost. This leads to profitability Good maintenance practice is one of the keys to increasing productivity and profits Produce qualitative as well as quantitative products Changing Customer Priorities Shareholder Wealth / Profit Migration Best Maintenance Practice Maintain International Products Standard Generates value, profit and wealth Lowest manufacturing cost Increase productivity

4 BEST MAINTENANCE PRACTICES IN PULP & PAPER MILLS TO IMPROVE PROFITABILTY BEST MAINTENANCE PRACTICES IN PULP & PAPER MILLS TO IMPROVE PROFITABILTY Slide No. 4 BRIEF MANUFACTURING PROCESS OF MULTI LAYER PACKAGING BOARD Pulping Screening & cleaning Thickening Refining Blending Dilution, centricleaning and screening Sheet formation & consolidation Drying Surface sizing Calendaring 3 Stage coating & IR Drying Reeling Rewinding Sheeting & Packing Storage in godown Dispatch

5 BEST MAINTENANCE PRACTICES IN PULP & PAPER MILLS TO IMPROVE PROFITABILTY BEST MAINTENANCE PRACTICES IN PULP & PAPER MILLS TO IMPROVE PROFITABILTY Slide No. 5 JK PAPER LTD – CPM UNIT – MAINTENANCAE POLICY JK Paper Unit; CPM is committed to maintain ZERO BREAKDOWNS and ZERO REPETITIVE FAILURE through:  Deployment of combination of Time Based (TBM) and Condition Based Maintenance (CBM).  Optimization of Processes, Plant and equipment efficiency.  Identify and evolve Best maintenance solutions through Preventive Maintenance (PM),  Maintenance Prevention (MP) and Maintainability Improvement (MI) to suit individual Equipment.  Establishment of effective training mechanism and motivational policies to engage maintenance crew to achieve common Goal – Trouble free Production.  Identifying and eliminating non-value adding processes and production bottlenecks.  Cost reduction through innovative Cost Compression Schemes.  Equipment protection, security and safety with environmental and other applicable statutory compliances.  Nurturing Team work and Development of Individual skill at all levels.  Creating lively, energetic, healthy and safe work environment.

6 BEST MAINTENANCE PRACTICES IN PULP & PAPER MILLS TO IMPROVE PROFITABILTY BEST MAINTENANCE PRACTICES IN PULP & PAPER MILLS TO IMPROVE PROFITABILTY Slide No. 6 MAINTENANCE PRACTICE STEPS STEP BY STEP - PLANNED MAINTENACE

7 BEST MAINTENANCE PRACTICES IN PULP & PAPER MILLS TO IMPROVE PROFITABILTY BEST MAINTENANCE PRACTICES IN PULP & PAPER MILLS TO IMPROVE PROFITABILTY Slide No. 7 CATAGORISATION EQUIPMENT According to Equipment contribution in Production, equipment categorized in ABC Critical group. A.Critical Equipment B. Sub-Critical Equipment C. Non critical Equipment

8 BEST MAINTENANCE PRACTICES IN PULP & PAPER MILLS TO IMPROVE PROFITABILTY BEST MAINTENANCE PRACTICES IN PULP & PAPER MILLS TO IMPROVE PROFITABILTY Slide No. 8 EQUIPMENT DATA SHEET Equipment data sheet contains information regarding Specification, MOC, Drawing details, Lubrication details & Spare details.

9 BEST MAINTENANCE PRACTICES IN PULP & PAPER MILLS TO IMPROVE PROFITABILTY BEST MAINTENANCE PRACTICES IN PULP & PAPER MILLS TO IMPROVE PROFITABILTY Slide No. 9 BASIC OF ALL MAINTENANCE ACTIVITIES IS 5S PRACTICE

10 BEST MAINTENANCE PRACTICES IN PULP & PAPER MILLS TO IMPROVE PROFITABILTY BEST MAINTENANCE PRACTICES IN PULP & PAPER MILLS TO IMPROVE PROFITABILTY Slide No. 10 MAINTENANCE PRACTICE STEPS STEP BY STEP - PLANNED MAINTENACE

11 BEST MAINTENANCE PRACTICES IN PULP & PAPER MILLS TO IMPROVE PROFITABILTY BEST MAINTENANCE PRACTICES IN PULP & PAPER MILLS TO IMPROVE PROFITABILTY Slide No. 11 EQUIPMENT HISTORY REGISTER Maintaining History register in soft copy helps retrieving information related to equipment. Area wise Equipment listed in excel sheet with asset no. Each equipment hyperlinked with, 1.History of jobs carried out 2.Specification with drawing details 3.Spare list with ERP code 4.SOP (Standard Overhauling procedure ) 5.Modification done if any

12 BEST MAINTENANCE PRACTICES IN PULP & PAPER MILLS TO IMPROVE PROFITABILTY BEST MAINTENANCE PRACTICES IN PULP & PAPER MILLS TO IMPROVE PROFITABILTY Slide No. 12 SOP – STANDARD OVERHAULING PROCEDURE SOP sheet contains details like dismantling & assembling procedures with check point, tools used & safety measure

13 BEST MAINTENANCE PRACTICES IN PULP & PAPER MILLS TO IMPROVE PROFITABILTY BEST MAINTENANCE PRACTICES IN PULP & PAPER MILLS TO IMPROVE PROFITABILTY Slide No BREAKDOWN MAINTENANCE Allow run machinery till failure. Repair or Replace equipment when obvious problem occurs. 7QC tools applied to study break downs. Find out root cause. Action plan prepare & implemented. Also Horizontal application formulated. 2. TIME BASED MAINTENACE (TBM) Schedule maintenance activities at per determined interval. Repair or replace equipment when obvious before problem occurs. TBM strategy followed in critical category equipment such as Pressure Screen, Rolls- Wire, Press, MG, Calendar. TBM jobs are planned in advance in details & clubbed with Shut down planning. Spare sub assemblies are kept ready to minimize replacement time. 3. CONDITION BASED MAINTENANCE Schedule maintenance activities when Mechanical or operational condition warrants. Repair or Replace equipment when obvious problem occurs. By continuous monitoring parameters like temperature, Vibration, Load, Noise level etc trends are plotted. Examine deviation with standard. Based on conclusions, Maintenance jobs are planned & clubbed with shut or opportunity. MAINTENANCE ACTIVITY 1. BREAK DOWN MAINTENANCE 2. TIME BASED MAINTENANCE (TBM ) 3. CONDITION BASED MAINTENANCE (CBM)

14 BEST MAINTENANCE PRACTICES IN PULP & PAPER MILLS TO IMPROVE PROFITABILTY BEST MAINTENANCE PRACTICES IN PULP & PAPER MILLS TO IMPROVE PROFITABILTY Slide No. 14 BREAKDOWN ANALYSIS FORMAT BREAK DOWN MAINTENANCE Basically it is activity of restoring equipment to make available for production. To avoid such unplanned failures following steps has been taken, 1.Prepare detailed analysis using 7QC tools 2.Collect details of incurred losses & cost – Direst & Indirect 3.Record findings & Kaizens plans for its implementation.

15 BEST MAINTENANCE PRACTICES IN PULP & PAPER MILLS TO IMPROVE PROFITABILTY BEST MAINTENANCE PRACTICES IN PULP & PAPER MILLS TO IMPROVE PROFITABILTY Slide No. 15 CASE STUDY NO.# 1 ( REPITATIVE FAILURE) Problem faced – Frequent Failure of Drive Motor Bearings - Drive Units 108 nos Root Cause – Generated Eddy currents flow through Bearing. Root Cause elimination suggestion - Replace regular bearing with Insocoat type Bearing. Fluting due to Flow of Eddy Current Inner Race Outer race Action Taken – One time replacement of bearing is Practically & Commercially not viable. After brain storming session, our electric team formulated action plan to provide proper earthing mechanism to carry away Eddy currents without harming Bearing. As per action plan, team separated all drive motors & Drive Units earthing electrodes. Individual Parallel earthing provided at Drive unit & Motor. This arrangement provide less resistance path for Eddy current passage.

16 BEST MAINTENANCE PRACTICES IN PULP & PAPER MILLS TO IMPROVE PROFITABILTY BEST MAINTENANCE PRACTICES IN PULP & PAPER MILLS TO IMPROVE PROFITABILTY Slide No. 16 CASE STUDY NO.# 2 (CONDITION MAINTENACE) Problem faced – Inaccessible Dryer Fabric roll Bearing failure Root Cause – Condition monitoring of rolls not possible as they covered by Hood. Root Cause elimination suggestion - Provide online Temperature indication mechanism & Lubrication arrangements. Action Taken – Bearing housing of DFR in inaccessible location fitted with RTD units. Signals carried from RTD through wires are processed & displayed at Controller cum Display unit in Operating desk. Alarm siren & Red light glow up, when Bearing housing Temperature rises than pre defined set point through DCS system. For lubrication purpose, Tubing arrangements done as accessible from floor level.

17 BEST MAINTENANCE PRACTICES IN PULP & PAPER MILLS TO IMPROVE PROFITABILTY BEST MAINTENANCE PRACTICES IN PULP & PAPER MILLS TO IMPROVE PROFITABILTY Slide No. 17 CASE STUDY NO.# 3 (DESIGN WEAKNESS) Problem faced – High Structural Vibration level in Coater unit – 6mm/s Root Cause – Protruded DFR fitting brackets at height rattle induce high vibration in structure. Root Cause elimination suggestion - Install crosswise members in M/c structure Action Taken – Fabricated Tie rods are installed crosswise in Coater unit Structure to dampen vibrations. Tie Rod

18 BEST MAINTENANCE PRACTICES IN PULP & PAPER MILLS TO IMPROVE PROFITABILTY BEST MAINTENANCE PRACTICES IN PULP & PAPER MILLS TO IMPROVE PROFITABILTY Slide No. 18 CASE STUDY NO.# 4 (DESIGN WEAKNESS) Problem faced – Frequently failure Paper roll Gear motors. Root Cause – 4 nos VFD Drive runs 16nos Paper roll Gear motor. Grouping Paper rolls in single VFD makes difficult in speed synchronizing, cause frequently Paper roll Gear motor failure. Root Cause elimination suggestion - Install separate VFD drive for each Paper roll. Action Taken – Electric Dept install new 12nos VDF drives for drive separation. Now each paper roll can run at required speed as per its location. This arrangements eliminates any adverse effect of one Gear motor failure as previously happening in grouping system. Load shearing on electrical system improved a lot.

19 BEST MAINTENANCE PRACTICES IN PULP & PAPER MILLS TO IMPROVE PROFITABILTY BEST MAINTENANCE PRACTICES IN PULP & PAPER MILLS TO IMPROVE PROFITABILTY Slide No. 19 CASE STUDY NO.# 5 (QUALITY MAINTENANCE) Problem faced – Physical defects like Blotches and Stamping etc are escaping to the consumer. Root Cause – At Reel speed 350 MPM, human eye can’t detect these physical defects. Root Cause elimination suggestion - Installation of On-line Web inspection system. Action Taken – Commercially available Web Inspection system cost Rs.2.0 Caror. It was thought to have some indigenously developed solution to curb this holes problem in paper board. Web inspection system consist – Laser Emitters & receiver system: Principle of Triangulation, detect hole >9mm. Auto Marking system: Activated when Blotch passed & auto blue marking on web edge. Developed page in DCS for Blotch records: Roll no., exact defect length on parent roll, trends etc. Alarm system garb attention of near by operator. Blue Dye markings Alarm System DSC panel for record Laser Sensor Blotch Detected Auto Marking system

20 BEST MAINTENANCE PRACTICES IN PULP & PAPER MILLS TO IMPROVE PROFITABILTY BEST MAINTENANCE PRACTICES IN PULP & PAPER MILLS TO IMPROVE PROFITABILTY Slide No. 20 SAFETY Safety measurement taken to safe guard  Occupants  Equipments  Raw & Finished product.  Company's Property CASE STUDY NO.# 6 ( SAFETY MAINTENANCE) Problem faced – Fire occurs at IR ( Infra red ) dryer propane gas operated in coater unit during power failure Root Cause – Power failure mode, fire fighting pump can’t start to provide water for fire extinguisher system. Root Cause elimination suggestion - Auto Fire extinguisher system which can start in power failure mode also. Action Taken – In power failure, Board web in front of IR ( Infra red ) Dryer, Propane gas operated catches fire. Previous arrangement of Fire Extinguisher run by Fire Fighting pump fail to provide water in Power failure mode. Delay in in Fire extinguish, may damage Backing roll, Dryer screen & Broke conveyor screen. Auto fire extinguisher installed in coater unit, which pump run by UPS. Water tanks provided at 15 mtrs height provide water with positive head, for Fire extinguish shower unit at Coater unit. IR IR DRYER P BACKING ROLL SHOWER WATER TANK

21 BEST MAINTENANCE PRACTICES IN PULP & PAPER MILLS TO IMPROVE PROFITABILTY BEST MAINTENANCE PRACTICES IN PULP & PAPER MILLS TO IMPROVE PROFITABILTY Slide No. 21 MAINTENANCE PREVENTATION Maintenance prevention activity impart on equipment’s,  Reliability,  Maintainability,  Economy, Operability,  Safety & flexibility,  Minimize Life Cycle Cost (LCC) CASE STUDY NO.# 7 ( MAINTENANCE PREVENTATION) Problem faced – Metal pipe carrying PAC –highly corrosive chemical, corroded heavily & wastage through leak. Root Cause – PAC chemical highly reactive towards Ferrous metal. ETFE coating coated on metal pipe also deteriorated by chemical action. Root Cause elimination suggestion – Replace metal pipe with chemically inactive make. Action Taken – PVC grade Teflon coated 3 layered pipeline replace ETFE coated metal pipe in PAC chemical supply line ETFE coated pipeline replacement cost Rs 90,000/- per year. One time replacement cost is Rs 60,000 /- Life expectance 10years for 3layered Teflon coated PVC grade pipeline PAC Storage P PAC Service M/L White Water Channel B/L White Water Channel T/L White Water Channel PPP 3 Layered Teflon coated PVC grade Pipe

22 BEST MAINTENANCE PRACTICES IN PULP & PAPER MILLS TO IMPROVE PROFITABILTY BEST MAINTENANCE PRACTICES IN PULP & PAPER MILLS TO IMPROVE PROFITABILTY Slide No. 22 Import substitution is attempt to reduce foreign dependency for particular equipment and service. Company benefited by import substitution activity in terms of,  Reduce input & Inventory cost  Shortened lead time – Procurement of spare  Development of domestic industry  Support to Indian Self –reliant policy IMPORT SUBSTITUTION TRAINING HRD take initiative in conducting training & development programs for our work force.  Training impart to maintenance crew on Technical, Self management & Safety.  Both On job & Off job training conducted out by Subject Expertise either Internal or External.  Training hall equipped with Audio – Visual system with ergonomically designed seating arrangements.  Technical books along with Literature, Issues, Manuals made available for reference.  Get-Together programs arranged for sharing Knowledge across work force in conducting environment.

23 BEST MAINTENANCE PRACTICES IN PULP & PAPER MILLS TO IMPROVE PROFITABILTY BEST MAINTENANCE PRACTICES IN PULP & PAPER MILLS TO IMPROVE PROFITABILTY Slide No. 23 EFFECTIVENESS OF SHUT DOWN MAINTENANCE Increase in effectiveness of Shut Down Maintenance depended on.  Reduction in shut down numbers. - Clubbing various jobs, Equipment Life enhancement  Reduction in Shut down time. – Use of Advance Tool & Tackles, Critical path methodology.  Reduction in shut down cost - Spare management, Optimization in Man power deployment FINAL RESULTS 1. BOARD PLANT MAINTENANCE COST

24 BEST MAINTENANCE PRACTICES IN PULP & PAPER MILLS TO IMPROVE PROFITABILTY BEST MAINTENANCE PRACTICES IN PULP & PAPER MILLS TO IMPROVE PROFITABILTY Slide No OVERALL EQUIPMENT EFFCTIVENESS (OEE)

25 BEST MAINTENANCE PRACTICES IN PULP & PAPER MILLS TO IMPROVE PROFITABILTY BEST MAINTENANCE PRACTICES IN PULP & PAPER MILLS TO IMPROVE PROFITABILTY Slide No BREAK DOWN CHART End of Presentation…


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