Contribution of Planned

Maintenance

8th TPM National Conference

18 19 March 2008: Chennai

Objectives of Planned Maintenance

1) Accomplishing zero failures and zero defect activities to enhance maintenance
technology and skills, to expand equipment MTBFs and to shorten equipment MTTR
2) Reducing input by activities to make equipment maintenance efficient
Functions of equp. Can be
demonstrated satisfactorily
whenever required

Accomplish
purpose best

Purpose of planned
maintenance
At Minimum cost

Keep means at
minimum

Approach

Step 1

Support and guidance of Jishu

Hozen activity & Evaluation of
Equipment Failure and
understand situation

Step2

Reverse Deterioration &

Correct weakness

Step3

Build an Information
Management system

Step 4

Build Periodic Maintenance

system

Step 5

Build Condition Based

Maintenance System

Step 6

Evaluate the Planned

Maintenance system

Criteria for Ranking

Use of Equipment
History Card
HINDUSTAN LEVER LIMITED
BEVERAGES FACTORY ,SAYLI
SILVASSA
Location
Item description :Total Nos :Supplier name & address :

Packing hall
Blending Machine

Evaluation
Element
S
Safety/
Environment

1 nos.
M/s. Pranson & Co.,
P 292/2 , Banaras Road , Howrah - 711108
Ph - 033 - 6516609 / 6512143/6512143

Specifications
Blending drum Details

Q
Quality and Yield

Capacity - 1400 kg of Tea

RPM - 22
MOC - MS.
Motor Make - NEC. Motors
Kw - 3.7
Hp - 5hp
Volts - 415v / Delta
Ampere - 8 amps
RPM - 1450
Bearing & Oilseals Bearing No- 6309 SKF
Oil Seal No- 50x72x10
Gear BoxMake - Greavs
Type - U - 500
Ratio - 40:1 L
Sr No -2BF 60096

W
Working
(operating )
Status
D
Delay factor
(opportunity
cost)

A Rank

B Rank

Equipment failure
with a possibility
resulting in an LTA
/ or causing a
serious
environmental case
Equipment whose
failure which cause
A / B defect or
result in a
consumer
complaint.
Working 24 hours
with non stop
operation

Equipment failure
With a possibility
of a reported
injury

Machines failure
with no injury
implication

Equipment whose
failure would
result in C and D
defect

Equipment whose
failure does not
affect the quality.

Batch operation
for 24 hours

Operation for a
few hours a day

Failure which would

Shut down the
entire Cascade
operation

Failure which
would result in
shutting part of
one cascade

Failure of once or
more in a Week

Failure of once in
a month

Equipment failure
which would not
result in
production
stoppage
Failure of less than
once in a quarter

Repair time of more

than 8 hours or
cost more than
10,000

Repair time of
more than 4
hours less than 8
hour cost
between 5000
and 10000

Shift vibrator Mesh size - 6 mm Up

Mesh size - 16 mm Down
Motor Make - NEC. Motors
Kw - 2.2

P
Period( interval
Between failure)
M
Maintainability

C Rank

Repair time less

than 4 hours and
repair cost of less
than 5000

A
B
C
Equip Equip Equip

Maintenance Management Process

Planned
Maintenance

Jishu Hozen

Find
abnormalities

Correct
Abnormalities

Breakdown
Maintenance

Corrective
Maintenance

Time Based
Maintenance

Condition Based
Maintenance

Why Why
Analysis

Improvement in
MTBF / MTTR

Identify TBM

Monitor / Restore

Countermeasures
Daily
Cleaning,
Lubrication &
Inspection

Perform TBM
Spare Part
Management

Zero Equipment
Failure

Cost Monitor /
Control

Support Jishu Hozen

Jishu Hozen

Planned Maintenance

Step 1 - Initial Cleaning

Support for red tag

strategy

Step 2 Countermeasures

Countermeasures for
Sources of contamination
Support
Activities

Step 3 - Tentative
standards

Support for Cleaning &

Lubrication standard
strategy

Step 4 - Equipment
knowledge & Inspection

Education on General
Inspection

Breakdown Maintenance
Equipment
Failure
Occurrence

Poor Jishu
Hozen
Poor Planned
Maintenance

Immediate
Repair
Breakdown
Maintenance
Record

Poor Design
Why
Why
Analysis

Kaizens for repetitive

failures

Tools

Poor Skill

Update JH
Standard

JH Standard
OPLs

Update
TBM/ CBM

TBM / CBM

Strengthen
Design

M.P Sheet

Training

OPL, OJT

No

Chronic
Stoppages

Yes

Circle
activity

WWBLA
Analysis, 5 W
, PM Analysis

Kaizens

Summarize
and Review
the data

Zero
Equipment
Failure

Building Information Management System

w
o
D

im
nt

m
su

y
ar
m
o
et
r
Pa

F
TB

s
ne trie
i
h n
ac e e
M im
nt
w
do

nd
e
tr

s
si
y
al
n
A

p
Re

M
TB eet
&
I ksh
L
C ec
Ch

ts
r
o

Nakano Sans approach for ZERO

Failures
Life extension 1 Restoration to
basic condition

Life extension 2
Kaizen on
weaknesses (CM)

Time

Inspection

Standard
Forced
deterioration

Breakdown

Natural
deterioration

Condition Based Maintenance

(measurement diagnosis of
deterioration)

Degree of deterioration

Restoration

Limit line

Historical perspective:

Maintenance Strategy

Proactive Maintenance

Predictive Maintenance

Preventive Maintenance

Technique Needed

Human Body Parallel

Monitoring & correction of

failure root causes,
e.g., contamination
Monitoring of vibration,heat
Alignment,wear debris
(condition monitoring & analysis)

Cholestrol and blood

pressure monitoring with
Diet control
Detection of heart diseases
using ECG or Ultrasonics

Periodic component replacement

By-pass or transplant
surgery

Breakdown Maintenance Large maintenance budget

Heart attack or stroke

Contribution of PM in Haldia plant

Haldia Detergents Factory

About Unilever
UNILEVER WORLDWIDE
Unilever is a Fortune 500 company
Turnover of 39.6 Billion Euros (2006)
It employs 2,47,000 employees
The operation of Unilever extends over 150 countries
Business Groups broadly classified into 2 categories
- Home and Personal care
- Foods

HINDUSTAN UNILEVER LIMITED

HUL is a 51% subsidiary of Unilever
Total sales for company is US $ 2.7 billion (2006)
It employs about 40,000 employees
It has over 100 Units across India. TPM in all key
factories.
The distribution network consists of 7000
redistribution stockists and 4.8 million retailers
Share holder - 3,51,415

About HUL Businesses

Haldia Products

Businesses

Home & Personal Care

Personal Wash, Fabric Wash,

Household Care, Oral Care, Skin Care,
Color Cosmetics, Baby Care, Adult Care,
Feminine Hygiene Care

Home & Personal Care

Foods & Beverages
Tea, Coffee, Cooking Fats & Oils, Dairy
Products, Ice Creams, Tomato Products,
Fruit & Vegetable Products, Staples Rice, Salt, Atta and Rava, Marine
Products

Foods & Beverages

Business Share

HUL : Turnover

Blown Route Volume %

FW Volume %
120

140000

100
120000

100

Blown Route
Powder 11%

80

100000

HPC
PW-24%

60000

HHC - 8%
40000

20000

FW - 30%

Others
Foods

60

40

20

Skin Care - 18

HALDIA 58%
Dry Mix
Powder
89%

Volumes %

80000

Volumes %

Rs. Millions

80
60

40

CHIPLUN 15%
20

RAJPURA 27%

Hair Care - 7%
Oral Care - 15%

Bars

National Volume of FW Blown route distribution across the various Factories

Haldia Factory is important unit for Fabric Wash Business
(It is the largest Spray Drying Facility for Detergents in India)

About Factory An Overview

Factory View

Real Estate
Land area

10 acres

Covered area

05 acres
Packing Floor

Capacity & Investment

Production capacity

60,000 TPA

Total connected load

2100 HP
HP Pump area

No. of vehicles handled/day

100 (avg)

No. of Employees

200

5 BRANDS

Capable of producing different

types powder in the same plant

40 SKUs

One of the major contributor

Of blown powder in HUL

BLOWN ROUTE PROCESS PLANT

LABSA SILICATE NaOH

H2O

P
P
T
S

T
L
A
S

A
D
O
S

AIR-LIFT
SEPERATOR SILO
AIR-LIFT FAN
WEIGHING
HOPPER

VIBRO SCREEN

CRUTCHER

BLOWING
TOWER

98 C
HOT-AIR OUT

AGGING
VESSEL

BASE
POWDER
BD BELT

HOT-AIR IN

REITZT MILL

375 C

E
N
I
L
T
IF
L
IR
A

SILO

POST DOSING

40 BAR

LP PUMP

HP PUMP

FINISHED
PRODUCT

BUGGI
ES

HIGH PRESSURE PUMP

NEED FOR HP PUMP RELIABILITY

PRODUCTION DEMAND
60000
50000

G
O
O
D

40000

Ton

60000

30000
20000

31000

35000

2005

2006

41000

10000
0

2007

2008

300
275
250
225
200
175
150
125
100
75
50
25
0

8
7
6

148

G
O
O
D

150

Hrs.

G
O
O
D

Hrs.

YEAR

5
4
3

G
O
O
D

2
1
0

2005

YEAR FH 2006

MTBF OF HP-PUMP

2005

FH 2006
YEAR

MTTR OF HP-PUMP

NEED FOR HP PUMP RELIABILITY

50
45

100
90

40
35

80
70

30
25
20

60
50
40

25
18

15
10

30
20

Lube Oil P ump

Bush Be a ring of

5
0
Art ic ula t e d
Conne c t ing Rod
Bush

P lunge r Gla nd S e a l Cross He a d P in

NRVS e a t

Parts name

Cra nk J urna l

P lunge r

Cross He a d

10
0

Nos of Break Down

Parts break down pareto of HP Pump

G
O
O
D

THEME
To Achieve improvement in reliability of
HP Pump to increase production

TARGET
60000
50000

G
O
O
D

40000
Production
( Ton )

30000
20000
10000
0

Production

2005

2006

2007

2008

31000

35000

41000

60000

1000
800

G
O
O
D

600
M T BF
( Hr. )

400
200
0

Target M TBF

2005

2006

2007

2008

148

350

750

950

2005

2006

2007

2008

1.4

G
O
O
D

3
MTTR
(hrs.)

2
1
0

Target M TTR

DATA COLLECTION
HP-PUMP SPECIFICATION
CATEGORY OF THE EQUIPMENT A

CLASS

EQIPMENT NAME APGV HIGH PRESSURE PUMP.

LOCATION - GROUND FLOOR
SUPPLIERS BALLESTRA SPA (ITALY)
MODEL NO. C2B28
PUMP TYPE 6110
YEAR OF MANUFACTURING 2001

HP-PUMP FAILURE ANALYSIS

Part name

No of failurs

Plunger Seal
Articulated Connecting Rod Bush
Cross Head Pin
NRV Seat
Lube Oil Pump
Bush Bearing of Crank Jurnal
Plunger
Cross Head

47
18
6
5
3
3
2
2

ORIGINAL COST RS. 10 MILLION.

DESIGN PRESSURE 70 KG / SQCM
LIQUID HANDLEED DETERGENT SLURRY
LIQID TEMPERATURE 8O C
NOS. OF VALVES 24
SUCTION PRESSURE 1 TO 4 KG / SQCM

12

HP PUMP STOP

OPERATING PRESSUR 40 TO 50 KG / SQCM

HP PUMP START

Lube oil Pr. (Kg/cm2) & H

10

DETORIARATION OF BUSH & BEARINGS

DUE TO INSUFFICIENT LUBE OIL PR.
DURING EVERY START-STOP OPERATION
OF HP-PUMP (DRY RUN)

OPERATING SPEED OF THE PUMP (5 NOZZLES

OPERTION) 34 STROKES / MIN @ 11.5 Hz

LUBE OIL PR. FALL

4
LUBE OIL PR. RISE

0
1

8 15

8 15

HP-PUMP DRY RUN 20 SEC

HP Pum p Opra ting Hz.

8 15

Tim e (Se c)

Lube Oil Pr Rise & Fa ll

Lube Oil ope ra ting Pr

HP-PUMP PRESSURE DATA

DATA COLLECTION
NO. OF START-STOP IN HP PUMP PER DAY
25

20

15

NOS.
10

20
16

14

2005

2006 FH

YEAR

2006 SH

TPM ANALYTICAL TOOLS USED

TO IMPROVE RELIABILITY OF HP-PUMP
IMPROVEMENT ON MTBF
AREA OF CONCERN

ANALYTICAL TOOLS
USED

COUNTER MEASURES PROVIDED

KAIZEN

Lub oil pumping system

WWBLA

Separate motor driven oil pump with improved inter lock

K1

Pre mature failure of gland seals

WWBLA

Change of MOC of bellow

K3

Scoring marks on plunger

Why - Why

Change of MOC of seal ring

K2

LUb oil Pump

WWBLA

Double pressure switch provide

K1

Chocking of gland seal water line

Why - Why

Pressure switch provided

K8

SL.No.

IMPROVEMENT ON MTTR
SL.No.

AREA OF CONCERN

ANALYTICAL TOOLS
USED

COUNTER MEASURES PROVIDED

KAIZEN

Plunger removal time

Why - Why

Internal thread provided

K4

Plunger installation time

Why - Why

Jig made for installation

K5

Seat removal & installation time

Why - Why

Jig made for installation

K6

2.1. Deterioration or poor

quality of lubricating oil

Go

No
2.1.1 By CBMS techniqe LubeGo
oil quality checked & found ok

Phenomenon

2.2. Low Lube-oil level in crankGo

case.

No
2.2.1 Regulerly checked & and Go
lube-oil level is OK

Frequent failure of
Bush bearings &
"Plunger Gland
Seals", due to high
wear & tear.
MTBF of HP-Pump is
very poor only 150
hrs

2.3. Oil flow is not sufficient Go

why ? 4th fator for

phenomenon

why ? 5th fator for

phenomenon

Verification

No
Go

why ? 3rd fator for

phenomenon

Verification

Verification

1.1. Material is OK as per

specification

why ? 1 st fator for

phenomenon

Verification

Verification

why ? 2nd fator for

phenomenon

Description of
phennmenon

Verification

WHY WHY BECAUSE LOGIC WORKSHEET

Page 1 of 2

Counter measure

Size of problem
1.

# High production
loss # Bottleneck for
capacity
enhancement of plant
due to non reliability
of HP-Pump

Poor Quality MOC of Bush

Bearings

2.

Improper Lubrication in
Bush

Go

Go

2.3.1 Chocking in oil line

Go

No
2.3.1.1 Oil Line Checked & found
Go
OK

2.3.2 Insufficient Oil flow in

Lube-Oil pump suction line

Go

1.2.3.2 High Suction head in LubeGo

Oil pump

BUSH

2.3.3 Cloging in suction line

Go

No
2.3.3.1 Oil Line Checked & found
Go
OK

JURNAL

2.3.4 Chocking of ports in

Bearings

Go

Mechanism

2.3.4.1 Chocking of ports in

Bearings

Go

METAL TO METAL
CONTACT

3. Over Heating of bush

bearing

Go

3.1 Poor lubrication & high

friction

Go

3.1.1 Sufficient oil film not build

up between Crank-Shaft journal Go
& Bush

3.1.1.1 Lube Oil pressure is lees

than the designed pressure & very
Go
low when it is running at low RPM

3.1.1.2 Lube oil pump directly

coupled with HP-Pump and takes
Go
20 sec to build-up pressure, so
every start-stop of HP-Pump it runs
20 sec in Dry Condition.

Lube-oil pump need to

be relocated below the
crank-case oil level so
the pump can get
sufficient flow in
suction

2.3.4.1 Presence of Metal chip

in the port of Bearings

Separate Lube-oil
pump need to install
which will give
sufficient oil pressure
continiously &
independent of pump
RPM & to provide
lubrication before start
and after stop
Lube-oil Pr will be
interlocked with HPPump

BEFORE
HP PUMP STOP

Lube oil Pr. (Kg/cm2) & Hz

12

HP-PUMP LUBRICATION
SYSTEM IS START STOP
DEPENDENT

HP PUMP START

10

DETORIARATION OF BUSH & BEARINGS

DUE TO INSUFFICIENT LUBE OIL PR.
DURING EVERY START-STOP OPERATION
OF HP-PUMP (DRY RUN)

LUBE OIL PR. FALL

LUBE OIL PR. RISE

4
1.5 Kg / cm2

0
1

17

4 SEC
12 2 0
HP-PUMP DRY RUN 20

15

Time (Sec)
HP Pump Operating Hz.

Lube Oil Pr Rise & Fall

Lube Oil operating Pr

Clearance Bush & JRNL

AFTER
NO DRY RUN OF HP-PUMP. LUBRICATION
SYSTEM IS START-STOP INDEPENDENT
12

HP PUMP STOP

HP PUMP START

Lube oil Pr. (Kg/cm2) & Hz

10
HP PUMP STOPED
FOR LONG TIME

LUBE OIL PR. RISE

BEFORE HP-PUMP START

LUBE OIL PR. FALL

AFTER HP-PUMP STOP

4
4 Kg / cm2

2
HP PUMP STOPED
FOR SHORT TIME

0
2

10 18

13 2 1

14

Time (Sec)

HP Pump Oprating Hz.

Lube Oil Pr Rise & Fall

Lube Oil operating Pr

Clearance Bush & JRNL

why ? 4th fator for

phenomenon

why ? 5th fator for

phenomenon

Verification

why ? 3rd fator for

phenomenon

Verification

why ? 2nd fator for

phenomenon

Verification

why ? 1 st fator for

phenomenon

Verification

Verification

Description of
phennmenon

Verification

WHY WHY BECAUSE LOGIC WORKSHEET

Page 2 of 2

Counter measure

Size of problem
4. Damage of Gland Seal of HPPump Plunger
Go

4.1 Over Heating of "Plunger

Gland Seal" During HP-Pump
Operation

Go

4.1.1 No Gland cooling water

Go
supply During operation of HPPump

4.1.1 .1 Gland cooling water supply Go

Line get Chocked

4.1.1.2 Gland Cooling Pump

performance & Pressure fall

Phenomenon

PLUNGER
GLAND SEAL

4.1.2 Temperature Rise of

Gland Cooling Water

Go

Go

4.1.2.1 There is no temperature

Go
indicator for Gland Cooling Water

4.1.3 Very High Friction bwteen

Teflon Gland Seal &
Go
Reciprocating Metal Plunger

4.1.3.1 There is no provition of

Lubrication between Teflon Seal &
Go
Reciprocating Metal Plunger

4.1.1.1.1 Gland cooling water

No
supply Line Checked & found
Go
OK
Gland cooling water
Pressure intelocking
with HP-Pump
(Interlock at 1 Kg/Cm2)

Temperature Indicator
VCS need to be
installed

Self lubricating Type

material need to be
used as a substitute of
Teflon Seal

PLUNGER

Mechanism

4.2 Very quick wear & tear of

Go
Rubber seal in gland

4.2.1 Toughness of Rubber

seal is very poor not able to
withstand continious high
pressure and abbration

Go

4.2.1.1 No Reinforcement in
Rubber Seal

Go

Reinforced Rubber seal

need to be provide

HP Pump Lube-Oil
Temperature display

HP Pump Cooling Water

Temperature display

RESULTS
950

MTBF (Hrs)

1000
5 times
increment
over 2005

750
500
250

790

G
O
O
D

400

148

0
2005

2006

2007

2008

Target

ACTUAL

TARGET

MTTR (Hrs)

TARGET

6
4

62%
reduction
over 2005

4
1.5

1.4

2005

2006

2007

2008

G
O
O
D

Cost of Kaizens :S.No.

Cost vs Benefit

KAIZEN

Investment in Rs.

1
2

KAIZEN NO # 1
KAIZEN NO # 2

RS. 12000/RS.6000/-

KAIZEN NO # 3

RS.2400/-

4
5

KAIZEN NO # 4

RS.3800/-

KAIZEN NO # 5

RS. 1500/

KAIZEN NO # 6

RS. 4,000/-

KAIZEN NO # 7

RS.2800/-

KAIZEN NO # 8

RS.3000/-

Total investment

Rs. 35,500/-

PRODUCTION GROWTH 5000 TS IN 2007

BUSINESS GROWTH Rs. 350 million

Improve HP Pump MTBF from 148 hrs

to 790 hrs & Reduce MTTR 4 hrs to 1.5hrs

BENEFITS
INCREASE IN PRODUCTION

Ton

65000
60000
55000
50000
45000
40000
35000
30000
25000
20000
15000
10000
5000
0

37000

31000

2005

2006

42000

2007

YEAR

ENSURED NO Bulk Density VARIATION IN

PRODUCT Leading to Quality improvement
Convesion cost
4500

20%
REDUCTION
IN CONVERSION
COST OVER 2006

4000
3500
3000

2500
2000
1500
1000
500
0
2 005

2006

200 7

BENEFITS

D
S
M

ABLE TO DELIVER AS PER THE

BUSINESS REQUIREMENT

ENSURED EQUIPMENT
SAFETY OF HP-PUMP

HIGH MORALE DUE TO

RELIABILITY IN PROCESS

PM Contribution
Increase in MTBF and Decrease in MTTR
Reliability

Increase in Production Volume

Improvement in Quality

Reduction in Cost

Improved Safety std.

Consumers needs met on time in full

Sustainable Profitable Business Growth

In HUL, across all factories, PM contribution resulted in 10%
improvement in availability
On a volume base of 2.1 Ml Ton, this translates to 2L Ton additional
capacity
Virtually, capital investment as well as fixed cost equivalent to >3 factory
operations have been avoided

THANKS

MAINTENANCE COST REDUCTION

COST OF COMPONENTS
LUBE OIL PUMP
Per Year 1X Rs. 55000
GLAND SEAL ASSLY. REPLACEMENT
Per year 8X Rs 40000
PLUNGER CHANGE
Per year 36X Rs 6000
JOURNAL BEARING
Per year 3X Rs 6000
LUBE OIL
Per year 3X Rs 18000
TOTAL

BEFORE
RS 55000

Rs 320000 Rs.240000
Rs 216000 Rs.108000
Rs 18000

Rs. 0

Rs 54000

Rs. 36000

Rs 663000

Rs

Maintenance Cost
700000
600000
500000
400000
300000
200000
100000
0

384000

2007
Year

Rs 384000

42%
Reduction

663000

2006

AFTER
Rs. 0