10-breakdown analysis, key indicators & informatic system
TRANSCRIPT
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PIC
Calusco 5-8 June 2006
BREAK DOWN ANALYSIS
MAINTENANCE KEY INDICATORS
2006
&
Informatic System
PIC
Calusco, 5-8 June 2006
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INFORMATIC SYSTEM FOR MAINTENANCE
in ITC RO!"
Ita#cementi ro$% $se SA" as main informatic too# for t'e
maintenance(
ro$% r$#es are a%%#ie) in a## S$*si)iaries +e,en if -it' some
)ifferences.(
T'e ista##ations are c#assifie) at ,ario$s #e,e# accor)in/ t'e %'ysica#str$ct$res ro$% c#assification
By SA" are 'an)#e)0
"#annin/ +an) *$)/et. Notifications an) -or1 or)ers
Ins%ections Costs contro# +monitorin/ . "arts cons$ma*#e re2$isition an) stoc1
2
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INFORMATIC SYSTEM FOR MAINTENANCE
in ITC RO!"
Benc'mar1 of res$#ts0 *y %#ant year o,er year3 %#ants in 'omo/eneo$s
c#$sters in t'e S$*si)iaries an) in t'e ro$%3 *enc'mar1 at
S$*si)iaries #e,e#(
Sto%%a/es ca$ses ana#ysis(
Monitorin/ of t'e $ti#i4ation of interna# an) esterna# %ersonne# an)
cost.
Definition of 1ey in)icators for maintenance %erformances e,a#$ation(
In)ications for com%ara*#e inter,entions in ot'er %#ants of t'e ro$%(
Recor) of maintenance e2$i%ment 'istory
The data analysis allows for
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MAIN KEY INDICATORS IN MAINTENANCE
"#$ %aintenance cost u& to clin'er (includin) )eneral ser*ices &art+
"# u "2
Cost 5t %ro)$ct $ ------ ----- ------ of the es&ensed %aintenance & C& C&
"2$ %anutenance cost u& to ce%ent (includin) )eneral ser*ices &art+
The )eneral ser*ices cost is shared /5 to clin'er e 25 to ce%ent
& $ clin'er &roduction u $ clin'er )round in the ce%ent
C& $ ce%ent &roduction
Interna# %ersonne# 'o$rs +an) costs. 1y s&ecialiation, 1y de&art%ent and 1y
%onth.
Esterna# %ersonne# 'o$rs an) costs *y contractor 1y de&art%ent and 1y
%onth.
Esterna# e6%erts costs 1y de&art%ent and 1y %onth.
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MAIN KEY INDICATORS IN MAINTENANCE
Ratio maintenance cost 5 ,a#$e insta##ations as re%#ace) *y t'e ne- ones
on study.
or 'ilns (and %ills+
MTBF refer to sto&&a)es due to %aintenance causes of the &hase.MTBY refer to sto&&a)es due to %aintenance causes of the &hase and esternal to the &hase.
MTB7 refer to sto&&a)es due to %aintenance and &roduction causes e*en esternal to the &hase.
O,era## e2$i%ment efficiency +for 1i#ns.0 net run factor t&d
Tota# in,estment for maintenance costs (accordin) 4rou& rules+ in)e6 calculated
&ro&orionally to the es&ensed %aintenance inde.
8 OEE 9 :;; 6 +net r$n factor 6 t%). act$a# 5 +net r$n factor 6 t%). tar/etT&d $ 2! h (&roduction runnin) hours+
et run factor $ runnin) hours ( total hours 7 hours lost for esternal causes and &roduction &lan+.
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7 = stoppages due to production plan
1+2 = external causes + management causes ( 2 should be monitored)
8 = stoppage due to maintenance plan (should be monitored)
RE"ORTIN OF TIME EFFICIENCYRE"ORTIN OF TIME EFFICIENCY INDE7ES & OEEINDE7ES & OEE
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MAIN KEY INDICATORS IN MAINTENANCE
Ki#ns +an) mi##s. *rea1)o-n ana#ysis(
Pre&aration of re&orts with the indications of the %ain reasons
for sto&&a)es, nu%1ers and hours of downti%e.
nalysis of the re&orts in order to identify and re%o*e thecritical situations and recurrent &ro1le%s.
ocus on &ro9ects of i%&ro*in) %aintenance and sa*in)
e*aluation.
In*ol*e%ent of &roduction and %aintenance e%&loyees in
facin) the &ro1le%s of the &lants
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Stoppages & Causes
BREAK DOWN ANALYSIS
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BREAK DOWN ANALYSIS
Brea1)o-n ana#ysis0 ro$% r$#es(
"andatory for each 'iln
:tron)ly su))ested for %ills (%ainly if runnin) in critical
condition of relia1ility
;ata in&ut u& to the &roduction de&art%ent (control roo%
o&erators or &roduction %ana)er+ e*en if other &rocedures can
1e ado&ted.
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Operating time
Up time
Disabled
timeTotal time
Required
time
Non required
time
Standby
time
Down time
Externaldisabled
time
Potentialavailabilitytime
PM! Stoppages due to produ"tion plan
Potential
unavailability
time
PM#! Stoppages due to maintenan"e plan
PM$! %auses due to line &due to maint'(
PM)! %auses due to line &due to pro"ess(
PM*! %auses outside line &due to
pro"ess(
PM+! Management "auses
PM,! External "auses
PM-! %auses outside line &due to maint'(
: < = 0 E,ents c#assification: < = 0 E,ents c#assification
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, Ele"tri"al power pea.s
+ /ull stores
- Produ"t quality
* Emission quality
$ S0ortage o1 raw materials2 et"
) Ot0er external de"isions
, Permits and aut0orisations
+ Trade Unions problems
- Transportation blo".
* Ele"tri"al power la".
$ Natural events
, O""lusion 3 obstru"tion
+ %rusts 3 rings s0ooting
- Pro"ess transition &warming(
* Produ"t "0ange
$ %ombustion system
) ot0er "auses
, 4uxiliary and general servi"es
+ Upstream p0ases
- Downstream p0ases
5oo. at next pages
5oo. at next pages
: 0 E,ents c#assification cata#o/$e: 0 E,ents c#assification cata#o/$e
Operating time
Standby
time
Down time
Externaldisabled
time
6P! Stoppages due to produ"tion plan
6P#! Stoppages due to maintenan"e plan
6P$x ! %auses inside line due to Maint'
6P* ! %auses outside line &due to pro"ess(
'(
Operating time
Standby
time
Down time
Externaldisabled
time
Potential
availabilitytime
Potential
Unavailability
time
6P)! %auses due to line &due to pro"ess(
6P+ ! Management "auses
6P, ! External "auses
6P-x ! %auses outside line due to Maint''(
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/un"t'
5o"atio
n
PPPP3+73 7,--737,895N n:7,
PPPP3,$37,,#737,Raw Mill n:,
PPPP3 +$37,*+737,%ement Mill n:,PPPP3 -$37+)7737,
%oal Mill n:,
PM-x ! %auses outside line &due to
maint'(
:6
6P-, %4USES OUTS9DE 895N 59NE
&DUE TO M49NTEN4N%E(
7, P54NT PO>ER D9STR9;' S4TER SNSTRE4M
,7 OT=ER UPSTRE4M
,, OT=ER 6ENER45 SER@9%E
6P-+ %4USES OUTS9DE M955 59NE
&DUE TO M49NTEN4N%E(
7, R4> M4TER945 STOR46E &"rane2 et"(
7+ TR4NSPORT TO STOR46E
7- OT=ER DO>NSTRE4M
7* OT=ER UPSTRE4M
7$ OT=ER 6ENER45 SER@9%E
Ot0ers
6P-- %4USES OUTS9DE OT=ER
59NES
&DUE TO M49NTEN4N%E(
7, 4uxiliary and general servi"es
7+ Upstream p0ases
7- Downstream p0ases
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!otal time
"e#uired time
$on re#uired time
%p time
&isabled time
'perating time
(running time)
tandb time
&o*n time
xternal disabled
time
!heoretical
up time
!heoretical
do*n time
2) ,anagement causes
1) xternal causes
-) .auses due to phase/maint
6) .auses due to phase/proc
3) .auses outside phase/maint
) .auses outside phase/proc
7) toppages due to production plan
8) toppages due to maintenance plan
MT;/"unning time / number o
stoppages belonging
to class -
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!otal time
"e#uired time
$on re#uired time
%p time
&isabled time
'perating time
(running time)
tandb time
&o*n time
xternal disabled
time
!heoretical
up time
!heoretical
do*n time
2) ,anagement causes
1) xternal causes
-) .auses due to phase/maint
6) .auses due to phase/proc
3) .auses outside phase/maint
) .auses outside phase/proc
7) toppages due to production plan
8) toppages due to maintenance plan
MT;<"unning time / number o
stoppages belonging
to class 3 and -
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!otal time
"e#uired time
$on re#uired time
%p time
&isabled time
'perating time
(running time)
tandb time
&o*n time
xternal disabled
time
!heoretical
up time
!heoretical
do*n time
2) ,anagement causes
1) xternal causes
-) .auses due to phase/maint
6) .auses due to phase/proc
3) .auses outside phase/maint
) .auses outside phase/proc
7) toppages due to production plan
8) toppages due to maintenance plan
MT;C"unning time / number o
stoppages belonging
to class 3- and 6
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!otal time
"e#uired time
$on re#uired time
%p time
&isabled time
'perating time
(running time)
tandb time
&o*n time
xternal disabled
time
!heoretical
up time
!heoretical
do*n time
2) ,anagement causes
1) xternal causes
-) .auses due to phase/maint
6) .auses due to phase/proc
3) .auses outside phase/maint
) .auses outside phase/proc
7) toppages due to production plan
8) toppages due to maintenance plan
MT;M"unning time / number o
stoppages belonging
to class - and 8
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!otal time
"e#uired time
$on re#uired time
%p time
&isabled time
'perating time
(running time)
tandb time
&o*n time
xternal disabled
time
!heoretical
aailabilit time
!heoretical
unaailabilit time
-) .auses due to phase/maint
6) .auses due to phase/proc
3) .auses outside phase/maint
) .auses outside phase/proc
( Stoppages due to produ"tion plan
#( Stoppages due to maintenan"e plan
Operation 1a"tor
!heoretical 4ctual
actual o&eration factor $ run factor
5Permits and aut0orisations5Trade Unions problems5Transportation blo".5Ele"tri"al power la".5Natural events
5Ele"tri"al power pea.s5/ull stores5Produ"t quality5Emission quality5S0ortage o1 raw materials2
et"
1) xternal causes
2) ,anagement causes
net run factor $ runnin) ti%e hours ( total ti%e hours - hours fro% # and / +
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!otal time
"e#uired time
$on re#uired time
%p time
&isabled time
'perating time
(running time)
tandb time
&o*n time
xternal disabled
time
!heoretical
aailabilit time
!heoretical
unaailabilit time
2) ,anagement causes
1) xternal causes
-) .auses due to phase/maint
6) .auses due to phase/proc
3) .auses outside phase/maint
) .auses outside phase/proc
7) toppages due to production plan
8) toppages due to maintenance plan
4vailability 1a"tor
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!otal time
"e#uired time
$on re#uired time
%p time
&isabled time
'perating time
(running time)
tandb time
&o*n time
xternal disabled
time
!heoretical
aailabilit time
!heoretical
unaailabilit time
2) ,anagement causes
1) xternal causes
-) .auses due to phase/maint
6) .auses due to phase/proc
3) .auses outside phase/maint
) .auses outside phase/proc
7) toppages due to production plan
8) toppages due to maintenance plan
Usage 1a"tor
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>0 List of sto%%a/es *y ca$se
;y sele"ting t0e line&s(2 you "an download data to ex"el
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DEFINITIONS +!NI ISO an) Ita#cementi STDs.DEFINITIONS +!NI ISO an) Ita#cementi STDs.
TOT45 T9ME RE/EREN%E T9ME PER9OD SET /OR T=E T9ME S%45E
NON3REU9RED T9MET=E T9ME PER9OD DUR9N6 >=9%= T=E USER DOES NOT DEM4ND T=4T T=E >OR8
%ENTER 9S 9N %OND9T9ON /OR ECE%UT9N6 4 REUESTED /UN%T9ON
POTENT945 UN4@4954;959T<T9ME
P4RT O/ NON3REU9RED T9ME DUR9N6 >=9%= T=E >OR8 %ENTER 9S NOT4@4954;5E
POTENT945 4@4954;959T< T9MEP4RT O/ NON3REU9RED T9ME DUR9N6 >=9%= T=E >OR8 %ENTER 9S 9N REST
%OND9T9ON &4@4954;5E ;UT NON3OPER4T9N6(
REU9RED T9MET=E T9ME PER9OD DUR9N6 >=9%= T=E USER DEM4NDS T=4T T=E >OR8 %ENTER 9S
9N %OND9T9ON /OR ECE%UT9N6 4 REUESTED /UN%T9ON
D9S4;5ED T9ME T=E T9ME PER9OD DUR9N6 >=9%= 4 >OR8 %ENTER 9S NOT 4;5E TO %4RR< OUTT=E REU9RED /UN%T9ONS
ECTERN45 D9S4;5ED T9ME
&or ECTERN45 5OSS T9ME(
T=E T9ME PER9OD DUR9N6 >=9%= 4 >OR8 %ENTER 9S NOT 4;5E TO %4RR< OUT
T=E REU9RED /UN%T9ONS DUE TO ECTERN45 %4USES
DO>N T9MET=E T9ME PER9OD DUR9N6 >=9%= 4 >OR8 %ENTER 9S NOT 4;5E TO %4RR< OUT
T=E REU9RED /UN%T9ONS DUE TO 9NTERN45 %4USES
UP T9ME T=E T9ME PER9OD DUR9N6 >=9%= 4 >OR8 %ENTER 9S 4;5E TO %4RR< OUT T=EREU9RED /UN%T9ONS
ST4ND;< T9ME T=E T9ME PER9OD DUR9N6 >=9%= 4 >OR8 %ENTER 9S 9N ST4ND;<
OPER4T9N6 T9MET=E T9ME PER9OD DUR9N6 >=9%= 4 >OR8 %ENTER 9S %4RR
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DEFINITIONS +!NI ISO an) Ita#cementi STDs.DEFINITIONS +!NI ISO an) Ita#cementi STDs.
OPER4T9N6 T9MET=E T9ME PER9OD DUR9N6 >=9%= 4 >OR8 %ENTER 9S %4RROR8ED =OURS
S4P
T=E T9ME PER9OD DUR9N6 >=9%= 4 >OR8 %ENTER PRODU%ED 4
SPE%9/9% PRODU%T'
THE SUM TOTAL OF THE "WORKED HOURS“
FOR PRODUC! ALL THE PRODUCTS
WTH THE WORK CE!TER
S E#UAL TO THE WORK CE!TER "OPERAT! TME"
PP PRO%ESS ORDER REU9RES SEP4R4TED 9NPUT O/ T=E F>'='G
USED 9N T=E >OR8 %ENTER /OR PRODU%9N6 E4%= PRODU%T'
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DEFINITIONS +!NI ISO an) Ita#cementi STDs.DEFINITIONS +!NI ISO an) Ita#cementi STDs.
MT;/ 3 ME4N T9ME ;ET>EEN
/495URES
ME4N OPER4T9N6 T9ME ;ET>EEN /495URES &NON3P54NNED STOPP46ES /OR
M49NTEN4N%E( 9NS9DE T=E >OR8 %ENTER'
MT;M 3 ME4N T9ME ;ET>EEN
M49NTEN4N%E
ME4N OPER4T9N6 T9ME ;ET>EEN P54NNED H NON3P54NNED STOPP46ES /OR
M49NTEN4N%E 9NS9DE T=E >OR8 %ENTER'
MT;C 3 ME4N T9ME ;ET>EEN
/495URES 4ND PRO%ESS
STOPP46ES &9tal"ementi STD(
ME4N OPER4T9N6 T9ME ;ET>EEN P54NNED H NON3P54NNED STOPP46ES /OR
M49NTEN4N%E 4ND PRO%ESS %4USES 9NS9DE T=E >OR8 %ENTER'
MT;< 3 ME4N T9ME ;ET>EEN
PRO%ESS STOPP46ES
&9tal"ementi STD(
ME4N OPER4T9N6 T9ME ;ET>EEN NON3P54NNED STOPP46ES /OR PRO%ESS
%4USES 9NS9DE H OUTS9DE T=E >OR8 %ENTER'
4@4954;959T< /4%TOR
T=E 4@4954;959T< O/ T=E IREU9RED T9MEI DUE TO T=E /495URES &NON3
P54NNED STOPP46ES /OR M49NTEN4N%E( 9NS9DE H OUTS9DE T=E >OR8
%ENTER'
US46E /4%TOR
T=E 4@4954;959T< O/ T=E IREU9RED T9MEI DUE TO NON3P54NNED STOPP46ES
/OR M49NTEN4N%E H PRO%ESS 9NS9DE H OUTS9DE T=E >OR8 %ENTER 4ND
M4N46EMENT 4ND ECTERN45 %4USES'
O S
+ SO i S . f
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DEFINITIONS +!NI ISO an) Ita#cementi STDs.0 referencesDEFINITIONS +!NI ISO an) Ita#cementi STDs.0 references