JK PAPER LTD.
UNIT: CPM
IPPTA PRESENTATION
BEST MAINTENANCE PRACTICES
FOLLOWED
AT JK PAPER LTD TO IMPROVE PROFITABILITY
Presented by: Sandesh Joshi
18 July -2014
BEST MAINTENANCE PRACTICES IN PULP & PAPER MILLS TO IMPROVE PROFITABILTY
Slide No. 1
CPM
Present Capacity , 145000 TPA
Pulp & Paper Plant
•Commenced production in 1968
•Acquired by JK Group in 1992
•Turn around in 1994-95
•Capacity: 55,000 TPA
•Products: Cut size multi purpose office paper and security
paper
Packaging Board Plant
•Commenced production in 2007
•Capacity: 90,000 TPA
•Products: Multi Layer Packaging Boards
BEST MAINTENANCE PRACTICES IN PULP & PAPER MILLS TO IMPROVE PROFITABILTY
Slide No. 2
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
Increase
productivity
Shareholder
Wealth / Profit
Migration
Maintain International
Products Standard
Produce
qualitative as
well as
quantitative
products
Generates value,
profit and wealth
Lowest manufacturing
cost
Best
Maintenance
Practice
Changing
Customer
Priorities
Good maintenance practice is one of the keys to increasing productivity and profits
BEST MAINTENANCE PRACTICES IN PULP & PAPER MILLS TO IMPROVE PROFITABILTY
Slide No. 3
BRIEF MANUFACTURING PROCESS OF MULTI LAYER PACKAGING BOARD
Screening
& cleaning
Pulping
Surface
sizing
Calendaring
Thickening
Drying
3 Stage coating
& IR Drying
Dispatch
Refining
Sheet formation
& consolidation
Reeling
Blending
Dilution,
centricleaning
and screening
Rewinding
Storage in
godown
BEST MAINTENANCE PRACTICES IN PULP & PAPER MILLS TO IMPROVE PROFITABILTY
Sheeting &
Packing
Slide No. 4
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.
BEST MAINTENANCE PRACTICES IN PULP & PAPER MILLS TO IMPROVE PROFITABILTY
Slide No. 5
MAINTENANCE PRACTICE STEPS
STEP BY STEP - PLANNED MAINTENACE
BEST MAINTENANCE PRACTICES IN PULP & PAPER MILLS TO IMPROVE PROFITABILTY
Slide No. 6
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
BEST MAINTENANCE PRACTICES IN PULP & PAPER MILLS TO IMPROVE PROFITABILTY
Slide No. 7
EQUIPMENT DATA SHEET
Equipment data sheet contains information regarding Specification, MOC, Drawing
details, Lubrication details & Spare details.
EQUPIMENT DATA SHEET
BOTTOM LAYER RICH WATER PUMP - ABS SCAN - NL 80-160
APPROCH PROCESS WHITE WATER TANK
B
EQUIPEMENT NAME
LOCATION
EQUIPMENT CATEGORY
STUFFING BOX
BEARING
HOUSING
SHAFT COUPLING
ROTATING SHAFT
Sr No.
1
2
3
4
5
6
7
Descripation
Input shaft
Mech Seal
Bearing 6306 ZZ
V Ring
Coupling F- 70
Coupling Tyre F- 70
Type
Grade
Qty
Relubrication Interval
Relubrication Qty
Amp 37.7
1
1
2
2
1
1
Lubrication
Lithium Soap Bearing Grease
Shell Alvania Water repallent - 2
200gms
Every 2500 hrs opration
30 gms
ABS SCAN
NL 80-160
165 m3/hr
31 mtrs
rpm 2900
frame 180M
ERP code
7010050643
7010050530
1122063063
7015140060
1930450069
1930050700
Foot mounted
8
27
PRIME MOVER
MAKE
MODEL
DISCHARGE
HEAD
MOTOR
KW 22
SPARE DETAILS
Location
Qty
Pump
Shaft
Shaft
Shaft
Shaft
Shaft
MECHANICAL SEAL
24
Pump shaft
8
27
SPECIFICATION OF PUMP
IMPELLER
24
Motor shaft
BEST MAINTENANCE PRACTICES IN PULP & PAPER MILLS TO IMPROVE PROFITABILTY
Slide No. 8
BASIC OF ALL MAINTENANCE ACTIVITIES IS 5S PRACTICE
BEST MAINTENANCE PRACTICES IN PULP & PAPER MILLS TO IMPROVE PROFITABILTY
Slide No. 9
MAINTENANCE PRACTICE STEPS
STEP BY STEP - PLANNED MAINTENACE
BEST MAINTENANCE PRACTICES IN PULP & PAPER MILLS TO IMPROVE PROFITABILTY
Slide No. 10
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.
2.
3.
4.
5.
History of jobs carried out
Specification with drawing details
Spare list with ERP code
SOP (Standard Overhauling procedure )
Modification done if any
BEST MAINTENANCE PRACTICES IN PULP & PAPER MILLS TO IMPROVE PROFITABILTY
Slide No. 11
SOP – STANDARD OVERHAULING PROCEDURE
SOP sheet contains details like dismantling & assembling procedures with check point
, tools used & safety measure
BEST MAINTENANCE PRACTICES IN PULP & PAPER MILLS TO IMPROVE PROFITABILTY
Slide No. 12
MAINTENANCE ACTIVITY
DOWN
MAINTENANCE
1.1. BREAK
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.
TIMEBASED
BASED
MAINTENANCE
2.2. TIME
MAINTENACE
(TBM) (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, RollsWire, 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.
CONDITION
BASED
MAINTENANCE (CBM)
3.3.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.
BEST MAINTENANCE PRACTICES IN PULP & PAPER MILLS TO IMPROVE PROFITABILTY
Slide No. 13
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.
BREAKDOWN ANALYSIS FORMAT
BEST MAINTENANCE PRACTICES IN PULP & PAPER MILLS TO IMPROVE PROFITABILTY
Slide No. 14
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.
Outer race
Inner Race
Fluting due to Flow of
Eddy Current
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.
BEST MAINTENANCE PRACTICES IN PULP & PAPER MILLS TO IMPROVE PROFITABILTY
Slide No. 15
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.
DFR 4
DFR 5
DFR 3
DFR 2
D1
D3
DFR 1
D5
DFR 6
D2
D4
98.3 ⁰C
Temperature
Scanner
Grease Panel
1ST GROUP DRYER
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.
BEST MAINTENANCE PRACTICES IN PULP & PAPER MILLS TO IMPROVE PROFITABILTY
Slide No. 16
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
Tie Rod
Action Taken – Fabricated Tie rods are installed crosswise in Coater unit Structure to dampen
vibrations.
BEST MAINTENANCE PRACTICES IN PULP & PAPER MILLS TO IMPROVE PROFITABILTY
Slide No. 17
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.
BEST MAINTENANCE PRACTICES IN PULP & PAPER MILLS TO IMPROVE PROFITABILTY
Slide No. 18
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.
Laser Sensor
Blotch
Detected
Auto Marking
system
Blue Dye
markings
DSC panel for
record
Alarm 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.
BEST MAINTENANCE PRACTICES IN PULP & PAPER MILLS TO IMPROVE PROFITABILTY
Slide No. 19
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.
IR DRYER
P
WATER TANK
SHOWER
BACKING ROLL
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.
BEST MAINTENANCE PRACTICES IN PULP & PAPER MILLS TO IMPROVE PROFITABILTY
Slide No. 20
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 .
P
M/L White
Water
Channel
PAC Service
PAC Storage
P
P
P
B/L White
Water
Channel
T/L White
Water
Channel
3 Layered Teflon coated PVC grade Pipe
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
BEST MAINTENANCE PRACTICES IN PULP & PAPER MILLS TO IMPROVE PROFITABILTY
Slide No. 21
IMPORT SUBSTITUTION
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
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.
BEST MAINTENANCE PRACTICES IN PULP & PAPER MILLS TO IMPROVE PROFITABILTY
Slide No. 22
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
BEST MAINTENANCE PRACTICES IN PULP & PAPER MILLS TO IMPROVE PROFITABILTY
Slide No. 23
2. OVERALL EQUIPMENT EFFCTIVENESS (OEE)
BEST MAINTENANCE PRACTICES IN PULP & PAPER MILLS TO IMPROVE PROFITABILTY
Slide No. 24
3. BREAK DOWN CHART
End of Presentation…
BEST MAINTENANCE PRACTICES IN PULP & PAPER MILLS TO IMPROVE PROFITABILTY
Slide No. 25