Reliability Management Consultant Private Limited

Brief of Engagement • To improve availability of Bliss Mill to 95% plus from the present level that varies between 80% to 90% and improve the productivity of the hundred year old mill by at least 10% Results • Availability rose to 95% in less than 6 months. Productivity increased by 25% and power consumption decreased by 17%

Engagement One –

We aimed at reducing the dangerously high levels of vibration (around 5000 microns) of Cement Mill to less than 1000 microns so that various product blends could be produced.

Results Achieved:

• Vibrations reduced to around 500 microns

Engagement Two –

To bring improvement in plant availability from 289 days to 320 days within one year.

Result Achieved:

• Plant availability improved to 330 days within one year

Engagement One –

 

Here, our aim was to reduce breakdown of critical machines from level of 24 failures a month to as low as possible. Further, we also aimed towards identifying weak areas that would not sustain stress of running the facility to around 120% of its capacity.

 

Results Achieved:

• Failures reduced from 24 failures a month to 1 failure a year for 36 identified critical machines
• The plant runs at 129% of its designed capacity

 

Engagement Two –

 

Here, the need was to redesign existing machine so as to obtain productivity gain of around 50% as well as reduce maintenance time and effort. Further, we also aimed at building the machine locally at less than 10% of price which would otherwise have to be paid if machine was imported.

 

Result Achieved:

• All objectives of engagement were achieved within 6 months of start of the project

Brief of Engagement • Improve availability of machines from the present level of 80% to 100% in six months' time. • Improve the function of the machine so that the quality of the output is within 6sigma Results • Availability increased to more than 100% in less than 6 months. • A grinding machine relegated to rough finishing could now be used for final finishing and added 31 more gears to the total production. This could be achieved in less than 1 month's effort. • Quality output is now within 6 sigma limit within 6 months for gear grinding machines.

Engagement –

 

We wanted to reduce dangerous vibration of refrigerant screw compressors from 28 mm/s to 2.5 mm/s.

 

Result Achieved:

• Results achieved within three months after implementation of the solutions

Engagement –

 

We aimed at increasing the productivity by 2 times in 6 months time & then by 3 times in 1.5 years.

 

Results Achieved:

• Productivity increased by 2 times within the first six months
• By ninth month, productivity increased by 3 times

Brief of Engagement • Total organizational change - from Operational and functional strategy, structure, operational performance • How to increase productivity by 3 times within three years • Achieve a delivery commitment of 90% within one year Results • Productivity improved by 2 times in less than 8 months • Delivery commitment has improved to 95% in less than 9 months time i.e. a delivery backlog from 11 months delay reduced to delivery within 17 days from placement of orders for 80% of the orders

Engagement One –

We planned to increase yield of continuous pig casting machine to 97% from a level of 92 to 93%. Further, we also wanted to decrease quality defects to zero as well as improve availability to 100% & functional accuracy to 100%.

Results Achieved:

• Yield increased to 98% plus in less than 5 months
• Quality defects reduced to almost zero in less than 12 months
• Percentage of poor pigs reduced by 70%
• Availability to 100% & functional accuracy to 100% within 9 months

 

Engagement Two –

 

To increase plant availability from 90% to 98% in two years’ time.

 

Result Achieved:

• Plant availability improved to 98% in two years’ time