National Aluminium Company Limited

Mechanical Department, Alumina Refinery

MAINTENANCE EXCELLENCE INDEX

A 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 F G

Plant availability, Cal.Alumina, (DT for Maint)

Stock availability - Spare parts w.rt.Planned &

Corrective maintenace converted to Preventive
Planned Work in relation to unplanned work
Overall Realization of Predictive Maintenace
Overall Compliance of the maintenance Plan

Documentation/ knowledge management/OL

Worker level participation in Improvements

through QCCs, Kaizens, Sarjanas, Tool Box
Plant Modernization Realization w.r.t.Plan
Plant availability,Hydrate (DT for maint.)

Overall realized Operation Work Orders

Work Orders with reliable planned time

Employee Training and Development

Workshop Overhauling Realization

Statutory Compliance Realization

Contract Cost w.r.t.Production

Spares Costs w.r.t. production
Workshop Repair Realization

Weighted Value of Metric

Performance Level Scores
Incidents (First-aid cases)
Strategic Improvements

Incidents (Major cases)

Performance Measures

running Maintenance

Near-misses Reports

PME Compliance
(CapEx)
Works

Talks
UoM % % % % % % % % % % % % % Rs./ No. of No. of
Rs./ % % No of Nos. Nos. % Score Description Numerical
MT Completed Mandays
MT projects
Projects completed
Current 2.00 1.45 92.00 97.00 99.00 50.00 97.00 98.00 60.00 50.00 98.00 80.00 50.00 350.00 60.00 90.00 18 600 70 195 15 20 1 90
Performance
Performance Extremely
2.66 1.33 96.00 98.00 100 80.00 98.00 99.00 85 60 100 100 95 375 75 95.00 16 660 85.00 200 20 10 0 100 10 6
Goal Important
Very
2.70 1.40 95.00 97.50 99.50 78.00 97.75 98.75 83 58 99.50 98 90 378 77 94.00 16 630 75.00 190 15 12 1 90 5
9 Important
2.75 1.45 94.00 97.00 99.00 76.00 97.50 98.50 81 56 99.00 96 85 380 78 92.00 14 600 70.00 185 12 14 2 85 8 Important 4
Baseline Performance

Less
2.80 1.50 93.00 96.50 98.50 74.00 97.25 98.25 79 54 98.50 95 80 382 78 90.00 13 570 65.00 180 10 16 3 80 3
7 Important
2.85 1.55 92.00 96.00 98.00 72.00 97.00 98.00 77 52 98.00 94 75 380 82 88.00 12 540 60.00 175 8 18 4 75 6 Influential 2
Less
2.90 1.58 91.00 95.50 97.75 70.00 96.75 97.75 75 50 97.50 93 70 381 83 86.00 11 510 58.00 170 7 20 5 70 1
5 Influential
2.92 1.60 90.00 95.00 97.50 68.00 96.50 97.50 73 48 97.00 92 65 382 84 84.00 10 480 56.00 165 6 25 6 65 4
2.94 1.62 89.00 94.50 97.25 66.00 96.25 97.25 71 46 96.75 91 60 383 85 82.00 9 450 55.00 160 5 30 8 60 3
2.96 1.64 88.00 94.00 97.00 64.00 96.00 97.00 70 44 96.50 90 55 384 86 80.00 8 420 54.00 155 4 35 10 58 2
2.98 1.65 87.00 93.50 96.75 62.00 95.75 96.90 69 42 96.25 89 50 385 87 78.00 7 390 53.00 150 2 40 15 56 1 Excellent 759-900
3.00 1.66 85.00 93.00 96.50 60.00 95.50 96.80 68 40 95.00 88 45 386 88 76.00 6 360 52.00 145 0 45 20 55 0 Very Good 669-758
Performance
Level w.r.t D 10 8 6 8 8 0 6 6 0 5 6 0 1 10 10 7 10 8 8 9 9 5 9 9 Satisfactory 579-668

Weighted Value Not

6 6 5 4 4 4 4 4 2 3 5 4 4 4 4 5 2 2 2 3 2 3 4 4 <579
of Importance Satisfactory
Performance
Level Score (E 60 48 30 32 32 0 24 24 0 15 30 0 4 40 40 35 20 16 16 27 18 15 36 36 598 Satisfactory
X H)

Max.MEI Valie 60 60 50 40 40 40 40 40 20 30 50 40 40 40 40 50 20 20 20 30 20 30 40 40 900 Index of Excellence

(H X 10)