BREAK DOWN ANALYSIS

MAINTENANCE KEY INDICATORS

&

Informatic System
2006
PIC
PIC 2006
Calusco, 5-8 June
Calusco, 5-8 June 2006

INFORMATIC SYSTEM FOR MAINTENANCE

in ITC GROUP
Italcementi Group use SAP, as main informatic tool for the
maintenance.

Group rules are applied in all Subsidiaries (even if with some

differences).

The istallations are classified at various level according the physical

structures Group classification

By SAP are handled:

Planning (and budget)
Notifications and work orders
Inspections
Costs control (monitoring )
Parts, consumable requisition and stock
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Calusco, 5-8 June 2006

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INFORMATIC SYSTEM FOR MAINTENANCE

in ITC GROUP
The data analysis allows for:

Benchmark of results: by plant year over year; plants in homogeneous

clusters in the Subsidiaries and in the Group; benchmark at
Subsidiaries level.

Stoppages causes analysis.

Monitoring of the utilization of internal and esternal personnel and

cost.

Definition of key indicators for maintenance performances evaluation.

Indications for comparable interventions in other plants of the Group.

Record of maintenance equipment history

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Calusco, 5-8 June 2006

MAIN KEY INDICATORS IN MAINTENANCE

M1
Ku
M2
Cost /t product = ------ x ----- + -----of the espensed maintenance
Kp
Cp
Cp
M1= maintenance cost up to clinker (including general services part)
M2= manutenance cost up to cement (including general services part)
The general services cost is shared 75% to clinker e 25% to cement
Kp = clinker production
Ku = clinker ground in the cement
Cp = cement production

Internal personnel hours (and costs) by specialization, by department and by

month.

Esternal personnel hours and costs by contractor, by department and by

month.

Esternal experts costs by department and by month.

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Calusco, 5-8 June 2006

MAIN KEY INDICATORS IN MAINTENANCE

Total investment for maintenance costs (according Group rules) index, calculated
proporzionally to the espensed maintenance index.

Ratio maintenance cost / value installations as replaced by the new ones,

on study.

For kilns (and mills):

MTBF refer to stoppages due to maintenance causes of the phase.
MTBY refer to stoppages due to maintenance causes of the phase and esternal to the phase.
MTBX refer to stoppages due to maintenance and production causes even esternal to the phase.

Overall equipment efficiency (for kilns):

net run factor x tpd

% OEE = 100 x (net run factor x tpd) actual / (net run factor x tpd) target
Tpd = 24 h x (production / running hours)
Net run factor = running hours / ( total hours hours lost for esternal causes and production plan).

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Calusco, 5-8 June 2006

REPORTING OF TIME EFFICIENCY INDEXES & OEE

1+2 =

stoppages due to production plan

external causes + management causes ( 2 should be monitored)

8 = stoppage due to maintenance plan (should be monitored)

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Calusco, 5-8 June 2006

MAIN KEY INDICATORS IN MAINTENANCE

Kilns (and mills) breakdown analysis.

Preparation of reports with the indications of the main reasons
for stoppages, numbers and hours of downtime.
Analysis of the reports in order to identify and remove the
critical situations and recurrent problems.
Focus on projects of improving maintenance and saving
evaluation.
Involvement of production and maintenance employees in
facing the problems of the plants
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Calusco, 5-8 June 2006

Stoppages & Causes

BREAK DOWN

ANALYSIS

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Calusco, 5-8 June 2006

BREAK DOWN ANALYSIS

Breakdown analysis:

Group rules.

Mandatory for each kiln

Strongly suggested for mills (mainly if running in critical
condition of reliability
Possible at less detailed level for the other installations
Data input up to the production department (control room
operators or production manager) even if other procedures can
be adopted.
Both production and maintenance involved in recognize the
problems of the plants
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Calusco, 5-8 June 2006

1 - 2 : Events classification
Operating time
Up time
PM1: External causes

Standby
time

Required
time

PM2: Management causes

PM5: Causes due to line (due to maint.)

Down time
PM6: Causes due to line (due to process)

Total time

Disabled
time

PM3: Causes outside line (due to maint.)

External
disabled
time

Non required
time

Potential
availability
time
Potential
unavailability
time

PM4: Causes outside line (due to

process)
PM7: Stoppages due to production plan

PM8: Stoppages due to maintenance plan

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Calusco, 5-8 June 2006

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1-3 : Events classification catalogue

1 Permits and authorisations
2 Trade Unions problems
3 Transportation block
4 Electrical power lack
5 Natural events

Operating time

Standby
time

1 Electrical power peaks

2 Full stores
3 Product quality
4 Emission quality
5 Shortage of raw materials, etc
6 Other external decisions

GP1 : External causes

GP2 : Management causes
GP5x : Causes inside line due to Maint.

Look at next pages

Down time
GP6: Causes due to line (due to process)

External
disabled
time
Potential
availability
time
Potential
Unavailability
time

1 Occlusion - obstruction
2 Crusts - rings shooting
3 Process transition (warming)
4 Product change
5 Combustion system
6 other causes

GP3x : Causes outside line due to Maint..)

GP4 : Causes outside line (due to process)

GP7: Stoppages due to production plan

Look at next pages

1 Auxiliary and general services
2 Upstream phases
3 Downstream phases

GP8: Stoppages due to maintenance plan

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Calusco, 5-8 June 2006

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1- 4 : New Events classification catalogue PM5x

PM5x : Causes inside line (due to maint.)
PPPP-20- 01330-01
KILN n01
GP51 CAUSES INSIDE KILN LINE
(DUE TO MAINTENANCE)
01 KILN FEEDING
02 KILN BY PASS
03 KILN ID FAN
04 KILN DEDUSTING SYSTEM
05 PREHEATHER REFRACTORY
06 CONDITIONING TOWER
07 KILN SHELL
08 KILN REFRACTORY
09 KILN DRIVE
10 KILN TIRES/ROLLERS
11 OTHER KILN MECHANIC PARTS
12 KILN DUST HANDLING SYSTEM
13 COMBUSTION SYSTEM
14 COOLER VENT FANS
15 COOLER GRATES / FRAMES
16 COOLER DRIVES
17 COOLER BREAKERS
18 COOLER DRAG CHAIN
19 COOLER ID FAN
20 COOLER DEDUSTING
21 COOLER REFRACTORY
22 KILN POWER DISTRIBUTION
23 KILN CONTROL SYSTEM / INSTRUM
24 VARIOUS OTHER

Funct.
Locatio
n

PPPP-15-01180-01
Raw Mill n1
PPPP- 25-01420-01
Cement Mill n1
PPPP- 35-02600-01
Coal Mill n1

Others

GP53 CAUSES INSIDE OTHER

LINES
(DUE TO MAINTENANCE)
01 Mechanical
02 Electrical
03 Instrumentation and control
04 Various other

GP52 CAUSES INSIDE MILL LINE

(DUE TO MAINTENANCE)
01 MILL FFEDING
02 BALL MILL JOURNAL BEARING
03 MILL DRIVE SYSTEM
04 MILL RECYCLING ELEVATOR
05 MILL CLASSIFIER
06 MILL RECIRCULATING FAN
07 MILL EXHAUST FAN
08 MILL DEDUSTING SYSTEM
09 VERTICAL MILL ROLLERS TABLE
10 VERTICAL MILL BALLS / RING
11 HORIZONTAL MILL LINERS / DIAPHARAGMS
12 OTHER DEPARTMENT TRANSPORT
13 PREGRINDER
14 MILL POWER DISTRIBUTION
15 MILLCENTRAL SYSTEM / INSTRUMENTATION
16 VARIOUS OTHER

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1-5 : New Events classification catalogue PM3x

PM3x : Causes outside line (due to
maint.)

PPPP-20- 01330-01
KILN n01

GP31 CAUSES OUTSIDE KILN LINE

(DUE TO MAINTENANCE)
01 PLANT POWER DISTRIB. SYSTEM
02 WATER SYSTEM
03 CLINKER HANDLING
04 LIQUID FUEL SYSTEM
05 COAL MILL GRINDING
06 COAL DUST HANDLING
07 RAW MEAL GRINDING
08 HOMOGENIZATION
09 OTHER DOWNSTREAM
10 OTHER UPSTREAM
11 OTHER GENERAL SERVICE

Funct.
Locatio
n

PPPP-15-01180-01
Raw Mill n1
PPPP- 25-01420-01
Cement Mill n1
PPPP- 35-02600-01
Coal Mill n1

Others
GP32 CAUSES OUTSIDE MILL LINE
(DUE TO MAINTENANCE)

GP33 CAUSES OUTSIDE OTHER

LINES
(DUE TO MAINTENANCE)

01 RAW MATERIAL STORAGE (crane, etc)

02 TRANSPORT TO STORAGE
03 OTHER DOWNSTREAM
04 OTHER UPSTREAM
05 OTHER GENERAL SERVICE

01 Auxiliary and general services

02 Upstream phases
03 Downstream phases

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Calusco, 5-8 June 2006

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Operating time
(running time)

MTBF
Running time / number of
stoppages belonging
to class 5

Up time
1) External causes
Standby time
2) Management causes

Required time
5) Causes due to phase/maint.
Down time
6) Causes due to phase/proc.
Disabled time
External disabled
time

Total time

3) Causes outside phase/maint.

4) Causes outside phase/proc.

Theoretical
up time

7) Stoppages due to production plan

Theoretical
down time

8) Stoppages due to maintenance plan

Non required time

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Calusco, 5-8 June 2006

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Operating time
(running time)

MTBY
Running time / number of
stoppages belonging
to class 3 and 5

Up time
1) External causes
Standby time
2) Management causes

Required time
5) Causes due to phase/maint.
Down time
6) Causes due to phase/proc.
Disabled time
External disabled
time

Total time

3) Causes outside phase/maint.

4) Causes outside phase/proc.

Theoretical
up time

7) Stoppages due to production plan

Theoretical
down time

8) Stoppages due to maintenance plan

Non required time

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Calusco, 5-8 June 2006

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Operating time
(running time)

MTBX
Running time / number of
stoppages belonging
to class 3,4,5 and 6

Up time
1) External causes
Standby time
2) Management causes

Required time
5) Causes due to phase/maint.
Down time
6) Causes due to phase/proc.
Disabled time
External disabled
time

Total time

3) Causes outside phase/maint.

4) Causes outside phase/proc.

Theoretical
up time

7) Stoppages due to production plan

Theoretical
down time

8) Stoppages due to maintenance plan

Non required time

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Calusco, 5-8 June 2006

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Operating time
(running time)

MTBM
Running time / number of
stoppages belonging
to class 5 and 8

Up time
1) External causes
Standby time
2) Management causes

Required time
5) Causes due to phase/maint.
Down time
6) Causes due to phase/proc.
Disabled time
External disabled
time

Total time

3) Causes outside phase/maint.

4) Causes outside phase/proc.

Theoretical
up time

7) Stoppages due to production plan

Theoretical
down time

8) Stoppages due to maintenance plan

Non required time

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1) External causes
Operating time
(running time)

Operation factor
actual operation factor = run factor

Up time

Permits and authorisations

Trade Unions problems
Transportation block
Electrical power lack
Natural events
2) Management causes

Standby time
Required time

Theoretical

Actual
Down time
Disabled time

5) Causes due to phase/maint.

6) Causes due to phase/proc.

External disabled
time

Total time

Electrical power peaks

Full stores
Product quality
Emission quality
Shortage of raw materials,
etc

3) Causes outside phase/maint.

4) Causes outside phase/proc.

Theoretical
availability time

7) Stoppages due to production plan

Non required time

Theoretical
unavailability time

8) Stoppages due to maintenance plan

net run factor = running time hours / ( total time hours - hours from 1 and 7
PIC
Calusco, 5-8 June 2006

)
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Operating time
(running time)

Availability factor
Up time

1) External causes
Standby time
2) Management causes
Required time
5) Causes due to phase/maint.
Down time
6) Causes due to phase/proc.
Disabled time
External disabled
time

Total time

3) Causes outside phase/maint.

4) Causes outside phase/proc.

Theoretical
availability time

7) Stoppages due to production plan

Theoretical
unavailability time

8) Stoppages due to maintenance plan

Non required time

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Calusco, 5-8 June 2006

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Operating time
(running time)

Usage factor
Up time

1) External causes
Standby time
2) Management causes
Required time
5) Causes due to phase/maint.
Down time
6) Causes due to phase/proc.
Disabled time
External disabled
time

Total time

3) Causes outside phase/maint.

4) Causes outside phase/proc.

Theoretical
availability time

7) Stoppages due to production plan

Theoretical
unavailability time

8) Stoppages due to maintenance plan

Non required time

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Calusco, 5-8 June 2006

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3-1 : ZPM13: List of stoppages by cause

By selecting the line(s), you can download data to excel

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Calusco, 5-8 June 2006

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3 -2 : ZPM14: Stoppage analysis

Calculated Indexes
Run factor
Net run factor
Ton Per Day (target)
Actual production of the
WC (For all products)
TPD (actual)
OEE target
OEE actual
MTBF
MTBM
MTBY
MTBX
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Calusco, 5-8 June 2006

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DEFINITIONS (UNI ISO and Italcementi STDs)

TOTAL TIME

REFERENCE TIME PERIOD SET FOR THE TIME SCALE

NON-REQUIRED TIME

THE TIME PERIOD DURING WHICH THE USER DOES NOT DEMAND THAT THE WORK
CENTER IS IN CONDITION FOR EXECUTING A REQUESTED FUNCTION

POTENTIAL UNAVAILABILITY
TIME

PART OF NON-REQUIRED TIME DURING WHICH THE WORK CENTER IS NOT

AVAILABLE

POTENTIAL AVAILABILITY TIME

PART OF NON-REQUIRED TIME DURING WHICH THE WORK CENTER IS IN REST

CONDITION (AVAILABLE BUT NON-OPERATING)

REQUIRED TIME

THE TIME PERIOD DURING WHICH THE USER DEMANDS THAT THE WORK CENTER IS
IN CONDITION FOR EXECUTING A REQUESTED FUNCTION

DISABLED TIME

THE TIME PERIOD DURING WHICH A WORK CENTER IS NOT ABLE TO CARRY OUT
THE REQUIRED FUNCTIONS

EXTERNAL DISABLED TIME

(or EXTERNAL LOSS TIME)

THE TIME PERIOD DURING WHICH A WORK CENTER IS NOT ABLE TO CARRY OUT
THE REQUIRED FUNCTIONS DUE TO EXTERNAL CAUSES

DOWN TIME

THE TIME PERIOD DURING WHICH A WORK CENTER IS NOT ABLE TO CARRY OUT
THE REQUIRED FUNCTIONS DUE TO INTERNAL CAUSES

UP TIME

THE TIME PERIOD DURING WHICH A WORK CENTER IS ABLE TO CARRY OUT THE
REQUIRED FUNCTIONS

STANDBY TIME

THE TIME PERIOD DURING WHICH A WORK CENTER IS IN STANDBY

OPERATING TIME

THE TIME PERIOD DURING WHICH A WORK CENTER IS CARRYING OUT THE
REQUESTED FUNCTIONS

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DEFINITIONS (UNI ISO and Italcementi STDs)

OPERATING TIME

THE TIME PERIOD DURING WHICH A WORK CENTER IS CARRYING OUT

THE REQUESTED FUNCTIONS

THE TIME PERIOD DURING WHICH A WORK CENTER PRODUCED A

SPECIFIC PRODUCT.

THE SUM TOTAL OF THE "WORKED HOURS

WORKED HOURS
SAP

FOR PRODUCING ALL THE PRODUCTS

WITH THE WORK CENTER
IS EQUAL TO THE WORK CENTER "OPERATING TIME"
PP PROCESS ORDER REQUIRES SEPARATED INPUT OF THE W.H.
USED IN THE WORK CENTER FOR PRODUCING EACH PRODUCT.

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Calusco, 5-8 June 2006

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DEFINITIONS (UNI ISO and Italcementi STDs)

MTBF - MEAN TIME BETWEEN
FAILURES

MEAN OPERATING TIME BETWEEN FAILURES (NON-PLANNED STOPPAGES FOR

MAINTENANCE) INSIDE THE WORK CENTER.

MTBM - MEAN TIME BETWEEN

MAINTENANCE

MEAN OPERATING TIME BETWEEN PLANNED & NON-PLANNED STOPPAGES FOR

MAINTENANCE INSIDE THE WORK CENTER.

MTBX - MEAN TIME BETWEEN

FAILURES AND PROCESS
STOPPAGES (Italcementi STD)

MEAN OPERATING TIME BETWEEN PLANNED & NON-PLANNED STOPPAGES FOR

MAINTENANCE AND PROCESS CAUSES INSIDE THE WORK CENTER.

MTBY - MEAN TIME BETWEEN

PROCESS STOPPAGES
(Italcementi STD)

MEAN OPERATING TIME BETWEEN NON-PLANNED STOPPAGES FOR PROCESS

CAUSES INSIDE & OUTSIDE THE WORK CENTER.

AVAILABILITY FACTOR

THE AVAILABILITY OF THE "REQUIRED TIME" DUE TO THE FAILURES (NONPLANNED STOPPAGES FOR MAINTENANCE) INSIDE & OUTSIDE THE WORK
CENTER.

USAGE FACTOR

THE AVAILABILITY OF THE "REQUIRED TIME" DUE TO NON-PLANNED STOPPAGES

FOR MAINTENANCE & PROCESS INSIDE & OUTSIDE THE WORK CENTER AND
MANAGEMENT AND EXTERNAL CAUSES.

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DEFINITIONS (UNI ISO and Italcementi STDs): references

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Calusco, 5-8 June 2006

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