Extrusion Process Equipment Upkeep for Better Plant Performance
Rajat Agarwal, Prasanna B. Venkatesha, Bhoruka Aluminium Ltd., Mysore, India
Track: MANAGEMENT ISSUES - Operations
ABSTRACT—The focus of the paper is to showcase a substantial increase in the plant
performance by controlling equipment downtime. Project “MISSION 95” was started at Bhoruka
Aluminium Ltd., (BAL), Mysore, India, in August 2008. The goal was to achieve 95 percent
equipment availability, excluding preventive maintenance stoppage and breakdowns. The firm
had experienced average equipment availability of 70 percent in the past two decades. Reducing
the breakdown and upkeep of the equipment posted many challenges, which can be categorized
as: Technical, including changes in planning technique and implementation of new processes like
KPI, Preventive maintenance and planning, SAP, MTTR, MTBF, daily checks etc.; and Adaptive,
including motivating and training the employees towards the project goals by RCA, OPLs,
Kaizens, and training and motivation modules. Starting in early 2010, BAL crossed the 95
percent barrier, and since then has been consistently maintaining uptime of 95 percent or above.
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