JK PAPER LTD. UNIT: CPM

1. 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

2. CPM Present Capacity , 145000 TPA Pulp & Paper Plant Packaging Board 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 • Commenced production in 2007 • Capacity: 90,000 TPA • Products: Multi Layer Packaging Boards

3. 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 Shareholder Wealth / Profit Migration Increase productivity Generates value, profit and wealth Maintain International Products Standard Lowest manufacturing cost Best Maintenance Practice Produce qualitative as well as quantitative products Changing Customer Priorities Good maintenance practice is one of the keys to increasing productivity and profits

4. BRIEF MANUFACTURING PROCESS OF MULTI LAYER PACKAGING BOARD Screening Pulping Thickening Refining Blending & cleaning Dilution, centricleaning Surface Sheet formation Drying and screening sizing & consolidation 3 Stage coating & IR Drying Calendaring Reeling Rewinding Storage in Sheeting & Dispatch godown Packing

5. 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 MaintainabilityImprovement (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.

6. MAINTENANCE PRACTICE STEPS STEP BY STEP - PLANNED MAINTENACE

7. CATAGORISATION EQUIPMENT • According to Equipment contribution in Production, equipment categorized in ABC Critical group. • Critical Equipment • Sub-Critical Equipment • Non critical Equipment

8. EQUIPMENT DATA SHEET Equipment data sheet contains information regarding Specification, MOC, Drawing details, Lubrication details & Spare details.

9. BASIC OF ALL MAINTENANCE ACTIVITIES IS 5S PRACTICE

10. MAINTENANCE PRACTICE STEPS STEP BY STEP - PLANNED MAINTENACE

11. 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, History of jobs carried out Specification with drawing details Spare list with ERP code SOP (Standard Overhauling procedure ) Modification done if any

12. SOP – STANDARD OVERHAULING PROCEDURE SOP sheet contains details like dismantling & assembling procedures with check point , tools used & safety measure

13. MAINTENANCE ACTIVITY 1. BREAK DOWN MAINTENANCE • 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. • 2. TIME BASED MAINTENACE (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, Rolls- Wire, 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. • 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. 2. TIME BASED MAINTENANCE (TBM) 3. CONDITION BASED MAINTENANCE (CBM)

14. 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, Prepare detailed analysis using 7QC tools Collect details of incurred losses & cost – Direst & Indirect Record findings & Kaizens plans for its implementation. BREAKDOWN ANALYSIS FORMAT

15. 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.

16. 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. 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.

17. Tie Rod 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 Action Taken – Fabricated Tie rods are installed crosswise in Coater unit Structure to dampen vibrations.

18. 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 - Installseparate 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.

19. 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. Blotch Detected Auto Marking system Blue Dye markings Alarm System Laser Sensor DSC panel for record • 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.

20. SAFETY • Safety measurement taken to safe guard • Occupants • Equipments • Raw & Finished product. • Company's Property WATER TANK CASE STUDY NO.# 6 ( SAFETY MAINTENANCE) P 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 SHOWER IR 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. BACKING ROLL

21. MAINTENANCE PREVENTATION • Maintenance prevention activity impart on equipment’s, • Reliability , • Maintainability , • Economy, Operability, • Safety & flexibility , • Minimize Life Cycle Cost (LCC) PAC Service PAC Storage M/L White Water Channel B/L White Water Channel T/L White Water Channel CASE STUDY NO.# 7 ( MAINTENANCE PREVENTATION) P P P P 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 . 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

22. 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.

23. 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

24. 2. OVERALL EQUIPMENT EFFCTIVENESS (OEE)

25. 3. BREAK DOWN CHART End of Presentation…