1. Asset Optimization TSPL-Jan,15 Observations

2. Shop floor observations
Section 1
Shop floor observations
Audit Observations • TSPL-January 2015 1

3. Cover plate given in wagon tippler in CHP area
Section 1 – Shop floor observations
Good Observations
Cover plate given in wagon tippler in CHP area
Audit Observations • TSPL-January 2015 2

4. Good practices observed in the unit
Formation of MOC committee for MOC finalization
SAP PM roll out has been done
PM plans have been uploaded in SAP.
Catalog profile for object, cause and event codes have been made in SAP.
Equipment is linked with the unique tag number/ID(KKS code) for greater ease of searching in SAP.
EHS module has been rolled out. Unit has started to use the WCM module for issuing work permits.
Measurement points have been configured in SAP.
Auto notification for marginal anomalies have been configured in SAP.

5. Good practices observed in the unit
Scheduling & tracking of CBM vibration and data collection non compliance has been started.
Thermal imaging started by EMD.
Oil analysis initiated in the unit.
Insurance spare healthiness check started for MMD

6. Shop floor observations in the CHP area
Section 1 – Shop floor observations
Shop floor observations in the CHP area
Audit Observations • TSPL-January- 2015 3

7. Shop floor observations in the CHP area
Section 1 – Shop floor observations
Shop floor observations in the CHP area
Audit Observations • TSPL-January- 2015 4

8. Way Forward- Areas of Improvement

9. Potential areas for improvement – TSPL
Module
SNo
Observations
BEC 1
RCA policy needs to be made for the unit for making RCA for PQC defects. 2
Usage of SAP to be done for capturing data pertaining to maintenance activities. 3
Use of DMS in SAP to be started for creating a central repository for equipment drawings and manuals. 4
Training tobe given in RCA for the team for improving RCA rigour. 5
Criticality analysis to be done for equipment's as per nine point matrix.
For the most critical(top 5) equipment's, condition appraisal needs to be done.
Refurbishment plans need to be drawn up for the equipment based on the results of the condition appraisal. 6
CLTI checklists to be implemented as a pilot in CHP and DM plant.
PM/CBM 7
Monthly MTBF to be calculated for critical equipment's.
MTTR targets to be taken for equipment's with maximum number of defects in the month.
PM compliance(schedule as well as day on day compliance) to be done in SAP.
PM task-list compliance to be monitored in SAP.
Spare Parts 8
Insurance spare policy to be finalised for the plant
VED criteria to be finalised for the plant
SOP Compliance 9
Pictorial representation may be done in the SOP. 10
SOP/SMP audits to be done by the AO/BE team. 11
Critical SOP/SMP to be translated in local language. 12
SOP/SMP training calendar with effectiveness tracking to be made.
Audit Observations • TSPL-January-2015

10. Potential areas for improvement – TSPL
Module
SNo
Observations
Safety 13
Area to be defined for the fire extinguishers. Testing to be done for the same. 14
Interlock bypass register is being maintained. The escalation criteria needs to be made. 15
5S awareness training to be given in the plant including outsourced personnel.
Model area for 5S to be defined in each area and internal audits for 5S to be started.
Contractor Performance 16
Evaluation of the module will be done after contractor mobilisation is over. PO 17
Process score card to be made for the units. 18
MSA to be initiated for the water chemistry lab. Schedule for the same to be made. CI 19
CIP can be taken in energy and water conservation 20
Training in Kaizen to be given by BE team. 21
Suggestion scheme/idea box can be started in the unit.
Audit Observations • TSPL- January-2015

11. Potential areas for improvement – TSPL
Module
SNo
Observations
R&R policy 22
R&R policy to be drafted for recognising best Kaizen and best suggestion, Employee of the month, best contractor partner for the month and best shift. 23
War room to be initiated in the main plant and BOP.
Org & Performance management 24
AO awareness training to be given to the plant personnel by the BE team
Posters for AO to be placed for increasing AO awareness
BP to be communicated to plant personnel
Audit Observations • TSPL-January-2015

12. Thank You