Param Express. Key Activities Concluded. Watch Out For

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1 Param Express Key Activities Concluded Maintenance optimization for 1st wave of critical equipment completed for all assets except MPL & Haldia 155 equipment FMEAs have been customized by sites. Spares level setting exercise for high value items completed at all sites. Overhaul assessment Time & motion study launched in MPL. CGPL merit order tool rolled out. Three RCM Immersion training program conducted across sites to develop trainers. First reliability analytics training conducted by Prof. M Kulkarni, IIT Bombay. Watch Out For Preparation of Phase B plan. Strong push on value initiatives across all sites. Conduct value initiative workshop across sites Roll-out of the modified RCA process. Complete balance data cleansing for all equipment in the first set/ wave-1. Review of FMEA by external expert. Conduct 2 nd reliability analytics training conducted by Prof. M Kulkarni, IIT Bombay. Launch of RCM Corporate video. Finalization of IT vendor.

2 Phase B As Param Sankalp completes one successful year in Nov 2017, it would be a great time to reflect on the key achievements of the past year. During the past year (Phase A), Param Sankalp has laid a foundation to adopt the RCM way of working on the ground. As a part of this exercise, multiple processes were standardized, e.g. codification and classification, affecting overall over 32,000 equipment across 7 sites at Tata Power. 65 equipment FMEAs were created as a proactive measure to improve equipment reliability. 7 process FMEAs were created to minimize process losses including Coal management, SHR, APC, Water management, Ash management, Start-up management and Billing. Based on the outcomes of codification / classification and FMEAs, maintenance tasks were optimized for top 10 out of 65 equipment. Data management and cleansing remained a continuous enabler during Phase A to accelerate the changes through IT systems like SAP. While a few pending activities remain to be closed from Phase A, we have kicked off phase B to sustain the momentum of change. The focus of Phase B will be to sustainably adopt the newly defined RCM ways of working while capturing defined value targets. Changing the operatingmodelfromphasea,phasebwillhaveanincreasingroletobeplayedbythe respective sites which will be defined in the site handover document. As we start Phase B, site teams will become the torch bearer to drive tangible (monetary and non-monetary) value through the program. To capture the defined targets, initiative identification is expected to happen through internal workshops at respective sites, external experts visits, etc. The sites have already initiated these brainstorming workshops e.g., CGPL conducted their first workshop on the topic of SHR on 22th Nov. Similar other workshops are planned across all sites covering key O&M topics to identify areas of value opportunity. The program sponsors look forward to continued support from the broader Tata Power team, to make Param Sankalp a great success. Let us all take the pledge (Sankalp) to make our work place a safer and more efficient one on this occasion!

3 Spares Management Significant progress in BOM implementation Upload of spares BOM created in the first phase of the program is being initiated across sites. The excel files created by each site were further refined during level setting exercise as some discrepancies were noticed. Uploaded BOM will be accessible to all users and new items can be added or existing items can be modified/ deleted using the ib02 transaction in SAP. This will enable simplified processes for inventory tracking and ordering. Since items are mapped to multiple equipment, an exact number for the installed quantity will be available which is being used in ensuring appropriate inventory levels. Further to the level setting exercise, the safety stock, reorder level and quantity, once verified by department heads, will be uploaded in SAP to enable tracking of inventory against desired levels. We will also initiate criticality classification of items not covered in level setting till now, i.e. low value items. This will act as a guide in deciding which items should be focused on from inventory management perspective. RCM Training session conducted for contract workers by Aakar As a part of the Param Sankalp initiative, Tata Power along with Aakar Empowerment private Limited conducted a half day training module for contractors and supervisors, emphasising on basic aspects of Reliability Centred Maintenance(RCM). The Module focussed on development of various behaviour and technical traits required for successful implementation of RCM across Tata Power and the role of supervisors in Param Sankalp. The program was successfully launched at CGPL on 3rd of August 2017 and subsequently was conducted at Jojobera, MPL, Haldia, Trombay, Transmission, Distribution and Hydro's. There wasactive participations across various operating assets in "Role Plays" designed to illustrate various pit falls in day to day maintenance activities and the corrective measure to be taken to enhance the overall health of the asset. Total 320 supervisors (Service providers and on company roles) were trained in the first wave of the training module.

4 My Corner Conversations with you Mr. Purushottam Thakur, CEO, MPL. Lead for all RCM Initiatives at MPL RCM has the goal of ensuring that the system operates reliably through the application of an integrated maintenance strategy. RCM is a systematic approach to defining a maintenance Param Sankalp or RCM, is an initiative for excellence in Operation and Maintenance of the plants and the assets of Tata power. A time proven strategy deployed in aviation industry which is now being deployed at Tata Power. The initiative will help in defining optimized maintenance strategies, improved operational processes / practices and better resource utilization. It is known that a group activity can lead to a better outcome and this mechanism has been rightly ploughed in to complete the arduous tasks of various phases in the RCM program. Boot Camps, knowledge sharing, brainstorming sessions, detailed discussions and many such activities are taking place across all the divisions of Tata Power and it s heartening to know that everyone is contributing to this initiative of transformation. RCM is about knowing your equipment better than anyone else; it is about analyzing and predicting failures; it is about learning together to become the master of your system and most importantly, it is about documenting your learnings and converting them into action points to eliminate the risks of failure. A very enriching experience in the whole process. We have a long way to go on this path of transformation and I am sure you would have plucked a lot of low hanging fruits in our journey to make the journey a worthwhile. Mr. Tarun Kant, Lead Engineer - Mechanical Maintenance, Part of Codification, FMEA and Spares Management teams strategy, hence it will help us to select the right mix of PM, CM and CBM making sure we are cost effective and are paying more attention to our critical equipment. RCM is a data-driven approach that provides a rational for maintenance to minimize unnecessary and potentially risky disruption while maximizing the durability and health. The core purpose of this program is to avoid failures at all levels, preserving function and performance continuity. Codification of equipment is the backbone of the RCM program as it will help us to address the dominant cause of the equipment failures. The right Parent-Child mapping of equipment will help us to use analytical processes to determine the proper balance of planned and unplanned maintenance of equipment based upon the failure rate of equipment. The program has several stages to achieve its ultimate goal, which will be difficult to achieve without the coherence of the people involved/affected by this programme. We should make RCM a habit in our current maintenance approach and not wait till the program is fully implemented. We should start from now and work hard to make this strategy a habit.

5 Answers for quiz of the month - Crossword Answers: % (66 out of 66) 2. Merit Order Tool 3. Maintenance & Resource; equipment availability 4. Ash and Water Management 5. Four What percentage of equipment FMEAs planned has been completed? 2. Which tool is being rolled out in CGPL in the next month? (Hint: This will help the control room to efficiently load the units and run the units at minimum heat rate?) 3. Legacy maintenance practices which do not follow a data-driven approach lead to high and low. 4. Which two process FMEAs have been completed in October? 5. number of RCM immersion trainings have happened at Tata Power. 6. number of measurement points have been added to SAP as a part of maintenance optimization exercise. Winner of August Newsletter are: Anoop Singhal Sanjay Neve Rohan Todankar Quiz of the Month Newsletter Quiz 1. How many supervisors were trained in the first RCM training conducted by Aakar? 2. How many RCM Immersion trainings have been conducted till now? 3. How many equipment have been covered under codification and classification? 4. and study was done in MPL for overhaul assessment. 5. How many FMEAs have been customized by sites? 6. New items can be added or existing items can be modified/ deleted in BOM using the transaction in SAP Send your responses to paramsankalp@tatapower.com First three correct responses would be awarded. Did you know? Below mentioned seven questions sets out the minimum criteria that any process should meet before it can be called RCM. 1. What is the item supposed to do and its associated performance standards? 2. In what ways can it fail to provide the required functions? 3. What are the events that cause each failure? 4. What happens when each failure occurs? 5. In what way does each failure matter? 6. What systematic task can be performed proactivelytoprevent,ortodiminishtoa satisfactory degree, the consequences of the failure? 7. What must be done if a suitable preventive task cannot be found?

6 A complex RCA (Root Cause Analysis) process leads to extra effort but ineffective outputs A comprehensive yet streamlined RCA process with minimal manual intervention is an important foundational element to ensure system reliability The 8D report is now automatically triggered for all important failure notifications! RCA notifications are helping me and my team keep track of the status of CAPAs. If you have any questions, please write to us at paramsankalp@tatapower.com