This document contains charts and data related to maintenance performance and energy consumption at Kirloskar Brothers Limited facilities from April 2016 to December 2016. It shows trends in metrics like MTBF and MTTR as well as consumption of resources like oil, coolant, power. Overall the data indicates that maintenance performance was mostly good with metrics either meeting or below targets, while energy consumption was higher than expected/benchmarks in some areas. It also lists some specific maintenance issues addressed at different equipment during this period.

1. This is a proprietary document of Kirloskar Brothers Limited 115-Jan-17

2. This is a proprietary document of Kirloskar Brothers Limited 215-Jan-17
Cumulative MTBF & MTTR
13.96
21.10
28.20
34.10 34.20
36.40
36.15 37.51 33.14
25
0
10
20
30
40
50
Apr-16
May-16
Jun-16
Jul-16
Aug-16
Sep-16
Oct-16
Nov-16
Dec-16
DAYS
MONTHS
TARGET - 25
MTBF Trend
GOOD
4.60 3.40 3.60 3.30 3.90
7.13 7.67 8.07
14.27
1.50
0
2
4
6
8
10
12
14
16
18
Apr-16
May-16
Jun-16
Jul-16
Aug-16
Sep-16
Oct-16
Nov-16
Dec-16
MONTHS
H
O
U
R
S
TARGET – 1.5
MTTR Trend
GOOD

3. This is a proprietary document of Kirloskar Brothers Limited 315-Jan-17
PLD Equipment – Maintenance Performance
17.85
17.82 22.76
23.70
22.62
20.76
13.88
20.45
21.80
25
10
20
30
Apr-16
May-16
Jun-16
Jul-16
Aug-16
Sep-16
Oct-16
Nov-16
Dec-16
DAYS
MONTHS
TARGET - 25
MTBF Trend
GOOD
4.80
3.20
2.82
3.24
5.67
6.62
11.06
4.54
9.37
1.50
0
2
4
6
8
10
12
Apr-16
May-16
Jun-16
Jul-16
Aug-16
Sep-16
Oct-16
Nov-16
Dec-16
MONTHS
H
O
U
R
S
TARGET – 1.5
MTTR Trend
GOOD
24.2
20.2
18
19
20
21
22
23
24
25
D
a
y
s
FY 2015-16
FY 2016-17
1.82
5.70
0
1
2
3
4
5
6
7
8
H
o
u
r
s
FY 2015-16
FY 2016-17

4. This is a proprietary document of Kirloskar Brothers Limited 415-Jan-17
Foundry Equipment – Maintenance Performance
17.52
16.50
21.82
17.87
16.69
22.82
20.17 21.85 24.02
25
0
5
10
15
20
25
30
Apr-16
May-16
Jun-16
Jul-16
Aug-16
Sep-16
Oct-16
Nov-16
Dec-16
DAYS
MONTHS
TARGET - 25
MTBF Trend
GOOD
0.81
2.40
0.80 1.23
2.78
1.28
6.23
3.08
9.8
1.50
0
2
4
6
8
10
Apr-16
May-16
Jun-16
Jul-16
Aug-16
Sep-16
Oct-16
Nov-16
Dec-16
MONTHS
H
O
U
R
S
TARGET – 1.5
MTTR Trend
GOOD

5. This is a proprietary document of Kirloskar Brothers Limited 515-Jan-17
SMPD Equipment – Maintenance Performance
25
20.25 13.73
15.87 16.08
13.49
18.22 18.02 18.18
20.82
0
5
10
15
20
25
30
Apr-16
May-16
Jun-16
Jul-16
Aug-16
Sep-16
Oct-16
Nov-16
Dec-16
DAYS
MONTHS
TARGET - 25
MTBF Trend
GOOD
10.65 5.8
4.70
4.6
8.90
15.50
4.72
3.02
1.81
1.50
0
2
4
6
8
10
12
14
16
18
Apr-16
May-16
Jun-16
Jul-16
Aug-16
Sep-16
Oct-16
Nov-16
Dec-16
MONTHS
H
O
U
R
S
TARGET – 1.5
MTTR Trend
GOOD KVBT 65-Geometrical accuracy problem
Both ball screw repaired & bearing replaced
Miven 500(RKB)-Turret indexing problem

6. This is a proprietary document of Kirloskar Brothers Limited 615-Jan-17
LPD Equipment – Maintenance Performance
15.78
23.23
30.58 37.14
37.68
21.24
16.11
21.03
21.63
25
0
10
20
30
40
50
Apr-16
May-16
Jun-16
Jul-16
Aug-16
Sep-16
Oct-16
Nov-16
Dec-16
DAYS
MONTHS
TARGET - 25
MTBF Trend
GOOD
2.93 1.44 2.97
3.88 5.34
3.07
21.6
5.37
15.60
1.50
0
3
6
9
12
15
18
21
24
Apr-16
May-16
Jun-16
Jul-16
Aug-16
Sep-16
Oct-16
Nov-16
Dec-16
MONTHS
H
O
U
R
S
TARGET – 1.5
MTTR Trend
GOOD
SK 40- Spindle gear box gear worn out.
New gear & bearing fitted

7. This is a proprietary document of Kirloskar Brothers Limited 715-Jan-17
Preventive maintenance
7
47 48
40 38
43
47 48
43
38
46
0
10
20
30
40
50
60
Aug-16
Sep-16
Oct-16
Nov-16
Dec-16
MONTHS
PM
Planned
achieved
M
A
C
H
I
N
E
11
16
26
14
9
18
7
9
8
10
0
10
20
30
40
50
60
Aug-16 Sep-16 Oct-16 Nov-16 Dec-16
Breakdown monitoring of PM m/cs
Nov-16 m/cs
Oct-16 m/cs
Sep-16 m/cs
Aug-16 m/cs

8. This is a proprietary document of Kirloskar Brothers Limited 815-Jan-17
Bar chart-MTBF
8
4.38 4.61
5.83
12.40 12.60
0.00
2.00
4.00
6.00
8.00
10.00
12.00
14.00
16.00
18.00
DOOSAN
HMC(RKB)
HELLER 250(DB) MIVEN 500(KPD) DYNA 100(KPDS) MIVEN 500(DB)
Top m/c With lowest MTBF(SMPD)
D
a
y
s
Turret indexing problem
Set indexing proxy & pressure setting
3.51
6.85 7.27
8.18 8.27
0.00
2.00
4.00
6.00
8.00
10.00
12.00
YOUJI
2000(ATPD)
KBL 120 CNC WOTON
RAPID
VW 4 AXIS
MACHINE
CARANAGI
Top m/c With lowest MTBF(LPD)
D
a
y
s
I/o channel prob
SMPS changed
1.13
3.55 3.63
4.15 4.21
0.00
1.00
2.00
3.00
4.00
5.00
6.00
7.00
8.00
GF MIXER K-LINE SAND PLANT 28CFT SUPERTUMBLAST SHOT
BLAST
BMD MOULDING DRAG CIF NEW SAND PLANT
Top m/c With lowest MTBF(Foundry)
D
a
y
s
Sand accumulation prob
Main chain driving shaft damage
Shaft & spockit changed
427 belt damage
Belt changed427 belt damage
Belt changed
Spindle speed problem
Replaced speed changing coil
Machine stabilizer problem
Check stabilizer & repaired
Sliding door problem
Replaced door bearing

9. This is a proprietary document of Kirloskar Brothers Limited 915-Jan-17
Bar chart-MTTR
9
24.16
6.53 6.06 5.11
4.13
1
6
11
16
21
26
KBL 46” VTL MAZAK
MULTIPLEX
DOOSAN
HMC(SC)
HELLER 250 (KPD) MKL C-600(DB)
Top m/c With lowest MTTR(SMPD)
D
a
y
s
Door jamming problem
adjusted flow control valve
Hydraulic pump problem
Replaced hydraulic pump
235.35
157.00
27.06 27.06
9.45
-30.00
20.00
70.00
120.00
170.00
220.00
270.00
MOULDING M/C NO-1 FAME SHAKE OUT CUPOLA FURNACE NO 1 RAW MATERIAL FEEDING
SYSTEM FOR CUPOLA
PLATE CONVEYOR IN CIF
Top m/c With lowest MTTR(FOUNDRY)
D
a
y
s
259.24
115.16
10.50 9.17 7.01
0.00
50.00
100.00
150.00
200.00
250.00
300.00
STANKO VBM CARANAGI VBM TITAN 3300 VBM KBL 120 CNC YOUJI 2000(ATPD)
Top m/c With lowest MTTR(LPD)
D
a
y
s
I/o channel prob
SMPS changed
Spindle rotating problem

10. This is a proprietary document of Kirloskar Brothers Limited 1015-Jan-17
Oil consumption
2478
2854
2584
2893
2795
3019
2612
2540
2677
2800
3150
2350
2450
2550
2650
2750
2850
2950
3050
3150
3250
Apr-16
May-16
Jun-16
Jul-16
Aug-16
Sep-16
Oct-16
Nov-16
Dec-16
LITERS
PLD
Consumption
TARGET
Bench mark
3663300
2821980
1770353
0
1000000
2000000
3000000
4000000
FY 14-15 FY 15-16 FY 16-17
Oil cost in Rs
45830
37800
24451
1000
11000
21000
31000
41000
51000
FY 14-15 FY 15-16 FY 16-17
Oil in liters

11. This is a proprietary document of Kirloskar Brothers Limited 1115-Jan-17
Coolant oil consumption
11
3354978 3351559
2075131
0
1000000
2000000
3000000
4000000
Coolant oil cost in Rs
FY 14-15 FY 15-16 FY 16-17
31610
22855
13694
0
10000
20000
30000
40000
Coolant oil in liters
FY 14-15 FY 15-16 FY 16-17
1486
801
1330
1527.1
1836
1506.7
1825.2
1881.4
1501
1700
1900
500
1000
1500
2000
2500
Apr-16
May-16
Jun-16
Jul-16
Aug-16
Sep-16
Oct-16
Nov-16
Dec-16
LITERS
PLD
Consumption
Target
Bench mark

12. This is a proprietary document of Kirloskar Brothers Limited 1215-Jan-17
Power consumption
1320276
1509403
1555571
1589122
1548173
1636559 1621182 1640358
1775961
1497657
1422774
1000000
1100000
1200000
1300000
1400000
1500000
1600000
1700000
1800000
1900000
Apr-16
May-16
Jun-16
Jul-16
Aug-16
Sep-16
Oct-16
Nov-16
Dec-16
KWH
PLD
Consumption
Bench mark
Target
17677583 18132649
14196605
1000000
6000000
11000000
16000000
21000000
Power consumption in KWH
FY 14-15 FY 15-16 FY 16-17
111788470 109096400
127476360.4
100000
50100000
100100000
150100000
Power consumption in Rs
FY 14-15 FY 15-16 FY 16-17

13. This is a proprietary document of Kirloskar Brothers Limited 1315-Jan-17
Power consumption
168420
191651184222
189609
199918
232630
153983
178104
163632
50000
100000
150000
200000
250000
Apr-16
May-16
Jun-16
Jul-16
Aug-16
Sep-16
Oct-16
Nov-16
Dec-16
KWH
SMPD Actual
consumption
Expected
consumption
699824
653189
870946
721641
694737
715493
731532
795914
864502
460000
510000
560000
610000
660000
710000
760000
810000
860000
910000
Apr-16
May-16
Jun-16
Jul-16
Aug-16
Sep-16
Oct-16
Nov-16
Dec-16
KWH
Foundries
Actual
consumption
Expected
consumption
147475
158655
156329
159450
143485
154892
114069
120844
140611
100000
120000
140000
160000
180000
200000
220000
Apr-16
May-16
Jun-16
Jul-16
Aug-16
Sep-16
Oct-16
Nov-16
Dec-16
KWH
LPD Actual
consumption
Expected
consumption
29832
41263 43378
27670
20603
55201
61089
50178 48157
20000
30000
40000
50000
60000
70000
80000
90000
Apr-16
May-16
Jun-16
Jul-16
Aug-16
Sep-16
Oct-16
Nov-16
Dec-16
MONTHS
HRC
K
W
H

14. This is a proprietary document of Kirloskar Brothers Limited 1415-Jan-17
Cont..
24780
32250
35337
31738 31951
3726136774
33007
47264
20000
25000
30000
35000
40000
45000
50000
55000
Apr-16
May-16
Jun-16
Jul-16
Aug-16
Sep-16
Oct-16
Nov-16
Dec-16
MONTHS
K
W
H
Pump testing
155475
176718
161764
179422
186708
202614
189442
196630
202869
140000
160000
180000
200000
220000
240000
Apr-16
May-16
Jun-16
Jul-16
Aug-16
Sep-16
Oct-16
Nov-16
Dec-16
MONTHS
K
W
H
Compressor
7043 7097
7314 7379
7215
7673
8293
9053
9494
6000
6500
7000
7500
8000
8500
9000
9500
10000
Apr-16
May-16
Jun-16
Jul-16
Aug-16
Sep-16
Oct-16
Nov-16
Dec-16
MONTHS
Street light
K
W
H
87746
248580
96281
272213263556
230795
326000
256628
299432
30000
80000
130000
180000
230000
280000
330000
380000
Apr-16
May-16
Jun-16
Jul-16
Aug-16
Sep-16
Oct-16
Nov-16
Dec-16
MONTHS
K
W
H
Others

15. This is a proprietary document of Kirloskar Brothers Limited 1515-Jan-17
Pareto chart for power consumption
15
864502
202869
171534 163632
140611 127898
48157 47264
9494
0.00
20.00
40.00
60.00
80.00
100.00
120.00
0
100000
200000
300000
400000
500000
600000
700000
800000
900000
1000000
Power
consumption

16. This is a proprietary document of Kirloskar Brothers Limited 1615-Jan-17
16
4139
4630
3060
3874
4519
3090
3350
3085
3628
3128
0
500
1000
1500
2000
2500
3000
3500
4000
4500
5000
5500
Apr-16 May-16 Jun-16 Jul-16 Aug-16 Sep-16 Oct-16 Nov-16 Dec-16
KWH
Consumption pattern per million
Units/million sale
Bench mark
717.2
636.9
486.4
572.5
467.2
533.9
657.4
529.7 526.2
863
0.0
100.0
200.0
300.0
400.0
500.0
600.0
700.0
800.0
900.0
1000.0
Apr-16 May-16 Jun-16 Jul-16 Aug-16 Sep-16 Oct-16 Nov-16 Dec-16
KWH
Consumption pattern per pump
Units/pump sale
Bench mark
Electricity consumption pattern

17. This is a proprietary document of Kirloskar Brothers Limited 1715-Jan-17
• Titan 2700 vertical screw nut replaced by new one & hard limit dog position corrected to seize heavy oil leakage.
• Titan CNC lubrication pressure low alarm problem corrected by replacing PLC card.
• Carnaghi CNC Z ball screw was jammed. Ball screw repaired & fitted in machine.
• 9B Lathe new rack & pinion fitted.
• Spm boring contractor replaced.
• FN3 milling noise problem solved.
• Kws 500 new telescopic cover fitted.
• Norton grinder gear box piston was damaged, New piston was prepared in house and fitted in machine.
• Woton stabilizer starting in auto mode work completed.
• VBM-150(MF) spindle disc spring replaced.
• New sliding rack & pinion fitted in 9B lathe
• Dyna-65 x & z axis ball screw overhauled.
• NFF furnace lied cover repair & refitted.
• Supetumblast machine main chain driving shaft and sprocket changed.
• Tata shakeout overhauled.
• GF mixer gear box hollow shaft changed.
• K-Line sand plant Magnet belt changed.
• 426 idler pulley remove, rework & fitted.
• 436 belt drive end pulley remove rework & fitted.
• 427 belt replaced
• 116 belt replaced
• cupola no 1 CI bricks lining done
• Arp BMD 1300 cope new scraper ring & guide bar bush fitted.
17
Major work

18. This is a proprietary document of Kirloskar Brothers Limited 1815-Jan-17
Improvement
18
• Stanko VBM gear box & spindle motor overhauled.
• Youji 2000 motor overloading ,ATC over travelled & lubrication pressure problems are permanently solved.
• Pensotti CNC lubrication made functional.
• 52” VTL panel reconditioning work started.
• 437 Elevator Belt replaced by light weight SS fabricated Bucket in K-line.
• Omega Sand Mixer(HF) arm made motor driven for movement.
• Teflon scraper inserted to minimize sand contact to Table of BMD ARPA1300 & KBMD 450 Molding Machines.
• Doosan(SC) oil leakage arrested.
• Emergency stop problem solved in mazak multiplex.
• Miven 500(DB) oil leakage from pump arrested.
• KWS-500(SC) oil leakage arrested.

19. This is a proprietary document of Kirloskar Brothers Limited 1915-Jan-17
Encon
• Replacement of 30 nos of 67W PL lamps with 30 nos of 30W LED lamps.
• Rescheduling of heavy foundry and HRC to maximize “A” zone utilization.
• Introduction of cold washing