SHASHI THAKUR Project Report

PREVENTIVE SERVICE MAINTENANCE OF RMC PLANT
Project Report
On
“Preventive Service Maintenance of RMC Plant”

For
“Ultratech Cement Ltd. (Ready Mix Division)”
Goregaon, Mumbai.
Submitted to the University of Pune
In Partial Fulfillment of
MASTER OF BUSINESS ADMINISTRATION
By
“Shashi Dinanath Thakur”
Under the guidance of
“Dr. M. S. Kadam”
“JSPM’s ABACUS INSTITUTE OF COMPUTER APPLICATION”
2008-2010
JSPM’S AIOCA, PUNE

ACKNOWLEDGEMENT
A work is never a work of an individual. I owe a sense of gratitude to the

intelligence and co-operation of those people who had been so easy to let me
understand what I needed from time to time for completion of this exclusive
project.
I am greatly indebted to my guides Dr. M. S. KADAM , faculty guide for

Production & Materials Management (Summer Internship), JSPM’s Abacus
Institute Of Computer Applications & Mr. ANIL NAYAR , Plant Head ,
Ultratech Cement Ltd. (Ready Mix Division), Goregaon , Mumbai for their
constant guidance ,advice and help which enabled me to finish this project
report properly in time .
I am also grateful to Dr. SAGAR S. JHAMBHORKAR, DIRECTOR,

JSPM’s Abacus Institute of Computer Applications, for permitting me to
undertake this study.
Last but not the least, I would like to forward my gratitude to my friends &
other faculty members who always endured me and stood with me and
without whom I could not have completed the project.
Shashi Dinanath Thakur
DECLARATION
2

I do hereby declare that this piece of project report entitled “Preventive

Service Maintenance of RMC Plant” at different units of Ultratech
Cement Ltd. (Ready Mix Division) for partial fulfillment of the requirements
for the award of the degree of “MASTERS OF BUSINESS
ADMINISTRATION” is a record of original work done by me under the
supervision and guidance of Dr. M. S. Kadam, JSPM’s Abacus Institute Of
Computer Applications. This project work is my own and has neither been
submitted nor published elsewhere.
PLACE: SHASHI D. THAKUR

DATE:
CONTENTS

page
Sr. no. Topic no.
ACKNOWLEDGEMENT
EXECUTIVE SUMMARY
1 Chapter 1: INTRODUCTION
1. A Concept & context of the study
1. B Objectives of the study
1. C Scope & limitation of the study
2 Chapter 2: PROFILE OF THE ORGANISATION 20

2. A Name, Address & Location of company 21
2. B Vision & Mission 22
2. C Historical background 23
2. D Organizational chart 27
2. E Product profile of company 34
2. F Awards
3 Chapter 3: RESEARCH DESIGN & METHODOLOGY 35

3. A Sources of data collection 36
3. B Sample Description 37
4 Chapter 4: CONCEPTUAL BACKGROUND 38

4. A Theoretical Background 39
4. B Conceptual description of topic
5 Chapter 5: DATA PRESENTATION & ANALYSIS 49
6 Chapter 6: FINDINGS & CONCLUSION 75
BIBLIOGRAPHY 81
ANNEXURE 83
COLLEGE
4

CERTIFICATE
COMPANY
5

CERTIFICATE
EXECUTIVE SUMMARY
Summer training is an integral part of the course curriculum for the degree of
MASTER OF BUSINESS ADMINISTRATION. It provides valuable

experience to management students & exposes them to functional areas of

management.
It also provides them with an opportunity to be a part of real corporate

world. With the same object, I took my summer training at Ultratech Cement
Ltd. (Ready Mix Division).
The main points on which I laid stress were:-
Ξ To gain depth knowledge about the actual working of the company.
Ξ To study the various maintenance procedures practiced & adopted.
Ξ To set up and follow a regular maintenance schedule to keep the batch

plant in good working condition.
The work environment of Ultratech Cement Ltd. was absolutely encouraging

and full of support. During my training, on one hand I learned much about
Ultratech their work culture, on other hand I got the knowledge of
maintenance activities.
The knowledge I have gained has been presented in the form of report has
been made in a manner such that it is easy for the reader to know maximum
details in minimum time.

Chapter 1
INTRODUCTION
CONCEPT & CONTEXT OF THE STUDY
Maintenance
Maintenance is defined as “the combination of all technical

and administration actions, including supervision actions,
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intended to retain an item in, or restore it to, a state in which

it can perform a required function”. It is a very important
part of running any industrial plant.Maintenance can also be
described as the action that sustains plant production. Many
industries all over the world have begun to realize the
importance of having an effective maintenance policy,
especially because the typical situation is that the activity is
constrained by resource availability. Millions of dollars are
now spent every year trying to preserve the different
processes involved in production. There are three major
reasons why maintenance is perceived as important and
they include the following:
1) Safety:
Most plant incidents are a result of bad maintenance

practices or when maintenance is not done properly.
Equipment pieces can hardly be isolated from each other in a
process plant and therefore the effect of improper
maintenance on one piece of equipment leading to its failure
is felt in other equipment and can lead to unsafe situations.
Unfortunately, some of these equipment effects do not
present themselves immediately.
2) Equipment and Equipment Parts replacement

Costs:

The costs associated with any piece of equipment can be

related to the speed with which that piece of equipment
deteriorates. The faster the condition worsens, the faster the
equipment performance worsens. Usually, the decline of
equipment conditions is slowed down by proper
maintenance.
3) Economic Losses:
Maintenance reduces downtime in a plant associated to

major failures. A large cost (lost revenue) is associated to
each plant shutdown on top of the cost of repairs. However,
not all equipment failures lead to plant shutdown. Some
failures deteriorate plant performance and most have
associated lost revenue on top of the cost of repair as well.
Because of its significant impact on plant performance (both

in economic and technical term), maintenance management
and optimization have been extensively studied by people in
the field of Operations Research and Manufacturing
Engineering.
Plant maintenance can easily be divided into two general

types. They include the following:
1) Corrective Maintenance
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2) Preventive Maintenance
1) Corrective Maintenance (repair):
This type of maintenance deals with fixing already

malfunctioning equipment. The key here is the ability to
react quickly to any failure. For corrective maintenance
alone, no steps are taken before the actual breakdown of the
equipment. When this occurs, the equipment is immediately
replaced as long as resources (labor and/or parts) are
available.
2) Preventive Maintenance:
This type of maintenance is geared towards taking actions

that help reduce the number of failures of specific
equipment. It is usually time and equipment driven. In other
words, preventive maintenance has to follow a schedule that
is created based on different factors depending on the piece
of equipment being considered. Two major factors that help
the scheduling of preventive maintenance are the difference
between the cost of the maintenance program and the
reduction in repair costs and secondly, the regularity of that
equipments use. That is, it might not be profitable to perform
preventive maintenance on some equipment pieces because
they have low replacement costs or are not used regularly. In
addition, Resource limitations usually subvert carefully
planned maintenance schedules because at times certain
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equipment failure is in need of immediate repair (because of

safety or high economic loss issues) that personnel assigned
to preventive maintenance is required to attend these
emergency repairs.
OBJECTIVES
PRIMARY OBJECTIVES:
(i) Ensuring maximum plant availability by preventing unexpected

breakdowns & by reducing shutdown periods.
(ii) Elimination of unsafe conditions that cause accidents thereby

ensuring safety of the workmen.
SECONDARY OBJECTIVES:
(iii) To keep all productive assets in good working condition.
(iv) To minimize accidents through regular inspection.
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SCOPE OF THE PROJECT
♣ Ultratech Concrete is already well established in the market, but there

are lots of others things that have to be understood such as identifying
and examining plant deficiencies.
♣ One of the main purposes is to help the organization implement

procedures that will lead to efficient maintenance practices.
♣ The study also aimed to recognize how the maintenance process

affects sales & other aspects.
♣ Ultratech’s ability to manage efficiently its logistics, as well as to

ensure the quality, safety, security and timely delivery of its products,
services and solutions.
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♣ Some other benefits of preventive maintenance include reduction in

number of safety hazards, lowering inventory costs & reduction in
number of physical plant failures calling for emergency.
LIMITATIONS OF THE PROJECT
Due to the following unavoidable and uncontrollable factors, the result might
not be accurate. Some of the problems faced while are as follows:-
o Stipulated time period and cost constraints.
o Chances of some biasness could not be eliminated.
o The study is based on the perception, ideas and preferences of the
respondent, which are complex in nature and depend upon subjectivity
of the individual.
o The research was carried out at GOREGAON RMC PLANT;
therefore findings and suggestions are limited to that plant only.
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Chapter 2
PROFILE OF THE
ORGANIZATION
15

GOREGAON RMC PLANT
UltraTech Concrete comes from the house of the Aditya

Birla Group. Its experience in cement production using state of the art
technology has helped it in meeting requirements of discerning customers by
providing variety of cements to suit different needs. The group has forayed
into forward integration into high quality concrete in production, delivery
and placing. UltraTech has developed expertise to meet national and
international standards in meeting customer expectations. Aditya Birla
Group, of which UltraTech Concrete plants are present in Mumbai, Pune,
Nasik, Nagpur, Ahmedabad, Surat, Gurgaon, Noida, Jaipur, Chandigarh,
Chennai, Bangalore, Hyderabad, Cochin, Vizag, Ludhiana, Kolkata and
many more are coming up. UltraTech Concrete is manufactured at state-of-
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the-art computerized automatic batching & mixing plants with contemporary

technology.
Handling of fly ash and slag are done from closed bunkers to silos directly.
Separate weigh-batchers are provided for each ingredient like cement, water,
admixtures and aggregates.
The weighing is done on

sophisticated electronic weigh
batchers. Precise weighing of all
materials is done through
electronic load cells made up of
special alloys. Homogeneous
mixing of concrete is ensured by
use of special high-efficiency
mixers like pan-type or turbo-twin
shaft mixers.
A fully equipped onsite plant laboratory is available at each plant. A

Sprinkler system is installed to ensure temperature control of aggregates in
hot weather. In line with Group’s focus towards environment and eco-
friendliness all silos are installed with bag filters and level indicators to
avoid any kind of pollution.
Processes are in place for effective and periodic maintenance and calibration
of all critical components. Laser sensor and moisture control are used for a
stringent quality assurance.
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Well trained and experienced engineers are available at every plant to take
care of the quality of concrete.
VISION & MISSION
 Vision
To be a premium global conglomerate with a clear focus on each

business.
 Mission
To deliver superior value to our customers, shareholders, employees and

society at large.
 Values
Integrity
Commitment
Passion
Seamlessness
Speed
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HISTORICAL BACKGROUND
Ready mix concrete was first patented in Germany in 1903, its

commercial delivery was not possible due to lack of transportation needs.
The first commercial delivery was made in Baltimore USA in 1913.The first
revolving drum type transit mixer was developed in 1926.
In 1931, a RMC plant was set up for

the construction of Heathrow airport,
London. In the mid 90’s there were
about 1100 RMC plants in UK
consuming about 45% of cement
produced in that country. In Europe in
1997 there were 5850 companies
producing a total of 305 million cusecs
of RMC.
In USA by 1990, around 72% (more than

2/3rd) of cement produced was being used by various RMC plants. In Japan
first RMC plant was set up in 1949. By 1992 Japan was the then largest
producer of RMC, producing 18196 million tons of concrete. In many other
19

countries of the world including some of the developing countries like

Taiwan, Malaysia etc, RMC industry is well developed.
Development in India
In India RMC plant arrived in 1950’s and use was
restricted to only major construction projects such as, Bhakra dam was the
first projects were RMC was used. Later on RMC was used for other large
projects such as construction of long span bridges, industrial complexes etc.
The first RMC plant was set up in Pune in 1993.
During the past decade, the construction industry in India

witnessed remarkable growth, in which the ready mix (RMC) industry can
claim to be a proud partner. Historically speaking, India missed the benefits
of RMC technology for decades. It was only in the early nineties. During the
past few years, housing & infrastructure have remained the major expansion
areas. Faster speed & improved quality of concrete have been the two major
demands of these sectors. Ready mixed concrete was the right solution for
this & it was heartening to see that the RMC industry responded positively to
these demands. The result was rapid growth of RMC industry. This industry,
which was initially confined to metropolitan cities, later spread to the two
tier & three tier cities, maintaining the fact that RMC was the right solution
for different markets. Currently it is estimated that India produces around
20-25 m3 of concrete annually from around 400-500 RMC facilities.
In all the developed as well as most of the developing nations,

use of RMC for construction has made it possible to achieve speed and
quality. The introduction of commercial RMC in India is about a decade old,
but in recent years it has become the favorite choice of architects, engineers
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and consumers. The ingredients of good and bad concrete are the same. The
difference lies in the technology used for production, transportation and
placement. The making of concrete is an art as well as a science. Science
because all the ingredients are proportioned as per the standard codes of
practice to get the targeted strength & durability, and an art because in
addition to accurate proportioning, quality of concrete depends on the way it
is mixed, placed, compacted, finished, cured and protected. Ready mix
Concrete (RMC) technology results in a perfect blend of the Art and
Science.
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ORGANIZATIONAL CHART
PLANT
INCHARGE
Mr. Anil Nair
VERSOVA PLANT GOREGAON PLANT
QUALITY LAB STORES ACCOUNTS
Mr. Amar Mr. Prakash Mr. Bhushan
PRODUCTION & OPERATIONS

MAINTENANCE
Mr. Rajesh Mallick
Mr. Asis Minoj
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PRODUCT PROFILE OF THE COMPANY
On the basis of the applications of the concrete supplied by Ultratech

Concrete Ltd. it can be classified as follows:
Classification Grade Applications
M10 PCC (Plain Cement Concrete) e.g. Leveling course,

bedding for footing, concrete roads, etc.
Ordinary M15 PCC e.g. Leveling course, bedding for footing, concrete
roads, etc.
M20 RCC (Reinforced Cement Concrete) e.g. Slabs, beams,
columns, footings, etc. (for mild exposure)
M25 RCC (Reinforced Cement Concrete) e.g. Slabs, beams,
columns, footings, etc.
M30 RCC e.g. Slabs, beams, columns, footings, etc.
M35 RCC e.g. Slabs, beams, columns, footings, etc.
M40 RCC e.g. Pre-stressed concrete, slabs, beams, columns,
Standard
footings, etc.
M45 RCC e.g. Runways, Concrete Roads (PQC), Prestressed
Concrete Girders, RCC Columns, Prestressed beams
M50 RCC e.g. Runways, Concrete Roads (PQC), Prestressed
Concrete Girders, RCC Columns, Prestressed beams
M55 RCC e.g..Prestressed Concrete Girders and Piers
RCC work Where high compressive strength is required

M60
such as high rise buildings, long span bridges, ultra-thin
High Strength
white topping etc and constructions in aggressive
to
environment e.g. Spillways of dams, coastal construction
M80
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In addition to producing normal grade concrete ranging from M10 to M80, we

produce customized special types of concrete for different applications.
Types of Special Application

Concrete
High Volume Fly Ash Mass concrete, raft foundations, roads, pavements etc.
Concrete
Silica fume concrete All high strength concrete applications in extreme
environmental exposure condition like marine structure etc.
GGBS, Slag based All underground RCC application requiring high chemical
concrete resistance and enhanced durability
Ternary blend All RCC application directly in contact with aggressive soil /
concrete chemicals in marine environment and in sewage / effluent
treatment plants
Light weight concrete Repair and rehabilitation work, for thermal insulation, light
weight structural fill, and light weight pre - cast panel etc
Corrosion resistant All types of RCC applications in high water table area
concrete including work near coastal areas, water tanks, etc
Polymer concrete Repair and rehabilitation work for floorings and buildings
where high early strength is required
Self Compacting Thin sections and elements with congested reinforcements.
Concrete Recently IS 456 has also included SCC with specifications in
its codal provision.
Colored Concrete For architectural and aesthetic use
Fibre-reinforced For concrete with higher ductility and abrasion/erosion
Concrete resistance
Pervious Concrete Concrete for parking areas, pavements, drive-ways to ensure
drainage or rain-water harvesting
Water-proof Concrete Terraces, basements, water contact structures
Temperature Mass concrete, hot-weather concrete etc.
Controlled Concrete
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As a preferred supplier to the Bandra-

Worli Sea Link, UltraTech has played an
integral role in the project. Its high quality
cement befitted the stringent essentials of
this demanding project, like the numerous
other projects it does across India.
Construction of such a monumental
landmark comes with a host of challenges
where quality and precision are non-
negotiable.
25

AWARDS
Clients have consistently endorsed UltraTech's highest quality standards. The
list of awards it has won is testimony to UltraTech's uncompromising
standards on product quality.
National awards
2000-2001 Indo-German Greentech Environment Excellence Awards

by the Greentech Foundation, New Delhi
1999-2000 Business / Trade Award Jamanalal Bajaj Uchit Vyavahar
Purashkar
1994-95 Special Gold Award By The Council of Industry & Trade
Development for Quality
1992 Productivity National Award By Indian Merchant's
Chamber, Mumbai
State level awards
2000 Vidarbha Industrial Industry Safety Committee
1994 Nagpur Garden Club, Nagpur
1993 Horiculture District Collectorate, Chandrapur

Vidarbha Industrial Industry Safety Committee
1992-93 Mineral Conservation Award IBM, Nagpur Region
26

Chapter 3
RESEARCH DESIGN
&
METHODOLOGY
RESEARCH DESIGN
27

A research design is a framework for conducting the research project. It details the
procedure necessary for obtaining the required information, and its purpose is to design a
study that will test the hypothesis of interest, determine possible answers to research
questions and provide the information needed for decision making.
Formulating the research design involves the following steps:-
1. TYPE OF RESEARCH DESIGN: EXPERIMENTAL RESEARCH.
Experimental Research was used to examine the usefulness of preventive maintenance

on the RMC plant & its various components.
2. METHOD OF DATA COLLECTION:
(a) Primary data collection:
Primary data is the first hand information obtained by investigator. Primary data can be
collected by observation, by interviews, by face to face questioning, by using
questionnaire, when the needed data does not exist or are out-dated, inaccurate,
incomplete, or unreliable.
(i) Observation Method
Observation Method was used for 15 days as a scientific tool to

record the data & was subjected to checks & controls on reliability
& validity
(ii) Interview Method
Interview Method was used to gain in depth information & the
most spontaneous reactions were secured.
(b) Secondary data collection:
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Secondary data is collected by others already and the researcher is using that information
for his own research purpose. Secondary data can be collected from published reports,
newspaper, websites, and journals, publications of national and international organization.
It was obtained from:
(i) Maintenance Register

(ii) Check Lists
3. Sample Description
(a) Method of sample selection
(ii) Non-Probability sampling
Non-Probability sampling method was used for sample selection as

the items were selected deliberately which included all the units of
RMC plant.
(b) Size of sample.
The sample includes 8 elements viz., the compressor, mixer & other
components of RMC plant etc.
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Chapter 4
CONCEPTUAL
BACKGROUND
THEORETICAL BACKGROUND
DEFINITION:
30

Θ Maintenance encompasses all those activities that maintain facilities & equipment
in good working order so that a system can perform as intended.
Θ Maintenance can also be termed as asset management system which keeps them in
optimum operating condition.
THEORY:
Maintenance is often viewed as an activity for slow times, and

its importance is underestimated. This attitude, however, is a shortsighted one that can
cost plant money in both repair costs and lost business due to downtime. The way to keep
batch plant in good working condition is to follow a regular preventive maintenance
schedule. Depending on the specific batch plant, manufacturers may recommend different
schedules for lubrication and inspection of components.
When it comes to the batching control panel and its related

electrical equipment, having a qualified specialist perform the maintenance may be a
good idea. After you have determined the recommended maintenance procedures for your
batch plant, you then must consider what other items at your plant may not have been
mentioned in the operation manual. Such components may include gear boxes, bearings,
bushings, and an air system.
Because such items and other devices are common at ready mix
operations, manufacturers may not provide specific maintenance instructions for them. It
is necessary, therefore, to determine the best schedule for these components based on
experience and other recommendations. It should be kept in mind that safety is crucial
when maintenance is being performed. Employees should be instructed to lock out
equipment that is being worked on, tag it, and notify other employees in the work area
that maintenance is under way. Many accidents can be prevented if all employees at the
plant is made aware of maintenance procedures being done.
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Preventive Maintenance
Preventive maintenance has the following meanings:
The care and servicing by personnel for the purpose of maintaining equipment and
facilities in satisfactory operating condition by providing for systematic inspection,
detection, and correction of incipient failures either before they occur or before they
develop into major defects.
1. Maintenance, including tests, measurements, adjustments, and parts replacement,

performed specifically to prevent faults from occurring.
While preventive maintenance is generally considered to be worthwhile, there are risks

such as equipment failure or human error involved when performing PM, just as in any
maintenance operation. PM as scheduled overhaul or scheduled replacement provides two
of the three proactive failure management policies available to the maintenance engineer.
Common methods of determining what PM (or other) failure management policies should
be applied are; OEM recommendations, requirements of codes and legislation within a
jurisdiction, what an "expert" thinks ought to be done, or the maintenance that's already
done to similar equipment. However Reliability Centered Maintenance, provides the most
rigorous and method to determine applicable and effective failure management policies -
which may include PM tasks - for an item.
To make it simple:
• Preventive maintenance is conducted to keep equipment working and/or extend the life of
the equipment.
• Corrective maintenance, sometimes called "repair", is conducted to get equipment
working again.
The primary goal of maintenance is to avoid or mitigate the consequences of failure of

equipment. This may be by preventing the failure before it actually occurs which PM and
condition based maintenance help to achieve. It is designed to preserve and restore
equipment reliability by replacing worn components before they actually fail. Preventive
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maintenance activities include partial or complete overhauls at specified periods, oil

changes, lubrication and so on. In addition, workers can record equipment deterioration
so they know to replace or repair worn parts before they cause system failure. The ideal
preventive maintenance program would prevent all equipment failure before it occurs.
There is a controversy of sorts regarding the propriety of the usage “Preventative

Maintenance.” The consensus of internet entries concerning the respective usages seems
to indicate that “Preventive” is the preferred term. However, practitioners of preventive
maintenance appear as or more likely to use “preventative” as the adjective.
Preventive maintenance is a schedule of planned maintenance actions aimed at the

prevention of breakdowns and failures. The primary goal of preventive maintenance is to
prevent the failure of equipment before it actually occurs. It is designed to preserve and
enhance equipment reliability by replacing worn components before they actually fail.
Preventive maintenance activities include equipment checks, partial or complete
overhauls at specified periods, oil changes, lubrication and so on. In addition, workers can
record equipment deterioration so they know to replace or repair worn parts before they
cause system failure. Recent technological advances in tools for inspection and diagnosis
have enabled even more accurate and effective equipment maintenance. The ideal
preventive maintenance program would prevent all equipment failure before it occurs.
CONCEPTUAL DESCRIPTION
To keep the plant in excellent working order at minimal cost decision makers have two
options: - CORRECTIVE or PREVENTIVE MAINTENANCE.
The best approach is to seek a balance between preventive maintenance and breakdown
maintenance as shown.
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TOTAL PREVENTIVE
COST MAINTENANCE
COST
DEMAN
D
CORRECTIVE
MAINTENANCE
COST
OPTIMU
M
AMOUNT OF PREVENTIVE
MAINTENANCE
Total maintenance cost, a function of preventive maintenance.
Value of Preventive Maintenance
There are multiple misconceptions about preventive maintenance. One such

misconception is that PM is unduly costly. This logic dictates that it would cost more for
regularly scheduled downtime and maintenance than it would normally cost to operate
equipment until repair is absolutely necessary. This may be true for some components;
however, one should compare not only the costs but the long-term benefits and savings
34

associated with preventive maintenance. Without preventive maintenance, for example,

costs for lost production time from unscheduled equipment breakdown will be incurred.
Also, preventive maintenance will result in savings due to an increase of effective system
service life.
Benefits of preventive maintenance include:
• Improved system reliability.

• Decreased cost of replacement.
• Decreased system downtime.
• Better spares inventory management.
Long-term effects and cost comparisons usually favor preventive maintenance over
performing maintenance actions only when the system fails.
Preventive maintenance is a logical choice if, and only if, the following two conditions
are met:
• Condition #1: The component in question has an increasing failure rate. In other
words, the failure rate of the component increases with time, thus implying wear-
out. Preventive maintenance of a component that is assumed to have an
exponential distribution (which implies a constant failure rate) does not make
sense!
• Condition #2: The overall cost of the preventive maintenance action must be less
than the overall cost of a corrective action. (Note: In the overall cost for a
corrective action, one should include ancillary tangible and/or intangible costs,
such as downtime costs, loss of production costs, lawsuits over the failure of a
safety-critical item, loss of goodwill, etc.)
If both of these conditions are met, then preventive maintenance makes sense.
Additionally, based on the costs ratios, an optimum time for such action can be easily
computed for a single component.
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36

Chapter 5
DATA PRESENTATION
& ANALYSIS
1. PREVENTIVE MAINTENANCE OF MIXER
MIXER
CHECKS TO BE DONE 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15
Check all hydraulic lines
& cylinder
Discharge gate & chute
to be cleaned
Check oil level
Check for abnormal sound

Check the condition of
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arm protector rubber

Checking of mixer seal
for leakage
Check for any damage in
arms & showels
Cleaning of skip discharge
area
ANALYSIS & INTERPRETATION
CONDITION OK CONDITION NOT OK
(i) On the 1st three days one of the arm protector rubbers was found to be damaged &
was brought to notice on the 1st day itself. Although it was not repaired the plant
functioned accurately.
(ii) On the 4th day the mixer seal was found damaged & was brought to notice on the
1st day itself. Although it was not replaced the plant functioned accurately.
(iii) One of the showels was found damaged on the 4th day & was brought to notice
on the 1st day itself. Although it was not replaced the plant functioned accurately.
2. PREVENTIVE MAINTENANCE OF COMPRESSOR
COMPRESSOR
CHECKS TO BE DONE 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15
Check the condition
of V-belts
Check oil level

Check pressure switch
on off settings
Drain water from
FRL Unit
Check oil level in
FRCL unit
Drain water from
receiver tank
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(i) On the 10th day a cut was found on one of the V-belts & was brought
to notice. It was repaired on the same day.
(ii) The oil level was found to be below normal on the 11th day & was
brought to notice. The correct oil level was maintained.
(iii) No other problems were encountered with the compressor during the
15 days.
3. PREVENTIVE MAINTENANCE OF ADDMIXTURE
ADDMIXITURE
CHECKS TO BE DONE 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15
Check connection of
threaded union for leaks
Cleaning of pipes, motor &
jars with fresh water
Checking of foot valves
Check motors & pumps

for abnormal sound
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(i) Addmixture pipe was found to be damaged on the 2nd day, which
leaded to slow charging of addmixture. It was repaired on the same
day.
(ii) On the 9th day the motor pipe was found to be leaking & was brought
to notice. It was repaired on the same day.
4. PREVENTIVE MAINTENANCE OF SKIP BUCKET
SKIP BUCKET
CHECKS TO BE DONE 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15
Check wire rope condition
& apply compound
Check for wear & tear
& proper working
Check wire rope clamps

Check wire rope slack
steel rope switch
Remove accumulation of
material under the bucket
Check gear box oil level

Cleaning & greasing of
skip track
Check for any damage in
40

discharge gates
(i) The ready mix discharge gate was found to be damaged on the
12th day & was brought to notice. Although it was not replaced the
plant functioned accurately.
(ii) The Gear-Box oil level was found to be below normal on the
14th day & was brought to notice. The correct oil level was
maintained.
5. PREVENTIVE MAINTENANCE OF ADDMIXTURE
WATER PUMP
CHECKS TO BE DONE 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15
Checking of foot valves.

Check correct function
of water distribution
to mixer .
Check & adjust
proximity switches
if necessary.

41

(i) Foot valves were absent. As the absence of foot

valves did not make any difference the problem was not
considered as serious.
6. PREVENTIVE MAINTENANCE OF HOPPER
CEMENT / WATER HOPPER

CHECKS TO BE DONE 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15
Check all rubber bellows if
jammed by cement/flyash
Check oil level for screw
conveyors
Tie rods to be checked

Sensors & load cells to
be cleaned
Check vibrators in cement
hopper
Check for empty screw

Check for hopper empty
when shutting down
Check & clean overflow
pipe
Clean hopper tops
42


(i) Overflow pipe was found to be damaged & was brought to notice.
(ii) Cement hopper was found to be damaged & was brought to notice.
7. PREVENTIVE MAINTENANCE OF AGGREGATE
AGGREGATE
CHECKS TO BE DONE 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15
Check wear & tear of bins
if any
Check vibrators in
aggregate hopper
Check if load is evenly
distributed on load cell
Cleaning & checking of
aggregate holding hopper
Check aggregates gates
for smooth working
Check pneumatic cylinder
for leaks

43

(i) Load cell stud was found broken on the 8th day. It
was brought to notice & repaired.
(ii)On the 10th day the CRUSH SAND GATE was found
to be broken. It was removed & welded.
(iii) The vibrators & aggregate gates were functioning

smoothly.
8. SAFETY PREVENTIVE MAINTENANCE
SAFETY
CHECKS TO BE DONE 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15
Check limit switches
Check for open wires
Check for proper safety

equipments provided
Check for damage of
cables
Clean motor surface
areas
Check for leakages

44

(i) The mixture was not working on the 10th day as the limit switch stopped
functioning. The problem was conveyed & was solved on the same day
itself.
(ii) All the labors & the workmen were equipped with safety helmets, safety
shoes & safety jackets on all the 15 days.
(iii) The motors were protected with safety covers & functioned well with
intermediate preventive maintenance.
Chapter 6
FINDINGS,
SUGGESTIONS &
CONCLUSION
45

FINDINGS
1. Most of the equipments at the Goregaon RMC plant are well maintained
& function to the desired level.
2. There is always a prompt reaction to any malfunction or breakdown at the

premature stage itself.
3. Except for the arm protector rubber & over flow pipe no major
maintenance problems were recorded.
4. Maximum plant availability is maintained by preventing unexpected

breakdowns & by reducing shutdown periods.
5. Unsafe conditions are eliminated through planned & regular inspection &
lubrication procedures.
6. All productive assets of the plant are in fine working form.
46

7. Any event of accident was not recorded during the study
SUGGESTIONS
1. The arm protector rubber & the overflow pipe require immediate
attention or if these defects not corrected on time may cause
malfunctioning of the equipment or result in the breakdown of the plant,
or be a reason for hazards.
2. Although the absence of foot valves did not make any difference it would
be tolerable to have them.
3. More improvements can be made in the existing maintenance schedules

to increase the productivity & accuracy through planned lubrication plan
by keeping the temperature of the moving parts within allowable limits.
4. In order to avoid conflicts between departments maintenance can be

carried out during break hours, non production hours, weekly-off &
holidays, machine set-ups.
47

5. An engineering store should be set up at the plant for the provision of

spares & consumables.
CONCLUSION
Today’s plants are regarded as high technology plants. These plants, compared to plants
of past years are bigger in capacity involve high speed machinery, complex & precise
designs, more automation & therefore pose difficulties in maintenance.
In lieu of large capital investment, downtime cost of these plants is enormous. Since
machinery & its arrangement are engineered for continuous production, stoppage /
malfunctioning / breakdown of a single machine can cause stoppage of the whole plant.
With the advancement of technology, production function is getting simplified day by day
due to built-in automated controls, while maintenance function is getting complex,
increasingly difficult & important for survival.
All machines tend to deteriorate in performance with use over the period due to the
process of wear & tear. A number of factors contribute to the functional degradation of
the machines of which typical ones are: temperature rise, vibrations, looseness, seasoning
of parts, accumulation of dust, rusting of parts etc.
48

Systematic maintenance though can’t eliminate the process of wear & tear yet it can
significantly lower it. A good maintenance system is therefore not a luxury but a
necessity.
Preventive maintenance advocates maintenance procedures whereby the condition of the

plant is continuously watched through systematic inspection to unearth unhealthy
conditions & preventive action is taken to prevent unscheduled interruption to the plant &
equipment.
PREVENTIVE MAINTENANCE is based on the famous old saying-
“A stitch in time saves nine”
BIBLIOGRAPHY
Books
1. Research Methodology C.R.Kothari

New Age International
Publishers
New Delhi
2nd Revised Edition - 2004
2. Manufacturing & Operations Management L.C. Jhamb

Everest Publishing House
New Delhi
5th Edition - 2007
Websites
49

1. www.adityabirla.com
2. www.ultratechconcrete.com
3. www.wikipedia.com
50

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PREVENTIVE SERVICE MAINTENANCE OF RMC PLANT

“Preventive Service Maintenance of RMC Plant”

“Ultratech Cement Ltd. (Ready Mix Division)”

Submitted to the University of Pune

MASTER OF BUSINESS ADMINISTRATION

“Shashi Dinanath Thakur”

Under the guidance of

“JSPM’s ABACUS INSTITUTE OF COMPUTER APPLICATION”

JSPM’S AIOCA, PUNE

A work is never a work of an individual. I owe a sense of gratitude to the

I am greatly indebted to my guides Dr. M. S. KADAM , faculty guide for

I am also grateful to Dr. SAGAR S. JHAMBHORKAR, DIRECTOR,

Shashi Dinanath Thakur

JSPM’S AIOCA, PUNE

I do hereby declare that this piece of project report entitled “Preventive

PLACE: SHASHI D. THAKUR

JSPM’S AIOCA, PUNE

2 Chapter 2: PROFILE OF THE ORGANISATION 20

3 Chapter 3: RESEARCH DESIGN & METHODOLOGY 35

4 Chapter 4: CONCEPTUAL BACKGROUND 38

5 Chapter 5: DATA PRESENTATION & ANALYSIS 49

6 Chapter 6: FINDINGS & CONCLUSION 75

JSPM’S AIOCA, PUNE

JSPM’S AIOCA, PUNE

JSPM’S AIOCA, PUNE

experience to management students & exposes them to functional areas of

It also provides them with an opportunity to be a part of real corporate

The main points on which I laid stress were:-

Ξ To gain depth knowledge about the actual working of the company.

Ξ To study the various maintenance procedures practiced & adopted.

Ξ To set up and follow a regular maintenance schedule to keep the batch

The work environment of Ultratech Cement Ltd. was absolutely encouraging

JSPM’S AIOCA, PUNE

CONCEPT & CONTEXT OF THE STUDY

Maintenance is defined as “the combination of all technical

JSPM’S AIOCA, PUNE

intended to retain an item in, or restore it to, a state in which

Most plant incidents are a result of bad maintenance

2) Equipment and Equipment Parts replacement

JSPM’S AIOCA, PUNE

The costs associated with any piece of equipment can be

Maintenance reduces downtime in a plant associated to

Because of its significant impact on plant performance (both

Plant maintenance can easily be divided into two general

JSPM’S AIOCA, PUNE

1) Corrective Maintenance (repair):

This type of maintenance deals with fixing already

This type of maintenance is geared towards taking actions

JSPM’S AIOCA, PUNE

equipment failure is in need of immediate repair (because of

(i) Ensuring maximum plant availability by preventing unexpected

(ii) Elimination of unsafe conditions that cause accidents thereby

(iii) To keep all productive assets in good working condition.

(iv) To minimize accidents through regular inspection.

JSPM’S AIOCA, PUNE

SCOPE OF THE PROJECT

♣ Ultratech Concrete is already well established in the market, but there

♣ One of the main purposes is to help the organization implement

♣ The study also aimed to recognize how the maintenance process

♣ Ultratech’s ability to manage efficiently its logistics, as well as to

JSPM’S AIOCA, PUNE

♣ Some other benefits of preventive maintenance include reduction in

LIMITATIONS OF THE PROJECT