Customer Background
Founded in 1984, Orissa Power Generation Corporation Ltd (OPGC) has two thermal power generating units (IB Thermal Power Station) with a total capacity of 420 MW in the IB valley area of Jharsuguda District in Orissa. Started as a wholly owned Government Company of the State of Orissa, it divested 49% of the equity in favor of AES Corporation, USA in early 1999 as part of the reform process in the energy sector of the state. Over the years, it has firmly established its credentials as a successful power generation company and won several awards in the areas of plant performance, safety and environment management.
Need for a Solution
Soon after starting generation, OPGC felt the need for a centralized Enterprise Asset Management solution that can take the business performance to a higher level of operational efficiency. With diverse applications for multiple functions, the company's data and workflows were disparate. Manual procedures were followed in various maintenance activities and planning. There was no system for Inventory Tracking. For an effective asset management strategy, OPGC decided to implement EAM system and procured Ramco Enterprise Asset Management System (version 3.1).
Some of the key needs that had to be addressed were
- Higher availability of the assets by reducing unplanned downtimes, enhancing equipment life and streamlining work practices
- Improved and sustained performance
- Greater visibility of the condition and utilization of enterprise assets
- Streamlining of the purchase function
- Reduction of inventory cost along with better planning and visibility
- Centralization and Automation of key processes
Ramco Solution
Ramco implemented its Enterprise Asset Management System (version 3.1) that centralized and automated the key processes of IB Thermal Power Station. The scope of implementation was as follows:
- Asset Management to take care of more than 18,000 equipments and 23,000 items
- Maintenance Management and Asset Life Cycle Management for diverse and interdependent assets worth Rs. 1000 Crore (USD 200m)
- Maintenance planning and scheduling for maintenance crew of 100 people
- Purchasing for the entire company worth close to Rs. 10 crores (USD 2m) annually
- Inventory control for the entire company
Why Ramco
OPGC evaluated all major offerings in the EAM space and decided in favor of Ramco. The key reasons for selecting Ramco were:
- Rich and highly comprehensive EAM functionality
- Flexibility of the product to adapt to the business needs
- Assurance of local support and responsiveness
Benefits
- Better asset information availability leading to faster and improved decision making
- Better availability of equipment through preventive and predictive maintenance leading to reduced downtime
- Steady improvement in plant performance resulting in increased PLF over the last decade
- Streamlining of procurement for spare parts, consumables and fuel
- Better inventory management of over 18,000 items
- Effortless handling of over 15,000 transactions per year related to material issue, receipt, return and purchase and 12,000 transactions per year related to maintenance planning
- Increased purchasing efficiency because of automation and centralization of the purchasing process
Customer speaks
“Better availability of asset information and streamlining of maintenance processes led to significant improvement in plant performance over last decade in terms of availability, PLF and specific fuel consumption. Additionally, we benefited with fast & more accurate maintenance information retrieval, predictive analysis & performance measures, effective materials management & spares inventory control.”
Tushar Mahakul
Manager (Electrical), Head-IT
IB Thermal Power Station,
Orissa Power Generation Corporation
|
