Improve performance of maintenance system at matralayam plant of ITC agro tech-Indian Institution of Management Baqngalore: Bangalore.

Abstract

ITC Agro -Tech Limited is one of the affiliated companies of ITC Limited, which is multinational company,ITC Limited is dealing with manufacturing of cigarette and processing of smoking tobacco- ITC Agro Tech manufactures edible oils under the brand names of SUNDROP, CRYSTAL, REALGOLD, SUDHAM and SURUCHI. In February 93, 300 TPD Seed preparatory plant , 300 TPD solvent extraction plant and 200 TPD refinery were commissioned in Mantralayam as backward integration in addition to 100 TPD refinery- Edible oil business is a high volume and low margin business.The brand image which ITC enjoyed earlier by product differentiation (dewaxed clear refined SUNFLOWER oil) does not exist any longer due to competitors and technology ava ability. Hence higher volume production with better capacity utilisation can alone provide sustained revenue. Plant uptime is the single most crucial factor in determining the volume of oil produced. Hence this project is focused on establishing the improved man enance system in the newly commissioned plant. Dat^ are analysed for process breakdown. Remedial actions have been suggested in addition to ideas for avoiding the future breakdowns. A maintenance schedule was evolved. An experimental preventive maintenance was also attributed during the study period. Even though the experiments could be not carried out as per the schedule, it was possible to establish norms for time taken for preventive maintenance activities. During the experimental period Decoupling was derived as an idea to carry out th& preventive maintenance with out stopping the pi ant. Based on the breakdown & equipment analyst and general causes for failure^, general recommendations have been made for future.