SUSTAINABILITY REPORT 2013-15

People Overview Self Managed Teams Mechanisation Safety Overview The Parivartan     Journey Progress on     Roadmap Incident Statistics Robust Governance Standardised     Processes Enhanced Awareness Capability Building Safety Infrastructure Safety Audits Quality Overview Top-down    Accountability Quality by Design Quality Culture     Transformation Quality Assurance Quality     Best Practices All Time Audit     Readiness Availability Overview Strategic Sourcing Risk Management Product    Rationalisation Success stories Environment Overview Roadmap Energy Management Emissions Water Waste Case Study KPIs Community Overview Focus Areas Education Livelihoods Healthcare Infrastructure     Initiatives Creating Change     Makers Productivity Overview Productivity Streams Case Study PACE Update Initiatives Engineering Excellence Overview Digitisation Automation Mechanisation Lean Manufacturing Capital Equipment Strategy Predictive Maintenance Continuous Improvement Overview Continuous     Improvement     at Work Best Practices Annexures GRI Index Acronyms Assurance Statement   Summary Report     ENGINEERING EXCELLENCE PREDICTIVE MAINTENANCE Equipment downtime doesn't only mean loss of money, it also implies unavailability of our medicines. Hence, predictive maintenance is practiced to prevent occurrence of failure. We use a host of technologies such as thermography, vibration monitoring, oil analysis, ultrasonic measurement and condition-based monitoring in a proactive manner to improve plant efficiency, reduce breakdowns, cut downtime, undertake root cause analysis and reduce energy consumption.   Spotting the Heat via Thermography The use of thermographs to study heat distribution was initiated to improve electrical safety. The first study was conducted in April 2013 and is now an annual exercise. 45 hotspots identified and corrective actions taken to eliminate them 6-monthly thermography study of PCCs & MCCs initiated Detecting Leakages by Way of Ultrasound Leak detection of compressed gaseous fluids of overhead lines is done using a portable ultrasound diagnostic device - CTRL UL 101. It detects leakages using a piezo electric sensor and converts it into acoustic range, which in turn helps to pinpoint the position of the leak.   Condition-based Monitoring In addition to planned scheduled maintenance, condition-based monitoring helps spot upcoming equipment failure and enables proactive maintenance. Vibration analysis was carried out for process equipment like blowers, air handling units, air compressors, pumps and chillers. ANALYSIS   CORRECTIVE ACTION   OUTCOME Dominant vibration occurring at 1X motor rpm   Blower impeller was found cracked and was repaired   Vibration readings reduced from 12.40 mm/sec to 4.69 mm/sec   Maintenance through MES Dr. Reddy's took up various maintenance projects under MES including preventive, predictive, breakdown or reliability-centred maintenance for sustainable performance of the plants. Some of the key initiatives include harmonisation through SAP and user verification. Both these initiatives brought in more transparency, easy tracking of engineering operations and better compliance.