| COST BENEFIT ANALYSIS | ||||||
| PLANT OR LOAD FUNCTION: | Transformer (T3) Supply of electricity to the Resin Plant | |||||
| COST OF PLANT DOWNTIME | ||||||
| No of production days / annum | 320 | |||||
| Cost of product / ton | 15000 | |||||
| Production rate / ton | 40 | |||||
| Total | R21,917.81 | p/hr | ||||
| PREDOMINANT FAILURE MECHANISM: | Failure of TC switch contacts | |||||
| Failure effects: | ||||||
| a) Plant shutdown | ||||||
| b) Damage to equipment | ||||||
| c) Loss of product (raw material) | ||||||
| d) Operations staff – idle | ||||||
| MEAN TIME BETWEEN FAILURE WITHOUT MAINT: | 8 | years | ||||
| PRICE OF NON CONFORMANCE | ||||||
| Cost of failure: | ||||||
| Description | Qty | Unit | Cost / Unit | Total | ||
| Plant shutdown | 8 | hr | R 21,918 | R 175,342 | ||
| Operations staff standing time | 0 | hr | R 0 | R 0 | ||
| Damage to equipment | 0 | R 0 | R 0 | |||
| Isolate and disconnect transformer | 2 | hr | R 80 | R 160 | ||
| Rigging to remove transformer | 0 | hr | R 300 | R 0 | ||
| Repairs by service company | 1 | pc | R 60,000 | R 60,000 | ||
| Rigging to replace transformer | 0 | hr | R 300 | R 0 | ||
| Connect and energise transformer | 3 | hr | R 80 | R 240 | ||
| R 235,742 | ||||||
| PRICE OF CONFORMANCE | ||||||
| Description | Qty | Unit | Cost / Unit | Total | ||
| Tasks: | ||||||
| Oil Analysis | A | 1 | serv | 353 | R 353 | |
| Check General condition of transformer | K | 6 | hr | 80 | R 480 | |
| Painting | K | 0.2 | serv | 1200 | R 240 | |
| Oil Purification | M | 0.25 | serv | 4000 | R 1,000 | |
| K=Keep A=Add: M=Modify: D=Delete | R 2,073 | |||||
| MEANTIME BETWEEN FAILURE WITH MAINTENANCE: | 30 | years | ||||
| ANALYSIS | ||||||
| Annual cost without PM | R29,467.81 | (Total PONC / MTBF wo PM) | ||||
| Annual cost with PM | R9,931.08 | (Total PONC /MTBF w PM) + Annual | ||||
| (POC) | ||||||
| Annual saving | R19,536.73 | Approved: | Y | |||
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