Preventive Maintenance for Mechanized Poultry Operations

1. Mr Vinay Kelkar Preventive Maintenance Or TPM Total Productive Maintenance A stitch in time saves nine

2. What is Preventive maintenance Preventive maintenance is Systematic inspection, detection, correction and prevention of likely failures to avoid any unexpected , major and expensive failures of critical equipment and machines (in terms of cost & time)

3. Why Preventive maintenance Restoring the basic condition Extending the life and reliability of equipment Avoiding forced degradation Avoiding unexpected and expensive failures Reduced cost of maintenance Achieving higher productivity Achieving better output quality

4. Why Preventive maintenance • Restoring the basic condition • Extending the life and reliability of equipment • Avoiding forced degradation • Avoiding unexpected and expensive failures • Reduced cost of maintenance • Achieving higher productivity • Achieving better output quality

5. FDA requirements Preventive maintenance of equipment and calibration of instruments are good essential practices for cost, quality, time saving etc. It is also essential from the GMP/GAP (Good manufacturing practices, Good Agricultural Practices) which are compulsory to meet FDA regulations applicable to Poultry industry.

6. Today’s market scenario For any product • Raw material/ input cost are going up • Operating cost are going up and • Finished product selling prices are becoming more and competitive • consumer is demanding more/better for less price • Profit margins are getting squeezed • Producer have no control over input material cost or final product pricing

7. Issues in Poultry Industry (Hatcheries, Layers/Broiler farms, processing plants) • Controlling diseases and mortality • Maintaining feed efficiency, • Proper handling of wastes • Proper sanitizing of the poultry house • Maintaining quality of processed products • Remaining cost competitive and profitable

8. Transformation happening • Automatic feeding, watering, egg collection, environment control, litter/waste handling and processing, automated feed manufacturing systems, sprayers, weighing scales, fans, coolers, refrigerators, incubators, hatchers, feed mills, hammer mills, batch mixers, feed storage systems/cellos, conveyors for feed, litter conveyors are becoming need of hour due to labour shortages, productivity issues, quality issues, cost issues as well as FDA guidelines and rules. • These are technologically advanced equipment with programmable and remote control systems having huge benefits on long term. • Preventive or productive maintenance of such equipment becomes very essential considering the investments made and it pays back handsomely.

9. To sustain profits producer needs to cut down operating expenses / OPEX without compromising quality of the final product Major components of operating Expenses Inputs Energy Manpower Maintenance Logistics

10. Key parameters effecting OPEX in Poultry industry • Economy conversion ratio (ECR) • Mortality • Feed conversion ratio (FCR) • Other major operating expenses • Manpower cost • Utilities (Energy, water, ventilation etc.,) cost • Maintenance cost • Logistics … Can be reduced /controlled using Preventive maintenance

11. Mortality • Mortality is end consequence / result but not the reason • Mortality in India is ~ 10% , bench mark is < 5 % ( 100% higher) • Main reasons for mortality or less FCR could be • Poor feed quality or quantity • Diseases not controlled • Hygienic conditions • Cleaning and cleanliness • Odour due to poor air quality • Environmental control … Can be reduced /controlled using Preventive maintenance

12. Mortality is the final event which occurs due to the combination of many invisible problems. Latent problems are normally neglected or ignored. Mortality is the consequence… Poor feed quality Cleaning and cleanliness … Can be reduced /controlled using Preventive maintenance

13. Human body (Me) Machine Goal of TPM Keep the body healthy & fully efficient all the time Keep the machine fully efficient & without problems Break Down Maintenance Heart attack, Illness like Pneumonia, Jaundice, chickengunia? Breaking of part, Compressor seizure sudden stoppage due to malfunction etc. Preventive Maintenance Inoculation, Regular check-ups like BP, Sugar. Modify food habits to avoid total break down Regular inspection Periodic change of parts etc. TPM * Habit of cleanliness * Proper diet & exercise from beginning * Avoiding bad habits like smoking * Keeping close watch on our body & taking immediate countermeasures. * Housekeeping * Regular lubrication * Proper operation of machine * Close watch on M/C & taking immediate actions if any abnormality is noticed TPM & Me

14. Financial Impact of PM on Mortality • Assuming a farm with 1 Lakh birds • Mortality is 10,000 birds in a year ( 10%) • Loss is Rs 16 Lakhs • (10,000birds * x 2.5Kg/bird * 65 Rs/ kg) • Mortality can be reduced by2.5% ( ie., 2,500 birds)with good & simple preventive maintenance practices • Possible gain with PM will Rs 4 Lakhs • (2,500birds * x 2.5Kg/bird * 65 Rs/ kg)

15. Economy conversion ratio(ECR) • Feed conversion ratio (FCR) • Other operating expenses • Manpower cost • Utilities (Energy, water, ventilation etc.,) cost • Maintenance cost • Logistics

16. Feed conversion ratio(FCR) Field average of FCR for broiler is ~ 1.75 (Industry standard is 1.6) and Field average of FCR for egg production is 135 gm (Industry standard is 125 gm) Both are ~ 8 % higher and industry standard

17. Reasons for Low FCR • Rearing conditions • Ventilation • Water • Litter • Health issues • Cleaning and cleanliness • Damaged eggs • Jerks in equipment • Damaged parts • Wastage of feed … Can be reduced /controlled using Preventive maintenance

18. Other operating expenses • Manpower cost • Manpower for Cleaning of eggs • Manpower for cleaning due to lack of maintenance • Utilities (Energy, water, ventilation etc.,) cost • Clogged cooling pads • Poor maintenance or lack of maintenance of equipment • Loose Fan belts • Energy inefficient lighting system • Non insulated roofs • Dripping water • Maintenance cost • Spares • Service … Can be reduced /controlled using Preventive maintenance

19. Actions as part of prevention • lubricating with correct lubricants, changing oil and filters, replacing worn out parts, tightening loose bolts, screws, nuts adjusting tension and alignment of conveyor belts, drive chains, pulleys and belts. Checking electrical / electronic controls • Inspect equipment for potential problems such as leakages, cracked or pitted surfaces and leaking oil. • Maintaining cleanliness (all around & equipment) • Using correct tools for all such activities • Ensuring availability of correct tools and spares

20. Cooling Pads Clogged cooling Pad Good cooling Pad Good practice to protect from clogging

21. Poor maintenance

22. Poor maintenance Vs Good maintenance lack of maintenance Good maintenance

23. Lack of Cleaning & inefficient Lighting Clean Shed with proper lighting Poor maintenance Vs Good maintenance

24. Poor maintenance Vs Good maintenance Lack of maintenance Good maintenance

25. Realistic targets achievable with Preventive or productive maintenance in 3 years • Reduction of mortality by 50 % • Improving FCR by 8 to 10% • Reduction in operating expenses by10 to 15 % • Reduction of breakdowns ( frequency & time) – 50 to 70 % • Reduction of maintenance cost – 20 to 30% • Capital equipment life – 200 %

26. Improving Preventive maintenance • Man (training and retraining) • Machine (Equipment) like Feed systems, water dispensers, incubators, stacked cages, conveyors, environment control equipment, fans/ventilators, feed plants, etc • Materials ( Spares, tools ) • Methods (SOPs, Visual Management, • Check list) VSM/2013-06-04urityLevel A stitch in time saves nine

27. Man• Training and retraining of workers in • Equipment • Critical processes and parameters • Cleaning & cleanliness • Sensing abnormality and taking early corrective action • Ownership & Self discipline • No short cuts • No quick fixes • Short time pains – long term gains • Sharing and caring • Recognition and rewarding VSM/2013-06-04 SecurityLevel

28. Machine • Pictorial depiction of simple PM jobs • Tightening of fan belt • Checking of clogged filter • Creating CIL standards • Cleaning, inspection and lubrication standards • SOP for what to clean, where to inspect and how to lubricate (KISS) @ location • Visual inspection • Equipment history • Details Modifications done on the machine and why • Breakdown history • Details of breakdowns with actions taken VSM/2013-06-04SecurityLevel

29. Checking of Belt and pulley

30. Materials (Tools and spares) • Quick fix is OK but temporary should not become permanent • Usage of right spares and tools for optimum performance • Right tools and methodologies to achieve world class performance

31. Tool box/ boards Indian tool Kit Tool Kit- else where

32. • Standard Operating practices and procedures (SOP) • @ machine • Pictorial • KISS • Local language • Visual Management • Display of critical parameters • Safety and hygiene practices • Sharing and Deployment of best practices • Poultry India • Check lists • Hourly, shift wise, daily, weekly • Before and after photos Methods

33. Check list example Check list helps in easy monitoring , data collection, problem identification

34. Measurement (5th M) • For any improvement measurement is must • Examples of measurements • Mortality • Cleaning time • Spares and maintenance cost per lakh birds • Equipment downtime analysis/costs., • Define and set KPIs VSM/2013-06-04urityLevel

35. Summary/Recap TPM type preventive activities help organizations in saving money, reducing wastes, improving productivity, improving quality, improving competitiveness in market. Let us all progress using such global practices and techniques Thank You