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Integrating Reliability and Lean Six Sigma Tools to Improve Availability of Vacuum Generation Systems
Victor de Menezes Vidal, Samarco Company
Abstract 

Samarco is a privately held Brazilian mining company whose main product is iron ore pellets. They transform minerals with low ore content into a valuable product, with high added value, and sell them to steelmakers worldwide. A reliability project was applied in a vacuum generation system for the preparation of pellet feed into an Iron Ore Pellet Plant. Reliability tools were applied integrating with the Lean Six Sigma methodology to increase the reliability and availability of vacuum pumps at Samarco Company. Samarco achieved an increase in the MTBF of the electrical motors from 133 days to 420 days; MTTR of the electrical motors from 155 hours to 12 hours. The system availability was increased from 84.2% to 95.5%, with its capability (sigma level) from 1.3 to 2.9. With these gains, maintenance costs were reduced more than 30%.