TPM Implementation in Coal Washery – A Benchmark Process-Volume-1

Description

This book presents a comprehensive and practice-oriented exploration of Total Productive Maintenance (TPM) implementation in coal washeries, with particular emphasis on heavy media cyclone and dry air jig technologies, supported by a real-world case study from an Indian coal beneficiation plant. It systematically examines existing maintenance systems, identifies critical problem areas affecting availability, performance, and cost, and proposes a structured TPM framework integrating autonomous and planned maintenance to enhance Overall Equipment Effectiveness (OEE). Blending theoretical foundations with extensive operational data, analytical discussions, and implementation roadmaps, the book demonstrates how strategic maintenance transformation can significantly improve productivity, reliability, product quality, and economic performance in coal processing industries, making it a valuable reference for engineers, plant managers, researchers, and students in mining and mechanical engineering.

About The Author

Sudhanshu Pandey holds a B.E. in Mechanical Engineering (2008 pass-out) and an M.Tech in Production Technology from CSVTU with Honours. He is an industry professional with over 18 years of experience in Coal Beneficiation and Mineral Beneficiation Operations & Maintenance (O&M).
He has extensive hands-on experience in coal washery and mineral processing plants, including Heavy Media Cyclone (HMC) circuits, dense medium systems, desliming, screening, dewatering, slurry handling, magnetite management, and process optimization. His expertise lies in stabilizing plant operations, troubleshooting chronic process issues, and improving plant performance through practical, field-driven solutions.
He has served in senior leadership roles such as Plant Head and General Manager, overseeing operations, maintenance planning, manpower management, safety compliance, and production targets. His exposure covers both coking and non-coking coal washeries, along with mineral beneficiation plants.
With a strong foundation in production technology and applied mechanical engineering, he effectively bridges the gap between process design and on-site execution. He is currently focused on documenting real-world beneficiation challenges and solutions to contribute practical knowledge to the coal and mineral processing industry.

Dr. Sharda Pratap Shrivas has over 16 years of experience in higher education. He has degrees in BE (Mechanical Engineering), ME (Production Engineering), Ph.D (Mechanical Production and Industrial Engineering). He has write more than 55 research paper in various streams. He is live member of Indian Society for Technical Education and has 02 granted patents in research areas. He is a tech enthusiast and expert, passionate about the latest advancements and their impact on society. With a background in mechanical engineering, he has a deep understanding of emerging technologies like welding. optimization, CAD/CAM and engineering drawing. Through his writing, he simplifies complex concepts, making them accessible to readers of all backgrounds. His ability to bridge the gap between technical jargon and everyday readers makes her an invaluable resource for those seeking clarity in the advance in mechanical engineering.

Dr. Roopesh Kumar Sinha, BE (Mechanical Engineering), ME ( Production Engineering) Ph.D (Mechanical Engineering) ,he has completed all degree from CSVTU (Government University) Bhilai Chhattisgarh. Currently work as lecturer in the department of Mechanical engineering at NMDC DAV POLYTECHNIC DANTEWADA CG INDIA. with an more than 16 years teaching experience . In his teaching career,he has taught the subject material science, manufacturing process, engineering mechanics, strength of materials, production management and theory of machine and many more.He has published research paper in various national and international journals. He is also continuosly working in composite material. He is a life time member of various professional bodies. His commitment to continuous learning is evident through his participation in various events including seminar, conference,workshop, faculty development program ,webinars, training program and other short term courses.