Lab.utilisation X Effi. 100
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PIONEER CEMENT INDUSTRIES LLC, RAK, UAE KEY PERFORMANCE INDICATORS - Maintenance Dept. FIRST WEEK OF 2012 MECHANICAL DEPT. Efficiency
Labour Utilisation Sl.No
DESCRIPTION
RAW MILLS & STACKER RECLAIMER SECTION PYRO & COAL MILL, 2 HANDLING SECTION 1
CEMENT MILLS & PACKING PLANT SECTION WORKSHOP & WATER 4 WORKS PROJECT & DEVELOPMENT 5 WORKS 3
6 AUTO GARAGE
Available Labour Hours
Actual Hours
%
Productivity
Estimated Hours
Actual Hours
%
Lab.Utilisation X Effi. 100
Plan Attainment Estmiated Hours of Estimated completed time of all jobs(excluding jobs unplanned)
PMR
%
Preventive Available Maintenanc Labour e Routine Hours Hours
Un Planned
%
Actual hours Estimated on completed hours on all unplanned completed work orders work orders
%
230.00
230.00 100.00
226.00
230.00
98.26
98.26
226.00
226.00
100.00
152.00
230.00
66.09
0.00
226.00
0.00
381.00
381.00 100.00
371.00
381.00
97.38
97.38
371.00
371.00
100.00
338.00
381.00
88.71
0.00
371.00
0.00
215.00
215.00 100.00
215.00
215.00 100.00
100.00
215.00
215.00
100.00
130.00
215.00
60.46
0.00
215.00
0.00
191.50
191.50 100.00
186.50
191.50
97.39
97.39
186.50
186.50
100.00
0.00
186.50
0.00
835.00
835.00 100.00
1100.00
1236.00 89.00
89.00
79.00
79.00 100.00
104.00
110.00
94.55
93.00
93.00
100.00
11.00
104.00
10.60
94.55
31.00
110.00
28.18
PIONEER CEMENT INDUSTRIES LLC, RAK, UAE MECHANICAL DEPT KEY PERFORMANCE INDICATORS - KPI FIRST WEEK OF 2012
Labour Utilization(%) Sl. No 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40
Names
Sandeep Singh Pillai Bhanu Pratap Ramana Reddy Hanumath Reddy Abu Backer Jose Bhukya Sreenu Assan Vallabha Rao Moinuddin Babu Kumar Chendra Sekhar Dhanesh Gupta Naresh Rauth Anil Saleem Rajiman Prasannan Jamshid
Firoz Khan Radha Krishna Shabir ali Iqbal Basha Rajesh Kumar Kusva Ansari Murali Dharan Ajmal Basha Jelaludhin Babu Babi Paswan Ramesh Asraf Suru Kumar Musthafa Mahindra Murthy Ramakrishna Rajesh yadav Total
=
Actual Labour Hours on work orders/Available Labour Hours X 100 Available Labour hours 0 39.5 39.5 39.5 39.5 45.5 39.5 39.5 39.5 39.5 39.5 64.5 39.5 71 39.5 64.5 64.5 39.5 39.5 39.5 39.5 39.5 78 78 78 78 74 74 74 74 39.5 39.5 39.5 39.5 65.5 39.5 39.5 39.5 39.5 1931.5
Actual Labour Hours(Work Orders) 0 39.5 39.5 39.5 39.5 45.5 39.5 39.5 39.5 39.5 39.5 64.5 39.5 71 39.5 64.5 64.5 39.5 39.5 39.5 39.5 39.5 78 78 78 78 74 74 74 74 39.5 39.5 39.5 39.5 65.5 39.5 39.5 39.5 39.5 1931.5
Labour Utilization(%)
100.00%
PIONEER CEMENT INDUSTRIES LLC, RAK, UAE MECHANICAL DEPT. KEY PERFORMANCE INDICATORS - KPI FIRST WEEK OF 2012
Efficiency (%) = Estimated Time of completed Jobs / Actual Time of Completed Jobs Sl No . 1 2 3 4 5 6 7 8 9 10 11 12
1 2 3 4 5 6
7
Job RAW MILLS & STACKER RECLAIMER SECTION BC-7 drive gearbox internals inspection & oil replacement work RM-1&2 O-sepa fan impeller inspection work RM-1 LCD choked slots cleaning work(with gas cut) RABh 4th module RAL rotor replacement & module inside inspection work Storage weigh feeder head pulley bearings greasing work Dump hopper no-4 tyre stopper pipe fixing and full welding work Rawmill hot air duct insulation work Raw mill -1 cyclone Patch up work Raw mill-1 Girth gear FLR unit replacing work. Bridge reclaimer Scrapper chain buckets fixing bolts removing and new bolts fixing work. Raw mill-2 pressing side main gearbox lub system filters cleaning. General Maintenance:1.RM-1&2 slide shoe bearings visual checking 2.Rawmill area checklist & general maintenance works 4.Rawmill area house keeping done PYRO & COAL MILL, HANDLING SECTION Alternate fuel feeding hopper & pin gates fabrication and Erection Work at Preheater Second Floor. Alternate fuel Feeding system Hopper platform with hand railing & monkey ladder . Alternate fuel feeding Belt conveyor top skirt board fabrication and fixing work Alternate fuel feeding belt conveyor discharge flap fabrication and fixing work Spare Air blasters reconditioning work. Coal Mill maintenance :Coal mill Auxiliary Drive Alignment work Coal Crusher Grizzly bar gap adjustment work. Coal mill apron weigh feeder maintenance work General Maintenance:1. Kiln all Tyres lubricated 2. Cooler Drives Chain lubricated 3. En-mass conveyors chain condition inspected&missed chain pins circlips refixed. 4.DDPC-1 chain condition inspection 5. Compressors Suction Filter & Cooler cleaned 6. K.C. & P.C. Roots Blowers Suction Filters cleaned 7. Silo bottom & Pre-heater top Blowers Suction Filters cleaned. 8. Kiln Supporting Rollers Bearings Oil Seals lubricated. 9. Air blaster Quick exhaust valves replaced & Overhauled
1 2 3 4 5 6
CEMENT MILLS & PACKING PLANT SECTION Cement mill-2 Girth gear Bolts 3 nos to be replaced with new. Cement mill-2 Girth Gear Guard Supports fixing. Cement mill -2 Inlet Chute Patch up work. Gypsum Belt conveyor travel Drive input coupling rubber bushes & Bolts replacing work Cement mill-1 Outlet water spray system inspection work Cement mill-1 Inlet Chute worn out plate replacement. Cement mill-1 O-Sepa Inspection Spare Dosing Valve maintenance work and House keeping. Cement mill area check list work and general maintenance works Packing Plant: Roto Packing and auto packer Schedule maintenance works. Silo 1&2 Extraction chutes Jam cleaning work. preparatory works for packing plant maintenance works. Roto Packing and auto packer Schedule maintenance works. Bulk loading Bucket elevator Belt joint bottom side rubber jointing work Packing plant area house keeping
1 2 3 4 5
WORKSHOP & WATER WORKS Hydra gearbox cover drilling and tapping Clinker breaker hammer pin washer machining Material handling trolley pin and bushes machining Cement mill door bolt threading work Connectors machining for src hopper
1 2 3 4 5 6 7 8 9
Type
Estimated Hours
Job Comple ted
Actual Hours
PM PM Repair PM PM Repair Repair Repair Repair PM PM
12 12 8.5 34 12 10 34 17.5 8 22 10
13.5 12 8.5 34 12 10 34 17.5 8 24.5 10
PM PM PM
4 24 18 226
4 Yes 24 Yes 18 Yes 230
PM PM PM Repair
60 56 68 66 25.5
68 56 68 68 25.5
Yes yes Yes Yes Yes
PM Repair PM
6 15 8
6 15 8
6 6 12 4 6 10 10 10 2.5 371
6 6 12 4 6 10 10 10 2.5 381
Yes yes Yes Yes Yes Yes Yes
Repair Repair Repair PM PM Repair PM PM PM
12.5 13 17 8 5 34 5 8.5 21.5
12.5 13 17 8 5 34 5 8.5 21.5
Yes Yes Yes Yes Yes Yes Yes Yes Yes
PM Repair PM PM PM PM
34 8.5 5.5 20 14 8.5 215
34 8.5 5.5 20 14 8.5 215
Yes Yes Yes Yes Yes Yes
8.5 17 17 17 8.5
8.5 19 17 17 8.5
Yes Yes Yes Yes Yes
PM
PM PM PM PM PM PM PM Repair
Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes
Yes Yes Yes Yes Yes
Sl No . 6 7 8 9
Job Bogie Wheel welding work. Cooler track wheels welding work Clinker breaker hammer pins washers preparation work Plumbing works at workers & staff colony
Type
1 2 4 5 6 7
PROJECT & DEVELOPMENT WORKS Paper Bags Go down opening Covering clading fabrication and erection work. SRC clinker tank and accessories erection work SRC clinker tank approaching stair case fabrication & erection Rejects clinker discharge pipe dismantling work & feed pipe erection work CSP top roof openings sheeting work SRC Clinker tank Civil structure side cladding work.
Development Project Project Project Development Development
1 2 3 4 5 6
AUTO GARAGE General Maintenance Hydra engine overhauling work Cat loader engine oil and filters treplacement Man truck left side door handle replacement work Man truck 21475 rear axle repair work Man truck 21475 rear type puncure
PM Repair PM Unplanned Unplanned Unplanned
Job Estimated Actual Comple Hours Hours ted 17 20 Yes 14 14 Yes 8.5 8.5 Yes 79 79 Yes 186.5 191.5 200 720 350 280 100 150 1100
56 796 347.5 330 110 89.5 1236
No Yes No Yes Yes No
28 62 3 3 3 5
28 68 3 3 3 5
Yes Yes Yes Yes Yes Yes
PIONEER CEMENT INDUSTRIES LLC, RAK, UAE MECHANICAL DEPT. KEY PERFORMANCE INDICATORS - KPI FIRST WEEK OF 2012
Efficiency
98.26
97.38
100.00
97.39
97.39 Efficiency
89.00
94.55
PIONEER CEMENT INDUSTRIES LLC, RAK, UAE MECHANICAL DEPT.KEY PERFORMANCE INDICATORS - KPI FIRST WEEK OF 2012
Productivity Productivity(%) = Sl.No 1 2 3 4 5 6
Section RAW MILLS & STACKER RECLAIMER SECTION PYRO & COAL MILL, HANDLING SECTION CEMENT MILLS & PACKING PLANT SECTION WORKSHOP & WATER WORKS PROJECT & DEVELOPMENT WORKS AUTO GARAGE
Labour Utilisation X Efficiency 100 Labour Utilisation Efficiency 100.00 98.26 100.00 97.38 100.00 100.00 100.00 97.39 100.00 89.00 100.00 94.55
Productivity 98.26 97.38 100.00 97.39 89.00 94.55
PIONEER CEMENT INDUSTRIES LLC, RAK, UAE MECHANICAL DEPT.KEY PERFORMANCE INDICATORS - KPI FIRST WEEK OF 2012
Plan Attainment (%) = Estimated Time of completed Jobs excluding unplanned works / Estimated Time of all Jobs Sl No. 1 2 3 4 5 6 7 8 9 10
Job RAW MILLS & STACKER RECLAIMER SECTION BC-7 drive gearbox internals inspection & oil replacement work RM-1&2 O-sepa fan impeller inspection work RM-1 LCD choked slots cleaning work(with gas cut) RABh 4th module RAL rotor replacement & module inside inspection work Storage weigh feeder head pulley bearings greasing work Dump hopper no-4 tyre stopper pipe fixing and full welding work Rawmill hot air duct insulation work Raw mill -1 cyclone Patch up work Raw mill-1 Girth gear FLR unit replacing work. Bridge reclaimer Scrapper chain buckets fixing bolts removing and new bolts fixing work.
PM PM Repair PM PM Repair Repair Repair Repair
12 12 8.5 34 12 10 34 17.5 8
Job Actual Complet Hours ed 13.5 12 8.5 34 12 10 34 17.5 8
Yes Yes Yes Yes Yes Yes Yes Yes Yes
PM PM
22 10
24.5 Yes 10 Yes
PM PM PM
4 24 18
4 Yes 24 Yes 18 Yes
60
68
PM PM PM Repair
56 68 66 25.5
56 68 68 25.5
PM Repair PM
6 15 8
6 15 8
PM PM
6 6
6 6
Yes yes Yes Yes Yes Yes
3. En-mass conveyors chain condition inspected&missed chain pins circlips refixed.
PM
12
12
Yes
4.DDPC-1 chain condition inspection 5. Compressors Suction Filter & Cooler cleaned 6. K.C. & P.C. Roots Blowers Suction Filters cleaned 7. Silo bottom & Pre-heater top Blowers Suction Filters cleaned. 8. Kiln Supporting Rollers Bearings Oil Seals lubricated. 9. Air blaster Quick exhaust valves replaced & Overhauled
PM PM PM PM Repair
4 6 10 10 10 2.5
4 6 10 10 10 2.5
Yes Yes Yes Yes Yes
Repair Repair Repair PM PM Repair PM PM PM
12.5 13 17 8 5 34 5 8.5 21.5
12.5 13 17 8 5 34 5 8.5 21.5
Yes Yes Yes Yes Yes Yes Yes Yes Yes
PM Repair PM PM PM PM
34 8.5 5.5 20 14 8.5
34 8.5 5.5 20 14 8.5
Yes Yes Yes Yes Yes Yes
8.5 17 17 17
8.5 19 17 17
Yes Yes Yes Yes
11 Raw mill-2 pressing side main gearbox lub system filters cleaning. 12 General Maintenance:1.RM-1&2 slide shoe bearings visual checking 2.Rawmill area checklist & general maintenance works 4.Rawmill area house keeping done PYRO & COAL MILL, HANDLING SECTION Alternate fuel feeding hopper & pin gates fabrication and Erection Work at Preheater 1 Second Floor. 2 Alternate fuel Feeding system Hopper platform with hand railing & monkey ladder . 3 4 5 6
Alternate fuel feeding Belt conveyor top skirt board fabrication and fixing work Alternate fuel feeding belt conveyor discharge flap fabrication and fixing work Spare Air blasters reconditioning work. Coal Mill maintenance :Coal mill Auxiliary Drive Alignment work Coal Crusher Grizzly bar gap adjustment work. Coal mill apron weigh feeder maintenance work 7 General Maintenance:1. Kiln all Tyres lubricated 2. Cooler Drives Chain lubricated
1 2 3 4 5 6
CEMENT MILLS & PACKING PLANT SECTION Cement mill-2 Girth gear Bolts 3 nos to be replaced with new. Cement mill-2 Girth Gear Guard Supports fixing. Cement mill -2 Inlet Chute Patch up work. Gypsum Belt conveyor travel Drive input coupling rubber bushes & Bolts replacing work Cement mill-1 Outlet water spray system inspection work Cement mill-1 Inlet Chute worn out plate replacement. Cement mill-1 O-Sepa Inspection Spare Dosing Valve maintenance work and House keeping. Cement mill area check list work and general maintenance works Packing Plant: Roto Packing and auto packer Schedule maintenance works. Silo 1&2 Extraction chutes Jam cleaning work. preparatory works for packing plant maintenance works. Roto Packing and auto packer Schedule maintenance works. Bulk loading Bucket elevator Belt joint bottom side rubber jointing work Packing plant area house keeping
1 2 3 4
WORKSHOP & WATER WORKS Hydra gearbox cover drilling and tapping Clinker breaker hammer pin washer machining Material handling trolley pin and bushes machining Cement mill door bolt threading work
1 2 3 4 5 6 7 8 9
Type
Estimated Hours
PM
Plan Attainment
226 x 100 226 = 100
Yes yes Yes Yes Yes
371 x 100 371 = 100
215 x 100 215 = 100
186.5 x 100 186.5 = 100
Sl No. 5 6 7 8 9
Job Connectors machining for src hopper Bogie Wheel welding work. Cooler track wheels welding work Clinker breaker hammer pins washers preparation work Plumbing works at workers & staff colony
Type
Job Estimated Actual Complet Hours Hours ed 8.5 8.5 Yes 17 20 Yes 14 14 Yes 8.5 8.5 Yes 79 79 Yes
1 2 4 5 6 7
PROJECT & DEVELOPMENT WORKS Paper Bags Go down opening Covering clading fabrication and erection work. SRC clinker tank and accessories erection work SRC clinker tank approaching stair case fabrication & erection Rejects clinker discharge pipe dismantling work & feed pipe erection work CSP top roof openings sheeting work SRC Clinker tank Civil structure side cladding work.
Development Project Project Project Development Development
1 2 3 4 5 6
AUTO GARAGE General Maintenance Hydra engine overhauling work Cat loader engine oil and filters treplacement Man truck left side door handle replacement work Man truck 21475 rear axle repair work Man truck 21475 rear type puncure
PM Repair PM Unplanned Unplanned Unplanned
200 720 350 280 100 150
56 796 347.5 330 110 89.5
No Yes No Yes Yes No
28 62 3 3 3 5
28 68 3 3 3 5
Yes Yes Yes Yes Yes Yes
186.5 x 100 Plan Attainment 186.5 = 100
93 x 100 93 = 100
PIONEER CEMENT INDUSTRIES LLC, RAK, UAE MECHANICAL DEPT.KEY PERFORMANCE INDICATORS - KPI FIRST WEEK OF 2012 PMR Preventive Maint. Routine Hrs PMR = Available Labour Hours Sl No. 1 2 3 4 5 6 7 8 9 10 11 12
Job RAW MILLS & STACKER RECLAIMER SECTION BC-7 drive gearbox internals inspection & oil replacement work RM-1&2 O-sepa fan impeller inspection work RM-1 LCD choked slots cleaning work(with gas cut) RABh 4th module RAL rotor replacement & module inside inspection work Storage weigh feeder head pulley bearings greasing work Dump hopper no-4 tyre stopper pipe fixing and full welding work Rawmill hot air duct insulation work Raw mill -1 cyclone Patch up work Raw mill-1 Girth gear FLR unit replacing work. Bridge reclaimer Scrapper chain buckets fixing bolts removing and new bolts fixing work. Raw mill-2 pressing side main gearbox lub system filters cleaning. General Maintenance:1.RM-1&2 slide shoe bearings visual checking 2.Rawmill area checklist & general maintenance works 4.Rawmill area house keeping done
PYRO & COAL MILL, HANDLING SECTION Alternate fuel feeding hopper & pin gates fabrication and Erection Work at Preheater Alternate fuel Feeding system Hopper platform with hand railing & monkey ladder . Alternate fuel feeding Belt conveyor top skirt board fabrication and fixing work Alternate fuel feeding belt conveyor discharge flap fabrication and fixing work Spare Air blasters reconditioning work. Coal Mill maintenance :Coal mill Auxiliary Drive Alignment work Coal Crusher Grizzly bar gap adjustment work. Coal mill apron weigh feeder maintenance work 7 General Maintenance:1. Kiln all Tyres lubricated 2. Cooler Drives Chain lubricated 3. En-mass conveyors chain condition inspected&missed chain pins circlips refixed. 4.DDPC-1 chain condition inspection 5. Compressors Suction Filter & Cooler cleaned 6. K.C. & P.C. Roots Blowers Suction Filters cleaned 7. Silo bottom & Pre-heater top Blowers Suction Filters cleaned. 8. Kiln Supporting Rollers Bearings Oil Seals lubricated. 9. Air blaster Quick exhaust valves replaced & Overhauled 1 2 3 4 5 6
1 2 3 4 5 6
CEMENT MILLS & PACKING PLANT SECTION Cement mill-2 Girth gear Bolts 3 nos to be replaced with new. Cement mill-2 Girth Gear Guard Supports fixing. Cement mill -2 Inlet Chute Patch up work. Gypsum Belt conveyor travel Drive input coupling rubber bushes & Bolts replacing work Cement mill-1 Outlet water spray system inspection work Cement mill-1 Inlet Chute worn out plate replacement. Cement mill-1 O-Sepa Inspection Spare Dosing Valve maintenance work and House keeping. Cement mill area check list work and general maintenance works Packing Plant: Roto Packing and auto packer Schedule maintenance works. Silo 1&2 Extraction chutes Jam cleaning work. preparatory works for packing plant maintenance works. Roto Packing and auto packer Schedule maintenance works. Bulk loading Bucket elevator Belt joint bottom side rubber jointing work Packing plant area house keeping
1 2 3 4 5 6 7
WORKSHOP & WATER WORKS Hydra gearbox cover drilling and tapping Clinker breaker hammer pin washer machining Material handling trolley pin and bushes machining Cement mill door bolt threading work Connectors machining for src hopper Bogie Wheel welding work. Cooler track wheels welding work
1 2 3 4 5 6 7 8 9
Type PM PM Repair PM PM Repair Repair Repair Repair PM PM PM PM PM
Estimated Hours 12 12 8.5 34 12 10 34 17.5 8 22 10 4 24 18
x 100
Actual Hours 13.5 12 8.5 34 12 10 34 17.5 8 24.5 10
Job Complet ed Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes
60 56 68 66 25.5
68 56 68 68 25.5
Yes yes Yes Yes Yes
PM Repair PM
6 15 8
6 15 8
6 6 12 4 6 10 10 10 2.5 371
6 6 12 4 6 10 10 10 2.5 381
Yes yes Yes Yes Yes Yes Yes
Repair Repair Repair PM PM Repair PM PM PM
12.5 13 17 8 5 34 5 8.5 21.5
12.5 13 17 8 5 34 5 8.5 21.5
Yes Yes Yes Yes Yes Yes Yes Yes Yes
PM Repair PM PM PM PM
34 8.5 5.5 20 14 8.5 215
34 8.5 5.5 20 14 8.5 215
Yes Yes Yes Yes Yes Yes
8.5 17 17 17 8.5 17 14
8.5 19 17 17 8.5 20 14
Yes Yes Yes Yes Yes Yes Yes
PM PM PM PM Repair
152 x 100 230 = 66.09
4 Yes 24 Yes 18 Yes
PM PM PM PM Repair
PM PM PM
P.M.R(%)
338 x 100 381 = 88.71
Yes Yes Yes Yes Yes
130 x 100 215 = 60.46
Sl No. Job 8 Clinker breaker hammer pins washers preparation work 9 Plumbing works at workers & staff colony
Type
1 2 4 5 6 7
PROJECT & DEVELOPMENT WORKS Paper Bags Go down opening Covering clading fabrication and erection work. SRC clinker tank and accessories erection work SRC clinker tank approaching stair case fabrication & erection Rejects clinker discharge pipe dismantling work & feed pipe erection work CSP top roof openings sheeting work SRC Clinker tank Civil structure side cladding work.
Development Project Project Project Development Development
1 2 3 4 5 6
AUTO GARAGE General Maintenance Hydra engine overhauling work Cat loader engine oil and filters treplacement Man truck left side door handle replacement work Man truck 21475 rear axle repair work Man truck 21475 rear type puncure
PM Repair PM Unplanned Unplanned Unplanned
Job Estimated Actual Complet Hours Hours ed 8.5 8.5 Yes 79 79 Yes 186.5 191.5 200 720 350 280 100 150 1100
56 796 347.5 330 110 89.5 1236
No Yes No Yes Yes No
28 62 3 3 3 5 104
28 68 3 3 3 5 110
Yes Yes Yes Yes Yes Yes
P.M.R(%)
31 x 100 110 = 28.18
PIONEER CEMENT INDUSTRIES LLC, RAK, UAE MECHANICAL DEPT.KEY PERFORMANCE INDICATORS - KPI FIRST WEEK OF 2012 UNPLANNED Unplanned % = Sl No.
Job RAW MILLS & STACKER RECLAIMER SECTION 1 BC-7 drive gearbox internals inspection & oil replacement work 2 RM-1&2 O-sepa fan impeller inspection work 3 RM-1 LCD choked slots cleaning work(with gas cut) 4 RABh 4th module RAL rotor replacement & module inside inspection work 5 Storage weigh feeder head pulley bearings greasing work 6 Dump hopper no-4 tyre stopper pipe fixing and full welding work 7 Rawmill hot air duct insulation work 8 Raw mill -1 cyclone Patch up work 9 Raw mill-1 Girth gear FLR unit replacing work. 10 Bridge reclaimer Scrapper chain buckets fixing bolts removing and new bolts fixing work. 11 Raw mill-2 pressing side main gearbox lub system filters cleaning. 12 General Maintenance:1.RM-1&2 slide shoe bearings visual checking 2.Rawmill area checklist & general maintenance works 4.Rawmill area house keeping done
1 2 3 4 5 6
7
PYRO & COAL MILL, HANDLING SECTION Alternate fuel feeding hopper & pin gates fabrication and Erection Work at Preheater Alternate fuel Feeding system Hopper platform with hand railing & monkey ladder . Alternate fuel feeding Belt conveyor top skirt board fabrication and fixing work Alternate fuel feeding belt conveyor discharge flap fabrication and fixing work Spare Air blasters reconditioning work. Coal Mill maintenance :Coal mill Auxiliary Drive Alignment work Coal Crusher Grizzly bar gap adjustment work. Coal mill apron weigh feeder maintenance work General Maintenance:1. Kiln all Tyres lubricated 2. Cooler Drives Chain lubricated 3. En-mass conveyors chain condition inspected&missed chain pins circlips refixed. 4.DDPC-1 chain condition inspection 5. Compressors Suction Filter & Cooler cleaned 6. K.C. & P.C. Roots Blowers Suction Filters cleaned 7. Silo bottom & Pre-heater top Blowers Suction Filters cleaned. 8. Kiln Supporting Rollers Bearings Oil Seals lubricated. 9. Air blaster Quick exhaust valves replaced & Overhauled
1 2 3 4 5 6
CEMENT MILLS & PACKING PLANT SECTION Cement mill-2 Girth gear Bolts 3 nos to be replaced with new. Cement mill-2 Girth Gear Guard Supports fixing. Cement mill -2 Inlet Chute Patch up work. Gypsum Belt conveyor travel Drive input coupling rubber bushes & Bolts replacing work Cement mill-1 Outlet water spray system inspection work Cement mill-1 Inlet Chute worn out plate replacement. Cement mill-1 O-Sepa Inspection Spare Dosing Valve maintenance work and House keeping. Cement mill area check list work and general maintenance works Packing Plant: Roto Packing and auto packer Schedule maintenance works. Silo 1&2 Extraction chutes Jam cleaning work. preparatory works for packing plant maintenance works. Roto Packing and auto packer Schedule maintenance works. Bulk loading Bucket elevator Belt joint bottom side rubber jointing work Packing plant area house keeping
1 2 3 4 5 6 7
WORKSHOP & WATER WORKS Hydra gearbox cover drilling and tapping Clinker breaker hammer pin washer machining Material handling trolley pin and bushes machining Cement mill door bolt threading work Connectors machining for src hopper Bogie Wheel welding work. Cooler track wheels welding work
1 2 3 4 5 6 7 8 9
Actual hours on completed unplanned work orders
Estimated hours on all completed work orders
Type PM PM Repair PM PM Repair Repair Repair Repair PM PM PM PM PM
Estimated Actual Hours Hours 12 12 8.5 34 12 10 34 17.5 8 22 10 4 24 18
13.5 12 8.5 34 12 10 34 17.5 8 24.5 10
Job Completed Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes
X 100
Unplanned(%)
0 x 100 226 =0
4 Yes 24 Yes 18 Yes
PM PM PM PM Repair
60 56 68 66 25.5
68 56 68 68 25.5
Yes yes Yes Yes Yes
PM Repair PM
6 15 8
6 15 8
PM PM PM PM PM PM PM Repair
6 6 12 4 6 10 10 10 2.5
6 6 12 4 6 10 10 10 2.5
Yes yes Yes Yes Yes Yes Yes
Repair Repair Repair PM PM Repair PM PM PM
12.5 13 17 8 5 34 5 8.5 21.5
12.5 13 17 8 5 34 5 8.5 21.5
Yes Yes Yes Yes Yes Yes Yes Yes Yes
PM Repair PM PM PM PM
34 8.5 5.5 20 14 8.5
34 8.5 5.5 20 14 8.5
Yes Yes Yes Yes Yes Yes
8.5 17 17 17 8.5 17 14
8.5 19 17 17 8.5 20 14
Yes Yes Yes Yes Yes Yes Yes
0 x 100 371 =0
Yes Yes Yes Yes Yes
0 x 100 215 =0
0 x 100 186.5 =0
Sl No. Job 8 Clinker breaker hammer pins washers preparation work 9 Plumbing works at workers & staff colony
Type
Estimated Actual Job Hours Hours Completed 8.5 8.5 Yes 79 79 Yes
1 2 4 5 6 7
PROJECT & DEVELOPMENT WORKS Paper Bags Go down opening Covering clading fabrication and erection work. SRC clinker tank and accessories erection work SRC clinker tank approaching stair case fabrication & erection Rejects clinker discharge pipe dismantling work & feed pipe erection work CSP top roof openings sheeting work SRC Clinker tank Civil structure side cladding work.
Development Project Project Project Development Development
1 2 3 4 5 6
AUTO GARAGE General Maintenance Hydra engine overhauling work Cat loader engine oil and filters treplacement Man truck left side door handle replacement work Man truck 21475 rear axle repair work Man truck 21475 rear type puncure
PM Repair PM Unplanned Unplanned Unplanned
200 720 350 280 100 150
56 796 347.5 330 110 89.5
No Yes No Yes Yes No
28 62 3 3 3 5
28 68 3 3 3 5
Yes Yes Yes Yes Yes Yes
0 x 100 186.5 =0 Unplanned(%)
11 x 100 104 = 10.6
Labour Utilisation Sl.No
DESCRIPTION
RAW MILLS & STACKER RECLAIMER SECTION PYRO & COAL MILL, 2 HANDLING SECTION 1
CEMENT MILLS & PACKING PLANT SECTION WORKSHOP & WATER 4 WORKS PROJECT & DEVELOPMENT 5 WORKS 3
6 AUTO GARAGE
Available Labour Hours
Actual Hours
%
Productivity
Estimated Hours
Actual Hours
%
Lab.Utilisation X Effi. 100
Plan Attainment Estmiated Hours of Estimated completed time of all jobs(excluding jobs unplanned)
PMR
%
Preventive Available Maintenanc Labour e Routine Hours Hours
Un Planned
%
Actual hours Estimated on completed hours on all unplanned completed work orders work orders
%
230.00
230.00 100.00
226.00
230.00
98.26
98.26
226.00
226.00
100.00
152.00
230.00
66.09
0.00
226.00
0.00
381.00
381.00 100.00
371.00
381.00
97.38
97.38
371.00
371.00
100.00
338.00
381.00
88.71
0.00
371.00
0.00
215.00
215.00 100.00
215.00
215.00 100.00
100.00
215.00
215.00
100.00
130.00
215.00
60.46
0.00
215.00
0.00
191.50
191.50 100.00
186.50
191.50
97.39
97.39
186.50
186.50
100.00
0.00
186.50
0.00
835.00
835.00 100.00
1100.00
1236.00 89.00
89.00
79.00
79.00 100.00
104.00
110.00
94.55
93.00
93.00
100.00
11.00
104.00
10.60
94.55
31.00
110.00
28.18
PIONEER CEMENT INDUSTRIES LLC, RAK, UAE MECHANICAL DEPT KEY PERFORMANCE INDICATORS - KPI FIRST WEEK OF 2012
Labour Utilization(%) Sl. No 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40
Names
Sandeep Singh Pillai Bhanu Pratap Ramana Reddy Hanumath Reddy Abu Backer Jose Bhukya Sreenu Assan Vallabha Rao Moinuddin Babu Kumar Chendra Sekhar Dhanesh Gupta Naresh Rauth Anil Saleem Rajiman Prasannan Jamshid
Firoz Khan Radha Krishna Shabir ali Iqbal Basha Rajesh Kumar Kusva Ansari Murali Dharan Ajmal Basha Jelaludhin Babu Babi Paswan Ramesh Asraf Suru Kumar Musthafa Mahindra Murthy Ramakrishna Rajesh yadav Total
=
Actual Labour Hours on work orders/Available Labour Hours X 100 Available Labour hours 0 39.5 39.5 39.5 39.5 45.5 39.5 39.5 39.5 39.5 39.5 64.5 39.5 71 39.5 64.5 64.5 39.5 39.5 39.5 39.5 39.5 78 78 78 78 74 74 74 74 39.5 39.5 39.5 39.5 65.5 39.5 39.5 39.5 39.5 1931.5
Actual Labour Hours(Work Orders) 0 39.5 39.5 39.5 39.5 45.5 39.5 39.5 39.5 39.5 39.5 64.5 39.5 71 39.5 64.5 64.5 39.5 39.5 39.5 39.5 39.5 78 78 78 78 74 74 74 74 39.5 39.5 39.5 39.5 65.5 39.5 39.5 39.5 39.5 1931.5
Labour Utilization(%)
100.00%
PIONEER CEMENT INDUSTRIES LLC, RAK, UAE MECHANICAL DEPT. KEY PERFORMANCE INDICATORS - KPI FIRST WEEK OF 2012
Efficiency (%) = Estimated Time of completed Jobs / Actual Time of Completed Jobs Sl No . 1 2 3 4 5 6 7 8 9 10 11 12
1 2 3 4 5 6
7
Job RAW MILLS & STACKER RECLAIMER SECTION BC-7 drive gearbox internals inspection & oil replacement work RM-1&2 O-sepa fan impeller inspection work RM-1 LCD choked slots cleaning work(with gas cut) RABh 4th module RAL rotor replacement & module inside inspection work Storage weigh feeder head pulley bearings greasing work Dump hopper no-4 tyre stopper pipe fixing and full welding work Rawmill hot air duct insulation work Raw mill -1 cyclone Patch up work Raw mill-1 Girth gear FLR unit replacing work. Bridge reclaimer Scrapper chain buckets fixing bolts removing and new bolts fixing work. Raw mill-2 pressing side main gearbox lub system filters cleaning. General Maintenance:1.RM-1&2 slide shoe bearings visual checking 2.Rawmill area checklist & general maintenance works 4.Rawmill area house keeping done PYRO & COAL MILL, HANDLING SECTION Alternate fuel feeding hopper & pin gates fabrication and Erection Work at Preheater Second Floor. Alternate fuel Feeding system Hopper platform with hand railing & monkey ladder . Alternate fuel feeding Belt conveyor top skirt board fabrication and fixing work Alternate fuel feeding belt conveyor discharge flap fabrication and fixing work Spare Air blasters reconditioning work. Coal Mill maintenance :Coal mill Auxiliary Drive Alignment work Coal Crusher Grizzly bar gap adjustment work. Coal mill apron weigh feeder maintenance work General Maintenance:1. Kiln all Tyres lubricated 2. Cooler Drives Chain lubricated 3. En-mass conveyors chain condition inspected&missed chain pins circlips refixed. 4.DDPC-1 chain condition inspection 5. Compressors Suction Filter & Cooler cleaned 6. K.C. & P.C. Roots Blowers Suction Filters cleaned 7. Silo bottom & Pre-heater top Blowers Suction Filters cleaned. 8. Kiln Supporting Rollers Bearings Oil Seals lubricated. 9. Air blaster Quick exhaust valves replaced & Overhauled
1 2 3 4 5 6
CEMENT MILLS & PACKING PLANT SECTION Cement mill-2 Girth gear Bolts 3 nos to be replaced with new. Cement mill-2 Girth Gear Guard Supports fixing. Cement mill -2 Inlet Chute Patch up work. Gypsum Belt conveyor travel Drive input coupling rubber bushes & Bolts replacing work Cement mill-1 Outlet water spray system inspection work Cement mill-1 Inlet Chute worn out plate replacement. Cement mill-1 O-Sepa Inspection Spare Dosing Valve maintenance work and House keeping. Cement mill area check list work and general maintenance works Packing Plant: Roto Packing and auto packer Schedule maintenance works. Silo 1&2 Extraction chutes Jam cleaning work. preparatory works for packing plant maintenance works. Roto Packing and auto packer Schedule maintenance works. Bulk loading Bucket elevator Belt joint bottom side rubber jointing work Packing plant area house keeping
1 2 3 4 5
WORKSHOP & WATER WORKS Hydra gearbox cover drilling and tapping Clinker breaker hammer pin washer machining Material handling trolley pin and bushes machining Cement mill door bolt threading work Connectors machining for src hopper
1 2 3 4 5 6 7 8 9
Type
Estimated Hours
Job Comple ted
Actual Hours
PM PM Repair PM PM Repair Repair Repair Repair PM PM
12 12 8.5 34 12 10 34 17.5 8 22 10
13.5 12 8.5 34 12 10 34 17.5 8 24.5 10
PM PM PM
4 24 18 226
4 Yes 24 Yes 18 Yes 230
PM PM PM Repair
60 56 68 66 25.5
68 56 68 68 25.5
Yes yes Yes Yes Yes
PM Repair PM
6 15 8
6 15 8
6 6 12 4 6 10 10 10 2.5 371
6 6 12 4 6 10 10 10 2.5 381
Yes yes Yes Yes Yes Yes Yes
Repair Repair Repair PM PM Repair PM PM PM
12.5 13 17 8 5 34 5 8.5 21.5
12.5 13 17 8 5 34 5 8.5 21.5
Yes Yes Yes Yes Yes Yes Yes Yes Yes
PM Repair PM PM PM PM
34 8.5 5.5 20 14 8.5 215
34 8.5 5.5 20 14 8.5 215
Yes Yes Yes Yes Yes Yes
8.5 17 17 17 8.5
8.5 19 17 17 8.5
Yes Yes Yes Yes Yes
PM
PM PM PM PM PM PM PM Repair
Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes
Yes Yes Yes Yes Yes
Sl No . 6 7 8 9
Job Bogie Wheel welding work. Cooler track wheels welding work Clinker breaker hammer pins washers preparation work Plumbing works at workers & staff colony
Type
1 2 4 5 6 7
PROJECT & DEVELOPMENT WORKS Paper Bags Go down opening Covering clading fabrication and erection work. SRC clinker tank and accessories erection work SRC clinker tank approaching stair case fabrication & erection Rejects clinker discharge pipe dismantling work & feed pipe erection work CSP top roof openings sheeting work SRC Clinker tank Civil structure side cladding work.
Development Project Project Project Development Development
1 2 3 4 5 6
AUTO GARAGE General Maintenance Hydra engine overhauling work Cat loader engine oil and filters treplacement Man truck left side door handle replacement work Man truck 21475 rear axle repair work Man truck 21475 rear type puncure
PM Repair PM Unplanned Unplanned Unplanned
Job Estimated Actual Comple Hours Hours ted 17 20 Yes 14 14 Yes 8.5 8.5 Yes 79 79 Yes 186.5 191.5 200 720 350 280 100 150 1100
56 796 347.5 330 110 89.5 1236
No Yes No Yes Yes No
28 62 3 3 3 5
28 68 3 3 3 5
Yes Yes Yes Yes Yes Yes
PIONEER CEMENT INDUSTRIES LLC, RAK, UAE MECHANICAL DEPT. KEY PERFORMANCE INDICATORS - KPI FIRST WEEK OF 2012
Efficiency
98.26
97.38
100.00
97.39
97.39 Efficiency
89.00
94.55
PIONEER CEMENT INDUSTRIES LLC, RAK, UAE MECHANICAL DEPT.KEY PERFORMANCE INDICATORS - KPI FIRST WEEK OF 2012
Productivity Productivity(%) = Sl.No 1 2 3 4 5 6
Section RAW MILLS & STACKER RECLAIMER SECTION PYRO & COAL MILL, HANDLING SECTION CEMENT MILLS & PACKING PLANT SECTION WORKSHOP & WATER WORKS PROJECT & DEVELOPMENT WORKS AUTO GARAGE
Labour Utilisation X Efficiency 100 Labour Utilisation Efficiency 100.00 98.26 100.00 97.38 100.00 100.00 100.00 97.39 100.00 89.00 100.00 94.55
Productivity 98.26 97.38 100.00 97.39 89.00 94.55
PIONEER CEMENT INDUSTRIES LLC, RAK, UAE MECHANICAL DEPT.KEY PERFORMANCE INDICATORS - KPI FIRST WEEK OF 2012
Plan Attainment (%) = Estimated Time of completed Jobs excluding unplanned works / Estimated Time of all Jobs Sl No. 1 2 3 4 5 6 7 8 9 10
Job RAW MILLS & STACKER RECLAIMER SECTION BC-7 drive gearbox internals inspection & oil replacement work RM-1&2 O-sepa fan impeller inspection work RM-1 LCD choked slots cleaning work(with gas cut) RABh 4th module RAL rotor replacement & module inside inspection work Storage weigh feeder head pulley bearings greasing work Dump hopper no-4 tyre stopper pipe fixing and full welding work Rawmill hot air duct insulation work Raw mill -1 cyclone Patch up work Raw mill-1 Girth gear FLR unit replacing work. Bridge reclaimer Scrapper chain buckets fixing bolts removing and new bolts fixing work.
PM PM Repair PM PM Repair Repair Repair Repair
12 12 8.5 34 12 10 34 17.5 8
Job Actual Complet Hours ed 13.5 12 8.5 34 12 10 34 17.5 8
Yes Yes Yes Yes Yes Yes Yes Yes Yes
PM PM
22 10
24.5 Yes 10 Yes
PM PM PM
4 24 18
4 Yes 24 Yes 18 Yes
60
68
PM PM PM Repair
56 68 66 25.5
56 68 68 25.5
PM Repair PM
6 15 8
6 15 8
PM PM
6 6
6 6
Yes yes Yes Yes Yes Yes
3. En-mass conveyors chain condition inspected&missed chain pins circlips refixed.
PM
12
12
Yes
4.DDPC-1 chain condition inspection 5. Compressors Suction Filter & Cooler cleaned 6. K.C. & P.C. Roots Blowers Suction Filters cleaned 7. Silo bottom & Pre-heater top Blowers Suction Filters cleaned. 8. Kiln Supporting Rollers Bearings Oil Seals lubricated. 9. Air blaster Quick exhaust valves replaced & Overhauled
PM PM PM PM Repair
4 6 10 10 10 2.5
4 6 10 10 10 2.5
Yes Yes Yes Yes Yes
Repair Repair Repair PM PM Repair PM PM PM
12.5 13 17 8 5 34 5 8.5 21.5
12.5 13 17 8 5 34 5 8.5 21.5
Yes Yes Yes Yes Yes Yes Yes Yes Yes
PM Repair PM PM PM PM
34 8.5 5.5 20 14 8.5
34 8.5 5.5 20 14 8.5
Yes Yes Yes Yes Yes Yes
8.5 17 17 17
8.5 19 17 17
Yes Yes Yes Yes
11 Raw mill-2 pressing side main gearbox lub system filters cleaning. 12 General Maintenance:1.RM-1&2 slide shoe bearings visual checking 2.Rawmill area checklist & general maintenance works 4.Rawmill area house keeping done PYRO & COAL MILL, HANDLING SECTION Alternate fuel feeding hopper & pin gates fabrication and Erection Work at Preheater 1 Second Floor. 2 Alternate fuel Feeding system Hopper platform with hand railing & monkey ladder . 3 4 5 6
Alternate fuel feeding Belt conveyor top skirt board fabrication and fixing work Alternate fuel feeding belt conveyor discharge flap fabrication and fixing work Spare Air blasters reconditioning work. Coal Mill maintenance :Coal mill Auxiliary Drive Alignment work Coal Crusher Grizzly bar gap adjustment work. Coal mill apron weigh feeder maintenance work 7 General Maintenance:1. Kiln all Tyres lubricated 2. Cooler Drives Chain lubricated
1 2 3 4 5 6
CEMENT MILLS & PACKING PLANT SECTION Cement mill-2 Girth gear Bolts 3 nos to be replaced with new. Cement mill-2 Girth Gear Guard Supports fixing. Cement mill -2 Inlet Chute Patch up work. Gypsum Belt conveyor travel Drive input coupling rubber bushes & Bolts replacing work Cement mill-1 Outlet water spray system inspection work Cement mill-1 Inlet Chute worn out plate replacement. Cement mill-1 O-Sepa Inspection Spare Dosing Valve maintenance work and House keeping. Cement mill area check list work and general maintenance works Packing Plant: Roto Packing and auto packer Schedule maintenance works. Silo 1&2 Extraction chutes Jam cleaning work. preparatory works for packing plant maintenance works. Roto Packing and auto packer Schedule maintenance works. Bulk loading Bucket elevator Belt joint bottom side rubber jointing work Packing plant area house keeping
1 2 3 4
WORKSHOP & WATER WORKS Hydra gearbox cover drilling and tapping Clinker breaker hammer pin washer machining Material handling trolley pin and bushes machining Cement mill door bolt threading work
1 2 3 4 5 6 7 8 9
Type
Estimated Hours
PM
Plan Attainment
226 x 100 226 = 100
Yes yes Yes Yes Yes
371 x 100 371 = 100
215 x 100 215 = 100
186.5 x 100 186.5 = 100
Sl No. 5 6 7 8 9
Job Connectors machining for src hopper Bogie Wheel welding work. Cooler track wheels welding work Clinker breaker hammer pins washers preparation work Plumbing works at workers & staff colony
Type
Job Estimated Actual Complet Hours Hours ed 8.5 8.5 Yes 17 20 Yes 14 14 Yes 8.5 8.5 Yes 79 79 Yes
1 2 4 5 6 7
PROJECT & DEVELOPMENT WORKS Paper Bags Go down opening Covering clading fabrication and erection work. SRC clinker tank and accessories erection work SRC clinker tank approaching stair case fabrication & erection Rejects clinker discharge pipe dismantling work & feed pipe erection work CSP top roof openings sheeting work SRC Clinker tank Civil structure side cladding work.
Development Project Project Project Development Development
1 2 3 4 5 6
AUTO GARAGE General Maintenance Hydra engine overhauling work Cat loader engine oil and filters treplacement Man truck left side door handle replacement work Man truck 21475 rear axle repair work Man truck 21475 rear type puncure
PM Repair PM Unplanned Unplanned Unplanned
200 720 350 280 100 150
56 796 347.5 330 110 89.5
No Yes No Yes Yes No
28 62 3 3 3 5
28 68 3 3 3 5
Yes Yes Yes Yes Yes Yes
186.5 x 100 Plan Attainment 186.5 = 100
93 x 100 93 = 100
PIONEER CEMENT INDUSTRIES LLC, RAK, UAE MECHANICAL DEPT.KEY PERFORMANCE INDICATORS - KPI FIRST WEEK OF 2012 PMR Preventive Maint. Routine Hrs PMR = Available Labour Hours Sl No. 1 2 3 4 5 6 7 8 9 10 11 12
Job RAW MILLS & STACKER RECLAIMER SECTION BC-7 drive gearbox internals inspection & oil replacement work RM-1&2 O-sepa fan impeller inspection work RM-1 LCD choked slots cleaning work(with gas cut) RABh 4th module RAL rotor replacement & module inside inspection work Storage weigh feeder head pulley bearings greasing work Dump hopper no-4 tyre stopper pipe fixing and full welding work Rawmill hot air duct insulation work Raw mill -1 cyclone Patch up work Raw mill-1 Girth gear FLR unit replacing work. Bridge reclaimer Scrapper chain buckets fixing bolts removing and new bolts fixing work. Raw mill-2 pressing side main gearbox lub system filters cleaning. General Maintenance:1.RM-1&2 slide shoe bearings visual checking 2.Rawmill area checklist & general maintenance works 4.Rawmill area house keeping done
PYRO & COAL MILL, HANDLING SECTION Alternate fuel feeding hopper & pin gates fabrication and Erection Work at Preheater Alternate fuel Feeding system Hopper platform with hand railing & monkey ladder . Alternate fuel feeding Belt conveyor top skirt board fabrication and fixing work Alternate fuel feeding belt conveyor discharge flap fabrication and fixing work Spare Air blasters reconditioning work. Coal Mill maintenance :Coal mill Auxiliary Drive Alignment work Coal Crusher Grizzly bar gap adjustment work. Coal mill apron weigh feeder maintenance work 7 General Maintenance:1. Kiln all Tyres lubricated 2. Cooler Drives Chain lubricated 3. En-mass conveyors chain condition inspected&missed chain pins circlips refixed. 4.DDPC-1 chain condition inspection 5. Compressors Suction Filter & Cooler cleaned 6. K.C. & P.C. Roots Blowers Suction Filters cleaned 7. Silo bottom & Pre-heater top Blowers Suction Filters cleaned. 8. Kiln Supporting Rollers Bearings Oil Seals lubricated. 9. Air blaster Quick exhaust valves replaced & Overhauled 1 2 3 4 5 6
1 2 3 4 5 6
CEMENT MILLS & PACKING PLANT SECTION Cement mill-2 Girth gear Bolts 3 nos to be replaced with new. Cement mill-2 Girth Gear Guard Supports fixing. Cement mill -2 Inlet Chute Patch up work. Gypsum Belt conveyor travel Drive input coupling rubber bushes & Bolts replacing work Cement mill-1 Outlet water spray system inspection work Cement mill-1 Inlet Chute worn out plate replacement. Cement mill-1 O-Sepa Inspection Spare Dosing Valve maintenance work and House keeping. Cement mill area check list work and general maintenance works Packing Plant: Roto Packing and auto packer Schedule maintenance works. Silo 1&2 Extraction chutes Jam cleaning work. preparatory works for packing plant maintenance works. Roto Packing and auto packer Schedule maintenance works. Bulk loading Bucket elevator Belt joint bottom side rubber jointing work Packing plant area house keeping
1 2 3 4 5 6 7
WORKSHOP & WATER WORKS Hydra gearbox cover drilling and tapping Clinker breaker hammer pin washer machining Material handling trolley pin and bushes machining Cement mill door bolt threading work Connectors machining for src hopper Bogie Wheel welding work. Cooler track wheels welding work
1 2 3 4 5 6 7 8 9
Type PM PM Repair PM PM Repair Repair Repair Repair PM PM PM PM PM
Estimated Hours 12 12 8.5 34 12 10 34 17.5 8 22 10 4 24 18
x 100
Actual Hours 13.5 12 8.5 34 12 10 34 17.5 8 24.5 10
Job Complet ed Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes
60 56 68 66 25.5
68 56 68 68 25.5
Yes yes Yes Yes Yes
PM Repair PM
6 15 8
6 15 8
6 6 12 4 6 10 10 10 2.5 371
6 6 12 4 6 10 10 10 2.5 381
Yes yes Yes Yes Yes Yes Yes
Repair Repair Repair PM PM Repair PM PM PM
12.5 13 17 8 5 34 5 8.5 21.5
12.5 13 17 8 5 34 5 8.5 21.5
Yes Yes Yes Yes Yes Yes Yes Yes Yes
PM Repair PM PM PM PM
34 8.5 5.5 20 14 8.5 215
34 8.5 5.5 20 14 8.5 215
Yes Yes Yes Yes Yes Yes
8.5 17 17 17 8.5 17 14
8.5 19 17 17 8.5 20 14
Yes Yes Yes Yes Yes Yes Yes
PM PM PM PM Repair
152 x 100 230 = 66.09
4 Yes 24 Yes 18 Yes
PM PM PM PM Repair
PM PM PM
P.M.R(%)
338 x 100 381 = 88.71
Yes Yes Yes Yes Yes
130 x 100 215 = 60.46
Sl No. Job 8 Clinker breaker hammer pins washers preparation work 9 Plumbing works at workers & staff colony
Type
1 2 4 5 6 7
PROJECT & DEVELOPMENT WORKS Paper Bags Go down opening Covering clading fabrication and erection work. SRC clinker tank and accessories erection work SRC clinker tank approaching stair case fabrication & erection Rejects clinker discharge pipe dismantling work & feed pipe erection work CSP top roof openings sheeting work SRC Clinker tank Civil structure side cladding work.
Development Project Project Project Development Development
1 2 3 4 5 6
AUTO GARAGE General Maintenance Hydra engine overhauling work Cat loader engine oil and filters treplacement Man truck left side door handle replacement work Man truck 21475 rear axle repair work Man truck 21475 rear type puncure
PM Repair PM Unplanned Unplanned Unplanned
Job Estimated Actual Complet Hours Hours ed 8.5 8.5 Yes 79 79 Yes 186.5 191.5 200 720 350 280 100 150 1100
56 796 347.5 330 110 89.5 1236
No Yes No Yes Yes No
28 62 3 3 3 5 104
28 68 3 3 3 5 110
Yes Yes Yes Yes Yes Yes
P.M.R(%)
31 x 100 110 = 28.18
PIONEER CEMENT INDUSTRIES LLC, RAK, UAE MECHANICAL DEPT.KEY PERFORMANCE INDICATORS - KPI FIRST WEEK OF 2012 UNPLANNED Unplanned % = Sl No.
Job RAW MILLS & STACKER RECLAIMER SECTION 1 BC-7 drive gearbox internals inspection & oil replacement work 2 RM-1&2 O-sepa fan impeller inspection work 3 RM-1 LCD choked slots cleaning work(with gas cut) 4 RABh 4th module RAL rotor replacement & module inside inspection work 5 Storage weigh feeder head pulley bearings greasing work 6 Dump hopper no-4 tyre stopper pipe fixing and full welding work 7 Rawmill hot air duct insulation work 8 Raw mill -1 cyclone Patch up work 9 Raw mill-1 Girth gear FLR unit replacing work. 10 Bridge reclaimer Scrapper chain buckets fixing bolts removing and new bolts fixing work. 11 Raw mill-2 pressing side main gearbox lub system filters cleaning. 12 General Maintenance:1.RM-1&2 slide shoe bearings visual checking 2.Rawmill area checklist & general maintenance works 4.Rawmill area house keeping done
1 2 3 4 5 6
7
PYRO & COAL MILL, HANDLING SECTION Alternate fuel feeding hopper & pin gates fabrication and Erection Work at Preheater Alternate fuel Feeding system Hopper platform with hand railing & monkey ladder . Alternate fuel feeding Belt conveyor top skirt board fabrication and fixing work Alternate fuel feeding belt conveyor discharge flap fabrication and fixing work Spare Air blasters reconditioning work. Coal Mill maintenance :Coal mill Auxiliary Drive Alignment work Coal Crusher Grizzly bar gap adjustment work. Coal mill apron weigh feeder maintenance work General Maintenance:1. Kiln all Tyres lubricated 2. Cooler Drives Chain lubricated 3. En-mass conveyors chain condition inspected&missed chain pins circlips refixed. 4.DDPC-1 chain condition inspection 5. Compressors Suction Filter & Cooler cleaned 6. K.C. & P.C. Roots Blowers Suction Filters cleaned 7. Silo bottom & Pre-heater top Blowers Suction Filters cleaned. 8. Kiln Supporting Rollers Bearings Oil Seals lubricated. 9. Air blaster Quick exhaust valves replaced & Overhauled
1 2 3 4 5 6
CEMENT MILLS & PACKING PLANT SECTION Cement mill-2 Girth gear Bolts 3 nos to be replaced with new. Cement mill-2 Girth Gear Guard Supports fixing. Cement mill -2 Inlet Chute Patch up work. Gypsum Belt conveyor travel Drive input coupling rubber bushes & Bolts replacing work Cement mill-1 Outlet water spray system inspection work Cement mill-1 Inlet Chute worn out plate replacement. Cement mill-1 O-Sepa Inspection Spare Dosing Valve maintenance work and House keeping. Cement mill area check list work and general maintenance works Packing Plant: Roto Packing and auto packer Schedule maintenance works. Silo 1&2 Extraction chutes Jam cleaning work. preparatory works for packing plant maintenance works. Roto Packing and auto packer Schedule maintenance works. Bulk loading Bucket elevator Belt joint bottom side rubber jointing work Packing plant area house keeping
1 2 3 4 5 6 7
WORKSHOP & WATER WORKS Hydra gearbox cover drilling and tapping Clinker breaker hammer pin washer machining Material handling trolley pin and bushes machining Cement mill door bolt threading work Connectors machining for src hopper Bogie Wheel welding work. Cooler track wheels welding work
1 2 3 4 5 6 7 8 9
Actual hours on completed unplanned work orders
Estimated hours on all completed work orders
Type PM PM Repair PM PM Repair Repair Repair Repair PM PM PM PM PM
Estimated Actual Hours Hours 12 12 8.5 34 12 10 34 17.5 8 22 10 4 24 18
13.5 12 8.5 34 12 10 34 17.5 8 24.5 10
Job Completed Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes
X 100
Unplanned(%)
0 x 100 226 =0
4 Yes 24 Yes 18 Yes
PM PM PM PM Repair
60 56 68 66 25.5
68 56 68 68 25.5
Yes yes Yes Yes Yes
PM Repair PM
6 15 8
6 15 8
PM PM PM PM PM PM PM Repair
6 6 12 4 6 10 10 10 2.5
6 6 12 4 6 10 10 10 2.5
Yes yes Yes Yes Yes Yes Yes
Repair Repair Repair PM PM Repair PM PM PM
12.5 13 17 8 5 34 5 8.5 21.5
12.5 13 17 8 5 34 5 8.5 21.5
Yes Yes Yes Yes Yes Yes Yes Yes Yes
PM Repair PM PM PM PM
34 8.5 5.5 20 14 8.5
34 8.5 5.5 20 14 8.5
Yes Yes Yes Yes Yes Yes
8.5 17 17 17 8.5 17 14
8.5 19 17 17 8.5 20 14
Yes Yes Yes Yes Yes Yes Yes
0 x 100 371 =0
Yes Yes Yes Yes Yes
0 x 100 215 =0
0 x 100 186.5 =0
Sl No. Job 8 Clinker breaker hammer pins washers preparation work 9 Plumbing works at workers & staff colony
Type
Estimated Actual Job Hours Hours Completed 8.5 8.5 Yes 79 79 Yes
1 2 4 5 6 7
PROJECT & DEVELOPMENT WORKS Paper Bags Go down opening Covering clading fabrication and erection work. SRC clinker tank and accessories erection work SRC clinker tank approaching stair case fabrication & erection Rejects clinker discharge pipe dismantling work & feed pipe erection work CSP top roof openings sheeting work SRC Clinker tank Civil structure side cladding work.
Development Project Project Project Development Development
1 2 3 4 5 6
AUTO GARAGE General Maintenance Hydra engine overhauling work Cat loader engine oil and filters treplacement Man truck left side door handle replacement work Man truck 21475 rear axle repair work Man truck 21475 rear type puncure
PM Repair PM Unplanned Unplanned Unplanned
200 720 350 280 100 150
56 796 347.5 330 110 89.5
No Yes No Yes Yes No
28 62 3 3 3 5
28 68 3 3 3 5
Yes Yes Yes Yes Yes Yes
0 x 100 186.5 =0 Unplanned(%)
11 x 100 104 = 10.6
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