KPI-MECH-2nd WK.xlsx

8/22/2019 KPI-MECH-2nd WK.xlsx

1/13

Productivity

Available

Labour

Hours

Actual

Hours

(Work

orders)

%Estimated

Hours

Actual

Hours%

Lab.Utilisation X Effi.

100

Estmiated

Hours of

completed

jobs(excluding

unplanned)

Estimated

time of all

jobs

%

Preventive

Maintenanc

e Routine

Hours

Availa

Labo

Hou

1RAW MILLS & STACKER

RECLAIMER SECTION273.00 273.00 100 261 275.5 96.91 96.91 267 267 100 145 275.

2PYRO & COAL MILL,

HANDLING SECTION603.00 603.00 100 472.5 483 97.83 97.83 472.5 822.5 57.45 284.5 630

3CEMENT MILLS & PACKING

PLANT SECTION319.00 319.00 100 311 325 95.69 95.69 311 311 0 199 325

4WORKSHOP & WATER

WORKS185.50 185.50 100 178 183.5 97 97.00 178 178 100

5 PROJECT & DEVELOPMENTWORKS

347.50 347.50 100 184 191.5 96.08 96.08

6 AUTO GARAGE 96.00 96.00 100 90 96 93.75 93.75 90 90 100 40 96

PIONEER CEMENT INDUSTRIES LLC, RAK, UAE

KEY PERFORMANCE INDICATORS - Maintenance Dept.

SECOND WEEK OF 2012

MECHANICAL DEPT.

PMR

Sl.No DESCRIPTION

Plan AttainmentLabour Utilisation Efficiency


2/13

Labour Utilization(%) = Actual Labour Hours on work orders/Available Labour Hours X 100

Sl. No NamesAvailable Labour

hours

Actual Labour

Hours(Work

Orders)

Labour Utilization(%)

1 Sandeep Singh 0 0

2 Pillai 48 48

3 Bhanu Pratap 48 48

4 Ramana Reddy 48 48

5 Hanumath Reddy 48 48

6 Abu Backer 48 48

7 Jose 48 48

8 Bhukya Sreenu 48 48

9 Assan 48 48

10 Vallabha Rao 48 48

11 Moinuddin 48 48

12 Babu Kumar 48 48

13 Chendra Sekhar 48 48

14 Dhanesh Gupta 48 48

15 Naresh Rauth 48 48

16 Anil 48 48

17 Saleem 48 48

18 Rajiman 48 48

20 Prasannan 48 48

21 Jamshid 48 4822 Firoz Khan 48 48

23 Radha Krishna 48 48

24 Shabir ali 48 48

25 Iqbal Basha 48 48

26 Rajesh Kumar Kusva 48 48

27 Ansari 48 48

28 Murali Dharan 48 48

29 Ajmal Basha 48 48

30 Jelaludhin 48 48

31 Babu Babi 48 4832 Paswan 48 48

33 Ramesh 48 48

34 Asraf 48 48

35 Suru Kumar 48 48

36 Musthafa 48 48

37 Mahindra 48 48

38 Murthy 48 48

39 Ramakrishna 48 48

40 Rajesh yadav 48 48


MECHANICAL DEPT KEY PERFORMANCE INDICATORS - KPI

SECOND WEEK OF 2012

100.00


3/13

Sl

No

. Job Type

Estimated

Hours

Actual

Hours

Job

Comple

ted Efficiency

RAW MILLS & STACKER RECLAIMER SECTION

1 RABH 2nd module inspection & damaged bags to be replaced. PM 30 30 Yes

2 Raw mill-2 O-sepa Cyclone Patch up and Raw mill-1 O-sepa Hopper patch up work. Repair 25.5 25.5 Yes

3 Raw mill-1 & 2 Vent bag filters Impeller inspection and coating cleaning work. PM 17 17 Yes

4 Stacker Spare bogie wheels bearings assembling work . PM 34 34 Yes

5 Raw mills section general checklist checking and Raw mill-1 condition monitoring. PM 8.5 8.5 Yes

6 Stacker drive bogie wheel assembling and replacement towards stock pile side work . Repair 79.5 88 Yes

7 Raw mills 1&2 O-sepa impellers coating cleaning and raw mill-2 O-sepa fan Bearings bed bolts re-

tightening. PM 11 11 Yes

8 Raw mill-1 Vent bag filter Fan impeller coating cleaning work. PM 19.5 19.5 Yes

9 Raw mill-2 Silica Weigh feeder discharge chute patch up work. Repair 7 7 Yes

10 Raw mill-2 Inlet chute patch up work. Repair 10 10 Yes

11 General Maintenance:-

1.RM-1&2 slide shoe bearings visual checking PM 4 4 Yes

2.Rawmill area checklist & general maintenance works PM 17 17 Yes

3.Enmass conveyor-1,2,3&7 inspection PM 4 4

267 275.5

PYRO & COAL MILL, HANDLING SECTION

1 Cooler Back side castable box fabrication and f ixing work. Repair 24 24 Yes

2 Alkali Baghouse hopper-2 Bulk loading head flange fabrication . 24 28 Yes

3 Alkali Baghouse Inlet duct bleed air damper flanges fabrication and safety guards fabrication work.68 74.5

Yes

4 Hot kiln Alignment Preparation works. PM 350 147 No

5 Kiln Girth gear to pinion Root Clearance and backlash readings taken. PM 36 36 Yes

6 Kiln inlet Pneumatic Cylinders replacement work( Leakage Cylinders only ). Repair 34 34 Yes

Kiln Out let dust protection baffle plate (2nos ) Fixing work.

Fine coal pumping line slide gate bolts retightening

P.C Simplex Bin Inspection door opening for inspection.

Kiln II tyre lifting side roller up hill bearing oil replacement

Pre heater fan motor Vibration sensor fixing work.10 Cooler RFT Cross head shaft NDE Wheel Track replacement with spare. PM 34 34 Yes

Kiln feed Standby Bucket Elevator change over

Fine coal pumping roots blower belts tightening work

12 Cooler Drive -1 Chain tentioning work. PM 34 34 Yes

P.C and K.C FK pumps bearings Greasing work.

Kiln II tyre up hill chair pad shim adjustment

14 Coal Mill maintenance :-

Raw coal dump hopper top grills repair work and housekeeping. Repair 34 34 Yes

Coal mill girth gear grease spray pattern checking work. PM 6 6 Yes

15 General Maintenance:- Yes

1. Kiln all Tyres lubricated PM 6 6 Yes

2. Cooler Drives Chain lubricated PM 6 6 Yes

3. En-mass conveyors chain condition inspected&missed chain pins circlips refixed. PM 12 12 Yes

4.DDPC-1 chain condition inspection PM 4 4 Yes

5. Compressors Suction Filter & Cooler cleaned PM 6 6 Yes

6. K.C. & P.C. Roots Blowers Suction Filters cleaned PM 10 10 Yes

7. Silo bottom & Pre-heater top Blowers Suction Filters cleaned. PM 10 10 Yes

8. Kiln Supporting Rollers Bearings Oil Seals lubricated. PM 10 10 Yes

9. Air blaster Quick exhaust valves replaced & Overhauled Repair 2.5 2.5 Yes

10.Cooler spillage hopper double flap valve pneumatic cylinder recondtioned Repair 1.5 1.5 Yes

472.5 483

CEMENT MILLS & PACKING PLANT SECTION

1 Cement Silo-1 4th comportment dosing Valve replacing with reconditioning one. PM 15 17 Yes

2 spare Belt preparation for hopper feed belt. PM 15 17 Yes

3 O-Sepa outlet duct patch up work and Vent bag house inlet duct patch up work. Repair 25.5 25.5 Yes

4 BC-21 Input Coupling Head and tail pulleys bearings inspection and greasing work. PM 17 17 Yes

5 Base frames fabrications for Online centrifugal separator units ( For C.M-1&2 ). PM 20 20 Yes

6 Cement mill-1&2 O-sepa Return Oil Protection pipes fabrication work. PM 14 14 Yes

7 DDPC-4 Discharge chute Worn out plate replacing with new plate. Repair 34 34 Yes

8 Cement mill-1 outlet airslide blower motor(7.5 KW) replacement work. Repair 10 10 Yes

9 DDPC-4 Discharge chute Full welding. Repair 5.5 5.5 Yes

10Cement mills 1&2, Clinker , Lime Stone & Gypsum Weigh Feeders Bearings Greasing work.

PM 12 12 Yes

13 PM 25.5 25.5 Yes

11 PM 25.5 25.5 Yes


MECHANICAL DEPT. KEY PERFORMANCE INDICATORS - KPI

SECOND WEEK OF 2012

Efficiency (%) = Estimated Time of completed Jobs / Actual Time of Completed Jobs

97.83

96.91

7 PM 34 34 Yes

8 PM 25.5 25.5 Yes


4/13

Sl

No

. Job Type

Estimated

Hours

Actual

Hours

Job

Comple

ted Efficiency

11

Gypsum Dump hopper bottom feed belt no-26 Drive pulley non drive end side bearing replaced

with new ( Bearing No 22220 cck ) and Bearings Greasing done. PM 15 17 Yes

12 Cement mill area general checklist and general maintenance works PM 25.5 25.5 Yes

Packing Plant

13

Auto packer roller locking plate fabrication and Bottom timing belt Spare gear box bad holes

tapping work and Roto packer blower suction filter changing. PM 8.5 8.5 Yes

14 Bulk loading spout no-3 Repairing work. Repair 22 25.5 Yes

15 Bulk loading spout no-3 Fixing work. Repair 21 25.5 Yes

16

Roto Packing and auto packer Schedule maintenance works and packer Bucket elevator

inspection, Bulk loading and Roto packer De-dusting system Pipe line patch up work. PM 34 34 Yes

17Bulk loading spout no-2 inspection and bulk loading bin-1 aeration flexible hoses replacement.

PM 8.5 8.5 Yes

18 House keeping PM 8.5 8.5 Yes

311 325

WORKSHOP & WATER WORKS

1 Clinker breaker pin tapping work 8.5 8.5 Yes

2 Gypsum schuttle conveyor coupling bolts maching work 24 24 Yes

3 cooler track wheel rough maching 34 34 Yes

4 Lathe machines maintenance works 8.5 8.5 Yes

5 Cooler spare track wheel welding work 34 39.5 Yes

6 Miscellaneous mahining works 21 21 Yes

7 STP,staff colony plumbing works& plant drip line repair works 48 48 Yes

178 183.5

PROJECT & DEVELOPMENT WORKS

1 Paper Bags Go down opening Covering clading fabrication and erection work. Developme 200 56 No

2 SRC clinker tank approaching stair case fabrication & erection Project 350 347.5 No

3 SRC Clinker tank Civil structure side cladding work. Developme 150 157.5 Yes

4 SRC Hopper De-dusting Bag filter fan erection Project 34 34 Yes

5 SRC Hopper De-dusting Bag filter Ducting fabrication work. Project 170 141.5 No

6SRC Clinker tank De-dusting Bag filter Supporting structure fabrication and erection work.

Project 180 146 No

184 191.5

AUTO GARAGE

1 General maintenance PM 28 28 Yes

2 Man truck 21475 tyres have been interchanged Repair 16 20 Yes

3 Man truck 21475 rear tyre puncture Unplanned 6 6 Yes

4 Man truck 21476 leaf springs pad has been replaced Unplanned 12 13 Yes

5 Fork lift front steering bearing replaced Repair 16 17 Yes

6 Fork lift engine service PM 6 6 Yes

93.75

97.00

96.08

95.69


5/13

Sl.No Section Labour Utilisation Efficiency Productivity

1 RAW MILLS & STACKER RECLAIMER SECTION 100.00 96.91 96.91

2 PYRO & COAL MILL, HANDLING SECTION 100.00 97.83 97.83

3 CEMENT MILLS & PACKING PLANT SECTION 100.00 95.69 95.69

4 WORKSHOP & WATER WORKS 100.00 97 97.00

5 PROJECT & DEVELOPMENT WORKS 100.00 96.08 96.08

6 AUTO GARAGE 100.00 93.75 93.75


MECHANICAL DEPT.KEY PERFORMANCE INDICATORS - KPI

SECOND WEEK OF 2012

Productivity

Productivity(%) = 100

Labour Utilisation X Efficiency


6/13

Sl

No. Job Type

Estimated

Hours

Actual

Hours

Job

Complet

ed Plan Attainment


1 RABH 2nd module inspection & damaged bags to be replaced. PM 30 30 Yes

2 Raw mill-2 O-sepa Cyclone Patch up and Raw mill-1 O-sepa Hopper patch up work. Repair 25.5 25.5 Yes3 Raw mill-1 & 2 Vent bag filters Impeller inspection and coating cleaning work. PM 17 17 Yes




7 Raw mills 1&2 O-sepa impellers coating cleaning and raw mill-2 O-sepa fan Bearings bed PM 11 11 Yes








267 275.5


1 Cooler Back side castable box fabrication and fixing work. Repair24 24

Yes


3 Alkali Baghouse Inlet duct bleed air damper flanges fabrication and safety guards fabrication 68 74.5 Yes








Pre heater fan motor Vibration sensor fixing work.

10 Cooler RFT Cross head shaft NDE Wheel Track replacement with spare. PM 34 34 Yes
















7. Silo bottom & Pre-heater top Blowers Suction Filters cleaned. PM 10 10 Yes




472.5 483









8 Cement mill-1 outlet airslide blower motor(7.5 KW) replacement work. Repair 10 10 Yes9 DDPC-4 Discharge chute Full welding. Repair 5.5 5.5 Yes


PM 12 12 Yes

11

Gypsum Dump hopper bottom feed belt no-26 Drive pulley non drive end side bearing

replaced with new ( Bearing No 22220 cck ) and Bearings Greasing done. PM 15 17 Yes

SECOND WEEK OF 2012


Plan Attainment (%) = Estimated Time of completed Jobs excluding unplanned works / Estimated Time of all Jobs


267 x 100

267

= 100

7 PM 34 34 Yes

8 PM 25.5 25.5 Yes

11 PM 25.5 25.5 Yes

13 PM 25.5 25.5 Yes

472.5 x 100

822.5

= 57.45

311 x 100

311


7/13

Sl

No. Job Type

Estimated

Hours

Actual

Hours

Job

Complet

ed Plan Attainment


Packing Plant

13





16

Roto Packing and auto packer Schedule maintenance works and packer Bucket elevatorinspection, Bulk loading and Roto packer De-dusting system Pipe line patch up work.

PM 34 34 Yes

17

Bulk loading spout no-2 inspection and bulk loading bin-1 aeration flexible hoses

replacement. PM 8.5 8.5 Yes


311 325









178 183.5


1 Paper Bags Go down opening Covering clading fabrication and erection work. Developm 200 56 No

2 SRC clinker tank approaching stair case fabrication & erection Project 350 68 No

3 SRC Clinker tank Civil structure side cladding work. Developm 150 157.5 Yes




Project 180 146 No

184 191.5

AUTO GARAGE




4 Man truck 21476 leaf springs pad has been replaced Unplanned 12 13 Yes5 Fork lift front steering bearing replaced Repair 16 17 Yes


7 Komatsu loader engine service PM 6 6 Yes

90 96

90 x 100

90= 100

= 100

178 x 100

178

= 100


8/13

Sl

No. Job Type

Estimated

Hours

Actual

Hours

Job

Complet

ed P.M.R(%)


1 RABH 2nd module inspection & damaged bags to be replaced. PM 30 30 Yes2 Raw mill-2 O-sepa Cyclone Patch up and Raw mill-1 O-sepa Hopper patch up work. Repair 25.5 25.5 Yes













267 275.5


1 Cooler Back side castable box fabrication and fixing work. Repair 24 24 Yes

2 Alkali Baghouse hopper-2 Bulk loading head flange fabrication . Repair 24 28 Yes

3 Alkali Baghouse Inlet duct bleed air damper flanges fabrication and safety guards Safety 68 74.5 Yes
























6. K.C. & P.C. Roots Blowers Suction Filters cleaned PM 10 10 Yes7. Silo bottom & Pre-heater top Blowers Suction Filters cleaned. PM 10 10 Yes




472.5 483









8 Cement mill-1 outlet airslide blower motor(7.5 KW) replacement work. Repair 10 10 Yes9 DDPC-4 Discharge chute Full welding. Repair 5.5 5.5 Yes


PM 12 12 Yes

11

Gypsum Dump hopper bottom feed belt no-26 Drive pulley non drive end side bearing

replaced with new ( Bearing No 22220 cck ) and Bearings Greasing done. PM 15 17 Yes

Available Labour Hoursx 100PMR =

145 x 100

275.5

= 52.63

284.5 x 100

630

= 45.16



SECOND WEEK OF 2012

PMR

Preventive Maint. Routine Hrs

7 PM 34 34 Yes

8 PM 25.5 25.5 Yes

11 PM 25.5 25.5 Yes

13 PM 25.5 25.5 Yes

199 x 100

325


9/13

Sl

No. Job Type

Estimated

Hours

Actual

Hours

Job

Complet

ed P.M.R(%)


Packing Plant

13





16

Roto Packing and auto packer Schedule maintenance works and packer Bucket elevatorinspection, Bulk loading and Roto packer De-dusting system Pipe line patch up work.

PM 34 34 Yes

17

Bulk loading spout no-2 inspection and bulk loading bin-1 aeration flexible hoses

replacement. PM 8.5 8.5 Yes


311 325









178 183.5


1 Paper Bags Go down opening Covering clading fabrication and erection work. Developmen 200 56 No

2 SRC clinker tank approaching stair case fabrication & erection Project 350 68 No

3 SRC Clinker tank Civil structure side cladding work. Developmen 150 157.5 Yes




Project 180 146 No

184 191.5

AUTO GARAGE




4 Man truck 21476 leaf springs pad has been replaced Unplanned 12 13 Yes5 Fork lift front steering bearing replaced Repair 16 17 Yes



90 96

= 61.23

40 x 100

96= 41.66


10/13


11/13


12/13

Sl

No. Job Type

Estimated

Hours

Actual

Hours

Job

Completed Unplanned(%)


1 RABH 2nd module inspection & damaged bags to be replaced. PM 30 30 Yes2 Raw mill-2 O-sepa Cyclone Patch up and Raw mill-1 O-sepa Hopper patch up work. Repair 25.5 25.5 Yes













267 275.5


1 Cooler Back side castable box fabrication and fixing work. Repair 24 24 Yes


3 Alkali Baghouse Inlet duct bleed air damper flanges fabrication and safety guards 68 74.5 Yes











Fine coal pumping roots blower belts t ightening work














7. Silo bottom & Pre-heater top Blowers Suction Filters cleaned. PM 10 10 Yes8. Kiln Supporting Rollers Bearings Oil Seals lubricated. PM 10 10 Yes



472.5 483









8 Cement mill-1 outlet airslide blower motor(7.5 KW) replacement work. Repair 10 10 Yes

9 DDPC-4 Discharge chute Full welding. Repair 5.5 5.5 Yes10 Cement mills 1&2, Clinker , Lime Stone & Gypsum Weigh Feeders Bearings Greasing PM 12 12 Yes

11 Gypsum Dump hopper bottom feed belt no-26 Drive pulley non drive end side bearing PM 15 17 Yes


Packing Plant

13 Auto packer roller locking plate fabrication and Bottom timing belt Spare gear box bad PM 8.5 8.5 Yes



SECOND WEEK OF 2012

UNPLANNED

Unplanned % =Actual hours on completed unplanned work orders

Estimated hours on all completed work ordersX 100

0 x 100

267

= 0

0 x 100

472.5

= 0

0 x 100311

= 0

7 PM 34 34 Yes

8 PM 25.5 25.5 Yes

11 PM 25.5 25.5 Yes

13 PM 25.5 25.5 Yes


13/13

Sl

No. Job Type

Estimated

Hours

Actual

Hours

Job

Completed Unplanned(%)



16 Roto Packing and auto packer Schedule maintenance works and packer Bucket elevator PM 34 34 Yes

17 Bulk loading spout no-2 inspection and bulk loading bin-1 aeration flexible hoses PM 8.5 8.5 Yes18 House keeping PM 8.5 8.5 Yes

311 325









178 183.5


1 Paper Bags Go down opening Covering clading fabrication and erection work. Developme 200 56 No

2 SRC clinker tank approaching stair case fabrication & erection Project 350 68 No3 SRC Clinker tank Civil structure side cladding work. Developme 150 157.5 Yes



6SRC Clinker tank De-dusting Bag filter Supporting structure fabrication and erection

work.Project 180 146 No

184 191.5

AUTO GARAGE




4 Man truck 21476 leaf springs pad has been replaced Unplanned 12 13 Yes

5 Fork lift front steering bearing replaced Repair 16 17 Yes



90 96

21 x 100

178

= 11.79

19 x 100

90

= 21.11

KPI-MECH-2nd WK.xlsx

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