Maint. success story

Maintenance Dep. Success Journey

JEDDAH

Head lines JEDDAH

1 - Launch PMP for all production lines ( Bun , Puff , Cup cake , Tortilla ) & utilities equipment ( a/c & steam boiler) 2 - Improve machinery & infra-structure GMP’s 3- Improve safety level for major utilities equipment 4- Initiate maintenance activities & Team evaluation KPI’s 5- Maintenance budget control , Energy cost follow up 6- Initiate a Training plan for maint. Team for the priority topics 7- Implement for approved Projects 8- Study for new projects implementation 9- Initiate CAPEX plan for both units 1 , 2

Head lines JEDDAH

1 - Launch PMP for all production lines ( Bun , Puff , Cup cake , Tortilla ) & utilities equipment ( a/c & steam boiler) 2 - Improve machinery & infra-structure GMP’s 3- Improve safety level for major utilities equipment 4- Initiate maintenance activities & Team evaluation KPI’s 5- Maintenance budget control , Energy cost follow up 6- Initiate a Training plan for maint. Team for the priority topics 7- Implement for approved Projects 8- Study for new projects implementation 9- Initiate CAPEX plan for both units 1 , 2

PMP initiation for • Bun • Puff • Cup cake • Tortilla

JEDDAH

1 - Launch PMP for all production lines & utilities equipment

PMP initiation for a/c package units (33 units)

JEDDAH

TORTILLA line PMP result • 330 hr during 5 months Some of its Major tasks

1- Apply deep cleaning for all Proofer pockets ( 300 pc)

2- Apply service for dough divider ( deep cleaning , lubrication , bearing check ) 3- Oven belt cleaning & apply service for hydraulic unit

Example of some PMP task result at Tortilla line

Some of its Major tasks

4- Silo sifter check

5- Divider belts change & all basket check

6- Mixer gearbox check

7- Cooler in feed & out feed conveyor check

8- HARTMANN packaging m/c all rotating parts check

9- Oven lubrication

JEDDAH TORTILLA line PMP result

JEDDAH

Puff line PMP result

• 550 hr during 5

months Some of its Major tasks

1- Proofer humidity control filter change

2- OMEGA water chiller service

3- RONDO lamination section full service

4- Cooler full service ( bearing , Gearbox check)

Example of some PMP task result at Puff line

JEDDAH

BUN line PMP result 680 hr at 5 months

tasksof its Major Some 1- Silo sifter check 3- Pan depanner suction cup change 4- Oven burner check 5- Proofer & oven drive and bearing check

Example of some PMP task result at Bun line

Some of its Major tasks

6- Proofer 2 tracks check

7- TURKISTAN mixer check & leakage repair

JEDDAH

Example of some PMP task result at Bun line

JEDDAH

Package a/c PMP 1 Unit

result • 220 working hr at 5

months Major tasks

1- Cleaning for all filters

2- Apply deep cleaning for a/c body

3- Check evaporator coil status & apply painting for it 4- Check blower status

Example of some PMP task result at a/c

JEDDAH

Package a/c PMP 2 Unit

result • 185 working hr at 5

months Major tasks

1- Cleaning for all filters

2- Apply deep cleaning for a/c body

3- Check evaporator coil status & apply painting for it 4- Check blower status

Example of some PMP task result at a/c

Head lines JEDDAH

1 - Launch PMP for all production lines ( Bun , Puff , Cup cake , Tortilla ) & utilities equipment ( a/c & steam boiler) 2 - Improve machinery & infra-structure GMP’s 3- Improve safety level for major utilities equipment 4- Initiate maintenance activities & Team evaluation KPI’s 5- Maintenance budget control , Energy cost follow up 6- Initiate a Training plan for maint. Team for the priority topics 7- Implement for approved Projects 8- Study for new projects implementation 9- Initiate CAPEX plan for both units 1 , 2

JEDDAH

BEFORE AFTER Silos breather filter

1change unit Change filter for the 1 st time

years ago 18

2 - Improve machinery & infra-structure GMP’s

JEDDAH

BEFORE

AFTER

1 , 2 UNIT

Main water tank cleaning

2 - Improve machinery & infra-structure GMP’s

JEDDAH

BEFORE AFTER

2 - Improve machinery & infra-structure GMP’s

Problem Definition Bad condition for water tank infra- structure At unit 1 due to No proper service for it 18 years ago

Action Apply a deep cleaning which generate 25 kg of waste material ( rusted material , Algae ) , Repair wall , floor , roof by a food grade special epoxy 180 m2

JEDDAH

BEFORE AFTER

2 - Improve machinery & infra-structure GMP’s

Action Repair wall , floor , roof by a food grade special epoxy 95 m2

Problem Definition Bad condition for water tank infra- structure At unit 2 due to No proper service for it 8 years ago

JEDDAH

system filter Reclaim

overhauling )( filter & pulsating valve

1 st time changing 18 years ago

2 - Improve machinery & infra-structure GMP’s

AFTER

BEFORE

TURKISTAN mixer calibration

4 years ago

Yum audit success by score 845

Yum audit 2 Unit

success

2 - Improve machinery & infra-structure GMP’s

Sponge mixer filter

overhauling )( filter & pulsating valve

1 st time changing 18 years ago

JEDDAH

Head lines JEDDAH

1 - Launch PMP for all production lines ( Bun , Puff , Cup cake , Tortilla ) & utilities equipment ( a/c & steam boiler) 2 - Improve machinery & infra-structure GMP’s 3- Improve safety level for major utilities equipment 4- Initiate maintenance activities & Team evaluation KPI’s 5- Maintenance budget control , Energy cost follow up 6- Initiate a Training plan for maint. Team for the priority topics 7- Implement for approved Projects 8- Study for new projects implementation 9- Initiate CAPEX plan for both units 1 , 2

JEDDAH

steam boiler 2 UNIT

Overhauling

Apply the first overhauling for this boiler ( 8 years ago)

Major tasks

of carbon kg 20 Remove -1

black powder from fire side & exhaust chimney

2- Apply calibration for firing burner

3- Check all safety devices ( water level indicator & pressure safety switch )

4- change main door gasket & V belt

AFTER

BEFORE

3- Improve safety level for major utilities equipment

JEDDAH

steam boiler 1 UNIT

Overhauling

Apply a complete overhauling for this boiler

Major tasks

of carbon kg 8 Remove -1

black powder from fire side & exhaust chimney

2- Apply calibration for firing burner

3- Check all safety devices ( water level indicator & pressure safety switch )

4- change main door gasket & V belt

5- Repair the dangerous leakage at lower drainage area

3- Improve safety level for major utilities equipment

Waiting Management approval

Factory Roof replacement project

study

3- Improve safety level for our facility JEDDAH

bad Glycol tanks room wiring

wiring at a/c plate Bad Form

ON GOING

JEDDAH

3- Improve safety level for our facility

Head lines JEDDAH

1 - Launch PMP for all production lines ( Bun , Puff , Cup cake , Tortilla ) & utilities equipment ( a/c & steam boiler) 2 - Improve machinery & infra-structure GMP’s 3- Improve safety level for major utilities equipment 4- Initiate maintenance activities & Team evaluation KPI’s 5- Maintenance budget control , Energy cost follow up 6- Initiate a Training plan for maint. Team for the priority topics 7- Implement for approved Projects 8- Study for new projects implementation 9- Initiate CAPEX plan for both units 1 , 2

2015Bun line PM plan compliance % achievement at March.

JEDDAH

0%

5%

10%

15%

20%

25%

30%

35%

40%

45%

Avr. 2014 Jan. 2015 Feb. 2015 March.

26%

37%

41%

14%

BUN lines b/d %

2015A/C PM plan compliance % achievement at March.

2015Work order distribution per Month in

School vacations

0%

10%

20%

30%

40%

50%

60%

70%

80%

Jan. Feb March

0%

75%

62%

0

200

400

600

800

1000

1200

1400

1600

1800

2000

Average2014

Jan 2015 Feb 2015 Mar-15

789

1491 1487

1865

0.00%

0.50%

1.00%

1.50%

2.00%

2.50%

Aver. 2014 Jan-15 Feb-15 March. 2015

1.80%

1.10%

1.80%

2.30%

Direct effect of PM%

4- Initiate maintenance activities & Team evaluation KPI’s

UNIT 1

JEDDAH

2015Work order distribution per Technician name at March

per technician per month hrAverage working 2015Vs. 2014 hr. actual working MaintNo of

0

50

100

150

200

250

300

350

400

Anna Imran Dhanesh Bandu bali Thapa Shamshad Manikant Pervez Jebon

165 171 172 177 185 196 219 225

355

0

200

400

600

800

1000

1200

1400

1600

1800

Avr. 2014 Jan 2015 Feb 2015 March. 2015

334

1415 1355

1650

0

1

2

3

4

5

6

7

8

Avr. 2014 Jan 2015 Feb 2015 March. 2015

3.1

6.5

7.5 6.9

4- Initiate maintenance activities & Team evaluation KPI’s

UNIT 1

0

0.005

0.01

0.015

0.02

0.025

0.03

0.035

Aver. 2014 Jan. 2015 Feb. 2015 March. 2015

2.90% 2.70%

3.30%

Tortilla line PM plan compliance % achievement 2015at March. lines b/d %2 Unit

?

JEDDAH

2015Work order distribution per Month in 2015Puff line PM plan compliance % achievement at March.

0

100

200

300

400

500

600

700

800

900

1000

Avr. 2014 Jan. 2015 feb. 2015 March. 2015

45

419

942 927

0%

10%

20%

30%

40%

50%

60%

70%

80%

Avr. 2014 Jan. 2015 Feb. 2015 March. 2015

1%

12% 18%

78%

0%

20%

40%

60%

80%

100%

Avr. 2014 Jan. 2015 Feb. 2015 March. 2015

0% 2%

42%

82%

4- Initiate maintenance activities & Team evaluation KPI’s

UNIT 2

2015Work order distribution per Technician name at March

2015Vs. 2014 hr. Actual working MaintNo of per technician per month hrAverage working

0

50

100

150

200

250

Bahadhur Rafiqul Amin Pasang Hilal Rajan

50

128 148

187 200 213

0

200

400

600

800

1000

1200

Avr. 2014 Jan. 2015 Feb. 2015 March. 2015

130

779

1171 1185

0

1

2

3

4

5

6

7

8

9

Avr. 2014 Jan. 2015 Feb. 2015 March. 2015

0.72

4.3

8.5

7.1

4- Initiate maintenance activities & Team evaluation KPI’s

UNIT 2

Head lines JEDDAH

1 - Launch PMP for all production lines ( Bun , Puff , Cup cake , Tortilla ) & utilities equipment ( a/c & steam boiler) 2 - Improve machinery & infra-structure GMP’s 3- Improve safety level for major utilities equipment 4- Initiate maintenance activities & Team evaluation KPI’s 5- Maintenance budget control , Energy cost follow up 6- Initiate a Training plan for maint. Team for the priority topics 7- Implement for approved Projects 8- Study for new projects implementation 9- Initiate CAPEX plan for both units 1 , 2

134

136

138

140

142

144

146

148

2015 2014

138.8

147.3

360

380

400

420

440

460

480

2015 2014

464.8

395.491

cost

)2015Vs. 2014 Energy Cost monthly B/D ( )2015Vs. 2014 ( 1 YTD Energy Cost for unit

)2015Vs. 2014 ( 2 YTD Energy Cost for unit

-

20

40

60

80

100

120

140

160

180

Average2014

Jan. 2015 Feb. 2015 March.2015

176

155

133

122 115

145 145 145

Actual Target

)2015Vs. 2014 . Expenses b/d ( Maint

JEDDAH

1UNIT

2UNIT

)2015Vs. 2014 Energy Cost monthly B/D (

5- Maintenance budget control , Energy cost follow up

Head lines JEDDAH

1 - Launch PMP for all production lines ( Bun , Puff , Cup cake , Tortilla ) & utilities equipment ( a/c & steam boiler) 2 - Improve machinery & infra-structure GMP’s 3- Improve safety level for major utilities equipment 4- Initiate maintenance activities & Team evaluation KPI’s 5- Maintenance budget control , Energy cost follow up 6- Initiate a Training plan for maint. Team for the priority topics 7- Implement for approved Projects 8- Study for new projects implementation 9- Initiate CAPEX plan for both units 1 , 2

JEDDAH

Apply a safety training by certified training center from OSHA USA

Waiting management approval

Stuff safety training

Apply a PLC professional training by SIEMENS training center

Waiting management approval

Professional PLC training

6- Initiate a Training plan for maint. Team for the priority topics

Head lines JEDDAH

1 - Launch PMP for all production lines ( Bun , Puff , Cup cake , Tortilla ) & utilities equipment ( a/c & steam boiler) 2 - Improve machinery & infra-structure GMP’s 3- Improve safety level for major utilities equipment 4- Initiate maintenance activities & Team evaluation KPI’s 5- Maintenance budget control , Energy cost follow up 6- Initiate a Training plan for maint. Team for the priority topics 7- Implement for approved Projects 8- Study for new projects implementation 9- Initiate CAPEX plan for both units 1 , 2

7- Implement for approved Projects

Installation for new cup cake cooler m/c

JEDDAH

7- Implement for approved Projects

New bread store high speed door installation

BEFORE

AFTER

2 unit tank for LPG 2

installation

JEDDAH

BEFORE

AFTER

BEFORE

AFTER

Head lines JEDDAH

1 - Launch PMP for all production lines ( Bun , Puff , Cup cake , Tortilla ) & utilities equipment ( a/c & steam boiler) 2 - Improve machinery & infra-structure GMP’s 3- Improve safety level for major utilities equipment 4- Initiate maintenance activities & Team evaluation KPI’s 5- Maintenance budget control , Energy cost follow up 6- Initiate a Training plan for maint. Team for the priority topics 7- Implement for approved Projects 8- Study for new projects implementation 9- Initiate CAPEX plan for both units 1 , 2

New Pound cake product machinery study

New Panda cake product study

8- Study for new projects implementation

JEDDAH

Puff line printing quality upgrading project study

Puff line Promo pack project study

8- Study for new projects implementation

Apply a technical assessment for confectionery area with proposed budget

8- Study for new projects implementation JEDDAH

Head lines JEDDAH

1 - Launch PMP for all production lines ( Bun , Puff , Cup cake , Tortilla ) & utilities equipment ( a/c & steam boiler) 2 - Improve machinery & infra-structure GMP’s 3- Improve safety level for major utilities equipment 4- Initiate maintenance activities & Team evaluation KPI’s 5- Maintenance budget control , Energy cost follow up 6- Initiate a Training plan for maint. Team for the priority topics 7- Implement for approved Projects 8- Study for new projects implementation 9- Initiate CAPEX plan for both units 1 , 2

Initiate CAPEX plan for 2015 by total proposed budget

million SR3

9- Initiate CAPEX plan for both units 1 , 2 JEDDAH