KPI-MECH-1st WK

8/22/2019 KPI-MECH-1st WK

1/13

Productivity

Available

Labour

Hours

Actual

Hours%

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

Avail

Labo

Hou

1RAW MILLS & STACKER

RECLAIMER SECTION230.00 230.00 100.00 226.00 230.00 98.26 98.26 226.00 226.00 100.00 152.00 230

2PYRO & COAL MILL,

HANDLING SECTION381.00 381.00 100.00 371.00 381.00 97.38 97.38 371.00 371.00 100.00 338.00 381

3CEMENT MILLS & PACKING

PLANT SECTION215.00 215.00 100.00 215.00 215.00 100.00 100.00 215.00 215.00 100.00 130.00 215

4WORKSHOP & WATER

WORKS191.50 191.50 100.00 186.50 191.50 97.39 97.39 186.50 186.50 100.00

5 PROJECT & DEVELOPMENTWORKS

835.00 835.00 100.00 1100.00 1236.00 89.00 89.00

6 AUTO GARAGE 79.00 79.00 100.00 104.00 110.00 94.55 94.55 93.00 93.00 100.00 31.00 110

PIONEER CEMENT INDUSTRIES LLC, RAK, UAE

KEY PERFORMANCE INDICATORS - Maintenance Dept.

FIRST 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 39.5 39.5

3 Bhanu Pratap 39.5 39.5

4 Ramana Reddy 39.5 39.5

5 Hanumath Reddy 39.5 39.5

6 Abu Backer 45.5 45.5

7 Jose 39.5 39.5

8 Bhukya Sreenu 39.5 39.5

9 Assan 39.5 39.5

10 Vallabha Rao 39.5 39.511 Moinuddin 39.5 39.5

12 Babu Kumar 64.5 64.5

13 Chendra Sekhar 39.5 39.5

14 Dhanesh Gupta 71 71

15 Naresh Rauth 39.5 39.5

16 Anil 64.5 64.5

17 Saleem 64.5 64.5

18 Rajiman 39.5 39.5

20 Prasannan 39.5 39.5

21 Jamshid 39.5 39.522 Firoz Khan 39.5 39.5

23 Radha Krishna 39.5 39.5

24 Shabir ali 78 78

25 Iqbal Basha 78 78

26 Rajesh Kumar Kusva 78 78

27 Ansari 78 78

28 Murali Dharan 74 74

29 Ajmal Basha 74 74

30 Jelaludhin 74 74

31 Babu Babi 74 74

32 Paswan 39.5 39.5

33 Ramesh 39.5 39.5

34 Asraf 39.5 39.5

35 Suru Kumar 39.5 39.5

36 Musthafa 65.5 65.5

37 Mahindra 39.5 39.5

38 Murthy 39.5 39.5

39 Ramakrishna 39.5 39.5

40 Rajesh yadav 39.5 39.5

Total 1931.5 1931.5


MECHANICAL DEPT KEY PERFORMANCE INDICATORS - KPI

FIRST WEEK OF 2012

100.00%


3/13

Sl

No

. Job Type

Estimated

Hours

Actual

Hours

Job

Comple

ted

RAW MILLS & STACKER RECLAIMER SECTION

1 BC-7 drive gearbox internals inspection & oil replacement work PM 12 13.5 Yes

2 RM-1&2 O-sepa fan impeller inspection work PM 12 12 Yes

3 RM-1 LCD choked slots cleaning work(with gas cut) Repair 8.5 8.5 Yes

4 RABh 4th module RAL rotor replacement & module inside inspection work PM 34 34 Yes

5 Storage weigh feeder head pulley bearings greasing work PM 12 12 Yes

6 Dump hopper no-4 tyre stopper pipe fixing and full welding work Repair 10 10 Yes

7 Rawmill hot air duct insulation work Repair 34 34 Yes

8 Raw mill -1 cyclone Patch up work Repair 17.5 17.5 Yes

9 Raw mill-1 Girth gear FLR unit replacing work. Repair 8 8 Yes

10 Bridge reclaimer Scrapper chain buckets fixing bolts removing and new bolts fixing work. PM 22 24.5 Yes

11 Raw mill-2 pressing side main gearbox lub system filters cleaning. PM 10 10 Yes

12 General Maintenance:-

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

2.Rawmill area checklist & general maintenance works PM 24 24 Yes

4.Rawmill area house keeping done PM 18 18 Yes

226 230

PYRO & COAL MILL, HANDLING SECTION

1Alternate fuel feeding hopper & pin gates fabrication and Erection Work at Preheater Second

Floor.PM

60 68 Yes

2 Alternate fuel Feeding system Hopper platform with hand railing & monkey ladder . PM 56 56 yes

3 Alternate fuel feeding Belt conveyor top skirt board fabrication and fixing work PM 68 68 Yes

4 Alternate fuel feeding belt conveyor discharge flap fabrication and fixing work PM 66 68 Yes

5 Spare Air blasters reconditioning work. Repair 25.5 25.5 Yes

6 Coal Mill maintenance :-

Coal mill Auxiliary Drive Alignment work PM 6 6 Yes

Coal Crusher Grizzly bar gap adjustment work. Repair 15 15 yes

Coal mill apron weigh feeder maintenance work PM 8 8 Yes

7 General Maintenance:- Yes

1. Kiln all Tyres lubricated PM 6 6 Yes2. 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 4 4

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

371 381

CEMENT MILLS & PACKING PLANT SECTION

1 Cement mill-2 Girth gear Bolts 3 nos to be replaced with new. Repair 12.5 12.5 Yes

2 Cement mill-2 Girth Gear Guard Supports fixing. Repair 13 13 Yes

3 Cement mill -2 Inlet Chute Patch up work. Repair 17 17 Yes

4 Gypsum Belt conveyor travel Drive input coupling rubber bushes & Bolts replacing work PM 8 8 Yes

5 Cement mill-1 Outlet water spray system inspection work PM 5 5 Yes

6 Cement mill-1 Inlet Chute worn out plate replacement. Repair 34 34 Yes

7 Cement mill-1 O-Sepa Inspection PM 5 5 Yes

8 Spare Dosing Valve maintenance work and House keeping. PM 8.5 8.5 Yes

9 Cement mill area check list work and general maintenance works PM 21.5 21.5 Yes

Packing Plant:

1 Roto Packing and auto packer Schedule maintenance works. PM 34 34 Yes

2 Silo 1&2 Extraction chutes Jam cleaning work. Repair 8.5 8.5 Yes

3 preparatory works for packing plant maintenance works. PM 5.5 5.5 Yes


5 Bulk loading Bucket elevator Belt joint bottom side rubber jointing work PM 14 14 Yes

6 Packing plant area house keeping PM 8.5 8.5 Yes

215 215

WORKSHOP & WATER WORKS

1 Hydra gearbox cover drilling and tapping 8.5 8.5 Yes

2 Clinker breaker hammer pin washer machining 17 19 Yes

3 Material handling trolley pin and bushes machining 17 17 Yes

4 Cement mill door bolt threading work 17 17 Yes

5 Connectors machining for src hopper 8.5 8.5 Yes


MECHANICAL DEPT. KEY PERFORMANCE INDICATORS - KPI

FIRST WEEK OF 2012

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


4/13

Sl

No

. Job Type

Estimated

Hours

Actual

Hours

Job

Comple

ted

6 Bogie Wheel welding work. 17 20 Yes

7 Cooler track wheels welding work 14 14 Yes

8 Clinker breaker hammer pins washers preparation work 8.5 8.5 Yes

9 Plumbing works at workers & staff colony 79 79 Yes

186.5 191.5

PROJECT & DEVELOPMENT WORKS

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

2 SRC clinker tank and accessories erection work Project 720 796 Yes

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

5 Rejects clinker discharge pipe dismantling work & feed pipe erection work Project 280 330 Yes

6 CSP top roof openings sheeting work Development 100 110 Yes7 SRC Clinker tank Civil structure side cladding work. Development 150 89.5 No

1100 1236

AUTO GARAGE

1 General Maintenance PM 28 28 Yes

2 Hydra engine overhauling work Repair 62 68 Yes

3 Cat loader engine oil and filters treplacement PM 3 3 Yes

4 Man truck left side door handle replacement work Unplanned 3 3 Yes

5 Man truck 21475 rear axle repair work Unplanned 3 3 Yes

6 Man truck 21475 rear type puncure Unplanned 5 5 Yes


5/13

Efficiency

97.39

100.00

97.38

98.26


6/13

Efficiency

94.55

89.00


7/13

Sl.No Section Labour Utilisation Efficiency Productivity

1 RAW MILLS & STACKER RECLAIMER SECTION 100.00 98.26 98.26

2 PYRO & COAL MILL, HANDLING SECTION 100.00 97.38 97.38

3 CEMENT MILLS & PACKING PLANT SECTION 100.00 100.00 100.00

4 WORKSHOP & WATER WORKS 100.00 97.39 97.39

5 PROJECT & DEVELOPMENT WORKS 100.00 89.00 89.00

6 AUTO GARAGE 100.00 94.55 94.55


MECHANICAL DEPT.KEY PERFORMANCE INDICATORS - KPI

FIRST WEEK OF 2012

Productivity

Productivity(%) = 100

Labour Utilisation X Efficiency


8/13

Sl

No. Job Type

Estimated

Hours

Actual

Hours

Job

Complet

ed Plan Attainment


1 BC-7 drive gearbox internals inspection & oil replacement work PM 12 13.5 Yes

2 RM-1&2 O-sepa fan impeller inspection work PM 12 12 Yes3 RM-1 LCD choked slots cleaning work(with gas cut) Repair 8.5 8.5 Yes







10Bridge reclaimer Scrapper chain buckets fixing bolts removing and new bolts fixing work.

PM 22 24.5 Yes







1Alternate fuel feeding hopper & pin gates fabrication and Erection Work at Preheater

Second Floor.PM

60 68 Yes

2 Alternate fuel Feeding system Hopper platform with hand railing & monkey ladder .PM 56 56

yes









1. Kiln all Tyres lubricated PM 6 6 Yes

2. Cooler Drives Chain lubricated PM 6 6 Yes











3 Cement mill -2 Inlet Chute Patch up work. Repair 17 17 Yes4 Gypsum Belt conveyor travel Drive input coupling rubber bushes & Bolts replacing work PM 8 8 Yes


6 Cement mill-1 Inlet Chute worn out plate replacement. Repair 34 34 Yes

7 Cement mill-1 O-Sepa Inspection PM 5 5 Yes



Packing Plant:









2 Clinker breaker hammer pin washer machining 17 19 Yes

3 Material handling trolley pin and bushes machining 17 17 Yes


FIRST WEEK OF 2012


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


226 x 100

226

= 100

215 x 100

215

= 100

371 x 100

371

= 100

186.5 x 100


9/13

Sl

No. Job Type

Estimated

Hours

Actual

Hours

Job

Complet

ed Plan Attainment







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




6 CSP top roof openings sheeting work Developm 100 110 Yes

7 SRC Clinker tank Civil structure side cladding work. Developm 150 89.5 No

AUTO GARAGE







186.5

= 100

93 x 100

93

= 100


10/13

Sl

No. Job Type

Estimated

Hours

Actual

Hours

Job

Complet

ed P.M.R(%)


1 BC-7 drive gearbox internals inspection & oil replacement work PM 12 13.5 Yes2 RM-1&2 O-sepa fan impeller inspection work PM 12 12 Yes















1 Alternate fuel feeding hopper & pin gates fabrication and Erection Work at Preheater PM 60 68 Yes



















371 381







6 Cement mill-1 Inlet Chute worn out plate replacement. Repair 34 34 Yes7 Cement mill-1 O-Sepa Inspection PM 5 5 Yes



Packing Plant:







215 215



2 Clinker breaker hammer pin washer machining 17 19 Yes3 Material handling trolley pin and bushes machining 17 17 Yes







FIRST WEEK OF 2012

PMR

Preventive Maint. Routine Hrs

Available Labour Hoursx 100PMR =

152 x 100

230

= 66.09

338 x 100

381

= 88.71

130 x 100

215

= 60.46


11/13

Sl

No. Job Type

Estimated

Hours

Actual

Hours

Job

Complet

ed P.M.R(%)



186.5 191.5


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




6 CSP top roof openings sheeting work Developmen 100 110 Yes

7 SRC Clinker tank Civil structure side cladding work. Developmen 150 89.5 No

1100 1236AUTO GARAGE







104 110

31 x 100

110

= 28.18


12/13

Sl

No. Job Type

Estimated

Hours

Actual

Hours

Job

Completed Unplanned(%)


1 BC-7 drive gearbox internals inspection & oil replacement work PM 12 13.5 Yes2 RM-1&2 O-sepa fan impeller inspection work PM 12 12 Yes















1 Alternate fuel feeding hopper & pin gates fabrication and Erection Work at Preheater PM 60 68 Yes

























6 Cement mill-1 Inlet Chute worn out plate replacement. Repair 34 34 Yes7 Cement mill-1 O-Sepa Inspection PM 5 5 Yes



Packing Plant:









2 Clinker breaker hammer pin washer machining 17 19 Yes3 Material handling trolley pin and bushes machining 17 17 Yes





0 x 100

226

= 0

0 x 100

371

= 0

0 x 100

215

= 0

0 x 100

186.5

= 0



FIRST WEEK OF 2012

UNPLANNED

Unplanned % =Actual hours on completed unplanned work orders

Estimated hours on all completed work ordersX 100


13/13

Sl

No. Job Type

Estimated

Hours

Actual

Hours

Job

Completed Unplanned(%)




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




6 CSP top roof openings sheeting work Developme 100 110 Yes

7 SRC Clinker tank Civil structure side cladding work. Developme 150 89.5 No

AUTO GARAGE







11 x 100

104

= 10.6

Documents

KPI-MECH-1st WK