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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
