kpi-mech-5th wk

8/22/2019 KPI-MECH-5th WK

1/11

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

Availa

Labo

Hour

1RAW MILLS & STACKER

RECLAIMER SECTION146.00 146.00 100.00 143.00 146.00 97.95 97.95 143.00 143.00 100.00 56.50 146.0

2PYRO & COAL MILL,

HANDLING SECTION364.50 364.50 100.00 347.50 364.50 95.34 95.34 347.50 488.50 71.14 89.50 471.5

3CEMENT MILLS & PACKING

PLANT SECTION471.50 471.50 100.00 460.50 480.00 95.94 95.94 460.50 460.50 100.00 199.50 480.0

4WORKSHOP & WATER

WORKS152.50 152.50 100.00 144.50 152.50 94.75 94.75 144.50 144.50 100.00

5 PROJECT & DEVELOPMENTWORKS

311.50 311.50 100.00 246.00 282.00 87.23 87.23

6 AUTO GARAGE 96.00 96.00 100.00 91.00 96.00 94.79 94.79 91.00 91.00 100.00 84.00 96.0

PIONEER CEMENT INDUSTRIES LLC, RAK, UAE

KEY PERFORMANCE INDICATORS - Maintenance Dept.

FIFTH WEEK OF 2012

MECHANICAL DEPT.

PMR

Sl.No DESCRIPTION

Plan AttainmentLabour Utilisation Efficiency


2/11

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 39.5 39.5

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 54.5 54.5

7 Jose 54.5 54.5

8 Bhukya Sreenu 54.5 54.5

9 Assan 39.5 39.5

10 Vallabha Rao 0 0

11 Moinuddin 39.5 39.5

12 Babu Kumar 39.5 39.5

13 Chendra Sekhar 0 0

14 Dhanesh Gupta 50.5 50.5

15 Naresh Rauth 39.5 39.5

16 Anil 39.5 39.5

17 Saleem 39.5 39.5

18 Rajiman 0 0

20 Prasannan 48.5 48.5

21 Jamshid 45.5 45.5

22 Firoz Khan 39.5 39.523 Radha Krishna 39.5 39.5

24 Shabir ali 39.5 39.5

25 Iqbal Basha 0 0

26 Rajesh Kumar Kusva 39.5 39.5

27 Ansari 39.5 39.5

28 Murali Dharan 39.5 39.5

29 Ajmal Basha 0 0

30 Jelaludhin 39.5 39.5

31 Babu Babi 39.5 39.5

32 Musthafa 54.5 54.5

33 Paswan 52 5234 Ramesh 61.5 61.5

35 Asraf 50.5 50.5

36 Suru Kumar 61.5 61.5

37 Mahindra 39.5 39.5

38 Murthy 44.5 44.5

39 Kesar Dev 40.5 40.5

40 Ramakrishna 39.5 39.5

41 Rajesh yadav 39.5 39.5

Total 1542 1542


MECHANICAL DEPT KEY PERFORMANCE INDICATORS - KPI

FIFTH WEEK OF 2012

100.00


3/11

Sl

No

. Job Type

Estimated

Hours

Actual

Hours

Job

Comple

ted Efficiency

RAW MILLS & STACKER RECLAIMER SECTION

1 Raw mill-2 LCD Centre mesh repairing work. Repair 18 19 Yes

2 Raw mill-2 Drying Diaphragm Centre mesh repairing work. Repair 6.5 6.5 Yes

3 Raw mill-2 Inlet HLPC unit filters cleaning work. PM 5 5 Yes

4 BC-11 Discharge chute patch up work. Repair 6 6 Yes

5 R.M-1 Auxiliary drive thruster fixing work. PM 6 6 Yes

6 Auto sampler panel frames fixing work at raw mill building 1st floor. Project 15 16 Yes

7 BC-1 to BC-14 All the belt conveyor belt condition , joint condition & return scrapper Inspection. PM 10 10 Yes

8 Raw mill-2 O-sepa returns pipe (near Flap bend area)patch work. Repair 21 22 Yes

9 BC-5 Belt sides dressing work. Repair 20 20 Yes

10 Stacker shed area house keeping. PM 5.5 5.5 Yes

11 Raw mill Section checklist and general maintenance works PM 30 30 Yes

143 146

PYRO & COAL MILL, HANDLING SECTION

1 Flap fabrication for alternative fuel feeding system. Project 141 107 No

2 Bin Fabrication for Alternative fuel feeding system (Dia 2500X3500mm long ) Project 140 151 Yes3 Bin Transsion piece fabrication for Alternative fuel feeding system Project 46 52 Yes

4 Bin Ribs setting and full welding work. Project 24 24 Yes

5 T.A.D top bend castable box preparation(Size : 600X600 and 600X500) and fixing work. Repair 24 24 Yes

6 Weigh feeder body plate cutting for alternative fuel feeding system. Project 24 24 Yes

7 Spare roots blower 1016 WC dismantling work. PM 25.5 25.5 yes

8 General Maintenance:-

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 Yes347.5 364.5

CEMENT MILLS & PACKING PLANT SECTION

1 Cement mill General check list work and general maintenance works PM 32 32 Yes

2 Inspection door fabrication and fixing for BC-29 Transfer point Bag filter discharge pipe. Repair 12 12 Yes

3 Centrifugal oil separator fixing work for cement mill-2 Outlet HLPC PM 22 22 Yes

4 Cement mill-2 Vent Bag Filter Bags replacement work. PM 38 38 Yes

Packing plant:

5 SRC Bulk loading bin in side airsides inspection and maintenance work. Repair 130 140 Yes

6 SRC Bulk loading bin in side airsides cloth replacement work. Repair 54 59.5 Yes

7 SRC Bulk loading bin inspection door fabrication and fixing work. Repair 54 58 Yes

8 Cement Silo-1 Spare Extraction blower assembling work PM 25.5 25.5 Yes

9 SRC Bulk loading Loading spout Dosing Valve and Shut off valve fixing work. PM 24 24 Yes

10 Hoist Motor dismantling and shifting to Packing plant Repair 11 11 Yes

11 Roto Packing and auto packer Schedule maintenance works and Auto packer Hoist Motor

replacement work

PM 34 34

Yes

12 Roto Packer Dosing Valve Fixing work. PM 24 24 Yes

460.5 480

WORKSHOP & WATER WORKS

1 Shaft machining for pet coke flop valve. 20 20 Yes

2 Pet coke flop shaft's bushes machining and key way m/c 17 22 Yes

3 Pet coke shaft key way cutting connectors machining 17 17 Yes

4 M30 Sq.Nut machining 17 17 Yes

6 SRc flap shaft and bushes machining work 17 20 Yes

7 Auto sampler panel box frame fabrication work 8.5 8.5 Yes

8 Flanges fabrication for Pump house pipeline . 8.5 8.5 Yes

9 All water coolers filters elements changing work 8.5 8.5 Yes

10 Plumbing works at plant and colony 17 17 Yes

11 Pipeline fixing at STP plant 14 14 Yes

144.5 152.5PROJECT & 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 350 370 No

3 SRC Clinker tank feed pipe modification work Repair 190 226 Yes87.23


MECHANICAL DEPT. KEY PERFORMANCE INDICATORS - KPI

FIFTH WEEK OF 2012

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

95.34

97.95

94.75

95.94


4/11

Sl

No

. Job Type

Estimated

Hours

Actual

Hours

Job

Comple

ted Efficiency

4 SRC unit bag filter bottom plat form and stair case fabrication work. Project 56 56 Yes

5 Platform fabrication and erection over the stores office. Developme 120 68 No

246 282

AUTO GARAGE

1 General Maintenance PM 45 45 yes

2 Man truck all tyres replaced by new 21475 PM 17 20 Yes3 Road sweeping m/c 's diesel pump removal and fixing. Unplanned 6 6 Yes

4 Komatsu loader front tyre replacement PM 17 19 Yes

5 21475 man truck gear problem Unplanned 4 4 Yes

6 Cat loader starting problem Unplanned 2 2 Yes

94.79


5/11

Sl.No Section Labour Utilisation Efficiency Productivity

1 RAW MILLS & STACKER RECLAIMER SECTION 100.00 97.95 97.95

2 PYRO & COAL MILL, HANDLING SECTION 100.00 95.34 95.34

3 CEMENT MILLS & PACKING PLANT SECTION 100.00 95.94 95.94

4 WORKSHOP & WATER WORKS 100.00 94.75 94.75

5 PROJECT & DEVELOPMENT WORKS 100.00 87.23 87.23

6 AUTO GARAGE 100.00 94.79 94.79


MECHANICAL DEPT.KEY PERFORMANCE INDICATORS - KPI

FIFTH WEEK OF 2012

Productivity

Productivity(%) = 100

Labour Utilisation X Efficiency


6/11

Sl

No. Job Type

Estimated

Hours

Actual

Hours

Job

Complet

ed Plan Attainment


1 Raw mill-2 LCD Centre mesh repairing work. Repair 18 19 Yes

2 Raw mill-2 Drying Diaphragm Centre mesh repairing work. Repair 6.5 6.5 Yes3 Raw mill-2 Inlet HLPC unit filters cleaning work. PM 5 5 Yes




7 BC-1 to BC-14 All the belt conveyor belt condition , joint condition & return scrapper PM 10 10 Yes





143 146



2 Bin Fabrication for Alternative fuel feeding system (Dia 2500X3500mm long ) Project 140 151 Yes

3 Bin Transsion piece fabrication for Alternative fuel feeding system Project 46 52 Yes










5. Compressors Suction Filter & Cooler c leaned PM 6 6 Yes



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

347.5 364.5






Packing plant:







11 Roto Packing and auto packer Schedule maintenance works and Auto packer Hoist Motor PM 34 34 Yes

12 Roto Packer Dosing Valve Fixing work. PM 24 24 Yes460.5 480












144.5 152.5

PROJECT & DEVELOPMENT WORKS1 Paper Bags Go down opening Covering clading fabrication and erection work. Developm 200 56 No


3 SRC Clinker tank feed pipe modification work Repair 190 226 Yes


5 Platform fabrication and erection over the stores office. Developm 120 68 No

FIFTH WEEK OF 2012


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


143 x 100

143

= 100

347.5 x 100

488.5

= 71.14

460.5 x 100

460.5

= 100

144.5 x 100

144.5

= 100


7/11

Sl

No. Job Type

Estimated

Hours

Actual

Hours

Job

Complet

ed Plan Attainment

246 282

AUTO GARAGE


2 Man truck all tyres replaced by new 21475 PM 17 20 Yes

3 Road sweeping m/c 's diesel pump removal and fixing. Unplanned 6 6 Yes

4 Komatsu loader front tyre replacement PM 17 19 Yes5 21475 man truck gear problem Unplanned 4 4 Yes


91 96

91 x 100

91

= 100


8/11

Sl

No. Job Type

Estimated

Hours

Actual

Hours

Job

Complet

ed P.M.R(%)


1 Raw mill-2 LCD Centre mesh repairing work. Repair 18 19 Yes2 Raw mill-2 Drying Diaphragm Centre mesh repairing work. Repair 6.5 6.5 Yes










143 146














5. Compressors Suction Filter & Cooler c leaned PM 6 6 Yes




347.5 364.5CEMENT MILLS & PACKING PLANT SECTION





Packing plant:







11 Roto Packing and auto packer Schedule maintenance works and Auto packer Hoist Motor

replacement work

PM 34 34

Yes12 Roto Packer Dosing Valve Fixing work. PM 24 24 Yes

460.5 480












144.5 152.5

PROJECT & DEVELOPMENT WORKS

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




PMR =

56.5 x 100

146

= 38.69

89.5 x 100

471.5 =

18.98



FIFTH WEEK OF 2012

PMR

Preventive Maint. Routine Hrs

199.5 x 100

480

= 41.56

Available Labour Hoursx 100


9/11

Sl

No. Job Type

Estimated

Hours

Actual

Hours

Job

Complet

ed P.M.R(%)

5 Platform fabrication and erection over the stores office. Developmen 120 68 No

246 282

AUTO GARAGE




4 Komatsu loader front tyre replacement PM 17 19 Yes

5 21475 man truck gear problem Unplanned 4 4 Yes


91 96

84 x 100

96= 87.5


10/11

Sl

No. Job Type

Estimated

Hours

Actual

Hours

Job

Completed Unplanned(%)


1 Raw mill-2 LCD Centre mesh repairing work. Repair 18 19 Yes2 Raw mill-2 Drying Diaphragm Centre mesh repairing work. Repair 6.5 6.5 Yes










143 146














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




347.5 364.5






Packing plant:







11 Roto Packing and auto packer Schedule maintenance works and Auto packer Hoist PM 34 34 Yes

12 Roto Packer Dosing Valve Fixing work. PM 24 24 Yes460.5 480












144.5 152.5

PROJECT & DEVELOPMENT WORKS1 Paper Bags Go down opening Covering clading fabrication and erection work. Developme 200 56 No




5 Platform fabrication and erection over the stores office. Developme 120 68 No



FIFTH WEEK OF 2012

UNPLANNED

Unplanned % =Actual hours on completed unplanned work orders

Estimated hours on all completed work ordersX 100

0 x 100

143

= 0

0 x 100

347.5

= 0

0 x 100

460.5

= 0


11/11

Sl

No. Job Type

Estimated

Hours

Actual

Hours

Job

Completed Unplanned(%)

246 282

AUTO GARAGE




4 Komatsu loader front tyre replacement PM 17 19 Yes5 21475 man truck gear problem Unplanned 4 4 Yes


91 96

12 x 100

91

= 13.19

kpi-mech-5th wk

Documents