PIONEER CEMENT INDUSTRIES LLC, RAK, UAE KEY PERFORMANCE INDICATORS - Maintenance Dept.

SECOND WEEK OF 2012 MECHANICAL DEPT. Labour Utilisation Sl.No DESCRIPTION Available Labour Hours 273.00 603.00 319.00 185.50 347.50 96.00 Actual Hours (Work orders) 273.00 603.00 319.00 185.50 347.50 96.00 Efficiency Productivity Plan Attainment PMR Preventive Available Maintenanc Labour e Routine Hours Hours 145 284.5 199 275.5 630 325 Un Planned Actual hours Estimated on completed hours on all unplanned completed work orders work orders 0 0 0 21 267 472.5 311 178

Estimated Actual Hours Hours

Estmiated Hours of Estimated Lab.Utilisation X Effi. completed time of all 100 jobs(excluding jobs unplanned) 96.91 97.83 95.69 97.00 96.08 93.75 90 90 267 472.5 311 178 267 822.5 311 178

RAW MILLS & STACKER RECLAIMER SECTION PYRO & COAL MILL, 2 HANDLING SECTION 1 CEMENT MILLS & PACKING PLANT SECTION WORKSHOP & WATER 4 WORKS PROJECT & DEVELOPMENT 5 WORKS 3 6 AUTO GARAGE

100 100 100 100 100 100

261 472.5 311 178 184 90

275.5 483 325 183.5 191.5 96

96.91 97.83 95.69 97 96.08 93.75

100 57.45 0 100

52.63 45.16 61.23

0 0 0 11.79

100

40

96

41.66

19

90

21.11

PIONEER CEMENT INDUSTRIES LLC, RAK, UAE MECHANICAL DEPT KEY PERFORMANCE INDICATORS - KPI SECOND WEEK OF 2012

Labour Utilization(%)
Sl. No 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 Names

Actual Labour Hours on work orders/Available Labour Hours X 100 Available Labour hours 0 48 48 48 48 48 48 48 48 48 48 48 48 48 48 48 48 48 48 48 48 48 48 48 48 48 48 48 48 48 48 48 48 48 48 48 48 48 48 Actual Labour Hours(Work Orders) 0 48 48 48 48 48 48 48 48 48 48 48 48 48 48 48 48 48 48 48 48 48 48 48 48 48 48 48 48 48 48 48 48 48 48 48 48 48 48

Labour Utilization(%)

Sandeep Singh Pillai Bhanu Pratap Ramana Reddy Hanumath Reddy Abu Backer Jose Bhukya Sreenu Assan Vallabha Rao Moinuddin Babu Kumar Chendra Sekhar Dhanesh Gupta Naresh Rauth Anil Saleem Rajiman Prasannan
Jamshid

100.00

Firoz Khan Radha Krishna Shabir ali Iqbal Basha Rajesh Kumar Kusva Ansari Murali Dharan Ajmal Basha Jelaludhin Babu Babi Paswan Ramesh Asraf Suru Kumar Musthafa Mahindra Murthy Ramakrishna Rajesh yadav

PIONEER CEMENT INDUSTRIES LLC, RAK, UAE MECHANICAL DEPT. KEY PERFORMANCE INDICATORS - KPI SECOND WEEK OF 2012

Efficiency (%) = Estimated Time of completed Jobs / Actual Time of Completed Jobs
Sl No . 1 2 3 4 5 6 7 8 9 10 11 Estimated Hours 30 25.5 17 34 8.5 79.5 11 19.5 7 10 4 17 4 267 24 24 68 350 36 34 34 25.5 34 25.5 34 25.5 34 6 6 6 12 4 6 10 10 10 2.5 1.5 472.5 15 15 25.5 17 20 14 34 10 5.5 12 Job Actual Comple Hours ted 30 25.5 17 34 8.5 88 11 19.5 7 10 Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes

Job RAW MILLS & STACKER RECLAIMER SECTION RABH 2nd module inspection & damaged bags to be replaced. Raw mill-2 O-sepa Cyclone Patch up and Raw mill-1 O-sepa Hopper patch up work. Raw mill-1 & 2 Vent bag filters Impeller inspection and coating cleaning work. Stacker Spare bogie wheels bearings assembling work . Raw mills section general checklist checking and Raw mill-1 condition monitoring. Stacker drive bogie wheel assembling and replacement towards stock pile side work . Raw mills 1&2 O-sepa impellers coating cleaning and raw mill-2 O-sepa fan Bearings bed bolts retightening. Raw mill-1 Vent bag filter Fan impeller coating cleaning work. Raw mill-2 Silica Weigh feeder discharge chute patch up work. Raw mill-2 Inlet chute patch up work. General Maintenance:1.RM-1&2 slide shoe bearings visual checking 2.Rawmill area checklist & general maintenance works 3.Enmass conveyor-1,2,3&7 inspection

Type PM Repair PM PM PM Repair PM PM Repair Repair PM PM PM

Efficiency

96.91

4 Yes 17 Yes 4 275.5 24 Yes 28 Yes Yes 74.5 147 No 36 Yes 34 Yes 34 Yes 25.5 Yes 34 Yes 25.5 Yes 34 Yes 25.5 Yes 34 Yes 6 Yes Yes 6 Yes 6 Yes 12 Yes 4 Yes 6 Yes 10 Yes 10 Yes 10 Yes 2.5 Yes 1.5 Yes 483 17 17 25.5 17 20 14 34 10 5.5 Yes Yes Yes Yes Yes Yes Yes Yes Yes

PYRO & COAL MILL, HANDLING SECTION 1 Cooler Back side castable box fabrication and fixing work. 2 Alkali Baghouse hopper-2 Bulk loading head flange fabrication . 3 Alkali Baghouse Inlet duct bleed air damper flanges fabrication and safety guards fabrication work. 4 Hot kiln Alignment Preparation works. 5 Kiln Girth gear to pinion Root Clearance and backlash readings taken. 6 Kiln inlet Pneumatic Cylinders replacement work( Leakage Cylinders only ). Kiln Out let dust protection baffle plate (2nos ) Fixing work. 7 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 8 Pre heater fan motor Vibration sensor fixing work. 10 Cooler RFT Cross head shaft NDE Wheel Track replacement with spare. Kiln feed Standby Bucket Elevator change over 11 Fine coal pumping roots blower belts tightening work 12 Cooler Drive -1 Chain tentioning work. P.C and K.C FK pumps bearings Greasing work. 13 Kiln II tyre up hill chair pad shim adjustment 14 Coal Mill maintenance :Raw coal dump hopper top grills repair work and housekeeping. Coal mill girth gear grease spray pattern checking work. 15 General Maintenance:1. Kiln all Tyres lubricated 2. Cooler Drives Chain lubricated 3. En-mass conveyors chain condition inspected&missed chain pins circlips refixed. 4.DDPC-1 chain condition inspection 5. Compressors Suction Filter & Cooler cleaned 6. K.C. & P.C. Roots Blowers Suction Filters cleaned 7. Silo bottom & Pre-heater top Blowers Suction Filters cleaned. 8. Kiln Supporting Rollers Bearings Oil Seals lubricated. 9. Air blaster Quick exhaust valves replaced & Overhauled 10.Cooler spillage hopper double flap valve pneumatic cylinder recondtioned CEMENT MILLS & PACKING PLANT SECTION Cement Silo-1 4th comportment dosing Valve replacing with reconditioning one. spare Belt preparation for hopper feed belt. O-Sepa outlet duct patch up work and Vent bag house inlet duct patch up work. BC-21 Input Coupling Head and tail pulleys bearings inspection and greasing work. Base frames fabrications for Online centrifugal separator units ( For C.M-1&2 ). Cement mill-1&2 O-sepa Return Oil Protection pipes fabrication work. DDPC-4 Discharge chute Worn out plate replacing with new plate. Cement mill-1 outlet airslide blower motor(7.5 KW) replacement work. DDPC-4 Discharge chute Full welding. Cement mills 1&2, Clinker , Lime Stone & Gypsum Weigh Feeders Bearings Greasing work.

Repair

PM PM Repair PM PM PM PM PM PM Repair PM PM PM PM PM PM PM PM PM Repair Repair

97.83

1 2 3 4 5 6 7 8 9 10

PM PM Repair PM PM PM Repair Repair Repair PM

12 Yes 95.69

Sl No . 11 12

13 14 15

Job 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. Cement mill area general checklist and general maintenance works Packing Plant Auto packer roller locking plate fabrication and Bottom timing belt Spare gear box bad holes tapping work and Roto packer blower suction filter changing. Bulk loading spout no-3 Repairing work. Bulk loading spout no-3 Fixing work.

Type PM PM

Estimated Hours 15 25.5

Job Actual Comple Hours ted 17 Yes 25.5 Yes

Efficiency 95.69

PM Repair Repair PM PM PM

8.5 22 21 34 8.5 8.5 311 8.5 24 34 8.5 34 21 48 178

8.5 Yes 25.5 Yes 25.5 Yes 34 Yes 8.5 Yes 8.5 Yes 325 8.5 24 34 8.5 39.5 21 48 183.5 56 347.5 157.5 34 141.5 Yes Yes Yes Yes Yes Yes Yes

Roto Packing and auto packer Schedule maintenance works and packer Bucket elevator 16 inspection, Bulk loading and Roto packer De-dusting system Pipe line patch up work. 17 18 House keeping Bulk loading spout no-2 inspection and bulk loading bin-1 aeration flexible hoses replacement.

1 2 3 4 5 6 7

WORKSHOP & WATER WORKS Clinker breaker pin tapping work Gypsum schuttle conveyor coupling bolts maching work cooler track wheel rough maching Lathe machines maintenance works Cooler spare track wheel welding work Miscellaneous mahining works STP,staff colony plumbing works& plant drip line repair works PROJECT & DEVELOPMENT WORKS Paper Bags Go down opening Covering clading fabrication and erection work. SRC clinker tank approaching stair case fabrication & erection SRC Clinker tank Civil structure side cladding work. SRC Hopper De-dusting Bag filter fan erection SRC Hopper De-dusting Bag filter Ducting fabrication work. SRC Clinker tank De-dusting Bag filter Supporting structure fabrication and erection work. AUTO GARAGE General maintenance Man truck 21475 tyres have been interchanged Man truck 21475 rear tyre puncture Man truck 21476 leaf springs pad has been replaced Fork lift front steering bearing replaced Fork lift engine service

97.00

1 2 3 4 5 6

Development Project Development Project Project Project

200 350 150 34 170 180 184

No No Yes Yes No

96.08

146 No 191.5 28 20 6 13 17 6 Yes Yes Yes Yes Yes Yes

1 2 3 4 5 6

PM Repair Unplanned Unplanned Repair PM

28 16 6 12 16 6

93.75

PIONEER CEMENT INDUSTRIES LLC, RAK, UAE MECHANICAL DEPT.KEY PERFORMANCE INDICATORS - KPI SECOND WEEK OF 2012

Productivity
Productivity(%) = Sl.No 1 2 3 4 5 6 Section RAW MILLS & STACKER RECLAIMER SECTION PYRO & COAL MILL, HANDLING SECTION CEMENT MILLS & PACKING PLANT SECTION WORKSHOP & WATER WORKS PROJECT & DEVELOPMENT WORKS AUTO GARAGE Labour Utilisation X Efficiency 100 Labour Utilisation Efficiency 100.00 96.91 100.00 97.83 100.00 95.69 100.00 97 100.00 96.08 100.00 93.75

Productivity
96.91 97.83 95.69 97.00 96.08 93.75

PIONEER CEMENT INDUSTRIES LLC, RAK, UAE MECHANICAL DEPT.KEY PERFORMANCE INDICATORS - KPI SECOND WEEK OF 2012

Plan Attainment (%) = Estimated Time of completed Jobs excluding unplanned works / Estimated Time of all Jobs
Sl No. 1 2 3 4 5 6 7 8 9 10 11 Estimated Hours 30 25.5 17 34 8.5 79.5 11 19.5 7 10 4 17 4 267 Job Actual Complet Hours ed 30 25.5 17 34 8.5 88 11 19.5 7 10 Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes

Job RAW MILLS & STACKER RECLAIMER SECTION RABH 2nd module inspection & damaged bags to be replaced. Raw mill-2 O-sepa Cyclone Patch up and Raw mill-1 O-sepa Hopper patch up work. Raw mill-1 & 2 Vent bag filters Impeller inspection and coating cleaning work. Stacker Spare bogie wheels bearings assembling work . Raw mills section general checklist checking and Raw mill-1 condition monitoring. Stacker drive bogie wheel assembling and replacement towards stock pile side work . Raw mills 1&2 O-sepa impellers coating cleaning and raw mill-2 O-sepa fan Bearings bed Raw mill-1 Vent bag filter Fan impeller coating cleaning work. Raw mill-2 Silica Weigh feeder discharge chute patch up work. Raw mill-2 Inlet chute patch up work. General Maintenance:1.RM-1&2 slide shoe bearings visual checking 2.Rawmill area checklist & general maintenance works 3.Enmass conveyor-1,2,3&7 inspection PYRO & COAL MILL, HANDLING SECTION

Type PM Repair PM PM PM Repair PM PM Repair Repair PM PM PM

Plan Attainment

267 x 100 267 = 100

4 Yes 17 Yes 4 275.5 Yes Yes Yes No Yes Yes

1 Cooler Back side castable box fabrication and fixing work. 2 3 4 5 6 7 8 10 11 12 13 14 Alkali Baghouse hopper-2 Bulk loading head flange fabrication . Alkali Baghouse Inlet duct bleed air damper flanges fabrication and safety guards fabrication Hot kiln Alignment Preparation works. Kiln Girth gear to pinion Root Clearance and backlash readings taken. Kiln inlet Pneumatic Cylinders replacement work( Leakage Cylinders only ). 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. Cooler RFT Cross head shaft NDE Wheel Track replacement with spare. Kiln feed Standby Bucket Elevator change over Fine coal pumping roots blower belts tightening work Cooler Drive -1 Chain tentioning work. P.C and K.C FK pumps bearings Greasing work. Kiln II tyre up hill chair pad shim adjustment Coal Mill maintenance :Raw coal dump hopper top grills repair work and housekeeping. Coal mill girth gear grease spray pattern checking work. General Maintenance:1. Kiln all Tyres lubricated 2. Cooler Drives Chain lubricated 3. En-mass conveyors chain condition inspected&missed chain pins circlips refixed. 4.DDPC-1 chain condition inspection 5. Compressors Suction Filter & Cooler cleaned 6. K.C. & P.C. Roots Blowers Suction Filters cleaned 7. Silo bottom & Pre-heater top Blowers Suction Filters cleaned. 8. Kiln Supporting Rollers Bearings Oil Seals lubricated. 9. Air blaster Quick exhaust valves replaced & Overhauled 10.Cooler spillage hopper double flap valve pneumatic cylinder recondtioned CEMENT MILLS & PACKING PLANT SECTION Cement Silo-1 4th comportment dosing Valve replacing with reconditioning one. spare Belt preparation for hopper feed belt. O-Sepa outlet duct patch up work and Vent bag house inlet duct patch up work. BC-21 Input Coupling Head and tail pulleys bearings inspection and greasing work. Base frames fabrications for Online centrifugal separator units ( For C.M-1&2 ). Cement mill-1&2 O-sepa Return Oil Protection pipes fabrication work. DDPC-4 Discharge chute Worn out plate replacing with new plate. Cement mill-1 outlet airslide blower motor(7.5 KW) replacement work. DDPC-4 Discharge chute Full welding. Cement mills 1&2, Clinker , Lime Stone & Gypsum Weigh Feeders Bearings Greasing work.

Repair

PM PM Repair PM PM PM PM PM PM Repair PM PM PM PM PM PM PM PM PM Repair Repair

24 24 68 350 36 34 34 25.5 34 25.5 34 25.5 34 6 6 6 12 4 6 10 10 10 2.5 1.5 472.5 15 15 25.5 17 20 14 34 10 5.5 12 15

24 28 74.5 147 36 34

34 Yes 25.5 Yes 34 Yes 25.5 Yes 34 Yes 25.5 Yes 34 Yes 6 Yes Yes 6 Yes 6 Yes 12 Yes 4 6 10 10 10 2.5 1.5 483 17 17 25.5 17 20 14 34 10 5.5 Yes Yes Yes Yes Yes Yes Yes

472.5 x 100 822.5 = 57.45

15

1 2 3 4 5 6 7 8 9 10

PM PM Repair PM PM PM Repair Repair Repair PM PM

Yes Yes Yes Yes Yes Yes Yes Yes Yes

12 Yes 17 Yes 311 x 100 311 = 100

Gypsum Dump hopper bottom feed belt no-26 Drive pulley non drive end side bearing 11 replaced with new ( Bearing No 22220 cck ) and Bearings Greasing done.

Sl No. Job 12 Cement mill area general checklist and general maintenance works Packing Plant Auto packer roller locking plate fabrication and Bottom timing belt Spare gear box bad holes 13 tapping work and Roto packer blower suction filter changing. 14 Bulk loading spout no-3 Repairing work. 15 Bulk loading spout no-3 Fixing work. 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.

Type PM

Job Estimated Actual Complet Hours Hours ed 25.5 25.5 Yes

311 x 100 311 Plan Attainment = 100

PM Repair Repair

8.5 22 21

8.5 Yes 25.5 Yes 25.5 Yes

16

PM PM PM

34 8.5 8.5 311 8.5 24 34 8.5 34 21 48 178

34 Yes 8.5 Yes 8.5 Yes 325 8.5 24 34 8.5 39.5 21 48 183.5 56 68 157.5 34 141.5 Yes Yes Yes Yes Yes Yes Yes

Bulk loading spout no-2 inspection and bulk loading bin-1 aeration flexible hoses 17 replacement. 18 House keeping WORKSHOP & WATER WORKS Clinker breaker pin tapping work Gypsum schuttle conveyor coupling bolts maching work cooler track wheel rough maching Lathe machines maintenance works Cooler spare track wheel welding work Miscellaneous mahining works STP,staff colony plumbing works& plant drip line repair works PROJECT & DEVELOPMENT WORKS Paper Bags Go down opening Covering clading fabrication and erection work. SRC clinker tank approaching stair case fabrication & erection SRC Clinker tank Civil structure side cladding work. SRC Hopper De-dusting Bag filter fan erection SRC Hopper De-dusting Bag filter Ducting fabrication work. SRC Clinker tank De-dusting Bag filter Supporting structure fabrication and erection work. AUTO GARAGE 1 2 3 4 5 6 7 General maintenance Man truck 21475 tyres have been interchanged Man truck 21475 rear tyre puncture Man truck 21476 leaf springs pad has been replaced Fork lift front steering bearing replaced Fork lift engine service Komatsu loader engine service

1 2 3 4 5 6 7

178 x 100 178 = 100

1 2 3 4 5 6

Development Project Development Project Project Project

200 350 150 34 170 180 184

No No Yes Yes No

146 No 191.5 28 20 6 13 17 6 6 96 Yes Yes Yes Yes Yes Yes Yes

PM Repair Unplanned Unplanned Repair PM PM

28 16 6 12 16 6 6 90

90 x 100 90 = 100

PIONEER CEMENT INDUSTRIES LLC, RAK, UAE MECHANICAL DEPT.KEY PERFORMANCE INDICATORS - KPI SECOND WEEK OF 2012 PMR Preventive Maint. Routine Hrs PMR = Available Labour Hours Sl No. 1 2 3 4 5 6 7 8 9 10 11 Estimated Hours 30 25.5 17 34 8.5 79.5 11 19.5 7 10 4 17 4 267 24 24 68 350 36 34 34 25.5 34 25.5 34 25.5 34 6 6 6 12 4 6 10 10 10 2.5 1.5 472.5 15 15 25.5 17 20 14 34 10 5.5 12 15 Actual Hours 30 25.5 17 34 8.5 88 11 19.5 7 10

x 100 Job Complet ed Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes

Job RAW MILLS & STACKER RECLAIMER SECTION RABH 2nd module inspection & damaged bags to be replaced. Raw mill-2 O-sepa Cyclone Patch up and Raw mill-1 O-sepa Hopper patch up work. Raw mill-1 & 2 Vent bag filters Impeller inspection and coating cleaning work. Stacker Spare bogie wheels bearings assembling work . Raw mills section general checklist checking and Raw mill-1 condition monitoring. Stacker drive bogie wheel assembling and replacement towards stock pile side work . Raw mills 1&2 O-sepa impellers coating cleaning and raw mill-2 O-sepa fan Bearings bed Raw mill-1 Vent bag filter Fan impeller coating cleaning work. Raw mill-2 Silica Weigh feeder discharge chute patch up work. Raw mill-2 Inlet chute patch up work. General Maintenance:1.RM-1&2 slide shoe bearings visual checking 2.Rawmill area checklist & general maintenance works 3.Enmass conveyor-1,2,3&7 inspection PYRO & COAL MILL, HANDLING SECTION Cooler Back side castable box fabrication and fixing work. Alkali Baghouse hopper-2 Bulk loading head flange fabrication . Alkali Baghouse Inlet duct bleed air damper flanges fabrication and safety guards Hot kiln Alignment Preparation works. Kiln Girth gear to pinion Root Clearance and backlash readings taken. Kiln inlet Pneumatic Cylinders replacement work( Leakage Cylinders only ). 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. Cooler RFT Cross head shaft NDE Wheel Track replacement with spare. Kiln feed Standby Bucket Elevator change over Fine coal pumping roots blower belts tightening work Cooler Drive -1 Chain tentioning work. P.C and K.C FK pumps bearings Greasing work. Kiln II tyre up hill chair pad shim adjustment Coal Mill maintenance :Raw coal dump hopper top grills repair work and housekeeping. Coal mill girth gear grease spray pattern checking work. General Maintenance:1. Kiln all Tyres lubricated 2. Cooler Drives Chain lubricated 3. En-mass conveyors chain condition inspected&missed chain pins circlips refixed. 4.DDPC-1 chain condition inspection 5. Compressors Suction Filter & Cooler cleaned 6. K.C. & P.C. Roots Blowers Suction Filters cleaned 7. Silo bottom & Pre-heater top Blowers Suction Filters cleaned. 8. Kiln Supporting Rollers Bearings Oil Seals lubricated. 9. Air blaster Quick exhaust valves replaced & Overhauled 10.Cooler spillage hopper double flap valve pneumatic cylinder recondtioned CEMENT MILLS & PACKING PLANT SECTION Cement Silo-1 4th comportment dosing Valve replacing with reconditioning one. spare Belt preparation for hopper feed belt. O-Sepa outlet duct patch up work and Vent bag house inlet duct patch up work. BC-21 Input Coupling Head and tail pulleys bearings inspection and greasing work. Base frames fabrications for Online centrifugal separator units ( For C.M-1&2 ). Cement mill-1&2 O-sepa Return Oil Protection pipes fabrication work. DDPC-4 Discharge chute Worn out plate replacing with new plate. Cement mill-1 outlet airslide blower motor(7.5 KW) replacement work. DDPC-4 Discharge chute Full welding. Cement mills 1&2, Clinker , Lime Stone & Gypsum Weigh Feeders Bearings Greasing work.

Type PM Repair PM PM PM Repair PM PM Repair Repair PM PM PM

P.M.R(%)

145 x 100 275.5 = 52.63

4 Yes 17 Yes 4 275.5 24 28 74.5 147 36 34 Yes Yes Yes No Yes Yes

1 2 3 4 5 6 7 8 10 11 12 13 14

Repair Repair Safety PM PM Repair PM PM PM PM PM PM Repair PM PM PM PM PM PM PM PM PM Repair Repair

34 Yes 25.5 Yes 34 Yes 25.5 Yes 34 Yes 25.5 Yes 34 Yes 6 Yes Yes 6 Yes 6 Yes 12 Yes 4 6 10 10 10 2.5 1.5 483 17 17 25.5 17 20 14 34 10 5.5 Yes Yes Yes Yes Yes Yes Yes

284.5 x 100 630 = 45.16

15

1 2 3 4 5 6 7 8 9 10

PM PM Repair PM PM PM Repair Repair Repair PM PM

Yes Yes Yes Yes Yes Yes Yes Yes Yes

12 Yes 17 Yes 199 x 100 325 = 61.23

Gypsum Dump hopper bottom feed belt no-26 Drive pulley non drive end side bearing 11 replaced with new ( Bearing No 22220 cck ) and Bearings Greasing done.

Sl No. Job 12 Cement mill area general checklist and general maintenance works Packing Plant Auto packer roller locking plate fabrication and Bottom timing belt Spare gear box bad holes 13 tapping work and Roto packer blower suction filter changing. 14 Bulk loading spout no-3 Repairing work. 15 Bulk loading spout no-3 Fixing work. 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.

Type PM

Job Estimated Actual Complet Hours Hours ed 25.5 25.5 Yes

199 x 100 325 P.M.R(%) = 61.23

PM Repair Repair

8.5 22 21

8.5 Yes 25.5 Yes 25.5 Yes

16

PM PM PM

34 8.5 8.5 311 8.5 24 34 8.5 34 21 48 178

34 Yes 8.5 Yes 8.5 Yes 325 8.5 24 34 8.5 39.5 21 48 183.5 56 68 157.5 34 141.5 Yes Yes Yes Yes Yes Yes Yes

Bulk loading spout no-2 inspection and bulk loading bin-1 aeration flexible hoses 17 replacement. 18 House keeping WORKSHOP & WATER WORKS Clinker breaker pin tapping work Gypsum schuttle conveyor coupling bolts maching work cooler track wheel rough maching Lathe machines maintenance works Cooler spare track wheel welding work Miscellaneous mahining works STP,staff colony plumbing works& plant drip line repair works PROJECT & DEVELOPMENT WORKS Paper Bags Go down opening Covering clading fabrication and erection work. SRC clinker tank approaching stair case fabrication & erection SRC Clinker tank Civil structure side cladding work. SRC Hopper De-dusting Bag filter fan erection SRC Hopper De-dusting Bag filter Ducting fabrication work. SRC Clinker tank De-dusting Bag filter Supporting structure fabrication and erection work. AUTO GARAGE 1 2 3 4 5 6 7 General maintenance Man truck 21475 tyres have been interchanged Man truck 21475 rear tyre puncture Man truck 21476 leaf springs pad has been replaced Fork lift front steering bearing replaced Fork lift engine service Komatsu loader engine service

1 2 3 4 5 6 7

1 2 3 4 5 6

Development Project Development Project Project Project

200 350 150 34 170 180 184

No No Yes Yes No

146 No 191.5 28 20 6 13 17 6 6 96 Yes Yes Yes Yes Yes Yes Yes

PM Repair Unplanned Unplanned Repair PM PM

28 16 6 12 16 6 6 90

40 x 100 96 = 41.66

PIONEER CEMENT INDUSTRIES LLC, RAK, UAE MECHANICAL DEPT.KEY PERFORMANCE INDICATORS - KPI SECOND WEEK OF 2012 UNPLANNED Unplanned % = Sl No.
Actual hours on completed unplanned work orders

Estimated hours on all completed work orders

X 100

Job RAW MILLS & STACKER RECLAIMER SECTION 1 RABH 2nd module inspection & damaged bags to be replaced. 2 Raw mill-2 O-sepa Cyclone Patch up and Raw mill-1 O-sepa Hopper patch up work. 3 Raw mill-1 & 2 Vent bag filters Impeller inspection and coating cleaning work. 4 Stacker Spare bogie wheels bearings assembling work . 5 Raw mills section general checklist checking and Raw mill-1 condition monitoring. 6 Stacker drive bogie wheel assembling and replacement towards stock pile side work . 7 Raw mills 1&2 O-sepa impellers coating cleaning and raw mill-2 O-sepa fan Bearings bed 8 Raw mill-1 Vent bag filter Fan impeller coating cleaning work. 9 Raw mill-2 Silica Weigh feeder discharge chute patch up work. 10 Raw mill-2 Inlet chute patch up work. 11 General Maintenance:1.RM-1&2 slide shoe bearings visual checking 2.Rawmill area checklist & general maintenance works 3.Enmass conveyor-1,2,3&7 inspection PYRO & COAL MILL, HANDLING SECTION Cooler Back side castable box fabrication and fixing work. Alkali Baghouse hopper-2 Bulk loading head flange fabrication . Alkali Baghouse Inlet duct bleed air damper flanges fabrication and safety guards Hot kiln Alignment Preparation works. Kiln Girth gear to pinion Root Clearance and backlash readings taken. Kiln inlet Pneumatic Cylinders replacement work( Leakage Cylinders only ). 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. Cooler RFT Cross head shaft NDE Wheel Track replacement with spare. Kiln feed Standby Bucket Elevator change over Fine coal pumping roots blower belts tightening work Cooler Drive -1 Chain tentioning work. P.C and K.C FK pumps bearings Greasing work. Kiln II tyre up hill chair pad shim adjustment Coal Mill maintenance :Raw coal dump hopper top grills repair work and housekeeping. Coal mill girth gear grease spray pattern checking work. General Maintenance:1. Kiln all Tyres lubricated 2. Cooler Drives Chain lubricated 3. En-mass conveyors chain condition inspected&missed chain pins circlips refixed. 4.DDPC-1 chain condition inspection 5. Compressors Suction Filter & Cooler cleaned 6. K.C. & P.C. Roots Blowers Suction Filters cleaned 7. Silo bottom & Pre-heater top Blowers Suction Filters cleaned. 8. Kiln Supporting Rollers Bearings Oil Seals lubricated. 9. Air blaster Quick exhaust valves replaced & Overhauled 10.Cooler spillage hopper double flap valve pneumatic cylinder recondtioned

Type PM Repair PM PM PM Repair PM PM Repair Repair PM PM PM

Estimated Actual Hours Hours 30 25.5 17 34 8.5 79.5 11 19.5 7 10 4 17 4 267 24 24 68 350 36 34 34 25.5 34 25.5 34 25.5 34 6 6 6 12 4 6 10 10 10 2.5 1.5 472.5 15 15 25.5 17 20 14 34 10 5.5 12 15 25.5 8.5 30 25.5 17 34 8.5 88 11 19.5 7 10

Job Completed Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes

Unplanned(%)

0 x 100 267 =0

4 Yes 17 Yes 4 275.5 24 28 74.5 147 36 34 Yes Yes Yes No Yes Yes

1 2 3 4 5 6 7 8 10 11 12 13 14

Repair

PM PM Repair PM PM PM PM PM PM Repair PM PM PM PM PM PM PM PM PM Repair Repair

34 Yes 25.5 Yes 34 Yes 25.5 Yes 34 Yes 25.5 Yes 34 Yes 6 Yes Yes 6 Yes 6 Yes 12 Yes 4 Yes 6 Yes 10 Yes 10 Yes 10 Yes 2.5 Yes 1.5 Yes 483 17 17 25.5 17 20 14 34 10 5.5 12 17 25.5 Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes

0 x 100 472.5 =0

15

CEMENT MILLS & PACKING PLANT SECTION Cement Silo-1 4th comportment dosing Valve replacing with reconditioning one. spare Belt preparation for hopper feed belt. O-Sepa outlet duct patch up work and Vent bag house inlet duct patch up work. BC-21 Input Coupling Head and tail pulleys bearings inspection and greasing work. Base frames fabrications for Online centrifugal separator units ( For C.M-1&2 ). Cement mill-1&2 O-sepa Return Oil Protection pipes fabrication work. DDPC-4 Discharge chute Worn out plate replacing with new plate. Cement mill-1 outlet airslide blower motor(7.5 KW) replacement work. DDPC-4 Discharge chute Full welding. Cement mills 1&2, Clinker , Lime Stone & Gypsum Weigh Feeders Bearings Greasing Gypsum Dump hopper bottom feed belt no-26 Drive pulley non drive end side bearing Cement mill area general checklist and general maintenance works Packing Plant 13 Auto packer roller locking plate fabrication and Bottom timing belt Spare gear box bad 1 2 3 4 5 6 7 8 9 10 11 12

PM PM Repair PM PM PM Repair Repair Repair PM PM PM PM

0 x 100 311 =0

8.5 Yes

0 x 100 311 =0 Sl No. 14 15 16 17 18 Estimated Actual Job Hours Hours Completed 22 25.5 Yes 21 25.5 Yes 34 34 Yes 8.5 8.5 Yes 8.5 8.5 Yes 311 325 8.5 24 34 8.5 34 21 48 178 Development Project Development Project Project Project 200 350 150 34 170 180 184 AUTO GARAGE 1 2 3 4 5 6 7 General maintenance Man truck 21475 tyres have been interchanged Man truck 21475 rear tyre puncture Man truck 21476 leaf springs pad has been replaced Fork lift front steering bearing replaced Fork lift engine service Komatsu loader engine service PM Repair Unplanned Unplanned Repair PM PM 28 16 6 12 16 6 6 90 28 20 6 13 17 6 6 96 Yes Yes Yes Yes Yes Yes Yes 8.5 24 34 8.5 39.5 21 48 183.5 56 68 157.5 34 141.5 Yes Yes Yes Yes Yes Yes Yes

Type Bulk loading spout no-3 Repairing work. Repair Bulk loading spout no-3 Fixing work. Repair Roto Packing and auto packer Schedule maintenance works and packer Bucket elevator PM Bulk loading spout no-2 inspection and bulk loading bin-1 aeration flexible hoses PM House keeping PM WORKSHOP & WATER WORKS Clinker breaker pin tapping work Gypsum schuttle conveyor coupling bolts maching work cooler track wheel rough maching Lathe machines maintenance works Cooler spare track wheel welding work Miscellaneous mahining works STP,staff colony plumbing works& plant drip line repair works PROJECT & DEVELOPMENT WORKS Paper Bags Go down opening Covering clading fabrication and erection work. SRC clinker tank approaching stair case fabrication & erection SRC Clinker tank Civil structure side cladding work. SRC Hopper De-dusting Bag filter fan erection SRC Hopper De-dusting Bag filter Ducting fabrication work. SRC Clinker tank De-dusting Bag filter Supporting structure fabrication and erection work.

Job

Unplanned(%)

1 2 3 4 5 6 7

21 x 100 178 = 11.79

1 2 3 4 5 6

No No Yes Yes No

146 No 191.5

19 x 100 90 = 21.11