2. Safety
Safety data Jan '2023
Safety Training conducted / Peoples attended 9/74
TBT Conducted / Peoples attended 27/293
Hazard Identification / Hazard Closed 29
Near miss / Near miss closed 0
3. CBM- Condition base monitoring activities
• Total 284 equipment covered for
vibration analysis in Jan-23 month.
Vibration
• CM6 outlet blower Z6U01B1 balancing done.
Balancing
• Raw mill 2 elevator head shaft UT.
NDT
• Z2J01 Chain elongation - 0.5% ( Acceptable )
• Z1J01 Chain elongation-0.2% ( Acceptable )
• 514BE620 Chain elongation-0.2 % ( Acceptable )
• 526BE170 Chain elongation – 0.4%( Acceptable )
Elongation
• CHRP group conveyor belts hardness
measurement.
• Elevator - 526BE470 ( 81 Shore A ) , 526BE600 (
78 Shore A ) , 534BE220 ( 85 Shore A ) , 535BE
240 ( 81 Shore A ).
Belt hardness
• 117 equipment scanned. Abnormality found in
P3J01 and 463HY110M2.
Thermography
• Cement Mill 4 and 5 internal inspection and liner
wear measurement.
• CPP Boiler tube thickness measurement.
Wear
• Blower Z6U01B1 vibration reduced after
balancing.
• 333.FN.573 fan vibration reduced after coating
cleaned.
• 526.FN.717 vibration reduced after alignment
work.
CBM corrective
action
Vibration Analysis Summary
Section
Total no
equipment
Status
Satisfactory
Just
Satisfactory
Critical
Crusher 34 32 02 0
Raw mill 37 37 0 0
Kiln 79 70 09 0
Cement mill 106 93 13 0
Packing plant 28 25 03 0
Total 284 257 27 0
CPP Boiler tube thickness
measurement
Mines equipment vibration
measurement
4. Critical observation during WBI/Stop inspection
A3LO4 Belt joint open from
edge
333RF662 One coupling bolt
loose & coupling gap high
473BF150 suction line wear
out
Kiln – 3 shell temp. diff found
high at 47 m from outlet (150)
D1P30_Auto grease feeder
found empty.
U4J08G1_Take up pulley
bearing cover found missing
Z2M01_CM 2 inlet bearing oil
leakage.
526.RF516_Rotary air lock
coupling bolt found missing.
6. Kaizen
Before Kaizen (Photo / Sketch)
After Kaizen (Photo / Sketch)
Kaizen Activities: We have provided
½” Ball Valve in-place of drain plug
making ease in draining excess old
grease in coal VRM FK pump
Before Kaizen (Photo / Sketch)
After Kaizen (Photo / Sketch)
Kaizen Activities: Now we have provided a RCC
Floor with Level Increase up to 200mm from
ground level to place Empty & Scrap Oil Drum
in Order. This has been now a designated place
for storing oil/grease drum
Before Kaizen (Photo / Sketch)
After Kaizen (Photo / Sketch)
Kaizen Activities: We have provided civil
Amirah with wooden cover. Now we have
designated Amirah space for Lube Cans &
Fitting Spares in Proper Order. Now overall lube
room 5S is improved.
7. Work Order Monthly status -Jan’2023
Plant & Dept. Order Total Order Completed Order Open Cost (Lakh) Order Closer %
@plant level Total 1055 961 94 424.39 91%
1001-Nimbahera 988 900 88 408.06 91%
Civil 8 8 4.00 100%
Electrical 285 258 27 28.75 91%
Enviornment 1 1 0.92 0%
Instrument 168 159 9 8.24 95%
Mechanical 266 238 28 173.83 89%
Mechanical-PP 48 42 6 5.18 88%
Mines 68 58 10 58.93 85%
PM Cell 71 71 14.40 100%
Process 50 46 4 108.98 92%
Process-PP 5 3 2 1.83 60%
QC Lab 10 10 1.34 100%
Safety 1 1 0.05 0%
Security 7 7 1.62 100%
1003-WHR & CPP 42 39 3 6.73 93%
Electrical 14 14 0.38 100%
Instrument 14 14 0.00 100%
Mechanical 14 11 3 6.36 79%
1044-Maliyakhera 25 22 3 9.59 88%
Electrical 8 7 1 2.21 88%
Instrument 3 3 0.39 100%
Mechanical 14 12 2 6.99 86%
May be most of jobs has been already
completed, if so make a practice of
closing Notification/orders after
completion of work by usages of
Mworkorder Mobile App for real time
data to be recorded in system.
11. HRP Mills & Kiln3 Performance – Jan’23
109 111
64 53
259
158 161
247
653 664
703
633
518
630 644
741
6 6
11
12
2
4 4
3
0
2
4
6
8
10
12
14
0
100
200
300
400
500
600
700
800
Dec-22 Jan-23 Dec-22 Jan-23 Dec-22 Jan-23 Dec-22 Jan-23
CM-3 CM-3 CM-4/HRP CM-4/HRP RM3HRP RM3HRP KILN3ILC KILN3ILC
MTBF Running Hrs. Freq.
Major reason for low equipment running/MTBF:
Cement Mill-3: Inclined belt overload due to Gypsum flushing (2.40hrs) & Gypsum WF Jack bolt bend (2.40Hr)
CHRP: BE600 bucket elevator trip on BSS due to drum Crowning lower side (5:05Hrs), CM4 BH conveyor trip on overload by
discharge pipe jammed (3:55Hrs)
Kiln-3: Feeder bus fault tripping (freq-2 & 25Minutes), PH Cyclone spreader CN110 trip on Lubrication system interloack (Freq-1 &
15Minutes)
12. Good Initiatives
Good Initiatives:
1. 5’S program initiated @ TLM room & PM cell Office.
2. Safety WBI start for identification of unsafe condition & circulate to concerned.
3. WBI performed 100% through Mobile App. RDF form.
4. 3Nos. Kaizen done related to Lubrication activities
13. Way forward
Way forward:
1. @plant level Mobile app. usages & adoptability in improving trend & Weekly department
level adoption w.r.t User ID to be circulated.
2. Mworkorder Reward/ recognition to best Users will be given in month of Feb’23.
3. 100% calibration through RDF form
4. RCA through SAP recording for Nimbahera & Circulate process with all JKC units.
5. PM10-Opertunity order Spares, Duration & manpower make mandatory, report will be
generated CCRO on basis of breakdown duration.
6. HRP Online monitoring system vendor discussion ongoing.
7. Lubricant Oil analysis cloud base recording & for fast analysis report results to take prompt
action at plant level.-Mobil.
