Maint. success story

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  1. 1. Maintenance Dep. Success Journey JEDDAH
  2. 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 GMPs 3- Improve safety level for major utilities equipment 4- Initiate maintenance activities & Team evaluation KPIs 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
  3. 3. 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 GMPs 3- Improve safety level for major utilities equipment 4- Initiate maintenance activities & Team evaluation KPIs 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
  4. 4. 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)
  5. 5. 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
  6. 6. 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
  7. 7. 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
  8. 8. JEDDAH BUN line PMP result 680 hr at 5 months tasksof its MajorSome 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
  9. 9. 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
  10. 10. JEDDAH Package a/c PMP1Unit 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
  11. 11. JEDDAH Package a/c PMP2Unit 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
  12. 12. 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 GMPs 3- Improve safety level for major utilities equipment 4- Initiate maintenance activities & Team evaluation KPIs 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
  13. 13. JEDDAH BEFORE AFTER Silos breather filter 1change unit Change filter for the 1 st time years ago18 2 - Improve machinery & infra-structure GMPs
  14. 14. JEDDAH BEFORE AFTER 1,2UNIT Main water tank cleaning 2 - Improve machinery & infra-structure GMPs
  15. 15. JEDDAH BEFORE AFTER 2 - Improve machinery & infra-structure GMPs 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
  16. 16. JEDDAH BEFORE AFTER 2 - Improve machinery & infra-structure GMPs 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
  17. 17. JEDDAH system filterReclaim overhauling )( filter & pulsating valve 1 st time changing 18 years ago 2 - Improve machinery & infra-structure GMPs AFTER BEFORE TURKISTAN mixer calibration 4 years ago
  18. 18. Yum audit success by score 845 Yum audit2Unit success 2 - Improve machinery & infra-structure GMPs Sponge mixer filter overhauling )( filter & pulsating valve 1 st time changing 18 years ago JEDDAH
  19. 19. 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 GMPs 3- Improve safety level for major utilities equipment 4- Initiate maintenance activities & Team evaluation KPIs 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
  20. 20. JEDDAH steam boiler2UNIT Overhauling Apply the first overhauling for this boiler ( 8 years ago) Major tasks of carbonkg20Remove-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 AFTERBEFORE 3- Improve safety level for major utilities equipment
  21. 21. JEDDAH steam boiler1UNIT Overhauling Apply a complete overhauling for this boiler Major tasks of carbonkg8Remove-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
  22. 22. Waiting Management approval Factory Roof replacement project study 3- Improve safety level for our facility JEDDAH
  23. 23. badGlycol tanks room wiring wiring at a/c plateBad Form ON GOING JEDDAH 3- Improve safety level for our facility
  24. 24. 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 GMPs 3- Improve safety level for major utilities equipment 4- Initiate maintenance activities & Team evaluation KPIs 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
  25. 25. 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 Average 2014 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 KPIs UNIT 1
  26. 26. JEDDAH 2015Work order distribution per Technician name at March per technician per monthhrAverage working2015Vs.2014hr. actual workingMaintNo 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 KPIs UNIT 1
  27. 27. 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 %2Unit ? JEDDAH 2015Work order distribution per Month in2015Puff 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 KPIs UNIT 2
  28. 28. 2015Work order distribution per Technician name at March 2015Vs.2014hr. Actual workingMaintNo of per technician per monthhrAverage 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 KPIs UNIT 2
  29. 29. Head lines JEDDAH 1 - Launch PMP for all production lines ( Bun , Puff , Cup cake , Tortilla ) & utilities equipment ( a/c & steam boiler) 2 - Improve machine