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

SECOND WEEK OF 2014 MECHANICAL DEPT. Labour Utilisation Sl.No DESCRIPTION Available Labour Hours 200.0 152.0 285.0 Efficiency Productivity Plan Attainment Estmiated Hours of Estimated completed time of all jobs(excluding jobs unplanned) PMR Preventive Available Maintenanc Labour e Routine Hours Hours Un Planned Actual hours Estimated on completed hours on all unplanned completed work orders work orders

Actual Hours

Estimated Hours

Actual Hours

Lab.Utilisation X Effi. 100

1 2 3 4 5

RAW MILLS & STACKER RECLAIMER SECTION PYRO & COAL MILL, HANDLING SECTION CEMENT MILLS & PACKING PLANT SECTION WORKSHOP & WATER WORKS AUTO GARAGE

200.0 152.0 285.0

100.00 100.00 100.00 100.00 100.00

637.0

PIONEER CEMENT INDUSTRIES LLC, RAK, UAE MECHANICAL DEPT KEY PERFORMANCE INDICATORS - KPI SECOND WEEK OF 2014

Labour Utilization(%)
Sl. No 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 Names

Actual Labour Hours on work orders/Available Labour Hours X 100 Available Labour hours 40.0 40.0 0.0 40.0 32.0 32.0 40.0 32.0 32.0 40.0 40.0 0.0 32.0 32.0 Actual Labour Hours(Work Orders)

Labour Utilization(%)

Sandeep singh Firoz Khan Hanumath Reddy Jalaluddin

Abu Backer

Jose Moinuddin Bukya Seenu

Johnson

Dhanesh Gupta
Anil

Salim
Mahendra Naresh rawat Paswan

100.00

Ramesh
Suru Kumar

Murthy Kesar Dev Rajesh Yadav

PIONEER CEMENT INDUSTRIES LLC, RAK, UAE MECHANICAL DEPT. KEY PERFORMANCE INDICATORS - KPI SECOND WEEK OF 2014

Efficiency (%) = Estimated Time of completed Jobs / Actual Time of Completed Jobs
Sl No. 1 2 3 4 5 6 7 8 9 10 11 12 13 Job RAW MILLS & STACKER RECLAIMER SECTION BC-14 head,tail & counter weight pulleys bearings inspection & greasing BC-14 gearbox output coupling inspection & greasing RM-2 girth gear grease spray strainers cleanin,spray pattern checking RM-2 both pinions cleaning and inspection(3nos teeth in each pinion) RM-2 area gearboxes oil top up New gears mounting on reconditioned stacker drive bogie wheels Bearing mounting on reconditioned stacker drive bogie wheel Stacker drive boghie wheels set assembling work RM-1 Lifting side pinion bearings inspection & greasing RM-1 both maingearbox input couplings inspection & greasing RM-1 high grade & low grade weigh feeders calibration work RM-2 O-sepa O/L cyclone,Transition piece wornout area patch work Rawmill area checklist & general maintenance works PYRO & COAL MILL SECTION New pipe line fabrication work for replacing the water line of Kiln III & II Tyre supporting roller Bearings. Coal drop test arrangement work at Coal Mill inlet. General Maintenance:1. Kiln all Tyres lubricated 2. Cooler Drives Chain lubricated 3. DDPC-1 Chain ,Roolers Inspected & En-mass conveyors chain condition inspected & missed chain pins circlips refixed. 4. Compressors Suction Filters cleaning 5.Silo Bottom & PreHeater Top Blowers filter cleaned 6.BC-16 Belt joint opened area belt clamps fixed and one impact idlers replaced 7.Pyosection Check List 8. K.C. & P.C. Roots Blowers Suction Filters cleaned 9.DDPC-1 Damaged pan roller Replaced by reconditioned one 10.Kiln supporting roller shaft seals & Dynamic seperator Bearings Lubricated. 11.Kiln Hydraulic thruster Cylinder bushes greased CEMENT MILLS & PACKING PLANT SECTION 1 2 3 Type PM PM PM PM PM Repair Repair Repair PM PM PM Repair PM Estimated Hours 15.0 8.0 6.0 1.0 1.0 18.0 12.0 24.0 32.0 16.0 14.0 23.0 20.0 Actual Hours 16.0 8.0 6.0 1.0 1.0 20.0 12.0 28.0 32.0 16.0 16.0 24.0 20.0 Job Completed Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes

190.0
1 2 PM PM

200.0 60.0 12.0

Yes Yes

54.0 11.0

PM PM Repair PM PM Repair PM PM Repair PM PM

5.0 5.0 5.0 4.0 4.0 4.0 38.0 4.0 4.0 6.0 1.0 145.0
15 32 100

5.0 5.0 5.0 4.0 4.0 4.0 38.0 4.0 4.0 6.0 1.0 152.0
15 36 108

Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes

Cement mills section check list. CM-1 O-sepa Fan bearings and couplings and vent fan coupling grease replacing work CM-1&2 Main drive gear boxes and HLPC cooling water out let line replacing work Packing plant

PM PM PM

yes yes yes

1 2 3 4 5 6

PM Stationary packer weekly maintenance. 8 PM 16 Auto &Roto packer weekly maintenance. Repair Roto packer spare bag saddles repair work 8 PM Weigh bridge-1&2 and bulk loading weigh bridges maintenance 24 PMadjusting work Silo-1 Bulk loading elevator head drum liner inside srips fixing work and belt centrening and tail drum counter 60 . PM Packing plant genaral check list work 10

8 16 8 24 60 10

yes yes yes yes

273.0 WORKSHOP & WATER WORKS

1 2 3 4 5 Clinker breaker hammer pins washers cutting 6 7 8 9 10 11 12

285.0

Planned

16.0

8.0

No

PIONEER CEMENT INDUSTRIES LLC, RAK, UAE ANICAL DEPT. KEY PERFORMANCE INDICATORS - KPI SECOND WEEK OF 2014

Efficiency

95.00

95.39

95.79

90.13

PIONEER CEMENT INDUSTRIES LLC, RAK, UAE MECHANICAL DEPT.KEY PERFORMANCE INDICATORS - KPI SECOND WEEK OF 2014

Productivity
Productivity(%) = Sl.No 1 2 3 4 5 Section RAW MILLS & STACKER RECLAIMER SECTION PYRO & COAL MILL, HANDLING SECTION CEMENT MILLS & PACKING PLANT SECTION WORKSHOP & WATER WORKS AUTO GARAGE Labour Utilisation X Efficiency 100 Labour Utilisation Efficiency 100.00 95.0 100.00 93.4 100.00 91.4 100.00 90.1 100.00 92.2

Productivity
95.0 93.4 91.4 90.1 92.2

PIONEER CEMENT INDUSTRIES LLC, RAK, UAE MECHANICAL DEPT.KEY PERFORMANCE INDICATORS - KPI SECOND WEEK OF 2014

Plan Attainment (%) = Estimated Time of completed Jobs excluding unplanned works / Estimated Time of all Jobs
Sl No. 1 2 3 4 5 6 7 Estimated Hours 10.0 19.0 32.0 10.0 21.0 6.0 16.0 Job Actual Complet Hours ed 12.0 20.0 32.0 10.0 24.0 6.0 16.0 Yes Yes Yes Yes Yes Yes Yes

Job
RAW MILLS & STACKER RECLAIMER SECTION Brdige Reclaimer CRD torque adjustment work RM-1&2 Outlet airslides standby air line modification work RM-1 pressing side pinion brgs inspection & greasing BC-13 discharge chute patch work RM-1 O-sepa cyclone patch work RM-1 O-sepa O/L duct worn out draft point replacement work Rawmill area checklist & general maintenance works

Type PM Repair PM Repair Repair Repair PM

114.0
1 2 3 4 5 PYRO & COAL MILL SECTION PM Blending Silo Extraction Gate-3 Dosing valve replacement Work 21.0 PM 1)Pre-Calicner Bricks Retainer cutting work . 2)Clinker Breaker Hammers Fixing Spare Pins Tapping work. 30.0 Repair Blending Silo Extraction Gate Spare dosing valve reconditioning work 10.0 Repair TAD Top Expansion joint area Red spot castable box fixing 10.0 General Maintenance:PM 1. Kiln all Tyres lubricated 4.0 PM 2. Cooler Drives Chain lubricated 5.0 3. DDPC-1 Chain ,Roolers Inspected & En-mass conveyors chain condition inspected & missed chain PM pins circlips refixed. 4.0 PM 4. Compressors Suction Filters cleaning 4.0 PM 5.Silo Bottom & PreHeater Top Blowers filter cleaned 4.0 PM 6.Pyosection Check List 17.0 PM 7. K.C. & P.C. Roots Blowers Suction Filters cleaned 4.0 PM 8.DDPC-1 Damaged pan roller Replaced by reconditioned one 4.0 PM 9.Kiln supporting roller shaft seals & Dynamic seperator Bearings Lubricated. 6.0 PM 10.PC simplex bin aeration purpose sintered bronze silencers assemebled 4.0

120.0 24.0 32.0 12.0 12.0 4.0 5.0 4.0 4.0 4.0 17.0 4.0 4.0 6.0 4.0 136.0
17 28 32 4 28 40 6 8 9 8

Yes Yes 3)Sprocket fixing toCooler Dri Yes

Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes

127.0
CEMENT MILLS & PACKING PLANT SECTION 1 2 3 4 5 6 7 8 1 2 PM PM PM PM PM Repair CM-1 vent bag house inspection work PM CM-1 grease spray compressor line modification work Repair CM-1&2 1st chamber missing rubber plugs 25 nos replaced and CM-1 shell liner 2nos nuts replaced Packing plant PM Stationary packer weekly maintenance. PM Auto &Roto packer weekly maintenance. Repair Roto packer Bottom bearing grease replaced PM Silo-1 & Silo2 and bulk loading roots blower bearings grease replaced and oil PM Packing plant genaral check list work

Cement mills section check list. CM-2 o-sepa drive and vent fan bearings grease replacing work CM-2 gypsum weigh feeder belt replacing work CM-2 grease spray strainers cleaning work CM-1 o-sepa drive and vent fan bearings grease replacing work

17 26 30 4 26 26 6 8 9 8

yes yes yes yes yes yes yes yes yes yes yes yes

3 4 5

8.0 32.0 13.0 213.0 8.0 21.0 7.0 8.0 16.0 14.0 14.0 4.0 15.0 10.0 14.0 22.0 137.0 38.0 4.0 4.0 5.0 8.0 59.0

8.0 32.0 13.0 233.0 8.0 24.0 8.0 8.0 8.0 16.0 16.0 4.0 16.0 12.0 16.0 24.0 152.0 43.0 4.0 4.0 5.0 8.0 64.0

1 2 3 4 5 6 7 8 9 10 11 12

WORKSHOP & WATER WORKS Hydax 38 coupling m/c for utility pump no -1 Stacker bogie wheel m/c(6th ) m/c Packing plant stationery packer impeller hub m/c Hydax 38 coupling m/c for utility pump no -3 Clinker breaker hammer pins washers cutting QC lab overhead water tank cleaned CCR overhead tank cleaned STP chemical shifted to STP Plumbing works at SB 4 & 5 Workshop overhead water tank cleaned Workers wash room overhead water tank cleaned Utility pump no -1 coupling replaced and alligned AUTO GARAGE

Planned Planned Planned Planned Planned Planned Planned Planned Planned Planned Planned Planned

Yes Yes Yes Yes No Yes Yes Yes Yes Yes Yes Yes

1 2 3 4 5

Autogarage general maintenance 21476 Man truck intercooler hose replaced Nissan sunny inspected and reported Cat telehandler alternator repaired Store inventory auditing has been done

PM Repair PM Repair PM

Yes Yes Yes Yes Yes

DUSTRIES LLC, RAK, UAE RFORMANCE INDICATORS - KPI WEEK OF 2014

Plan Attainment

100.00

100.00

114 127 213 59

114 127 213 59

100 100 100 100

100.00

100.00

PIONEER CEMENT INDUSTRIES LLC, RAK, UAE MECHANICAL DEPT.KEY PERFORMANCE INDICATORS - KPI SECOND WEEK OF 2014 PMR Preventive Maint. Routine Hrs PMR = Available Labour Hours Sl No. 1 2 3 4 5 6 7 Estimated Hours 10.0 19.0 32.0 10.0 21.0 6.0 16.0 Actual Hours 12.0 20.0 32.0 10.0 24.0 6.0 16.0

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

Job RAW MILLS & STACKER RECLAIMER SECTION Brdige Reclaimer CRD torque adjustment work RM-1&2 Outlet airslides standby air line modification work RM-1 pressing side pinion brgs inspection & greasing BC-13 discharge chute patch work RM-1 O-sepa cyclone patch work RM-1 O-sepa O/L duct worn out draft point replacement work Rawmill area checklist & general maintenance works

Type PM Repair PM Repair Repair Repair PM

P.M.R(%)

50.00

114.0
1 2 3 4 5 PYRO & COAL MILL SECTION PM Blending Silo Extraction Gate-3 Dosing valve replacement Work 21.0 PM 1)Pre-Calicner Bricks Retainer cutting work . 2)Clinker Breaker Hammers Fixing Spare Pins Tapping work. 30.0 Repair Blending Silo Extraction Gate Spare dosing valve reconditioning work 10.0 Repair TAD Top Expansion joint area Red spot castable box fixing 10.0 General Maintenance:PM 1. Kiln all Tyres lubricated 4.0 PM 2. Cooler Drives Chain lubricated 5.0 3. DDPC-1 Chain ,Roolers Inspected & En-mass conveyors chain condition inspected & missed chain PM pins circlips refixed. 4.0 PM 4. Compressors Suction Filters cleaning 4.0 PM 5.Silo Bottom & PreHeater Top Blowers filter cleaned 4.0 PM 6.Pyosection Check List 17.0 PM 7. K.C. & P.C. Roots Blowers Suction Filters cleaned 4.0 PM 8.DDPC-1 Damaged pan roller Replaced by reconditioned one 4.0 PM 9.Kiln supporting roller shaft seals & Dynamic seperator Bearings Lubricated. 6.0 PM 10.PC simplex bin aeration purpose sintered bronze silencers assemebled 4.0

120.0 24.0 32.0 12.0 12.0 4.0 5.0 4.0 4.0 4.0 17.0 4.0 4.0 6.0 4.0 136.0
17 28 32 4 28 40 6 8 9 8

Yes 82.35 Yes 3)Sprocket fixing toCooler Drive spare Yes

Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes

127.0
CEMENT MILLS & PACKING PLANT SECTION 1 2 3 4 5 6 7 8 1 2 PM PM PM PM PM Repair CM-1 vent bag house inspection work PM CM-1 grease spray compressor line modification work Repair CM-1&2 1st chamber missing rubber plugs 25 nos replaced and CM-1 shell liner 2nos nuts replaced Packing plant PM Stationary packer weekly maintenance. PM Auto &Roto packer weekly maintenance. Repair Roto packer Bottom bearing grease replaced PM Silo-1 & Silo2 and bulk loading roots blower bearings grease replaced and oil PM Packing plant genaral check list work

Cement mills section check list. CM-2 o-sepa drive and vent fan bearings grease replacing work CM-2 gypsum weigh feeder belt replacing work CM-2 grease spray strainers cleaning work CM-1 o-sepa drive and vent fan bearings grease replacing work

17 26 30 4 26 26 6 8 9 8

yes yes yes yes yes yes yes yes yes yes yes yes

75.97

3 4 5

8.0 32.0 13.0 213.0 8.0 21.0 7.0 8.0 16.0 14.0 14.0 4.0 15.0 10.0 14.0 22.0 137.0 38.0 4.0 4.0 5.0 8.0 59.0

8.0 32.0 13.0 233.0 8.0 24.0 8.0 8.0 8.0 16.0 16.0 4.0 16.0 12.0 16.0 24.0 152.0 43.0 4.0 4.0 5.0 8.0 64.0

1 2 3 4 5 6 7 8 9 10 11 12

WORKSHOP & WATER WORKS Hydax 38 coupling m/c for utility pump no -1 Stacker bogie wheel m/c(6th ) m/c Packing plant stationery packer impeller hub m/c Hydax 38 coupling m/c for utility pump no -3 Clinker breaker hammer pins washers cutting QC lab overhead water tank cleaned CCR overhead tank cleaned STP chemical shifted to STP Plumbing works at SB 4 & 5 Workshop overhead water tank cleaned Workers wash room overhead water tank cleaned Utility pump no -1 coupling replaced and alligned AUTO GARAGE

Planned Planned Planned Planned Planned Planned Planned Planned Planned Planned Planned Planned

Yes Yes Yes Yes No Yes Yes Yes Yes Yes Yes Yes

1 2 3 4 5

Autogarage general maintenance 21476 Man truck intercooler hose replaced Nissan sunny inspected and reported Cat telehandler alternator repaired Store inventory auditing has been done

PM Repair PM Repair PM

Yes Yes Yes Yes Yes

85.94

60 112 177 55

120.0 136.0 233.0 64.0

50 82.35294 75.96567 85.9375

PIONEER CEMENT INDUSTRIES LLC, RAK, UAE MECHANICAL DEPT.KEY PERFORMANCE INDICATORS - KPI SECOND WEEK OF 2014 UNPLANNED Unplanned % = Sl No. 1 2 3 4 5 6 7
Actual hours on completed unplanned work orders

X 100

Estimated hours on all completed work orders

Job RAW MILLS & STACKER RECLAIMER SECTION Brdige Reclaimer CRD torque adjustment work RM-1&2 Outlet airslides standby air line modification work RM-1 pressing side pinion brgs inspection & greasing BC-13 discharge chute patch work RM-1 O-sepa cyclone patch work RM-1 O-sepa O/L duct worn out draft point replacement work Rawmill area checklist & general maintenance works

Type PM Repair PM Repair Repair Repair PM

Estimated Actual Hours Hours 10.0 19.0 32.0 10.0 21.0 6.0 16.0 12.0 20.0 32.0 10.0 24.0 6.0 16.0

Job Completed Yes Yes Yes Yes Yes Yes Yes

Unplanned(%)

0.00

114.0
1 2 3 4 5 PYRO & COAL MILL SECTION PM Blending Silo Extraction Gate-3 Dosing valve replacement Work 21.0 PM 1)Pre-Calicner Bricks Retainer cutting work . 2)Clinker Breaker Hammers Fixing Spare Pins Tapping work. 30.0 Repair Blending Silo Extraction Gate Spare dosing valve reconditioning work 10.0 Repair TAD Top Expansion joint area Red spot castable box fixing 10.0 General Maintenance:PM 1. Kiln all Tyres lubricated 4.0 PM 2. Cooler Drives Chain lubricated 5.0 PM pins circlips4.0 3. DDPC-1 Chain ,Roolers Inspected & En-mass conveyors chain condition inspected & missed chain refixed. PM 4. Compressors Suction Filters cleaning 4.0 PM 5.Silo Bottom & PreHeater Top Blowers filter cleaned 4.0 PM 6.Pyosection Check List 17.0 PM 7. K.C. & P.C. Roots Blowers Suction Filters cleaned 4.0 PM 8.DDPC-1 Damaged pan roller Replaced by reconditioned one 4.0 PM 9.Kiln supporting roller shaft seals & Dynamic seperator Bearings Lubricated. 6.0 PM 10.PC simplex bin aeration purpose sintered bronze silencers assemebled 4.0

120.0 24.0 32.0 12.0 12.0 4.0 5.0 4.0 4.0 4.0 17.0 4.0 4.0 6.0 4.0 136.0
17 28 32 4 28 40 6 8 9 8

Yes 0.00 Yes 3)Sprocket fixing toCooler Drive spare Yes

Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes

127.0
CEMENT MILLS & PACKING PLANT SECTION 1 2 3 4 5 6 7 8 1 2 PM PM PM PM PM Repair CM-1 vent bag house inspection work PM CM-1 grease spray compressor line modification work Repair CM-1&2 1st chamber missing rubber plugs 25 nos replaced and CM-1 shell liner 2nos nuts replaced Packing plant PM Stationary packer weekly maintenance. PM Auto &Roto packer weekly maintenance. Repair Roto packer Bottom bearing grease replaced PM Silo-1 & Silo2 and bulk loading roots blower bearings grease replaced and oil PM Packing plant genaral check list work

Cement mills section check list. CM-2 o-sepa drive and vent fan bearings grease replacing work CM-2 gypsum weigh feeder belt replacing work CM-2 grease spray strainers cleaning work CM-1 o-sepa drive and vent fan bearings grease replacing work

17 26 30 4 26 26 6 8 9 8

yes yes yes yes yes yes yes yes yes yes yes yes

0.00

3 4 5

8.0 32.0 13.0 213.0 8.0 21.0 7.0 8.0 16.0 14.0 14.0 4.0 15.0 10.0 14.0 22.0 137.0 38.0 4.0 4.0 5.0 8.0 59.0

8.0 32.0 13.0 233.0 8.0 24.0 8.0 8.0 8.0 16.0 16.0 4.0 16.0 12.0 16.0 24.0 152.0 43.0 4.0 4.0 5.0 8.0 64.0

1 2 3 4 5 6 7 8 9 10 11 12

WORKSHOP & WATER WORKS Hydax 38 coupling m/c for utility pump no -1 Stacker bogie wheel m/c(6th ) m/c Packing plant stationery packer impeller hub m/c Hydax 38 coupling m/c for utility pump no -3 Clinker breaker hammer pins washers cutting QC lab overhead water tank cleaned CCR overhead tank cleaned STP chemical shifted to STP Plumbing works at SB 4 & 5 Workshop overhead water tank cleaned Workers wash room overhead water tank cleaned Utility pump no -1 coupling replaced and alligned AUTO GARAGE

Planned Planned Planned Planned Planned Planned Planned Planned Planned Planned Planned Planned

Yes Yes Yes Yes No Yes Yes Yes Yes Yes Yes Yes

1 2 3 4 5

Autogarage general maintenance 21476 Man truck intercooler hose replaced Nissan sunny inspected and reported Cat telehandler alternator repaired Store inventory auditing has been done

PM Repair PM Repair PM

Yes Yes Yes Yes Yes

0.00

0 0 0 0

114 127 213 59

0 0 0 0