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

FIRST WEEK OF 2014 MECHANICAL DEPT. Labour Utilisation Sl.No DESCRIPTION Available Labour Hours 120.0 136.0 233.0 160.0 64.0 Efficiency Productivity Plan Attainment Estmiated Hours of Estimated completed time of all jobs(excluding jobs unplanned) 114.0 127.0 213.0 114.0 127.0 213.0 PMR Preventive Available Maintenanc Labour e Routine Hours Hours 60.0 112.0 177.0 120.0 136.0 233.0 Un Planned Actual hours Estimated on completed hours on all unplanned completed work orders work orders 0.0 0.0 0.0 114.0 127.0 213.0

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

120.0 136.0 233.0 160.0 64.0 713.0

100.00 100.00 100.00 100.00 100.00

114.0 127.0 213.0 137.0 59.0

120.0 136.0 233.0 152.0 64.0

95.0 93.4 91.4 90.1 92.2

95.0 93.4 91.4 90.1 92.2

100.0 100.0 100.0

50.0 82.4 76.0

0.0 0.0 0.0

59.0

59.0

100.0

55.0

64.0

85.9

0.0

59.0

0.0

PIONEER CEMENT INDUSTRIES LLC, RAK, UAE MECHANICAL DEPT KEY PERFORMANCE INDICATORS - KPI FIRST 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 24.0 32.0 0.0 32.0 32.0 32.0 24.0 32.0 32.0 32.0 24.0 32.0 33.0 32.0 24.0 32.0 0.0 32.0 32.0 40.0 Actual Labour Hours(Work Orders) 24.0 32.0 0.0 32.0 32.0 32.0 24.0 32.0 32.0 32.0 24.0 32.0 33.0 32.0 24.0 32.0 0.0 32.0 32.0 40.0

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 FIRST WEEK OF 2014

Efficiency (%) = Estimated Time of completed Jobs / Actual Time of Completed Jobs
Sl No. 1 2 3 4 5 6 7 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 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 Job Completed Yes Yes Yes Yes Yes Yes Yes

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

120.0

21.0 30.0 10.0 10.0 4.0 5.0 4.0 4.0 4.0 17.0 4.0 4.0 6.0 4.0 127.0
17 26 30 4 26 26 6 8 9 8

Yes 24.0 Yes toCooler Drive spar 3)Sprocket fixing 32.0 Yes 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 Yes Yes Yes Yes Yes Yes Yes Yes

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
CM-1 vent bag house inspection work CM-1 grease spray compressor line modification work CM-1&2 1st chamber missing rubber plugs 25 nos replaced and CM-1 shell liner 2nos nuts replaced Packing plant Stationary packer weekly maintenance. Auto &Roto packer weekly maintenance.

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

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

3 Roto packer Bottom bearing grease replaced 4 Silo-1 & Silo2 and bulk loading roots blower bearings grease replaced and oil replaced 5 Packing plant genaral check list work 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

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

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

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

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

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

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

Efficiency

95.00

93.38

91.42

90.13

PIONEER CEMENT INDUSTRIES LLC, RAK, UAE MECHANICAL DEPT.KEY PERFORMANCE INDICATORS - KPI FIRST 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 FIRST 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 EEK 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 FIRST 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 Yes 3)Sprocket fixing toCooler Drive spare Yes

Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes

82.35

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 FIRST 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 Yes 3)Sprocket fixing toCooler Drive spare Yes

Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes

0.00

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