Maintenance Department

Langkawi Plant
JUN 2017
 Summary :
 Maintenance Department
 Langkawi Plant –Maintenance Grouping Distribution
 Maintenance - Manpower Organization And Distribution.
 Maintenance- Work Flow Process
 Maintenance Policy
 Summary of Works Flow Process
 Plant codification System ( ACS)
 Langkawi Plant – Process Flow
 Plant function Location
 ACS is use for ……..
 Equipment Codification Structure – Legacy Lafarge Vs Lafargeholcim
 ADAP (Advance Downtime Analysis Program)
 ADAP Menu
 ADAP - Function and process
 ADAP - Sample of Failure Reports
 IP21- REAL TIME ONLINE PROCESS MONITORING
 IP21 – Online Process flow.
 Section in maintenance

Finish grinding &

Shipping
Pyro
(Burning)
Raw grinding

Quarry
 Maintenance Department

85

Maintenance Manager

Mohammad Kashif 1

Clerk

Rohayu Hashim 1

17 35 28 3

Methods Manager Mechanical Manager Electical Manager Manager - Projects

Mohd Amir Aizat Ibrahim Muhammad Zakaria Bakar Wan Osmezai

Notes:

Officer 1st Jun 2017

Unionized Teammates

FOR DETAIL MAINTENANCE ORGANIZATION

REFER ATTACHEMENT FILE.
INSPECTION

PLANNING

SCHEDULING
METHODS
EXECUTION

LAFARGE MAINTENANCE
STRUCTURE AND FUNCTIONS

MECHANICAL ELECTRICAL

MANAGEMENT
Maintenance Policy
Prevention is better than cure. Regular maintenance is
more reliable and cost effective than intermittent, curative
maintenance followed by periodic repair. Production and
Maintenance are inter-dependent.

We want to establish and sustain a

Condition Based Preventive Maintenance
System

Ensure that key processes are well mastered within the

organization:
 INSPECTION: Maintain in-depth knowledge of equipment condition.
 PLANNING: Every operation is well-prepared
 SCHEDULING: Efficient use of resources within time constraints
 EXECUTION: Performed safely by skilled resources
 MANAGEMENT: Results-driven, based upon delegation with clear goals
and objectives.

Develop our maintenance organization towards sustaining the

results.
 Sustaining equipment reliability target of 98%
 Operating at lowest possible maintenance cost
Maintenance Policy - Continue
Human Resources
 Maintenance personal is recognized as being one of the key lever for plant
performance
 Maintenance personal do their work according to Safety principles.
 Maintenance personal is motivated, skilled, experienced and cost-conscious.
 Maintenance is team work. Each individual is trained and upgraded to
evaluate risks and needs, be
 efficient in their work, adapt easily to production technologies and new
developments.

Practices
 A set of formalized Best Practices capitalizes on our maintenance policy. It is
our duty to use them,
 taking advantage of being part of a big group : there’s no need to reinvent the
wheel.
 Maintenance activity is monitored through relevant Key Performance
Indicators:
 98% of reliability and a Maintenance Cost Index <= 1 is our final goal.
 Effectiveness of each maintenance processes must be monitored with more
detailed.
Maintenance Policy - Continue

Tools
 ADAP is the Cement Division tool for calculating reliability, ensuring consistency of
methodology.

 Maximo Template – Have been terminated on April 2017

 MACSAP- SAP SYSTEM- Replacing the Maximo Template-is the Computerized

Maintenance Management System (CMMS). Once maintenance functions are
mastered, relevant maintenance data must be captured into MACSAP Template. This
tool encapsulates our processes and best practices, converting data into knowledge
in a suitable format for decision making.

 IP21- Monitor the plant operation condition – On line

 PLANT
CODIFICATION
SYSTEM
LANGKAWI PLANT PROCESS FLOW CHART
39A
331 361
211
292
291
332 362
212 31A
292 461
31B
33A
33B
221 294 39B
333 334
293 363 364
222 294
242

X1A X9A L22 462

L21
B53 X1A
L61 L62

L2A
L1A L1A

594 564 514

K11 K9A

59B
612
B52 593 563 513

51A
562 512
592

59A
51A

B51 611 5K1

 LEGACY KEDAH CEMENT CODIFICATION SYSTEM - MECHNICAL

LANGKAWI WORKS LOCATION & EQUIPMENT CODIFICATION MASTERLIST

# PLANT SHOP G4 G5 G6 G7 EQUIPMENT LOCATION DESCRIPTION Current LOCATION CODE CC

5 LGK 108 BC 01 Belt Conveyor 2210101 2210101 LGK-108-BC01 100

12 LGK 108 BC 01 MT 10 Motor, Drive, BC 2210101-01 LGK-108-BC01-MT10 100
LEGACY LAFARGE CODIFICATION SYSTEM LEGACY KEDAH
32 LGK 108 BC 03 Boom Belt / Limestone Stacker CEMENT
2210210-00 LGK-108-BC03 100
37 LGK 108 BC 03 DR 10 Drive Unit, Boom Belt CODIFICATION
2210210-00-01 LGK-108-BC03-DR10 100
57 LGK 114 HO 03 Limestone Hopper 1501 SYSTEM
LGK-114-HO03 11E
60 LGK 114 AF 05 Apron Conveyor (Feeder) 1502 LGK-114-AF05 11E
62 LGK 114 AF 05 QM 10 Apron Plates 1502-01 LGK-114-AF05-QM10 11E
75 LGK 114 AF 05 DR 10 Drive Unit 1, Apron Conveyor 1502-02-1 LGK-114-AF05-DR10 11E
80 LGK 114 AF 05 DR 20 Drive Unit 2, Apron Conveyor 1502-02-2 LGK-114-AF05-DR20 11E
87 LGK 114 CR 07 Hammer Crusher 1504 LGK-114-CR07 11E
114 LGK 114 DC 09 Dust Collector 1509 LGK-114-DC09 11E
118 LGK 114 DC 09 FA 10 Fan, DC 1510 LGK-114-DC09-FA10 11E
142 LGK 114 CM 11 Baby Compressor 1512 LGK-114-CM11 11E
147 LGK 114 CN 13 Overhead Crane 1511 LGK-114-CN13 11E
171 LGK 115 BC 01 Impact Belt Conveyor 1505 LGK-115-BC01 11E
182 LGK 115 BC 05 Belt Conveyor 1506 LGK-115-BC05 11E
188 LGK 115 BC 05 DR 10 Drive Unit 1, BC 1506-01 LGK-115-BC05-DR10 11E
192 LGK 115 BC 05 BK 10 Brake Unit, Drive Unit 1, BC 1506-01-2 LGK-115-BC05-BK10 11E
196 LGK 115 BC 05 DR 20 Drive Unit 2, BC 1506-02 LGK-115-BC05-DR20 11E
200 LGK 115 BC 05 BK 20 Brake Unit, Drive Unit 2, BC 1506-02-2 LGK-115-BC05-BK20 11E
212 LGK 124 HO 03 Limestone Feed Hopper 2150101 LGK-124-HO03 12E
221 LGK 124 AF 05 Apron Conveyor, Feeder RKF 2800 Type 2150201 LGK-124-AF05 12E
226 LGK 124 AF 05 LU 10 Lubrication unit for Sliding Rail, Apron Con. 2150205 LGK-124-AF05-LU10 12E
243 LGK 124 AF 05 HU 10 Hydraulic Unit for Hyd. Motor, Drive Unit 2150504 LGK-124-AF05-HU10 12E
 LK1- LEGACY KEDAH CEMENT CODIFICATION - ELECTRICAL

RATED NO.
ELECTRICAL Rated FRAME MOTOR
MACHINE TYPE OF MOTOR SPEED V F CURRENT OF
IDENT NO. kW SIZE MOUNTING
(AMP) POLE

1505AM01 Belt Conveyor SCIM 11 1450 415 50 21 4 160M FTM

1506AM01 Belt Conveyor SCIM 132 985 415 50 238 6 315M FTM
1506AM02 Belt Conveyor SCIM 132 985 415 50 238 6 315M FTM
1506AM03 Brake SCIM 0.25 415 50 0.24 4 FLM
1506AM04 Brake DM 0.25 415 50 0.24 4 FLM
1509GM01 Screw Conveyor DM 1.5 1420 415 50 3.3 4 90L FLM
1509GM02 Rotary Valve DM 0.4 1410 415 50 1.1 4 FLM
1510AM01 Exhaust Fan SCIM 37 1465 415 50 65.5 4 225S FTM

LK2- LEGACY KEDAH CEMENT CODIFICATION - ELECTRICAL

RATED NO. MOTOR

ELECTRICAL IDENT Rated IEC FRAME
MACHINE SPEED V F CURRENT OF MOUNTIN
NO. kW SIZE
(AMP) POLE G

21502/M01 HYD. OIL PUMP 90 1480 415 50 142 4 280M FTM

21502/M02 OIL COOLER FAN 0.55 1400 415 50 1.3 4 PLM
21503/M01 SCRAPER 5.5 4 415 50 10.6 GRM
21505/M01 HYD. OIL PUMP 15 1455 415 50 24.4 4 160L FLM
21505/M02 COOLER FAN 0.18 2740 415 50 0.52 2 FLM
21506/M01 SCRAPER 3 4 415 50 6.4 GRM
21507/M01 CRUSHER 2000 993 6600 50 230 6 FTM
21507/M02 STARTER 0.4 415 50 0.93 FTM
21507/M03 SEPARATE FAN 2.55 925 415 50 6.1 6 FLM
21507/M04 SEPARATE FAN 0.2 240 50 0.38 FLM
 Functional location codification use ACS rules

• Functional Location Funct.

codification: Funct. Loc.
Loc.
Code
• 4 digits for cement plants Lev
using the Plant ACS code LGKX 1

LGKX.4 2
1. LGKX = Plant code
2. 461 = Group code consisting
of 3 digits, LGKX.46 3
• Lev2-(Cost Center - Shop),
• Lev3-(sub-process) and
• Lev4- ( Process Line) LGKX.461 4
4. KL01 = Asset, consisting of
Asset Unit code (KL= Kiln) and
sequential numbering (01) by MDFX.461-KL01 5 (Equip lev)
numbers 01…99 in general.
LGKX. 361.BM01
 ADAP SYSTEM
(ADVANCE DOWN TIME ANALYSIS PROGRAM)
SAMPLE OF MACHINE FAILURE REPORTS
 IP 21- ONLINE REAL TIME PROCESS MONITORING
REAL TIME - ONLINE PROCESS MONITORING
System Explore.

 ADAP System – Login and basic

introduction.- 10 min

 SAP System - Login and basic

introduction.- 10 min (Detail training
will conduct by SAP Champion)

 IP21 - Login and basic introduction.- 10

min
Questions And Answer
Thank You