LEC – Lafarge Emirates Cement

Reliability Committees
 Reliability Committee

Definition

The Reliability Committee is a cross-functional group that studies,

reviews and follows up all incidents as identified by the Downtime
Incident Reporting System to propose and implement actions to
improve the area performance
Members
Mechanical

Inspection Process

Electrical Quality
Production
 Roles & Responsibilities

• Meet regularly Once monthly at least or more depending on the

1 number or type of incidents.

• Analyze the downtime and KPI’s.

2
• Trigger the RCA if incident hits the Trigger Criteria
3

• Review recommendations that are taken in RCA’s.

4

• Develop and follow up action plans to avoid chronic

failures/performance drop/ housekeeping issue/safety &
5 environment issues.

• Evaluate and assess RCA’s through reports presented.

6
 RC Champion Responsibilities

• Trigger the RCA based on the Criteria

1

• Prepare a monthly statistical analysis on the Area

2
• Prepare the agenda and the information to review in the
3 Reliability Committee and the Minutes of the Meeting.

• Upload a copy of all completed RCA’s in the Share folder

4

• Follow the Attendance/Involvement of RCA Team members

5

• Present the Area Monthly RC Analysis in the Steering

6 Committee meeting
 Steering Committee
OD Serefin Bugeja
Mnt MSamir Essabahi
CM & PK RC Team
Prd M Khaled Farrag
Mth M Rami Elsabbagh
Prs M Daniel AP

Qrry & RM RC Team Kiln & Coal RC Team CM & PK RC Team

GC Mahmoud Nasr GC Ehab Hamad GC Waqas Ali
PRCS Tarek Kamal PRCS Tarek Kamal PRCS Marcial Quimco
PRD Masoud Alhaq PRD Mahmoud Abolenin Mech Ahmed Hussein
INSP Eric posterado INSP Rodel sebastian INSP Mohamad Farooq
ELEC Arnel Lechoco Qlty Mohamed Samir ELEC Sherif Salah
Qrry Zakaria Mohamed Mech Gangadharan Qlty Umar Farooq
Auto Abdul Mansouri Auto Mohamed Balah H.K Abdelghafar
RC Meetings Agenda

• Safety : Highlight new issues that could be managed

1 as UC, UB, NM, ect..
• Analyze the downtime and KPI’s related to the
2 assigned shop.

3
• Identify through the trigger if RCA are needed
Reliability
4
• Review the actions taken in the related RCA’s.

• Develop an improvement plan and actions for the

5 equipment.

6
• Follow up the action log for every action.

7
• List up needed issues to be raised to SC.
LEC RCA Trigger Process
 RC ACTION PLAN Follow up sheet

Reliability Committee

ACTION PLAN Follow up

RC Gr. Equipment Origin of action Action In charge Issue date Due Date Status Comments
 RCA Trigger Criteria

Qry

RM

•All LT, SNM & FI

Kiln
Safety

Fuel

CM

PK
 RCA Trigger Criteria

Qry any Environmental Complains

•any Environmental Complains

RM •Visible Emissions for 1 hrs

•any Environmental Complains

Kiln •Dust Emissions >50mg for 15 Min
Environment

•any Environmental Complains

Fuel •Visible Emissions for 1 hrs

•any Environmental Complains

CM •Dust Emissions >50mg for 15 Min
•Visible Emissions for 24 hrs

•any Environmental Complains

PK •Dust Emissions >50mg for 15 Min
•Visible Emissions for 1 hrs
 RCA Trigger Criteria
•Mix storage Level =< 25 K ton
Qry •incident Duration=>6 hours

•Incident Duration =>4hours

•CF Silo Level < 40 %
RM •OPC =< 630 ton/hr for 24 hrs
•SRC =< 600 ton/hr for 24 hrs

•all kiln stops

Kiln •Feed < 500 ton/hr for 24 hrs
Performance

•Coal Mill =< 53 ton/hr for 24 hrs

Fuel •Sludge 5% below target/Week

•Incident Duration => 4hours

•Cement Silo Level 20 % avg
CM •OPC =<210 ton/hr for 24 hrs
•PLC =<230 ton/hr for 24 hrs
•Incident Duration => 4hours
PK •P =< 2100 bag/hr for 24 hrs
•Dispatch Complain
 RCA Trigger Criteria

Qry

RM

Kiln
Maintenance

•30,000 AED
Failure Cost

Fuel

CM

PK
 RCA Trigger Criteria
• NSFI = 8 NSFI/MTD
Qry •Incident recurrence => 3 NSFI/Month

• NSFI = 8 NSFI/MTD
RM •Incident recurrence => 2 Month

Kiln •>all kiln stops

Frequency of
Stoppage

•NSFI = 8 NSFI/MTD
Fuel • Incident recurrence => 3 NSFI/Month

•NSFI = 8 NSFI/MTD
CM • Incident recurrence => 3 NSFI/Month

•NSFI = 8 NSFI/MTD
PK •Incident repeated => 3 NSFI/Month
 RCA Trigger Criteria

Qry • 0.75 KW/T

RM • 22.5 KW/T

Kiln • 68.5 KW/T

Specific Pwr
Consumption

Fuel • 33.5 KW/T

CM1 • 39.15 Kw/T

CM2 • 38.9 KW/T

 RCA Trigger Criteria

Qry

RM

•All Valid Customer Complains

Valid Kiln
Customer
Complain
Fuel

CM

PK
 RC Decision
Qry

PK
CM
RM

Fuel
Kiln

•Incident that didn’t hit the trigger & Still Need Investigation
RCA Trigger Criteria
 APOLO RCA Management Trainee List

Trainee Designation Department

Sherif Salah Electrical Coordinator Maintenance
Ehab Hamad Electrical Coordinator Maintenance
Gangadharan Mechanical Coordinator Maintenance
Sharjeel Jillani CCR Operator Production
Srinivasulu Dasari CCR Operator Production
Mahesh Kumar Prd Shift Coordinator Production
Rodel Sebastian Mechanical Inspection Eng Maintenance
Waqas Ali Prd Cement Manager Production
Masudul mahabub Kiln Coach Production
Marcial Comico Sr Process Eng Optimization
 Reliability Committee 2014 Targets

Average # of days for action

MTBF NAI (%)
RC Group completion

Target Target Target

Raw Mill 10
Kiln Coal Mill 10
CMs & Packing 10
 Reliability & Steering Committee Meeting Calendar

1. RC Meeting to be held in the 1st week of the month

2. Steering Committee Meeting to be Held in the 2nd week of the month before the

Performance Meeting

JANUARY FEBRUARY MARCH APRIL

WK SUN MON TUE WED THU FRI SAT WK SUN MON TUE WED THU FRI SAT WK SUN MON TUE WED THU FRI SAT WK SUN MON TUE WED THU FRI SAT
1 1 2 3 4 5 5 1 2 9 1 2 14 1 2 3 4 5 6
2 6 7 8 9 10 11 12 6 3 4 5 6 7 8 9 10 3 4 5 6 7 8 9 15 7 8 9 10 11 12 13
11 10 11 12 13 14 15 16
3 13 14 15 16 17 18 19 7 10 11 12 13 14 15 16 16 14 15 16 17 18 19 20
12 17 18 19 20 21 22 23
4 20 21 22 23 24 25 26 8 17 18 19 20 21 22 23 17 21 22 23 24 25 26 27
13 24 25 26 27 28 29 30
5 27 28 29 30 31 9 24 25 26 27 28 18 28 29 30
14 31

MAY AUGUST
JUNE JULY
WK SUN MON TUE WED THU FRI SAT
WK SUN MON TUE WED THU FRI SAT WK SUN MON TUE WED THU FRI SAT WK SUN MON TUE WED THU FRI SAT
18 1 2 3 4
22 1 27 1 2 3 4 5 6 31 1 2 3
19 5 6 7 8 9 10 11
23 2 3 4 5 6 7 8 28 7 8 9 10 11 12 13 32 4 5 6 7 8 9 10
20 12 13 14 15 16 17 18 24 9 10 11 12 13 14 15
29 14 15 16 17 18 19 20 33 11 12 13 14 15 16 17
21 19 20 21 22 23 24 25 25 16 17 18 19 20 21 22
30 21 22 23 24 25 26 27 34 18 19 20 21 22 23 24
22 26 27 28 29 30 31 26 23 24 25 26 27 28 29
31 28 29 30 31 35 25 26 27 28 29 30 31
27 30

SEPTEMBER OCTOBER NOVEMBER DECEMBER

WK SUN MON TUE WED THU FRI SAT WK SUN MON TUE WED THU FRI SAT WK SUN MON TUE WED THU FRI SAT WK SUN MON TUE WED THU FRI SAT
36 1 2 3 4 5 6 7 44 1 2 48 1
40 1 2 3 4 5
37 8 9 10 11 12 13 14 49 1 2 3 4 5 6 7
41 6 7 8 9 10 11 12 45 3 4 5 6 7 8 9
38 15 16 17 18 19 20 21 50 8 9 10 11 12 13 14
42 13 14 15 16 17 18 19 46 10 11 12 13 14 15 16
39 22 23 24 25 26 27 28 51 16 16 17 18 19 20 21
40 29 30 43 20 21 22 23 24 25 26 47 17 18 19 20 21 22 23 52 23 23 24 25 26 27 28
44 27 28 29 30 31 48 24 25 26 27 28 29 30 53 29 30 31