ACI PREMIO PLASTICS

Presentation
Presentationon
onPerformance
Performancereport
reportof
of
Maintenance Department April”-2021
Maintenance Department April”-2021

1
 Overview of Maintenance Department, April21

Sl. Particulars unit Std. April-21 February-21 Growth with STD Growth in %
1 Total Manpower Nos 30 27 30 -10% -10%
2 HR Cost per KG Tk/Kg 0.5 1.24 0.77 148% 61%
3 Maintenance Cost per KG BDT 0.25 0.32 0.33 28% -3%
4 KPI Achievement % 95% 74% 72% -22% 3%
5 Machine Breakdown Hour 110 279 285.3 154% -2%
6 Preventive maint. IMM Nos 33 28 33 -15% -15%
7 Preventive maint. Auxiliary Nos 41 26 27 -37% -4%
8 KAIZEN Work Nos 8 5 5 -38% 0%
9 Compliance Audit Nos 2 1 1 -50% 0%
10 No. of Training taken Nos 5 3 4 -40% -25%
11 No. of Training given Nos 2 1 1 -50% 0%
12 No. of Meeting Nos 2 1 1 -50% 0%
13 Number of Accident Nos 0 2 (minor) 2 (minor) 200% 0%

2
 Manpower Overview of Maintenance Department
Maintenance manpower Manpower overview
Category/Position Manpower Category Manpower
Asstant Manager 0 Staff 17
Engineer 1 Contractual 1
Asst.Engineer 3
SIC 1
Casual 9
Trainee Engineer 0 Total 27
LIC 3
Sr. Mechanics 4
Mechanics 1 Total HR 27
Asst. Mechanics 5
Electrical Forman 1
Total Salary BDT 543,813.00
Sr Electrician 1 Total Incentive BDT 120,773.00
Electrician 2
Asst. Electrician 1 Total Reward/Bonus BDT 70,468.00
Sr. Welder 1
Chiller Foreman 1 Total HR Cost: BDT 735,081.00
Chiller Operator 1
Asst. Chiller Operator 1 Per KG HR Cost (TK/Kg) BDT 1.24
Total 27
3
 Improvement Areas
Hydraulic oil consumption reducing gradually.

Preventive Maintenance work done in proper way.

All Machine running by ensuring proper safety.

Per KG Maintenance cost reduce.

Nozzle Heater consumption reduce.

We have provide Sieving machine, water separator tray and chips dryer unit

We are providing Customized Rack to production floor to in continues manner .

4
 Total Maintenance cost April,2021
Overview
Row Labels Sum of Total Cost Total Maintenance Cost Overview
Development 177,400
Running Maintenance 162,328
Preventive Maintenance 31,780 Preventive
Maintenance; 31,780 ;
9%
Grand Total 371507.37
Development; 177,400
; 48%
APPL-DEV   Development
Running Maintenance;
Electrical Item DV BDT 98,237.00 162,328 ; 44% Running Maintenance
Mechanical Item DV BDT 79,163.00 Preventive Maintenance

OIL/ DEV BDT -

Import Spare Parts DV BDT -
Total: BDT 177,400.00

5
 Repair Maintenance cost April,2021
Overview
Maintenance Cost Report April -2021 Running and Preventive Maintenance Cost Overview,
Category Apr-21 % April,2021
Electrical Item BDT 35,435.60 19% stationery
Grease
Local
ImportRepair Preventive Maintenance
Spare Parts
[PERCENTAGE]
[PERCENTAGE]
[PERCENTAGE] 3% Electrical Item
Mechanical Item BDT 8,775.50 5%
Lubrication oil
1%
18%

Hydraulic oil BDT 109,510.00 57% 14%

Mechanical Item
Lubrication oil BDT 28,050.00 15% 4%
Grease BDT 3,660.00 2%
Local Repair BDT 550.00 0%
Import Spare Parts BDT 2,800.00 1%
stationery BDT 1,919.67 1%
Preventive Maintenance BDT 6,780.60 4%
Total: BDT 190,700.77 Hydraulic oil
55%

Total Raw material Consumption (Kg) 591,725

Total Maintenance Cost (TK) BDT 190,700.77 Electrical Item Mechanical Item Hydraulic oil Lubrication oil Grease
Per KG maintenance Cost (TK/Kg): 0.32 Local Repair Import Spare Parts stationery Preventive Maintenance

6
 Maintenance Dept. cost-Overview

Currective and Preventive maint. Cost overview

Amount in BDT

300,000

250,000

200,000

150,000

100,000

50,000

-
February March April

7
 Hydraulic oil cost April,2021
Overview
Row Labels Sum of Total Cost
D3-1200T 31,960
D2-750T 18,800 Hydraulic Oil consumption machine wise-April21
35000
C1-500T 8,225
B4-260T 8,225
30000
C3-400T 7,050
A2-400T 7,050 Conssumption Amount In BDT 25000
C9-250T 4,700
E1-658T 4,700 20000

D4-2200T 4,700
C8-120T 4,700 15000

B6-368T 3,525
D1-750T 2,350 10000

A6-400T 2,350
A4-160T 2,350 5000

B1-260T 2,350
Grand Total 113,035 0
8
D3-1200T D2-750T C1-500T B4-260T C3-400T A2-400T C9-250T E1-658T D4-2200T C8-120T B6-368T D1-750T A6-400T A4-160T B1-260T
 Hydraulic & Lubrication oil cost
April,2021 Overview
Row Labels Sum of Total Cost Hydraulic Oil Consumption overview

Oil leakage from core line 64,625

Drain from Mold 31,725 Oil drain from valve/nipple
4%
Leakage from Mold Cylinder
Oil leakage
Hydraulic from pump
pipe damage
3% 2%
5%

Leakage from Mold Cylinder 6,110 Oil leakage from core line
Drain from Mold
Oil drain from valve/nipple 4,700 Leakage from Mold Cylinder
Oil drain from valve/nipple
Hydraulic pipe damage 3,525 Drain from Mold
28%
Oil leakage from core line
57% Hydraulic pipe damage
Oil leakage from pump

Oil leakage from pump 2,350

Grand Total 113,035

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 Hydraulic oil cost Comparison

Hydraulic Oil Consumption Trendline

140,000

120,000 115,200 113,035

100,000
86,880

80,000

60,000

40,000

20,000

-
February March April

10
 Nozzle heater cost April,2021
Overview

Nozzle heater consumption overview

Row Labels Sum of Total Cost
Heater Damage 3,530.00
Material Leakage 2,230.00
Material Leakage
Grand Total 5,760.00 39% Heater Damage
Material Leakage
Heater Damage
61%

11
 Nozzle heater cost April,2021
Overview
Row Labels Sum of Total Cost
C8-120T 1,280 Nozzle heater consumption overview
C4-468T 840
C1-500T 660 C8-120T
C4-468T
B7-160T 605 A4-160T E1-658T
C1-500T
C9-250T 4% 4% C8-120T
A5-120T 460 B4-260T 4% 22% B7-160T
4%
D1-750t 400 D3-1200T A5-120T
4% D1-750t
A6-400T 325 A6-400T
A6-400T
6%
D3-1200T 250 D3-1200T
B4-260T 240 B4-260T
D1-750t C4-468T C9-250T
C9-250T 240 7% 15%
A4-160T
A4-160T 240 E1-658T
A5-120T
E1-658T 220 8%
C1-500T
B7-160T
Grand Total 5,760 11%
11%

12
 Nozzle Heater cost Comparison
Consumption Amount BDT

Nozzle Heater Consumption Trend line

February; 8,245
9,000
8,000
March; 6,630
7,000 April; 5,760
6,000
5,000
4,000
3,000
2,000
1,000
- February March April

13
 Preventive maintenance April,2021
Overview
35
Preventive Maintenance
30 Target vs. Achievement
25 April, 2021
20

15

10

0 IMM Chiller and Crane Tool Room M/C Mixture & Recycling M/C Printing Machine Fire Hydrant & AC

Target Achievement
14
 Preventive maintenance February to April
Comparison
35
Preventive Maintenance
30 Target vs. Achievement
25 April, 2021
20

15

10

0 IMM Chiller and Crane Tool Room M/C Mixture & Recycling M/C Printing Machine Fire Hydrant & AC

April March February

15
 Machine Downtime April,2021 Overview
Machine Name Downtime (HOUR)
C9-250T 69 IMM machine Down Time- April-21 (Top machines)
D5-450T 22 C5-250T A1-260T
B5-250T 3%
D1-750 18 D2-750T 4%
4%

D3-1200T 15 4% C9-250T
B6-368T 31%
D6-250T 15 4%
C1-500T 13 B4-260T
4%
C4-468T 11 C7-120T
4%
C7-120T 10
B4-260T 9
B6-368T 9 C4-468T
D2-750T 9 5%

B5-250T 8
C1-500T
C5-250T 8 6% D5-450T
10%
A1-260T 7 D6-250T
7% D1-750
D3-1200T
8%
7%

C9-250T D5-450T D1-750 D3-1200T D6-250T C1-500T C4-468T

C7-120T B4-260T B6-368T D2-750T B5-250T C5-250T A1-260T 16
 Maintenance room all materials are separation and house
keeping done

Previous Present
 Maintenance meeting and
Training of April,2021
Training on “Health, safety and
Environment management”

18
 KAIZEN work Overview, April,2021

Maintenance KAIZEN work of April, 2021.

Total 5 set KAIZEN works

Introduce Chips dryer unit by in-house technology

Captain bike wheel bearing press mold jig modified.

Automatic Sieving Machine Making

Captain bike body and wheel Disassemble Jig making.

Siemens PLC of Chillier 100TR repaired & modify.

19
 Introduce Chips dryer unit by in-house technology.

 Problems  Results of Problems  Solutions  Benefits from the Solution

  Sun light drying  Sieving Dray  Chips dryer machine making,
After cleaning the
material in water, sun system product is Machine Making. material dry system very fast.
light drying is very water mark problem.  Chips dryer machine making,
slow and cannot be our products good. Not water
dried well. mark come.
 Captain bike wheel bearing press mold jig modified

Problems Results of Problems Solutions Benefits from the Solution

 Previously It used to take 12 seconds, now it
 Bearing attaching  Now 4bearing attached  Captain bike wheel takes 8 seconds.
2times press in one by one pressure bearing press machine  previously per day capacity-3600pcs
wheel  Save time. Mold modified.  Now Per day capacity- 5400pcs
 Time & Manpower  Save Power.  Per day productivity increase-1800pcs
wastages.  Per pieces cost-2.25Tk , 1800 X 2.25= 4050tk
 Save manpower.
 Per Month Save : 4000x30=1;21,500Tk.
 Increase productivity  Continue process

Previous Condition: Present Condition:

 Process Improvement Drive: Automatic Sieving Machine Making.

 Problems  Results of Problems  Solutions  Benefits from the Solution

   The panel board of the machine

 Recyclable materials The panel board of the Automatic Sieving
will not be damaged by dust
contain dust. machine is ruined Machine Making.
with dust  Auto loader filter will not be
blocked and damaged
 Auto loader filter is  Inventory reduced.
blocked and damaged.
 Process Improvement Drive: Captain bike body and wheel
Disassemble Jig making.

 Problems  Results of Problems  Solutions  Benefits from the

  Solution
 Captain bike body Captain bike body and Now the Captain bike
and wheel wheel disassemble It body and wheel  It took less time to break
Disassemble by took more time Disassemble mold the Captain Bike body and
hand or floor . making. wheels.

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 Siemens PLC of Chillier 100TR repaired & modify

 Problems  Results of Problems  Solutions  Benefits from the Solution

  We have to depend on only
100TR Chiller can't
200TR chiller by this time.
run due to Chiller I/O
 malfunctioning.
malfunctioning. If anything happen in
200TR, then all plant will
 PLC is malfunctioning come to stop as 100TR
chiller stop.
 We have found chiller PLC  To get rid of this problem,
internal optocoupler Supplier charged around 80K
BDT and they want to replace
the PLC
 PLC 3 pieces optocoupler
has changed from unused  We have solved it internally
port and saving cost
 Electronics items Repaired List of April,2021
Electronics items List Repaired last month
Repair cost from out
Sl Motor Qty (pes) side (per unit) Total Cost Repair Cost Saving
1 UPS 3 1800 5400 1800 3600
2 Chiller PLC repair 1 8000 8000 200 7800
3 Re-M/C CPU unit repair 1 8000 8000 200 7800
4 LED light Chip 58 400 23200 8120 15080
5 Mold temperature Control Card 20 500 10000 2800 7200
6 Motor rewinding Works 4 3000 12000 4800 7200
7 Auto-loader Repair 3 5000 15000 4800 10200
8 Electric drill machine 1 500 500 120 380
9 Power supply Card 3 800 2400 420 1980
Total 94 84500 23260 61240
Electrical & Fire Safety Report-
April-21
 Safety & Compliance Report-April-21.

Problem Status Action Status

Power supply board was used by using carton tape. Now power supply is repaired.
Anyone can get electrical shock.
 Safety & Compliance Report-April-21.

Problem Status Action Status

MDB's lock was broken at MDB 4 MDB's lock is fitted properly

 Safety & Compliance Report-April-21.

Problem Status Action Status

There was no door lock in DB board .Ensuring door lock in DB board

 Safety & Compliance Report-April-21.

Problem Status Action Status

There was no safety latch of crane hook .

Ensuring a safety latch for crane hook
 Safety & Compliance Report-April-21.

Problem Status Action Status

Circuit breaker was not properly fixed and there was Now we fix breaker properly with safety cover.
no cover in front of breaker
Development planning and execution

Customize rack making for Support Bin Keeping

Making a jig fixture for dissemble of captain bike and My
Moto
Customize rack making for Captain bike top part.

Customize rack making for Captain bike bottom part.

Introducing vertical Chain Conveyor for Production area

 Future Planning of maintenance
Department.
Reduce Hydraulic Oil Consumption.

Reduce nozzle Heater Consumption.

Reduce Machine Downtime.

Power save by reduce air and water leakage.

Reduce product damage by making customized rack.

Automation work to make packaging work faster.

Increase repairing work to reduce maintenance cost.

Automatic SMS system of Chiller Plant.

Action plan of Reduce Hydraulic Oil
Consumption

Action plan: we have already taken some action

plan and we will done this work within April-21
which are given below.

1. To change the faulty hydraulic pipe.

2. To change the pipe nipple .
3. To Set more quick coupler.
4. To increase awareness of all production
operator.
Action plan to reduce nozzle heater
consumption

Action plan: we have already taken some

action plan and we will done this work within
22/04/2021 which are given below.

1. To make a nozzle heater guard as a

safety.
2. To increase awareness of all production
operator
Action plan Power save by reduce air and
water leakage.

Action plan: We have already taken some action

plan and We will done this work within April-21
which are given below.

1. To change the air nipple and water nipple.

2. To change the faulty air & water pipe.
3. To increase awareness of all production operator
Action Plan for Introducing Training to proper
utilization of manpower.

Action plan: We have already taken some action

plan and We will done this work within April-21
which are given below.

1. We are introducing training “EHS management”

for maintenance and others dept.
2. We will introduce training “wash plant
management” for maintenance and Recycle
plant.
3. We want to introduce training “IMM machine” for
maintenance and others
 The
Thanks
End

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