Critical

Leakages PC50 60%

Covered PC32 45%
NPC 60%

Line Areas Criticality Oct Nov Dec Jan Feb Status

PC-50 SMBW and Peelers B           - 
Slicers B            -
Dip Wash and Fryer A            IP
PROCESS Blancher A            IP
PIPING Chutes B            IP
PC-32 SMBW and Peelers B            -
UPGRADATION Slicers B            -
Dip Wash and Fryer A            IP
Blancher A            IP
Chutes B            -
NPCs Mixing B          -
Seasoning B            -
Main fresh-water lines A           IP 
*Spool fabrication has started
Walter Visit Updates
Total Scope: Total Jobs= 227
Completed= 94 Closure %
Pending= 115 45%
*Pending points are in progress
PC32 Blancher Drum Catch Box - Drive Shaft Failure (DT: 85 min)
Initial Observations Failure Details Shafts Visual Checks (Controls) Verified
 Continuous variation in blancher circulation pump Checks Status
flow causing low delta
 No choking in lines – Debris not coming out of catch Looseness in key No – Fixed in keyway
box Sprocket internal dia. Worn out No – Tight Fitted
Sequence of Actions Play in gearbox – inducing vibration No –Tight Fitted
Choking verification by dismantling line
Bearing size wear No
Air curtain of blower checked and fixed
MCB covers opened – found drive shaft broken Maintenance History
MCB Looped out for keeping line in operation Description Details
Lifted PC50 MCB to install on PC32 Last Replacement Approx. Annual SD-20
Replacement of entire catch box (30-40mins) to solve Last Inspection (physically) Stock Count Oct-22
issue on running line & save time (otherwise 2.5 hr.) –
Spare shaft was not available ConMon. at BOs Keys, keyway, bearing size
health check
Installed MCB on running line
Connections done twice – direction verified Any abnormal Observation -
Line started
Gaps
 No criteria of shafts inspection other than visual
 No specific replacement frequency of shafts other than visual
Shaft thickness = 25.5 mm, 2 sprockets mounted with Shaft Details health check – bearing size wear
Cotter key with 3 guides
Material SS Action Plan & Way Forward
Local/Import Imported Actions Status
Explore shaft inspection & testing criteria P
Root Cause:
Shaft failed from drive side keyway – Stress Riser Device replacement frequency for all shafts P
Fatigue failure due to torsional effect on keyway Backup availability to be ensured with proper IP
tagging
PC50 Startup Delay - Blancher Drum Catch Box(DT: 150 min)
Sequence of Actions Details Way Forward
Team got free from PC32 blancher catch box At 3:30 AM
Sequence of Activities at peeler infeed Details
Removed shaft from catch box Till 4:00 AM
Job started 9:26 PM
Inspection of removed conveyor (Missed) -
Conveyor removing and cleaning (gearbox, drive 1 hr.
Spare not available – available shaft required keyways No facility to make keyways in shaft and driven roller removal)
(Shafts backup arrangement is already in process) house
Team moved to attend peeler infeed horizontal conveyor bed replacement Till 6:00 AM Conveyor bed (H-type strip) dismantled from 1.5 hrs.
– H-type strips stuck in structure structure and shifted to workshop
Shaft sent to Pakistan Engineering At 7:00 AM Strips replacement (3 sets) (Badly stuck - 3.5 hrs.
Meanwhile broken shaft repairing started in house – 12mm rod inserted 2 hrs. (shaft & chain link repair) hammering and cutting)
and then welded
Structure fixing back on location 1 hr.
Conveyor Inspected – found chain link damaged Repaired via spot welding
Drive shaft, driven roller and sprockets installed 1 hr.
New shaft took longer so decided to install repaired shaft - along with conveyor
Installation of catch box on line 45 mins
Dry run pending (handed over to next shift -
Meanwhile other team replaced peeler infeed conveyor – replaced on Excessive Looseness – last minute artisan)
time observation
Conveyor excessive loose – replaced -
Dip wash FOB circulation pump seal leakage observed on wet run Replaced meanwhile
Dry run of catch box– conveyor trip Breaker Issue Way Forward
Breaker reset and PLC fault rectification 150 mins
Actions Status
Spare catch box availability to be ensured Pending
Spares of all shafts to be ensured on priority Already IP

Root Cause: Shaft replacement in next BO Pending

 Unavailability of spare shaft Complete overhauling of all catch boxes with Pending
critical replacements on Dec SD
PC32 Fryer Paddle Drive Chain Open
Maintenance History
2- Lack of SOPs
Last chain replacement 15-Oct-22
Last Inspection 15-Oct-22
 Absence of proper dry run
Responsibility Bilal Ahmad
SOPs/protocols
Helper Waqas  Lack in shift handover and closure
Activity Performed General Inspection/Paddle of overrun job
orientation
Immediate Interventions Way Forward
Initial Findings  New chain fixed with lock
 Dry Run SOPs to be made
 Old chain removed from fryer
 Fryer oil overflow  Dry run sheets development and
 Feed removed and line started
 Fryer choked with feed implementation
 Paddle drive chain missing Root Cause  Counselling session with artisan
Actions Items Status
1- Poor Workmanship
Action Item Status

 Chain removed as per production Dry run SOP – artisans to close IP

dry run observations of their
demand area before startup
 Responsible artisan didn’t close
the job properly Artisan counselling Done
 No dry run inspection was Dry run sheet development Done
performed