Sawan Jasoliya

Important Note: This SOP applies to all maintenance jobs except Preventive Maintenance. For complete SOP:  Click here

Both production lines are currently at a standstill. The persistent issue with the planetary cooler in Line #1 remains unresolved. I personally inspected the cooler and kiln from the inside, and what I found wasn’t surprising but certainly concerning. The kiln brick lining is in poor condition—something that has been ignored for far too long. Instead of executing a comprehensive maintenance plan, the practice here has been to apply small patches wherever issues arise, a short-sighted approach that does nothing to ensure long-term reliability. The absence of strategic, long-term planning has left the plant in a reactive mode, addressing failures as they occur rather than preventing them. This mindset needs to change. Meanwhile, in Line #2 , cooler overhauling is ongoing, though at an alarmingly slow pace. The bottleneck? Bearing availability. It’s a familiar story—critical spares are always in short supply, leading to unnecessary delays. I am trying to push for better planning in the ...

Let’s be honest— we all want to grow. Some of us, however, don’t just want to grow… we want to grow FAST. And here’s the thing: These are two very different results. If you want different results, you need to act differently. Growth Doesn’t Happen Just Because You’re Getting Older We’re talking about career growth —promotion, elevation, increment, or even all of them together. But here’s the reality check: 📌 Someone (a person or a system) has to approve your growth. 📌 Just getting older won’t get you there. Time alone doesn’t qualify you. 📌 You must prove that you’re ready for the next level before you’re given that role. 📌 In fact, you need to start doing the things required for that position—before you even get it. Read that again. Everything here has a deeper meaning. So, How Do You Become Eligible for the Next Big Thing in Your Career? The first step is clarity —you must know what’s next for you. Ask yourself: ✅ What is my next target role ? ✅ What are the prerequisites for t...

Whenever we take on a maintenance job, the first thing we focus on is planning. In preventive maintenance, it’s done in advance. In breakdowns, it comes after. But planning is ALWAYS a must before starting the work. Planning revolves around Man, Material, and Method. We plan or arrange for Man and Material without fail because perhaps nothing will happen without them. The Method part, however, is often overlooked. We rush to finish the job, but as the saying goes: "If you give me 6 hours to chop a tree, I will spend 4 hours sharpening my axe." Methodical preparation is crucial—it directly impacts Safety, Quality, and Productivity (S-Q-P). Key Steps in Methodical Preparation. 1️⃣ Make the Work Area Ready – Prepare the work area before starting the actual job. Job Safety Analysis (JSA) is a MUST. 2️⃣ Track the Progress – Once the job starts, track it against the bar chart. Monitor quality and make course corrections in real time. 3️⃣ Document the Journey – Take photos and vid...

Here’s a super simple trick I’ve used that works like magic. Ready? “Just do this: Arrive at your office first. Always.” It’s that simple. No complicated routines, no fancy formulas. But the impact? Miraculous. How Does It Work? 💥 It sets the tone for your entire day. When you start early, you control your day instead of letting it control you. 💥 It builds discipline. You’ll find yourself more focused, more productive, and more organized. 💥 It earns respect. People notice those who are committed and consistent. Trust me, your colleagues, family, and community will admire your dedication. 💥 It boosts confidence. Being ahead gives you a sense of control and purpose that reflects in everything you do—both personally and professionally. Start It. See the Magic. Show up early. Do it consistently. Watch how your personality transforms, how new opportunities open up, and how your growth skyrockets. The best part? Anyone can do it. No special skills required. Simple things create big mirac...

For cement plants that do not have advanced coal dosing systems such as Pfister, Coriolis, or Multicore, traditional coal feeding systems still dominate operations.  These include: Venturi-Based Coal Transfer and Firing System,   V1 – A successful project. FK Pump-Based Coal Transfer and Firing System, F1. FK Pump-Based Direct Coal Firing System, FD1 –  Two successful projects. Challenges in Traditional Coal Feeding Systems In these setups, coal transport starts when the coal firing bin reaches its lower limit and stops when it reaches the higher limit. However, this method introduces several challenges: SFM Draft Variation: Sudden coal transport starts and stops create fluctuations in the SFM (Solid Flow Meter) draft, leading to inconsistent feeding. Bin Pressurization & Flushing: During transport, the coal firing bin gets pressurized, causing erratic coal flushing, which disrupts stable firing. Continuous monitoring and regulating is a headache for operators. ...

1. Efficiency (Fundamental Formula) Efficiency = Output Input \text{Efficiency} = \frac{\text{Output}}{\text{Input}} This is the base formula, where "output" and "input" can be anything—energy, time, raw materials, or resources. 2. Productivity (Material-Based Efficiency) Productivity = Output Quantity Input Quantity (Material) \text{Productivity} = \frac{\text{Output Quantity}}{\text{Input Quantity (Material)}} Measures how much product is made from a given amount of raw material. Higher productivity means better utilization of raw materials. 3. Availability (Time-Based Efficiency) Availability = Actual Operating Time Total Scheduled Time \text{Availability} = \frac{\text{Actual Operating Time}}{\text{Total Scheduled Time}} Reflects how much time a machine or system is available for operation versus planned time. If a machine is down for maintenance, availability decreases. 4. Utilization (Machine Usage Efficiency) Utilization = Operating Time To...

Everyone Talks About Efficiency, But What Is It Really? Everyone wants efficiency. Everyone talks about efficiency. But if you ask ten people what efficiency really means, you’ll probably get ten different answers. For me, the definition is simple: Efficiency = Output ÷ Input It’s as basic as that. If the formula is so simple, then why do we often make efficiency improvement exercises so complicated? They don’t need to be. If you think as a layman and ask yourself: "How do I make something more efficient?" the answer is straightforward: 1️⃣ Remove existing inefficiencies. 2️⃣ Don’t allow new inefficiencies to enter your system. That’s it. Do these two things, and the major part of efficiency improvement is done. Where Do Inefficiencies Come From? Now, ask yourself: Why were these inefficiencies in your plant or systems in the first place? How did they enter? How did they build up over time? Do a basic root cause analysis , and you’ll find the answers. You...

" Your purchase team works only on L1, that’s why I don’t disturb you." These were the words of a young sales officer, sitting in my office years ago. He was fresh in the industry but had already helped me solve a major problem in the plant. After that meeting, he walked out with confidence. And later? He became a major supplier for our plant. His solutions helped us reduce costs in his product range—not by simply being the cheapest but by being the smartest choice. Because procurement isn’t about finding the cheapest option. It’s about finding the SMART option: S – Specification M – Material Quality A – After-Sales Support R – Return on Investment T – Timely Delivery Sales, Procurement & The Bigger Picture Over the years, I’ve built strong relationships with sales professionals from different companies. Some of them met me early in their careers—just like the one in this story. I shared insights on the cement industry, discussed their sales strategies, and taught ...