Inventory, Breakdown, and Lessons in Plant Maintenance: Reflections - 2nd March, 2025

More inventory does not always mean better availability of spares. In fact, the more unnecessary inventory you have, the less likely you are to find the exact spare you need when a breakdown happens.

This thought crossed my mind when I heard about the breakdown of a bucket elevator gearbox at Sebit, West Pokot plant—a place where I worked for a short time. The plant was shut down for 12 days due to the unavailability of a spare gearbox. Unfortunately, this is a recurring issue there.

There was no scientific approach to procurement—just blind purchasing to save their skins. But in reality, no one can escape the consequences of poor planning.

And then there’s the bigger issue: it was an old Chinese plant.
After running its full life in China and being exploited to the maximum, it was sold to Devki Group, Kenya. Imagine the situation for a mechanical maintenance engineer in a plant like this—no proper manuals, no part lists, and no structured systems. Every day and every night were about firefighting. It was nothing short of a nightmare.

The Lifecycle of a Cement Plant

A well-built plant follows a predictable life cycle:
✅ Commissioning → Stabilization in 1-2 years → Peak efficiency in 3 years → Sustained performance for X years → Deterioration.

The value of ‘X’ depends on the team and systems. But here’s the issue—
👉 There is no TEAM or SYSTEMS.
👉 Systems alone can’t deliver results.

The bathtub curve of equipment failures is a good theory, but it can’t be taken for granted. Only when a strong team and a reliable system work together can a plant sustain its peak performance.

I’ve decided to put together a basic SOP for HODs, focusing mainly on Maintenance and Production. I'll introduce and explain them later.

The Modern Information Overload – A Numbing Effect

People are becoming emotionally disconnected. The constant flood of news, videos, and information is making them less responsive.
1️⃣ They feel like they already know everything. And if they don’t, they assume they can find out by evening through some feed or WhatsApp group.
2️⃣ They start believing everything is fake. With so much contradictory information about food, politics, current affairs—trust is disappearing.

A few days ago, I saw a viral video where an Indian batsman supposedly won a match against Australia while chasing 438 runs. Something felt off. When I checked, I realized the video was real, but the scorecard was fake.

This is the problem with today’s information flow.

An Ex-Colleague’s Call – Predictions Coming True

An ex-colleague from my previous organization called me. He is not happy.

When I left that plant, I had warned management about two major issues they would face:
1️⃣ A price war – because of major capacity additions in the market.
2️⃣ Employee attrition – existing employees losing motivation and new positions opening due to new plants coming into operation.

Both issues became reality.

I listened to my ex-colleague’s concerns and guided him with my proven methods to excel in interviews. Hopefully, this will help him navigate his next move.

A Scorching Sunday in Tabligbo

Today was hot, humid, and cloudy. The heat was unbearable, making it feel like the air itself was weighing down on everything. A typical day in West Africa.


[An image of CEMTECH, Sebit, West Pokot from my archive]


Comments

Post a Comment

Must read

Building Dreams: The Humble Journey of a Cement Industry Enthusiast

Image
Meet Sawan Jasoliya , a man whose journey in the cement industry is as solid as the foundations he's helped build. Born on 26th October 1974 in the vibrant city of Ahmedabad and raised in the coastal town of Bhavnagar , Sawan's story is one of passion, perseverance, and performance . From hands-on mechanical expertise to leading entire cement plants, his career has been a testament to continuous learning, leadership, and innovation in the industry. Rising to the HOD of the Mechanical Department before the age of 35 and later taking charge as Plant Head before 44 , Sawan proved that age is no barrier to expertise and impact . His ability to drive efficiency, optimize processes, and build high-performing teams has set him apart as a leader who not only understands machines but also inspires people . Early life He has been fascinated by machines since childhood, always eager to explore how things work. Whether it was taking apart a toy plane, disassembling an old audio cas...
Read more

How to Use LinkedIn Smartly as a Job Seeker: Practical Tips That Actually Work

Image
Why this post? In today’s job market, having the right skills is not enough —you need the right visibility. And when it comes to building that visibility, LinkedIn is your best ally. And yes, do not think that this is a long or complicated process. It’s actually quite simple—and once you start, you’ll find it becoming more comfortable with each passing day. Soon, you’ll start enjoying it. Especially when you begin to see results—new connections, interview calls, and confidence in presenting yourself. I’ve been mentoring and helping job-seekers for over a decade, and just today, during a conversation with a mining engineer, I felt the need to share these tips in a detailed manner— not as theory, but as actionable guidance based on real experience. Step 1: Start With Your Profile ✅ Make it neat, complete, and keyword-rich. Your profile is your first impression. Spend some time reviewing it—add a good photo, a strong headline, your experience, and skills. 👉 Example: If you’re a...
Read more

Enhancing Coal Feeding Systems for Optimal Kiln Performance

Image
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. ...
Read more