Shutdowns: A Challenge or an Opportunity? Only Preparation Decides

Unplanned stoppages are bad. 
But shutdowns can be a big opportunity —
A really big opportunity… IF ONLY WE ARE PREPARED, our job-lists are ready.

There are two types of job-lists for any shutdown:

1. Standard Job-List

This is the list of jobs that we perform as part of our standard inspection and maintenance routines (mostly preventive maintenance).

  • Process Department: checks refractory conditions in cooler, kiln, and preheater; dip tube, feedpipe, flap valve condition, etc., and carries out the necessary maintenance.

  • Mechanical Department: checks DPC, cooler, kiln supporting roller bearings, drive, HTD, bucket elevator, blowers, process fans, mill internals, screw conveyors, etc., and performs the required maintenance.

  • Electrical Department: checks HT/LT panels, circuit breakers, cable terminations, MCCs, motors, lighting systems, earthing, and ensures functionality of interlocks and protection systems.

  • Instrument Department: calibrates and maintains field instruments like pressure transmitters, temperature sensors, flow meters, limit switches, and ensures control loops and interlocks are working as per design.

2. Observation-Based Job-List

This list includes jobs that are identified during plant operation but cannot be executed during running condition (e.g., during weekly maintenance, small stoppages, etc.).

Sources include:

  • CLTI observations / audits (Cleanliness, Lubrication, Tightness, Inspection)

  • S-Q-P (Safety-Quality-Productivity) inspections

  • Condition-based monitoring

  • Improvement or upgradation initiatives

This second list is dynamic and constantly evolving. It is often the center of our discussions — a Live Job List that we maintain and update through the Job Planning Register (JPR).

Basic Details Required in Every Job-List Entry

To ensure clarity, accountability, and effective execution, each job in the job-list must include the following essential information:

  1. Area of Work
    → The specific section, unit, or equipment where the job is to be carried out.

  2. Job Description
    → Clear and brief explanation of the work to be done, including scope and purpose.

  3. Job Duration
    → Estimated time required to complete the job (in hours or days).

  4. Material Availability
    → Whether all required materials/spares/tools are available.
    → If not available, clearly mention the current status (e.g., indented, ordered, to be fabricated, pending approval, etc.).

  5. FPR – First Person Responsible
    → Name/designation of the person who will take lead and ownership of the job execution.

  6. Other Important Details
    → Any specific safety precautions, coordination requirements, special instructions, or dependencies related to the job.



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