Sawan Jasoliya

 A structured explanation for each KPI, in the following format: Definition (in simple terms) Formula for Calculation Why Track It (advantages/benefits) Additional Notes (contextual use, interpretation, benchmarking, etc.) Please note: This is the second list of KPIs. First and the main list is here:  https://www.cementbook.com/downloads/tech/gen/fls_kpi_handbook.pdf 1. Utilization Factor Definition: Utilization Factor indicates how effectively the installed capacity of equipment or a plant is used over a period. It shows the actual operating time as a percentage of the total available time. Formula for Calculation: Utilization Factor (%) = ( Actual Running Hours Total Available Hours ) × 100 \text{Utilization Factor (\%)} = \left( \frac{\text{Actual Running Hours}}{\text{Total Available Hours}} \right) \times 100 Why Track It: Helps assess how well plant assets are being used. Identifies under-utilization or bottlene...

Problem Statement: The  belt bucket elevator (BBE)  feeding the kiln is  getting swayed during operation , leading to operational instability, potential mechanical damage, and interlock tripping. Objective: To achieve  stable, variation-free kiln feed , ensuring the  belt bucket elevator runs smoothly without sway , and preventing unnecessary shutdowns and mechanical failures. Action Plan: Step 1: Immediate Running Condition -> Controlled Operation Bypass the tripping interlocks  temporarily, but keep the elevator under  strict manual supervision. Continuously monitor  the elevator's operation during this period. Manually adjust  the elevator through tensioning device until relative stability is achieved. Restore interlocks  once the system behavior is stable and predictable. Step 2: Inspection of Material Discharge to Elevator Check material discharge ...

Last weekend, my team informed me that the bearing on the auxiliary drive side of the cement mill gear box has started making a slight noise. We checked it. Looking at the parameters like vibration and temperature, we decided that we will run the mill right away and fill the cement silo. And yes, we will monitor the equipment very carefully. And as we do, we started arranging the necessary equipment and tools and tackles. The silos were filled. Today my team opened the top cover of the gear box and invited me for inspection. We found the cage damaged. We saw that the alignment was correct. Lubrication was also correct. The bearing clearance was found to be slightly on the higher side. Now we will check all the other bearings as well. We will do all the necessary replacement and maintenance and start the cement mail again. Before there is any problem in dispatch. Cleaning – Inspection – Lubrication – Tightening i.e. CILT, this is a mantra which always proves to be a boon for us. [Planne...

Day - 10th June, 2025

What you can't imagine when you go from Production Manager to Plant Manager... As a Production Manager, you feel like you already see the whole plant. You see processes, shifts, indicators, costs and tons. But when you get to Plant Manager... You realize that was just one part of the game. What you don't imagine is that: Now you represent the entire plant, up, down, and out. The problems do not end at the mill... they start with the community, the union, the customers, the environment. You don't report figures... You deliver results to a country, to a corporation that expects total vision. You don't just manage resources... you answer for what a plant spends and produces that invoices $700,000 USD daily. You're no longer part of the pressure. You are the one who absorbs it, filters it and transforms it into decisions. And the most difficult thing is not to get there. It is to keep going. Because sustaining yourself as a Plant Manager requires more than results. Requ...