Critical Equipment Availability Report

Objective/Target: To achieve 99.5 % Equipment availability for Production

Year 2009 (%)
Availability
100
100
96.67
99.28
96.99
99.08
98.93

Year 2010 (%)

Availability
98.13
100
97.56
98.36
97.16
99.14
99.03

Year 2011(%)
Availability
100
100
97.97
99.94
96.97
98.27
99.36

99.7

95.21

99.41

99.49

99.93

100

92.08
38.24
99.71

99.49
99.06
99.97

98.0
98.61
99.96

98.83
-

94.72
-

96.99
-

99.82

99.34

99.63

<99.5 %

y Report

MNT/DPF/8.1.9

% Equipment availability for Production

Critical Equipment Description / Model

Make

Screw Air Compressor,CSDX 162

Refrigeration Air Dryer,TH451
Auto Shot Blasting Machine(AB-1)
Auto Shot Blasting Machine(AB-2)
Manual Blasting Chamber(MB-1)
Manual Blasting Chamber(MB-2)
Robo Plazma plate Cutting ; Z75W Robotic - 7 axis

Keaser - Germany
Keaser - Germany
Murzello - India
Murzello - India
Redemaco - India
Redemaco - India
Plazma - India

CNC XY Plazma plate Cutting ; Z100W Universal

Plazma - India

Circular Saw cutting machine(CSC-1)

Trennjager - Germany

Commissioning
date
Mar-08
Mar-08
Jan-08
Dec-07
Jan-08
Dec-07
Nov-07

Qty(nos.)
3
2
1
1
1
1
1

Mar-08

1989

Circular Saw cutting machine(CSC-2)

Amashei,Germany
Shearing Machine;CNC HVR 3100 X 13
Ermaksan - Turkey
Shearing Machine; model 1012 patent no 838635 Pearson - UK

2007
Dec-07
1985

1
1
1

H Beam welding m/c ; GM075

Zhejiang - China
Robo Plazma Beam Cutting ; Z75W Robotic - 8 axis Plazma - India

Dec-08
Aug-11

1
1

EOT Cranes

Dec-07

14

ABUS,Germany

MNT/DPF/8.1.9

Rev_0
Sheet 1 of 3

Availability
Jan' 12 (%)
100
100
99.96
100
98.05
99.67
99.36

Year 2012(%)
Availability
100
100
99.96
100
98.05
99.67
99.36

Remarks

100

100

100

100

Purchased Second hand

99.91
100
100

99.91
100
100

Purchased Second hand

99.97
99.66

99.97
99.66

99.91

99.91

Purchased Second hand

M/c put under trail production in Aug 2011

Maintenance Cost Expenditure Report for the Year 2012

S.no
1
2
3
4
5
6
7
8

Section
Year 2009 Year 2010 Year 2011 January February
Cutting
2886.28
797.678 5549.072
0
Drilling & Punching
547.144
108.199
50.3
556.54
Welding
2966.939 1801.449 6159.897
190.9
Blasting & Painting
12159.286 5835.507 4847.707 563.229
Utilities(Compressors+EO
1477.6
2265.4 4418.964
239.46
T Cranes)
Power Tools spares &
3993.268 2816.497 3322.194
62.012
consumables
Tools
240.98
48.5
340.654
0
Miscelleneous(includes
1976.37 3544.049 3479.873 231.068
local cash purchases)
Total(OMR) 26247.867 17217.279 28168.661 1843.209
0.000
Above Expenses derived from Store Issue report & Misc. Local Cash purchases

March

0.000

MNT/DPF/8.1.9
Sheet 2 of 3

April

0.000

May

0.000

Year 2012
Expenditure in OMR
June
July
August

0.000

0.000

0.000

September

0.000

October

0.000

November December

0.000

0.000

Rev_0

Total
0.000
556.540
190.900
563.229
239.460
62.012
0.000
231.068
1843.209

Measuring Point & Counter

Energy Consumption Report-Sohar Factory

Year 2009
Year 2010
Total
Energy
Total
Energy
Energy Cost(Omr) Energy
Cost(omr)
(KWH)
(KWH)

185070
160680
182260
189550
239330
195360
294880
236550
259090
220300
159435
199375
2521880

3701.4 174210
3213.6 160250
3645.2 190710
3791 185510
4786.6 266090
3907.2 217580
5897.6 216370
4731 198480
5181.8 192960
4406 206160
3188.7 176210
3987.5 173380
50437.6 2357910

Year 2011
Total
Energy
Energy Cost(omr)
(KWH)

3484.2 201060
3205 154600
3814.2 156440
3710.2 161850
5321.8 241830
4351.6 246630
4327.4 233940
3969.6 192590
3859.2 216440
4123.2 196310
3524.2 191490
3467.6 133060
47158.2 2326240

4021.2
3092
3128.8
3237
4836.6
4932.6
4678.8
3851.8
4328.8
3926.2
3829.8
2661.2
46524.8

Month

Year 201
Energy Consumption(KWH) of
Meters

Transform
Tfr-2
er No.
Meter 081Acc. No. 04250
Jan '12
Feb'12
Mar' 12
Apr' 12
May'12
June '12
July '12
Aug '12
Sep '12
Oct '12
Nov '12
Dec '12

Total Annual Energy Consump

Counter
MNT/DPF/8.1.9
Sheet 3 of 3
Year 2012
Energy Consumption(KWH) of Individual
Meters
Tfr-1
08104251

Tfr-4
08104252

Rev_0

Total
Energy
(KWH)

Energy
Cost(Omr)

Tfr-3
08104253
175000

Total Annual Energy Consumption(KWH)

175000
Total Annual Energy Cost(OMR)

3500 * Bill not recd. Yet.Approx. Value

3500

140.4
648.2
1042.2
338
2168.8

PM CONFORMANCE of MACHINERIES
MNT/DPF/8.0.3
Planned

S.no.
16

Equipment Decription
Iron worker(IW 1)

17

Lathe(LAT 1)

18

Auto Shot Blasting Machine(AB 1)

19

Manual Blast Chamber(MB 2)

20

Puncinng Machine(PM 2)

21

Radial Drill Machine(RD 2)

22

Iron worker(IW 2)

23

Lathe(LAT 2)

24

Cold Saw Cutting Machine(CSC 2)

25

EOT Cranes 9,10,1-r & Tower Crane (TC)

26

Auto Shot Blasting Machine(AB 2)

27

Manual Blast Chamber(MB 1)

28

Bending Machine(BM)

29

Radial Drill Machine(RD 3)

Planned & Completed

Supervisor

10

11

12

Rev_0

Sheet 2 of 2

Unplanned but Completed

13

14

15

Month16 17

Incharge

18

19

20

21

22

23

24

25

26

27

28

29

30

31 Remarks

PM Conformance for MDPs,SMDPs,DBs and

Electrical panels(EP,SP)

Equipment Decription
SMDP-1 & SMDP-2

SMDP-3 & SMDP-4

SMDP-5 & SMDP-6
SMDP-7 & SMDP-8
SMDP-9 & SMDP- 10
SMDP-11 & SMDP- 12
SMDP-13 & SMDP- 14
SMDP-15 & SMDP-16
SMDP-COMP,ESMDP,Generator,Fire & Water Pumps
MDPs-Electrical Room

Supervisor

PM CONFORMANC

S.no.

Equipment Decription

Robo Plazma Plate Cutting Machine(RPC),ELGI Air

Compressor(EL 1)
CNC XY Plazma Cutting Machine(CPC),Egi Air
Compressor(EL 2)
EOT Cranes 3,4-r & 2-r

Auto Shot Blasting Machine(AB 1)

Manual Blast Chamber(MB 2)

Cold Saw Cutting Machine(CSC 1)

H-Beam Welding Machine(HBW)

Shearing Machine(SM 2)

Kaeser Air Compressor(KAE-1,2&3)

10

Auto Shot Blasting Machine(AB 2)

11

Manual Blast Chamber(MB 1)

12

Puncinng Machine(PM 1)

13

Radial Drill Machine(RD 1)

14

Shearing Machine(SM 1)

15

Diesel Generator(GEN)

Supervisor

PM CONFORMANC

S.no.
16

Equipment Decription
Iron worker(IW 1)

17

Lathe(LAT 1)

18

Auto Shot Blasting Machine(AB 1)

19

Manual Blast Chamber(MB 2)

20

Puncinng Machine(PM 2)

21

Radial Drill Machine(RD 2)

22

Iron worker(IW 2)

23

Lathe(LAT 2)

24

Cold Saw Cutting Machine(CSC 2)

25

EOT Cranes 9,10,1-r & Tower Crane (TC)

26

Auto Shot Blasting Machine(AB 2)

27

Manual Blast Chamber(MB 1)

28

Bending Machine(BM)

29

Radial Drill Machine(RD 3)

Supervisor

MNT/DPF/8.0.4

10

11

12

13

14

Supervisor

15

Month16 17

18

19

20

21

Rev_0

22

23

24

25

26

24

25

26

Incharge

PM CONFORMANCE of MACHINERIES
MNT/DPF/8.0.3

10

11

12

13

14

Month15 16 17

18

19

20

21

Rev_0

22

23

Supervisor

Incharge

PM CONFORMANCE of MACHINERIES
MNT/DPF/8.0.3

10

11

12

13

14

Month15 16 17

18

19

20

21

Rev_0

22

23

24

25

26

Supervisor

Incharge

27

28

29

30

31 Remarks

30

31 Remarks

Sheet 1 of 2

27

28

29

Sheet 2 of 2

27

28

29

30

31 Remarks

PM Conformance for Fire Alarm System and

Fire Pump Station
MNT/DPF/8.0.5

Equipment Decription
Fire Alarm System

Rev_0

Month-JAN'2012
10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 Remarks

Fire Pump Station

Supervisor

Incharge