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AMMJ Mill Downtime Tracking 39
C. By Pareto’s 80/20 Rule: Equipment Causing 80% of the Breakdown Incidents.
Figure 8 is the same information as
presented in the graph in Figure 7
but now Pareto analysis is used to
identify the equipments costing OTML
in SAG2 Mill’s Availability by frequency
of breakdown incidents. Table 8 gives
the 20% of equipment causing 80% of
the breakdown incidents.
TABLE 8 EQUIPMENT CAUSING
80% OF BREAKDOWN
INCIDENTS IN SAG2 MILL
Equipment No. of Incidents
by %
0341ML01 28%
0341CV01 14%
0341FE01 8%
0341PP01 8%
0341CV02 7%
Unknown 5%
0341SC01 4%
0341CV03 4%
0341ML015D 4%
82%
D. By Pareto’s 80/20 Rule: Equipment Causing 80% of the
Breakdown Hours and the Equivalent in Cost of Production Loss
This is the same information as
provide by the graph in Figure 6 but
now we are using Pareto analysis
to identify the equipments costing
OTML in SAG2 Mill’s Availability by
breakdown hours. Table 9 gives the
20% of equipment causing 80% of the
breakdown hours.
TABLE 9 EQUIPMENT CAUSING 80% OF
BREAKDOWN HOURS AND EQUIVALENT
IN COST OF PRODUCTION LOSS IN SAG2
MILL
Equipment No. of Cumulative
Hours by %
0341CV01 37%
0341ML01 29%
0341FE01 8%
0341SC01 6%
80%
No. Of Incidents
No. Of Hours (Cumulative)
Figure 8 Equipment Breakdown Incidents Causing SAG2 Mill Downtime.
Equipment B/Down Incidents Causing SAG2 Mill Downtimes: Last 18 Months_Jul06-Dec07
8%
8%
7%
4%
4% 4%
2%
2%
FACILITATION FOR ZOOMING IN ON THE DOMINANT BREAKDOWN CAUSE
80
70
60
50
40
30
20
10
0
250
200
150
100
50
0
28%
14%
0341ML01
0341CV01
0341FE01
37%
2% 1% 1% 1% 1%
1% 1% 1% 1%
0% 0% 0% 0% 0% 0% 0% 0% 0% 0% 0%
This analysis provided some visibility to what has been costing OTML in Mill Availability in the last 18 months and
provided a facility for easy drill down to the ‘significant few’ plant equipment and their dominant breakdown causes.
Figure 10 is an example of this drill down facilitation.
Pivot tables from MS Excel were used to a large extent to achieve this easy drill downs. Also the pivot tables in MS
Excel were used for registering and tracking our action plans.
These drill down and tracking facilities were presented in [3] for SAG1 Mill and SAG2 Mill respectively.
5%
0341PP01
0341CV02
Unknown
0341SC01
0341CV03
0341ML015D
TPS/Ok Menga
0341CV04
0341FSL424-2
IPC/TARA
0342UPS02
0341ML01A
0341FSL424-1
0341ML015D-2
Equipment
0341SC01A
0341FSL4091
0341FSL4121
0212SGH01-18
0341ML011A
0341PP02A
0212SGH01-11
0341ML02
0341ML03
0341PP01A
0341ML01B
0341ML03A
0341PP02
0341CV01A
Figure 9 Equipment Breakdown Hours Causing SAG2 Mill Downtime.
29%
Equipment B/Down Hours Causing SAG2 Mill Downtime: Last 18 Months_Jul06-Dec07
8%
6%
4%
2% 2% 2% 2% 2% 1% 1% 1% 1% 1% 0% 0% 0% 0% 0% 0% 0% 0% 0% 0% 0% 0% 0% 0% 0% 0%
0341CV01
0341ML01
0341FE01
0341SC01
IPC/TARA
Unknown
0341PP01
0341CV02
0341CV03
0342UPS02
0341ML01A
0341CV04
0341ML015D
0341SC01A
TPS/Ok Menga
0212SGH01-18
0341ML011A
Equipment
0341PP02A
0212SGH01-11
0341PP01A
0341FSL424-2
0341ML02
0341FSL424-1
0341FSL4091
0341ML03
0341ML01B
0341ML03A
0341ML015D-2
0341FSL4121
0341PP02
0341CV01A
Vol 24 No 1