100%

76%

71%

65%

80%

51%
43%

6.92

15.50

6.67

4.92

24%

4.67

3.92

3.91

Replaced
carbon
brush;

Defective
motor
shafting

Low air
supply

3.67

3.17

3.17

3.00

40%
3.00

20%
0%

Replace SPR Fluctuation

Replace
Defective
Speed
of current worn out key flexible disc fluctuation
load, speed
coupling
and draw
SPR

3rd Press

Jactuator

3rd Press
Top roll

Hrs

6th Dryer

6th Dryer

Spray Starch
Air
Shower Compressor
Pump

Tripped
Replaced
Speed
Problem on
Speed
(overload) floating shaft fluctuation jactuator & fluctuation
spacer bolt
of 3rd Press
FDR/SCR

3rd Press

3rd Press & Jacuator &

5th Dryer
3rd Press

5th & 6th

Dryer

Year to Date PM1 Breakdown

600
500
400

80%
60%

8 of 13 cases contributes 80%

of total breakdown

59%

19.42

96%

93%

89%

85%

100%

475
422

300
200
50.92

100

69.84

113.52

192

129.19 157.42

0
2010

2011

Target 2012

Jan

Feb

Mar

Apr

PM1 2012 Actual

May

Jun

PM1 2011

Jul

Aug

Sep

Accum 2012

Oct

Nov

Dec

Target
2012

Target per month

Percent Cum

Hours

81.94
73.75
65.55
57.36
49.16
40.97
32.78
24.58
16.39
8.19
0.00

PM1 MTBF & MTTR

Hrs
120
80
40

40

36

19

18

27
26

17

0
2008

2009

2010

2011

2012

Jan

Feb

Actual 2008-2011

4
3
2
1
0

40

39

Mar

Apr

May

2012 Average

Jun

Jul

Aug

Actual 2012

Sep

Oct

Nov

Dec

Target 2012

Hrs

1.27
1.47 1.54 1.28
1.01 1.32
2008 2009 2010 2011 2012

Jan

Actual 2008-2011

1.82

0.92
0.11
Feb

Mar

Apr

2012 Average

May

Jun

Jul

Actual 2012

Aug

Sep

Oct

Target 2012

Nov

Dec

93%

85%

100%

100%

76%

80%

62%
48%

60%

6 of 8 cases contributes
85% of total breakdown

33%

40%

16%

20%
7.06

7.00

6.58

6.30

5.93

4.10

Stopped without
tripping

Group start trouble

Overload

All dryers stopped

Compa error

Johnson joint collor

broken

2nd Dryer & Press

DC Drive

2nd Dryer

Remot I/O

Press Section

Cylinder #28

Hrs

3.24

3.03

0%

Percent Cum

Hours

43.24
38.92
34.59
30.27
25.94
21.62
17.30
12.97
8.65
4.32
0.00

Drive stopped at Reposition of rope

normal run
pulley (welding job)
Supporting Wire

4th Dryer

Year to Date PM2 Breakdown

600
500

385

400
300

261

277

264

200

77.47

100

17.68

81.60

192

97.20

28.56

0
2008

2009

2010

Target 2012

2011

Jan

Feb

PM2 2012 Actual

Mar

Apr

May
PM2 2008-2011

Jun

Jul

Aug
Accum 2012

Sep

Oct

Nov

Dec

Target per month

Target
2012

PM2 MTBF & MTTR

Hrs

112

120

80
40

38

31

23

27

2010

2011

96
70

44

18

0
2008

2009

2012

Jan

Feb

Actual 2008-2011

4
3
2
1
0

Mar

Apr

May

2012 Average

Jun

Jul

Aug

Actual 2012

Sep

Oct

Nov

Dec

Nov

Dec

Target 2012

Hrs

2.95
1.34 1.11 1.58 1.75 1.36

1.21
2008 2009 2010 2011 2012

Jan

Actual 2008-2011

Feb

0.59

1.29
Mar

Apr

2012 Average

May

Jun

Jul

Actual 2012

Aug

Sep

Oct

Target 2012