Section Failure Mode(s) Frequency

Bagging and packaging cake clogging 5

Loose part 3
electrical failure 2
Feedstock clogging 2
safety precaution 2
Broken Part 1
Bagging and packaging Result 15
Farmet Line A Filtrate clogging 76
Crease return Failure 16
Feedstock clogging 14
cake clogging 11
Sensor Failure 9
Leakages 8
Low lubricant levels 7
safety precaution 7
Meat clogging 7
Improvement Project 6
electrical failure 5
Broken Part 4
worn out belt 4
Loose part 4
Misalignment 3
Overload 3
low pressure 3
Material Clogging 1
Overheating 1
Power Outage 1
process improvement 1
Rusting 1
air leakage 1
Farmet Line A Result 193
Farmet line B Feedstock clogging 65
Filtrate clogging 49
Sensor Failure 11
cake clogging 10
worn out belt 9
Loose part 8
electrical failure 7
Broken Part 6
Low lubricant levels 5
safety precaution 5
Misalignment 3
abnormal sound 2
low pressure 2
Improvement Project 1
Leakages 1
Network Failure 1
Farmet line B Result 185
Farmet Line C Filtrate clogging 26
cake clogging 17
Feedstock clogging 9
Material Clogging 4
Broken Part 2
electrical failure 1
Leakages 1
Loose part 1
Meat clogging 1
safety precaution 1
Farmet Line C Result 63
Ferro line Feedstock clogging 141
Wear on Part 19
Broken Part 14
worn out belt 12
Loose part 12
Misalignment 12
electrical failure 5
abnormal sound 5
Sensor Failure 4
safety precaution 4
Low lubricant levels 2
Improvement Project 2
Meat clogging 1
motor burn 1
Power Outage 1
Leakages 1
cake clogging 1
air leakage 1
Ferro line Result 238
Offices & buildings Improvement Project 5
electrical failure 4
safety precaution 4
Leakages 3
Offices & buildings Result 16
Oil storage Loose part 1
Oil storage Result 1
Utilities Power Outage 7
electrical failure 3
Leakages 3
Broken Part 2
Feedstock clogging 2
low pressure 2
Service 2
Misalignment 1
safety precaution 1
Seal Failure 1
 worn out belt 1
Utilities Result 25
(empty) Improvement Project 1
Loose part 1
Misalighnment 1
safety precaution 1
(empty) Result 4
Total Result 740
Section Failure Mode(s) Frequency
Bagging and packaging Feedstock clogging 2
Bagging and packaging Result 2
Farmet Line A Filtrate clogging 7
Feedstock clogging 4
Improvement Project 3
Meat clogging 3
cake clogging 2
Low lubricant levels 2
overload 2
electrical failure 1
Material Clogging 1
Misalignment 1
Overheating 1
Sensor Failure 1
worn out belt 1
Farmet Line A Result 29
Farmet line B Filtrate clogging 3
Feedstock clogging 2
Broken Part 1
cake clogging 1
Farmet line B Result 7
Farmet line c Filtrate clogging 4
Material Clogging 4
cake clogging 2
Farmet line c Result 10
Ferro line Feedstock clogging 6
abnormal sound 4
Wear on Part 3
Broken Part 1
Improvement Project 1
Leakages 1
Ferro line Result 16
Offices & buildings Leakages 1
Offices & buildings Result 1
Utilities Broken Part 1
Utilities Result 1
(empty) Misalighnment 1
(empty) Result 1
Total Result 67
 Section Failure Mode Frequency C. Frequency Cumulative % Range
Farmet Line A Filtrate clogging 7 7 24% 80%
Feedstock clogging 4 11 38% 80%
Meat clogging 3 14 48% 80% 120%
Improvement Project 3 17 59% 80% 100%
overload 2 19 66% 80% 80%
cake clogging 2 21 72% 80% 60%

Cumulative %
Low lubricant levels 2 23 79% 80% 40%
electrical failure 1 24 83% 80% 20%
worn out belt 1 25 86% 80% 0%
Sensor Failure 1 26 90% 80%
Misalignment 1 27 93% 80%
Overheating 1 28 97% 80%
Material Clogging 1 29 100% 80%
Farmet Line A Total 29

Section Failure Mode(s) Frequency C. Frequency Cumulative % Range

Ferro line Feedstock clogging 6 6 38% 80%
abnormal sound 4 10 63% 80%
Wear on Part 3 13 81% 80%
Leakages 1 14 88% 80%
Broken Part 1 15 94% 80% 7
Improvement Project 1 16 100% 80% 6
6
Ferro line Total 16
5

Failure Frequency
4
3
2
1
0
Feeds
clogg
 PARETO CHART
Failure Mode Analysis
120% 7 8
100% 7
6
80% 5
4
60% 3 3 4
Cumulative %

40% 3

Frequency
2 2 2
1 1 1 1 1 1 2
20% 1
0% 0

Failure Mode

Frequency Cumulative % Range

PARETO CHART
Failure Mode Analysis
7 120%
6
6 100%
5
Failure Frequency

4 80%

Cumulative %
4
3 60%
3
40%
2
1 1 1 20%
1
0 0%
Feedstock abnormal sound Wear on Part Leakages Broken Part Improvement
clogging Project
Failure Mode

Frequency Cumulative % Range

 8
7
6
5
4
3
Frequency

1 1 2
1
0
Failure Date Machine /
Day Week Month Year Asset Criticality Asset Ranking
Equipment

03/Jan/24 Wed 1 Jan-24y 24y Automatic

Filter_3.FI1.1

Bagging/ Sewing
04/Jan/24 Thu Jan-24y 24y Machine_Castor
LineBagging Section

Press
04/Jan/24 Thu Jan-24y 24y
FS_1010_2.FP1.1

Press
04/Jan/24 Thu Jan-24y 24y
FS_1010_2.FP1.1

04/Jan/24 Thu Jan-24y 24y Automatic

Filter_3.FI3.1

04/Jan/24 Thu Jan-24y 24y Conveyor_3.TL1.2

 Automatic
04/Jan/24 Thu 1 Jan-24y 24y
Filter_3.FI3.1

04/Jan/24 Thu 1 Jan-24y 24y Conveyor_3.TL1.2

04/Jan/24 Thu 1 Jan-24y 24y Bagging Machines

05/Jan/24 Fri Jan-24y 24y Press

FS1010_2.PP2.1

05/Jan/24 Fri Jan-24y 24y Conveyor_3.TL1.2

 Automatic
05/Jan/24 Fri Jan-24y 24y
Filter_3.FI2.1

05/Jan/24 Fri Jan-24y 24y Automatic

Filter_3.FI3.1

06/Jan/24 Sat Jan-24y 24y Conveyer_2.TP2.6

Pre Cleaner
06/Jan/24 Sat 1 Jan-24y 24y Overhead
ConveyerPC/OC

06/Jan/24 Sat 1 Jan-24y 24y Press FS10102.PP1.1

Pre Cleaner
06/Jan/24 Sat 1 Jan-24y 24y Machine
FeederPC/F

Press Cake
09/Jan/24 Tue 2 Jan-24y 24y cooler_2.CC3.1

09/Jan/24 Tue 2 Jan-24y 24y Meat Outlet Rotor

LiftRL-2

09/Jan/24 Tue 2 Jan-24y 24y Decorticator

 Electric
10/Jan/24 Wed 2 Jan-24y 24y Boiler_3.BE1.1

11/Jan/24 Thu 2 Jan-24y 24y Decorticator

Storage Bin Rotary

12-Jan-24 Fri 2 Jan-24 2024 Feeder-1SB/RF-1

13/Jan/24 Sat 2 Jan-24y 24y Decorticator

13/Jan/24 Sat 2 Jan-24y 24y Conveyer_2.TC1.1

14/Jan/24 Sun 3 Jan-24y 24y Extruder FE

1000_2.EX1.1

Extruder FE
14/Jan/24 Sun 3 Jan-24y 24y 1000_2.EX1.1

14/Jan/24 Sun 3 Jan-24y 24y Conveyor_3.TL1.2

16/Jan/24 Tue 3 Jan-24y 24y Press

FS_1010_2.FP1.1
17/Jan/24 Wed 3 Jan-24y 24y Canteen

17/Jan/24 Wed 3 Jan-24y 24y Decorticator

19/Jan/24 Fri 3 Jan-24y 24y Decorticator

Pre-Cleaner Feed
19/Jan/24 Fri 3 Jan-24y 24y
Bucket ElevatorBE-2

Press
20/Jan/24 Sat 3 Jan-24y 24y
FS_1010_2.FP1.1

Extruder FE
21/Jan/24 Sun 4 Jan-24y 24y
1000_2.EX1.1

Extruder FE
22/Jan/24 Mon 4 Jan-24y 24y
1000_2.EX1.1

Press
22/Jan/24 Mon 4 Jan-24y 24y
FS1010_2.PP2.1

Automatic
23/Jan/24 Tue 4 Jan-24y 24y
Filter_3.FI2.1

Ferro Oiltek
25/Jan/24 Thu 4 Jan-24y 24y Equipment A 5

Meat Outlet Rotor

27/Jan/24 Sat 4 Jan-24y 24y
LiftRL-2

Compressor_3.CO2.
30/Jan/24 Tue 5 Jan-24y 24y 1

Extruder FE
31/Jan/24 Wed 5 Jan-24y 24y
1000_2.EX1.1

31/Jan/24 Wed 5 Jan-24y 24y Farmet Line A 5

Multiseed Line

01/Feb/24 Thu 5 Feb-24y 24y Conveyor_3.TL1.2

01/Feb/24 Thu 5 Feb-24y 24y Bagging Machines

 Farmet Line
02/Feb/24 Fri 5 Feb-24y 24y Multiseed Line C 3

04/Feb/24 Sun 6 Feb-24y 24y Conveyer2.TF1.1

Pre Cleaner
05/Feb/24 Mon 6 Feb-24y 24y Overhead
ConveyerPC/OC
Two Tray Seed
06/Feb/24 Tue 6 Feb-24y 24y Cleaner
BlowerTTSC/BL

06/Feb/24 Tue 6 Feb-24y 24y Hulls Bale Press

Extruder FE
06/Feb/24 Tue 6 Feb-24y 24y
1000_2.EX1.1

Extruder FE
06/Feb/24 Tue 6 Feb-24y 24y
1000_2.EX1.1

Automatic
06/Feb/24 Tue 6 Feb-24y 24y
Filter_3.FI2.1

Extruder FE
06/Feb/24 Tue 6 Feb-24y 24y 1000_2.EX1.1

06/Feb/24 Tue 6 Feb-24y 24y Conveyor_3.TL1.2

Two Tray Seed

06/Feb/24 Tue 6 Feb-24y 24y Cleaner Machine
TrayTTSC/T

Press
07/Feb/24 Wed 6 Feb-24y 24y FS_1010_2.FP1.1

07/Feb/24 Wed 6 Feb-24y 24y Storage Bin Rotary

Feeder-1SB/RF-1

Pre Cleaner
07/Feb/24 Wed 6 Feb-24y 24y Overhead
ConveyerPC/OC

08/Feb/24 Thu 6 Feb-24y 24y Conveyer_2.TP3.4

 Press Cake
08/Feb/24 Thu 6 Feb-24y 24y
cooler_2.CC3.1

Press
10/Feb/24 Sat 6 Feb-24y 24y
FS_1010_2.FP1.1

10/Feb/24 Sat 6 Feb-24y 24y Conveyer_2.TP3.4

Integrated
10/Feb/24 Sat 6 Feb-24y 24y
Separator_2.PP3.5

Hopper_Castor
10/Feb/24 Sat 6 Feb-24y 24y
LineBagging Section

Integrated
10/Feb/24 Sat 6 Feb-24y 24y
Separator_2.PP3.5

11/Feb/24 Sun 7 Feb-24y 24y Conveyor_3.TL1.2

 Process Reason For
Work Impact if
Sub - Assembly Process Block Operating Section Downtime/work
not corrected
Blocks oders

Limiting operations
Oil Filtration Multiseed Line Farmet Line A Blocked filtration line ability to meets its
section
primary goals

Limiting operations
Packaging Section Castor Line Farmet line B Calibration ability to meets its
primary goals

Will affect operations

Final Pressing Fabrication of strainer after some time , not
Multiseed Line Farmet Line A
Section for oil bath immediately

Modification of press Will affect operations

Final Pressing
Multiseed Line Farmet Line A seal for main shaft after some time , not
Section
cooling immediately

Limiting operations
Oil Filtration Castor Line C Farmet line c clogged filtration line ability to meets its
section primary goals

Oil Filtration Limiting operations

Multiseed Line Farmet Line A Clogging ability to meets its
section
primary goals
 Limiting operations
Oil Filtration
Castor Line C Farmet line c clogged line ability to meets its
section primary goals

Limiting operations
Oil Filtration Multiseed Line Farmet Line A motor tripped ability to meets its
section primary goals

Limiting operations
Packaging Section Bagging Machines Bagging and chute leakage ability to meets its
packaging
primary goals

Limiting operations
Oil Pressing Castor Line B Farmet line B Oil pump blockage ability to meets its
primary goals

Limiting operations
Oil Filtration Multiseed Line Farmet Line A Material clogging ability to meets its
section
primary goals
 Limiting operations
Oil Filtration
Castor Line B Farmet line B Blockage ability to meets its
section primary goals

Limiting operations
Oil Filtration Castor Line C Farmet line c Blockage ability to meets its
section
primary goals

Limiting operations
Oil Pressing Castor Line B Farmet line B Clogging ability to meets its
primary goals

Limiting operations
Pre - Cleaning
Multiseed Line Ferro line clogged material ability to meets its
Section
primary goals

Limiting operations
Pre - Pressing Replacement of worn
Multiseed Line Farmet line A ability to meets its
Section out V belt primary goals

Limiting operations
Pre - Cleaning Multiseed Line Ferro line clogged feeder ability to meets its
Section primary goals

Cake Cooling Limiting operations

Section Castor Line C Farmet line c Clogged duct ability to meets its
primary goals

Limiting operations
Hulls Purification Multiseed Line Ferro line Worn out bush ability to meets its
Station primary goals

Decorticating Limiting operations

Section Multiseed Line Ferro line abnormal sound ability to meets its
primary goals
Homegenization Limiting operations
section Multiseed Line Farmet Line A low oil level ability to meets its
primary goals

Limiting operations
Decorticating Multiseed Line Ferro line Cleaning metals from ability to meets its
Section feeder and drums primary goals

Seed Receiving & Unblocking of the pc Limiting operations

Storage Section Multiseed Line Ferro line feeder ability to meets its
primary goals

Limiting operations
Decorticating
Multiseed Line Ferro line clogged cyclone duct ability to meets its
Section
primary goals

Limiting operations
Final Pressing Multiseed Line Farmet Line A Clogged conveyor ability to meets its
Section
primary goals

Limiting operations
Extrusion Section Multiseed Line Farmet line A Sensor failure ability to meets its
primary goals

low oil level at the Limiting operations

Extrusion Section Multiseed Line Farmet line A extruder main brearing ability to meets its
primary goals

Oil Filtration Will affect operations

section Multiseed Line Farmet Line A Clogged material after some time , not
immediately

Limiting operations
Final Pressing Multiseed Line Farmet Line A Clogged oil pump ability to meets its
Section
primary goals
 Will affect operations
Offices &
Canteen buildings leaking sink after some time , not
immediately

Decorticating Limiting operations

Multiseed Line Ferro line low meat yield ability to meets its
Section
primary goals
Limiting operations
Decorticating
Section Multiseed Line Ferro line low meat yield ability to meets its
primary goals

Pre - Cleaning Limiting operations

Multiseed Line Ferro line Duct leakage ability to meets its
Section
primary goals

Limiting operations
Final Pressing
Multiseed Line Farmet Line A clogged water line ability to meets its
Section primary goals

Limiting operations
Extrusion Section Multiseed Line Farmet Line A clogged material ability to meets its
primary goals
Limiting operations
extruder trip on
Extrusion Section Multiseed Line Farmet line A ability to meets its
overload
primary goals
Limiting operations
Oil Pressing Castor Line B Farmet line B separator chain broken ability to meets its
primary goals

Immediate threat to
Oil Filtration Blocked displacement
Castor Line B Farmet line B safety of people
section line &(or) Plant

Some conveyors lacking Limiting operations

Multiseed Line Farmet line A clips ability to meets its
primary goals

Hulls Purification Limiting operations

Multiseed Line Ferro line Motor trip ability to meets its
Station
primary goals

Compressed Air Fixing compressor Limiting operations

Supply Utilities Utilities bearing housing ability to meets its
primary goals
Limiting operations
Installation of external
Extrusion Section Multiseed Line Farmet line A ability to meets its
fan
primary goals

Limiting operations
Farmet Line Multiseed Line Farmet line A Installation of ability to meets its
Multiseed Line industrial sockets primary goals

Limiting operations
Oil Filtration
section Multiseed Line Farmet Line A clogged conveyor ability to meets its
primary goals

Bagging and Improve efficiency of

Packaging Section Bagging Machines packaging Semi annual activities operations or
process.
 Farmet Line Fabrication of extra
Multiseed Line Multiseed Line Farmet line A meat bin trias for
farmet B trials run

Limiting operations
Pre - Pressing Multiseed Line Farmet line A Conveyor tripped due ability to meets its
Section to overload
primary goals

Pre - Cleaning Limiting operations

Multiseed Line Ferro line Abnormal sound ability to meets its
Section
primary goals

Fine Cleaning Limiting operations

Section Multiseed Line Ferro line Abnormal sound ability to meets its
primary goals

Bale Pressing Installation of socket Will affect operations

Multiseed Line Ferro line for charging weigh after some time , not
Section
scale immediately

Limiting operations
Clogged infeed
Extrusion Section Multiseed Line Farmet Line A ability to meets its
conveyor
primary goals

Limiting operations
Extrusion Section Multiseed Line Farmet Line A Farmet Line A ability to meets its
primary goals

Limiting operations
Oil Filtration
Castor Line B Farmet line B clogged filling line ability to meets its
section
primary goals

meat feeding conveyor Limiting operations

Extrusion Section Multiseed Line Farmet Line A tripped ability to meets its
primary goals

Limiting operations
Oil Filtration
Multiseed Line Farmet Line A clogged conveyor ability to meets its
section primary goals

Fine Cleaning Limiting operations

Section Multiseed Line Alighnment ability to meets its
primary goals
Improve efficiency of
Final Pressing modification of crease
Section Multiseed Line Farmet line A return screw operations or
process.
Seed Receiving & Multiseed Line Ferro line Repair broken shaft
Storage Section

Pre - Cleaning repair broken sight Will affect operations

Section Multiseed Line Ferro line glass after some time , not
immediately

Limiting operations
Oil Pressing Castor Line C Farmet Line C Clogged conveyor ability to meets its
Section
primary goals
 Opened the top cover
of the conveyor
Also opened the
Cake Cooling bottom chute Limiting operations
Castor Line C Farmet Line C Removed the jammed ability to meets its
Section
material using craw bar primary goals
Fixed back the top
cover and chute

Final Pressing Press Hopper sensor Limiting operations

Multiseed Line Farmet Line A ability to meets its
Section Faulty
primary goals

Will affect operations

Oil Pressing Castor Line C Farmet Line C Unclog cake after some time , not
Section recirculation conveyor
immediately

Cake spillage at
Limiting operations
Oil Pressing seperator conveyor
Castor Line C Farmet Line C ability to meets its
Section discharge chute /
primary goals
Connector

Manual Cleaning the

cake hopper due Limiting operations
Packaging Section Castor Line Farmet Line C accumulation of wet ability to meets its
cake on the walls of primary goals
hopper.

Unclogging of Limiting operations

Oil Pressing
Castor Line C Farmet Line C seperator and crease ability to meets its
Section return conveyor primary goals

Limiting operations
Oil Filtration Multiseed Line Farmet Line A Unclog the cake ability to meets its
section recirculating conveyor primary goals
 Ranking for the Work Priority =
Task Assigned Work Status
Work Impact if not Asset Criticality x Job Priority Work Status
to Responsibility
corrected Work Impact

4 - - Antony Mugo Work Completed -

4 - - Caleb Makau Work Completed -

2 - - Fabian ngeli Work Completed -

2 - - Fabian ngeli Work Completed -

4 - - Vincent odera Work Completed -

4 - - Faboian Ngeli Work Completed -

4 - - kemboi Work Completed -

4 - - Charles kemboi Work Completed -

4 - - Vincent odera Work Completed -

4 - - Joel mutuku Work Completed -

4 - - Joel mutuku Work Completed -

4 - - Joel mutuku Work Completed -

4 - - Vincent Odera Work Completed -

4 - - Kennedy Gitonga Work Completed -

4 - - Vincent Odera Work Completed -

4 - - Charles Kemboi Work Completed -

4 - - Vincent odera Work Completed -

4 - - SECO Work Completed -

4 - - Fabian Ngeli Work Completed -

4 - - Joel mutuku Work Completed -

4 - - Antony mugo Work Completed -

4 - - Joel Mutuku Work Completed -

4 - - Fabian Ngeli Work Completed -

4 - - Vincent Odera Work Completed -

4 - - Vincent Odera Work Completed -

4 - - Kennedy Gitonga Work Completed -

4 - - Charles kemboi Work Completed -

2 - - Joel Mutuku Work Completed -

4 - - Charles Kemboi Work Completed -

2 - - Meshack Gikonyo Work Completed -

4 - - Justus ngala Work Completed -

4 - - Justus ngala Work Completed -

4 - - Joel mutuku Work Completed -

4 - - Charles Kemboi Work Completed -

4 - - Vincent Odera Work Completed -

4 - - Joel mutuku Work Completed -

4 - - Vincent odera Work Completed -

5 - - charles kemboi Work Completed -

4 20 Urgent ! Vincent Odera Work Completed -

4 - - Fabian Ngeli Work Completed -

4 - - Joel Mutuku Work Completed -

4 - - Ishmael Barasa Work In Progress -

4 20 Urgent ! Joel Mutuku Work Completed -

4 - - Charles Kemboi Work Completed -

1 4 Low Peter Kapala Work Completed -

 - - -

4 - - Charles Kemboi Work Completed -

4 - - Antony Mugo Work In Progress -

4 - - Vincent Odera Work In Progress -

2 - - Caleb Makau Work In Progress -

4 - - Antony mugo Work In Progress -

4 - - Antony Mugo Work Completed Work Completed

4 - - Fabian Ngeli Work Completed -

4 - - Meshack Gikonyo Work Completed -

4 - - Antony Mugo Work Completed -

4 - - Antonny Mugo Work Completed -

1 - - joel mutuku Work In Progress -

- - Antony mugo Work In Progress -

2 - - Cahrles Kemboi Work In Progress -

4 - - Vincent Odera Work Completed -

4 - - Vincent Odera Work Completed -

4 - - Caleb Makau Work Completed -

2 - - Fabian Ngeli Work Completed -

4 - - Meshack Gikonyo Work Completed -

4 - - Fabian Ngeli Work Completed -

4 - - Charles Kemboi Work Completed -

4 - - Charles Kemboi Work Completed -

 Downtime / Failure Category of
Failure Mode(s) Type Downtime Reported by
Resolution Downtime

Filled ptw
Isolated filtration line valve
Cut the displacement line pipe Filtrate clogging scheduled Downtime
welded a an inspection point
Fixex back the pipe
Handed over to production

Feedstock clogging Unscheduled Downtime

feedstock clogging Unscheduled Downtime

feedstock clogging Unscheduled Downtime

Opened and removed clogged Filtrate clogging Unscheduled Downtime

materials from the pipes

switched off the motor

opened the manhole for inspection
unclogged the materials
Closed back the manhole Filtrate clogging Unscheduled Downtime Alex Nyaoke
Reset the motor and test run the
conveyor
Handed over to the production
Transfered oil from the vessel to the
tank
Isolated the tankby closing all valves
in displacement line
Opened the displacement line
unclogged using the wire rope and Filtrate clogging Michael maina
compressed air
Closed back the line and the vessel
Flashed the line using compressed
air
Handed over to production

motor tripped
Opened the top manhole cover
Unclogged the material
Did a test run Filtrate clogging Unscheduled Downtime Sheila mwongela
Returned the manhole cover and
chute
handed over to production

Inspected the chute

Removed the blocked cake
sealed the leakage on the chute Feedstock clogging Unscheduled Downtime maina
elbow
handed over to the production

Applied LOTO
Opened pump inspection flanges
Unclogged the pipe using feedstock clogging Unscheduled Downtime Sheila Mwongeli
compressed air
Handed over to nightshift to fix back
the pipes

Tripped the motor

Opened chute and accessed man
hole for inspection
Unloggec the material Filtrate clogging Unscheduled Downtime Sheila Mwongeli
Did a test run
Returned the cover and chute
Hande over to producion
Stopped the filtarion process
Deppressurised the tank
Opened the pipe windows Filtrate clogging Unscheduled Downtime Sheila Mwongeli
Unclogged the pipe,tested and
handed over to production

Stopped the filtarion process

Deppressurised the tank
Opened the pipe windows Filtrate clogging Unscheduled Downtime Sheila Mwongeli
Unclogged the pipe,tested and
handed over to production

Power isolation
Openeing of screw top covers
Unclogging of the screw cake clogging Unscheduled Downtime Mathew tanui
Fixing the covers and test running
Handed over back to production

opened the top cover of the

conveyor
Removed the jammed material material overfeed
Feedstock clogging Unscheduled Downtime Cyprian Musyimi
Cleaning the hanger bearing downtime
Tested and handed over to
production

Applied Loto
Opened belt covers for inspection
Inspecte the belts found all te v belts
worn out Mechanical Failures
worn out belt Unscheduled Downtime Meshack odongo
Replaced the belt from pre press A Downtimes
tensioned the belt and did a test run
Returned back the pulley covers
Handed back to production

opened the top and boytoom sight

glasses
Removed the jammed glasses Feedstock clogging Unscheduled Downtime supplene
Opened the covers and cleaned the
drums
Handed over to production

Filtrate clogging

Power isolation from the panel

opening of rotor lift inspection
covers Feedstock clogging Unscheduled Downtime Mechanical Failures John Ober
Replacememnt of worn out bush Downtimes
Test running of the rotor lift
production resumed

Wear on Part
Topped the heating oil of the boiler Low lubricant levels Unscheduled Downtime

Applied loto
Disengaged the drums
Cleared metals from drums and abnormal sound Unscheduled Downtime Kelvin Ochola
feeder
Tested and handed over the
machine to production

1.Power isolation
2. Opening of the feeder cover
3.Unclogging of cotton materials
4.Unclogging of pre cleaner
overhead conveyor and
recirculation/overflow duct
5.Test run of the line material overfeed
Feedstock clogging Unscheduled Downtime downtime Stanley Mulinge

Applied Loto
opened the duct
Cleaned the clogged materials
Feedstock clogging Unscheduled Downtime Cyprian musyimi
Greased the bearing
Closed the duct and handed over to
production

opened the manhole covers

unclogged the conveyor
Test run the conveyor cake clogging
closed the manhole and handed
back to production

Applied Loto
Opened the sensor and was running
ok
Unblocked the sensor and cleaned
materila on it electrical failure Unscheduled Downtime Sheila Mwongeal
Checked material around its working
position
Did a test run and was okey
Handed over to production

Applied Loto to the extruder

Opened the oil storage container
Added oil AWS 68 Low lubricant levels scheduled Downtime Sheila Mwongela
Handed over to production

Applied Loto
opened the duct and unclogged
Did a test run was okey Filtrate clogging Unscheduled Downtime Sheila Mwongela
closed and handed to production

Stopped the pump

Opened the outlet pipe
Inspected and found it clogged by
cake feedstock clogging Unscheduled Downtime
Unclogged and tested okey
Assembled the outlet pipe and
handed over back to production
Replaced the leaking magic
connector Leakages Unscheduled Downtime Matilu

Adjusted feeder parameters to

Wear on Part Unscheduled Downtime Thaddeus wambua
ensure more material on the drums

Rectifield faulty hydraulic circuit Wear on Part Unscheduled Downtime francis Mutinda

Fixed the leakage with mask

Leakages Unscheduled Downtime Cyprian
awaiting shutdown widow

Unclogging of the water cooling line feedstock clogging Unscheduled Downtime John ober

Removed the nozzle and unclogged

Meat clogging Unscheduled Downtime Sheila
the material

Removed the working screws and

overload Unscheduled Downtime Meshack odongo
unclogged the clogged material

Replaced the faulty one from

Broken Part Unscheduled Downtime Cyprian musyimi
prepress A

opened the unions and unclogged

Filtrate clogging Unscheduled Downtime Cyprian musyimi
the displacement line

Clips fixed Misalignment scheduled Downtime

Applied Loto procedure

Opening of the conveyor inspection
covers
Removing metals stuck btween the
Feedstock clogging Unscheduled Downtime Mathew
screw
Test running of the rotor
Fixing back covers
Handed over back to production

Replaced the broken part after

welding Broken Part

Equipment Upgrade
Fixed Overheating Unscheduled Downtime
Downtime

Inspected the chute

Removed the blocked cake
sealed the leakage on the chute Improvement Project Unscheduled Downtime Equipment Upgrade
elbow Downtime
handed over to the production

Unclogged the conveyor Filtrate clogging

Greasing,tightening Feedstock clogging

 Improvement Project

1.Applied Loto procedure.

2.Dismantled the assembled the
bypass chute & unclogged Overload Unscheduled Downtime material overfeed Alex Nyakoe
accumulated material. downtime
3.Test Run and confirmed to be ok.

abnormal sound scheduled Downtime

abnormal sound scheduled Downtime

Improvement Project

Applied Lotto
Opened the conveyor covers
Unclogeed the clogged ,material Meat clogging
Tested and handed over to
production

Clogged infeed conveyor Cake clogging Unscheduled Downtime Stanley mulinge

Applied loto procedure

opened the inspection flanges
Uclogged the line
Filtrate clogging Unscheduled Downtime Cyprian Musyimi
cleared the line using compressed
air
handed over to production

Opened the chute and unclogged

the wet cotton Meat clogging Unscheduled Downtime David musyoka

Disconnected the top cover and the

bottom chute of the conveyor
Unclogged the conveyor
Filtrate clogging Unscheduled Downtime Mathew Tanui
Connected back the conveyor
Tested and handed over back to
production

Aligned the tie rods Misalighnment scheduled Downtime John Ober

Improvement Project

Broken Part

Abnormal sound

Opened the side covers of the

conveyor
Removed the jammed materials on Cake clogging Unscheduled Downtime Mathew Tanui
th feeder
Tested and handed over to
production
clogged conveyor Cake clogging Unscheduled Downtime Erick Mwaura

1. Inspected the sensor and

confirmed to be Faulty
Sensor Failure Unscheduled Downtime David Musyoka
2.Replaced with new one.
3. Tested and confirmed to be Ok.

1. Applied LOTO Procedures

2. Uncloged the accumulated cake Material Clogging Unscheduled Downtime Cyprian Musyimi
3. Test Run the conveyor and
confirmed to be ok

1.Applied LOTO Procedures

2.Unblocking the seperator
conveyor
3. Mounting of crease return Material Clogging Unscheduled Downtime Cyprian Musyimi
conveyor cover.
4. Test run both conveyor and
seperator and confirmed to be ok.

1. Opened the top cover of the

cyclone
2. Scrapped off stucked cake that Material Clogging Unscheduled Downtime Cyprian Musyimi
was moist
3. Closed back the top cover

1.Isolated motor for crease return

and seperator conveyor
2. Inspected the union connector
and noted a hardened cake inside Material Clogging scheduled Downtime Alex Nyaoke
the connector.
3. Unclogged the cake and test run
the conveyor & confirmed to be ok.

1. LOTO procedure for isolation of

the conveyor
2. Opened the chute and then
unblocked Material Clogging Unscheduled Downtime Thaddeus Wambua
3. Unclogged and test run the
conveyor
4. Mounting back the chute and
handing over to operation team.
 Planned
Repair Start Repair Start Restoration Restoration
Reported to Job Card no Operating
Date Time Date Time
Time

antony mugo 02/Jan/24 5:30 24:00 03/Jan/24 10:00

24:00

24:00

24:00

24:00

Fabian Ngeli 04/Jan/24 23:20 24:00 04/Jan/24 23:55

Vincent odera 04/Jan/24 8:30 24:00 04/Jan/24 9:30

Vincent odera 04/Jan/24 15:36 24:00 04/Jan/24 16:29

Vincent odera 04/Jan/24 17:30 24:00 04/Jan/24 18:00

Joel Mutuku 05/Jan/24 17:10 24:00 05/Jan/24 19:00

Joel Mutuku 05/Jan/24 10:30 24:00 05/Jan/24 11:00

Joel Mutuku 05/Jan/24 7:45 24:00 05/Jan/24 10:00

Joel Mutuku 05/Jan/24 2:00 24:00 05/Jan/24 4:30

Fabian Ngeli 06/Jan/24 1:00 24:00 06/Jan/24 2:00

justus ngala 06/Jan/24 23:50 24:00 07/Jan/24 0:20

JUstus Ngala 06/Jan/24 17:40 24:00 06/Jan/24 18:40

Vincent odera 06/Jan/24 24:00 06/Jan/24 0:20

24:00

Justus Ngala 09/Jan/24 8:40 24:00 09/Jan/24 11:40

24:00
Kennedy Maingi 10/Jan/24 20:00 24:00 10/Jan/24 21:30

JUstus Ngala 11/Jan/24 9:50 24:00 11/Jan/24 11:30

Fabian Ngeli 12-Jan-23 12/Jan/24 9:30 24:00 12/Jan/24 11:15

vincent odera 13/Jan/24 8:05 24:00 13/Jan/24 8:45

13/Jan/24 16:50 24:00 13/Jan/24 17:20

Gitonga 14/Jan/24 7:45 24:00 14/Jan/24 9:00

Charles kemboi 14/Jan/24 9:20 24:00 14/Jan/24 9:45

Charles kemboi 14/Jan/24 12:00 24:00 14/Jan/24 13:00

Alex Nyaoke 16/Jan/24 18:10 24:00 16/Jan/24 18:30

Daniel Kimathi 17/Jan/24 15:30 24:00 17/Jan/24 16:30

justus ngala 17/Jan/24 8:30 24:00 17/Jan/24 9:30

Justus Ngala 19/Jan/24 10:10 24:00 19/Jan/24 12:30

Joel Mutuku 20/Jan/00 7:09 24:00 20/Jan/00 7:57

Charles kemboi 20/Jan/24 2:30 24:00 20/Jan/24 3:00

Vincent odera 21/Jan/24 14:34 24:00 21/Jan/24 14:56

kennedy maingi 22/Jan/24 11:40 24:00 22/Jan/24 14:30

kennedy maingi 22/Jan/24 14:30 24:00 22/Jan/24 20:00

kennedy maingi 23/Jan/24 10:00 24:00 23/Jan/24 15:10

25/Jan/24 15:10 24:00 25/Jan/24 15:30

Fabian Ngeli 27/Jan/24 8:15 24:00 27/Jan/24 9:15

30/Jan/24 11:40 24:00 30/Jan/24 12:50

31/Jan/24 11:30 24:00 31/Jan/24 13:00

31/Jan/24 9:30 24:00 31/Jan/24 16:30

01/Feb/24 15:15 24:00 01/Feb/24 16:10

01/Feb/24 10:20 24:00 01/Feb/24 12:30

 02/Feb/24 9:30 24:00 02/Feb/24 12:00

Charles Kemboi 04/Feb/24 3:55 24:00 04/Feb/24 4:25

24:00

24:00

24:00

24:00

Antony mugo 06/Feb/24 11:30 24:00 06/Feb/24 12:00

fabian Ngeli 06/Feb/24 22:10 24:00 06/Feb/24 23:25

Meshack Gikonyo 06/Feb/24 19:20 24:00 06/Feb/24 19:45

Vincent odera 06/Feb/24 15:30 24:00 06/Feb/24 16:00

Antony mugo 06/Feb/24 13:10 24:00 06/Feb/24 13:50

24:00

24:00

24:00

Vincent Odera 08/Feb/24 20:40 24:00 08/Feb/24 21:00

Vincent Odera 08/Feb/24 6:20 24:00 08/Feb/24 6:50

Caleb Makau 10/Feb/24 12:10 24:00 10/Feb/24 12:30

Fabian Ngeli 10/Feb/24 10:20 24:00 10/Feb/24 11:20

Meshack Gikonyo 10/Feb/24 8:00 24:00 10/Feb/24 9:00

Meshack Gikonyo 10/Feb/24 8:10 24:00 10/Feb/24 9:00

Charles Kemboi 10/Feb/24 21:35 24:00 10/Feb/24 22:10

Charles Kemboi 11/Feb/24 4:30 24:00 11/Feb/24 5:10

 Actual Spare Parts / Work Executed by
Downtime
Operating Time operating Consumables or event Logged in
Duration
time used by

Union Antony Mugo

Ishmael Barasa
Vincent odera

4:30 24:00 -4:30

- 24:00

- 24:00

- 24:00

- 24:00

None Fabian ngeli

Meshack Gikonyo
Kennedy Gitonga

0:35 24:00 23:25

 None Vincent odera
Caleb Makau
Char;es Kemboi

1:00 24:00 23:00

Caleb Makau
charles kemboi
Vincent Odera
0:53 24:00 23:07 None

Caleb Makau
charles kemboi
Vincent Odera

0:30 24:00 23:30 None

None Caleb Makau

Chareles Kemboi
Joel Mutuku
1:50 24:00 22:10

None Caleb Makau

Chareles Kemboi
Joel Mutuku

0:30 24:00 23:30

 None Caleb Makau
Chareles Kemboi
Joel Mutuku
2:15 24:00 21:45

None Caleb Makau

Chareles Kemboi
Joel Mutuku
2:30 24:00 21:30

None Fabian Ngeli

Vincent Odera
Kennedy Gitonga

1:00 24:00 23:00

None Vincent Odera

Kennedy Gitonga
Meshack Gikonyo

0:30 24:00 23:30

belt predator
SPBP2240

1:00 24:00 23:00

- 24:00

- 24:00

Bush Fabian Ngeli

Meshack Gikonyo
Ishmael Barasa
3:00 24:00 21:00

- 24:00 None
 Charles Kemboi
1:30 24:00 22:30 None Antony mugo
Kennedy gitonga
None

1:40 24:00 22:20

1:45 24:00 22:15 None

Vincent Odera
Kennedy Gitonga
Joel mutuku
0:40 24:00 23:20 None

kennedy Gitonga
Vincent odera
joel mutuku
0:30 24:00 23:30 None

Kennedy Gitonga
Charles kemboi
Joel mutuku

1:15 24:00 22:45 None

Kennedy Gitonga
Charles kemboi
0:25 24:00 23:35 None Joel mutuku

Kennedy Gitonga
Charles kemboi
1:00 24:00 23:00 None Joel mutuku

None Charles Kemboi

Joel Mutuku
kennedy Gitonga
0:20 24:00
 magic connector Meshack GIkonyo
1:00 24:00 23:00

None justus ngala

1:00 24:00 23:00

None Charles Kemboi

2:20 24:00 21:40 Caleb Makau
Antony Makau
None Joel mutuku
0:48 24:00 23:12

None Kennedy maingi

justus Ngala
Meshack Gikonyo
0:30 24:00 23:30 Fabian Ngeli

None Vicent odera

0:22 24:00 23:38

None
2:50 24:00 21:10

None
5:30 24:00 18:30

None Kennedy maingi

justus ngala
Antony mugo
5:10 24:00 18:50 Caleb makau
Charles kemboi

Vincent Odera
0:20 24:00 23:40

None Fabian Ngeli

Meshack Gikonyo
Kennedy Gitonga

1:00 24:00 23:00

1:10 24:00 22:50

1:30 24:00 22:30

7:00 24:00 17:00

0:55 24:00 23:05

2:10 24:00 21:50

2:30 24:00 21:30

0:30 24:00 23:30

- 24:00

- 24:00

- 24:00

- 24:00

None Antony mugo

Vincent odera
0:30 24:00 23:30 Justus ngala

None

1:15 24:00 22:45

None Meshack Gikonyo

0:25 24:00 23:35 Fabian Ngeli

None Antony mugo

Vincent odera
Justus ngala
0:30 24:00 23:30

None
0:40 24:00 23:20

- 24:00

- 24:00

- 24:00

None

0:20 24:00 23:40

 None Vincent odera
Antony mugo
Ishmael barasa
0:30 24:00 23:30

Level Sensor Caleb Makau

0:20 24:00 23:40

1.Fabian Ngeli
2. Caleb Makau
3. Meshack Gikonyo

1:00 24:00 23:00

1.Fabian Ngeli
2. Caleb Makau
3. Meshack Gikonyo
1:00 24:00 23:00

1.Fabian Ngeli
2. Caleb Makau
3. Meshack Gikonyo
0:50 24:00 23:10

1. Charles Kemboi
2. Joel Mutuku
3. Ishmael Baraza
0:35 24:00 23:25

1. Charles Kemboi
2. Joel Mutuku
3. Ishmael Baraza
0:40 24:00 23:20
 Pre Cleaner
Overhead
05/Feb/24 ConveyerPC/
OC

Two Tray
Seed Cleaner
06/Feb/24 BlowerTTSC/
BL

06/Feb/24 Hulls Bale

Press

06/Feb/24 Extruder FE
1000_2.EX1.1

06/Feb/24 Extruder FE
1000_2.EX1.1
Automatic
06/Feb/24
Filter_3.FI2.1

06/Feb/24 Extruder FE
1000_2.EX1.1

06/Feb/24 Conveyor_3.T
L1.2
Two Tray
Seed Cleaner
06/Feb/24 Machine
TrayTTSC/T

Press
07/Feb/24 FS_1010_2.FP
1.1

Storage Bin
Rotary
07/Feb/24 Feeder-1SB/R
F-1

Pre Cleaner
Overhead
07/Feb/24 ConveyerPC/
OC

08/Feb/24 Conveyer_2.T
P3.4
Press Cake
08/Feb/24 cooler_2.CC3.
1
Press
10/Feb/24 FS_1010_2.FP
1.1
Conveyer_2.T
10/Feb/24
P3.4
Integrated
10/Feb/24 Separator_2.
PP3.5
10/Feb/24
10/Feb/24
11/Feb/24