Abstract:
East African Portland Cement Company has been operating at sub-optimal efficiency and effectiveness of the raw mill plant due to high rate of unplanned equipment failure and frequent stoppages. The existing maintenance system in the Company is based on
integration of all functions and processes with no cross-functional teams, which results
into high maintenance cost, low plant reliability, low production and low satisfaction of
workers. The main objective of this research is to determine how to improve overall
equipment effectiveness of the raw mill plant through implementation of an effective
maintenance concept. The specific objectives are to analyze and determine the overall
equipment effectiveness of the raw mill plant, to establish the causes of its low
availability and to identify and customize an effective maintenance concept for the raw
mill. This research adopted descriptive and quantitative case study approach. The data
collected was analyzed and presented in tables, pie charts, line graphs and bar graphs.
Consequently in this research analysis of various maintenance concepts were
investigated. From this research, it can be deduced that raw mill plant requires a
harmonized maintenance concept regarding inspection, preventive maintenance, repair
and overhaul of the main components as well as environmental auditing during operation to ensure that it is fully operational and efficient. Total productive maintenance concept therefore has been identified as key for meeting maintenance objectives of the raw mill. A customized framework of total productive maintenance deployment at East African Portland Cement Company has been developed with six step transformation approach used in embedding high performance culture. In this thesis the overall equipment effectiveness of the raw mill was evaluated and found to be below the world class target
of 85.41%
