Improving plant availability through Effective Maintenance System: A Case Study in MESSEBO CEMENT FACTORY

Abstract

Corrective maintenance technique is have long been one of an obstacle to Messebo cement factory’s efforts to maintain high plant availability. In the fiscal year 2023/24 MESSEBO cement factory is experiencing suboptimal operational efficiency due to the persistently low availability of critical machinery across its production lines. Key equipment essential for raw mill processing, clinker production, cement milling, and packaging is operating below industry- standard availability benchmarks (85-90%), leading to reduced production capacity, increased downtime costs, and potential delays in meeting customer demand. This research examines the existing maintenance system on plant availability and over all equipment effectiveness (OEE) in the context of messebo cement factory. The study’s main objectives were to assess current maintenance procedures, pinpoint the underlying reasons for outages, and suggest workable plans to improve operational effectiveness through manpower development, predictive technology, and infrastructure improvements. The research used mixed- methods quantitative and qualitative approach, through a comprehensive case stud approach analyze maintenance data in terms of performance metrics and downtime cases. The research findings highlighted several critical issues. A reactive maintenance culture prevailed, with over 56% of respondents indicating that preventive tasks were often skipped during peak production periods. Aging infrastructure and unstable power supply led to more than 30 major equipment failures annually. Furthermore, outdated manual record keeping practices undermined data accuracy, despite 83% participants acknowledging the link between downtime and the absence of predictive maintenance. Despite these challenges, the study identified several opportunities for improvement. Notably, 60% of the workforce expressed support for modernization efforts, while 50% believed that real-time monitoring systems could significantly enhance decision making and efficiency. The research recommended immediate piloting of IOT sensors on critical equipment (e.g, cement mill rollers), enforcing strict PM via digital checklists. Medium term strategies include CMMS implementation for centralized planning and predictive analytics, alongside specialized maintenance team training. Long term goals target transitioning to predictive maintenance (aiming for 20-40% downtime reduction), fostering cross departmental collaboration through shared KPIs, and securing leadership support by demonstrating ROI