Lux Diva P

Saturday Sunday
Driver Description Units Target Actual Target
Volume Produced tons 16.00 10.20 16.00
Productivity Equipment Efficiency % 75.00 63.80 75.00
Line Efficiency % 75.00 47.19 75
QDI+ : In-Use unit 2.50 1.00 2.50
Quality QDI+ : In-Store unit 2.50 1.30 2.50
Reject Level % 2.00 2.12 2.00

1. Power failure/Low air 1. Failure of the tablet

pressure twister bearings
Key Issues
2. Changeover to Peach 2. Low air pressure
and Cream variant
3. Stiffener/wrapper
jamming on the ACMA
machine
 Lux Diva Production Performance Report - Week 30
Sunday Monday Tuesday Wednesday Thursday
Actual Target Actual Target Actual Target Actual Target
7.90 16.00 13.19 16.00 0.00 16.00 0.00 16.00
40.69 75.00 71.20 75.00 0.00 75.00 0.00 75.00
36.56 75 61.06 75 0.00 75 0.00 75
1.00 2.50 1.00 2.50 #DIV/0! 2.50 #DIV/0! 2.50
1.00 2.50 1.00 2.50 #DIV/0! 2.50 #DIV/0! 2.50
2.53 2.00 2.46 2.00 0.00 2.00 0.00 2.00

Failure of the tablet 1. Power failure/Low air

ster bearings pressure

Low air pressure 2. Hopper Bridging/Poor

supply from stamper
3. Stiffener/wrapper
jamming on the ACMA
machine
Thursday Friday Total
Actual Target Actual Target Actual
0.00 16.00 0.00 112.00 31.29
0.00 75.00 0.00 75.00 25.10
0.00 75 0.00 75.00 20.69
#DIV/0! 2.50 0.00 2.50 #DIV/0!
#DIV/0! 2.50 0.00 2.50 #DIV/0!
0.00 2.00 0.00 2.00 1.02
l
Project DIVA NIGERIA
Line Performance Report

Line: Diva Line Batch Size: 500kg

Production Start: Saturday Date: 7/18/2009
Production Stop: Friday Machine Speed: 200.00 Week: 30
Aver Wt 75.00g
Saturday Sunday Monday Tuesday Wednesday Thursday Friday
Hours 24.00 24.00 24.00 24.00 24.00 24.00 24.00
Date 7/18/2009 7/19/2009 7/20/2009 7/21/2009 7/22/2009 7/23/2009 7/24/2009 Total

1. Non-machine losses

a. Planned losses
Meal breaks 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00
Training 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00
Team briefing / meeting 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00
Planned Maintenance 120.00 0.00 0.00 0.00 0.00 0.00 0.00 120.00
Machine Scheduled Cleaning/Lubrication 90.00 90.00 120.00 0.00 0.00 0.00 0.00 300.00
Product/Size Changeover 90.00 0.00 0.00 0.00 0.00 0.00 0.00 90.00
Others 0.00

b. Unplanned losses
Emergency Evacuation/Situation 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00
No materials / out of spec. material 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00
Down stream stops (i.e Process Issues) 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00
Utilites failure (compressed air & power etc) 75.00 56.00 85.00 0.00 0.00 0.00 0.00 216.00
Waiting for operator / engineer 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00

Total non-machine losses (minutes) 375.00 146.00 205.00 0.00 0.00 0.00 0.00 726.00

2. Machine Losses

Mixer Tripping 0.00

Mixer

Gear Box/motor Failure 0.00

Discharge Conveyor Failure 0.00
Hydraulic Pump Failure 0.00
Scrapping Blade Change 0.00
RollMill

Electric Motor failure 0.00

Gear Failure 0.00
Fan Belt Cut/Change 0.00
Transfer Conveyor Tripping/Failure 0.00
Chilled water pump failure 0.00
Plodder Tripping 25.00 25.00
Gear Failure 0.00
Fan Belt Cut/Change 0.00
Plodder

Electric Motor failure 0.00

Hopper Bridging 48.00 34.00 75.00 157.00
Soap Jamming 13.00 13.00
Clutch Failure 0.00
Recycle conveyor belt cut/failure 0.00
Cutting Blade Change 0.00
Cutter/Metal

Conveyor belt cut/change 0.00

Detector

Billet Jamming 8.00 25.00 33.00

Encoder Failure 0.00
Motor failure 0.00
Reciprocating Arm Failure 0.00
Electrical fault 0.00
Stamper Tripping 0.00
Gear Failure 0.00
Stamper/Twister

Fan Belt Cut/Change 0.00

Glycol Chiller failure
Poor Supply from Stamper 42.00
Electric Motor failure 0.00
Twister Roller Bearing Failure 210.00 210.00
Vacuum Generator Failure 0.00
Soap Jamming 0.00
Conveyor belt cut/failure 0.00
Registration Problem 28.00 35.00 63.00
Conveyor Cut/Change 0.00
/Diverter

Changing of wrapper/stiffener 45.00 28.00 55.00 128.00

 Chiller Failure 0.00

ACMA/Diver
Coding Machine failure 30.00 5.00 35.00
Stiffener/Wrapper Knife failure 0.00
Divider Roller Faulty 0.00
Wrapper/Stiffener Jamming 65.00 25.00 38.00 128.00
Soap Jamming at folder area 10.00 10.00
Heater Fluctuation/Failure 0.00
Tablet Jamming 0.00
Film winding on roller 0.00
Bundlers

Folder Safety fault 0.00

Motor failure 0.00
Changing of films 0.00
Electrical fault 0.00

Total machine losses (min) 234.00 310.00 300.00 0.00 0.00 0.00 0.00 844.00

3. Total Loss

Machine + Non-machine Losses 609.00 456.00 505.00 0.00 0.00 0.00 0.00 1570.00

4. Machine Performance

a. Machine Available time 1065.00 1294.00 1235.00 1440.00 1440.00 1440.00 1440.00 9354.00
b. Actual running time 831.00 984.00 935.00 1440.00 1440.00 1440.00 1440.00 8510.00
c. Effective time 679.50 526.50 879.20 0.00 0.00 0.00 0.00 2085.20
d. Average speed 163.54 107.01 188.06 0.00 0.00 0.00 0.00 458.61

Machine efficiency 63.80 40.69 71.19 0.00 0.00 0.00 0.00 25.10

Line efficiency 47.19 36.56 61.06 0.00 0.00 0.00 0.00 20.69

5. Product loss
a. Product Losses (tablets)
*Actual tablets produced 135900 105300 175840 417040.00
Waste from Suction Cup (Fall Down tablets) 0 0 0 0 0 0 0 0.00
Product waste Quality(tablets) 2876 2665 4330 9871.00
% of Product Waste 2.12 2.53 2.46 #DIV/0! #DIV/0! #DIV/0! #DIV/0! 2.37

b. Product Losses (shavings)

*Weight / tablets produced (Kg) 0 0 0 0 0 0 0 0.00
Weight of shavings 0.00 0.00 0.00 0.00
% of shaving Waste #DIV/0! #DIV/0! #DIV/0! #DIV/0! #DIV/0! #DIV/0! #DIV/0! #DIV/0!

(* This figure is the amount of tablets produced in the amount of time the machine was running. It does not
take in to account ramp-up and ramp-down times and therefore is not totally accurate)