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A process plant has a requirement to operate 320 days per year, producing at a rate of 1500 tones per 24 hour day. Over the year its performance has been as follows.

1. Scheduled operation time 320 days,

2. Number of Breakdowns are 6 ,

3. Delays for Breakdowns accounted for 200 hours.

4. Preventive Maintenance time is 100 hours

5. Shutdown due to lack of feed lasted for 100 hours

6. Process Slowdowns are for 80 hours at an 80% rate

7. Wet Feed Slowdowns is 60 hours at a 60% rate

8. Total rejected production is 1000 tons.

9. Second quality production is 2000 tones at 50% value

Answer :

Total Scheduled Operation Time: The process plant operates for 320 days per year. Number of Breakdowns: The process plant experienced 6 breakdowns throughout the year.

Delays for Breakdowns: The breakdowns accounted for 200 hours of delay in total.

Preventive Maintenance Time: The process plant underwent 100 hours of preventive maintenance.

Shutdown due to Lack of Feed: There was a shutdown for 100 hours due to the lack of feed.

Process Slowdowns: The process plant experienced 80 hours of process slowdowns at an 80% rate. It means that during those 80 hours, the plant was operating at 80% of its normal speed or efficiency.

Wet Feed Slowdowns: The process plant encountered 60 hours of wet feed slowdowns at a 60% rate. This indicates that during those 60 hours, the plant was operating at 60% of its normal capacity due to wet feed.

Total Rejected Production: The total rejected production amounted to 1000 tons.

Second Quality Production: The second quality production reached 2000 tons but at a 50% value compared to the standard quality.

To assess the overall performance and efficiency of the process plant, it would be useful to calculate metrics such as: Overall Equipment Effectiveness (OEE): This metric evaluates the performance, availability, and quality of the plant. It is calculated by multiplying the availability rate, performance rate, and quality rate.

Utilization: This metric measures the extent to which the plant is used during scheduled operation time.

Production Losses: These can be determined by analyzing the different types of delays, breakdowns, and shutdowns.

Yield: The yield can be calculated by considering the rejected production, second quality production, and the total desired output.

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