A Timely Catch and a Long Night Ahead

Key Points – 4th April

  • Very low participation in the morning meeting, requested support to increase it.

  • Kiln feeding bucket elevator issue identified by Mr. Ghanshyam – serious structural concern.

  • Monthly document signature routine completed.

  • Crusher output size discussed in DPM – linked to downstream performance and breakdowns.

  • Scheduled for night vigilance duty – gearing up mentally.

The morning started as usual, but the attendance at the morning meeting was again disappointingly low. After the prayer, I gently reminded everyone present to encourage their teammates to attend. This is not just a ritual—it’s a shared space to align, reflect, and stay safe. When people skip it, we lose the chance to connect and prepare mentally for the day.

A Timely Observation Saves the Day

Later in the morning, Mr. Ghanshyam did something that reminds us all of the importance of alertness and experience. He noticed an abnormal sound from the kiln feeding bucket elevator. His instincts kicked in, and upon inspection, we found many buckets damaged—deformed from hitting some obstruction inside.

Had this gone unnoticed, we were staring at a potential major breakdown. Worse, these buckets could have gotten dislodged while the elevator was running—risking life, equipment, and costly downtime.

But it's not a simple maintenance job either. The supporting platform structure itself is corroded and unsafe to work on. Reinforcement work must precede the actual bucket repairs. It's a chain of tasks—starting with safety.

Signatures and Systems

The rest of the morning passed with the usual monthly documentation cycle. The paperwork and signatures—the behind-the-scenes admin work that holds the plant’s rhythm together.

Crusher Output – A Root Cause Revisited

In the DPM, we focused on something that keeps coming back to haunt us—the crusher output size.

When the crusher fails to deliver the required particle size, it affects the Raw Mill’s throughput. But the chain doesn’t stop there—oversized material travels forward, causing belt blockages, problems during stacking, and jamming during reclaiming.

It’s not just one problem—it’s a cascading series of issues. It needs strict monitoring and maybe a revisit to crusher performance settings or even operator practices.

Night Vigilance – My Turn

And tonight, it’s my turn for night vigilance. There’s always something special about these nights—walking through the silent plant, listening to machines speak in their language, sensing what words can’t say. It’s where observation turns into instinct.

Let’s see what tonight unfolds.

Some days remind us why presence and participation matter. Others show how one sharp eye can avert disaster. And some nights call for quiet watchfulness. Today was all of that, and more.

Comments

Post a Comment

Popular posts from this blog

Respecting Time, Building Discipline, and Moving Forward: Diary Entry: Thursday, 6th March 2025

Image
This morning’s session started with prayer , attended by around 35 workmen . By the time it ended, the count had grown to 67, including me . I pointed this out to them, saying, “This happened in just five minutes. If we start a little earlier, we will always be on time.” I then shared a simple yet important message: "When we respect time, time will take care of us." I explained further: "At times, we wonder why unexpected or unfortunate events happen to us at odd times. The truth is, many of these situations occur because we fail to respect time. If we cultivate the habit of doing things in a timely manner, we will see that everything in our lives also aligns at the right time." To reinforce this, I asked them if they could come on time tomorrow . They agreed, and we all clapped in unison. Then, I posed another challenge: Could each of them bring one more person with them tomorrow? Again, they agreed, and we clapped once more.
Read more

Faith, Challenges, and Perseverance – A Day of Commitment: 11th March, 2025

Image
The day began with a soulful group prayer song led by Mensah. It’s my favorite one, even though I don’t understand the language. There’s something about the melody, the rhythm, and the way everyone joins in—it fills the air with an energy that words can’t describe. I recorded a video of it, hoping to capture that moment of unity and devotion. After the prayer, I shared a few thoughts: "God is Great. In God We Trust." These words are written everywhere—in India, in Togo—on shop signboards, vehicles, and walls. They serve as constant reminders. But in the struggles of life, we often forget. There are moments when we feel helpless, overwhelmed. Yet, when we truly believe that God is with us, that faith itself becomes our strength. It fuels us, pushes us to put in more effort. That’s how we move forward. That’s how we win. HOD Standing Meeting: The Final Countdown for Kiln#2 Light-Up The focus of our morning meeting was the final preparations for lighting up Kiln#2. Everyone ...
Read more

Barriers, Breakthroughs, and a Hattrick of Rain: Key takeaways and happenings - 18th March, 2025

Image
Morning Begins with a Blockade The day started on a frustrating note— OTR blocked all incoming and outgoing movement of our plant. I stood at the gate, watching. A plant must breathe—materials must flow in, cement must flow out. But today, everything was frozen. Let’s see how this unfolds. A Small Journey, A Big Question My driver had to go to Lomé for some vehicle-related document renewal. But with roads blocked, I wondered: 💭 How much fuel will be wasted today? Some losses are obvious—like shutdowns and breakdowns. Others, like unplanned fuel wastage, quietly eat into efficiency. Morning Meeting: The Power of Reporting Despite the roadblock, the morning meeting started on a positive note. I recited: "Sarve Bhavantu Sukhinaha, Sarve Santu Niramayah..." ( May all be happy, may all be free from illness... ) I explained its meaning—happiness and safety are interconnected. Then, I spoke about Reporting—the 5th and most important cardinal rule of safety. 📌...
Read more