Kiln Flames, Plastic Bits & the Bathtub Curve of Life | Diary Entry - 3rd June, 2025
The morning began with energy - both inside and out.
A cool breeze was blowing over Tabligbo, but there was a warmth in the hearts of those who gathered early for our morning session. As always, I picked up the plastic litter thrown along my way - and I do mean it when I say:
“People give me opportunities to serve the earth - one plastic bit at a time.”
It’s not sarcasm. It’s a way to turn irritation into action, and action into meditation.
A Prayer, a Note, and Silent Flames
Two of our team members sang the morning prayer, their voices unpolished but open-hearted. They weren't trained singers, but the way they sang - raw, sincere, and hopeful - made it beautiful. I joined them in their final line:
“Thank you, Lord.”
That line stayed with me the whole day.
Cleaning Work Appreciated
Mr. BVKR shared a note of appreciation for the successful and safe completion of the Clinker Silo Top cleaning by our contractor. I followed that up with a mention of the Crusher Mechanical team, who have been persistently cleaning gearboxes and exposed equipment, bit by bit.
I told everyone something I’ve believed in for years:
“A plant never gets old. It only gets ignored.”
Old machines are just like old minds - once you clean them, talk to them, care for them, they begin to function better than new ones.
Line #1 Kiln Lit at 10:30 AM
At long last, Kiln of Line #1 was lit at 10:30 AM.
This moment should have been a celebration - but once again, the team executed it quietly, like a routine chore.
Why?
My observation - and it's not the first time - is that there is a lack of confidence. The fear of failure overshadows the joy of creation. People hesitate to celebrate because they’re afraid something might go wrong immediately after. But this isn’t how leaders behave.
“Lighting up a kiln is like lighting up a Diya during Diwali - it deserves attention, intention, and reverence.”
I went to the burner platform myself, took photos, made a video, and yes, distributed toffees to everyone I met along the way. Small things, but they plant seeds of culture.
On the Bathtub Curve - Rethinking the Classic
In the afternoon, I revisited a topic close to my technical curiosity - the Bathtub Curve (BTC) used in reliability and failure analysis.
Traditionally, the curve shows:
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Infant Mortality Phase (early failures),
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Stable Operating Period, and
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Wear-out Phase.
But real-world plants don’t work that way. I no longer fully believe in the classic curve.
Here’s why:
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The race toward failure begins not with commissioning, but with design, equipment selection, and even the first civil foundation.
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Ideal conditions - perfect installation, flawless spares availability, immaculate preventive maintenance - don’t exist.
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No two cement plants, even if identical, follow the same failure behavior.
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Maintenance KPIs? They only make sense if aligned with your plant’s position on its own failure curve.
So the question that arises is:
“How do I plot the BTC for my plant?”
“How do I know where we stand now?”
It’ll take structured data:
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Maintenance logs
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MTBF (Mean Time Between Failures)
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Age and condition of equipment
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Installation records
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Breakdown patterns over months and years
But more than that, it requires the will to see patterns - not just numbers.
This reflection is leading me toward building a customized BTC Model for our plant, factoring in our unique journey, people, decisions, and conditions.
A Small Gift, A Quiet Impact
In the evening, I gave a new mobile phone to my driver.
It wasn’t expensive - under 10 USD - a basic phone similar to his old one. But I’ve seen him struggle every day, tapping keys that barely worked, missing messages, getting frustrated.
This gift made him smile.
He didn’t say much. But the way he carefully unboxed it, like it was gold, said everything.
Key Points of the Day - 3rd June, 2025:
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Participated in plastic clean-up during the morning walk - making it a habit and an act of service.
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Enjoyed a sincere morning prayer session with the team; ended with "Thank you, Lord."
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Acknowledged safe completion of Clinker Silo Top cleaning work.
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Appreciated Crusher Mechanical team for proactive cleaning of gearboxes and plant equipment.
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Declared: “A plant never gets old” - reinforcing the culture of continuous care.
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Kiln of Line #1 was lit at 10:30 AM - celebrated quietly, highlighting the need to rebuild confidence.
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DPM cancelled due to Light-Up focus.
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Visited burner platform post light-up; captured photos and video, distributed toffees to team members.
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Deep technical reflection on Bathtub Curve - challenging standard models and calling for plant-specific analysis.
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Gifted a basic mobile phone to the driver - a simple gesture with heartfelt impact.
Reflection:
Kilns are lit. So are lives. Whether it’s picking up a plastic wrapper or gifting a $10 phone, it’s the small sparks that light bigger fires.
And as for the Bathtub Curve - maybe it's not a curve after all.
Maybe it’s a mirror.
Showing us how we build, use, neglect, repair - and how we evolve.
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