Fly Ash Packaging Plant Downtime Assessment to Maintain Product Supply: A Case Study

• A.L. Tau Department of Operations Management, Tshwane University of Technology, South Africa https://orcid.org/0000-0002-5840-0037
• E.I. Edoun Department of Management, Tshwane University of Technology, South Africa https://orcid.org/0000-0003-0640-6880
• S. Pooe Department of Management, Tshwane University of Technology, South Africa https://orcid.org/0000-0002-1908-2646

DOI:

https://doi.org/10.7166/36-3-3325

Abstract

Fly ash is used as one of raw materials in cement and concrete industries. A fly ash packaging plant experienced downtime for two consecutive months due to automated fly ash transfer system failure. Pareto chart was used to map the failures from production log sheet. Simulation modelling approach through Arena software was used assess the feasibility of maintaining product supply by using a bulk tanker truck in 24-hour period. It was revealed that eight bulk tanker transfers can be completed which amounted to 256 tonnes production per day. Under this arrangement, the achievable production volumes were estimated at 5,888.00 tonnes for October and 5,632.00 tonnes for November. These figures represent 80.43% and 91.08% of typical monthly output, and 94.62% and 107.15% relative to the typical just-in-time production requirements. This equates to an additional cost of ZAR 1,166.46 per transfer. On a per-tonne basis, the intervention added ZAR 36.45 to the production cost of bulk bagged fly ash, compared with only ZAR 11.83 per tonne when using the automated transfer system. It was advised that the plant implement a new process control system incorporating artificial intelligence for enhanced early fault detection. Such a system supported by diagnostics and historical trend analysis would help prevent future instances of severe unplanned downtime.