01. BILLET HEATING
HEALTHY
Induction Billet Pusher & Ejector
SAP #MC0001-P · Temp: 1,050°C
Hydraulic Pusher Cylinder (160 Bar)
Billet Delivery: 1 billet / 45 sec
Billet Delivery: 1 billet / 45 sec
02. ROUGHING ST. 1-2
💰 $12.2K/MO DRAIN
Reduction Gearbox & Stand 1-2 Chocks
SAP #MC0004-R1 · FAG 22216 Bearings
Money Drain: Scale water ingress destroys bearing seals every 45 days.
03. ROUGHING ST. 3-4
🚨 ACTIVE BREAKDOWN
Stand 4 Universal Drive Spindle
SAP #MC0004-R2 · Shear Pin #SP/MECH/RM/0339
PART BROKEN: Universal spindle safety shear pins snapped during cold billet pass.
04. CROP SHEAR #1
ONLINE
Head & Tail Rotary Flying Shear
SAP #MC0004-SH1 · Blades H13 Tool Steel
Crops 150mm cold front head.
Blade Life: 4,200 cuts remaining.
Blade Life: 4,200 cuts remaining.
05. INTERMEDIATE ST. 5-8
ONLINE
Intermediate Continuous Stands 5-8
SAP #MC0004-INT · Speed: 6.2 m/s
Roll Neck Bearings: SKF 22220E.
Lube Circulation: 3.8 Bar Normal.
Lube Circulation: 3.8 Bar Normal.
06. LOOP FORMERS
ONLINE
Tension-Free Loop Table & Optical Eye
SAP #MC0004-LP · Loop Height: 120mm
Controls inter-stand tension.
Optical scanner clean & calibrated.
Optical scanner clean & calibrated.
07. FINISHING BLOCK
💰 $18.4K/MO DRAIN
Tungsten Carbide Roll Rings (St. 9-16)
SAP #MC0004-FIN · Speed: 14.2 m/s
Money Drain: Fast groove wear on 12mm rebar pass. Grinding required every 2,400t.
08. THERMEX TMT
🚨 DEFECT HOTSPOT
Thermex Fast Quench Cooling Box
SAP #MC0004-TMX · Water Pressure: 12.5 Bar
PART DEFECT: Spray nozzle #4 clogged with lime scale ➔ uneven martensite rim.
09. COOLING BED
ONLINE
66-Meter Rake Type Walking Beam Bed
Hydraulic Rake Stroke: 120mm.
Aligner Roller Bearings: OK. Temp: 850°C ➔ 120°C.
Aligner Roller Bearings: OK. Temp: 850°C ➔ 120°C.
10. BUNDLING & DISPATCH
💰 $6.8K/MO DRAIN
400T Cold Shear & Automatic Wire Tier
SAP #MC0004-BND · Binding Wire 3.2mm
Money Drain: Wire tie head jams from manual wire knots. Recommending auto-spool.
🚨
1
2
Bill of Materials: Stand 4 Universal Drive Spindle
1 Broken Part
🚨 BROKEN COMPONENT: Calibrated Shear Pin Ø20mm SAE 4340
SAP ItemCode: SP/MECH/RM/0339 · Qty Required: 4 Pins
Stock in Benin: 0 (OUT OF STOCK)
Stock in Ghana: 8 on hand
Hardened Steel Bushings (M20x2 PCD Ø540)
SAP ItemCode: SP/MECH/RM/0715 · Stock: 6 on hand
Standard Operating Procedure: SOP-MNT-RM-04
Procedure: "Stand Universal Spindle Fracture Clearing & Pin Replacement".
Extracted from Final Maintenance SOP.pdf (Knowledge Bank doc_id:
Extracted from Final Maintenance SOP.pdf (Knowledge Bank doc_id:
sp_01JLKD7NN5QQTCKGAANBCIWY6NYQ4B2VUX).
| Plant Entity | 1. Scrap Yard & Shredder | 2. Induction Meltshop / EAF | 3. 2-Strand CCM Caster | 4. Hot Rolling Mill Stands | 5. TMT Quench & Cooling | 6. Bundling & Dispatch |
|---|---|---|---|---|---|---|
|
🇧🇯 Benin
Fabrimetal Cotonou
OEE: 85.1%
|
OK MC0020 Baler Press |
CAD LINKED MC0001 10T Furnace |
CAD LINKED MC0002 2-Strand CCM |
🚨 BROKEN PART Stand 4 Spindle Pin |
NOZZLE CLOG Thermex Nozzle #4 |
OK 100T Weighbridge |
|
🇸🇳 Senegal
Sindia WRBM Mill
OEE: 88.6%
|
OK 1200T Shear |
OK 15T Meltshop |
OK 3-Strand CCM |
CAD BLUEPRINT 2109-WRBM Mill |
OK 66m Cooling Bed |
OK Dual Bundler |
|
🇨🇩 DRC
Fabrimetal Kinshasa
OEE: 78.4%
|
💰 TIRE PUNCTURES Loader 210LC |
OK 8T Furnace F1-F2 |
OK 2-Strand Caster |
0 BEARINGS Stockout Stand 1-4 |
OK Cooling Racks |
OK 100T Scale |
Scrap Yard & Mobile Fleet Consumable Drains (Tires, Baler Blades, Shear Liners)
Cost Hotspots Explorer
Top Money Drains in Scrap Processing
| Equipment Master | Cost Driver / Consumable | Monthly Drain | Root Cause & Fix |
|---|---|---|---|
| Tata Hitachi 210LC & Bobcat | Pneumatic Tire Punctures | $9,800 / mo | Sharp rebar offcuts piercing rubber. Fix: Switch to solid PU foam-filled tires (ROI: 2.1 mos). |
| Bonfiglioli 1200T Shear | Shear Cutting Blades H13 | $7,400 / mo | Heavy scrap contamination. Fix: Turn cutting edges every 3,000 tonnes. |
| Hydraulic Baler Press MC0020 | Wear Liners (Hardox 500) | $4,200 / mo | Abrasive rust scale. Fix: Weld overlay hardfacing on chamber floor. |
Knowledge Bank Remedy & SAP Purchase Action
SOP-SCRP-08: Solid Tire Conversion & Scrap Yard Floor Sweeping Protocol
Extracted from 08 - GROUP PROCUREMENT & STORES / Heavy Machinery Consumables Review.
Standardizing solid aperture tires across Benin, Senegal, and DRC eliminates 88% of mobile fleet punctures.
MMD Plant Knowledge Bank & Live SAP Query Engine
5,670 Group Files Index (136,811 Facts) · 8 Live SAP ERP Plant Maintenance Instances
● SAP Bridge: ONLINE
● Drive Bank: 100% SEARCHABLE
Enter a query above or click a button to execute live calls against SAP ERP and the MMD SharePoint knowledge bank.
MMD Plant Knowledge Bank & Live SAP Query Engine
5,670 Group Files Index (136,811 Facts) · 8 Live SAP ERP Plant Maintenance Instances
● SAP Bridge: ONLINE
● Drive Bank: 100% SEARCHABLE
Enter a query above or click a button to execute live calls against SAP ERP and the MMD SharePoint knowledge bank.