Mechanical Engineering • Thika Cloth Mills, Thika
Manufacturing Plant Upgrade
Installed new machinery, optimized production systems and improved operational efficiency. 14% downtime → 3% in 4 weeks, +18% throughput.
14% → 3% (-72%)
Downtime
+18%
Throughput
22 days
Time
Challenge
14% downtime, 22-day backlog, NCA findings.
Scope
Re-aligned 2 lines, replaced bearings, installed spares kit.
Result
-72% downtime (14% → 3% in 4 wks), +18% throughput, zero audit findings. Handover: O&M manual, spares kit, training.
What Was Delivered — Thika Cloth Mills
8 deliverables • Detailed for this project • Not generic
- 1Laser alignment (±0.05mm) of 2 automated lines — 24-point report, 6 hours downtime per line
- 218× SKF bearings, 12× seals, 4× SEW gearboxes replaced (all KEBS D-mark, batch-tracked)
- 31,200m HB 160 conveyor belting + skirting, scrapers and belt cleaners — spillage -70%
- 46-month critical spares kit kitted, labeled and shelved in stores (bearings, belts, seals, 8× V-belts)
- 587-page O&M manual + CMMS loaded with 124 PM tasks (daily/weekly/250h) + photo guides in Swahili
- 6Training: 12 operators (inspection) + 4 artisans (alignment/balancing) — 16h, certificates logged for OSHA file
- 772-hour trial at 110% capacity — vibration + thermography report, 0.8 mm/s RMS, 42°C max bearing temp
- 8Handover pack: EBK-stamped as-builts, KEBS docs, NDT + pressure test certs, spares list with local supplier contacts
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