Najran Cement Company

Learning & Development

 NCC TECHNICAL TRAINING

SULTANA TRAINING CENTER

Patroller Competency Development Program

D.P. SHARMA
Training “Kiln Mechanics” – MAY 2024
 Patroller
Patroller Competency
Competency Development
Development Program
Program
Objective Program
 Develop the competencies of the Production Patroller to improve plant maturity in production shift operations in line with
requirements of Cement Industrial Framework

Production Patroller Roles

Patrollers have a key role in achieving and sustaining operational excellence by:
o Monitoring equipment operation and safety through Walk By Inspections.
o Detecting abnormalities in running equipment, and having an ability to attend to minor repairs on detected abnormalities
and / or reporting to Maintenance.
o Production troubleshooting tasks including preheater coating cleaning, snowman clearing, cleaning material chute
blockages and material spillages, etc.
o Proposing improvements in safety, performance, and equipment availability

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Outline
Outline Patroller
Patroller Development
Development Program
Program
1 Weeks 5 Weeks 8 Weeks 3 Weeks 12 Weeks

Induction Patroller
Fundamentals Implement Professionalize Certify
Program

Consist of:
Objective : Consist Of:  Specific Production Consist Of:
 Safety Assignment: Consist Of:
Provide Awareness & Gain  Patroller Specific Roles & Task Exposure
o Identify tasks he can  Review Patroller Inspection
Commitment for the program Responsibility sheet (WBI)
 Field Inspection o Reclaimer skewing undertake alone to fix small
 Participate in RCA

Assessment
 Production internal processes o Cyclone blockage problems & tools required

Assessment
Consist of:  Post Assessment Patroller
 Pre-Assessment of  H&S Modules: MSR, Lone working, o Preheater coating
o  Inspection Assignment: Profile
Patroller Competency GWP, LOTO, Working at Height, Snowman
o o Review at least 10 check  Demonstrate ability to safely
 Team Building Confined Space, Safe lifting and MSR_Hot material
perform Specific Production
 Induction Program : rigging, Risk Identification & handling– Preheater sheet & update
o Review WBI Route Task
 Plant Organization assessment, etc. blockage, coating,
 Basic Plant Product  Cement Process Knowledge (CECIL cooler, snowman
 Evaluate the performance
understanding Modules) for Patroller  WBI inspection (coaching)
 Key Quality Control  Main Equipment Technology  Deep dive into with plant coach & MTCE
parameters (CR,VRM,KL ,CM) inspection routes for inspector
 Certification will be
 Environment &  Transport Equipment (BE,BC,SC,AS) assigned area  Shift communication
 Note : Coaching and conducted by internal Holcim
Housekeeping  Lubrication basics
Indonesia
 Supporting Module (SAP Notification, Mentoring with 7AMB
RCA, Cost Impact Awareness elements from superior

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Detailed
Detailed the
the Program
Program
Induction Program Patroller Fundamental Implement Professionalize Certify

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Resources
Resources Requirements
Requirements (1/3)
(1/3)
Activity PIC / Trainer Duration Noted / Venue

 Pre-Assessment Patroller Profile • OH&R • 4 Hrs • Holcim Academy

 Team Building
 Induction Modules • OH&R • 4 Hrs
• CIP & OHR • 16 Hrs
 Patroller Roles and Certification
• 4 Hrs • Holcim Academy
Process
 Health and Safety Module
• 32 Hrs • H&S School
 Cement Process (CECILS
Module)
• 136 Hrs • Holcim Academy
 Main Equipment Technology
 Transport and Auxiliaries
• 16 Hrs • Holcim Academy
Equipment
 Walk by Inspection Knowledge
• 16 Hrs • Holcim Academy
 Hyd and Pneumatic Application
 Field Inspection
• 4 Hrs • Holcim Academy

• 8 Hrs • Holcim Academy

• Field
• 8 Hrs

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Resources
Resources Requirements
Requirements (2/3)
(2/3)
Activity PIC / Trainer Duration Noted / Venue

 RCA Concept • RCA Champion • 4 Hrs • Holcim Academy

 SAP (Notification) • Mtc Planner • 8 Hrs
 Cost Production Cement • Process Engineer • 4 Hrs
Awareness • OH&R
 Assessment Test Building • 4 Hrs
Foundation

 Safety Assignment • Production Owner • 4 weeks

- Identify small job can doing • Field (plant)
alone safely. Review and validate
with N+1
- Perform job safely • Production Owner
• 4 weeks
 Inspection Assignment • Filed (plant)
- Assign check sheet
route
- To perform doing inspection

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 Resources
Resources Requirements
Requirements (3/3)
(3/3)
Activity PIC / Trainer Duration Noted / Venue

 Specific Production Task : • Production Owner / Shift • 2 weeks • Field (plant)

- Reclaimer skewing Manager
- Cyclone blocking
- Preheater coating
- Snowman
- MSR Hot material handling

• Holcim Academy
 Deep dive into inspection • Production Owner • 1 weeks

 Certification Process • Production Owner / • 12 Weeks • CCR Rooms

Shift Manager / RCA
- Review inspection check Champion / Reliability • Field
sheet doing each patroller Engineer
- Check propose improvement
done each patroller
- Participate on RCA
- Perform on WBI

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 Target
Target Participants
Participants and
and Implementation
Implementation
Target Participants

• Existing Plant Patroller

How to Implement?
• Kick of by Team Building Workshop on Induction Program Phase
• Induction Program by respective each department
• Build Foundation start by Patroller Roles and overview certification process
• CECILs Modules delivered by CRO Development Supervisor
• SAP Basic (Notification) delivered by Maintenance Planner
• Walk by Inspection delivered by Production owner and CBM Engineer

Let’s doing with confident and responsible

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Content
Content

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Content
Content

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Content
Content

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‫شكـــــرًا لـــــــــــــكم‬
Thank You

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