PRODU

PLANT : Sapphire
Month : September

Net RUNNING
Scheduled PLANNED Available L.E.
Date Week No Line Run VOLUME, kg Packed, Time, (Hr)
TIME,
(%)
(kg) (Hr)

01-Oct-24 40 1 DMBH 9,927 9299 22 17.22 78%

01-Oct-24 40 2 DMBH 12,739 17726.021 22 25.578673 116%

01-Oct-24 40 4 MAC H HP 14,369 10046.131 23 12.074676 52%

01-Oct-24 40 CWC 5,371 5888 24 23.552 98%

01-Oct-24 40 TST 9,978 10319 23.25 24.223005 104%

02-Oct-24 40 1 MED P FT 8,897 7,123.56 22.5 14.718099 65%

02-Oct-24 40 2 MED P FT 16,048 15,227.46 22.5 19.447587 86%

02-Oct-24 40 4 MED P FT 13547.174 22.5 15.553587 69%

16746.4575
02-Oct-24 40 CWC 5,371 4352 24 17.408 73%
02-Oct-24 40 TST 9,667 12020.321 23.25 28.216716 121%

03-Oct-24 40 1 P MED FT 8,354 11382.552 21.25 23.42089 110%

03-Oct-24 40 2 P MED FT 12,875 11936.329 21.25 16.624413 78%

03-Oct-24 40 4 P MED FT 15,969 16909.53 22.5 19.106814 85%

03-Oct-24 40 CWC 4,371 5376 24 23.9875 100%

03-Oct-24 40 TST 3,326 4536 8 10.647887 133%

04-Oct-24 40 1 EFS HP 10,463 10467 23.25 20.934 90%

04-Oct-24 40 2 TF REG 8,558 12021 23.25 13.769759 59%

04-Oct-24 40 4 MAC H HP 19,047 12137 22.5 13.591265 60%

04-Oct-24 40 CWC 5,371 4864 24 19.456 81%

05-Oct-24 40 1 EFS HP 5,708 5965 15 11.93 80%

05-Oct-24 40 2 TF REG 4,669 10,524.00 15 25.731051 172%

05-Oct-24 40 4 MED H HP 13,330 13,192.00 15.5 13.192 85%

05-Oct-24 40 CWC 5,371 2,816.00 24 11.264 47%

06-Oct-24 41

07-Oct-24 41 1 P MED FT 3,065 3575 7.75 9.4279835 122%

07-Oct-24 41 2 P MED FT 5,528 4582 7.75 5.2485682 68%

07-Oct-24 41 4 P MED FT 5,210 4582 7.5 5.0296378 67%

07-Oct-24 41 CWC 1,790 2048 8 8.192 102%

08-Oct-24 41 1 P MED FT 9,194 10280.754 22.25 21.15 95%

08-Oct-24 41 2 P MED FT 16,583 13889.926 22 15.91 72%

08-Oct-24 41 4 P MED FT 16,746 17015.105 22 18.68 85%

08-Oct-24 41 CWC 4,371 5376 24 21.504 90%

09-Oct-24 41 1 P MED FT/MRC HP 7,046 9064.252 21.25 21.841571 103%

09-Oct-24 41 2 P MED FT/TF REG 12,834 14,805.12 21.25 19.819442 93%

09-Oct-24 41 4 P MED FT 18,540 20,289.75 22.5 20.917264 93%

09-Oct-24 41 CWC 5,371 5,376.00 24 21.504 90%

10-Oct-24 41 1 MRC HP 6,856 7484.3509 22 19.643966 89%

10-Oct-24 41 2 TF REG 12,177 10455.411 22.5 15.285689 68%

10-Oct-24 41 4 MED H HP 19,350 17000 22.5 17 76%

10-Oct-24 41 CWC 4,371 4608 24 18.432 77%

11-Oct-24 41 1 EFS HP 8,224 4763 21.25 9.526 45%

11-Oct-24 41 2 TF REG 12,582 11244 23.25 16.438596 71%

11-Oct-24 41 4 MED H HP 19,350 14450 22.5 14.45 64%

11-Oct-24 41 CWC 5,371 3328 24 13.312 55%

12-Oct-24 41

13-Oct-24 42 1 EFS HP 2,999 2948 7 5.896 84%

13-Oct-24 42 2 TF REG 4,194 3742 6.33 5.4707602 86%

13-Oct-24 42 4 6,665 3750 7 3.75 54%

MED H HP

13-Oct-24 42 CWC 1,140 2304 8 9.216 115%

14-Oct-24 42 1 EFS HP 8,998 9635 22 19.27 88%

14-Oct-24 42 2 TF REG 12,582 16897 23 24.703216 107%

14-Oct-24 42 4 MED H HP/DMBH 19,995 17998 22 19.478355 89%

14-Oct-24 42 CWC 5,371 5632 24 22.528 94%

15-Oct-24 42 1 EFS HP 8,708 11226.526 22 22.453053 102%

15-Oct-24 42 2 TF REG 12,177 14741.903 22 21.55249 98%

15-Oct-24 42 4 MED H HP 19,350 16000 22 16 73%

15-Oct-24 42 CWC 5,371 5376 24 21.504 90%

16-Oct-24 42 1 EFS HP 8,708 9797.6957 22 19.595391 89%

16-Oct-24 42 2 TF REG 12,582 14242.947 22 20.823021 95%

16-Oct-24 42 4 MED H HP 19,350 16500 22 16.5 75%

16-Oct-24 42 CWC 4,371 4608 20 18.432 92%

17-Oct-24 42 1 EFS HP 8707.5 22 17.463485 79%

8731.7427
17-Oct-24 42 2 MED H HP 11,800 14432.482 21 21.038604 100%

17-Oct-24 42 4 MED H HP 19,995 17,250 22 17.25 78%

17-Oct-24 42 CWC 5371 5,376 24 21.50 90%

To-Date 1265 1079 85.32%

LE 85.32%
EPL 0.50%
OPL 16.68%
Plant Sapphire Emerald Diamond

Line 1
2
3
4
A
B
C
D

Cell Input done

not done

Month January
February
March
April
May
June
July
August
September
October
November
December
PRODUCTION OPERATION LOGSHEET COMPLIANCE MONITORING

POL COMPLIANCE CHECK

P V A P L L E O
l o v r i o P P
a l a o n s L L
n u i d e s
m l u D D
e a c E T e e
EPL OPL Comp., b t f i t t
EPL, (%) OPL, (%) l i f m a a
(Hr) (Hr) (%) e v i e i i
e c l l
T i s s
i t e
m i n
e m c
e y

4.78 0.21725589 91.67%

83.33%

2.5 10.87% 8.4253235 36.63% 91.67%

0 0.448 1.87% 100.00%

0 91.67%

7.7819012 34.59% 100.00%

3.0524128 13.57% 100.00%

6.9464132 30.87% 100.00%

6.592 27.47% 100.00%

 0.00% 91.67%

0.00% 83.33%

4.6255869 21.77% 91.67%

3.3931864 15.08% 91.67%

0.0125 0.05% 100.00%

0.00% 83.33%

2.316 9.96% 91.67%

9.4802405 40.78% 91.67%

8.9087346 39.59% 91.67%

4.544 18.93% 100.00%

3.07 20.47% 100.00%

 0.00% 83.33%

2.308 14.89% 91.67%

12.736 53.07% 100.00%

0.00%

91.67%

2.5014318 32.28% 100.00%

2.4703622 32.94% 100.00%

91.67%

1.1 4.94% 91.67%

6.09 27.68% 91.67%

3.32 15.09% 91.67%

2.496 10.40% 100.00%

91.67%
 1.4305577 6.73% 100.00%

1.5827356 7.03% 100.00%

2.496 10.40% 100.00%

2.3560344 10.71% 100.00%

7.2143108 32.06% 100.00%

5.5 24.44% 100.00%

5.568 23.20% 100.00%

11.724 55.17% 100.00%

6.8114035 29.30% 100.00%

8.05 35.78% 100.00%

10.688 44.53% 100.00%

0 0.00%

1.104 15.77% 100.00%

1.6 25.28% 100.00%

0.66 9.43% 2.59 37.00% 100.00%

91.67%

2.73 12.41% 100.00%

0.00% 91.67%

2.521645 11.46% 100.00%

1.472 6.13% 100.00%

91.67%

0.4475098 2.03% 100.00%

6 27.27% 100.00%

2.496 10.40% 100.00%

2.4046085 10.93% 100.00%

1.1769787 5.35% 100.00%

5.5 25.00% 100.00%

1.568 7.84% 100.00%

1.41 3.1265146 14.21% 100.00%

 0.00% 100.00%

0.1666667 0.76% 4.58 20.83% 100.00%

2.496 10.40% 100.00%
0.00%
0.00%
0.00%
0.00%
0.00%
0.00%
0.00%
0.00%
0.00%
0.00%
0.00%
0.00%
0.00%
0.00%
0.00%
0.00%
0.00%
0.00%
0.00%
0.00%
0.00%
0.00%
0.00%
0.00%
0.00%
0.00%
0.00%
0.00%
0.00%
0.00%
0.00%
0.00%

6.337 0.50% 211 16.68% 96.43% 100% 100% 100% 100% 100% 100% 100% 100%
NG

ANCE CHECK
S S B O
h u a t
i p l h
f t a e
t . n r
c s
R S e REMARKS
e i
p g
o .
r
t

a. 2:00-3:15PM - Shift change cleaning

b. 5:30-7:00PM Load cut off due to low pared meat supply
c. Incomplete signature - 2nd shift PQC

a. 1st shift 22-26rpm straight loading

b. 2nd shift 22rpm straight loading
c. 3rd shift 26rpm - 10:00-11:00PM underwent shift change cleaning
d. Total reworked = 6376.7 kg
e. Incomplete signature - 2nd shift PQC

a. 6:00-7:00AM- Underwent shift change cleaning

b. 7:25-9:30AM - delayed loading due to blinding of coil of 1st compt (door & fan
side both 1st layer) - EPL
c. Incomplete signature - 2nd shift PQC

a. 1st shift flowrate = 3500lph

b. 2nd shift flowrate = 3300lph
c. 3rd shift flowrate = 3800lph
No abnormalities encountered.
a. Straight loading
b. Incomplete signature - 2nd shift PQC

a. 1st shift - run under capacity due to low supply of pared meat
b. 2nd shift - 2:00PM-9:30PM - Unable to load due to low pared meat supply.
Reloaded at 9:30pm MedP FT @14rpm.
a. 1st shift - run under capacity due to low supply of pared meat
b. 2nd shift - 2:30-2:40PM - Switch load to MedP FT @22-20rpm

a. 1st shift - run under capacity due to low supply of pared meat
b. 2nd shift - 2:50-3:00PM Switch load to MedP FT @22-20rpm
c. 2nd shift - 9:30-10PM load cutoff and proceed to shift change cleaning
d. 3rd shift - 10:00-11:00PM underwent shift change cleaning

a. 1st shift - conducted CIP

Straight loading

a. 1st shift started at 15 rpm only

b. 2nd & 3rd shift - straight loading at 14 rpm
c. Incomplete signature - 1st shift Dry Process Foreman, PQC & WDS

a. 1st shift - 6:00-7:00AM - underwent shift change cleaning (planned)

b. Reloaded 7:00AM - 30 rpm
c. 2nd shift 3:00PM - reduced rpm from 30 to 24
d. 2nd shift 4:00PM - reduced rpm from 24 to 20 run under capacity
e. 3rd shift run under capacity at 20rpm
f. Incomplete signature - 1st shift Dry Process Foreman, PQC & WDS
a. 1st tp 3rd shift run under capacity at 20rpm
b. Incomplete signature - 1st shift Dry Process Foreman, PQC & WDS

a. 1st shift flowrate = 3500lph

b. 2nd shift flowrate = 3300lph low water collection
c. 3rd shift flowrate = 3000lph
No abnormalities encountered.
a. Proceeded to shutdown cleaning
b. Incomplete signature - 1st shift Dry Process Foreman, PQC & WDS

a. 1st shift - 5:20AM load cut off underwent cleaning, reloaded 7:30AM
b. 2nd shift - 6:10-6:20PM cutting head sudden stoppage proceed to replacement
c. 2nd shift - 8:35-9:20PM encountered Packer bucket entanglement (not EPL)
d. Incomplete signature - 1st shift Dry Process Foreman & PQC

a. 1st shift - 6:00am-8:00AM - Product type change cleaning. Reloaded at 8am TF

Reg @26-28rpm
b. 2nd shift - reduced rpm drom 28 to 22 run under capacity
c. 2rd shift - run at 26 rpm but still under capacity
d. Incomplete signature - 1st shift Dry Process Foreman & PQC

a. 1st shift 6:00-6:40AM - switch load; delayed loading due to low pared meat
supply
b. 2nd shift - run under capacity
c. Incomplete signature - 1st shift Dry Process Foreman & PQC

a. 1st shift 6:00-8:00 standby for process waiting for raw cocowater build up
b. 1st shift flowrate = 3800lph reduced to 3500
c. 2nd shift flowrate = 3000lph
d. 3rd shift flowrate = 3800-4000lph

a. 1st shift- straight run at 22Hz pre-sizer setting

b. 2nd shift - 2:40-4:30PM encountered Bucket entanglement
c. 8:30PM cut off load upon consuming all nuts, proceeded to shutdown cleaning
due to inavailabilty of nuts
d. Incomplete signature - 1st shift Dry Process Foreman & PQC
a. 1st shift- straight run at 28rpm
b. 2nd shift - 2:40-4:30PM encountered Bucket entanglement
c. 10:00PM cut off load upon consuming all nuts, proceeded to shutdown cleaning
due to inavailabilty of nuts
d. Incomplete signature - 1st shift Dry Process Foreman & PQC

a. 1st shift- straight run at 22Hz pre-sizer setting

b. 2nd shift - 10:15PM cut off load upon consuming all nuts, proceeded to
shutdown cleaning due to inavailabilty of nuts
c. Incomplete signature - 1st shift Dry Process Foreman & PQC
a. 1st shift = 3000lph low flowrate due to low supply of raw cocowater
b. 8:30PM stop evaporation process proceeded to shutdown cleaning/CIP
Shutdown

a. 1st shift - Shutdown

b. 2nd shift - Start-up
c. 3rd shift - Operation
d. 3rd shift 4:40AM load cut off due to low pared meat supply
e. Encountered product off sieve; generated off sieve:
P Med FT = 143kg
Mac = 136 kg

a. 1st shift - Shutdown

b. 2nd shift - Start-up
c. 3rd shift - Operation - run at 22 rpm under capacity

a. 1st shift - Shutdown

b. 2nd shift - Start-up
c. 3rd shift - Operation
d. Encountered product off sieve; generated 136kg off sieve

a. 1st shift - Shutdown

b. 2nd shift - Start-up/CIP
c. 3rd shift - Operation - flowrate at 3500lph

a. 1st shift - no POL report

b. 2nd shift - 5:00-6:20PM - load cut off due to low supply of pared meat
c. 3rd shift - straight loading at 14rpm only

a. 1st shift - no POL report

b. 2nd shift - straight loading at 20rpm only
c. 3rd shift - straight loading at 24-28rpm

a. 1st shift - no POL report

b. 2nd shift - straight loading at 20rpm only
c. 3rd shift - 10:00-11:20PM underwent shift change cleaning

a. 1st shift flowrate = 3500lph

b. 2nd shift flowrate = 3000lph low cocowater collection
c. 3rd shift flowrate = 3000-3500lph

a. 1st shift - straight run at 14 rpm; encountered off sieving

b. 2nd shift - Load cutoff at 5:15pm, proceed to product type change cleaning,
reloaded at 6:45pm with MRC HP
a. 1st shift -straight run
b. 2nd shift - Load cutoff at 6:40pm after consuming all FT nuts and proceeds to
intensive cleaning. Reloaded at 8:20pm with TF Reg

a. 1st shift - straight run

b. 2nd shift - Load cutoff at 6:50pm after consuming all FT nuts, switch load to
Med H HP @45hz

a. 1st shift flowrate = 3000lph

b. 2nd shift flowrate = 3300lph
c. 3rd shift flowrate = 3300-3500lph
a. 3rd shift - 4:20-6:00AM- load cut off upon completion of MRC HP requirements
proceed to intensive cleaning
a. 2nd shift - 3:00-4:20PM / 9:00-9:40PM - Load cut off due to low pared meat
supply

a. 1st shift flowrate = 3000lph

b. 2nd shift - Drilling stopped 3:50pm and proceeds to 4-step CIP. Resume drilling
at 5:35pm.
• Pasteurizer: process stop at 4:40pm and proceeds to 6-step CIP, process
resumed 8:50pm at 4200lph
• Evaporator: process stop at 5:30pm and proceeds to 6-step CIP, process
resumed 9:00pm at 3800lph
c. 3rd shift flowrate = 3800lph

a. 1st shift - 6:00-6:25AM - Underwent cleaning reloaded at 6:25am EFS HP @20hz

b. 9:10PM load cut off upon consuming all nuts
c. 3rd shift - proceeded to shutdown cleaning due to inavailability of nuts

a. 10:30PM load cut off upon consuming all nuts

b. 3rd shift - proceeded to shutdown cleaning due to inavailability of nuts

a. 10:45PM load cut off upon consuming all nuts

b. 3rd shift - proceeded to shutdown cleaning due to inavailability of nuts
Proceeded to shutdown CIP
Shutdown

a. 1st shift - shutdown

b. 2nd shift - start up
c. 3rd shift - operation, loaded 9:00PM

a. 1st shift - shutdown

b. 2nd shift - start up
c. 3rd shift - loaded 11:40PM, delayed loading due to blinding of coil in Compt. 1
a. 1st shift - shutdown
b. 2nd shift - start up
c. 3rd shift - loaded 10:30PM, delayed loading due to blinding of coil in Compt. 1
Fanside and Doorside

a. 1st shift - shutdown

b. 2nd shift - start up
c. 3rd shift - operation; flowrate 3500-3800lph

a. 1st shift - run at 20-22Hz, no abnormalities encountered

b. 2nd shift - run at 22Hz, no abnormalities encountered
c. 3rd shift - 4:30-4:50AM experienced clogged cutting head

a. 1st shift - run at 28-30rpm, no abnormalities encountered

b. 2nd shift - Run at 30rpm, no abnormalities encountered
c. 3rd shift - Run at 30rpm, no abnormalities encountered

a. 1st shift - Run at 45Hz presizer frequency, no abnormalities encountered

b. 2nd shift - 3:00PM-3:10PM cut off load switched load to DMBH
c. 5:45PM-5:55PM cut off load switched back to Med H HP
c. 3rd shift - Run at 40Hz presizer frequency, no abnormalities encountered

a. 1st shift - Straight process at 3500lph-3300lph

b. 2nd shift - Straight process at 3500lph
c. 3rd shift - Straight process at 3500lph

a. 1st shift - run at 22Hz, no abnormalities encountered

b. 2nd shift - run at 24Hz, no abnormalities encountered
5:15PM reduced capacity to 20Hz
c. 3rd shift - increased capacity to 24Hz, no abnormalities encountered

a. 1st shift - run at 30-32rpm, no abnormalities encountered

b. 2nd shift - reduced rpm to 24rpm, no abnormalities encountered
c. 3rd shift - 10:00-10:45PM underwent shift change cleaning

a. 1st shift - run at 40-42Hz, no abnormalities encountered

b. 2nd shift - reduced capacity to 35Hz, no abnormalities encountered
c. 3rd shift - run at 42Hz, no abnormalities encountered

a. 1st shift flowrate - 3000lph; 9:00AM reduced flowrate to 2700lph

b. 2nd shift flowrate - 3000-3500lph
c. 3rd shift flowrate - 3500lph
a. 1st & 2nd shift - straight loading but run under capacity due to low pared meat
supply

a. 2nd shift - 2:00-3:00PM underwent shift change cleaning

b. 3rd shift - load cut off 5:00AM after completing the TF reg proceeded to product
type change cleaning
a. 3rd shift - 10:00-11:00PM shift change cleaning
Underwent CIP
a. 2nd shift - load cut off 5:45PM-7:10Pm due to low pared meat supply and
detached holder of batchweigher. Proceed to unscheduled cleaning
 a. 1st shift - 5:00-7:00AM underwent shift change cleaning
b. 2nd shift - 6:15-7:00PM load cut off due to low pared meat supply
a. 2nd shift 9:10-9:20PM sudden stoppage of Comitrol due to low oil level

95% 79% 83% 100%

 100.00%

637670.00%

100.00%

100.00%

104.18%

100.00%

100.00%

100.00%
W
121.36%

110.22%

100.00%

100.00%

100.00%

133.10%

100.00%

100.00%

100.00%

100.00%

100.00%
 171.54%

100.00%

100.00%
0.00%

121.65%

#REF!

135.34%

#REF!

unn

100.00%

100.00%

100.00%

102.78%
100.00%

100.00%

100.00%

100.00%

100.00%
100.00%

100.00%

100.00%

100.00%

100.00%
100.00%
0.00%

100.00%

111.70%
100.00%

115.20%

100.00%

107.41%

100.00%

100.00%

102.06%

100.00%

100.00%

100.00%

100.00%

100.00%
100.00%
100.00%

93.59%
100.18%
100.00%
100.00%
0.00%
0.00%
0.00%
0.00%
0.00%
0.00%
0.00%
0.00%
0.00%
0.00%
0.00%
0.00%
0.00%
0.00%
0.00%
0.00%
0.00%
0.00%
0.00%
0.00%
0.00%
0.00%
0.00%
0.00%
0.00%
0.00%
0.00%
0.00%
0.00%
0.00%
0.00%
0.00%

102.50%
 30.00%

PLANT PERFORMANCE 25.00%

20.00%

15.00%
16.
68% 10.00%
0.5
0% 5.00%

0.00%
y) lt
pt esu
m
(e tal R
-5.00%
To

10

85.32% 9

LE EPL OPL 1

0
(empty) Total
Resul
30.00% Plant EPL (%)
25.00%

20.00%

15.00%

10.00%

5.00%

0.00%
y) lt
pt esu
m
(e tal R
-5.00%
To

Plant EPL, (Hr)

10

0
(empty) Total
Result
100.00%
Plant OPL (%)
90.00%
80.00%
70.00%
60.00%
50.00%
40.00%
30.00%
20.00%
10.00% 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0
0.00%

Plant OPL (Hr )

12

10

0
(empt Total
y) Result
 POL MTD Compliance

Over All 96.43%

Others 100%
0 0 0 0 0 0 0

Balance 83%

Supt. Sig. 79%

Shift Report 95%

OPL Details 100%

EPL Details 100%

Loss Time 100%

Line Efficiency 100%

Productive time 100%

Available Time 100%

Volume 100%

Plan 100%

0% 20% 40% 60% 80% 100%

 96.43%

100%

83%

9%

95%

100%

100%

100%

100%

100%

100%

100%

100%

80% 100% 120%

Column E (empty)
(empty)
Total Result
 AT LE EPL OPL
% 88.67% 3.80% 7.53%
HR 463.5 411 17.6 34.9
Column E (empty) Column E (empty)
(empty) (empty)
Total Result Total Result
Column E (empty) Column E (empty)
(empty) (empty)
Total Result Total Result