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Planning Planning Meeting Weekly Inspection Wear Measurement ( Maintenance Engineer ) Follow Mill lock-out procedure Use pin measurement template Check Data to make sure within constraints                 ( 0 - 1 5/8" wear ) Data Warrants change out contact Maintenance & Production Write work order (SAP System) STD Give assignment to appropriate Supervisor Data Warrants Immediate change out contact Maintenance & Production Write work order (SAP System) RED Give assignment to appropriate Supervisor Assign Maintenance Supervisor Assign Crew Define Tasks Check Inventory Schedule Crane Execute Crew meeting Hand out work orders Scan into Kronos Hold tailgate meeting Assign job tasks and duties Two of team goes to mill via pickup Pre-shift inspection Follow company operating procedures Two of team gather tools via pickup Pre-shift inspection Follow company operating procedures Supervisor assigns clean up duties to specific individuals. Crew supervisor calls control room to allow bypass and field permit of roller mill Clear mill table Open man door Chain off opening Call control room and verify roller mill ID fan is running, and dampers are set on zero Hook up air lance Raise rollers hydraulically per indicator light (one man stays at door opening) Verify roller position with Teammate Hydraulic man positions himself to start roller mill locally Use verbal communication between crew members prior to starting mill Push start button to start mill Door man starts air lance, cleaning off table ( clockwise ) Hydraulic man shuts down mill locally, maintain stop button to avoid restart Shut off 4 ram hydraulic valves to maintain up-position of rollers Lock out/tag out Supervisor calls control room and notifies it that mill circuit breakers are being locked out Supervisor will close guillotine gate at kiln ID fan Installs lock at MCC center at lower level of pre-heat tower While at lower level, lock out feed belt conveyor S-225 Locks out triple gate Locks out hydraulic system for roller mill Supervisor goes to 5th floor of preheat tower,to locally close off guillotine gate S-252 Supervisor returns to first floor of pre-heat tower MCC, pulls breaker, and locks out S-252 Supervisor then goes to second level of pre-heat tower MCC Goes to mill motor switch gear Verify with amp meter that motor is not energized Trips mill drive motor starter Pull handle of breaker to off position Installs MCC lock Goes to Roller Mill ID fan Verify that Amp meter is at zero Trips ID fan motor starter Pull handle of breaker to off position Installs MCC lock Store the Lock-out keys in lock-out box Locks-out lock-out box Supervisor calls control room for a bump start Supervisor fills out  S-230 lockout procedure form Crew members install personal locks Crew members do pre-job safety inspection Fill out daily job site inspection form Open journal door Properly place 8-foot ladder Workers put on fall protection Loosen nuts with 3/4 inch impact wrench.(top and sides of door) Remove thermocouple from journal bearing Attach safety removal tabs on door to journal yoke Loosen nuts on lower edge of door Use hoists to remove walkway and railings beside journals to accommodate journal yoke Install temporary railings Attach clevises on 15-ton monorail hoists to picking eyes on yoke assembly Attach 1/2-inch choker and comealongs to hydraulic cylinder connecting rods Remove taper pin lock cap screws and insert one cap screw in threaded pusher hole to break taper lock. Insert threaded slide hammer into pin threaded center hole. Remove pins (north and south) Relax the connecting rods with the comealongs already in place. Position one mechanic on the north hoist pendant and one on the south hoist pendant. The mechanic on the 20 degrees off vertical hoist begins lifting while other mechanic maintains proper tension on other line. When the 20 degree offset line becomes vertical, it maintains tension while the other hoist lowers the journal to the I-Beam stops below the removed grating Tire Removal (Top) Position the 8' extension ladder over journal, ascend ladder and attach to retractable fall protection. Co-worker hands air lance to worker in upper position. Clean ring retainer holes (approx. 20) Get 3/4" air impact wrench from co-worker and remove the (20) ring retainer bolts. Attach mobile crane to retainer ring. Attach I-Bolts 180 degrees apart through threaded picking holes. Worker on top of journal apparatus descends ladder and removes it from area. Swing out handrails Designated signaler posted to communicate with the crane operator. Signals crane operator to add light tension to line. Position mechanics(2) on opposite sides of journal with 8 lb sledge hammers. Impact retainer ring with sledge hammers to loosen ring from shoulder while maintaining tension on line. Lift ring with crane and position outside on ground out of work area. Close Handrails Detach crane from ring. Two mechanics attach spreader bar to crane. Two mechanics obtain ring of fire. Center ring on tire and attach propane and air hoses to proper connectors. Mechanic positions ladder to ascend onto top of journal, with proper fall protection to attach spreader bar. Attach spreader bar to top tire via two threaded holes on opposite sides. Mechanic descends ladder and removes from direct work area. Ignite ring of fire. Start heat check. Lift Tire Swing out handrails Signal crane operator to lift. Shut off propane/air valves. Pivot arms on ring of fire and lower. Continue lifting tire off of journal and lower to ground outside. Close Handrails Detach spreader bar from removed tire. Tire Removal (Bottom) Two mechanics center ring of fire on tire Attach spreader bar to bottom tire via two threaded holes on opposite sides. Ignite ring of fire. Start heat check. Lift Tire Swing out handrails Signal crane operator to lift. Shut off propane/air valves. Pivot arms on ring of fire and lower. Continue lifting tire off of journal and lower to ground outside. Close Handrails Detach spreader bar from crane. New Tire Installation Clean and de burr the key on hub. Put loc-tite on the entire circumference of the hub face. Attach spreader bar to new tire via two threaded holes on opposite sides. Ignite ring of fire. Start heat check. Lift Tire Shut off propane/air valves. Remove ring of fire. Attach spreader bar to crane. Swing out handrails Signal crane operator to lift. Lift tire off cribbing and raise into position above journal, lower into place Close Handrails Detach spreader bar from installed tire. Re-install top tire Determine which used tire to reinstall Attach spreader bar to tire to reinstall via two threaded holes on opposite sides. Install ring of fire Clean key way prior to heating tire Ignite ring of fire. Start heat check. Lift Tire Shut off propane/air valves. Remove ring of fire. Attach spreader bar to crane. Swing out handrails Signal crane operator to lift. Lift tire off cribbing and raise into position above journal, lower into place Close Handrails Detach spreader bar from installed tire. Swing spreader bar out of work area and place outside on pallet Attach crane to retainer ring chokers Swing out handrails Lift retaining ring in place on hub Close Handrails Tighten Retainer Bolts Position ladder and ascend to top of journal Attach harness to retractable fall protection Obtain 3/4" impact wrench from co-worker Tighten bolts in a 90 degree spread pattern Lower impact wrench to co-worker Descend from journal and remove ladder Close Journal Door One mechanic positioned on N and one on S at crane pendants Maintain tension on the vertical line while lifting with the 20 degree offset until vertical. Lift with the vertical and maintain tension on 20 degree offset. Position the hydraulic connecting rods with attached comealongs until eyelet alignment is met. Lift North pin into place Install taper lock bushing by tightening bolts in a 90 degree spread pattern. Lift South pin into place Install taper lock bushing by tightening bolts in a 90 degree spread pattern. Remove comealongs off arms. Remove hoists from yoke and secure out of the way. Replace grated walkways and handrails. Mechanic position ladder to ascend to top of yoke with proper fall protection in place. Obtain 3/4 ton comealong from coworker. Attach to eyelet approx. 3' above door opening on mill body and load chain attached to door eyelet. Put a strain on the comealong to support the door. Co-worker removes bolts from the safety tabs. Position door with comealong for height and to secure for tightening. Harnessed mechanic is handed 3/4" impact wrench. Tighten all bolts within reach. Mechanic descends and removes ladder. Mechanic below tightens remaining bolts on door. Call for oiler to check journal oil and add as needed. Mechanic re-install thermocouple on journal. Close mill access door and tighten all bolts. Open 2 hydraulic valves per cylinder at the cylinders. Start-Up Notify appropriate supervisor upon job completion if not at site. Supervisor instructs for personal locks to be removed. Supervisor completes a post-job site inspection. Supervisor removes MCC lock from roller mill lock box. Supervisor notifies control room that he/she will be closing out breakers. Supervisor removes all locks and energizes the breakers that were locked out. Supervisor to 5th floor preheat tower to S-252 Guillotine Gate and opens. Supervisor goes to 2nd floor preheat tower to S-251 Guillotine Gate. Notify control room that he/she is going to open S-251 Guillotine Gate and it may affect airflow. Open S-251 Guillotine Gate. Supervisor returns to MCC and returns locks to their respective positions in the Roller Mill Lock-Out Box Supervisor calls control room to inquire about any possible abnormals in the Roller Mill Circuit. If none, mill is released to production to start. Supervisor is positioned in Roller Mill area to ensure everything starts up properly. Prep Work Stage replacement Tire in proper location Use 8000 lb Fork Lift Perform pre shift inspection Ensure proper operator certification Place on 8 X 8 wood cribbing using metal spacers Clean cosmoline off tire Chase threads in tire for picking eyes Install Spreader bar Hang ring of fire on tire Pre Job Safety Inspection As Assigned Environmental Hazards Crane inspections - mobile and overhead Inspect rigging equipment Inspect air hoses, gas lines, gauges, electrical checks Inspect gang box Check fire extinguisher availibility Check 200 gallon Propane tank - 40 % minimum Stage mobile crane - 1 day prior to use Pre-op inspection Flag work area Ensure proper operator certification Production crew grinds out the mill Pull feed - 30 minutes prior to shut down Monitor mill bearing temperatures Shut off mill