Mill #4 Main Bearing Replacement
Emergency replacement of main pellet mill bearing following vibration analysis alarm and subsequent failure. Mill is currently down.
Approval timeline
- DirectorSarah KimApproved7 days ago
“Approved. Mill down — expedite. Let me know if vendor lead time slips.”
- VP SupplyMike ChenApproved6 days ago
“Confirmed sole-source justification with OEM. Approved.”
- VP OpsLinda RodriguezOverdue6 days in queue
- CFOMatt AndersonAwaiting
Problem
During the 0400 shift on April 6, the Mill #4 main bearing locked up following progressive vibration over the prior 72 hours. Initial teardown confirms catastrophic roller failure — bearing race is scored beyond repair. Mill is down and Kingwood has lost ~$42k/day in production since.
Proposed solution
Procure OEM replacement bearing assembly from Andritz (7-day lead time, expedited shipping included in quote), replace with on-site crew plus two OEM techs, and complete full vibration re-baseline before restart. Target return-to-service: 10 days from approval.
Justification
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Alternatives
| Option | Description | Total cost | Useful life | Recommended |
|---|---|---|---|---|
| Option 1 — Recommended | Procure OEM replacement bearing assembly from Andritz (7-day lead time, expedited shipping included in quote), replace with on-site crew plus two OEM techs, and complete full vibra | $118,400 | 8 yrs | ✓ |
| Option 2 — Rebuild in place | Rebuild existing equipment in place with refurbished components. Lower upfront cost but shorter useful life and higher maintenance ongoing. | $76,960 | 4 yrs | — |
Payback & benefit
Actuals (from ERP)
Sourced from the financial system integration. Last sync 2 hours ago.
| Date | Vendor | Description | Amount |
|---|---|---|---|
| Mar 12, 2026 | Grainger Industrial | Vendor down payment / mobilization | $1,953 |
| Mar 11, 2026 | Motion Industries | Progress billing | $1,898 |
| Mar 10, 2026 | Applied Industrial Technologies | Progress billing | $1,831 |
| Mar 9, 2026 | WW Grainger | Progress billing | $1,745 |
| Mar 8, 2026 | Kice Industries | Progress billing | $1,636 |
| Mar 7, 2026 | Peerless Mfg | Progress billing | $1,489 |
| Mar 6, 2026 | Schenck Process | Progress billing | $1,276 |
| Mar 5, 2026 | MAC Equipment | Final invoice | $672 |
Attachments
- vendor-quote.pdf(245 KB)
- site-photo.jpg(1820 KB)
Comments
(2)- BKBill Kerstetter·2 days ago
OEM confirms bearing is expedited for 7-day delivery once PO is released. Everyone on the approval chain has been cc'd.
- JBJesse Bryerton·3 days ago
Mill is still down. We're losing ~$42k/day in production. Let me know if anything is needed to move this through.