aug-oct month crm-pppl-arp-rwl presentation-3months
TRANSCRIPT
PRESENTATION ON PPPL, ARP, MILL AND RWL PH-III
PRESENTED BY : PAUL OSENDE(Asst. Manager)
SCOPE OF PRESENTATIONHIGHLIGHTSCRM DIVISION KPI’s AND KPA’sPRODUCTION AND YIELD SUMMARY
FOR ALL LINES(CRM DIVISION)TOTAL DIVISION YIELDCONSUMPTION ANALYSIS PER LINE
WITH TRENDSLTI FOR CRM DIVISION
HIGHLIGHTS• TOTAL PRODUCTION OF 204,426.080 MT SINCE
COMMISIONING OF CRM• ACHIEVED THE HIGHEST RECORDED YIELD OF
99.442% IN JUNE 2016 AT MILL WITH AVERAGE YIELD AT 99.175% SINCE JANUARY 2016
• HIGHEST DAILY PRODUCTION AT PPPL OF 571.270MT ON 31ST-05-2016 IN TWO SHIFTS
• PPPL AND ARP HAVE SPENT OVER 1090 DAYS WITHOUT LTI
• NO LTI AT MILL AND RWL IN 2016• ARP PRODUCED HIGHEST DAILY PRODUCTION OF
21.2KL IN JULY 2016• CONTINUOUS TRAINING OF STAFF ONGOING
CRM DIVISION KPI AND KPA
S.No KPA KPI Weighta
geKPI(Measurement
criteria) ScoringEvaluation
Actual Scored
Reason
1Production of
required quantities as per the production
plan
Productivity Production targets as per marketing's
requirement30 PPPL+CRM+
RWL-75% 90%-100% 30 100 30
2Maintain the quality
and reduce as per the production norms
Scrap Minimization Percentage rejection of the total output
30 PPPL+CRM+RWL<5.0% <5.5% 30 6.156 26.803
3 Finished goods inventory
Product stock Analysis Production cycle time 20 CRC 3 Days 75%-100% 20 100 20
4 Timely delivery
Time committed for completion of
special orders
Reduction in special order production time
20Completion within 3-7
days80%-100% 20 100 20
PPPL, ARP, MILL AND RWL PRODUCTION SUMMARY FOR AUG-OCT 2016
SECTION PPPL ARP MILL RWL
MONTH AUG SEPT OCT AUG SEPT OCT AUG SEPT OCT AUG SEPT OCT
PRODUCT HRPO(MT) REGENERATED ACID(KL) CRC(MT) TRIMMED CRC(MT)
CAPACITY 12500 468 12500 12500
TARGET 6500 5100 7850 240 200 300 6000 5400 7850 3600 7300 7300
PROD I/P 6548.720 5124.950 7894.180 248.100 204.900 308.200 6094.720 5517.050 7858.105 3806.295 7698.795 7736.610
PROD O/P 6513.140 5098.270 7853.540 338.900 295.300 390.200 6046.695 5477.585 7795.330 3622.645 7330.960 7319.115
YIELD % 99.457 99.479 99.485 99.212 99.285 99.201 95.175 95.222 94.604
UTILIZATION
PPPL CRM RWL0.00%
10.00%
20.00%
30.00%
40.00%
50.00%
60.00%
70.00%
52.11%48.37%
28.98%
40.79%43.82%
58.65%63.15% 62.36%
58.55%
Utilization=(Production OP/Line capacity)
AUGUST SEPTEMBER OCTOBER
AUGUST SEPT OCT AVERAGE94.5
95.5
96.5
97.5
98.5
99.5
100.5
99.45799.479 99.485 99.474
99.212 99.285 99.201 99.233
95.17595.259
94.604
95.0126666666667
PERCENTAGE YIELD PER MONTH CRM DIVISION
PPPL%YIELD CRM% YIELD RWL% YIELD%
YIE
LD
TOTAL YIELD FOR CRM DIVISIONAUGUST SEPTEMBER OCTOBER CURRENT AVERAGEPREVIOUS AVERAGE
92.6
92.8
93
93.2
93.4
93.6
93.8
94
94.2
94.4
94.6
93.845
94.023
93.29
93.934
93.664
94.5 94.5 94.5 94.5 94.5
TOTAL YIELD KPI STANDARD
MONTH
TOTA
L PE
RCEN
TAG
E YI
ELD
TOTAL AVERAGE YIELD PER YEAR CRM DIVISION
PPPL CRM RWL91.5
92.5
93.5
94.5
95.5
96.5
97.5
98.5
99.5
100.5
98.99
98.28
92.46
99.44198.71
95.44
99.405
98.76
95.55
99.414 99.175
95.319
Yield analysis trend 2013-2016
2013 2014 2015 2016
PRODUCTION LINE
Perc
enta
ge Y
ield
CRM YIELD ANALYSIS 2015/2016
JANUARY
FEBRUARY
MARCHAPR
ILMAY
JUNEJULY
AUGUST
SEPT
EMBER
OCTOBER
NOVEMBER
DECEM
BER98
98.2
98.4
98.6
98.8
99
99.2
99.4
99.6
99.8
100
98.806
98.64298.514
98.604 98.59298.689 98.687
98.80498.663
98.858
99.093 99.1299.08298.982
99.125 99.07599.193
99.442
99.21299.285
99.201
Yield per month
2015 Linear (2015) 2016 Linear (2016)
MONTH
PERC
ENTA
TGE
YIEL
D
WORK ROLL(um/ton) IMR(um/ton) BUR(um/ton)0
1
2
3
4
5
6
7
8
9
1.52645370735584
0.922818167610571
0.380373079839483
2.55222
1.17205
0.383382.616950.63371
0.00000
2.07170 0.77827
0.19019
8.301
4.03
1.21594394938567
3.497
1.89
0.276752933774182
ALL ROLLS CONSUMPTION
AUGUST SEPTEMBER OCTOBER AVERAGE 2015 AVG 2016 AVG
um/M
T2015 WR CONSUMPTION AVG=8.301um/MT2016 WR CONSUMPTION AVG=3.497um/MT Percentage decrease= 62.2%
2015 IMR CONSUMPTION AVG=4.03um/MT2016 IMR CONSUMPTION AVG=1.89um/MT Percentage decrease= 53.1%
CAUSES OF WORK ROLL CONSUMPTION
POWER FLUC/FAIL-
URE
HRC DEFECTS ELECTRICAL ROLLS PRODUCTION0
20
40
60
80
100
120
140
160
0.00000
0.50000
1.00000
1.50000
2.00000
2.50000
3.00000
1.00549
0.35268
0.01773
0.12286
0.40036
1.193690.93392
2.02394
0.10587
0.82232
2.10017
2.448732.19402
0.15490
0.54732
Trend analysis
2014 2015 2016 2014 mm/MT 2015 mm/MT 2016mm/MT
WR CONSUMPTION CAUSES
Roll
cons
umpt
ion(
um)
ROLLS’ CONSUMPTION TREND 2015/2016(mm/MT)
JAN FEB MAR APRIL MAY JUNE JULY AUG SEPT OCT NOV DEC0
0.01
0.02
0.03
0.04
0.05
0.06
0.07
All rolls’ consumption per MT 2015/2016 comparison
2015 2016
MONTH
CONS
UMPT
ION
MM
/mt
AUGUST SEPTEMBER OCTOBER CURRENT AVERAGE
PREVIOUS AVERAGE
0
0.1
0.2
0.3
0.4
0.5
0.6
0.7
0.4895
0.3377
0.5696
0.4656
0.6025
ROLLING OIL CONSUMPTION(KG/TON)
ROLLING OIL(kg/ton)
MONTH
OIL
CO
NSU
MPT
ION
(kg/
ton)
ACID CONSUMED PER MT PRODUCED
AUGUST
SEPTEMBER
OCTOBER
AVERAGE
PREVIOUS AVERAGE
48.00 49.00 50.00 51.00 52.00 53.00 54.00 55.00 56.00
52.95
55.18
50.54
54.07
52.06
LTR/MT of Acid
Ltr/MT of Acid
ARP REGENERATED ACID COMPARISON
AUGUST
SEPT
EMBER
OCTOBER
CURRENT A
VERAGE
PREV
IOUS AVER
AGE0
50
100
150
200
250
300
350
400
450
32.00
34.00
36.00
38.00
40.00
42.00
44.00
46.00
338.9295.3
416.6
317.1 324.575
38.15
43.8641.14
41.05
36.64
ACID PRODUCED Vs. LPG CONSUMED
RA Produced(KL) Ltr/m3 LPG
MONTH
ACID
(KL)
LTI FOR CRM DIVISION
MILL &RWL PPPL & ARP0
0.5
1
1.5
2
2.5
3
3.5
3
0
1
00 0
2014/2015/2016 LTI
2014 2015 2016
CONTINUAL TRAININGS AT ALL LINES
Training on POR at 6 hi CRM
Training on Roll actuation systems at CRM
PPPL hands-on line training
HSE Training 02-08-2016
Training on HRC & CRC Defects minimization
THANK YOU