plant -2016 annual plan presentation

1

DATE24TH NOV. 2015

VENUETOWER BOARD ROOM,LAGOS.

BUSINESS PLAN 2016YEARLY PERFORMANCE REVIEW - 2015

MIDLAND GALVANIGING PRODUCTS LIMITED

MIDLAND GALVANISING PRODUCTS LIMITED

TECHNICAL & MANAGEMENT SERVICES BY COMCRAFT SERVICES LTD., LONDON

PLANT PRESENTATION - 2015


ITA & CC4 MACHINE CC1 & CC2 MACHINE

YEARLY PERFORMANCE HIGHLIGHTS - 2015

1. Zinc coating:- CGL-3 Coating achieved avg. 62g/m² from 3rd Nov.

2015 by modification of zinc bath and minimizing fluttering of the strip from the bath to cooling tower by providing additional stabilizer rolls in passline.

The minimum coating of 77.71g/m² achieved since inception in Aug. 2015 after installation of new inductors.

With the new process, saving on coating for Nov. & Dec. is 13.78kg/t and 15.71g/m².

HIGHLIGHTS

MonthCGL-3 Prod. Zinc charged Zinc-Al Alloy consumption Coating Dross generated

Mt % Mt Kg/T % Mt Kg/T gm2 % Mt.June 2961 7.52 222.604 75.18 0.47 13.858 4.68 78.89 19.18 42.692July 1589 8.15 129.512 81.51 0.79 12.487 7.86 87.64 13.56 17.566August 3581 7.18 257.235 71.84 0.57 20.54 5.74 77.71 13.57 34.914September 2137 7.25 154.943 72.50 0.74 15.724 7.36 80.44 14.68 22.738October 2622 7.12 186.717 71.21 0.61 16.105 6.14 79.42 11.28 21.065 Sub Total 12890 7.38 951.011 73.78 0.61 78.714 6.11 80.04 14.61 138.98

EstimatedCGL-3 Prod. Zinc charged @ 6% Pure Aluminium consumption Coating Dross generated

Mt % Mt Kg/T % Mt Kg/T gm2 % MtNovember 3600 6 216 60 0.28 10 2.78 62 11.8 25.49December 3600 6 216 60 0.28 10 2.78 62 11.8 25.49 Total 7200 6 432 60 0.28 20 2.78 62 11.8 50.98

HIGHLIGHTS

COST OF METALS

Total zinc

chargedZinc cost @ #562.2/Kg.

Total alloy

charged

Zinc-Al cost @

#646.875/Kg. Total cost

Dross Output

Amount Recovered from dross

@ #230/Kg. Net cost

Qty. Prod.

Cost / Ton

MT (=N=) MT (=N=) (=N=) MT (=N=) (=N=) MT

Jun - Oct. 951 534,658,384 78.71 50,918,119 585,576,503 58 13,304,028 572,272,475 12,890 44,398

Estimated

Total zinc

chargedZinc cost @ #562.2/Kg.

Pure Alumini

um

Aluminium cost @

#630/Kg. Total costDross

Output

Amount Recovered from dross

@ #230/Kg. Net cost

Qty. Prod.

Cost / Ton

Nov - Dec 432 242,870,400 20 12600000 255,470,400 47.52 10,929,600 244,540,800 7600 32,176

ZincCost of Zinc

@#542.2/kg. Alloy

Cost of Zn-Al. @

#646.875/kg. Total cost Kg/T (=N=) Kg/T (=N=) (=N=)Jun - Oct 73.78 40004 6.11 3950 43954

ZincCost of Zinc

@#542.2/kg. Pure Alum.Cost of Alum. @ #630/kg. Total cost

Kg/T (=N=) Kg/T (=N=) (=N=)Nov - Dec 60 32532 2.63 1658 34190 Variance 13.78 7472 3.48 2292 9764 Cost saved/Mt 9764NGN

1mt = 31 Bundles Cost saved/Bdl 315NGN

COST SAVING

HIGHLIGHTSFor 1.0 Tons of GI @ 60 GSM

BMT (MM)

Coating (GSM)

TCT (MM) CRC (MT)

Zinc in coating(Kg)

Dross O/P (KG)

Totgal Zinc(KG)

Aluminium (Kg) Zinc (%) Dross (%)

Running Mtr

No. of 6Ft Bundles

Bundle weight

0.135 60 0.143 946.59 53.41 7.28 60.69 2.5 6.32 11.52 1176 32.5 30.79

Running metre gain on per ton GI with different coating grams

BMT : 0.135 MM Width : 755 MM

Coating (GSM)

TCT (MM)

Zinc per Ton GI

Gain/Loss Zinc (Kg) Zinc (%)

Running mtr

Gain/Loss Running

mtr

Number of sheets (6

ft)

Gain/Loss (no. of Sheets)

Number of bundles

Avg. bundle weight

120 0.152 114.34 -26.14 11.4 1110.61 -31.61 613.6 -17.5 30.7 32.59

110 0.150 105.79 -17.59 10.6 1120.95 -21.27 619.3 -11.8 31.0 32.29

100 0.149 97.08 -8.88 9.7 1131.49 -10.74 625.1 -5.9 31.3 31.99Budget

ref. 90 0.148 88.20 - 8.8 1142.22 - 631.1 - 31.6 31.69

80 0.146 79.15 9.05 7.9 1153.16 10.94 637.1 6.0 31.9 31.39

70 0.145 69.93 18.27 7.0 1164.32 22.10 643.3 12.2 32.2 31.09

Actual target 60 0.143 60.52 27.68 6.1 1175.69 33.47 649.6 18.5 32.5 30.79

50 0.142 50.93 37.27 5.1 1187.28 45.06 656.0 24.9 32.8 30.49

Per Ton GI – 2015

2015

Input to finishing

lines(CC & ITA)

(0.15)

Theoretical Bundle weight (0.15)

Theoretical Bundles (0.15)

Actual Bundles

produced (0.15)

Average bundle weight. (0.15) Actual

Theoretical number of bundle per

ton

Actual number of bundle per

ton (MT) (KG) (Bdls) (Bdls) (KG) (Bdls) (Bdls)Jun 1198 31.53 38005 37520 31.78 31.72 31.47Jul 1680 31.53 53284 53038 31.69 31.72 31.56Aug 2058 31.53 65282 65003 31.77 31.72 31.48Sep 1455 31.53 46149 45753 31.8 31.72 31.45Oct 1798 31.53 57041 56909 32 31.72 31.25 Sub-total 8189 31.53 259760 258223 31.81 31.72 31.44

Estimated as per 60gsm²Nov 2500 30.65 81566 80906 30.9 32.6 32.4Dec 2500 30.65 81566 80906 30.9 32.6 32.4 Sub-total 5000 30.65 163132 161812 30.9 32.6 32.4 Grand Total 13189 31.09 422893 420035 31.35 32.17 31.90

Remarks:- Nov & Dec. figure is estimated on average coating of 60gsm²

S/NDate of

LoadingCustomer's

nameNo of

Bundle Net WeightAverage

Bundle Wt.

1 20-11-15 Goodwill 500 15430 30.86

2 20-11-15 Jazil 450 13840 30.76

3 19-11-15 Alhaja Silifat 600 18670 31.12

4 19-11-15 Ms Baba 100 3100 31.00

5 19-11-15 Jazil 450 13820 30.71

6 18-11-15 Imudia 800 24750 30.94

7 18-11-15 Nathando 100 3000 30.00

8 17-11-15 Ms Baba 160 4940 30.88

9 16-11-15 Jazil 450 13810 30.69

TOTAL 3610 111360 30.85

Weighbridge Reference

HIGHLIGHTS

2. Replacement of Zinc-Al (10%) alloy ingots with pure Aluminum ingots for new bath chemistry resulted into saving in both consumptions and price variance

3. With the new process, saving on consumption and rate for Nov. & Dec. is 9764NGN/Ton and 315NGN/Bdl. (1mt=31bdls)

HIGHLIGHTS

Zinc CONSUMPTION

The figure indicated here is on total Zinc charged

Average Zinc (%) in 2015 is 8.86 against 9.16 average of 2014.

Two major reasons for increased Zinc (%) Inductors failure (3 No.) Decrease in CRC gauge.

Avg. 2014

Jan-15

Feb-15

Mar-15

Apr-15

May-15

Jun-15

Jul-15

Aug-15

Sep-15

Oct-15

Nov-15

Dec-15

Avg. 2015

0.00

2.00

4.00

6.00

8.00

10.00

12.00

14.00

(%) on GI Output

%

Coating AnalysisCGL-3 Coating Analysis from Year 2012 - 2015

Year CR inputZinc

ChargedAlloy

Charged

Total zinc charged

(Zinc+Alloy)Dross output

GI produced

Total Zinc % Dross %

Total Surface Area

Surface Area / Ton

% Increased

Zinc Coating

(Mt) (Mt) (Mt) (Mt) (Mt) (Mt) % % m² m² % gsm²2012 43050.1 3157.34 212.276 3369.616 229.6 45773.8 7.4 7.3 29,999,791 655 104.672013 43459.6 3585.97 196.014 3781.981 289.89 46552.4 8.1 8.1 35,604,857 765 16.7 98.082014 39158.9 3731.89 175.188 3907.081 492.41 42330.9 9.2 13.2 33,034,482 780 2.0 103.37

2015 till Oct. 24731.7 2302.11 123.246 2425.351 421.45 26639.7 9.1 18.3 22,236,614 835 7.0 90.12 Cummulative 150400 12777 706.724 13484.029 1433 161297 8.4 11.2 120,875,744 749 99.69

Abagal Coating Analysis from Year 2012 - 2015

Year CR inputZinc

ChargedAlloy

Charged

Total zinc charged

(Zinc+Alloy)

Dross / Ash

outputGI

producedTotal

Zinc %Dross / Ash %

Total Surface Area

Surface Area / Ton

% Increased

Zinc Coating


2015 till May. 4753.3 581.013 7.919 588.932 129.68 5273.18 11.2 22.3 4,623,229 877 4.1 99.34 Cummulative 28127 3025.3 50.964 3076.292 443.4 30535 10.1 14.7 25,334,865 830 103.92

Plant (CGL-3 & Abagal) Coating Analysis from Year 2012 - 2015

Year CR inputZinc

ChargedAlloy

Charged

Total zinc charged

(Zinc+Alloy)

Dross / Ash

outputGI

producedTotal

Zinc %Dross / Ash %

Total Surface Area

Surface Area / Ton

% Increased

Zinc Coating


2015 till Oct. 29485 2883.12 131.165 3014.283 551.12 31912.9 9.4 19.1 26,859,843 842 6.7 91.70 Cummulative 178527 15803 757.688 16560.321 1877 191832 8.6 11.9 146,210,609 762 100.43

Month Prod.Zinc

consumedAlloy

ConsumedDross

OutputZinc

CoatingZinc Kg/T

Alloy Kg/T

Total Zinc price @

542.2/kg

Zinc Cost /

Ton

Zinc-Al Alloy Price

@ 642.875/ kg

Zinc-Al Alloy

cost / TonsTotal Zinc & Alloy

Cost / Ton

(Mt) (Mt) (Mt) (Mt) gsm² KG KG (=N=) (=N=) (=N=) (=N=) (=N=)

2015 3500 346 20 34.6 100 98.86 5.71 187,601,200 53,600 12,857,500 3,674 57,274

Month ProdZinc

consumedAluminium Consumed

Dross Output

Zinc Coating

Zinc Kg/T

Alum. Kg/T

Total Zinc price @

542.2/kg

Zinc Cost /

Ton

Aluminium Price @ 550/kg

Zinc-Al Alloy

cost / TonsTotal Zinc & Alloy

Cost / Ton

(Mt) (Mt) (Mt) (Mt) gsm² KG KG (=N=) (=N=) (=N=) (=N=) (=N=)(Nov.- Dec. 2015) & 2016 3500 210 10 23.1 62 60.00 2.86 113,862,000 32,532 5,500,000 1,571 34,103

Variance / Ton 136 10 12 39 3 73,739,200 21,068 7,357,500 2,102 23,170

Monthly Saving (NGN) 81,096,700

Saving on Coating.

3. Modification of passline by providing additional stabilizer rolls between sink roll in the zinc bath and cooling tower.

Reduction in flattering by increased tension. Jet setting parameters (Gap between strip and jet lips

reduced for lower coating) Ease of cleaning of knives by operators, reducing strip

breakages at pot. Quality improvement:- Surface mark reduced on the strip. Uniform coating across the width achieved. Visible improvement in logo marking on the strip Dents/Pin holes reduced to zero from TOR.

HIGHLIGHTS

4. Saving on Inductors:9 Number of inductors made ready in-house New dry vibratable cement type technology adoptedExecuted independently under MIDGAL team lead

and supervision support from two Indian masons and distant

communication with AJAX(USA).4 Inductors installed successfully, working and in

healthy conditions5 Inductors available ready as spare .

HIGHLIGHTS

REARANGEMENT OF PROFILING MACHINES• All roll formers and ITA machine brought under one shed at ABAGAL

bay• KY bay space available for new projects/long span

ABAGAL BAY CRANES MODIFICATION• Cross travel of two Morris crane modified to avoid frequent breakdown • First crane modification through local contractor (Biopic Engineering

Ltd)• Second crane modification through in house resources

PIPELINE CNG COMMISSIONING• MIDGAL PRMS for CNG through pipeline from Nigerian Gas Company

commissioned – 13 July 2015• New price through pipeline N 51 per SCM in place of N 97.69 per SCM

+ VAT old price• On average consumption of 150,000 SCM per Month MIDGAL may

save 7.5 Million Naira from gas through pipeline every month STUCCO EMBOSSER

• Stucco Embosser installed and commissioned by in house team

HIGHLIGHTS

PRODUCTION SALES BUDGET0

10000

20000

30000

40000

50000

60000

70000

57212 5877554150

49384 50024

58080

31913 32728

44521

PRODUCTION, BUDGET & SALES

Tons

5. Scrap reduction:

HIGHLIGHTS

2014 2015

MT % MT %

CR scrap 151 0.39 53 0.21

GI scrap 387 0.91 78 0.29Downgradation @ finishing section (GI & PPGI) 1222 2.65 801 2.78

Finishing line scrap 218 0.61 33 0.16

Total 1978 4.56 965 3.44

MONTHCRC

INPUTCRC

SCRAPCRC

SCRAP %JAN 3877 18 0.47FEB 3849 22 0.57MAR 3798 27 0.72APR 3822 8 0.21MAY 4092 4 0.09JUN 2717 1 0.05JUL 1962 15 0.77AUG 3568 27 0.76SEPT 2549 8 0.32OCT 3367 8 0.24NOV 2306 8 0.34DEC 3251 5 0.14TOTAL 39159 151 0.39

CGL3 – CR DIVERSIONS

2014 2015

MONTHCRC

INPUTCRC

SCRAP CRC

SCRAP %JAN 2814 3 0.09FEB 2130 5 0.23MAR 2859 7 0.25APR 2349 3 0.13MAY 2538 5 0.22JUN 2806 14 0.49JUL 1463 1 0.08AUG 3331 4 0.12SEP 2001 7 0.35OCT 2439 4 0.16NOV DEC TOTAL 24732 53 0.21

CGL3 - GI PRODUCTION

2014 2015

MONTH

GI OUTPUT

(MT)

GI DIVERSION

(MT)

GI DIVERSION

%JAN 4188 32 0.77FEB 4115 26 0.64MAR 4063 38 0.95APR 4175 45 1.07MAY 4464 37 0.82JUN 2923 42 1.45JUL 2092 15 0.70AUG 3792 35 0.92SEPT 2765 18 0.64OCT 3655 32 0.86NOV 2522 25 0.99DEC 3580 42 1.17TOTAL 42333 387 0.91

MONTH

GI OUTPUT

(MT)

GI DIVERSION

(MT)

GI DIVERSION

%JAN 3165 0.4 0.94FEB 2295 0.4 0.67MAR 3065 4.0 0.01APR 2524 3.2 0.02MAY 2706 5.6 0.15JUN 2961 7.5 0.11JUL 1589 0.4 0.35AUG 3581 11.1 0.21SEP 2137 0.4 0.02OCT 2622 0.4 0.42NOV DEC TOTAL 26644 77.5 0.29

CGL 3 REJECTIONS (%)

Jan Feb Mar AprMay Jun Jul

AugSep Oct Nov

Dec

Avg. 2

0140.00

0.20

0.40

0.60

0.80

1.00

1.20

1.40

1.60

2014 Rejection %

%

Jan Feb Mar Apr May Jun Jul Aug Sep Oct Nov Dec Avg. 2015

0.00

0.10

0.20

0.30

0.40

0.50

0.60

0.70

0.80

0.90

1.00

2015 Rejection %

%

MONTHCR

INPUTCR

SCRAPCR

SCRAP %JAN 974 11 1.10FEB 1196 17 1.45MAR 1174 9 0.80APR 1073 2 0.19MAY 1576 2 0.11JUN 56 0 0JUL 0 0 0AUG 0 0 0SEPT 0 0 0OCT 0 0 0NOV 0 0 0DEC 410 1 0.30TOTAL 6459 43 0.66

2014/2015 ABAGAL CR DIVERSIONS

2014 2015

MONTHCR

INPUTCR

SCRAPCR

SCRAP %JAN 1468 1 0.08FEB 776 1 0.08MAR 734 1 0.13APR 1325 1 0.09MAY 449 0 0.08JUN 0 0 0JUL 0 0 0AUG 0 0 0SEPT 0 0 0OCT 0 0 0NOV 0DEC 0TOTAL 4753 4 0.09

2014/2015 ABAGAL GI PRODUCTION

2014 2015

MONTH

GI OUTPUT

(MT)

GI DIVERSION

(MT)

GI DIVERSION

%JAN 1628 5 0.28FEB 853 5 0.60MAR 809 4 0.45APR 1474 6 0.40MAY 509 1 0.21JUN 0 0 0JUL 0 0 0AUG 0 0 0SEP 0 0 0OCT 0 0 0NOV 0DEC 0TOTAL 5273 20 0.38

MONTH

GI OUTPUT

(MT)

GI DIVERSION

(MT)

GI DIVERSION

%JAN 1045 18 1.72FEB 1281 1 0.10MAR 1252 5 0.39APR 1194 7 0.61MAY 1773 8 0.46JUN 63 0 0.33JUL 0 0 0AUG 0 0 0SEP 0 0 0OCT 0 0 0NOV 0 0 0DEC 443 2.17 0.49TOTAL 7052 42 0.59

ABAGAL – REJECTION (%)


AugSep Oct

NovDec

Avg. 2

0140.00

0.20

0.40

0.60

0.80

1.00

1.20

1.40

1.60

1.80

2.00

2014

Axis Title


AugSep Oct Nov

Dec

Avg. 2

0150.00

0.10

0.20

0.30

0.40

0.50

0.60

0.70

2015

%

REJECTION at galvanizing

CGL 3 Salvaging of all GI baby defective coil

generated from CGL3 processing on finishing lines and scrap brought down to 0.29% as pencil and scrap against 0.91% average of 2014.

CR scraps has reduced from 0.39% in 2014 to 0.21% till date.

The coil end to end processing adopted to minimize CR scraps change in operation techniques

The reduction in overall CR gauge and improper trimming, off gauge head & tail ends and rapping at I.D. of the coil are major contribution in diversion.

ABAGAL Total rejection has come down from

1.25% in 2014 to 0.47% average 2015. As per trend line CR Scraps and GI

scraps inversely proportional CR Scraps has reduced from 0.66%

average of 2014 to 0.09% average for 2015

GI scraps has reduced from 0.59% in 2014 to 0.38% average for 2015

The online distinct collection and segregation of GI plain sheets adopted. (Prime,Gr1B,Gr2,Gr3 and Scraps)

The coil end to end processing adopted to minimize CR scraps

2015 ROLL FORMING g i DIVERSION.

DATE 2014 Jan Feb Mar Apr May Jun Jul Aug Sep Oct Nov DecCumm. Total.

Issue to finishing line (MT.) 35831 2638 2168 2471 2283 1777 1411 1725 2455 1467 1839 20235

Total bundles delivered 1009114 66673 59699 76894 58320 47053 41710 53848 72268 47391 57709 581565

Bundles in tonnage 35613 2630 2161 2461 2282 1775 1410 1723 2454 1467 1838 20202

Scrap in tons 218 8.0 6.5 10.2 1.3 1.4 1.026 2.08 1.08 0.34 0.93 33

Prime % 96.82 95.94 94.15 98.21 96.96 96.80 97.36 97.57 98.12 96.72 97.29 96.95

% of lower grade. 2.57 3.75 5.55 1.38 2.99 3.12 2.56 2.31 1.83 3.26 2.66 2.89

Scrap % 0.61 0.32 0.30 0.00 0.06 0.08 0.07 0.12 0.05 0.02 0.05 0.16

Average bundle wt. 34.91 38.56 36.42 32.00 39.13 37.73 33.8 32.00 33.96 30.96 31.86 34.63

2015 ABAGAL gi DIVERSION AT finishing SECTION

DATE 2014 Jan Feb Mar Apr May Jun Jul Aug Sep Oct Nov DecCumm. Total


Total bundles delivered 217640 48800 25450 25620 42580 19670 0 0 0 0 0 162120


Scrap in tons 10 3.0 1.7 5.1 6.9 0.8 0 0 0 0 0 17

Prime % 97.07 99.81 96.27 97.56 98.55 96.07 0 0 0 0 0 98.11

% of lower grade. 2.80 0.00 3.53 1.82 0.96 3.81 0 0 0 0 0 1.55

Scrap % 0.13 0.19 0.20 0.00 0.50 0.12 0 0 0 0 0 0.33

Average bundle wt. 32.99 32.21 32 31.80 32.17 32.00 0 0 0 0 0 32.07

2015 PLANT gi DIVERSION AT finishing SECTION

DATE 2014 Jan Feb Mar Apr May Jun Jul Aug Sep Oct Nov DecCumm. Total


Total bundles delivered 1226034115473 85149 102514 100900 66723 41710 53848 72268 47391 57709 743685


Scrap in tons 183 11.0 8.2 15.2 8.2 2.2 1.026 2.08 1.08 0.34 0.93 50

Prime % 97.06 97.57 94.78 98.05 97.65 96.59 97.36 97.57 98.12 96.72 97.29 97.21

% of lower grade. 2.51 2.16 4.95 1.49 2.13 3.32 2.56 2.31 1.83 3.26 2.66 2.60

Scrap % 0.43 0.26 0.27 0.00 0.22 0.09 0.07 0.12 0.05 0.02 0.05 0.20

Average bundle wt. 34.91 35.88 35.10 31.95 36.19 36.04 33.80 32.00 33.96 30.96 31.86 34.09

REJECTION at FINISHING SECTION

Finishing line diversion @ 2.66% due to salvaging of deffective coils from CGL-3, before it was sold in coil form directly to scrap customers.

Effective / actual diversion at CGL-3 has reduced from 0.69% to 0.12%, since most of the deffective coils has been salvaged.

750MM PPGI DIVERSION

years

Tolling GI sent to kkT

750 MM PPGI

Received from KKT

Scraps Received from KKT

750MM PPGI

processed @

finishing line

Output bundles

@ finishing

line

Downgradtion at MIDGAL on 750mm

PPGI

Color Diversion at MIDGAL on

750MM PPGI

Total Diversion

Total Diversion

on 750MM PPGI recpt frm KKT

Tons Tons Tons Tons Tons Tons Tons Tons %

Total year 2014 3422 3407 36 3325 3205 117.964 133.47 287 8.642015 Tons Tons Tons Tons Tons Tons Tons Tons %

Jan-15 384 245 1 229 226 1 2.97 5 6.85Feb-15 155 283 3 248 247 27 1.59 31 8.07Mar-15 447 210 1 256 259 27 1.12 25 9.72Apr-15 224 350 1 355 344 6 11.83 19 5.31

May-15 597 414 14 365 357 6 8.51 28 7.71Jun-15 936 507 5 257 259 7 2.1 14 5.49Jul-15 164 569 9 474 473 3 1.51 14 2.98

Aug-15 1069 649 7 671 669 24 1.57 32 4.81Sep-15 616 710 6 378 371 15 1.24 23 6.00Oct-15 569 663 10 240 250 31 0.39 41 17.17

Nov-15 0 Dec-15 0

Total year 2015 5159 4599 56 3474 3453 147 29 232 6.68***Calculation solely on KKT PPGI (Imported PPGI not included)

1000/1200MM PPGI DIVERSION

years Tolling GI sent

to kkT

1000/1200 MM PPGI Received

from KKTScraps Received

from KKT

Diversion on 1000/1200MM PPGI recpt frm

KKT Tons Tons Tons %

Total year 2014 2677 2445 126 5.13Jan-15 219 167 24 14.1Feb-15 33 164 22 13.4Mar-15 120 50 4 7.8Apr-15 262 255 11 4.3

May-15 286 296 11 3.6Jun-15 192 24 2 7.0Jul-15 141 317 3 1.0

Aug-15 0 3 3 86.0Sep-15 163 162 7 4.2Oct-15 74 44 3 6.2Nov-15 Dec-15

Total year 2015 1490 1482 89 5.98

PPGI DIVERSION (all sizes)

years

Tolling GI sent to kkT

PPGI Received from KKT (All sizes)

Wider Received + 750mm processed

Scraps Received from KKT (All sizes)

750MM PPGI

processed @

finishing line

Downgradtion at

MIDGAL on 750mm

PPGI

Color Scrap at MIDGAL

on 750MM

PPGI

Total Diversion

(Downgradation + scrap)

Total Diversion on PPGI

recpt frm KKT

Tons Tons Tons Tons Tons Tons Tons Tons %Total year 2014 6159 6104 5770 161 3325 117 133 412 7.14

Jan-15 603 412 396 24 229 1 2.97 28 7.1Feb-15 187 447 413 26 248 27 1.59 55 13.3Mar-15 567 260 306 5 256 27 1 33 10.8Apr-15 486 605 610 12 355 6 12 30 4.9

May-15 883 710 661 24 365 6 9 39 5.9Jun-15 1128 531 281 7 257 7 2 16 5.6Jul-15 305 886 791 12 474 3 2 17 2.2

Aug-15 1070 652 675 10 671 24 2 35 5.2Sep-15 780 872 540 13 378 15 1 29 5.4Oct-15 643 708 284 13 240 31 0 44 15.5

Nov-15 Dec-15

Total year 2015 6650 6082 4956 146 3474 147 33 327 6.59

***Calculation solely on KKT PPGI (Imported PPGI not included)

KKT - TOLLING

Jan-14

Feb-14

Mar-14

Apr-14

May-14

Jun-14

Jul-14

Aug-14

Sep-14

Oct-14

Nov-14

Dec-14

Jan - Dec

2014

Jan-15

Feb-15

Mar-15

Apr-15

May-15

Jun-15

Jul-15

Aug-15

Sep-15

Oct-15

Jan - Oct

2015

0

1000

2000

3000

4000

5000

6000

750MM

MT

KKT - TOLLING

Jan-14

Feb-14

Mar-14

Apr-14

May-14

Jun-14

Jul-14

Aug-14

Sep-14

Oct-14

Nov-14

Dec-14

Jan - Dec

2014

Jan-15

Feb-15

Mar-15

Apr-15

May-15

Jun-15

Jul-15

Aug-15

Sep-15

Oct-15

Jan - Oct

2015

0

500

1000

1500

2000

2500

3000

WIDER 1000MM - MT

MT

HIGHLIGHTS• Wide range of New Product Developed in 2015

against in 2014 for market to enhance sales.2014 2015

Products ITACorrugat

ion ITA Corrugation

PPGI in (8 colors) Plain Plain Total 24

product colour in market

Plain Plain Total 48 product mix in market (Additional 24

products added) Diamond

Emb Diamond

Emb Diamond Emb Stucco Emb Stucco Emb

GI Diamond Emb ITA - Total 2 product

introduced to the market

ITA CorrugationTotal 4 product

mix introduced to the market

(Additional 2 products added)GI Tuffzinc -

Corrugation ITA Corrugation

Total 26 product mix in bundles for PPGI and special products

Total 52 product mix in bundles for PPGI and special products

ENERGY CONSUMPTION

CNG consumption has slightly increased from 45 SCM to 46 SCM per Ton from 2014 (Avg.) to 2015 (Avg.) because of thinner gauge production.

KWH per Ton in 2015 is high because of low production.

Avg. 2014

.

Jan-15

Feb-15

Mar-15

Apr-15

May-15

Jun-15

Jul-15

Aug-15

Sep-15

Oct-15

Avg. 2015

0

50

100

150

200

250

300

350

400

GAS & POWER

KW

H /

SCM

ENERGY CONSUMPTION (POWER)

Power (KWH)Amount @

31.31Maximum Demand

Maximum Demand @484.01

Total power amount

Plant Production

Power / Ton

(=N=) (KVA) (=N=) (=N=) (MT) (=N=) Total year 2014 9,919,734 328,938,216 10071280 325177813 49384 6661

Jan-15 887,898 27,800,086 1,938 938,011 28,738,098 4,789 6,001

Feb-15 779,028 24,391,367 1,865 902,679 25,294,045 3,147 8,037 Mar-15 905,302 28,345,006 1,865 902,679 29,247,684 3,874 7,550 Apr-15 767,047 24,016,242 1,865 902,679 24,918,920 3,998 6,232

May-15 781,456 24,467,387 1,848 894,450 25,361,838 3,215 7,889 Jun-15 789,746 24,726,947 1,846 893,482 25,620,430 2,961 8,653 Jul-15 624,344 19,548,211 1,846 893,482 20,441,693 1,589 12,864

Aug-15 953,363 29,849,796 1,864 902,195 30,751,990 3,581 8,588 Sept-15 682,220 21,360,308 1,730 837,337 22,197,646 2,137 10,387 Oct-15 787,500 24,656,625 1,686 816,041 25,472,666 2,622 9,715

Total year 2015 7,957,904 249,161,974 18,353 8,883,036 258,045,010 31,913 8,086

ENERGY CONSUMPTION (CNG)

CNGAmount for

CNG CNG / Ton Plant

production SCM (=N=) (=N=) (MT)

Total year 2014 1,985,604 161,722,756 3275 49384

Jan-15 147,281 12,864,995 2,686 4,789 Feb-15 129,790 11,337,157 3,602 3,147 Mar-15 151,768 13,256,935 3,422 3,874 Apr-15 148,669 12,986,237 3,248 3,998

May-15 156,653 13,683,640 4,257 3,215 Jun-15 151,528 13,235,971 4,470 2,961 Jul-15 105,085 5,359,335 3,373 1,589

Aug-15 170,623 8,701,773 2,430 3,581 Sept-15 110,721 5,646,771 2,642 2,137 Oct-15 130,678 6,664,578 2,542 2,622

Total year 2015 1,402,796 103,737,391 3267 31,913

POWER COST WITH MINIMUM PRODUCTION.

Power Minimum Take

or Pay Power/Ton Production

KWH (=N=) (Ton)

900,000 6,001 5,000

900,000 7,557 4,000

900,000 8,653 3,000

900,000 9,500 2,000

1 2 3 4

0

1000

2000

3000

4000

5000

6000

7000

8000

9000

10000

6001

7557

8653

9500

5000

4000

3000

2000

Power Per Ton

(=N

=)

POWER COST WITH MINIMUM PRODUCTION.

CNGAmount for

CNG CNG / Ton Production

SCM (=N=) (=N=) M.T

150,000 7,650,000 1,530 5,000

150,000 7,650,000 1,913 4,000

150,000 7,650,000 2,550 3,000

150,000 7,650,000 3,825 2,000 1 2 3 40

1000

2000

3000

4000

5000

6000

1560

1950

2600

3900

5000

4000

3000

2000

CNG Per Ton

(=N

=)

JanFe

bMar

AprMay Jun Jul

AugSe

p OctNov

Dec

Avg. (Ja

n-Dec.)

0

500

1000

1500

2000

2500

3000

3500

4000

R EPAIR & MAINTENANCE COST - N / MT(=

N=)

JanFe

bMar Apr

May Jun JulAug

Sep

Oct NovDec

Avg. (Ja

n-Dec)

0

1000

2000

3000

4000

5000

6000

7000

8000

FUEL, OIL, LUBRICANTS AND GAS COSTS - N / MT(=

N=

)

JanFe

bMar

AprMay Jun Jul

AugSe

pOct Nov

Dec

Average (Ja

n-Dec)

0

5000

10000

15000

20000

25000

MANUFACTURING EXPENSES - N / MT(=

N=)

BREAKDOWN AND SUPPORT NEEDED URGENTLY.

Hydrogen plant:- Lye pump failure frequently. Gas- lye separator cum heat exchanger – LYE pipe started

leaking Electrolyser sagging & breakage of insulators resulted into

sparking at times. Modified dryer heaters needs to replace with existing in-

built heating coil in dryer. Need a space for above point and urgent visit of equipment

supplier from china to evaluate health of the plant.

BREAKDOWN AND SUPPORT NEEDED URGENTLY.

Nitrogen plant:- Need a spares as recommended by Nuberg person visit to change existing parts.

Electrical Automation:- Need control Technique personnel for fine tuning of existing system and update outdated parts and system. Complete health check up of equipments, programming and calibration etc.

BUDGET - 2016

Annual Plan - 2016

2016 PRODUCT MIX JAN FEB MAR APR MAY JUN JAN-JUN JUL AUG SEPT OCT NOV DEC JUL-

DEC BUDG

ET

GI Sheets-36G-.15MM 2,645

2,850

2,850

2,850 2,800

2,495 16,490 1,370 1,370

1,370

1,370

1,370

1,800

8,650

25,140 52%

GI Sheets-35/34G 100

100

100

100 100

50 550 50 50

50

50

50

50

300

850 2%

GI Sheets-36G-.15MM -TRIMDEK 200

250

250

250 250

200 1,400 200 175

175

175

175

200

1,100

2,500 5%

GI -EMB Sheets-.15MM - STUCCO

250

250

250

250 250

250 1,500 250 200

200

200

200

200

1,250

2,750 6%

GI -EMB Sheets-.15MM - DIAMOND

100

150

150

150 150

100 800 100 100

100

100

100

100

600

1,400 3%

PPGI Sheets-0.15MM -PLAIN 150

250

250

250 250

175 1,325 175 175

150

150

175

200

1,025

2,350 5%

PPGI Sheets-0.15MM -EMBOSSED

550

575

575

575 575

550 3,400 550 550

525

525

550

550

3,250

6,650 14%

GI Sheets-34G *.20X 1000-Domestic

300

500

500

500 400

100 2,300 75 75

75

75

100

300

700

3,000 6%

PPGI Sheets - EXPORT 30

30

30

30 30

30 180 30 30

30

30

30

30

180

360 1%

0.23/0.25 X 1000- COATED COILS 250

250

250

250 250

250 1,500 250 250

250

250

250

250

1,500

3,000 6%

TOTAL (MT) 4,575

5,205

5,205

5,205 5,055

4,200 29,445 3,050

2,975

2,925

2,925

3,000

3,680

18,555

48,000

2016 PLAN SUMMARY

G.I Total 3,595 4,100 4,100 4,100 3,950 3,195 23,040 2,045 1,970 1,970 1,970 1,995 2,650 12,600 35,640 74%

PP G.I Total 980 1,105 1,105 1,105 1,105 1,005 6,405 1,005 1,005 955 955 1,005 1,030 5,955 12,360 26%

4,575 5,205 5,205 5,205 5,055 4,200 29,445 3,050 2,975 2,925 2,925 3,000 3,680 18,555 48,000

Annual Production Plan 2016

Annual Production Plan 2016Annual Production Plan - 2016

MT/Hr JAN FEB MAR APR MAY JUN

JAN - JUN JUL AUG SEP OCT NOV DEC

JUL-DEC

BUDGET

2016 PRODUCT MIX - CGL 3 Tons Hrs Tons Hrs Tons Hrs Tons Hrs Tons Hrs Tons Hrs Tons Tons Hrs Tons Hrs Tons Hrs Tons Hrs Tons Tons Hrs Tons Tons

Mix(%)

GI Sheets-36G-.15MM

CGL 3

5.21 2021 388 1430 274 1866 322 1728 298 1938 334 2267 391 11250 1397 241 1397 241 1397 241 1397 241 1397 1836 317 8823 20453 41.44

GI Sheets-35/34G 5.74 92 16 92 16 102 16 102 16 102 16 51 8 541 51 8 51 8 51 8 51 8 51 51 8 306 867 1.76GI Sheets-36G-.15MM -TRIMDEK 5.21 184 35 230 44 255 44 255 44 255 44 204 35 1382 204 35 179 31 179 31 179 31 179 204 35 1122 2550 5.17GI -EMB Sheets-.15MM - STUCCO 5.21 230 44 230 44 255 44 255 44 255 44 255 44 1479 255 44 204 35 204 35 204 35 204 204 35 1275 2805 5.68GI -EMB Sheets-.15MM - DIAMOND 5.21 92 18 138 26 153 26 153 26 153 26 102 18 791 102 18 102 18 102 18 102 18 102 102 18 612 1428 2.89PPGI Sheets-0.15MM -PLAIN 5.21 142 27 236 45 263 45 263 45 263 45 184 32 1349 184 32 184 32 158 27 158 27 184 210 36 1076 2468 5.00PPGI Sheets-0.15MM -EMBOSSED 5.21 520 100 543 104 604 104 604 104 604 104 578 100 3452 578 100 578 100 551 95 551 95 578 578 100 3413 6983 14.15GI Sheets-34G *.20X 1000-Domestic 7.42 275 37 459 62 510 62 510 62 408 49 102 12 2264 77 9 77 9 77 9 77 9 102 306 37 714 3060 6.20PPGI Sheets - EXPORT 8.93 28 3 28 3 32 3 32 3 32 3 32 3 183 32 3 32 3 32 3 32 3 32 32 3 189 378 0.770.23/0.25 X 1000- COATED COILS 8.93 236 26 236 26 263 26 263 26 263 26 263 26 1523 263 26 263 26 263 26 263 26 263 263 26 1575 3150 6.38

TOTAL (MT) 3820 694 3622 646 4301 693 4163 670 4271 693 4036 670 24213 3141 516 3065 503 3012 494 3012 494 3090 3785 616 19105 44141 89.44

GI sheets - 36G- 0.15 MM

ABAGAL 2.35 876 330 1720 644 1041 399 1179 442 918 344 278 104 6037 ABAGAL under shutdown 5214 10.56

Plant Total Total 4696 5342 5342 1088 5342 1116 5189 1042 4314 776 302503141 518 3065 505 3012 496 3012 496 3090 508 3785 618 19105 49355 100

Assumptions: a. 2.0% diversion in GI and 5.0% diversion in PPGIb. 90% efficiency with available hours after shutdown

MIDGAL MATERIAL STOCKS AS ON 16th November, 2015. 07.00AM

Category PrimeNon-Prime (QC

WIP) Total Remarks Tons Tons Tons Raw Materials CR coils {762mm} 308.85 0 308.85 CR coils {1000mm} 0 0 0 Sub-Total 308.85 0 308.85 GI WIP GI coil for {corrugation & ITA} 321.624 7.256 328.88 GI coil for {KKT} 297.161 297.161 GI coil Return from {KKT} 0 GI plain sheet 0 GI {Diamond emboss} 1.497 1.497 GI {Stucco emboss 762mm} 27.89 27.89 GI pencil coil 2.054 2.054 GI corr. Sheets {QC WIP} 2.02 2.024 GI Reserved for LONGSPAN 4.92 4.92 GI Total 648.172 16.254 664.426 PPGI WIP Color coil {762mm} 684.814 684.814 Kolorkote GI Coils @ Kolorkote 233.196 233.196 PPGI Coils @ Kolorkote 202.712 202.712 Sub-Total 435.908 0 435.908 Total WIP 1768.894 16.254 1785.148 FG {Warehouse} FINISHED GOODS FOR SALEGI GI plain {Roofing Sheets} 1768.144 52.374 1820.518 GI {Stucco emboss 1000mm} 3.859 3.859 GI produced for LANGE & GRANT 10.135 10.135 GI Total 1782.138 52.374 1834.512 PPGI Coloured {Rofing sheets} 522.937 41.754 564.691 Steptiles 24.695 24.695 Aluminium 1.368 1.368 PPGI coils @ Warehouse 194.263 16.125 210.388 PPGI Total 743.263 57.879 801.142 FG Total 2525.401 110.253 2635.654 Grand Total 4603.145 126.507 4729.652

MANPOWER POSITION AS AT NOVEMBER 2015PRODUCTION SECTION S.STAFF JUNIOR STAFF TRAINNING W.ASSIST CONTRACT TOTAL 2014CGL3 ENTRY 6 4 0 2 0 12

43 POT 0 5 0 5 0 10 EXIT 0 2 0 3 0 5FINISHING LINE CC1 0 0 0 8 0 8 8 CC2 0 0 0 8 0 8 8 CC3 0 0 0 8 0 8 8 SUPERVISOR 0 2 0 0 0 2 2 CRANE 0 2 0 0 0 2 2 EMBOSSER 0 1 0 2 0 3 2 ABB .CUT UP 0 1 0 4 0 5 0 SAP 0 0 0 2 0 2 2QUALITY 2 0 0 2 0 4 4PPC 1 1 0 1 0 3 3FORKLIFT 0 1 0 2 0 3 3W/BRIDGE 0 1 0 0 0 1 1WAREHOUSE 1 1 0 3 0 5 6STORES 0 3 0 1 0 4 4MAINTENANCE ELECTRICAL 1 9 0 2 1 13 15 MECHANICAL 1 5 1 1 0 8 14 UTILITY 0 4 0 0 0 4 5TOTAL 12 42 1 54 1 110 130 0 ADMIN SECURITY 0 2 0 1 0 3 3 DRIVERS 0 9 0 0 4 13 14 MD OFFICE 1 0 0 1 0 2 2 TEA ROOM 0 0 0 1 0 1 1PURCHASE EXPORT 0 2 0 0 0 2 2ACCOUNTS 5 0 2 0 1 8 7MARKETING/SALES 5 0 0 0 0 5 5I.T DEPARTMENT 1 0 0 0 0 1 1TOTAL 35 35GRAND TOTAL 145 165

Manpower Status – 2015

20.11.2015CORRUGATION PROFILE ITA PROFILE

SON (Spec) ToleranceMidgal -

Roll forming G.I(0.15)

Midgal - Barrel

G.I(0.15)Kam Roof G.I(0.15)

Wempco 8FT

G.I(0.15)AARTI

G.I(0.20)

SUMO DIAMOND (0.15) (8FT)

G.I

KAM ROOF COLOUR

DIAMOND (0.15) (8FT)

IMPORTED COLOUR

PLAIN (8FT)

Midgal Diamond Colour. (0.15)

Wempco Plain

Colour (0.15)

Aarti Diamond

Colour (0.15)

CR Gauge 0.15 5% 0.136 0.136 0.136 0.156 0.144 - - - - - -GI Thickness 0.151 0.152 0.155 0.165 0.170 0.31 0.33 0.17 0.30 0.18 0.35Width of Corrugation(MM) 638 - 691 665±4% 665 660 655 695 665 645 647 690 685 700 715

Length (MM)1801-

1856.441829±1.5

% 1805 1805 1825 2434 1830 2440 2440 2440 2440 2440 2440Zinc Coating (G/M2) 100-120 58 62 87 47 100 - - - - - -

Depth(MM)16.56-19.44 ±8% 17.05 19 17.03 15.7 16.05 19.38 19.35 15.30 23 22.00 17.3

Pitch(MM) 74.3-78.11 ±2.5% 77 75 75 75 78 69 72 77 195 200 215Bundle Weight (Kg) - - - - - - - - - -Finishing gloss / shine BRIGHTER BRIGHTER FAIR BRIGHTER DULL BRIGHTER BRIGHTER BRIGHTER BRIGTHER OK OKDiamond Embossed - - - - YES YES - YES - YESStucco Embossed - - - - - - - - - - Quality of printing brand on sheets GOOD GOOD GOOD POOR FAIR GOOD GOOD NO NO NO GOOD

Jet Print YES

(GOOD) YES (GOOD) NO NO YES (FAIR)YES

(GOOD) NO NOYES

(GOOD) NO NOLogo GOOD GOOD GOOD POOR DULL NO NO NO NO NO NOStrapping - - - - - - - - - - -Quality of strips - - - - - - - - - - -

Strength

QUALITY AND

PACKAGINGQUALITY AND PACKAGING DEPTH FINISHING PROFILING FINISHING

QUALITY AND

PACKAGINGBRIGHTNES

SQUALITY

AND PACKAGING

FINISHING -

Weakness

NONE NONE FINISHING LOGO / DEPTH FINISHING NONE NONE

COATING, DEPTH &

FLAT GUTTER

NONE NONEFININSHING

/ WIDTH

1Sample size taken as per SON 60 MM x 60 MM size and test conducted2All samples from corrugated/profiled sheets3Same sample was taken for CGL 3(SOFT) and ABAGAL (HARD).

Competitors Analysis – 2015

THANKS FOR VALUABLE

DIRECTIONS

LONG LIVE MIDGAL….

plant -2016 annual plan presentation

Documents