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