1. PRESENTATION ON PPPL, ARP, MILL AND RWL PH-III
PRESENTED BY : PAUL OSENDE(Asst. Manager)
2. SCOPE OF PRESENTATION
HIGHLIGHTS
CRM DIVISION KPI’s AND KPA’s
PRODUCTION AND YIELD SUMMARY
FOR ALL LINES(CRM DIVISION)
TOTAL DIVISION YIELD
CONSUMPTION ANALYSIS PER LINE
WITH TRENDS
LTI FOR CRM DIVISION
3. 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
4. CRM DIVISION KPI AND KPA
S.N
o
KPA KPI
Weightag
e
KPI(Measurement
criteria)
Scoring
Evaluation
Actual
Score
d
Reaso
n
1
Production of
required quantities as
per the production
plan
Productivity Production targets as
per marketing's
requirement
30
PPPL+CRM+
RWL-75%
90%-100% 30 100 30
2
Maintain 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 20
Completion
within 3-7
days
80%-100% 20 100 20
5. 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
6. UTILIZATION
PPPL CRM RWL
AUGUST 52.11% 48.37% 28.98%
SEPTEMBER 40.79% 43.82% 58.65%
OCTOBER 63.15% 62.36% 58.55%
52.11%
48.37%
28.98%
40.79%
43.82%
58.65%
63.15% 62.36%
58.55%
0.00%
10.00%
20.00%
30.00%
40.00%
50.00%
60.00%
70.00%
Utilization=(Production OP/Line capacity)
AUGUST SEPTEMBER OCTOBER
8. TOTAL YIELD FOR CRM DIVISION
AUGUST SEPTEMBER OCTOBER CURRENT AVERAGE PREVIOUS AVERAGE
TOTAL YIELD 93.845 94.023 93.29 93.934 93.664
KPI STANDARD 94.5 94.5 94.5 94.5 94.5
93.845
94.023
93.29
93.934
93.664
94.5 94.5 94.5 94.5 94.5
92.6
92.8
93
93.2
93.4
93.6
93.8
94
94.2
94.4
94.6
TOTALPERCENTAGEYIELD
MONTH
TOTAL YIELD KPI STANDARD
9. TOTAL AVERAGE YIELD PER YEAR CRM DIVISION
98.99
98.28
92.46
99.441
98.71
95.44
99.405
98.76
95.55
99.414
99.175
95.319
91.5
92.5
93.5
94.5
95.5
96.5
97.5
98.5
99.5
100.5
PPPL CRM RWL
PercentageYield
PRODUCTION LINE
Yield analysis trend 2013-2016
2013 2014 2015 2016
13. ROLLS’ CONSUMPTION TREND
2015/2016(mm/MT)
JAN FEB MAR APRIL MAY JUNE JULY AUG SEPT OCT NOV DEC
2015 0.00898 0.00743 0.00901 0.02002 0.01948 0.05739 0.00778 0.00953 0.01526 0.02048 0.00189 0.0084
2016 0.00573 0.00379 0.00721 0 0.00783 0.0049 0.00256 0.00044 0.00411 0.00325
0
0.01
0.02
0.03
0.04
0.05
0.06
0.07
CONSUMPTIONMM/MT
MONTH
All rolls’ consumption per MT 2015/2016 comparison
2015 2016
15. ACID CONSUMED PER MT PRODUCED
52.95
55.18
50.54
54.07
52.06
48.00 49.00 50.00 51.00 52.00 53.00 54.00 55.00 56.00
AUGUST
SEPTEMBER
OCTOBER
AVERAGE
PREVIOUS AVERAGE
AUGUST SEPTEMBER OCTOBER AVERAGE PREVIOUS AVERAGE
Ltr/MT of Acid 52.95 55.18 50.54 54.07 52.06
LTR/MT OF ACID
Ltr/MT of Acid
16. ARP REGENERATED ACID COMPARISON
AUGUST SEPTEMBER OCTOBER
CURRENT
AVERAGE
PREVIOUS
AVERAGE
RA Produced(KL) 338.9 295.3 416.6 317.10 324.575
Ltr/m3 LPG 38.15 43.86 41.14 41.05 36.64
338.9
295.3
416.6
317.10 324.575
38.15
43.86
41.14
41.05
36.64
32.00
34.00
36.00
38.00
40.00
42.00
44.00
46.00
0
50
100
150
200
250
300
350
400
450
ACID(KL)
MONTH
ACID PRODUCED Vs. LPG CONSUMED
RA Produced(KL) Ltr/m3 LPG
18. 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
Introduce my self
Presenting for 4 lines
My manager
Summary of the presentation
Reduction in scrap of between 38 and 52% since 2013
PPE conformance as per HSE engineer. Continuous training. Target is zero accidents.
Training ensures high performance, repeatability and Quality in all processes highlighting employee safety always
Feedback from user lines continuously ensuring that supplier provides good quality material(e.g. JFE complaint on smaller weight coils in October)
As per IMS policy continual development of staff for better operations and longevity of machines. Seen higher material throughput which directly relates to productivity
Total score of 96.803%
Always produce as per production plan
Highest quality attained and maintain zero rejects through rerolling processes as per control of non-conformance in IMS
Highlight the reasons for difference in average yield and maximum capacities of the lines
Highlight highest Yield at Mill(99.285%)
Less yield at RWL in October due to stricter requirements of galvalume
Time as a factor of utilization cannot give a clear image of performance of the machines hence we use production values
PPPL and CRM have close utilizations as the delay between the two lines is less. Some accumulation of material occurs at RWL as its running depends on the CGL running program. Rough idea of the running time as we use standardized SOP and production throughput is almost the same.
Less scrap at PPPL, Higher at RWL due to edge trimmings, baby coils, off-gauge and pencil coils.
Drop in yield for RWL in October due to higher requirements for the galvalume material.
Constantly adjusting operational parameters to achieve the highest possible yield in all sections
KPI standard is a very ambitious target
Benchmarking yields with other companies. Less than 90% in some Indian steel companies
Approximately 52% REDUCTION IN SCRAP AT CRM SINCE 2013.
Approximately 42% REDUCTION IN SCRAP IN PPPL SINCE 2013
Approximately 38% REDUCTION IN SCRAP IN RWL SINCE 2013
CMI/ABB visit was at end of June through July. The trend shows this. The optimized parameters to reduce on impact of power fluctuation/failure thus the steady rise in yield
Best work methods employed over time enhanced the productivity. Overall less power fluctuation and failure couple with better communication between utility company and RRM.
WR ground depends on number of factors:
Production output
Power reliability
Avg OP gauge
Coolant consumption kg/MT
Number of roll changes
NOTE THE LEAST CONSUMPTION OF ROLLS IN NOVEMBER
Analyze cost per mm for each roll type.
WR: per mm
IMR: per mm
BUR: per mm
2015/2016 saw 58% decrease in WR consumption and 46.4% decrease in IMR consumption
Note the trend in 2014-2016 for the various causes of WR consumption is down for all
. CMI/ABB visit was at end of June through July. The trend shows this. The optimized parameters to reduce on impact of power fluctuation/failure thus the steady rise in yield
Multiple power fluctuations in June 2016
Always seek to optimize this metric. Least value that will not negatively impact on strip quality(SB, surface defects) and mill operational operators/equipment.(e.g. high load, roll damage). Maintain within supplier recommended value of 3%-4% coolant oil.
Higher value in May due to new coolant made. Old disposed of. Used approx. 12 barrels to make coolant of 80,000 ltrs.
Cost of 1kg is 6 euros
Yearly average is 0.28kg/MT in 2015
Check overall rolled length/ gauge thickness average
Relationship between stopping in the middle of the month and consumption in the next rolling oil consumption
Continuous production reduces on oil consumption.
SHYT DOWN PERIODS(23rd-7-31st-07; 01st-08-10th-08; 19th-09 to
This is acid at 18% concentration by weight.
Amount of acid depends on the lot(scale and rust), oxide formation on the surface some of which are a function of the Hot Rolling Process
For example 420055.6km pickled in May = 1203Km/KL of acid. Compare with June with 205139Km =1221Km/KL
FA: August-10.5MT
Sept-11.30MT
Oct-16.80MT
ARP capacity at 468KL. Acid concentration taken as 18%(target).
When no acid(WPL) is available the plant may run in water mode other than go off because it takes long and its costly to restart the plant
AUG-23.8%
SEPT-15%
OCT-10%
Most LTI occur at RWL due to nature of work at the line. Commendable for keeping this value low.
As per Annual EHS report by safety department on December 2015-June 2016
Less LTI due to strong emphasis on safety procedures, SOP, enforcement by engineers and mgmt. and tool box talks as per IMS processes, team work.
Continuous on Job training of all staff
A lost time injury (LTI) is an injury sustained by an employee that will ultimately lead to the loss of productive work time in the form of worker delays or absenteeism
415 days minus LTI at CRM
CRM was first department in history of RRM to conduct a training and there after test the participants
Trainings are ongoing during the shutdown period
