This document analyzes the production efficiency of the ISM RMC Plant in Islampur. It finds that the plant is not operating at full capacity, with efficiencies ranging from 36.5-80.93% depending on delivery site. Long delivery distances and insufficient number of transit trucks are identified as causes of low efficiency. Recommendations include limiting delivery sites to within 10km of the plant and increasing the number of transit trucks to optimize production.

1. RMC PRODUCTION EFFICIENCY
DATE : 03/01/2018
Prof. R. V. Kolhe
Department of Civil Engineering
SRES’s Sanjivani College of Engineering,
Kopargaon

2. Contents:
• Introduction
• Case study: ISM RMC Plant, Islampur
• Plant production efficiency
• Solutions Suggested
• Conclusion
Prof. R.V.Kolhe 2

3. Introduction
• General
“ The Concrete which is mixed in a central batching and
mixing plant or in a truck-mixer and supplied in the fresh
condition to the purchaser either at the site or into the
purchasers vehicles.”
Prof. R.V.Kolhe 3

4. Objectives
• Selection of the RMC plant for case study.
• To study the plant specifications, resources, operation and
processes.
• To collect data of three different sites for which RMC is
supplied.
• Check whether the RMC Plant working to its capacity or
not.
• Give the solution for efficient working of the plant.
Prof. R.V.Kolhe 4

5. Case study: ISM RMC Plant, Islampur
• Specifications
Plant Model/Make CP 30 Singh -
Production Capacity 30 m3
Capacity of Cement Silo 110 M.T
Capacity of Fly Ash Silo 42 M.T
Production min. per day 30 m3
Production max. per day 180 m3
Time for batch mixing 30 Seconds
Grade of concrete produced M15 to M35 -
Total plant site area 8093.71 m2
Area for stock piles 2023 m2
Total Production 18000 m3
Total Hours working 925 hrs.
Prof. R.V.Kolhe 5

6. Plant details
• Name of Owner: Jaydeep Patil
• Location of RMC Plant: IMS RMC, Islampur,
• Date of Establishment: 26 Jan. 2014
• Timings of working: maximum 12 hrs.
• Human resource: 15
• Financial Aspect: Investment cost = 4 Crores
i. Equipment’s cost = 1Crore
ii.Transit Mixer’s cost =1.5 Crores
iii. Land cost = 1.5 Crores
Prof. R.V.Kolhe 6

7. Plant details continued…
• Daily wages:
• Supervisors = Rs. 400
• Operators = Rs. 350
• Transit Drivers = Rs. 200
• Workers = Rs. 200
• Raw material cost:
• Cement = Rs.5000 /M.T Sand = Rs. 1766 / m2
• Aggregates = Rs.777 / m2 Fly ash = Rs. 900 /M.T
• Admixture = Rs. 500 /10 Ltr.
Prof. R.V.Kolhe 7

8. Cost of Ready Mix Concrete to Client:
Depends on concrete grade and the distance of delivery
• M15 grade = Rs. 3500 /per m3
• M20 grade = Rs. 4000 /per m3
• M25 grade = Rs. 4500 /per m3
• M30 grade = Rs. 5000 /per m3
Prof. R.V.Kolhe 8

9. Transit trucks
• The delivery of RMC to the site is made with the help of
transit mixers. It has a revolving drum with axis inclined to
the horizontal.
• Specifications
• Revolution speed: less than 2 rpm
• Capacity: 7 m3
• Time or Discharge limits: 90 min. or 300 rev.
• Water tank capacity: 300 ltrs.
Prof. R.V.Kolhe 9

10. PLANT PRODUCTION EFFICIENCY
• Total operating hours method
• Sample calculations
• Site: Karad
• Total working time = (Day End Time – Day Start Time) ×60 mins.
= (22:35 – 13:00) × 60 mins.
= 575 mins.
• Idle time = 246 (calculated from technical batch data reports)
• Efficiency=(total working time-idle time)/(total working time)
×100
=(575-246)/575 ×100
Efficiency = 57.22%
Prof. R.V.Kolhe 10

11. PLANT PRODUCTION EFFICIENCY
• Total operating hours method
Sr. No.
Location
of Site
Distance
(km)
Day
Start
Time
Day
End
Time
Total
Working
Time
(min)
Total
Idle
Time
(min)
Efficiency
(%)
1 Karad 33 13:00 22:35 575 246 57.22
2 Shirala 19 06:58 16:43 585 318 45.64
3 Islampur 5 12:01 23:02 661 179 72.92
Prof. R.V.Kolhe 11

12. • Cycle Time of Transit Mixer Method
• Sample calculations
• Site Name: Shirala
• Haul distance: 19 km
• Average Haul Speed: 35km/hr = 0.58 km/min
• Average Return speed: 40km/hr = 0.66km/min
• Time required to haul: 19 / 0.58 = 32.75 min
• Time required for return: 19 / 0.66 = 28.78 min
• Total Cycle time: 114.53 min
• Loading Time + Hauling Time + Dumping Time + Return Time +
Maneuver Time = 25 + 32.75 + 24 + 28.78 + 4 = 114.53 min
Prof. R.V.Kolhe 12

13. • Total transit mixers: 4
• Ideal Production Plant: 30 m3/hr
• Production of 4 fleet transit mixers:
• (Capacity of Each Transit) × (No. of Transit Mixers) × (60
min)
• (Total Time for 1 Cycle)
• = (7 m3/hr) × (4) × (60 min) ÷ (114.53 min)
• Production = 14.68 m3/hr
• Efficiency: (Actual production / Ideal production) × 100
= (14.68 / 30) × 100
• Efficiency = 48.93 %
Prof. R.V.Kolhe 13

14. • Cycle Time of Transit Mixer Method
Time Shirala Karad Islampur
Distance (km) 19 33 5
Hauling Speed 35km/hr 37km/hr 35 km/hr
Return Speed 40 km/hr 42 km/hr 40 km/hr
Loading (min) 25 25 25
Hauling (min) 32.75 53.22 8.62
Dumping (min) 24 24 24
Return (min) 28.78 47.14 7.58
Maneuver (min) 4 4 4
Cycle Time 114.53 153.36 69.2
PRODUCTION
(m3/hr)
14.68 10.95 24.28
EFFICIENCY 48.93 % 36.5 % 80.93 %
Prof. R.V.Kolhe 14

15. Solutions Suggested
• Above results shows that, the RMC plant is not working at its
full capacity.
• It is mainly due to following problems:
• Delivery distance
• the delivery distance is large
• the cycle time gets increased
• This is observed, for Islampur site there is less delivery
distance, therefore the production efficiency gets increased
• Approx. double efficiency as that of Karad Site
• take the site for concreting within periphery of 5 to 10 km
Prof. R.V.Kolhe 15

16. • No of transit mixers
• To increase production of the above mentioned plant
there needs to increase the numbers of transit trucks
• If there are less than optimum transit trucks available with
the owner then production get reduced
• There are now 4 nos. of transit trucks available with the
owner
• if additional three nos. of transit trucks introduced then
there is 75 percent increment in the production.
Prof. R.V.Kolhe 16

17. Conclusions
• The plant is not working at its full capacity due to the
distance they have taken for delivery is so large.
• Its efficiency is less than 50 percent because, no. of
transit trucks they are employing are less than that of
optimum no. of required for full working condition.
• The delivery distance, nos. of transit trucks, idle time
effects on the production. Therefore there is necessary of
optimize the plant by working out the working periphery
and also by using the optimum nos. of transit trucks.
Prof. R.V.Kolhe 17

18. Thank You…
Have a great day ahead…!
Prof. R.V.Kolhe 18