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GALVANIZING PLANTANNUAL REPORTJUNE 2013-JULY 2014
TEAM MEMBERS
Jahangir Ali KhanNadeem AhmedMuhammad Ahsan KhanFaizan AbbasMajid KhanSohail AshrafNadeem Uddin
ANNUAL REPORT SECTIONS
• Quarterly comparisons of Production• Trend of down time• Consumable item cost analysis• Loss trend Defect Wise
PRODUCTION
• Comparison of Budget and Actual cost• Down time hours of each item• Trend of proactive maintenance
MAINTENANCE
• Monthly comparison of packing cost over production
• Trend of packaging material consumption over production
PACKAGING
PRODUCTION DEPARTMENTThis report compares the actual and target productions of
whole year.Reflects the difference of production for every month.Depicts the tonnage of prime, second and reject wrt the total
production.Reveals the contribution of different departments in the loss
of targeted production.Compares the utilized capacity and downtime of plant.Shows the consumption and net saving of consumables.
Jul-13 Aug-13 Sep-13 Oct-13 Nov-13 Dec-13 Jan-14 Feb-14 Mar-14 Apr-14 May-14 Jun-140
100002000030000400005000060000700008000090000
100000110000120000130000140000150000160000170000180000190000200000210000220000230000240000250000260000270000280000290000300000310000320000330000340000
11,30323,508
36,511
50,514
64,518
78,522
93,027
107,030
121,033
135,786
150,541
165,045
11,504
21,002
34,598
45,000
59,542
70,903
86,884
100,232
116,035
129,700
146,242
158,996
TARGET V/S ACTUAL PRODUCTION FOR 2013 ~ 2014
TARGETS PRODUCTION
MONTHS
PR
OD
UC
TIO
N (
TO
NS)
JULY AUGUST SEP-TEMBER
OCTO-BER
NO-VEMBER
DE-CEM-BER
JANU-ARY
FEBRU-ARY
MARCH APRIL MAY JUNE
BUD-GETED
11300 12200 13000 14000 14000 14000 14500 14000 14000 14750 14750 14500
PLANNED
10805 13730 14220 14682 13010 13600 13000 13275 16000 15050 14134 16518
AC-TUAL
11509 9497 13596 10402 14542 11363 15978 13347.58 15803.142
13665 16542 12754
4,500
7,500
10,500
13,500
16,500
PRODUCTION COMPARISIONT
ON
NA
GE
1st quarter 2nd quarter 3rd quarter 4th quarter
Total 34601.854 36307.634 45128.978 42953.346
Prime 33527.52 34877.67 43908.8 41203.54
Second 914.29 1,284.73 1,051.22 1,540.39
Reject 160.04 145.23 168.96 209.41
1800
5300
8800
12300
15800
19300
22800
26300
29800
33300
36800
40300
43800
34601.854 36307.634
45128.97842953.346
33527.5234877.67
43908.8
41203.54
914.29 1,284.73 1,051.22 1,540.39 160.04 145.23 168.96 209.41
Annual production Summary
TotalPrimeSecondReject
July 2013-June 2014
Ton
nag
e
1st Quarter 2nd Quarter 3rd Quarter 4th Quarter95
95.5
96
96.5
97
97.5
96.9
96.1
97.3
95.9
Comparision of Prime ProductionTargeted V/s Actual
Actual Percentage
Targeted percentage
Quartely Percentage of Prime Production
Perc
enta
ge
• Target prime production is 97% which is nearly achieved in first quarter, and less in 2nd and 4th quarter due to highest percentage of secondary in that respective quarters. While in 3rd quarter it target is achieved because of highest total production in this quarter.
• Annual Avg. Prime Production is 96 .7 % which is closed to target production.
Scratch Line
Black Spots
Track off
Oth-ers
Black Patch
Jet Lines
Line Stop (Op-era-tion)
Threading (Op-era-
tions)
CR Mate-rial
Line Stop
(Main-ten-
ance)
Edge Buildu
p
Line Stop
(Elec-trical)
Non Chro-mated
HARDNESS
Weld Over Zinc Coat-ing
T-Bend (CRC)
Threading
Scratch Line
Black Spots
Track off
Oth-ers
Black Patch
Jet Lines
Line Stop (Op-era-tion)
Threading (Op-era-
tions)
CR Mate-rial
Line Stop
(Main-ten-
ance)
Edge Buildu
p
Line Stop
(Elec-trical)
Non Chro-mated
HARDNESS
Weld Over Zinc Coat-ing
T-Bend (CRC)
Threading
Second
1021.448
588.84
369.813
232.06
302.312
296.26
208.056
158.84
230.382
157.474
170.696
154.638
156.77
143.992
90.042
81.847
92.792
48.86
Reject
10.92 0 127.188
71.16 0.546 0 75.808
118.288
3.476 61.554
42.888
55.166
3.618 0.976 16.67 18.936
0 28.6
% age
0.65% 0.37% 0.31% 0.19% 0.19% 0.19% 0.18% 0.17% 0.15% 0.14% 0.13% 0.13% 0.10% 0.09% 0.07% 0.06% 0.06% 0.05%
100.00
300.00
500.00
700.00
900.00
1,100.00
0.3%
0.8%
0.65%
0.37%0.31%
0.19%0.19%0.19%0.18%0.17%0.15%0.14%0.13%0.13%
0.10%0.09%0.07%0.06%0.06%0.05%
LOSS TREND DEFECT WISE FOR THE YEAR 2013-14
DEFECTS
TO
NN
AG
E (
TO
NS)
PE
RC
EN
TA
GE
(%
)
TOTAL PRODUCTION 158,991 TONSTOTAL PRIME = 153,748 TONS (96.70 %)TOTAL SECONDARY = 4760 TONS (2.99 %)TOTAL REJECT = 683.62 TONS (0.43 %)TOTAL DOWN TIME = 444 HRS (6.17 %)
OPERATIONS CRM MAINTE-NANCE
ELECTRICAL PSA POWER HOUSE RESTART UP OPERATIONS CRM MAINTE-NANCE
ELECTRICAL PSA POWER HOUSE RESTART UP
SECOND
1779.849 1270.037 924.658 287.306 135.568 80.162 NaN
REJECT
299.84 123.752 106.866 96.578 11.236 14.14 NaN
%AGE
0.01 0.01 0.01 0.00 0.00 0.00 -NaN
100.00
300.00
500.00
700.00
900.00
1,100.00
1,300.00
1,500.00
1,700.00
1,900.00
0.01
0.02 0.01
0.01
0.01
0.00
0.00 0.00
LOSS TREND DEPARTMENT WISE FOR THE YEAR 2013-14SECOND REJECT
DEPARTMENTS
TON
NAG
E (T
ON
S)
PER
CEN
TAG
E (%
)
TOTAL PRODUCTION 158,991 TONSTOTAL PRIME = 153,748 TONS (96.70 %)TOTAL SECONDARY = 4760 TONS (2.99 %)TOTAL REJECT = 683.62 TONS (0.43 %)TOTAL DOWN TIME = 444 HRS (6.17 %)
OPERATIONS 302 days 83%
UNAVAILABILITY OF CRC
25 days 7%
MAINTENANCE SHUTDOWN24 days 6%
HOLIDAYS10 days 3%
OTHER1%
PLANT CAPACITY UTILIZATION
This Pie charts show the no of operational days and shut down days throughout the year. Plant is in operation 302days and in shut down for 24days for maintenance shutdown.
OPERATIONS46%
CRM 10%
ELECTRICAL15%
RE-START UP 1%
PSA 3%
MAINTENANCE22%
POWER HOUSE 3%
DOWNTIME GALVANIZING
Below is the Pie chart which highlights the downtime of plant of caused by different de-partment in terms of percentages. Operational downtime hours are major contributor. Maintenance and Electrical shut downs are also contributing substantially.
1st Quarter 2nd Quarter 3rd Quarter 4th Quarter
Down time % 6.2 5.9 6.8 6.2
5.50
5.70
5.90
6.10
6.30
6.50
6.70
6.90
6.2
5.9
6.8
6.2
Comparision of Down Time %Targeted V/s Actual
Down time % Quarterly
Perc
enta
ge
Target downtime is 6.5% which is crossed in 3rd quarter as in month of Feb and March highest down hours occurred subsequently . Furthermore total Maintenance days in these month are 5 days
Annual Avg downtime is 6.17 % which shows success in reducing the down hours.
Average Annual consumption 21.7 kg/ton
Target Zinc 25.5 kg/tonDifference of Consumption 3.8 kg/ton
Total production 158,991 Ton
Total Zinc consumption 603371 kg
Unit Cost of Zinc 233.5 Rs/kg
Cost of Net saving Rs 140,872,611
1st Quarter 2nd Quarter 3rd Quarter 4th Quarter
Quarters 21.55 21.02 22.15 22.1
19.25
19.75
20.25
20.75
21.25
21.75
22.25
22.75
21.55
21.02
22.15 22.1
Quarter wise Zinc Consumption
Quartely Zinc consumption
Kg/t
on
CONSUMABLES CONSUMPTIONTARGET V/S ACTUAL FOR 2012
S.No Items Total
Consumed Target Cost Total Saving / Loss
1 Zinc Consumption (Kgs/Ton) 21.7 25.5 233.5 Rs/kg PKR 140,872,611
2 AZAL-10 (Kgs/Ton) 0.43 0.5 210 Rs/kg PKR 2337241.2
3 Lead (Kgs/Ton) 0.01 0.013 175 Rs/kg PKR 83472.9
4 Antimony Alloy (Kgs/Ton) 0.07 0.028 1500 Rs/kg PKR ( 10016748)
5 Tin (Kgs/Ton) 0.03 0.027 2500 Rs/kg PKR (1192470)
6 Passerite (Kgs/Ton) 0.06 0.053 280 Rs/kg PKR (311632.2)
7 Gas Consumption (m3/Ton) 15.41 16 19 Rs/m3 PKR 1782345.2
8 Maintenance Cost (Rs/Ton) 64 65 PKR 514544
9 Packing Material (Kgs/Ton) 3.99 5 75 Rs/kg PKR 11,599,749
TOTAL PKR 145,107,050
ACHIEVED TARGETS
REDUCED DOWNTIME: Successfully we maintained our downtime to 6.17% below the target limit 6.5%. Plant is operational more than its target hours.
CONSUMABLES ITEMS:We saved the consumption of costly consumable item below the target and achieved the net saving of Rs 143,293,325.
GAS CONSUMPTION:Net saving in consumption is about Rs 1,782,345
ACHIEVED TARGETS
Jun-11 Jun-12 Jun-13 Jun-14 Jun-11 Jun-12 Jun-13 Jun-14
Production 40,272.75 111,064.37 139,953.80 158,996.44
Prime % 89.69% 96.04% 97.56% 96.70%
10,000.00
30,000.00
50,000.00
70,000.00
90,000.00
110,000.00
130,000.00
150,000.00
170,000.00
81.00%
83.00%
85.00%
87.00%
89.00%
91.00%
93.00%
95.00%
97.00%
99.00%
40,272.75
111,064.37 139,953.80
158,996.44
89.69%
96.04%97.56%
96.70%
Production Status for last four year
Production Prime %
REASONS OF NOT ACHIEVING THE TARGETS
Target ProductionTarget is lack by 6049 tons which is majorly contributed by following: Low productivity due to black sports. Unexpected downtime from operation sides. Maintenance and Electrical down time of 37 %.
Target Prime ProductionTarget to achieve prime production was marginally missed by 0.3%. Main reasons of reduced prime percentage are because of following defects: Scratch lines Black spots Track off
MAINTENANCE DEPARTMENT
Maintenance section covers the total actual cost and total budget cost
It compares the capital cost of each item of line
Evaluate the downtime hours of Maintenance in each quarter with different item.
Depicts the quarterly proactive Maintenance hours wrt to each items.
Jul Aug Sep Oct Nov Dec Jan Feb Mar Apr May Jun0
200,000
400,000
600,000
800,000
1,000,000
1,200,000
1,400,000
1,600,000
0
20
40
60
80
100
120
140
481,
576
666,
097
641,
691
958,
326
700,
359 1,51
4,54
8
1,09
5,41
1
461,
613
697,
821
1,06
6,21
3
949,
520
890,
524
Maintenance Cost 2013-14
Total Bud-get Rs
10,658,181Consumed Budget Rs 10,143,637
SUMMARY OF MONTHLY MAINTENANCE COST
Uncoiler
Seam Welder
Bridle Unit
Furnace
Pot Accessories
Quench Section
Tension Leveler
Chromate Section
Accumulator
Recoiler
- 2,000,000 4,000,000 6,000,000 8,000,000 10,000,000
339,517
87,400
1,039,849
7,837,281
5,414,645
188,352
889,640
999,867
566,779
105,740 Total Cost (Rs)
with Capital Items
MAINTENANCE EXPENSE
Radiant Tube
Hearth Roll Non Coated
Heat Exchanger Tubes
Stab/Correcting Roll
Work Roll Dia 55
Intermediate Roll Dia 40
- 1,000,000 2,000,000 3,000,000 4,000,000
371,539
3,428,289
749,840
540,685
78,952
1,562,449
2,402,835
218,868
48,217
91,028
208,069 Capital Items
CAPITAL EXPENSES
Uncoiler2%
Seam Welder
1%
Bridle Unit6%
Furnace45%
Pot Accessories31%
Quench Section
1%Tension Leveler
5%Chromate Section
6%
Accumulator 3%Recoiler
1%
Cost % by Equipment
EXPENSES ON EACH EQUIPMENT
- 20 40 60 80
100 120
38 35
2 8 - - - - 8
112
5 4 10 16 20 4 3
33 15
-
33
- - 14 6 1
21 47 46
10 16
Breakdown Maintenance Hrs
Jul 13- Sep 13 Oct 13- Dec 13 Jan 14- Mar 14 Apr 14- Jun 14 -
20
40
60
80
100
120
140
160
99 123 117
150
Quarterly Breakdown Maintenance Hrs
Unc
oile
r#1
Seam
Wel
der
Entry
Acc
umul
ator
Furna
ce
Steer
ing#
3SPM
Bridle
#5
Exit A
ccum
ulat
or
Recoi
ler
Slitte
r
Pack
ing
M/c
-
20
40
60
80
28
59
8 28 29
2 5 5 14
88
30 43
2 13
3 15
4 24 19
4 19 16
2 3 3 6 20 22
9 -
34
Proactive Maintenance Hrs
Jul 13- Sep 13 Oct 13- Dec 13 Jan 14- Mar 14 Apr 14- Jun 14 -
20
40
60
80
100
120
140
160
140 119
80
147
Quarterly Proactive Maintenance Hrs
PACKAGING SECTIONS
This section solely covers the cost analysis of packaging wrt the monthly production
Compares the consumption of packaging material with the actual production.
Depicts the causes of trend in over consumption of packaging material and its cost.
Jul-13 Aug-13 Sep-13 Oct-13 Nov-13 Dec-13 Jan-14 Feb-14 Mar-14 Apr-14 May-14 Jun-14 -
2,000
4,000
6,000
8,000
10,000
12,000
14,000
16,000
18,000
-
100
200
300
400
500
600
700
Monthly Comparison of Production & Packaging CostPRODUCTION PACKAGING COST
Months
Pro
ducti
on(t
ons)
Packagin
g C
ost
(R
s/to
n)
• Above chart reflects that initially packaging cost is high as compared to production.
• In 3rd quarter packaging cost is nearly same as that of production• While in the last quarter months packaging cost go down noticeably.• Production of PVC plant and less consumption of packaging items are certainly
the reason of this low packaging cost of finished coils.
Jul-13 Aug-13 Sep-13 Oct-13 Nov-13 Dec-13 Jan-14 Feb-14 Mar-14 Apr-14 May-14 Jun-14 -
2,000
4,000
6,000
8,000
10,000
12,000
14,000
16,000
18,000
-
10.00
20.00
30.00
40.00
50.00
60.00
70.00
Consumption of Packaging materials Over monthly Production
Production Consumption of Packaging materia
Months
Pro
ducti
on(t
ons)
consu
mpti
on o
f packagin
g
mate
rial(
tons)
• This chart clearly shows that packaging materials are over consumed than the production.
• Consumption matches with demanded production at the end of annual year.• Over consumption of packaging material leads to packing costly.