Professional Documents
Culture Documents
ANNUAL REPORT
JUNE 2013-JULY 2014
TEAM MEMBERS
Jahangir Ali Khan
Nadeem Ahmed
Muhammad Ahsan Khan
Faizan Abbas
Majid Khan
Sohail Ashraf
Nadeem Uddin
MAINTENANCE
PACKAGING
Quarterly comparisons of
Production
Trend of down time
Consumable item cost analysis
Loss trend Defect Wise
Comparison of Budget and
Actual cost
Down time hours of each item
Trend of proactive maintenance
Monthly comparison of packing
cost over production
Trend of packaging material
consumption over production
PRODUCTION DEPARTMENT
This report compares the actual and target
TARGETS
170000
PRODUCTION
165,045
160000
150,541
150000
135,786
140000
130000
121,033
120000
107,030
110000
100000
93,027
90000 (TONS)
PRODUCTION
78,522
80000
70000
64,518
60000
50,514
50000
36,511
40000
30000
23,508
20000
11,303
10000
21,002
158,996
146,242
129,700
116,035
100,232
86,884
70,903
59,542
45,000
34,598
11,504
0
41456
41487
41518
41548
41579
41609
41640
MONTHS
41671
41699
41730
41760
41791
PRODUCTION COMPARISION
18,000
15,000
TONNAGE
12,000
9,000
6,000
3,000
42050
41203.54
38550
35050
31550
33527.52
34877.67
28050
Total
24550
Tonnage
21050
17550
45128.98
Prime
42953.35
Second
Reject
36307.63
34601.85
14050
10550
7050
3550
50
914.29
160.04
1st quarter
1,284.73
145.23
2nd quarter
1,051.22
168.96
3rd quarter
1,540.39
209.41
4th quarter
97.5
97.3
96.9
97
Percentage
96.5
96.1
95.9
96
Actual Percentage
95.5
Targeted percentage
95
1st Quarter
2nd Quarter
3rd Quarter
4th Quarter
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.
0.7%
0.65%
1,000.00
TONNAGE
800.00 (TONS)
0.37%
600.00
0.31%
0.3%
400.00
200.00
PERCENTAGE (%)
0.19%0.19%0.19%
0.2%
0.18%0.17%
0.15%0.14%
0.13%0.13%
0.10%0.09%
0.1%
0.07%0.06%0.06%
0.05%
0.0%
DEFECTS
REJECT
2,000.00
0.01
0.01
1,800.00
1,600.00
1,400.00
TONNAGE (TONS)
0.01
1,200.00
1,000.00
0.01
0.01
PERCENTAGE (%)
0.01
0.01
0.01
800.00
600.00
0.00
0.00
400.00
0.00
200.00
0.00
0.00
OPERATIONS
CRM
MAINTENANCE
ELECTRICAL
DEPARTMENTS
PSA
POWER HOUSE
RESTART UP
MAINTENANCE SHUTDOWN; 6%
HOLIDAYS; 3%
OTHER; 1%
UNAVAILABILITY OF CRC; 7%
OPERATIONS; 83%
DOWNTIME GALVANIZING
Below is the Pie chart which highlights the downtime of plant of caused by different
department in terms of percentages. Operational downtime hours are major contributor.
Maintenance and Electrical shut downs are also contributing substantially.
POWER HOUSE; 3%
MAINTENANCE; 22%
OPERATIONS; 46%
PSA; 3%
RE-START UP; 1%
ELECTRICAL; 15%
CRM; 10%
6.2
6.00
5.9
5.80
5.60
5.40
1st Quarter
2nd Quarter
3rd Quarter
4th Quarter
22.15
22.1
3rd Quarter
4th Quarter
22
21.5
Kg/ton
21.55
21.02
21
20.5
20
19.5
19
1st Quarter
2nd Quarter
Average Annual
consumption
Target Zinc
Difference of Consumption
Total production
Total Zinc consumption
Unit Cost of Zinc
Cost of Net saving
21.7
kg/ton
25.5
kg/ton
3.8
kg/ton
158,991
Ton
603371
kg
233.5
Rs/kg
Rs 140,872,611
CONSUMABLES CONSUMPTION
TARGET V/S ACTUAL FOR 2012
S.N
o
1
Items
Total
Consume
d
Zinc Consumption
(Kgs/Ton)
Target
21.7
2 AZAL-10 (Kgs/Ton)
0.43
Cost
140,872,611
Rs/kg
PKR
2337241.2
25.5
233.5
Rs/kg
0.5
210
3 Lead (Kgs/Ton)
0.01
0.013
175
Rs/kg
PKR
83472.9
Antimony Alloy
(Kgs/Ton)
0.07
0.028
1500
Rs/kg
PKR
( 10016748)
0.027
2500
Rs/kg
PKR
(1192470)
0.053
280
Rs/kg
PKR
(311632.2)
16
19
Rs/m
3
PKR
65
PKR
75
5 Tin (Kgs/Ton)
0.03
6 Passerite (Kgs/Ton)
0.06
Gas Consumption
(m3/Ton)
Maintenance Cost
(Rs/Ton)
64
Packing Material
(Kgs/Ton)
3.99
TOTAL
15.41
Rs/kg
PKR
PKR
1782345.2
514544
11,599,749
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
Production Status for last four year
Production
Prime %
180,000.00
100.00%
97.56%
160,000.00
96.04%
96.70%
98.00%
96.00%
140,000.00
94.00%
120,000.00
92.00%
100,000.00
89.69%
90.00%
158,996.44
80,000.00
139,953.80
60,000.00
111,064.37
86.00%
40,000.00
20,000.00
88.00%
84.00%
40,272.75
82.00%
80.00%
1
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
SUMMARY OF MONTHLY
MAINTENANCE COST
Maintenance Cost 2013-14
1,600,000
140
1,400,000
120
1,200,000
100
1,000,000
80
800,000
1,514,548
60
600,000
1,095,411
1,066,213
958,326
949,520
890,52440
400,000
700,359
697,821
666,097
641,691
20
481,576
461,613
200,000
0
Jul
Aug
Sep
Oct
Nov
Dec
Jan
Feb
Total Budget Rs
10,658,181 Consumed Budget Rs
10,143,637
Mar
Apr
May
Jun
MAINTENANCE EXPENSE
Recoiler
105,740
Accumulator
566,779
Chromate Section
999,867
Tension Leveler
889,640
Quench Section
188,352
Pot Accessories
5,414,645
Furnace
7,837,281
Bridle Unit
Seam Welder
1,039,849
87,400
Uncoiler
339,517
2,000,000
4,000,000
6,000,000
8,000,000
10,000,000
CAPITAL EXPENSES
Intermediate Roll Dia 40
208,069
91,028
48,217
Capital Items
218,868
Stab/Correcting Roll
2,402,835
Sink Roll
Heat Exchanger Tubes
1,562,449
78,952
Heat Exchanger
Hearth Roll Non Coated
540,685
749,840
3,428,289
Radiant Tube
-
371,539
1,000,000
2,000,000
3,000,000
4,000,000
Furnace; 45%
Bridle Unit; 6%
Seam Welder; 1%
Pot Accessories; 31%
Uncoiler; 2%
Recoiler; 1%
Accumulator ;Quench
3%
Section; 1%
Chromate Section; 6% Tension Leveler; 5%
99
120
100
80
60
40
20
-
123
117
150
Breakdown
Maintenance Hrs
112
3835
28
8
- - - -
33
33
20
16
15
5 410
43
-
- -
4746
146 21
1016
1
140
119
80
147
90
80
59
70
43
60
34
50 28 28
30
29
24
22
40
20
19
19
16
14
13 15
30
9
8
4
255
2 3 4
2336
20
10
-
PACKAGING SECTIONS
This section solely covers the cost analysis of
PACKAGING COST
18,000
700
16,000
600
14,000
500
12,000
400
10,000
Production(tons)
8,000
6,000
200
4,000
100
2,000
41469
41501
41533
41564
41596
41627
41659
41691
41719
41750
41780
41811
Months
16,000
60.00
14,000
50.00
12,000
Production(tons)
10,000
40.00
8,000
30.00
6,000
20.00
4,000
10.00
2,000
-
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.