Professional Documents
Culture Documents
Barun Banerjee
Presentation to GM(WB)
[10-03-2017]
TSL Board Tata Steel Slide 2
2.1 QSE to strive for achieving ABP target Chief QSE Info
QSE wage cost found to be too high even after the transfer of some of
2.3 its equipment and manpower to QAB. Current year manpower found to Chief QSE Next Review A/C
be higher than last years. To be cross checked. (pending point)
Performance Overview
Quarry-SE Feb16 (Feb17) FY'17- Till Month
KPI UOM Act AOP Act Gap AOP Act Gap
Raw Coal- Total Ton 2.34 1.82 2.45 +0.63 22.58 19.08 -3.49
Raw Coal- High wall Ton 0 0.42 0.27 -0.15 4.54 2.44 -2.11
Seam Mix Compliance-AOP/
% 37/93 85-90 56/79 -29/-6 85-90 83/74 -2/-11
Revised
OB Cum 6.38 8.40 7.76 -0.64 97.66 85.93 -14.27
Re-handling+ Eco Dump+ HW
% 51 45 37 -8 45 23 -22
Loose
Excavator Availability % 83 82 85.4 +3.4 82 86.4 +4.4
Excavator Productivity Cum/Hr 647 640 602 -38 629 593 -36
Ex Run Hrs/ Ex - OB Hrs 6.23 6.5 6.15 -0.35 6.5 6.18 -0.3
Dec Quarry-SE
7940 39730 47670 Feb17
Dec Cum.
(FY'17- Till
14755 Month)
14755 -32915
Jan KPI
47670 UOM
AOP
47670 Act
Jan Gap AOP
9590 33363 Act 42953Gap
-4717
Raw Coal- Total Ton 41670 26170 14510 454330 243827 210503
Feb 15578 26092 41670 Feb 22198 1476 3486
27160 -14510
HWM availability % 70 62 8 70 41 29 -
Utilization 10013 13619
% 45433
60 38 22 60 13781 72 24382 12
21050
15578 81702 43446 8 7 77269 0 0 0 22198 11066 9 72744 7 3
Idle Hrs. 60 202 142 540 1035 495
Planned Maint. Hrs. 72 106 34 720 698 22
Unplanned B/Down Hrs. 108 96 12 1080 3440 2430
MTBF Hrs. 40 31 9 40 25.4 14.6
MTTR Hrs. 20 40 20 20 50 30
Seam Compliance Tata Steel Slide 5
OB-
Nov Dec Jan Feb Total
AOP
AOP Actual Dif AOP Actual Dif AOP Actual Dif AOP Actual Dif AOP Actual Dif
XI 0 105700 105700 0 13011 13011 0 120114 120114 0 90202 90202 243000 1272027 1029027
X 60000 422098 362098 89278 561045 471767 0 96556 96556 0 135400 135400 1223194 1924713 701519
IX 0 0 0 200000 103829 -96171 57030 164685 107655 0 35288 35288 501262 437247 -64015
VIII 0 0 0 0 0 77973 69073 -8900 0 33643 33643 234111 108953 -125158
VII 0 0 0 0 0 0 66437 66437 125000 68256 -56744 778270 454015 -324255
VI 200000 75725 -124275 113649 10933 -102716 0 65761 65761 0 349 349 980321 1072148 91827
V 65000 157540 92540 200000 102068 -97932 300000 64854 -235146 337378 123061 -214317 1447138 1331116 -116022
Loose 54600 242620 188020 101292 68660 -32632 73081 218156 145075 77680 289994 212314 908427 1769909 861482
Old
Dump 320000 0 -320000 320000 56433 -263567 320000 0 -320000 300000 0 -300000 2730000 130211
HW Re. 0 0 0 0 0 0 0 0 0 0 0 720000 92753 -627247
699600 1003683 304083 1024219 915979 -108240 828084 865636 37552 840058 776193 -63865 9765723 8593092 1427158
Raw Coal Over-burden
Plan Actual Dif Plan Actual Dif Plan Actual Dif Plan Actual Dif
Ashpond Area
Air Strip Existing Face
Bathantand Existing Face 0 0 0 353916 439359 85443 191315 89600 -101715 81138 6237 -74901
Rabidas Tola Existing
Face
Bathantand Ext Face 243000 1309377 1066377 430000 968457 538457 52917 107224 54307 75000 102716 27716
Rabidas Tola Ext Face 439278 519998 80720 257030 199973 -57057 77973 0 -77973
Highwall OB+ Loose
243000 1309377 1066377 1223194 1927814 704620 501262 396797 -104465 234111 108953 -125158
Rehandling/ Coal
VII OB VI OB V OB Old / Eco Dump
Shifting
Plan Actual Dif Plan Actual Dif Plan Actual Dif Plan Actual Dif Plan Actual Dif
25457 23887
Ashpond Area 0 254572
2
284760 523631
1
Plan Actual Dif Plan Actual Dif Plan Actual Dif Plan Actual Dif
Ashpond Area
Air Strip Existing Face 0 3770 3770
Bathantand Existing Face 106480 81010 -25470 56097 71146 15049 163352 173434 10082
Rabidas Tola Existing
Face
Bathantand Ext Face 58000 96241 38241 24500 64930 40430 9650 25150 15500 72000 96840 24840
Rabidas Tola Ext Face 80000 96095 16095 36046 11360 -24686 60000 82100 22100
Highwall Coal 15578 0 -15578 81702 0 -81702 43446 22198 -21248 100138 11066 -89072
73578 96241 22663 292682 242035 -50647 145239 129854 -15385 395490 367210 -28280
Summary Summary
Plan Actual Dif Plan Actual Dif
Ashpond Area 117529 271651 154122 Ashpond Area 284760 778203 493443
Air Strip Existing Air Strip Existing
215730 322790 107060 1053519 1570153 516634
Face Face
Bathantand Bathantand
860192 489906 -370286 1683288 836996 -846292
Existing Face Existing Face
Rabidas Tola Rabidas Tola
475531 0 -475531
Existing Face
109622 0 -109622 Existing Face
Bathantand Ext
Bathantand Ext 1010917 2713183 1702266
324150 390391 66241 Face
Face
Rabidas Tola Ext
Rabidas Tola Ext 899281 719971 -179310
176046 189555 13509 Face
Face
Highwall OB+
Highwall Coal 454330 243827 -210503 4358427 1974586 -2383841
Loose
2257599 1908120 -349479
9765723 8593092 -1172631
Plan : March17
RT
BT
AS
TSL Board Tata Steel Slide 13
Excavators- Feb-17
Feb-17
Total OB Productivi
GOD Sch UnSch Avail Avail Run No. of
Downti Util% CuM Run ty MTBF MTTR
Hours Maint Maint Hrs % Hours Failures
me Hours (Cum/Hr
Ex-01 672 9 44.5 53.5 618.5 92.0 492.9 79.7 217865 365.7 614 2 246 22.3
Ex-02 672 1.5 34.5 36 636.0 94.6 232.8 36.6 110740 222.8 523 4 58 8.6
Ex-03 672 27 69.66 96.66 575.3 85.6 380.3 66.1 115325 202.9 601 9 42 7.7
Ex-05 672 281.8 9.58 291.38 380.6 56.6 300.7 79.0 172660 290.7 617 4 75 2.4
PL-01 672 19.6 60.08 79.68 592.3 88.1 318 53.7 135243 215.7 661 18 18 3.3
PL-02 672 18 13.6 31.6
640.4 95.3 189 29.5 24360 46.2 527 14 17 1.0
3443.
4032 356.9 231.92 588.82 85.4 1913.7 55.6 776193 1344 602 51 34 4.5
2
TSL Board Tata Steel Slide 14
Excl Running
Maint 602
RD Utilization% FY17
90 90
Good
80 80
70 70
60 60
RD Utilization (%)
55
RD Utilization (%)
50 50
41.8
40 40
30 30
20 20
10 10
0 0
15
RD Availability% FY17
100 100
KPI YTD FY'17 Plan Actual
90 90
81.14
80
79 Good 80
70 70
60 60
RD Availability (%)
RD Availability (%)
50 50
40 40
30 30
20 20
10 10
0 0
16
RD Productivity FY17
200 200
180 180
161
160 160
139
Good
RD Productivity (Cum/Hr)
140 140
RD Productivity (Cum/Hr)
120 120
100 100
80 80
60 60
KPI YTD FY'17 Plan Actual
40 40
20 20
0 0
17
Ex Utilization FY17
80 80
KPI YTD FY'17 Plan Act
70 70
63 Good
60 60
55.2
50 50
Ex Utilization (%)
40 40
Ex Utilization (%)
30 30
20 20
10 10
0 0
18
Ex Availability% FY17
100 100
KPI YTD FY'17 Plan Actual
90 86.3 90
82
80 Good 80
70 70
60 60
Ex Availability (%)
50 50
Ex Availability (%)
40 40
30 30
20 20
10 10
0 0
19
Ex Productivity FY17
700 700
KPI YTD FY'17 Plan Actual
629
593 Good
600 600
Ex Productivity (Cum/Hr)
Ex Productivity (Cum/Hr)
500 500
400 400
300 300
200 200
100 100
0 0
20
Drill Utilization FY17
50 50
KPI YTD FY'17 Plan Act
45 45
40 40
Good
35 35
Drill Utilization (%)
29.41
30 30
15 15
10 10
OB Face
5 constraint 5
0 0
21
Drill Availability% FY17
80 80
73.0
Good
70 70
60 60
Ex Availability (%)
40 40
30 30
20 20
10 10
0 0
22
End of Presentation
23
Hourly RD Availability- Feb17
2nd 10th 11th 12th 13th 14th 15th 16th 17th 18th 19th 20th 21st 22nd 23rd 24th
1st Hr 3rd Hr 4th Hr 5th Hr 6th Hr 7th Hr 8th Hr 9th Hr
Hr Hr Hr Hr Hr Hr Hr Hr Hr Hr Hr Hr Hr Hr Hr Hr
5.00- 6.00- 7.00- 8.00- 9.00- 10.00- 11.00- 12.00- 1.00- 2.00- 3.00- 4.00- 5.00- 6.00- 7.00- 8.00- 9.00- 10.00- 11.00- 12:00- 1:00- 2:00- 3:00- 4:00-
6.00A 7.00A 8.00A 9.00A 10.00 11.00 12.00 1.00P 2.00P 3.00P 4.00P 5.00P 6.00P 7.00P 8.00P 9.00P 10.00 11.00 12.00 1:00A 2:00A 3:00A 4:00A 5:00A
M M M M AM AM PM M M M M M M M M M PM PM AM M M M M M
1st 2 3.5 3.67 4 3.75 4.5 5 5 4 5 6.5 5.5 4 4 5 4 2 2.5 2.5 3.5 3 2 3 2
4th 3 3.5 5 5.17 5 4.5 5.5 7 5 6.75 9.5 10 10.25 7.5 5.5 5 3 3.5 4 4 3 3 3 3
6th 2 3 3.5 3.5 3.5 3.5 7.5 8.75 4 3.5 6 7 6.25 8.25 5.75 4 2 2 3.25 3 3 2 2 2
B 8th 1 2.5 3 2.25 2.5 2.5 4 4.75 4 4 6 5.5 4.5 6 5.5 4.5 3 3 3 3 2 2 2 2
r 9th 5.5 6 6 6 5 4 4.5 5 6 6.75 8 8.25 6.75 7 7.75 6 7 6.5 6.5 5.5 5.75 5 5.5 6
k 12th 3 4 4.75 4.5 3.5 3.5 2.75 3 1 1.5 1.5 2.5 3 2.5 2.5 3.25 1 1 1 1.5 1.5 1 1 1.25
D 13th 3 4.5 4.5 4.25 3.75 4.5 6.5 8 4 5 5.5 5 5 4.5 5.5 3 1 1 1.5 1 0.5 1.5 1.5 0
o 14th 2 2.25 3.5 5.75 4.25 6.5 7 6 4 4.5 5.5 5 4.5 2.75 1.25 2 0 0 0 0 0 0.5 0 1
Date A B C A B C
A B C A B C
1st 7 6 12.9 1st 7 6 12.9
2nd 7 3 6 15.4 2nd 6 6 12.3
3rd 2 2 6 9.2 3rd 7 3 6 15.8
4th 6 5 6 16.8 4th 6 2 6 14.2
5th 3.8 5.5 6 15.3 5th 0.4 5.5 6 11.9
6th 2 5 4.4 11.4 6th 1.2 4.9 4.4 10.5
7th 1.2 2.4 0 3.6 7th 2.1 4.8 5.4 12.3
8th 0.0 0.0 0.0 0 8th 5.3 5.8 6.2 17.3
9th 0.0 2.3 0.0 2.3 9th 3.5 2.2 6.1 11.8
10th 1.1 4.4 6.1 11.6 10th 3.7 3.8 6.1 13.6
11th 1.7 4.1 6.5 12.3 11th 1 3.2 6.4 10.6
12th 3.9 3.5 2.3 9.7 12th 0.3 3.4 4.2 7.9
13th 1.7 1.7 13th 0
14th 0 14th 2 2.1
15th 0 15th 1 4 4.5
16th 0 16th 1 0.7
0
17th 0 17th
18th 0 18th 0
19th 0 19th 0
20th 0.0 2.5 1.1 3.6 20th 0
21st 1.90 3.10 5.80 10.8 21st 0.00 0.00 0.00 0
22nd 4.60 4.20 5.70 14.5 22nd 0
23rd 2.10 2.1 23rd 0
24th 1.30 1.3 24th 0
25th 0 25th 0
26th 0 26th 0
27th 0 27th 1.00 1
28th 3.00 2.20 5.2 28th 2.50 2.5
45.4 48.5 65.8 159.7 45.30 41.7 74.9 161.9
A B C A B C
1st 4 4 3 0 0 1
2nd 2 3 2 1 0 1
3rd 3 3 3 1 1 1
4th 3 3 3 1 1 1
5th 2 3 3 2 1 1
6th 3 4 3 1 1 1
7th 3 3 3 1 1 1
8th 3 3 3 1 2 1
9th 3 3 3 1 1 1
10th 3 3 3 1 1 1
11th 2 4 2 1 1 1
12th 4 4 3 1 1 1
13th 4 2 3 1 2 1
14th 3 3 3 1 1 1
15th 4 2 2 1 2 1
16th 2 3 2 1 1 1
Excavator Run Hrs/ Manshift (Hrs)
Variance: 0.35+Hrs
Material shortage
Downtime
HEMM
6.15 Loss
R1 R2
Rear Dumper Run Hrs/ Manshift:
Face Pb/ Material
HEMM Downtime
Target 6 Hrs
Shortage
5.40
Loss
1st 2nd 3rd 4th 5th 6th 7th 8th 9th 10th 11th 12th 13th 14th 15th
TOTAL NO OF RD Operator deployed 45 37 45 35 21 25 30 32 40 38 46 35 31 45 35
B/D occurance of RD 17 14 17 15 13 18 9 13 14 16 11 10 16 14 10
Total loss due to RD switch 5.61 4.62 5.61 4.95 4.29 5.94 2.97 4.29 4.62 5.28 3.63 3.3 5.28 4.62 3.3
Total down time loss in RD due to Ex 12.75 10.5 5.64 0 0.66 0 0 10 0 35.32 1 0 2.33 0 0
Total EX operator deployed in daily 13 9 7 7 6 7 9 8 11 10 10 0 10 11 8
Total RD operator deployed in daily 45 37 45 35 21 25 30 32 40 38 46 35 31 45 35
Total loss of hours of ex down in which Ex operator deployed 9.25 11 1.41 0 0.33 0 0 2.92 0.25 10.83 1.5 0 2.33 1 0
Loss per men per shift in RD 0.12 0.12 0.12 0.14 0.20 0.24 0.10 0.13 0.12 0.14 0.08 0.09 0.17 0.10 0.09
Loss per men per shift due to Ex 0.71 1.22 0.20 0.00 0.06 0.00 0.00 0.37 0.02 1.08 0.15 0.10 0.23 0.09 0.00
Total loss per man shift in RD 0.84 1.35 0.33 0.14 0.26 0.24 0.10 0.50 0.14 1.22 0.23 0.35 0.40 0.19 0.09
Total loss per manshift Ex 0.71 1.22 0.20 0.00 0.06 0.00 0.00 0.37 0.02 1.08 0.15 0.25 0.23 0.09 0.00
16t
h 17th 18th 19th 20th 21st 22nd 23rd 24th 25th 26th 27th 28th Feb'17
B/D occurance of RD 16 17 29 25 34 17 13 14 14 13 9 11 11 No
5.2
Total loss due to RD switch 8 5.61 9.57 8.25 11.22 5.61 4.29 4.62 4.62 4.29 2.97 3.63 3.63 hrs
Total loss of hours of ex down in which Ex operator deployed 0 0 7.95 6.08 1.32 1.25 1.5 4 0.83 8 7.5 12 1.5 hrs
0.1
Loss per men per shift in RD 5 0.14 0.21 0.19 0.24 0.14 0.14 0.13 0.12 0.13 0.09 0.13 0.09 hrs
Tata Steel Slide
Development Jobs
18 18 2 0
R1 R5 R6
R2 R3 R4
AOP
R1: Frequent Development Jobs/ Side casting for face opening/ widening/ Road Prep/ Face
Prep
R2: Long Marching of Excavators : 72.5 Hrs
R3: Shifting of coal 32 Hrs @ 474 CuM / Hr Loss Calc
TSL Board Tata Steel Slide 35
Excavator Productivity
UOM Fig.
Total OB Cum 776193
Excavator Run Hours - OB ( For productivity) Hrs 1289.4
Productivity Cum/Hr 602
High-wall
Q-SEB : High Wall Outage Feb17
57.4 64.1
80 70
70 70 70 70 70 70 70 70 70 70 70 80
61
60
35 41 41 60
40 25 60.1 16 40
20 46.9 20
0 0
FY'17(P) FY'17(A) May'16 Jun'16 Jul'16 Aug'16
13.9
Sep'16 Oct'16 Nov'16 Dec'16 Jan'17 Feb'17 Mar'17
Preventive Action:
Periodic Checking
HIGH WALL MINER MTBF - FEB 17)
Bette
31
62.4
60 60 60
82
14 40 40 40 40 MTBF
MTBF 25 25 25 25 17 21
7 11 12
3
17 22.8 Category 1 Plan
FY'17(P) FY'17(A) May'16 Jun'16 July'16 Aug'16 Sep'16 Oct'16 Nov'16 Dec'16 Jan'17 Feb'17 Mar'17
30
Hours
20
24 24 24 24 24 24 24 24
10 19
16 16 16 16 15
13 12 13
9 10 9
8 8 8 7
6
4 3 4
0
40
Summary of B/Downs of High wall Feb17
41
High Wall Performance Analysis Feb17
Hrs
Coal Conveyor; 12%
Hydraulic; 13% Push Beam; 40%
Misc; 35%
300 100%
H
250 75% 100%
o 88% 80%
u 200
60%
r
150 40% Total Down time
s =123.5 Hrs 40%
100
49 44
50 16 15 20%
0 0%
Push Beam Other&EMS Hydraulic Coal conveyor
42
B/Down Frequency Of High Wall - Feb17
10 120.0
100.0
90.0 100.0
8
Frequency Nos.
80.0
6 80.0
6 60.0 Total No. of B/down
= 10 Times 60.0 %
4
40.0
2
2 1 1 20.0
0 0.0
Misc/safety/env Push Beam Coal Conveyor Hydraulic
43
High-wall Coal Production from May to Feb17 ( Tonne)
Potential loss
Due to Idle Hrs.
Potential loss Target
Due to B/D
TPH
Actual Feb=131
243827 Avg=123
164870
41438
4195 0
R1 R2 R3
45
B/D Frequency Of High Wall - May16 to Feb17
120 1600
1391 B/D Hrs %Cumm. 100
97 99 1400
100 92
87
80 1200
80 75
69 1000
57
60 700 800
40 600
40 466
342 400
20
20 173
96 90 200
62 51 45 24
0 0
46
47
TSL Board Tata Steel Slide 48
OB Shortfall
Actual
Seam Plan (Solid+ Dif Reasons
Loose)
Delay in Approach road
XI 175000 90202 -84798
preparation
X 100000 21612 -78388
Bathantand Loose Handled: 158112 CuM
VIII 0 191755 191755
for approach road preparation
VII 85000 68256 -16744
Total 360000 371825 11825
X 150000 160821 10821 Delay in settlement of Rabidas
IX 50000 60024 10024 Tola; Against Plan of 1st
VIII 40000 0 -40000 Dec17, it was settled on 20
Rabidas Tola Jan17; Delay in top bench
VII 150000 0 -150000 movement slowed down
advancement of lower seams
Total 390000 220845 -169155
VI 0 349 349
Air Strip
V 90000 123061 33061
Total 90000 123410 33410
Plan Actual Dif ( Actual - Plan)
OB- OB- OB-
CuM/ Ton Coal S/R Coal S/R Coal S/R
Solid Solid Solid
Ashpond Area 284760 117529 2.42 778203 271651 2.86 493443 154122 0.44
Bathantand
1683288 860192 1.96 836996 489906 1.71 -846292 -370286 -0.25
Existing Face
Bathantand Ext
1010917 324150 3.12 2713183 390391 6.95 1702266 66241 3.83
Face
Rabidas Tola Ext
899281 176046 5.11 719971 189555 3.80 -179310 13509 -1.31
Face
5407296 1803269 3.00 6618506 1664293 3.98 1211210 -138976 0.98
49
TSL Board Tata Steel Slide 50
OB Shortfall
Actual
Seam Plan (Solid+ Dif Reasons
Loose)
Delay in Approach road
XI 175000 90202 -84798
preparation
X 100000 21612 -78388
Bathantand Loose Handled: 158112 CuM
VIII 0 191755 191755
for approach road preparation
VII 85000 68256 -16744
Total 360000 371825 11825
X 150000 160821 10821 Delay in settlement of Rabidas
IX 50000 60024 10024 Tola; Against Plan of 1st
VIII 40000 0 -40000 Dec17, it was settled on 20
Rabidas Tola Jan17; Delay in top bench
VII 150000 0 -150000 movement slowed down
advancement of lower seams
Total 390000 220845 -169155
VI 0 349 349
Air Strip
V 90000 123061 33061
Total 90000 123410 33410