ANALYSIS / TABULATION PROGRAM SMALL SCALE INDUSTRY 1. Percentage by Industrial group [GROUP] 2. Percentage by Location [LOC] 3.
Percentage by Nature of Production process [PCESS] Basic Information of Production Sales / Employment 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. 19. 20. If process is batchmaking [PCESS=2], shift per day [SHFTS] by [GROUP] If process is continuous [ PCESS=1], working days a year [TDAY] by [GROUP] Percentage products [PRODUCT] by [GROUP] Total and average sales in local markets [LMSL12] and exports [EXP12] by [GROUP] Average of total number of days worked normally [TDW] in a year by [GROUP] Average employment total [EMPT12] by [GROUP] Average rate of capacity utilization [CAPU] by [GROUP] Percentage of cost [EXP12] [WAGE12] [RM12] [REM12] [CWAPDA12] [SLFGN12], [OTHER12] by [GROUP] Total and Average electricity purchased [ELCP12] by [GROUP] Average and Total value of production [2012] by [GROUP] Compute production target [PTAR] = Actual Production [ATP1, ATP2]/ Target production [TTPP1, TTPP2] Average [PTAR] by [GROUP] Frequency reason for not meeting target [REANT1, REANT2, REANT3, REANT4] by GROUP Average production loss due to different reasons [PLSP1, PLSP2,PLSP,3,PLSP4] Incidence of outages Average number of times of planned outages daily [DPOTL] [DPOTL1] [DPOTL2] [DPOTL3] [DPOTL4] Average/ Frequency of unplanned outage daily [DPOTP] [DPOTP1] [DPOTP2] [DPOTP3] [DPOTP4] Total number of planned and unplanned outages TLOAD= [DPOTL + DPOTP], TLOAD1= [DPOTL1 + DPOTP1], TLOAD2= [DPOTL2 + DPOTP2], TLOAD3= [DPOTL3 + DPOTP3], TLOAD4= [DPOTL4 + DPOTP4] Total hours of loadshedding [THRLOAD] = 0.5[TLOAD]+ 1[TLOAD1]+ 2[TLOAD2]+ 3[TLOAD3]+ 4[TLOAD4] Monthly number of planned and unplanned outages [TMLOAD] = [TPOTL + TPOTP], [TMLOAD1] = [TPOTL1 + TPOTP1], [TMLOAD2] = [TPOTL2 + TPOTP2], [TMLOAD3] = [TPOTL3 + TPOTP3], [TMLOAD4] = [TPOTL4 + TPOTP4] Monthly hours of planned and unplanned outages [MHRLOAD]= [0.5 [TMLOAD] +1 [TMLOAD1] +2 [TMLOAD2] +3[TMLOAD3] +4[TMLOAD4]] /9 Average loadshedding [MXLM],[MXLA],[MXLMA], [MXLJ], [MXLAG], [MXLSEP] Cost of Outages Percentage rank most disruptive about outages [DISRUPT] by [GROUP] Percentage nature of impact due to outages [IMPNUR] by GROUP Average spoilage cost [SPOP] [SPOU] by GROUP Average restart time [RSTMP], [RSTMU] by GROUP
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29. proportion of output lost in planned outage and restart = LOSTOUTP =[SLDP + SLDRP], LOSTOUTP1 = [SLDP1+SLDRP1], LOSTOUTP2 =[SLDP2 + SLDRP2], LOSTOUTP3 = [SLDP3+SLDRP3], LOSTOUTP4 =[SLDP4 + SLDRP4] 30. Proportion of output lost in unplanned outage and restart = LOSTOUTU = [ SLDU+SLDRU] LOSTOUTU1 = [ SLDU1+SLDRU1], LOSTOUTU2 = [ SLDU2+SLDRU2] LOSTOUTU3 = [ SLDU3+SLDRU3], LOSTOUTU4 = [ SLDU4+SLDRU4] 31. Total idle factor planned [IFP] = [LOSTOUTP * TPOTL] + [LOSTOUTP1 * TPOTL1] + [LOSTOUTP2 * TPOTL2]+ [LOSTOUTP3* TPOTL3]+ [LOSTOUTP4 * TPOTL4] 32. Total idle factor unplanned [IFU] =[[LOSTOUTU * TPOTLP]+ [LOSTOUTU1 * TPOTLP1]+ [LOSTOUTU2 * TPOTLP2]+ [LOSTOUTU3 * TPOTLP3]+ [LOSTOUTU4 * TPOTLP4]] /100 33. Total idle factor [IFT] = [IFP]+[IFU] 34. Monthly idle factor [MIFT] = IFT/9 35. Monthly costly idle factors = [MCIFT] = [MIFT] * total production in 2012 [TP12] 36. Average [IFP],[IFU],[IFT][MIFT][MCIFT] By [GROUP] 37. Frequency, percentage lost contract due to loading [LOSCNT], Average Value of contract [CNTVAL] 38. Frequency, percentage made adjustment [ADJUST] By [GROUP] 39 A. Generate Sum[ADJUSTMENT] = [ BEXGP + WOTP + WASP + NMCP + CNSTP+ CWDP] / 100 39 B. Net Idle Factor Cost [NMCIFT] =MCIFT(1-[ADJUSTMENT]) By [GROUP]
40 period of overtime = [OVERTMI] = working overtime [[WOTP/100]/ADJUSTMENT]*[MHRLOAD] 41 Wage bill = [WAGE12] 42 If batch making [PCESS=2 ] Generate Hours worked [HRSWORK] = shifts operate[SHFTSO]* [days worked [TWD]*9/12] *8 43 If continuous [PCESS=1] HRSWORK =[[9/12 *TWD]*24 44 Monthly Overtime Cost (OTC) =[[WAGE12/HRSWORK(1 + OVERP)]*OVERTMI]/ 9 45 Average [OTC] By [GROUP] 46 Cost of Working additional shifts [CWASH] = labour costs [OVRTM] + other [OTHCST1] + capital cost [[CAPCST1] * 0.22]/3 47 Monthly Cost of changing working days [CCWDS] = [ Labour Costs [LRCST2] + others [OTHCST3] + [(capital costs [ CAPCST3] * 0.22]]/3 48 Monthly Cost of Increasing Intensity [CII] = Labour Cost [ LRCST] +other [OTHCST2] +[Capital Cost [ CAPCST2]*0.22]/3 49 Cost of Running Generator [ HRGENC] = [Deisel [GNDL] +Gas [ GNGS]+ wages[GNWG/8]+ repair [GNRP/3]+others [GNOTH/3] 50 Monthly Running Cost of Generator [RGCOST1] = HRGENC*[[BEXGP/100/ADJUSTMENT]* [MHRLOAD]] 51 Monthly Generator Capital Cost [CGCOST] = [ Capital Cost of Generator [CAPGN] * 0.32] / 12
52 Monthly Cost of Generator [GENCOST] = RGCOST1 + CGCOST [Tariff [TRFKW]*MHRLOAD] COST OF LOADSHEDDING 53 In case of full adjustment, if [ ADJUSTMENT] = 100 Monthly Cost of Loadshedding [ MCLOADF] = monthly overtime cost [OTC] + changing working shifts [CWASH] + changing working days [CCWDS] + more intensive use of machinery [ CII] + generator cost [GENCOST] 54 Cost per kwh of Loadshedding [ CLOADKWHF] = [MCLOAD/MHRLOAD] In case of partial adjustment, If [ADJUSTMENT] is less than 100 55 Monthly Cost of Loadshedding [MCLOADP] = Spoilage Cost[MSPOIL] + net idel factor cost [NMCIFT] +overtime cost [OTC] + changing working [CWASH]+ changing working days [CCWDS] + more intensive use of machinery [CII] + generator cost [GENCOST] 56 Cost per kwh of Loadshedding CLOADKWHP = MCLOADP/MHRLOAD 57 Average monthly and kwh cost of loadshedding [MCLOADF][CLOADKWHP][MCLOADP][CLOADKWHP] By [GROUP] 58 Percentage, frequency plan to invest in generators [INVINGN] By [ GROUP] 59 Average Estimated cost, [ADCACST] By [GROUP]
