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GUIDELINE MATRIX FOR AUDITING

Audit Stage
Compliance

State of Mind
S1

Appropriate
Management Style

Unaware and unable Direct

Required Contact Time

Definition

Full time or very high - increase attention The staff in question use the element, but only
if score is low or falls back.
because the they are being reviewed.

On the Ground Symptoms

Risk

Action to Mitigate Risk

Type of Audit Question

Audit Scoring

The staff in question do not see any benefit in If the review process were taken away the
using the element, or they are actually resisting element usage would probably stop
its usage.
immediately.

In this event short interval control or direct supervision


may be necessary until the element is used habitually.

Closed Ended
Questions:

Is the Element in place and available to 0 = Not Used


be used?
1 = Partially / Occasionally Used
Is the Element being used by the
3 = Systematically Used
individual in question?

"Mechanical Compliance"

Understanding

S2

Aware and unable

Coach

Significant time - focus on assurance


and positive feedback.

The staff in question realise the idea and


function of the element.

They know what they are doing will help, but


They will continue to comply with the system
they are not yet quite sure how it all fits into the element but they will not derive full benefit
big picture.
from it.
Questions about the usefulness of the
document may arise and these should be
addressed immediately.

It is important for the management to be positive and


supportive and to encourage the continued use of the
elements.
Visual aids such as charts should be used so that
meaningful pointers can be set on key improvement
areas.

Open Ended
Questions:

Can the individual demonstrate


understanding of how to apply the
Element correctly?
Does the individual fully comprehend
why they must use the Element?

0 = Does Not Understand Element Application


and reasons for Usage
1 = Partially Understands Element Application
and reasons for Usage
3 = Fully Understands Element Application and
reasons for Usage

Usage

S3

Aware and able

Support

Moderate as S1 and S2 scores


stabilise step back from direct
involvement as much as possible.

Having complied with and understood the


purpose of the system element the staff now
own it.

The full benefits are derived and modifications / It can be assumed that the system element
improvements may also be volunteered.
will continue to be used. At this stage the
management can begin to rely on delegation
of system elements rather than any direct
review or supervision.

Concerning modifications / improvements the


management should adopt a coaching role and should
encourage the staff to tackle the problems themselves.
In this manner the risk of having the element drop out is
minimised as the ownership will not be lost or tackled at
an inappropriate management level.

Demonstrative
Questions:

Can the individual demonstrate


consistent usage of the Element?
Does the individual have evidence that
shows correct and consistent
application of the Element?

0 = Can Not Yet Demonstrate Correct Application


of the Element
1 = Can Demonstrate Correct Application of the
Element, but Usage is not always Consistent
3 = Can Consistently Demonstrate Correct
Application of the Element

1
Shift Handover
(Process kiln-3)

Daily

Shift Incharge (Engineer)

Sr. Manager / Manager

Sr. No.

FREQUENCY

Responsible

Accountable

System Elements
Categories

S1:
Compliance

S2:
Understanding

Shift Inchar

Sr. Manag

(Process kiln-3)

S3:
Usage

Daily

Shift Incharge (Engineer)

Shift Handover
Mechanical

Sr. Manager / Manager

S1:
Compliance

S2:
Understanding

S3:
Usage

Shift I

Sr. M

S3:
Usage

Daily

Shift Handover
(E & I)

Shift Incharge (Engineer)

Sr. Manager / Manager

S1:
Compliance

S2:
Understanding

S3:
Usage

Shift

Sr.

S3:
Usage

Daily

Shift Handover (QC)

Shift Incharge (Engineer)

Sr. Manager / Manager

S1:
Compliance

S2:
Understanding

S3:
Usage

Shift

Sr.

S3:
Usage

Daily

Breakdown Slip
( Kiln- 3)

Engineers

Managers

S1:
Compliance

S2:
Understanding

S3:
Usage

Daily

Breakdown Management
System (BMS)

Engineers

Managers

S1:
Compliance

S2:
Understanding

Daily

Engine

Breakdown Management
System (BMS)

Manag

S2:
Understanding

Daily

Line Walk

S1:
Compliance

Managers

anager (Maintenance)

S3:
Usage

S2:
Understanding

Daily

Managers

General Manager (Maint

Line Walk
S2:
Understanding

S3:
Usage

OBSERVATIONS

(Based on ACTUAL observations and Interviews, use the following questions to help you decide which
best represent the level of compliance/understanding/usage of the MCS Tools being assessed

Whether template is filled completely?


Whether all concerned people have signed the template?
Whether any remark mentioned on the sheet?
Why do we need to fill the sheet?
Whether all blocks has been completely understood by shift incharge?
Whether the complete sheet is understood by the shift incharge?

How shift handover process has been improved?


Have the information flow became more effective with the templates?
Has all the information has been shared during shift handover.?
Whether template is filled completely?
Whether all concerned people have signed the template?
Whether any remark mentioned on the sheet?
Why do we need to fill the sheet?
Whether all blocks has been completely understood by shift incharge?
Whether the complete sheet is understood by the shift incharge?
How shift handover process has been improved?

Have the information flow became more effective with the templates?
Has all the information has been shared during shift handover.?
Whether template is filled completely?
Whether all concerned people have signed the template?
Whether any remark mentioned on the sheet?
Why do we need to fill the sheet?
Whether all blocks has been completely understood by shift incharge?
Whether the complete sheet is understood by the shift incharge?
How shift handover process has been improved?

Have the information flow became more effective with the templates?
Has all the information has been shared during shift handover.?
Whether template is filled completely?
Whether all concerned people have signed the template?
Whether any remark mentioned on the sheet?
Why do we need to fill the sheet?
Whether all blocks has been completely understood by shift incharge?
Whether the complete sheet is understood by the shift incharge?
How shift handover process has been improved?

Have the information flow became more effective with the templates?
Has all the information has been shared during shift handover.?
Have all the details related to breakdown are being filled by Operations person completely?
Have all the details related to Breakdown are being filled by Maintenance perosn completely?
Did you review breakdowns for previous day ?

What benefit is expected by recording breakdowns? Do you think both Maintenance and Operations
should get involved in recording of Breakdown slips?
Please give us reason why breakdown start time plus job start and finish time is important?
What analysis of information about breakdowns captured should be done on weekly basis ?

Demonstrate how you are doing basic Root Cause Analysis by using the Breakdwon Slips?

Have you discussed with your manager on action points based on your yesterdays
suggestions/message/pending jobs in breakdown slip?
What are the actions taken based on issues like spare information, high response time, correct desc
resolution of breakdown etc.
Have all the details related to breakdown are being filled by data feeding person completely?
Have all the details related to Breakdown are being correctly filled by the data operator?
Did you review the data of breakdowns slip before feeding ?

What benefit is expected by recording breakdowns? Do you think both Maintenance and Operations
should get involved in recording of Breakdown slips?
Please give us reason why breakdown start time plus job start and finish time is important?

What analysis of information about breakdowns captured should be done on weekly basis ?
Demonstrate how you are doing basic Root Cause Analysis by using the Breakdwon Slips?
Have you discussed with your manager on action points based on your yesterdays
suggestions/message/pending jobs in breakdown slip?

What are the actions taken based on issues like spare information, high response time, correct desc
resolution of breakdown etc.
Is line walk schedule prepared? Is it is done as per schedule.?
Is line walk log sheet is filled properly and reported as on the day?
Is line walk is done properly by the assigned person?
Are all the codes underdstood by the person.?

Is the line walk personnel understood the scope or area where he has to do the line walk?
What is the benfit of doing line walk?
Is line walk log sheet is reviewed by HOD?
Are task has been assigned with its priority?
Are all the high priority issues has been closed?

Rating Scale

0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)

0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)

1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)

1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)

1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)

0
(NIL)

1
(PARTIAL)
3
(HIGH)

0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)

0
(NIL)

1
(PARTIAL)

3
(HIGH)
0
(NIL)
1
(PARTIAL)

3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)

1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)

Power Plant - In Progress Audit Report

100%

100%
94%

90%
82%

79%

80%
70%
60%
50%
40%
30%
20%
10%
0%

Actual
S1-Compliance Plan

S2-Understanding Plan

Actual
S3-Usage Plan

Actual

Power Plant Audit - Progress Chart


Actual
100%

100%
S1-Compliance Plan

Actual

S2-Understanding Plan

Actual

S3-Usage Plan

94%
88%

90%
82%

79%

80%

82%

70%
60%
50%
40%
30%
20%
10%
0%
Wk-31

Wk-32

Wk-33

Power Plant - Audit Progress Chart


Actual

100%

Actual

S1-Compliance Plan

100%
94%

90%
80%

Actual

79%

94%
82%

70%
60%
50%

Percentage
40%
30%
20%
10%
0%

Week

88%

82%

82%

Power Plant Audit - Progress Chart


Actual
100%

100%

S1-Compliance Plan
94%

70%
60%
50%
40%
30%
20%
10%
0%

Actual

S3-Usage Plan
94%

92%

88%

90%
80%

Actual

S2-Understanding Plan

79%

82%

82%

82%

83%

Power Plant - Audit Progress Chart


Actual
100%

Actual

70%
60%
50%
40%
30%
20%
10%
0%

S1-Compliance Plan

S2-Understanding Plan

S3-Usage Plan

100%
94%

94%

92%

93%

88%

90%
80%

Actual

79%

82%

82%

82%

83%
78%

Power Plant Audit


- Progress Chart
Actual
Actual
S1-Compliance Plan

S2-Understanding Plan

Actual

S3-Usage Plan

100%

80%

60%

40%

20%

0%

Wk-31

Wk-32

Wk-33

Wk-34

Wk-35

Wk-36

Wk-37

Power Plant Audit - Progress Chart


Actual

S1-Compliance Plan

100%
90%
80%
70%
60%
50%
40%
30%
20%
10%
0%

92%

90%

89%

90%

91%

Actual

S2-Understanding Plan

94%
88%

92%

90%

S3-Usage

S3-Usage Plan

92%

92%

90%

91%

90%

90%

Section

S1-Compliance
S2-Understanding
S3-Usage

Progress
Plan
Actual
Plan
Actual
Plan
Actual

Wk-31

Wk-32

Wk-33

Wk-34

90%
80%
100%
70%
79%

90%
80%
94%
70%
82%

90%
80%
88%
70%
82%

90%
80%
94%
70%
82%

Graph data po
updation aft

Wk-35

Wk-36

Wk-37

Wk-38

Wk-39

Wk-40

Wk-41

Wk-42

90%
80%
92%
70%
83%

90%
80%
93%
70%
78%

90%
80%
93%
70%
87%

90%
80%
90%
70%
85%

90%
80%
93%
70%
85%

90%
80%
93%
70%
87%

90%
80%
93%
70%
80%

90%
80%
100%
70%
82%

ata points need


on after Audit

Wk-43

Wk-44

Wk-45

Wk-46

Wk-47

Wk-48

Wk-49

Wk-50

90%
80%
100%
70%
85%

90%
80%
100%
70%
88%

90%
80%
100%
70%
88%

90%
90%
100%
90%
87%

90%
90%
100%
90%
89%

90%
90%
100%
90%
90%

90%
90%
100%
90%
89%

90%
90%
100%
90%
88%

Wk-51

Wk-52

Wk-53

Wk-54

Wk-55

Wk-56

Wk-57

Wk-58

90%
90%
100%
90%
88%

90%
90%
100%
90%
85%

90%
90%
100%
90%
92%

90%
90%
93%
90%
85%

90%
90%
93%
90%
85%

90%
90%
100%
90%
92%

90%
90%
95%
90%
88%

90%
90%
90%
90%
88%

Wk-59

Wk-60

Wk-61

Wk-62

Wk-63

Wk-64

Wk-65

Wk-66

90%
90%
94%
90%
89%

90%
90%
100%
90%
88%

90%
90%
95%
90%
88%

90%
90%
90%
90%
85%

90%
90%
94%
90%
85%

90%
90%
94%
90%
81%

90%
90%
94%
90%
86%

90%
90%
94%
90%
85%

Wk-67

Wk-68

Wk-69

Wk-70

Wk-71

Wk-72

Wk-73

Wk-74

90%
90%
93%
90%
83%

90%
90%
94%
90%
86%

90%
90%
92%
90%
86%

90%
90%
92%
90%
86%

90%
90%
94%
90%
86%

90%
90%
94%
90%
82%

90%
90%
90%
90%
89%

90%
90%
95%
90%
89%

Wk-75

Wk-76

Wk-77

Wk-78

Wk-79

Wk-80

Wk-81

Wk-82

90%
90%
93%
90%
88%

90%
90%
90%
90%
87%

90%
90%
90%
90%
90%

90%
90%
89%
90%
85%

90%
90%
90%
90%
88%

90%
90%
90%
90%
89%

90%
90%
90%
90%
88%

90%
90%
88%
90%
88%

Wk-83

Wk-84

Wk-85

Wk-86

Wk-87

Wk-88

Wk-89

Wk-90

90%
90%
88%
90%
86%

90%
90%
90%
90%
88%

90%
90%
89%
90%
85%

90%
90%
89%
90%
88%

90%
90%
90%
90%
89%

90%
90%
89%
90%
88%

90%
90%
89%
90%
87%

90%
92%
90%
90%
90%
89%

Wk-91

Wk-92

Wk-93

Wk-94

Wk-95

Wk-96

Wk-97

Wk-98

90%
92%
90%
90%
90%
89%

90%
90%
90%
89%
90%
88%

90%
92%
90%
90%
90%
89%

90%
92%
90%
90%
90%
90%

90%
90%
90%
90%
90%
90%

90%
91%
90%
90%
90%
89%

90%
92%
90%
90%
90%
89%

90%
90%
90%
90%
90%
89%

Wk-99

Wk-100

Wk-101

Wk-102

Wk-103

Wk-104

Wk-105

Wk-106

90%
92%
90%
91%
90%
89%

90%
92%
90%
90%
90%
89%

90%
90%
90%
91%
90%
88%

90%
94%
90%
92%
90%
90%

90%
92%
90%
92%
90%
90%

90%
91%
90%
90%
90%
90%

90%
90%
90%
-

90%
90%
90%
-

Wk-107

Wk-108

90%
90%
90%
-

90%
90%
90%
-

Responsible

Shift Handover - Phase 1

r. Manager / Manager

ift Incharge (Engineer)

FREQUENCY

Accountable

Daily

Sr. No.
System Elements

Daily

Daily

Shift Incharge (E

Shift Incharge (Engineer)

Shift Handover - Phase 2

Sr. Manager / M

Sr. Manager / Manager

Shift Handover - Phase 1

intenance)

Managers
Weekly

All DRM Members


Daily

Daily Review Meeting

General Manager (Maintenance)

DRM Chairman

Line Walk - Phase

n)

Power Plant requirement


and fullfillment

AGM (operation)

Electrical HOD

Daily

Breakdown Slip (Phase 1)

Managers

Engineers

Daily

7
Breakdown Management
System (BMS) - Phase 1

Managers

Engineers
Monday, Wednesday, Friday

8
Shut Down Job Scoping
Kiln Phase 2

GM

Departmental HOD

As and When Required

9
Root Cause Analysis Phase 1

Sectional - General Manager

Sr.Manager / Manager
Weekly

10

Shutdown Review
Meeting

DRM Chairman

Process In charges

As and When Required - During


Shutdown

As

As and

Categories

S1:
Compliance

S2:
Understanding

S2:
Understanding

S3:
Usage

S1:
Compliance

S2:
Understanding

S3:
Usage

S1:
Compliance

S1:
Compliance

S2:
Understanding

S3:
Usage

S1:
Compliance

S2:
Understanding

S3:
Usage

S1:
Compliance

S1:
Compliance

S2:
Understanding

S3:
Usage

S1:
Compliance

S2:
Understanding

S3:
Usage

S1:
Compliance

S2:
Understanding

S3:
Usage

S1:
Compliance

S2:
Understanding

S3:
Usage

S3:
Usage

S1:
Compliance

S2:
Understanding

S3:
Usage

S1:
Compliance

S2:
Understanding

S3:
Usage

S3:
Usage

Name of Area / Department being Audited: Maintenance

Name of Area / Department Manager: Respective Manager

Name of Individuals Audited:

OBSERVATIONS

(Based on ACTUAL observations and Interviews, use the following quest


best represent the level of compliance/understanding/usage of

Whether template is filled completely?


Whether all concerned people have signed the template?
Whether any remark mentioned on the sheet?
Why do we need to fill the sheet?
Whether all blocks has been completely understood by shift incharge?

Whether the complete sheet is understood by the shift incharge?


How shift handover process has been improved?
Have the information flow became more effective with the templates?
Has all the information has been shared during shift handover.?
Whether template is filled completely?
Whether all concerned people have signed the template?
Whether any remark mentioned on the sheet?
Why do we need to fill the sheet?
Whether all blocks has been completely understood by shift incharge?
Whether the complete sheet is understood by the shift incharge?
How shift handover process has been improved?
Have the information flow became more effective with the templates?
Has all the information has been shared during shift handover.?
Is line walk schedule prepared? Is it done as per schedule.?

Is line walk log sheet is filled properly and reported as on the day?
Is line walk is done properly by the assigned person?
Are all the codes underdstood by the person.?

Is the line walk personnel understood the scope or area where he has t
What is the benfit of doing line walk?
Is line walk log sheet is reviewed by HOD?
Are task has been assigned with its priority?
Are all the high priority issues has been closed?
Did meeting start on time? Are all members reached at time?
Is Terms of reference & Agenda is prepared and followed?

Was the necessary pre-work done by participants i.e. Daily Stats sourc
solutions identified prior to meeting commencing?
Is Terms of reference understood by all DRM Members?
Are all members aware of their roles in the meeting?.
Do DRM Members understand the importance of the meeting.?

Were variances identified and corrective actions recorded in Action Pla

Were actions, responsibilities and due dates assigned on the Action Pla

Were the documentated action logs is reviewed and points are being cl
Did Template mailed or received on time?

Is generation is so planned that all department have sufficient power to


is there any remark generated against short fall in supply
Did template is understood to all/
Do everybody know about such planning?
Did this planning is conveyed to all department
Any action taken against short fall in supply against requirement.
Did daily study about GAP in supply and demand happen?
Export is reduceding or not.

Have all the details related to breakdown are being filled by Operations

Have all the details related to Breakdown are being filled by Maintenanc
Did you review breakdowns for previous day ?
What benefit is expected by recording breakdowns? Do you think both
should get involved in recording of Breakdown slips?

Please give us reason why breakdown start time plus job start and finis

What analysis of information about breakdowns captured should be do

Demonstrate how you are doing basic Root Cause Analysis by using th

Have you discussed with your manager on action points based on your
suggestions/message/pending jobs in breakdown slip?
What are the actions taken based on issues like spare information, high
resolution of breakdown etc.

Have all the details related to breakdown are being filled by data feedin

Have all the details related to Breakdown are being correctly filled by th
Did you review the data of breakdowns slip before feeding ?
What benefit is expected by recording breakdowns? Do you think both
should get involved in recording of Breakdown slips?

Please give us reason why breakdown start time plus job start and finis

What analysis of information about breakdowns captured should be do

Demonstrate how you are doing basic Root Cause Analysis by using th

Have you discussed with your manager on action points based on your
suggestions/message/pending jobs in breakdown slip?
What are the actions taken based on issues like spare information, high
resolution of breakdown etc.
Whether template is filled completely ?
Whether all the inter departmental jobs are incorporated?

Availability of spares and other critical equipment is done as per job sco
Why do we need to fill the sheet?
Whether all blocks has been completely understood by HOD?
Whether they are aware of how to track the system?
Whether the concerned people planning daily jobs as per Schedule?

Whether the information flow became more effective with the template

Has the information helped in taking pro active actions?

Are you carrying out root cause analysis for Bad actor (Equipment's) at

Are you filling up and updating RCA tracker ? Please show the RCA tra
Does "5 why" format exist and used please show.
What is the need for RCA policy?
Why do we need to Maintain RCA tracker log book. ?
What is the benefit of using 5 Why template ?

Show if any repetitive problem were corrected by using root cause anal
Please provide one example based on last RCA done?

Have you documented the actions and can you link the actions to the im
Did meeting start on time? Are all members reached at time?
Is Terms of reference & Agenda is prepared and followed?

Was the necessary pre-work done by participants i.e. Daily work done ,

Do the responsible members understand the importance of daily shutdo


Are all members aware of their roles in the meeting?.

Availability of spares, castable was checked as per the shutdown plan?

Were variances identified and corrective actions recorded in Action Pla

Were actions, responsibilities and due dates assigned on the Action Pla

Were the documented action logs is reviewed and points are being clos

Total number of Sys

AUDIT BY

AUDIT DATE

Rating Scale

0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)

Supervisory Actions Required


to Enable Improvement /
Sustain

3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)

1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)

1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)

0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)

3
(HIGH)
1
(PARTIAL)
3
(HIGH)
1
(PARTIAL)
1
(PARTIAL)
1
(PARTIAL)
1
(PARTIAL)
0
(NIL)
0
(NIL)
0
(NIL)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)

3
(HIGH)

0
10

TOTAL COMPLIANCE

TOTAL UNDERSTANDING
TOTAL USAGE

Taskforce

13-Dec-14

Observed Current Rating


for this category
(Score: 0, 1 or 3)

REMARKS

(Key in any remarks which justify the obser

Partial usage due to parallel running of


1

Partial usage due to parallel running of


1

the KPI's are not disussed in the meetin


1

ID fan for WHRB 1 was tripped and no one was a

The monthly bad actor list was not done


1

93%
87%
40%

REMARKS

rks which justify the observed rating given to the auditee)

e to parallel running of log sheet

e to parallel running of log sheet

disussed in the meeting

as tripped and no one was aware of the the fact

or list was not done

ACTION PLAN

(Key in the required action that needs to be taken to address issues - th


must be done for System Elements with a yellow or red scores)

taken to address issues - this


th a yellow or red scores)

Sr. No.
System Elements
Accountable

Responsible

FREQUENCY

Shift Handover - Phase 1

Sr. Manager / Manager

Shift Incharge (Engineer)

Daily

2
Shift Handover - Phase 2

Sr. Manager / Manager

Shift Incharge (Engineer)


Daily

Line Walk - Phase

General Manager (Maintenance)

Managers

Weekly

Shift I

Sr.

4
Daily Review Meeting

DRM Chairman

All DRM Members


Daily

Power Plant requirement


and fullfillment

AGM (operation)

Electrical HOD

Daily

General Man

Dai
Daily

Electric

Breakdown Slip (Phase 1)

Engineers

AGM (op

Power Plant requirement


and fullfillment

Managers

Breakdown Slip (Phase 2)

Managers

Engineers

Daily

Breakdown Management
System (BMS) - Phase 1

Managers

Engineers

Monday, Wednesday, Friday

GM

Monday, Wednesday, Friday

Shut Down Job Scoping


Phase 1

nd When Required

Managers

10

Engineers

Breakdown Management
System (BMS) - Phase 2

partmental HOD

Monday

Shut Down Job Scoping


Kiln Phase 2

12

Root Cause Analysis Phase 1

Weekly

ager / Manager

As and When Required

Departmental HOD

As and When R

Departmental

GM

11

GM

Shut Down Job Scoping


Phase 1

- General Manager

10

14

Sr.Manager / Manager
Weekly

Required

Job Quality Check -

ge (Engineer)

Root Cause Analysis Phase 2

Weekly

Sr.Manager / Man

Sectional - General

13

Sectional - General Manager

Root Cause Analysis Phase 1

er / Manager

12

(Engineer)

Job Quality Check Phase 2

As When Required

Shift In charge (Engineer)

As When Required

Shift Incharge (Engineer)

Sr. Manager / Manager

15

Sr. Manager / Manager

Job Quality Check Phase 1

/ Manager

14

- During

es

Monthly Power
Generation Plan

1st of every month

Shift Incharge (Engineer)

Daily

Shift Incharge (Engineer)

Sr. Manager / Manager

17

Sr. Manager / Manager

Preventive Maintenance
Planning

16

18

As and When Required - During


Shutdown

Process In charges

DRM Chairman

Shutdown Review
Meeting

Categories

S1:
Compliance

S2:
Understanding

S3:
Usage

S3:
Usage

S1:
Compliance

S2:
Understanding

S3:
Usage

S1:
Compliance

S2:
Understanding

S3:
Usage

S3:
Usage

S1:
Compliance

S2:
Understanding

S3:
Usage

S1:
Compliance

S2:
Understanding

S3:
Usage

S1:
Compliance

S2:
Understanding

S3:
Usage

S1:
Compliance

S1:
Compliance

S2:
Understanding

S3:
Usage

S1:
Compliance

S2:
Understanding

S3:
Usage

S3:
Usage

S1:
Compliance

S2:
Understanding

S3:
Usage

S1:
Compliance

S2:
Understanding

S2:
Understanding

S3:
Usage

S1:
Compliance

S2:
Understanding

S3:
Usage

S1:
Compliance

S2:
Understanding

S2:
Understanding

S3:
Usage

S1:
Compliance

S2:
Understanding

S3:
Usage

S1:
Compliance

S2:
Understanding

S3:
Usage

S1:
Compliance

S2:
Understanding

S3:
Usage

S1:
Compliance

S1:
Compliance

S2:
Understanding

S3:
Usage

S1:
Compliance

S2:
Understanding

S3:
Usage

S1:
Compliance

S1:
Compliance

S2:
Understanding

S3:
Usage

Name of Area / Department being Audited: Operations / Maintenance

Name of Area / Department Manager: Respective Manager

Name of Individuals Audited:

OBSERVATIONS
(Based on ACTUAL observations and Interviews, use the following quest
best represent the level of compliance/understanding/usage of

Whether template is filled completely?


Whether all concerned people have signed the template?
Whether any remark mentioned on the sheet?
Why do we need to fill the sheet?
Whether all blocks has been completely understood by shift incharge?
Whether the complete sheet is understood by the shift incharge?
How shift handover process has been improved?
Have the information flow became more effective with the templates?

Have you used the system to achieve the KPI's?


Has all the information has been shared during shift handover.?
Whether template is filled completely?
Whether all concerned people have signed the template?
Whether any remark mentioned on the sheet?
Why do we need to fill the sheet?
Whether all blocks has been completely understood by shift incharge?
Whether the complete sheet is understood by the shift incharge?
How shift handover process has been improved?
Have the information flow became more effective with the templates?
Have you used the system to achieve the KPI's?
Has all the information has been shared during shift handover.?
Is line walk schedule prepared? Is it done as per schedule.?
Is line walk log sheet is filled properly and reported as on the day?
Is line walk is done properly by the assigned person?
Are all the codes underdstood by the person.?

Is the line walk personnel understood the scope or area where he has t
What is the benfit of doing line walk?
Is line walk log sheet is reviewed by HOD?

Are task has been assigned with its priority?


Have you used the system to achieve the KPI's?
Are all the high priority issues has been closed?
Did meeting start on time? Are all members reached at time?
Is Terms of reference & Agenda is prepared and followed?

Was the necessary pre-work done by participants i.e. Daily Stats sourc
solutions identified prior to meeting commencing?
Is Terms of reference understood by all DRM Members?
Are all members aware of their roles in the meeting?.
Do DRM Members understand the importance of the meeting.?

Were variances identified and corrective actions recorded in Action Pla

Were actions, responsibilities and due dates assigned on the Action Pla
Have you used the system to achieve the KPI's?

Were the documentated action logs is reviewed and points are being cl
Did Template mailed or received on time?

Is generation is so planned that all department have sufficient power to


is there any remark generated against short fall in supply
Did template is understood to all/
Do everybody know about such planning?
Did this planning is conveyed to all department

Any action taken against short fall in supply against requirement.


Did daily study about GAP in supply and demand happen?

Have you used the system to achieve the KPI's?


Export is reduceding or not.

Have all the details related to breakdown are being filled by Operations

Have all the details related to Breakdown are being filled by Maintenanc
Did you review breakdowns for previous day ?
What benefit is expected by recording breakdowns? Do you think both
should get involved in recording of Breakdown slips?

Please give us reason why breakdown start time plus job start and finis

What analysis of information about breakdowns captured should be do

Demonstrate how you are doing basic Root Cause Analysis by using th

Have you discussed with your manager on action points based on your
suggestions/message/pending jobs in breakdown slip?
Have you used the system to achieve the KPI's?
What are the actions taken based on issues like spare information, high
resolution of breakdown etc.

Have all the details related to breakdown are being filled by Operations

Have all the details related to Breakdown are being filled by Maintenanc
Did you review breakdowns for previous day ?
What benefit is expected by recording breakdowns? Do you think both
should get involved in recording of Breakdown slips?

Please give us reason why breakdown start time plus job start and finis

What analysis of information about breakdowns captured should be do

Demonstrate how you are doing basic Root Cause Analysis by using th

Have you discussed with your manager on action points based on your
suggestions/message/pending jobs in breakdown slip?
Have you used the system to achieve the KPI's?
What are the actions taken based on issues like spare information, high
resolution of breakdown etc.

Have all the details related to breakdown are being filled by data feedin

Have all the details related to Breakdown are being correctly filled by th
Did you review the data of breakdowns slip before feeding ?
What benefit is expected by recording breakdowns? Do you think both
should get involved in recording of Breakdown slips?

Please give us reason why breakdown start time plus job start and finis

What analysis of information about breakdowns captured should be do

Demonstrate how you are doing basic Root Cause Analysis by using th
Have you used the system to achieve the KPI's?

Have you discussed with your manager on action points based on your
suggestions/message/pending jobs in breakdown slip?
What are the actions taken based on issues like spare information, high
resolution of breakdown etc.

Have all the details related to breakdown are being filled by data feedin

Have all the details related to Breakdown are being correctly filled by th
Did you review the data of breakdowns slip before feeding ?
What benefit is expected by recording breakdowns? Do you think both
should get involved in recording of Breakdown slips?

Please give us reason why breakdown start time plus job start and finis

What analysis of information about breakdowns captured should be do

Demonstrate how you are doing basic Root Cause Analysis by using th

Have you used the system to achieve the KPI's?


Have you discussed with your manager on action points based on your
suggestions/message/pending jobs in breakdown slip?
What are the actions taken based on issues like spare information, high
resolution of breakdown etc.
Whether template is filled completely ?
Whether all the inter departmental jobs are incorporated?

Availability of spares and other critical equipment is done as per job sco
Why do we need to fill the sheet?
Whether all blocks has been completely understood by HOD?

Whether they are aware of how to track the system?


Whether the concerned people planning daily jobs as per Schedule?
Have you used the system to achieve the KPI's?

Whether the information flow became more effective with the template
Has the information helped in taking pro active actions?
Whether template is filled completely ?
Whether all the inter departmental jobs are incorporated?

Availability of spares and other critical equipment is done as per job sco
Why do we need to fill the sheet?
Whether all blocks has been completely understood by HOD?
Whether they are aware of how to track the system?
Whether the concerned people planning daily jobs as per Schedule?
Have you used the system to achieve the KPI's?

Whether the information flow became more effective with the template
Has the information helped in taking pro active actions?
Are you carrying out root cause analysis as per RCA Policy?

Are you maintaning a RCA documentation file? Please show the RCA lo
Does "5 why" format exist and used please show.
What is the need for RCA policy?

Why do we need to Maintain RCA log book. ?


What is the benefit of using 5 Why template ?

Show if any repetitive problem were corrected by using root cause anal
Please provide one example based on last RCA done?

Have you documented the actions and can you link the actions to the im
Are you carrying out root cause analysis as per RCA Policy?

Are you maintaning a RCA documentation file? Please show the RCA lo
Does "5 why" format exist and used please show.
What is the need for RCA policy?
Why do we need to Maintain RCA log book. ?
What is the benefit of using 5 Why template ?

Show if any repetitive problem were corrected by using root cause anal
Please provide one example based on last RCA done?
Have you used the system to achieve the KPI's?

Have you documented the actions and can you link the actions to the im
Whether the Job checking is done as per shut down planning?
Whether the job checking is done by the team formed?
Whether remarks are mentioned against poor quality of jobs?

Whether the team Is aware of importance of job quality checking?


Whether all jobs compered were completely understood ?
Whether they are aware of how to do job checking?
Whether the frequency of equipment failure reduced post light up?
Have you used the system to achieve the KPI's?
Whether Any counter measures taken to avoid critical issues.?

Whether the Job checking is done as per shut down planning?


Whether the job checking is done by the team formed?
Whether remarks are mentioned against poor quality of jobs?
Whether the team Is aware of importance of job quality checking?
Whether all jobs compered were completely understood ?
Whether they are aware of how to do job checking?
Whether the frequency of equipment failure reduced post light up?
Whether Any counter measures taken to avoid critical issues.?
Have you used the system to achieve the KPI's?
Is PM Schedule followed regularly?
Is PM Checklist completely filled by the Engineers?

Is any remarks mentioned against the work done?


Why do we need to follow the PM Plan?

Whether all plans & Checklist has been completely understood by conc
Whether concern people know how to perform PM?
Has the equipment life been improved with this plan?
Has the PM Plan helped in improving MTBF?
Have you used the system to achieve the KPI's?
Is monthly generation plan prepared by the department?
Is monthly production plan of SID taken into account?
Is the plan ready on the first working day of the month?
Why do we need to make the monthly generation plan?

Is the power gneration plan has been completely understood by the con
Whether sponge iron department head was aware of the planning?
Has the overall power generation has increased??

Has the monthly generation plan helped in better weekly and daily pow
Have you used the system to achieve the KPI's?
Was the generation plan on track??
Did meeting start on time? Are all members reached at time?
Is Terms of reference & Agenda is prepared and followed?

Was the necessary pre-work done by participants i.e. Daily work done ,

Do the responsible members understand the importance of daily shutdo


Are all members aware of their roles in the meeting?.

Availability of spares, castable was checked as per the shutdown plan?

Were variances identified and corrective actions recorded in Action Pla

Were actions, responsibilities and due dates assigned on the Action Pla
Have you used the system to achieve the KPI's?

Were the documented action logs is reviewed and points are being clos

Total number of Sys

AUDIT BY

AUDIT DATE

Rating Scale

0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)

Supervisory Actions Required


to Enable Improvement /
Sustain

3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)

Retraining by the
departement heads

Retraining by the
departement heads

It should be merge with


shift log sheet

1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)

0
(NIL)
1
(PARTIAL)
3
(HIGH)

0
(NIL)

1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)

3
(HIGH)
0
(NIL)

1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)

3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)

1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)

3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
1
(PARTIAL)
3
(HIGH)
1
(PARTIAL)
1
(PARTIAL)

1
(PARTIAL)
1
(PARTIAL)
0
(NIL)
0
(NIL)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
1
(PARTIAL)
1
(PARTIAL)
1
(PARTIAL)
1
(PARTIAL)
0
(NIL)
0
(NIL)
0
(NIL)
0
(NIL)
1
(PARTIAL)
3
(HIGH)

0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)

3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)

3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)

10
18

TOTAL COMPLIANCE
TOTAL UNDERSTANDING
TOTAL USAGE

Taskforce

16-Dec-14

Observed Current Rating for


this category
(Score: 0, 1 or 3)

REMAR

(Key in any remarks which justify the

This has to be replaced with log sh


week

This has to be replaced with log sh


week
3

the sign of shift incharge was not p


incharge was present
1

They don't understand the importa


1

Currently shift log sheet is used for


resulting in low usage of the implem
0

This will be merge in th


3

It was delayed as the power plant d


requirement from Ferro Alloys
3

It was decided in the DRM that SIC


communication regarding power su
1

The BMS has been installed in phase


generated bas

No Bre

Not Audited

Not Audited

Not Audited

The shutdown is still going on. The usage w


shutdown
1

The actions have been identi


same has been incorporated
DC breaker to avoid further o
1

Not A

Not A

Not A

Not A

Not A

Not A

Since the shift incharges take part in the me


improving day by day
3

Actions were taken and the maintenance ac


day
1

92%
79%
46%

REMARKS

arks which justify the observed rating given to the auditee)

placed with log sheet and merge with the IMS in this

placed with log sheet and merge with the IMS in this

ncharge was not present even when the shift


esent

stand the importance of shift handover

g sheet is used for seeing the data for past shift,


sage of the implemented system

will be merge in the IMS from next week

s the power plant didn't receive the power


m Ferro Alloys

the DRM that SIC will be used for inter plant


egarding power supply.

een installed in phase one. Monthly bad actor list needs to be


generated based on the data

No Breakdown

going on. The usage will be determind by the duration of

ave been identified for the black out. The


n incorporated permanently closing phase 2
avoid further occurrence.

Not Audited

Not Audited

Not Audited

Not Audited

Not Audited

Not Audited

ges take part in the meeting , the level of understanding is


y

nd the maintenance activity is running ahead of schedule as per

ACTION PLAN
(Key in the required action that needs to be taken to address issues - th
must be done for System Elements with a yellow or red scores)

Seniors need to take review on regular basis to make sure the


shift handover properly takes place

Retraining by the departement heads

To be merged with shift log sheet and implement it by next week

The usage has been very good.

The usage will built up only when there proper flow on informatio

A special training has to be provided on how to generate bad actor list based up
the given data

the phase head should make sure that all the jobs are being complete on time a
per the shutdown job scoping and planning

N
taken to address issues - this
th a yellow or red scores)

r basis to make sure the

implement it by next week

very good.

e proper flow on information

generate bad actor list based upon


a

bs are being complete on time as

Sr. No.
System Elements
Accountable

Responsible

FREQUENCY

Shift Handover and log


sheet - Phase 1

Sr. Manager / Manager

Shift Incharge (Engineer)

Daily

2
Shift Handover and log
sheet - Phase 2

Sr. Manager / Manager

Shift Incharge (Engineer)


Daily

Line Walk - Phase

General Manager (Maintenance)

Managers

Weekly

Shift I

Sr.

4
Daily Review Meeting

DRM Chairman

All DRM Members


Daily

Power Plant requirement


and fullfillment

AGM (operation)

Electrical HOD

Daily

General Man

Dai
Daily

Electric

Breakdown Slip (Phase 1)

Engineers

AGM (op

Power Plant requirement


and fullfillment

Managers

Breakdown Slip (Phase 2)

Managers

Engineers

Daily

Breakdown Management
System (BMS) - Phase 1

Managers

Engineers

Monday, Wednesday, Friday

GM

Monday, Wednesday, Friday

Shut Down Job Scoping


Phase 1

nd When Required

Managers

10

Engineers

Breakdown Management
System (BMS) - Phase 2

partmental HOD

Monday

Shut Down Job Scoping


Kiln Phase 2

12

Root Cause Analysis Phase 1

Weekly

nager / Manager

As and When Required

Departmental HOD

As and When R

Departmental

GM

11

GM

Shut Down Job Scoping


Phase 1

l - General Manager

10

Job Quality Check Phase 1

en Required

Weekly

Sr.Manager / Manager

14

arge (Engineer)

Root Cause Analysis Phase 2

Weekly

Sr.Manager / Mana

Sectional - General M

13

Sectional - General Manager

Root Cause Analysis Phase 1

ger / Manager

12

Job Quality Check Phase 2

16

Preventive Maintenance
Planning

Daily

rge (Engineer)

As When Required

Shift In charge (Engineer)

As When Require

Shift Incharge (Engin

Sr. Manager / Mana

15

Sr. Manager / Manager

Job Quality Check Phase 1

ger / Manager

14

ired - During
n

harges

Monthly Power
Generation Plan

1st of every month

Shift Incharge (Engineer)

Daily

Shift Incharge (Engine

Sr. Manager / Manage

17

Sr. Manager / Manager

Preventive Maintenance
Planning

rman

16

18

As and When Required - During


Shutdown

Process In charges

DRM Chairman

Shutdown Review
Meeting

Categories

S1:
Compliance

S2:
Understanding

S3:
Usage

S3:
Usage

S1:
Compliance

S2:
Understanding

S3:
Usage

S1:
Compliance

S2:
Understanding

S3:
Usage

S3:
Usage

S1:
Compliance

S2:
Understanding

S3:
Usage

S1:
Compliance

S2:
Understanding

S3:
Usage

S1:
Compliance

S2:
Understanding

S3:
Usage

S1:
Compliance

S1:
Compliance

S2:
Understanding

S3:
Usage

S1:
Compliance

S2:
Understanding

S3:
Usage

S3:
Usage

S1:
Compliance

S2:
Understanding

S3:
Usage

S1:
Compliance

S2:
Understanding

S2:
Understanding

S3:
Usage

S1:
Compliance

S2:
Understanding

S3:
Usage

S1:
Compliance

S2:
Understanding

S2:
Understanding

S3:
Usage

S1:
Compliance

S2:
Understanding

S3:
Usage

S1:
Compliance

S2:
Understanding

S2:
Understanding

S3:
Usage

S1:
Compliance

S2:
Understanding

S3:
Usage

S1:
Compliance

S2:
Understanding

S3:
Usage

S1:
Compliance

S2:
Understanding

S3:
Usage

S1:
Compliance

S1:
Compliance

S2:
Understanding

S3:
Usage

Name of Area / Department being Audited: Operations / Maintenance

Name of Area / Department Manager: Respective Manager

Name of Individuals Audited:

OBSERVATIONS
(Based on ACTUAL observations and Interviews, use the following quest
best represent the level of compliance/understanding/usage of

Whether template is filled completely?


Whether all concerned people have signed the template?
Whether any remark mentioned on the sheet?
Why do we need to fill the sheet?
Whether all blocks has been completely understood by shift incharge?
Whether the complete sheet is understood by the shift incharge?
How shift handover process has been improved?
Have the information flow became more effective with the templates?

Have you used the system to achieve the KPI's?


Has all the information has been shared during shift handover.?
Whether template is filled completely?
Whether all concerned people have signed the template?
Whether any remark mentioned on the sheet?
Why do we need to fill the sheet?
Whether all blocks has been completely understood by shift incharge?
Whether the complete sheet is understood by the shift incharge?
How shift handover process has been improved?
Have the information flow became more effective with the templates?
Have you used the system to achieve the KPI's?
Has all the information has been shared during shift handover.?
Is line walk schedule prepared? Is it done as per schedule.?
Is line walk log sheet is filled properly and reported as on the day?
Is line walk is done properly by the assigned person?
Are all the codes underdstood by the person.?

Is the line walk personnel understood the scope or area where he has t
What is the benfit of doing line walk?
Is line walk log sheet is reviewed by HOD?

Are task has been assigned with its priority?


Have you used the system to achieve the KPI's?
Are all the high priority issues has been closed?
Did meeting start on time? Are all members reached at time?
Is Terms of reference & Agenda is prepared and followed?

Was the necessary pre-work done by participants i.e. Daily Stats sourc
solutions identified prior to meeting commencing?
Is Terms of reference understood by all DRM Members?
Are all members aware of their roles in the meeting?.
Do DRM Members understand the importance of the meeting.?

Were variances identified and corrective actions recorded in Action Pla

Were actions, responsibilities and due dates assigned on the Action Pla
Have you used the system to achieve the KPI's?

Were the documentated action logs is reviewed and points are being cl
Did Template mailed or received on time?

Is generation is so planned that all department have sufficient power to


is there any remark generated against short fall in supply
Did template is understood to all/
Do everybody know about such planning?
Did this planning is conveyed to all department

Any action taken against short fall in supply against requirement.


Did daily study about GAP in supply and demand happen?

Have you used the system to achieve the KPI's?


Export is reduceding or not.

Have all the details related to breakdown are being filled by Operations

Have all the details related to Breakdown are being filled by Maintenanc
Did you review breakdowns for previous day ?
What benefit is expected by recording breakdowns? Do you think both
should get involved in recording of Breakdown slips?

Please give us reason why breakdown start time plus job start and finis

What analysis of information about breakdowns captured should be do

Demonstrate how you are doing basic Root Cause Analysis by using th

Have you discussed with your manager on action points based on your
suggestions/message/pending jobs in breakdown slip?
Have you used the system to achieve the KPI's?
What are the actions taken based on issues like spare information, high
resolution of breakdown etc.

Have all the details related to breakdown are being filled by Operations

Have all the details related to Breakdown are being filled by Maintenanc
Did you review breakdowns for previous day ?
What benefit is expected by recording breakdowns? Do you think both
should get involved in recording of Breakdown slips?

Please give us reason why breakdown start time plus job start and finis

What analysis of information about breakdowns captured should be do

Demonstrate how you are doing basic Root Cause Analysis by using th

Have you discussed with your manager on action points based on your
suggestions/message/pending jobs in breakdown slip?
Have you used the system to achieve the KPI's?
What are the actions taken based on issues like spare information, high
resolution of breakdown etc.

Have all the details related to breakdown are being filled by data feedin

Have all the details related to Breakdown are being correctly filled by th
Did you review the data of breakdowns slip before feeding ?
What benefit is expected by recording breakdowns? Do you think both
should get involved in recording of Breakdown slips?

Please give us reason why breakdown start time plus job start and finis

What analysis of information about breakdowns captured should be do

Demonstrate how you are doing basic Root Cause Analysis by using th
Have you used the system to achieve the KPI's?

Have you discussed with your manager on action points based on your
suggestions/message/pending jobs in breakdown slip?
What are the actions taken based on issues like spare information, high
resolution of breakdown etc.

Have all the details related to breakdown are being filled by data feedin

Have all the details related to Breakdown are being correctly filled by th
Did you review the data of breakdowns slip before feeding ?
What benefit is expected by recording breakdowns? Do you think both
should get involved in recording of Breakdown slips?

Please give us reason why breakdown start time plus job start and finis

What analysis of information about breakdowns captured should be do

Demonstrate how you are doing basic Root Cause Analysis by using th

Have you used the system to achieve the KPI's?


Have you discussed with your manager on action points based on your
suggestions/message/pending jobs in breakdown slip?
What are the actions taken based on issues like spare information, high
resolution of breakdown etc.
Whether template is filled completely ?
Whether all the inter departmental jobs are incorporated?

Availability of spares and other critical equipment is done as per job sco
Why do we need to fill the sheet?
Whether all blocks has been completely understood by HOD?

Whether they are aware of how to track the system?


Whether the concerned people planning daily jobs as per Schedule?
Have you used the system to achieve the KPI's?

Whether the information flow became more effective with the template
Has the information helped in taking pro active actions?
Whether template is filled completely ?
Whether all the inter departmental jobs are incorporated?

Availability of spares and other critical equipment is done as per job sco
Why do we need to fill the sheet?
Whether all blocks has been completely understood by HOD?
Whether they are aware of how to track the system?
Whether the concerned people planning daily jobs as per Schedule?
Have you used the system to achieve the KPI's?

Whether the information flow became more effective with the template
Has the information helped in taking pro active actions?
Are you carrying out root cause analysis as per RCA Policy?

Are you maintaning a RCA documentation file? Please show the RCA lo
Does "5 why" format exist and used please show.
What is the need for RCA policy?

Why do we need to Maintain RCA log book. ?


What is the benefit of using 5 Why template ?

Show if any repetitive problem were corrected by using root cause anal
Please provide one example based on last RCA done?

Have you documented the actions and can you link the actions to the im
Are you carrying out root cause analysis as per RCA Policy?

Are you maintaning a RCA documentation file? Please show the RCA lo
Does "5 why" format exist and used please show.
What is the need for RCA policy?
Why do we need to Maintain RCA log book. ?
What is the benefit of using 5 Why template ?

Show if any repetitive problem were corrected by using root cause anal
Please provide one example based on last RCA done?
Have you used the system to achieve the KPI's?

Have you documented the actions and can you link the actions to the im
Whether the Job checking is done as per shut down planning?
Whether the job checking is done by the team formed?
Whether remarks are mentioned against poor quality of jobs?
Whether the team Is aware of importance of job quality checking?

Whether all jobs compered were completely understood ?


Whether they are aware of how to do job checking?
Whether the frequency of equipment failure reduced post light up?
Have you used the system to achieve the KPI's?
Whether Any counter measures taken to avoid critical issues.?

Whether the Job checking is done as per shut down planning?


Whether the job checking is done by the team formed?
Whether remarks are mentioned against poor quality of jobs?
Whether the team Is aware of importance of job quality checking?
Whether all jobs compered were completely understood ?
Whether they are aware of how to do job checking?
Whether the frequency of equipment failure reduced post light up?
Whether Any counter measures taken to avoid critical issues.?
Have you used the system to achieve the KPI's?
Is PM Schedule followed regularly?
Is PM Checklist completely filled by the Engineers?
Is any remarks mentioned against the work done?

Why do we need to follow the PM Plan?

Whether all plans & Checklist has been completely understood by conc
Whether concern people know how to perform PM?
Has the equipment life been improved with this plan?
Has the PM Plan helped in improving MTBF?
Have you used the system to achieve the KPI's?
Is monthly generation plan prepared by the department?
Is monthly production plan of SID taken into account?
Is the plan ready on the first working day of the month?
Why do we need to make the monthly generation plan?

Is the power gneration plan has been completely understood by the con
Whether sponge iron department head was aware of the planning?
Has the overall power generation has increased??

Has the monthly generation plan helped in better weekly and daily pow
Have you used the system to achieve the KPI's?
Was the generation plan on track??
Did meeting start on time? Are all members reached at time?
Is Terms of reference & Agenda is prepared and followed?

Was the necessary pre-work done by participants i.e. Daily work done ,

Do the responsible members understand the importance of daily shutdo


Are all members aware of their roles in the meeting?.

Availability of spares, castable was checked as per the shutdown plan?

Were variances identified and corrective actions recorded in Action Pla

Were actions, responsibilities and due dates assigned on the Action Pla
Have you used the system to achieve the KPI's?

Were the documented action logs is reviewed and points are being clos

Total number of Sys

AUDIT BY

AUDIT DATE

Rating Scale

0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)

Supervisory Actions Required


to Enable Improvement /
Sustain

3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)

1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)

0
(NIL)
1
(PARTIAL)
3
(HIGH)

0
(NIL)

1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)

3
(HIGH)
0
(NIL)

1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)

3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)

1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)

3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
1
(PARTIAL)
3
(HIGH)
1
(PARTIAL)
1
(PARTIAL)

1
(PARTIAL)
1
(PARTIAL)
0
(NIL)
0
(NIL)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
1
(PARTIAL)
1
(PARTIAL)
1
(PARTIAL)
1
(PARTIAL)
0
(NIL)
0
(NIL)
0
(NIL)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)

1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)

0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)

3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)

5
18

TOTAL COMPLIANCE
TOTAL UNDERSTANDING
TOTAL USAGE

Taskforce

27-Dec-14

Observed Current Rating for


this category
(Score: 0, 1 or 3)

REMAR

(Key in any remarks which justify the

This will be merge in th


3

KPI is not discussed in detail


1

template is not mailed to power pla


1

system is not us

It is not used

analysis is not done

analysis is not done

Analysis is in progress

Some daily Job is delayed in night shift

RCA is not used for problem rectificatio


1

Not Re

Not Re

it will be done after h

Not A

Not A

Plan vs Actual is not same and there is dela

87%
85%
46%

REMARKS

arks which justify the observed rating given to the auditee)

will be merge in the IMS from next week

sed in detail

mailed to power plant from ferro alloy dept. on time

system is not used to achiev KPI

It is not used to achieve KPI

layed in night shift

r problem rectification and problem correction

Not Required

Not Required

be done after hydro test for WHRB 4

Not Audited

Not Audited

same and there is delay in finishing job

ACTION PLAN
(Key in the required action that needs to be taken to address issues - th
must be done for System Elements with a yellow or red scores)

AGM operation is awared about this and he said okay he will ev


lock generation planning and other KPI in DRM action log sheet

a mail dropped to ferro alloy dept. from Mr. Kamlesh Paikra.

KPI and its correlation should be made such so that KPI could be achieved.

Training should be schedule for shift inchagre to use it.

Phase 1 and 2 should be merge in 1 BMS sheet.

it have effect on achieving the KPI

Sectional HOD should have to take responsibilty of RCA out come and
analysis

N
taken to address issues - this
th a yellow or red scores)

nd he said okay he will even


I in DRM action log sheet.

m Mr. Kamlesh Paikra.

so that KPI could be achieved.

hift inchagre to use it.

BMS sheet.

sibilty of RCA out come and

Sr. No.
System Elements
Accountable

Responsible

FREQUENCY

Shift Handover and log


sheet - Phase 1

Sr. Manager / Manager

Shift Incharge (Engineer)

Daily

2
Shift Handover and log
sheet - Phase 2

Sr. Manager / Manager

Shift Incharge (Engineer)


Daily

Line Walk - Phase

General Manager (Maintenance)

Managers

Weekly

Shift I

Sr.

4
Daily Review Meeting

DRM Chairman

All DRM Members


Daily

Power Plant requirement


and fullfillment

AGM (operation)

Electrical HOD

Daily

General Man

Dai
Daily

Electric

Breakdown Slip (Phase 1)

Engineers

AGM (op

Power Plant requirement


and fullfillment

Managers

Breakdown Slip (Phase 2)

Managers

Engineers

Daily

Breakdown Management
System (BMS) - Phase 1

Managers

Engineers

Monday, Wednesday, Friday

GM

Monday, Wednesday, Friday

Shut Down Job Scoping


Phase 1

nd When Required

Managers

10

Engineers

Breakdown Management
System (BMS) - Phase 2

partmental HOD

Monday

Shut Down Job Scoping


Kiln Phase 2

12

Root Cause Analysis Phase 1

Weekly

nager / Manager

As and When Required

Departmental HOD

As and When R

Departmental

GM

11

GM

Shut Down Job Scoping


Phase 1

l - General Manager

10

Job Quality Check Phase 1

en Required

Weekly

Sr.Manager / Manager

14

arge (Engineer)

Root Cause Analysis Phase 2

Weekly

Sr.Manager / Mana

Sectional - General M

13

Sectional - General Manager

Root Cause Analysis Phase 1

ger / Manager

12

Job Quality Check Phase 2

16

Preventive Maintenance
Planning

Daily

rge (Engineer)

As When Required

Shift In charge (Engineer)

As When Require

Shift Incharge (Engin

Sr. Manager / Mana

15

Sr. Manager / Manager

Job Quality Check Phase 1

ger / Manager

14

ired - During
n

harges

Monthly Power
Generation Plan

1st of every month

Shift Incharge (Engineer)

Daily

Shift Incharge (Engine

Sr. Manager / Manage

17

Sr. Manager / Manager

Preventive Maintenance
Planning

rman

16

18

As and When Required - During


Shutdown

Process In charges

DRM Chairman

Shutdown Review
Meeting

Categories

S1:
Compliance

S2:
Understanding

S3:
Usage

S3:
Usage

S1:
Compliance

S2:
Understanding

S3:
Usage

S1:
Compliance

S2:
Understanding

S3:
Usage

S3:
Usage

S1:
Compliance

S2:
Understanding

S3:
Usage

S1:
Compliance

S2:
Understanding

S3:
Usage

S1:
Compliance

S2:
Understanding

S3:
Usage

S1:
Compliance

S1:
Compliance

S2:
Understanding

S3:
Usage

S1:
Compliance

S2:
Understanding

S3:
Usage

S3:
Usage

S1:
Compliance

S2:
Understanding

S3:
Usage

S1:
Compliance

S2:
Understanding

S2:
Understanding

S3:
Usage

S1:
Compliance

S2:
Understanding

S3:
Usage

S1:
Compliance

S2:
Understanding

S2:
Understanding

S3:
Usage

S1:
Compliance

S2:
Understanding

S3:
Usage

S1:
Compliance

S2:
Understanding

S2:
Understanding

S3:
Usage

S1:
Compliance

S2:
Understanding

S3:
Usage

S1:
Compliance

S2:
Understanding

S3:
Usage

S1:
Compliance

S2:
Understanding

S3:
Usage

S1:
Compliance

S1:
Compliance

S2:
Understanding

S3:
Usage

Name of Area / Department being Audited: Operations / Maintenance

Name of Area / Department Manager: Respective Manager

Name of Individuals Audited:

OBSERVATIONS
(Based on ACTUAL observations and Interviews, use the following quest
best represent the level of compliance/understanding/usage of

Whether template is filled completely?


Whether all concerned people have signed the template?
Whether any remark mentioned on the sheet?
Why do we need to fill the sheet?
Whether all blocks has been completely understood by shift incharge?
Whether the complete sheet is understood by the shift incharge?
How shift handover process has been improved?
Have the information flow became more effective with the templates?

Have you used the system to achieve the KPI's?


Has all the information has been shared during shift handover.?
Whether template is filled completely?
Whether all concerned people have signed the template?
Whether any remark mentioned on the sheet?
Why do we need to fill the sheet?
Whether all blocks has been completely understood by shift incharge?
Whether the complete sheet is understood by the shift incharge?
How shift handover process has been improved?
Have the information flow became more effective with the templates?
Have you used the system to achieve the KPI's?
Has all the information has been shared during shift handover.?
Is line walk schedule prepared? Is it done as per schedule.?
Is line walk log sheet is filled properly and reported as on the day?
Is line walk is done properly by the assigned person?
Are all the codes underdstood by the person.?

Is the line walk personnel understood the scope or area where he has t
What is the benfit of doing line walk?
Is line walk log sheet is reviewed by HOD?

Are task has been assigned with its priority?


Have you used the system to achieve the KPI's?
Are all the high priority issues has been closed?
Did meeting start on time? Are all members reached at time?
Is Terms of reference & Agenda is prepared and followed?

Was the necessary pre-work done by participants i.e. Daily Stats sourc
solutions identified prior to meeting commencing?
Is Terms of reference understood by all DRM Members?
Are all members aware of their roles in the meeting?.
Do DRM Members understand the importance of the meeting.?

Were variances identified and corrective actions recorded in Action Pla

Were actions, responsibilities and due dates assigned on the Action Pla
Have you used the system to achieve the KPI's?

Were the documentated action logs is reviewed and points are being cl
Did Template mailed or received on time?

Is generation is so planned that all department have sufficient power to


is there any remark generated against short fall in supply
Did template is understood to all/
Do everybody know about such planning?
Did this planning is conveyed to all department

Any action taken against short fall in supply against requirement.


Did daily study about GAP in supply and demand happen?

Have you used the system to achieve the KPI's?


Export is reduceding or not.

Have all the details related to breakdown are being filled by Operations

Have all the details related to Breakdown are being filled by Maintenanc
Did you review breakdowns for previous day ?
What benefit is expected by recording breakdowns? Do you think both
should get involved in recording of Breakdown slips?

Please give us reason why breakdown start time plus job start and finis

What analysis of information about breakdowns captured should be do

Demonstrate how you are doing basic Root Cause Analysis by using th

Have you discussed with your manager on action points based on your
suggestions/message/pending jobs in breakdown slip?
Have you used the system to achieve the KPI's?
What are the actions taken based on issues like spare information, high
resolution of breakdown etc.

Have all the details related to breakdown are being filled by Operations

Have all the details related to Breakdown are being filled by Maintenanc
Did you review breakdowns for previous day ?
What benefit is expected by recording breakdowns? Do you think both
should get involved in recording of Breakdown slips?

Please give us reason why breakdown start time plus job start and finis

What analysis of information about breakdowns captured should be do

Demonstrate how you are doing basic Root Cause Analysis by using th

Have you discussed with your manager on action points based on your
suggestions/message/pending jobs in breakdown slip?
Have you used the system to achieve the KPI's?
What are the actions taken based on issues like spare information, high
resolution of breakdown etc.

Have all the details related to breakdown are being filled by data feedin

Have all the details related to Breakdown are being correctly filled by th
Did you review the data of breakdowns slip before feeding ?
What benefit is expected by recording breakdowns? Do you think both
should get involved in recording of Breakdown slips?

Please give us reason why breakdown start time plus job start and finis

What analysis of information about breakdowns captured should be do

Demonstrate how you are doing basic Root Cause Analysis by using th
Have you used the system to achieve the KPI's?

Have you discussed with your manager on action points based on your
suggestions/message/pending jobs in breakdown slip?
What are the actions taken based on issues like spare information, high
resolution of breakdown etc.

Have all the details related to breakdown are being filled by data feedin

Have all the details related to Breakdown are being correctly filled by th
Did you review the data of breakdowns slip before feeding ?
What benefit is expected by recording breakdowns? Do you think both
should get involved in recording of Breakdown slips?

Please give us reason why breakdown start time plus job start and finis

What analysis of information about breakdowns captured should be do

Demonstrate how you are doing basic Root Cause Analysis by using th

Have you used the system to achieve the KPI's?


Have you discussed with your manager on action points based on your
suggestions/message/pending jobs in breakdown slip?
What are the actions taken based on issues like spare information, high
resolution of breakdown etc.
Whether template is filled completely ?
Whether all the inter departmental jobs are incorporated?

Availability of spares and other critical equipment is done as per job sco
Why do we need to fill the sheet?
Whether all blocks has been completely understood by HOD?

Whether they are aware of how to track the system?


Whether the concerned people planning daily jobs as per Schedule?
Have you used the system to achieve the KPI's?

Whether the information flow became more effective with the template
Has the information helped in taking pro active actions?
Whether template is filled completely ?
Whether all the inter departmental jobs are incorporated?

Availability of spares and other critical equipment is done as per job sco
Why do we need to fill the sheet?
Whether all blocks has been completely understood by HOD?
Whether they are aware of how to track the system?
Whether the concerned people planning daily jobs as per Schedule?
Have you used the system to achieve the KPI's?

Whether the information flow became more effective with the template
Has the information helped in taking pro active actions?
Are you carrying out root cause analysis as per RCA Policy?

Are you maintaning a RCA documentation file? Please show the RCA lo
Does "5 why" format exist and used please show.
What is the need for RCA policy?

Why do we need to Maintain RCA log book. ?


What is the benefit of using 5 Why template ?

Show if any repetitive problem were corrected by using root cause anal
Please provide one example based on last RCA done?

Have you documented the actions and can you link the actions to the im
Are you carrying out root cause analysis as per RCA Policy?

Are you maintaning a RCA documentation file? Please show the RCA lo
Does "5 why" format exist and used please show.
What is the need for RCA policy?
Why do we need to Maintain RCA log book. ?
What is the benefit of using 5 Why template ?

Show if any repetitive problem were corrected by using root cause anal
Please provide one example based on last RCA done?
Have you used the system to achieve the KPI's?

Have you documented the actions and can you link the actions to the im
Whether the Job checking is done as per shut down planning?
Whether the job checking is done by the team formed?
Whether remarks are mentioned against poor quality of jobs?
Whether the team Is aware of importance of job quality checking?

Whether all jobs compered were completely understood ?


Whether they are aware of how to do job checking?
Whether the frequency of equipment failure reduced post light up?
Have you used the system to achieve the KPI's?
Whether Any counter measures taken to avoid critical issues.?

Whether the Job checking is done as per shut down planning?


Whether the job checking is done by the team formed?
Whether remarks are mentioned against poor quality of jobs?
Whether the team Is aware of importance of job quality checking?
Whether all jobs compered were completely understood ?
Whether they are aware of how to do job checking?
Whether the frequency of equipment failure reduced post light up?
Whether Any counter measures taken to avoid critical issues.?
Have you used the system to achieve the KPI's?
Is PM Schedule followed regularly?
Is PM Checklist completely filled by the Engineers?
Is any remarks mentioned against the work done?

Why do we need to follow the PM Plan?

Whether all plans & Checklist has been completely understood by conc
Whether concern people know how to perform PM?
Has the equipment life been improved with this plan?
Has the PM Plan helped in improving MTBF?
Have you used the system to achieve the KPI's?
Is monthly generation plan prepared by the department?
Is monthly production plan of SID taken into account?
Is the plan ready on the first working day of the month?
Why do we need to make the monthly generation plan?

Is the power gneration plan has been completely understood by the con
Whether sponge iron department head was aware of the planning?
Has the overall power generation has increased??

Has the monthly generation plan helped in better weekly and daily pow
Have you used the system to achieve the KPI's?
Was the generation plan on track??
Did meeting start on time? Are all members reached at time?
Is Terms of reference & Agenda is prepared and followed?

Was the necessary pre-work done by participants i.e. Daily work done ,

Do the responsible members understand the importance of daily shutdo


Are all members aware of their roles in the meeting?.

Availability of spares, castable was checked as per the shutdown plan?

Were variances identified and corrective actions recorded in Action Pla

Were actions, responsibilities and due dates assigned on the Action Pla
Have you used the system to achieve the KPI's?

Were the documented action logs is reviewed and points are being clos

Total number of Sys

AUDIT BY

AUDIT DATE

Rating Scale

0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)

Supervisory Actions Required


to Enable Improvement /
Sustain

3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)

1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)

0
(NIL)
1
(PARTIAL)
3
(HIGH)

0
(NIL)

1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)

3
(HIGH)
0
(NIL)

1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)

3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)

1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)

3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
1
(PARTIAL)
3
(HIGH)
1
(PARTIAL)
1
(PARTIAL)

1
(PARTIAL)
1
(PARTIAL)
0
(NIL)
0
(NIL)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
1
(PARTIAL)
1
(PARTIAL)
1
(PARTIAL)
1
(PARTIAL)
0
(NIL)
0
(NIL)
0
(NIL)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)

1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)

0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)

3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)

9
18

TOTAL COMPLIANCE
TOTAL UNDERSTANDING
TOTAL USAGE

Taskforce

3-Jan-15

Observed Current Rating for


this category
(Score: 0, 1 or 3)

REMAR

(Key in any remarks which justify the

usage is improved because the pu


fulfilled

usage is improved because the pu


fulfilled
3

usage is improved because the pu


fulfilled
3

weekly analysis of line walk data


breakdown al
3

KPI is discussed and now lock in D


each job of DRM action log is com
3

Export is minimized and now from


basis of export is done by MR. R K
1

BMS need correction because there are few


BFP 1 data but break down is minimized
down

Data needs to be accurate


1

need few checking of data regarding BFP 1


it is fulfilled

need few checking of data regarding BFP 1


it is fulfilled
1

There is lack clarity regaring the RCA Policy


1

system is able to achieve KPI but root caus

Not Re

Not Re

Not A

Not A

not re
0

not re
0

93%
93%
63%

REMARKS

arks which justify the observed rating given to the auditee)

ed because the purpose of its implementation is

ed because the purpose of its implementation is

ed because the purpose of its implementation is

is of line walk data is done by AGM operation and


breakdown also minimized.

and now lock in DRM action log also and almost


action log is completed.

zed and now from next week daily analysis on hourly


done by MR. R K shakar.

n because there are few detail which have to be checked regarding


ak down is minimized and from date 22-12-2014 no major break
down occur

curate

data regarding BFP 1 .but break down is minimized so purpose of

data regarding BFP 1 .but break down is minimized so purpose of

egaring the RCA Policy

ieve KPI but root cause analysis should be done on weekly basis.

Not Required

Not Required

Not Audited

Not Audited

not required

not required

ACTION PLAN
(Key in the required action that needs to be taken to address issues - th
must be done for System Elements with a yellow or red scores)

to make more effective communiation sheet is now filled in capit


letter and it is implemented

to make more effective communiation sheet is now filled in capit


letter and it is implemented

now weekly analysis of DRM action log is done by manager


operation.

There is planning to install auto generated chart to show gap in


supply and demand

it is conveyed to maintenace staff to do weekly analysis of all BMS slip so tha


break down can be minimized

N
taken to address issues - this
th a yellow or red scores)

sheet is now filled in capital

sheet is now filled in capital

g is done by manager

ated chart to show gap in

y analysis of all BMS slip so that


inimized

Sr. No.
System Elements
Accountable

Responsible

FREQUENCY

Shift Handover and log


sheet - Phase 1

Sr. Manager / Manager

Shift Incharge (Engineer)

Daily

2
Shift Handover and log
sheet - Phase 2

Sr. Manager / Manager

Shift Incharge (Engineer)


Daily

Line Walk - Phase

General Manager (Maintenance)

Managers

Weekly

Shift I

Sr.

4
Daily Review Meeting

DRM Chairman

All DRM Members


Daily

Power Plant requirement


and fullfillment

AGM (operation)

Electrical HOD

Daily

General Man

Dai
Daily

Electric

Breakdown Slip (Phase 1)

Engineers

AGM (op

Power Plant requirement


and fullfillment

Managers

Breakdown Slip (Phase 2)

Managers

Engineers

Daily

Breakdown Management
System (BMS) - Phase 1

Managers

Engineers

Monday, Wednesday, Friday

GM

Monday, Wednesday, Friday

Shut Down Job Scoping


Phase 1

nd When Required

Managers

10

Engineers

Breakdown Management
System (BMS) - Phase 2

partmental HOD

Monday

Shut Down Job Scoping


Kiln Phase 2

12

Root Cause Analysis Phase 1

Weekly

nager / Manager

As and When Required

Departmental HOD

As and When R

Departmental

GM

11

GM

Shut Down Job Scoping


Phase 1

l - General Manager

10

Job Quality Check Phase 1

en Required

Weekly

Sr.Manager / Manager

14

arge (Engineer)

Root Cause Analysis Phase 2

Weekly

Sr.Manager / Mana

Sectional - General M

13

Sectional - General Manager

Root Cause Analysis Phase 1

ger / Manager

12

Job Quality Check Phase 2

16

Preventive Maintenance
Planning

Daily

rge (Engineer)

As When Required

Shift In charge (Engineer)

As When Require

Shift Incharge (Engin

Sr. Manager / Mana

15

Sr. Manager / Manager

Job Quality Check Phase 1

ger / Manager

14

ired - During
n

harges

Monthly Power
Generation Plan

1st of every month

Shift Incharge (Engineer)

Daily

Shift Incharge (Engine

Sr. Manager / Manage

17

Sr. Manager / Manager

Preventive Maintenance
Planning

rman

16

18

As and When Required - During


Shutdown

Process In charges

DRM Chairman

Shutdown Review
Meeting

Categories

S1:
Compliance

S2:
Understanding

S3:
Usage

S3:
Usage

S1:
Compliance

S2:
Understanding

S3:
Usage

S1:
Compliance

S2:
Understanding

S3:
Usage

S3:
Usage

S1:
Compliance

S2:
Understanding

S3:
Usage

S1:
Compliance

S2:
Understanding

S3:
Usage

S1:
Compliance

S2:
Understanding

S3:
Usage

S1:
Compliance

S1:
Compliance

S2:
Understanding

S3:
Usage

S1:
Compliance

S2:
Understanding

S3:
Usage

S3:
Usage

S1:
Compliance

S2:
Understanding

S3:
Usage

S1:
Compliance

S2:
Understanding

S2:
Understanding

S3:
Usage

S1:
Compliance

S2:
Understanding

S3:
Usage

S1:
Compliance

S2:
Understanding

S2:
Understanding

S3:
Usage

S1:
Compliance

S2:
Understanding

S3:
Usage

S1:
Compliance

S2:
Understanding

S2:
Understanding

S3:
Usage

S1:
Compliance

S2:
Understanding

S3:
Usage

S1:
Compliance

S2:
Understanding

S3:
Usage

S1:
Compliance

S2:
Understanding

S3:
Usage

S1:
Compliance

S1:
Compliance

S2:
Understanding

S3:
Usage

Name of Area / Department being Audited: Operations / Maintenance

Name of Area / Department Manager: Respective Manager

Name of Individuals Audited:

OBSERVATIONS
(Based on ACTUAL observations and Interviews, use the following quest
best represent the level of compliance/understanding/usage of

Whether template is filled completely?


Whether all concerned people have signed the template?
Whether any remark mentioned on the sheet?
Why do we need to fill the sheet?
Whether all blocks has been completely understood by shift incharge?
Whether the complete sheet is understood by the shift incharge?
How shift handover process has been improved?
Have the information flow became more effective with the templates?

Have you used the system to achieve the KPI's?


Has all the information has been shared during shift handover.?
Whether template is filled completely?
Whether all concerned people have signed the template?
Whether any remark mentioned on the sheet?
Why do we need to fill the sheet?
Whether all blocks has been completely understood by shift incharge?
Whether the complete sheet is understood by the shift incharge?
How shift handover process has been improved?
Have the information flow became more effective with the templates?
Have you used the system to achieve the KPI's?
Has all the information has been shared during shift handover.?
Is line walk schedule prepared? Is it done as per schedule.?
Is line walk log sheet is filled properly and reported as on the day?
Is line walk is done properly by the assigned person?
Are all the codes underdstood by the person.?

Is the line walk personnel understood the scope or area where he has t
What is the benfit of doing line walk?
Is line walk log sheet is reviewed by HOD?

Are task has been assigned with its priority?


Have you used the system to achieve the KPI's?
Are all the high priority issues has been closed?
Did meeting start on time? Are all members reached at time?
Is Terms of reference & Agenda is prepared and followed?

Was the necessary pre-work done by participants i.e. Daily Stats sourc
solutions identified prior to meeting commencing?
Is Terms of reference understood by all DRM Members?
Are all members aware of their roles in the meeting?.
Do DRM Members understand the importance of the meeting.?

Were variances identified and corrective actions recorded in Action Pla

Were actions, responsibilities and due dates assigned on the Action Pla
Have you used the system to achieve the KPI's?

Were the documentated action logs is reviewed and points are being cl
Did Template mailed or received on time?

Is generation is so planned that all department have sufficient power to


is there any remark generated against short fall in supply
Did template is understood to all/
Do everybody know about such planning?
Did this planning is conveyed to all department

Any action taken against short fall in supply against requirement.


Did daily study about GAP in supply and demand happen?

Have you used the system to achieve the KPI's?


Export is reduceding or not.

Have all the details related to breakdown are being filled by Operations

Have all the details related to Breakdown are being filled by Maintenanc
Did you review breakdowns for previous day ?
What benefit is expected by recording breakdowns? Do you think both
should get involved in recording of Breakdown slips?

Please give us reason why breakdown start time plus job start and finis

What analysis of information about breakdowns captured should be do

Demonstrate how you are doing basic Root Cause Analysis by using th

Have you discussed with your manager on action points based on your
suggestions/message/pending jobs in breakdown slip?
Have you used the system to achieve the KPI's?
What are the actions taken based on issues like spare information, high
resolution of breakdown etc.

Have all the details related to breakdown are being filled by Operations

Have all the details related to Breakdown are being filled by Maintenanc
Did you review breakdowns for previous day ?
What benefit is expected by recording breakdowns? Do you think both
should get involved in recording of Breakdown slips?

Please give us reason why breakdown start time plus job start and finis

What analysis of information about breakdowns captured should be do

Demonstrate how you are doing basic Root Cause Analysis by using th

Have you discussed with your manager on action points based on your
suggestions/message/pending jobs in breakdown slip?
Have you used the system to achieve the KPI's?
What are the actions taken based on issues like spare information, high
resolution of breakdown etc.

Have all the details related to breakdown are being filled by data feedin

Have all the details related to Breakdown are being correctly filled by th
Did you review the data of breakdowns slip before feeding ?
What benefit is expected by recording breakdowns? Do you think both
should get involved in recording of Breakdown slips?

Please give us reason why breakdown start time plus job start and finis

What analysis of information about breakdowns captured should be do

Demonstrate how you are doing basic Root Cause Analysis by using th
Have you used the system to achieve the KPI's?

Have you discussed with your manager on action points based on your
suggestions/message/pending jobs in breakdown slip?
What are the actions taken based on issues like spare information, high
resolution of breakdown etc.

Have all the details related to breakdown are being filled by data feedin

Have all the details related to Breakdown are being correctly filled by th
Did you review the data of breakdowns slip before feeding ?
What benefit is expected by recording breakdowns? Do you think both
should get involved in recording of Breakdown slips?

Please give us reason why breakdown start time plus job start and finis

What analysis of information about breakdowns captured should be do

Demonstrate how you are doing basic Root Cause Analysis by using th

Have you used the system to achieve the KPI's?


Have you discussed with your manager on action points based on your
suggestions/message/pending jobs in breakdown slip?
What are the actions taken based on issues like spare information, high
resolution of breakdown etc.
Whether template is filled completely ?
Whether all the inter departmental jobs are incorporated?

Availability of spares and other critical equipment is done as per job sco
Why do we need to fill the sheet?
Whether all blocks has been completely understood by HOD?

Whether they are aware of how to track the system?


Whether the concerned people planning daily jobs as per Schedule?
Have you used the system to achieve the KPI's?

Whether the information flow became more effective with the template
Has the information helped in taking pro active actions?
Whether template is filled completely ?
Whether all the inter departmental jobs are incorporated?

Availability of spares and other critical equipment is done as per job sco
Why do we need to fill the sheet?
Whether all blocks has been completely understood by HOD?
Whether they are aware of how to track the system?
Whether the concerned people planning daily jobs as per Schedule?
Have you used the system to achieve the KPI's?

Whether the information flow became more effective with the template
Has the information helped in taking pro active actions?
Are you carrying out root cause analysis as per RCA Policy?

Are you maintaning a RCA documentation file? Please show the RCA lo
Does "5 why" format exist and used please show.
What is the need for RCA policy?

Why do we need to Maintain RCA log book. ?


What is the benefit of using 5 Why template ?

Show if any repetitive problem were corrected by using root cause anal
Please provide one example based on last RCA done?

Have you documented the actions and can you link the actions to the im
Are you carrying out root cause analysis as per RCA Policy?

Are you maintaning a RCA documentation file? Please show the RCA lo
Does "5 why" format exist and used please show.
What is the need for RCA policy?
Why do we need to Maintain RCA log book. ?
What is the benefit of using 5 Why template ?

Show if any repetitive problem were corrected by using root cause anal
Please provide one example based on last RCA done?
Have you used the system to achieve the KPI's?

Have you documented the actions and can you link the actions to the im
Whether the Job checking is done as per shut down planning?
Whether the job checking is done by the team formed?
Whether remarks are mentioned against poor quality of jobs?
Whether the team Is aware of importance of job quality checking?

Whether all jobs compered were completely understood ?


Whether they are aware of how to do job checking?
Whether the frequency of equipment failure reduced post light up?
Have you used the system to achieve the KPI's?
Whether Any counter measures taken to avoid critical issues.?

Whether the Job checking is done as per shut down planning?


Whether the job checking is done by the team formed?
Whether remarks are mentioned against poor quality of jobs?
Whether the team Is aware of importance of job quality checking?
Whether all jobs compered were completely understood ?
Whether they are aware of how to do job checking?
Whether the frequency of equipment failure reduced post light up?
Whether Any counter measures taken to avoid critical issues.?
Have you used the system to achieve the KPI's?
Is PM Schedule followed regularly?
Is PM Checklist completely filled by the Engineers?
Is any remarks mentioned against the work done?

Why do we need to follow the PM Plan?

Whether all plans & Checklist has been completely understood by conc
Whether concern people know how to perform PM?
Has the equipment life been improved with this plan?
Has the PM Plan helped in improving MTBF?
Have you used the system to achieve the KPI's?
Is monthly generation plan prepared by the department?
Is monthly production plan of SID taken into account?
Is the plan ready on the first working day of the month?
Why do we need to make the monthly generation plan?

Is the power gneration plan has been completely understood by the con
Whether sponge iron department head was aware of the planning?
Has the overall power generation has increased??

Has the monthly generation plan helped in better weekly and daily pow
Have you used the system to achieve the KPI's?
Was the generation plan on track??
Did meeting start on time? Are all members reached at time?
Is Terms of reference & Agenda is prepared and followed?

Was the necessary pre-work done by participants i.e. Daily work done ,

Do the responsible members understand the importance of daily shutdo


Are all members aware of their roles in the meeting?.

Availability of spares, castable was checked as per the shutdown plan?

Were variances identified and corrective actions recorded in Action Pla

Were actions, responsibilities and due dates assigned on the Action Pla
Have you used the system to achieve the KPI's?

Were the documented action logs is reviewed and points are being clos

Total number of Sys

AUDIT BY

AUDIT DATE

Rating Scale

0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)

Supervisory Actions Required


to Enable Improvement /
Sustain

3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)

1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)

0
(NIL)
1
(PARTIAL)
3
(HIGH)

0
(NIL)

1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)

3
(HIGH)
0
(NIL)

1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)

3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)

1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)

3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
1
(PARTIAL)
3
(HIGH)
1
(PARTIAL)
1
(PARTIAL)

1
(PARTIAL)
1
(PARTIAL)
0
(NIL)
0
(NIL)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
1
(PARTIAL)
1
(PARTIAL)
1
(PARTIAL)
1
(PARTIAL)
0
(NIL)
0
(NIL)
0
(NIL)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)

1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)

0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)

3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)

10
18

TOTAL COMPLIANCE
TOTAL UNDERSTANDING
TOTAL USAGE

Taskforce- Bhanupratap Singh

7-Jan-15

Observed Current Rating for


this category
(Score: 0, 1 or 3)

REMAR

(Key in any remarks which justify the

Not Audited

Export is minimized and now from


basis of export is done by MR. R K
1

maintained to all types b

maintained to all types b

need few checking of data regarding BFP 1


it is fulfilled

need few checking of data regarding BFP 1


it is fulfilled
1

system is able to achieve KPI but root caus

Not Re

Not Re

Not A

Not A

not re
0

not re
0

100%
92%
58%

REMARKS

arks which justify the observed rating given to the auditee)

zed and now from next week daily analysis on hourly


done by MR. R K shakar.

aintained to all types breakdown in BMS report

aintained to all types breakdown in BMS report

data regarding BFP 1 .but break down is minimized so purpose of

data regarding BFP 1 .but break down is minimized so purpose of

ieve KPI but root cause analysis should be done on weekly basis.

Not Required

Not Required

Not Audited

Not Audited

not required

not required

ACTION PLAN
(Key in the required action that needs to be taken to address issues - th
must be done for System Elements with a yellow or red scores)

N
taken to address issues - this
th a yellow or red scores)

Sr. No.
System Elements
Accountable

Responsible

FREQUENCY

Shift Handover - Phase 1

Sr. Manager / Manager

Shift Incharge (Engineer)

Daily

2
Shift Handover - Phase 2

Sr. Manager / Manager

Shift Incharge (Engineer)


Daily

Line Walk - Phase

General Manager (Maintenance)

Managers

Weekly

Shift I

Sr.

4
Daily Review Meeting

DRM Chairman

All DRM Members


Daily

Power Plant requirement


and fullfillment

AGM (operation)

Electrical HOD

Daily

General Man

Dai
Daily

Electric

Breakdown Slip (Phase 1)

Engineers

AGM (op

Power Plant requirement


and fullfillment

Managers

Breakdown Slip (Phase 2)

Managers

Engineers

Daily

Breakdown Management
System (BMS) - Phase 1

Managers

Engineers

Monday, Wednesday, Friday

GM

Monday, Wednesday, Friday

Shut Down Job Scoping


Phase 1

nd When Required

Managers

10

Engineers

Breakdown Management
System (BMS) - Phase 2

partmental HOD

Monday

Shut Down Job Scoping


Kiln Phase 2

12

Root Cause Analysis Phase 1

Weekly

ager / Manager

As and When Required

Departmental HOD

As and When R

Departmental

GM

11

GM

Shut Down Job Scoping


Phase 1

- General Manager

10

14

Sr.Manager / Manager
Weekly

Required

Job Quality Check -

ge (Engineer)

Root Cause Analysis Phase 2

Weekly

Sr.Manager / Man

Sectional - General

13

Sectional - General Manager

Root Cause Analysis Phase 1

er / Manager

12

(Engineer)

Job Quality Check Phase 2

As When Required

Shift In charge (Engineer)

As When Required

Shift Incharge (Engineer)

Sr. Manager / Manager

15

Sr. Manager / Manager

Job Quality Check Phase 1

/ Manager

14

- During

es

Monthly Power
Generation Plan

1st of every month

Shift Incharge (Engineer)

Daily

Shift Incharge (Engineer)

Sr. Manager / Manager

17

Sr. Manager / Manager

Preventive Maintenance
Planning

16

18

As and When Required - During


Shutdown

Process In charges

DRM Chairman

Shutdown Review
Meeting

Categories

S1:
Compliance

S2:
Understanding

S3:
Usage

S3:
Usage

S1:
Compliance

S2:
Understanding

S3:
Usage

S1:
Compliance

S2:
Understanding

S3:
Usage

S3:
Usage

S1:
Compliance

S2:
Understanding

S3:
Usage

S1:
Compliance

S2:
Understanding

S3:
Usage

S1:
Compliance

S2:
Understanding

S3:
Usage

S1:
Compliance

S1:
Compliance

S2:
Understanding

S3:
Usage

S1:
Compliance

S2:
Understanding

S3:
Usage

S3:
Usage

S1:
Compliance

S2:
Understanding

S3:
Usage

S1:
Compliance

S2:
Understanding

S2:
Understanding

S3:
Usage

S1:
Compliance

S2:
Understanding

S3:
Usage

S1:
Compliance

S2:
Understanding

S2:
Understanding

S3:
Usage

S1:
Compliance

S2:
Understanding

S3:
Usage

S1:
Compliance

S2:
Understanding

S3:
Usage

S1:
Compliance

S2:
Understanding

S3:
Usage

S1:
Compliance

S1:
Compliance

S2:
Understanding

S3:
Usage

S1:
Compliance

S2:
Understanding

S3:
Usage

S1:
Compliance

S1:
Compliance

S2:
Understanding

S3:
Usage

Name of Area / Department being Audited: Operations / Maintenance

Name of Area / Department Manager: Respective Manager

Name of Individuals Audited:

OBSERVATIONS
(Based on ACTUAL observations and Interviews, use the following quest
best represent the level of compliance/understanding/usage of

Whether template is filled completely?


Whether all concerned people have signed the template?
Whether any remark mentioned on the sheet?
Why do we need to fill the sheet?
Whether all blocks has been completely understood by shift incharge?
Whether the complete sheet is understood by the shift incharge?
How shift handover process has been improved?
Have the information flow became more effective with the templates?

Have you used the system to achieve the KPI's?


Has all the information has been shared during shift handover.?
Whether template is filled completely?
Whether all concerned people have signed the template?
Whether any remark mentioned on the sheet?
Why do we need to fill the sheet?
Whether all blocks has been completely understood by shift incharge?
Whether the complete sheet is understood by the shift incharge?
How shift handover process has been improved?
Have the information flow became more effective with the templates?
Have you used the system to achieve the KPI's?
Has all the information has been shared during shift handover.?
Is line walk schedule prepared? Is it done as per schedule.?
Is line walk log sheet is filled properly and reported as on the day?
Is line walk is done properly by the assigned person?
Are all the codes underdstood by the person.?

Is the line walk personnel understood the scope or area where he has t
What is the benfit of doing line walk?
Is line walk log sheet is reviewed by HOD?

Are task has been assigned with its priority?


Have you used the system to achieve the KPI's?
Are all the high priority issues has been closed?
Did meeting start on time? Are all members reached at time?
Is Terms of reference & Agenda is prepared and followed?

Was the necessary pre-work done by participants i.e. Daily Stats sourc
solutions identified prior to meeting commencing?
Is Terms of reference understood by all DRM Members?
Are all members aware of their roles in the meeting?.
Do DRM Members understand the importance of the meeting.?

Were variances identified and corrective actions recorded in Action Pla

Were actions, responsibilities and due dates assigned on the Action Pla
Have you used the system to achieve the KPI's?

Were the documentated action logs is reviewed and points are being cl
Did Template mailed or received on time?

Is generation is so planned that all department have sufficient power to


is there any remark generated against short fall in supply
Did template is understood to all/
Do everybody know about such planning?
Did this planning is conveyed to all department

Any action taken against short fall in supply against requirement.


Did daily study about GAP in supply and demand happen?

Have you used the system to achieve the KPI's?


Export is reduceding or not.

Have all the details related to breakdown are being filled by Operations

Have all the details related to Breakdown are being filled by Maintenanc
Did you review breakdowns for previous day ?
What benefit is expected by recording breakdowns? Do you think both
should get involved in recording of Breakdown slips?

Please give us reason why breakdown start time plus job start and finis

What analysis of information about breakdowns captured should be do

Demonstrate how you are doing basic Root Cause Analysis by using th

Have you discussed with your manager on action points based on your
suggestions/message/pending jobs in breakdown slip?
Have you used the system to achieve the KPI's?
What are the actions taken based on issues like spare information, high
resolution of breakdown etc.

Have all the details related to breakdown are being filled by Operations

Have all the details related to Breakdown are being filled by Maintenanc
Did you review breakdowns for previous day ?
What benefit is expected by recording breakdowns? Do you think both
should get involved in recording of Breakdown slips?

Please give us reason why breakdown start time plus job start and finis

What analysis of information about breakdowns captured should be do

Demonstrate how you are doing basic Root Cause Analysis by using th

Have you discussed with your manager on action points based on your
suggestions/message/pending jobs in breakdown slip?
Have you used the system to achieve the KPI's?
What are the actions taken based on issues like spare information, high
resolution of breakdown etc.

Have all the details related to breakdown are being filled by data feedin

Have all the details related to Breakdown are being correctly filled by th
Did you review the data of breakdowns slip before feeding ?
What benefit is expected by recording breakdowns? Do you think both
should get involved in recording of Breakdown slips?

Please give us reason why breakdown start time plus job start and finis

What analysis of information about breakdowns captured should be do

Demonstrate how you are doing basic Root Cause Analysis by using th
Have you used the system to achieve the KPI's?

Have you discussed with your manager on action points based on your
suggestions/message/pending jobs in breakdown slip?
What are the actions taken based on issues like spare information, high
resolution of breakdown etc.

Have all the details related to breakdown are being filled by data feedin

Have all the details related to Breakdown are being correctly filled by th
Did you review the data of breakdowns slip before feeding ?
What benefit is expected by recording breakdowns? Do you think both
should get involved in recording of Breakdown slips?

Please give us reason why breakdown start time plus job start and finis

What analysis of information about breakdowns captured should be do

Demonstrate how you are doing basic Root Cause Analysis by using th

Have you used the system to achieve the KPI's?


Have you discussed with your manager on action points based on your
suggestions/message/pending jobs in breakdown slip?
What are the actions taken based on issues like spare information, high
resolution of breakdown etc.
Whether template is filled completely ?
Whether all the inter departmental jobs are incorporated?

Availability of spares and other critical equipment is done as per job sco
Why do we need to fill the sheet?
Whether all blocks has been completely understood by HOD?

Whether they are aware of how to track the system?


Whether the concerned people planning daily jobs as per Schedule?
Have you used the system to achieve the KPI's?

Whether the information flow became more effective with the template
Has the information helped in taking pro active actions?
Whether template is filled completely ?
Whether all the inter departmental jobs are incorporated?

Availability of spares and other critical equipment is done as per job sco
Why do we need to fill the sheet?
Whether all blocks has been completely understood by HOD?
Whether they are aware of how to track the system?
Whether the concerned people planning daily jobs as per Schedule?
Have you used the system to achieve the KPI's?

Whether the information flow became more effective with the template
Has the information helped in taking pro active actions?
Are you carrying out root cause analysis as per RCA Policy?

Are you maintaning a RCA documentation file? Please show the RCA lo
Does "5 why" format exist and used please show.
What is the need for RCA policy?

Why do we need to Maintain RCA log book. ?


What is the benefit of using 5 Why template ?

Show if any repetitive problem were corrected by using root cause anal
Please provide one example based on last RCA done?

Have you documented the actions and can you link the actions to the im
Are you carrying out root cause analysis as per RCA Policy?

Are you maintaning a RCA documentation file? Please show the RCA lo
Does "5 why" format exist and used please show.
What is the need for RCA policy?
Why do we need to Maintain RCA log book. ?
What is the benefit of using 5 Why template ?

Show if any repetitive problem were corrected by using root cause anal
Please provide one example based on last RCA done?
Have you used the system to achieve the KPI's?

Have you documented the actions and can you link the actions to the im
Whether the Job checking is done as per shut down planning?
Whether the job checking is done by the team formed?
Whether remarks are mentioned against poor quality of jobs?

Whether the team Is aware of importance of job quality checking?


Whether all jobs compered were completely understood ?
Whether they are aware of how to do job checking?
Whether the frequency of equipment failure reduced post light up?
Have you used the system to achieve the KPI's?
Whether Any counter measures taken to avoid critical issues.?

Whether the Job checking is done as per shut down planning?


Whether the job checking is done by the team formed?
Whether remarks are mentioned against poor quality of jobs?
Whether the team Is aware of importance of job quality checking?
Whether all jobs compered were completely understood ?
Whether they are aware of how to do job checking?
Whether the frequency of equipment failure reduced post light up?
Whether Any counter measures taken to avoid critical issues.?
Have you used the system to achieve the KPI's?
Is PM Schedule followed regularly?
Is PM Checklist completely filled by the Engineers?

Is any remarks mentioned against the work done?


Why do we need to follow the PM Plan?

Whether all plans & Checklist has been completely understood by conc
Whether concern people know how to perform PM?
Has the equipment life been improved with this plan?
Has the PM Plan helped in improving MTBF?
Have you used the system to achieve the KPI's?
Is monthly generation plan prepared by the department?
Is monthly production plan of SID taken into account?
Is the plan ready on the first working day of the month?
Why do we need to make the monthly generation plan?

Is the power gneration plan has been completely understood by the con
Whether sponge iron department head was aware of the planning?
Has the overall power generation has increased??

Has the monthly generation plan helped in better weekly and daily pow
Have you used the system to achieve the KPI's?
Was the generation plan on track??
Did meeting start on time? Are all members reached at time?
Is Terms of reference & Agenda is prepared and followed?

Was the necessary pre-work done by participants i.e. Daily work done ,

Do the responsible members understand the importance of daily shutdo


Are all members aware of their roles in the meeting?.

Availability of spares, castable was checked as per the shutdown plan?

Were variances identified and corrective actions recorded in Action Pla

Were actions, responsibilities and due dates assigned on the Action Pla
Have you used the system to achieve the KPI's?

Were the documented action logs is reviewed and points are being clos

Total number of Sys

AUDIT BY

AUDIT DATE

Rating Scale

0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)

Supervisory Actions Required


to Enable Improvement /
Sustain

3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)

1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)

0
(NIL)
1
(PARTIAL)
3
(HIGH)

0
(NIL)

1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)

3
(HIGH)
0
(NIL)

1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)

3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)

1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)

3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
1
(PARTIAL)
3
(HIGH)
1
(PARTIAL)
1
(PARTIAL)

1
(PARTIAL)
1
(PARTIAL)
0
(NIL)
0
(NIL)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
1
(PARTIAL)
1
(PARTIAL)
1
(PARTIAL)
1
(PARTIAL)
0
(NIL)
0
(NIL)
0
(NIL)
0
(NIL)
1
(PARTIAL)
3
(HIGH)

0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)

3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)

3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)

6
18

TOTAL COMPLIANCE
TOTAL UNDERSTANDING
TOTAL USAGE

Taskforce

8-Jan-14

Observed Current Rating for


this category
(Score: 0, 1 or 3)

REMAR

(Key in any remarks which justify the

Not a

Not a

Not a

Not a

Not a

Not a

Not audited

Not audited

94%
100%
72%

REMARKS

arks which justify the observed rating given to the auditee)

Not audited

Not audited

Not audited

Not audited

Not audited

Not audited

ACTION PLAN
(Key in the required action that needs to be taken to address issues - th
must be done for System Elements with a yellow or red scores)

N
taken to address issues - this
th a yellow or red scores)

Sr. No.
System Elements
Accountable

Responsible

FREQUENCY

Shift Handover - Phase 1

Sr. Manager / Manager

Shift Incharge (Engineer)

Daily

2
Shift Handover - Phase 2

Sr. Manager / Manager

Shift Incharge (Engineer)


Daily

Line Walk - Phase

General Manager (Maintenance)

Managers

Weekly

Shift I

Sr.

4
Daily Review Meeting

DRM Chairman

All DRM Members


Daily

Power Plant requirement


and fullfillment

AGM (operation)

Electrical HOD

Daily

General Man

Dai
Daily

Electric

Breakdown Slip (Phase 1)

Engineers

AGM (op

Power Plant requirement


and fullfillment

Managers

Breakdown Slip (Phase 2)

Managers

Engineers

Daily

Breakdown Management
System (BMS) - Phase 1

Managers

Engineers

Monday, Wednesday, Friday

GM

Monday, Wednesday, Friday

Shut Down Job Scoping


Phase 1

nd When Required

Managers

10

Engineers

Breakdown Management
System (BMS) - Phase 2

partmental HOD

Monday

Shut Down Job Scoping


Kiln Phase 2

12

Root Cause Analysis Phase 1

Weekly

nager / Manager

As and When Required

Departmental HOD

As and When R

Departmental

GM

11

GM

Shut Down Job Scoping


Phase 1

l - General Manager

10

Job Quality Check Phase 1

en Required

Weekly

Sr.Manager / Manager

14

arge (Engineer)

Root Cause Analysis Phase 2

Weekly

Sr.Manager / Mana

Sectional - General M

13

Sectional - General Manager

Root Cause Analysis Phase 1

ger / Manager

12

Job Quality Check Phase 2

16

Preventive Maintenance
Planning

Daily

rge (Engineer)

As When Required

Shift In charge (Engineer)

As When Require

Shift Incharge (Engin

Sr. Manager / Mana

15

Sr. Manager / Manager

Job Quality Check Phase 1

ger / Manager

14

ired - During
n

harges

Monthly Power
Generation Plan

1st of every month

Shift Incharge (Engineer)

Daily

Shift Incharge (Engine

Sr. Manager / Manage

17

Sr. Manager / Manager

Preventive Maintenance
Planning

rman

16

18

As and When Required - During


Shutdown

Process In charges

DRM Chairman

Shutdown Review
Meeting

Categories

S1:
Compliance

S2:
Understanding

S3:
Usage

S3:
Usage

S1:
Compliance

S2:
Understanding

S3:
Usage

S1:
Compliance

S2:
Understanding

S3:
Usage

S3:
Usage

S1:
Compliance

S2:
Understanding

S3:
Usage

S1:
Compliance

S2:
Understanding

S3:
Usage

S1:
Compliance

S2:
Understanding

S3:
Usage

S1:
Compliance

S1:
Compliance

S2:
Understanding

S3:
Usage

S1:
Compliance

S2:
Understanding

S3:
Usage

S3:
Usage

S1:
Compliance

S2:
Understanding

S3:
Usage

S1:
Compliance

S2:
Understanding

S2:
Understanding

S3:
Usage

S1:
Compliance

S2:
Understanding

S3:
Usage

S1:
Compliance

S2:
Understanding

S2:
Understanding

S3:
Usage

S1:
Compliance

S2:
Understanding

S3:
Usage

S1:
Compliance

S2:
Understanding

S2:
Understanding

S3:
Usage

S1:
Compliance

S2:
Understanding

S3:
Usage

S1:
Compliance

S2:
Understanding

S3:
Usage

S1:
Compliance

S2:
Understanding

S3:
Usage

S1:
Compliance

S1:
Compliance

S2:
Understanding

S3:
Usage

Name of Area / Department being Audited: Operations / Maintenance

Name of Area / Department Manager: Respective Manager

Name of Individuals Audited:

OBSERVATIONS
(Based on ACTUAL observations and Interviews, use the following quest
best represent the level of compliance/understanding/usage of

Whether template is filled completely?


Whether all concerned people have signed the template?
Whether any remark mentioned on the sheet?
Why do we need to fill the sheet?
Whether all blocks has been completely understood by shift incharge?
Whether the complete sheet is understood by the shift incharge?
How shift handover process has been improved?
Have the information flow became more effective with the templates?

Have you used the system to achieve the KPI's?


Has all the information has been shared during shift handover.?
Whether template is filled completely?
Whether all concerned people have signed the template?
Whether any remark mentioned on the sheet?
Why do we need to fill the sheet?
Whether all blocks has been completely understood by shift incharge?
Whether the complete sheet is understood by the shift incharge?
How shift handover process has been improved?
Have the information flow became more effective with the templates?
Have you used the system to achieve the KPI's?
Has all the information has been shared during shift handover.?
Is line walk schedule prepared? Is it done as per schedule.?
Is line walk log sheet is filled properly and reported as on the day?
Is line walk is done properly by the assigned person?
Are all the codes underdstood by the person.?

Is the line walk personnel understood the scope or area where he has t
What is the benfit of doing line walk?
Is line walk log sheet is reviewed by HOD?

Are task has been assigned with its priority?


Have you used the system to achieve the KPI's?
Are all the high priority issues has been closed?
Did meeting start on time? Are all members reached at time?
Is Terms of reference & Agenda is prepared and followed?

Was the necessary pre-work done by participants i.e. Daily Stats sourc
solutions identified prior to meeting commencing?
Is Terms of reference understood by all DRM Members?
Are all members aware of their roles in the meeting?.
Do DRM Members understand the importance of the meeting.?

Were variances identified and corrective actions recorded in Action Pla

Were actions, responsibilities and due dates assigned on the Action Pla
Have you used the system to achieve the KPI's?

Were the documentated action logs is reviewed and points are being cl
Did Template mailed or received on time?

Is generation is so planned that all department have sufficient power to


is there any remark generated against short fall in supply
Did template is understood to all/
Do everybody know about such planning?
Did this planning is conveyed to all department

Any action taken against short fall in supply against requirement.


Did daily study about GAP in supply and demand happen?

Have you used the system to achieve the KPI's?


Export is reduceding or not.

Have all the details related to breakdown are being filled by Operations

Have all the details related to Breakdown are being filled by Maintenanc
Did you review breakdowns for previous day ?
What benefit is expected by recording breakdowns? Do you think both
should get involved in recording of Breakdown slips?

Please give us reason why breakdown start time plus job start and finis

What analysis of information about breakdowns captured should be do

Demonstrate how you are doing basic Root Cause Analysis by using th

Have you discussed with your manager on action points based on your
suggestions/message/pending jobs in breakdown slip?
Have you used the system to achieve the KPI's?
What are the actions taken based on issues like spare information, high
resolution of breakdown etc.

Have all the details related to breakdown are being filled by Operations

Have all the details related to Breakdown are being filled by Maintenanc
Did you review breakdowns for previous day ?
What benefit is expected by recording breakdowns? Do you think both
should get involved in recording of Breakdown slips?

Please give us reason why breakdown start time plus job start and finis

What analysis of information about breakdowns captured should be do

Demonstrate how you are doing basic Root Cause Analysis by using th

Have you discussed with your manager on action points based on your
suggestions/message/pending jobs in breakdown slip?
Have you used the system to achieve the KPI's?
What are the actions taken based on issues like spare information, high
resolution of breakdown etc.

Have all the details related to breakdown are being filled by data feedin

Have all the details related to Breakdown are being correctly filled by th
Did you review the data of breakdowns slip before feeding ?
What benefit is expected by recording breakdowns? Do you think both
should get involved in recording of Breakdown slips?

Please give us reason why breakdown start time plus job start and finis

What analysis of information about breakdowns captured should be do

Demonstrate how you are doing basic Root Cause Analysis by using th
Have you used the system to achieve the KPI's?

Have you discussed with your manager on action points based on your
suggestions/message/pending jobs in breakdown slip?
What are the actions taken based on issues like spare information, high
resolution of breakdown etc.

Have all the details related to breakdown are being filled by data feedin

Have all the details related to Breakdown are being correctly filled by th
Did you review the data of breakdowns slip before feeding ?
What benefit is expected by recording breakdowns? Do you think both
should get involved in recording of Breakdown slips?

Please give us reason why breakdown start time plus job start and finis

What analysis of information about breakdowns captured should be do

Demonstrate how you are doing basic Root Cause Analysis by using th

Have you used the system to achieve the KPI's?


Have you discussed with your manager on action points based on your
suggestions/message/pending jobs in breakdown slip?
What are the actions taken based on issues like spare information, high
resolution of breakdown etc.
Whether template is filled completely ?
Whether all the inter departmental jobs are incorporated?

Availability of spares and other critical equipment is done as per job sco
Why do we need to fill the sheet?
Whether all blocks has been completely understood by HOD?

Whether they are aware of how to track the system?


Whether the concerned people planning daily jobs as per Schedule?
Have you used the system to achieve the KPI's?

Whether the information flow became more effective with the template
Has the information helped in taking pro active actions?
Whether template is filled completely ?
Whether all the inter departmental jobs are incorporated?

Availability of spares and other critical equipment is done as per job sco
Why do we need to fill the sheet?
Whether all blocks has been completely understood by HOD?
Whether they are aware of how to track the system?
Whether the concerned people planning daily jobs as per Schedule?
Have you used the system to achieve the KPI's?

Whether the information flow became more effective with the template
Has the information helped in taking pro active actions?
Are you carrying out root cause analysis as per RCA Policy?

Are you maintaning a RCA documentation file? Please show the RCA lo
Does "5 why" format exist and used please show.
What is the need for RCA policy?

Why do we need to Maintain RCA log book. ?


What is the benefit of using 5 Why template ?

Show if any repetitive problem were corrected by using root cause anal
Please provide one example based on last RCA done?

Have you documented the actions and can you link the actions to the im
Are you carrying out root cause analysis as per RCA Policy?

Are you maintaning a RCA documentation file? Please show the RCA lo
Does "5 why" format exist and used please show.
What is the need for RCA policy?
Why do we need to Maintain RCA log book. ?
What is the benefit of using 5 Why template ?

Show if any repetitive problem were corrected by using root cause anal
Please provide one example based on last RCA done?
Have you used the system to achieve the KPI's?

Have you documented the actions and can you link the actions to the im
Whether the Job checking is done as per shut down planning?
Whether the job checking is done by the team formed?
Whether remarks are mentioned against poor quality of jobs?
Whether the team Is aware of importance of job quality checking?

Whether all jobs compered were completely understood ?


Whether they are aware of how to do job checking?
Whether the frequency of equipment failure reduced post light up?
Have you used the system to achieve the KPI's?
Whether Any counter measures taken to avoid critical issues.?

Whether the Job checking is done as per shut down planning?


Whether the job checking is done by the team formed?
Whether remarks are mentioned against poor quality of jobs?
Whether the team Is aware of importance of job quality checking?
Whether all jobs compered were completely understood ?
Whether they are aware of how to do job checking?
Whether the frequency of equipment failure reduced post light up?
Whether Any counter measures taken to avoid critical issues.?
Have you used the system to achieve the KPI's?
Is PM Schedule followed regularly?
Is PM Checklist completely filled by the Engineers?
Is any remarks mentioned against the work done?

Why do we need to follow the PM Plan?

Whether all plans & Checklist has been completely understood by conc
Whether concern people know how to perform PM?
Has the equipment life been improved with this plan?
Has the PM Plan helped in improving MTBF?
Have you used the system to achieve the KPI's?
Is monthly generation plan prepared by the department?
Is monthly production plan of SID taken into account?
Is the plan ready on the first working day of the month?
Why do we need to make the monthly generation plan?

Is the power gneration plan has been completely understood by the con
Whether sponge iron department head was aware of the planning?
Has the overall power generation has increased??

Has the monthly generation plan helped in better weekly and daily pow
Have you used the system to achieve the KPI's?
Was the generation plan on track??
Did meeting start on time? Are all members reached at time?
Is Terms of reference & Agenda is prepared and followed?

Was the necessary pre-work done by participants i.e. Daily work done ,

Do the responsible members understand the importance of daily shutdo


Are all members aware of their roles in the meeting?.

Availability of spares, castable was checked as per the shutdown plan?

Were variances identified and corrective actions recorded in Action Pla

Were actions, responsibilities and due dates assigned on the Action Pla
Have you used the system to achieve the KPI's?

Were the documented action logs is reviewed and points are being clos

Total number of Sys

AUDIT BY

AUDIT DATE

Rating Scale

0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)

Supervisory Actions Required


to Enable Improvement /
Sustain

3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)

1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)

0
(NIL)
1
(PARTIAL)
3
(HIGH)

0
(NIL)

1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)

3
(HIGH)
0
(NIL)

1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)

3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)

1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)

3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
1
(PARTIAL)
3
(HIGH)
1
(PARTIAL)
1
(PARTIAL)

1
(PARTIAL)
1
(PARTIAL)
0
(NIL)
0
(NIL)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
1
(PARTIAL)
1
(PARTIAL)
1
(PARTIAL)
1
(PARTIAL)
0
(NIL)
0
(NIL)
0
(NIL)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)

1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)

0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)

3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)

6
18

TOTAL COMPLIANCE
TOTAL UNDERSTANDING
TOTAL USAGE

Taskforce

9-Jan-14

Observed Current Rating for


this category
(Score: 0, 1 or 3)

REMAR

(Key in any remarks which justify the

Not a

Not a

Not a

Not audited

Not audited

92%
92%
64%

REMARKS

arks which justify the observed rating given to the auditee)

Not audited

Not audited

Not audited

ACTION PLAN
(Key in the required action that needs to be taken to address issues - th
must be done for System Elements with a yellow or red scores)

N
taken to address issues - this
th a yellow or red scores)

Sr. No.
System Elements
Accountable

Responsible

FREQUENCY

Shift Handover - Phase 1

Sr. Manager / Manager

Shift Incharge (Engineer)

Daily

2
Shift Handover - Phase 2

Sr. Manager / Manager

Shift Incharge (Engineer)


Daily

Line Walk - Phase

General Manager (Maintenance)

Managers

Weekly

Shift I

Sr.

4
Daily Review Meeting

DRM Chairman

All DRM Members


Daily

Power Plant requirement


and fullfillment

AGM (operation)

Electrical HOD

Daily

General Man

Dai
Daily

Electric

Breakdown Slip (Phase 1)

Engineers

AGM (op

Power Plant requirement


and fullfillment

Managers

Breakdown Slip (Phase 2)

Managers

Engineers

Daily

Breakdown Management
System (BMS) - Phase 1

Managers

Engineers

Monday, Wednesday, Friday

GM

Monday, Wednesday, Friday

Shut Down Job Scoping


Phase 1

nd When Required

Managers

10

Engineers

Breakdown Management
System (BMS) - Phase 2

partmental HOD

Monday

Shut Down Job Scoping


Kiln Phase 2

12

Root Cause Analysis Phase 1

Weekly

nager / Manager

As and When Required

Departmental HOD

As and When R

Departmental

GM

11

GM

Shut Down Job Scoping


Phase 1

l - General Manager

10

Job Quality Check Phase 1

en Required

Weekly

Sr.Manager / Manager

14

arge (Engineer)

Root Cause Analysis Phase 2

Weekly

Sr.Manager / Mana

Sectional - General M

13

Sectional - General Manager

Root Cause Analysis Phase 1

ger / Manager

12

Job Quality Check Phase 2

16

Preventive Maintenance
Planning

Daily

rge (Engineer)

As When Required

Shift In charge (Engineer)

As When Require

Shift Incharge (Engin

Sr. Manager / Mana

15

Sr. Manager / Manager

Job Quality Check Phase 1

ger / Manager

14

ired - During
n

harges

Monthly Power
Generation Plan

1st of every month

Shift Incharge (Engineer)

Daily

Shift Incharge (Engine

Sr. Manager / Manage

17

Sr. Manager / Manager

Preventive Maintenance
Planning

rman

16

18

As and When Required - During


Shutdown

Process In charges

DRM Chairman

Shutdown Review
Meeting

Categories

S1:
Compliance

S2:
Understanding

S3:
Usage

S3:
Usage

S1:
Compliance

S2:
Understanding

S3:
Usage

S1:
Compliance

S2:
Understanding

S3:
Usage

S3:
Usage

S1:
Compliance

S2:
Understanding

S3:
Usage

S1:
Compliance

S2:
Understanding

S3:
Usage

S1:
Compliance

S2:
Understanding

S3:
Usage

S1:
Compliance

S1:
Compliance

S2:
Understanding

S3:
Usage

S1:
Compliance

S2:
Understanding

S3:
Usage

S3:
Usage

S1:
Compliance

S2:
Understanding

S3:
Usage

S1:
Compliance

S2:
Understanding

S2:
Understanding

S3:
Usage

S1:
Compliance

S2:
Understanding

S3:
Usage

S1:
Compliance

S2:
Understanding

S2:
Understanding

S3:
Usage

S1:
Compliance

S2:
Understanding

S3:
Usage

S1:
Compliance

S2:
Understanding

S2:
Understanding

S3:
Usage

S1:
Compliance

S2:
Understanding

S3:
Usage

S1:
Compliance

S2:
Understanding

S3:
Usage

S1:
Compliance

S2:
Understanding

S3:
Usage

S1:
Compliance

S1:
Compliance

S2:
Understanding

S3:
Usage

Name of Area / Department being Audited: Operations / Maintenance

Name of Area / Department Manager: Respective Manager

Name of Individuals Audited:

OBSERVATIONS
(Based on ACTUAL observations and Interviews, use the following quest
best represent the level of compliance/understanding/usage of

Whether template is filled completely?


Whether all concerned people have signed the template?
Whether any remark mentioned on the sheet?
Why do we need to fill the sheet?
Whether all blocks has been completely understood by shift incharge?
Whether the complete sheet is understood by the shift incharge?
How shift handover process has been improved?
Have the information flow became more effective with the templates?

Have you used the system to achieve the KPI's?


Has all the information has been shared during shift handover.?
Whether template is filled completely?
Whether all concerned people have signed the template?
Whether any remark mentioned on the sheet?
Why do we need to fill the sheet?
Whether all blocks has been completely understood by shift incharge?
Whether the complete sheet is understood by the shift incharge?
How shift handover process has been improved?
Have the information flow became more effective with the templates?
Have you used the system to achieve the KPI's?
Has all the information has been shared during shift handover.?
Is line walk schedule prepared? Is it done as per schedule.?
Is line walk log sheet is filled properly and reported as on the day?
Is line walk is done properly by the assigned person?
Are all the codes underdstood by the person.?

Is the line walk personnel understood the scope or area where he has t
What is the benfit of doing line walk?
Is line walk log sheet is reviewed by HOD?

Are task has been assigned with its priority?


Have you used the system to achieve the KPI's?
Are all the high priority issues has been closed?
Did meeting start on time? Are all members reached at time?
Is Terms of reference & Agenda is prepared and followed?

Was the necessary pre-work done by participants i.e. Daily Stats sourc
solutions identified prior to meeting commencing?
Is Terms of reference understood by all DRM Members?
Are all members aware of their roles in the meeting?.
Do DRM Members understand the importance of the meeting.?

Were variances identified and corrective actions recorded in Action Pla

Were actions, responsibilities and due dates assigned on the Action Pla
Have you used the system to achieve the KPI's?

Were the documentated action logs is reviewed and points are being cl
Did Template mailed or received on time?

Is generation is so planned that all department have sufficient power to


is there any remark generated against short fall in supply
Did template is understood to all/
Do everybody know about such planning?
Did this planning is conveyed to all department

Any action taken against short fall in supply against requirement.


Did daily study about GAP in supply and demand happen?

Have you used the system to achieve the KPI's?


Export is reduceding or not.

Have all the details related to breakdown are being filled by Operations

Have all the details related to Breakdown are being filled by Maintenanc
Did you review breakdowns for previous day ?
What benefit is expected by recording breakdowns? Do you think both
should get involved in recording of Breakdown slips?

Please give us reason why breakdown start time plus job start and finis

What analysis of information about breakdowns captured should be do

Demonstrate how you are doing basic Root Cause Analysis by using th

Have you discussed with your manager on action points based on your
suggestions/message/pending jobs in breakdown slip?
Have you used the system to achieve the KPI's?
What are the actions taken based on issues like spare information, high
resolution of breakdown etc.

Have all the details related to breakdown are being filled by Operations

Have all the details related to Breakdown are being filled by Maintenanc
Did you review breakdowns for previous day ?
What benefit is expected by recording breakdowns? Do you think both
should get involved in recording of Breakdown slips?

Please give us reason why breakdown start time plus job start and finis

What analysis of information about breakdowns captured should be do

Demonstrate how you are doing basic Root Cause Analysis by using th

Have you discussed with your manager on action points based on your
suggestions/message/pending jobs in breakdown slip?
Have you used the system to achieve the KPI's?
What are the actions taken based on issues like spare information, high
resolution of breakdown etc.

Have all the details related to breakdown are being filled by data feedin

Have all the details related to Breakdown are being correctly filled by th
Did you review the data of breakdowns slip before feeding ?
What benefit is expected by recording breakdowns? Do you think both
should get involved in recording of Breakdown slips?

Please give us reason why breakdown start time plus job start and finis

What analysis of information about breakdowns captured should be do

Demonstrate how you are doing basic Root Cause Analysis by using th
Have you used the system to achieve the KPI's?

Have you discussed with your manager on action points based on your
suggestions/message/pending jobs in breakdown slip?
What are the actions taken based on issues like spare information, high
resolution of breakdown etc.

Have all the details related to breakdown are being filled by data feedin

Have all the details related to Breakdown are being correctly filled by th
Did you review the data of breakdowns slip before feeding ?
What benefit is expected by recording breakdowns? Do you think both
should get involved in recording of Breakdown slips?

Please give us reason why breakdown start time plus job start and finis

What analysis of information about breakdowns captured should be do

Demonstrate how you are doing basic Root Cause Analysis by using th

Have you used the system to achieve the KPI's?


Have you discussed with your manager on action points based on your
suggestions/message/pending jobs in breakdown slip?
What are the actions taken based on issues like spare information, high
resolution of breakdown etc.
Whether template is filled completely ?
Whether all the inter departmental jobs are incorporated?

Availability of spares and other critical equipment is done as per job sco
Why do we need to fill the sheet?
Whether all blocks has been completely understood by HOD?

Whether they are aware of how to track the system?


Whether the concerned people planning daily jobs as per Schedule?
Have you used the system to achieve the KPI's?

Whether the information flow became more effective with the template
Has the information helped in taking pro active actions?
Whether template is filled completely ?
Whether all the inter departmental jobs are incorporated?

Availability of spares and other critical equipment is done as per job sco
Why do we need to fill the sheet?
Whether all blocks has been completely understood by HOD?
Whether they are aware of how to track the system?
Whether the concerned people planning daily jobs as per Schedule?
Have you used the system to achieve the KPI's?

Whether the information flow became more effective with the template
Has the information helped in taking pro active actions?
Are you carrying out root cause analysis as per RCA Policy?

Are you maintaning a RCA documentation file? Please show the RCA lo
Does "5 why" format exist and used please show.
What is the need for RCA policy?

Why do we need to Maintain RCA log book. ?


What is the benefit of using 5 Why template ?

Show if any repetitive problem were corrected by using root cause anal
Please provide one example based on last RCA done?

Have you documented the actions and can you link the actions to the im
Are you carrying out root cause analysis as per RCA Policy?

Are you maintaning a RCA documentation file? Please show the RCA lo
Does "5 why" format exist and used please show.
What is the need for RCA policy?
Why do we need to Maintain RCA log book. ?
What is the benefit of using 5 Why template ?

Show if any repetitive problem were corrected by using root cause anal
Please provide one example based on last RCA done?
Have you used the system to achieve the KPI's?

Have you documented the actions and can you link the actions to the im
Whether the Job checking is done as per shut down planning?
Whether the job checking is done by the team formed?
Whether remarks are mentioned against poor quality of jobs?
Whether the team Is aware of importance of job quality checking?

Whether all jobs compered were completely understood ?


Whether they are aware of how to do job checking?
Whether the frequency of equipment failure reduced post light up?
Have you used the system to achieve the KPI's?
Whether Any counter measures taken to avoid critical issues.?

Whether the Job checking is done as per shut down planning?


Whether the job checking is done by the team formed?
Whether remarks are mentioned against poor quality of jobs?
Whether the team Is aware of importance of job quality checking?
Whether all jobs compered were completely understood ?
Whether they are aware of how to do job checking?
Whether the frequency of equipment failure reduced post light up?
Whether Any counter measures taken to avoid critical issues.?
Have you used the system to achieve the KPI's?
Is PM Schedule followed regularly?
Is PM Checklist completely filled by the Engineers?
Is any remarks mentioned against the work done?

Why do we need to follow the PM Plan?

Whether all plans & Checklist has been completely understood by conc
Whether concern people know how to perform PM?
Has the equipment life been improved with this plan?
Has the PM Plan helped in improving MTBF?
Have you used the system to achieve the KPI's?
Is monthly generation plan prepared by the department?
Is monthly production plan of SID taken into account?
Is the plan ready on the first working day of the month?
Why do we need to make the monthly generation plan?

Is the power gneration plan has been completely understood by the con
Whether sponge iron department head was aware of the planning?
Has the overall power generation has increased??

Has the monthly generation plan helped in better weekly and daily pow
Have you used the system to achieve the KPI's?
Was the generation plan on track??
Did meeting start on time? Are all members reached at time?
Is Terms of reference & Agenda is prepared and followed?

Was the necessary pre-work done by participants i.e. Daily work done ,

Do the responsible members understand the importance of daily shutdo


Are all members aware of their roles in the meeting?.

Availability of spares, castable was checked as per the shutdown plan?

Were variances identified and corrective actions recorded in Action Pla

Were actions, responsibilities and due dates assigned on the Action Pla
Have you used the system to achieve the KPI's?

Were the documented action logs is reviewed and points are being clos

Total number of Sys

AUDIT BY

AUDIT DATE

Rating Scale

0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)

Supervisory Actions Required


to Enable Improvement /
Sustain

3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)

1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)

0
(NIL)
1
(PARTIAL)
3
(HIGH)

0
(NIL)

1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)

3
(HIGH)
0
(NIL)

1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)

3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)

1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)

3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
1
(PARTIAL)
3
(HIGH)
1
(PARTIAL)
1
(PARTIAL)

1
(PARTIAL)
1
(PARTIAL)
0
(NIL)
0
(NIL)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
1
(PARTIAL)
1
(PARTIAL)
1
(PARTIAL)
1
(PARTIAL)
0
(NIL)
0
(NIL)
0
(NIL)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)

1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)

0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)

3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)

14
18

TOTAL COMPLIANCE
TOTAL UNDERSTANDING
TOTAL USAGE

Taskforce

10-Jan-14

Observed Current Rating for


this category
(Score: 0, 1 or 3)

REMAR

(Key in any remarks which justify the

Not a

analysis need to be done departme


and export minimization
1

Not a

Not a

Not a

Not audited

Not audited

100%
100%
67%

REMARKS

arks which justify the observed rating given to the auditee)

Not audited

be done departmental plan vs actula consumption


mization

Not audited

Not audited

Not audited

ACTION PLAN
(Key in the required action that needs to be taken to address issues - th
must be done for System Elements with a yellow or red scores)

N
taken to address issues - this
th a yellow or red scores)

Sr. No.
System Elements
Accountable

Responsible

FREQUENCY

Shift Handover and log


sheet - Phase 1

Sr. Manager / Manager

Shift Incharge (Engineer)

Daily

2
Shift Handover and log
sheet - Phase 2

Sr. Manager / Manager

Shift Incharge (Engineer)


Daily

Line Walk - Phase

General Manager (Maintenance)

Managers

Weekly

Shift I

Sr.

4
Daily Review Meeting

DRM Chairman

All DRM Members


Daily

Power Plant requirement


and fullfillment

AGM (operation)

Electrical HOD

Daily

General Man

Dai
Daily

Electric

Breakdown Slip (Phase 1)

Engineers

AGM (op

Power Plant requirement


and fullfillment

Managers

Breakdown Slip (Phase 2)

Managers

Engineers

Daily

Breakdown Management
System (BMS) - Phase 1

Managers

Engineers

Monday, Wednesday, Friday

Managers

10

Shut Down Job Scoping


Phase 1

GM

When Required

Monday, Wednesday, Friday

Engineers

Breakdown Management
System (BMS) - Phase 2

rtmental HOD

Monday,

Shut Down Job Scoping


Kiln Phase 2

GM

12

Root Cause Analysis Phase 1

eneral Manager

eekly

As and When Required

Departmental HOD

11

er / Manager

Shut Down Job Scoping


Phase 1

As and When Requi

Departmental HO

GM

10

equired

(Engineer)

Root Cause Analysis Phase 2

Weekly

Sr.Manager / Manager

Weekly

Sr.Manager / Manager

Sectional - General Mana

13

Sectional - General Manager

Root Cause Analysis Phase 1

/ Manager

12

(Engineer)

Job Quality Check Phase 2

As When Required

Shift In charge (Engineer)

As When Required

Shift Incharge (Engineer)

Sr. Manager / Manager

15

Sr. Manager / Manager

Job Quality Check Phase 1

/ Manager

14

- During

es

Monthly Power
Generation Plan

1st of every month

Shift Incharge (Engineer)

Daily

Shift Incharge (Engineer)

Sr. Manager / Manager

17

Sr. Manager / Manager

Preventive Maintenance
Planning

16

18

As and When Required - During


Shutdown

Process In charges

DRM Chairman

Shutdown Review
Meeting

Categories

S1:
Compliance

S2:
Understanding

S3:
Usage

S3:
Usage

S1:
Compliance

S2:
Understanding

S3:
Usage

S1:
Compliance

S2:
Understanding

S3:
Usage

S3:
Usage

S1:
Compliance

S2:
Understanding

S3:
Usage

S1:
Compliance

S2:
Understanding

S3:
Usage

S1:
Compliance

S2:
Understanding

S3:
Usage

S1:
Compliance

S1:
Compliance

S2:
Understanding

S3:
Usage

S1:
Compliance

S2:
Understanding

S3:
Usage

S3:
Usage

S1:
Compliance

S2:
Understanding

S3:
Usage

S1:
Compliance

S2:
Understanding

S2:
Understanding

S3:
Usage

S1:
Compliance

S2:
Understanding

S3:
Usage

S1:
Compliance

S2:
Understanding

S3:
Usage

S1:
Compliance

S2:
Understanding

S3:
Usage

S1:
Compliance

S2:
Understanding

S3:
Usage

S1:
Compliance

S2:
Understanding

S3:
Usage

S1:
Compliance

S1:
Compliance

S2:
Understanding

S3:
Usage

S1:
Compliance

S2:
Understanding

S3:
Usage

S1:
Compliance

S1:
Compliance

S2:
Understanding

S3:
Usage

Name of Area / Department being Audited: Operations / Maintenance

Name of Area / Department Manager: Respective Manager

Name of Individuals Audited:

OBSERVATIONS
(Based on ACTUAL observations and Interviews, use the following quest
best represent the level of compliance/understanding/usage of

Whether template is filled completely?


Whether all concerned people have signed the template?
Whether any remark mentioned on the sheet?
Why do we need to fill the sheet?
Whether all blocks has been completely understood by shift incharge?
Whether the complete sheet is understood by the shift incharge?
How shift handover process has been improved?
Have the information flow became more effective with the templates?

Have you used the system to achieve the KPI's?


Has all the information has been shared during shift handover.?
Whether template is filled completely?
Whether all concerned people have signed the template?
Whether any remark mentioned on the sheet?
Why do we need to fill the sheet?
Whether all blocks has been completely understood by shift incharge?
Whether the complete sheet is understood by the shift incharge?
How shift handover process has been improved?
Have the information flow became more effective with the templates?
Have you used the system to achieve the KPI's?
Has all the information has been shared during shift handover.?
Is line walk schedule prepared? Is it done as per schedule.?
Is line walk log sheet is filled properly and reported as on the day?
Is line walk is done properly by the assigned person?
Are all the codes underdstood by the person.?

Is the line walk personnel understood the scope or area where he has t
What is the benfit of doing line walk?
Is line walk log sheet is reviewed by HOD?

Are task has been assigned with its priority?


Have you used the system to achieve the KPI's?
Are all the high priority issues has been closed?
Did meeting start on time? Are all members reached at time?
Is Terms of reference & Agenda is prepared and followed?

Was the necessary pre-work done by participants i.e. Daily Stats sourc
solutions identified prior to meeting commencing?
Is Terms of reference understood by all DRM Members?
Are all members aware of their roles in the meeting?.
Do DRM Members understand the importance of the meeting.?

Were variances identified and corrective actions recorded in Action Pla

Were actions, responsibilities and due dates assigned on the Action Pla
Have you used the system to achieve the KPI's?

Were the documentated action logs is reviewed and points are being cl
Did Template mailed or received on time?

Is generation is so planned that all department have sufficient power to


is there any remark generated against short fall in supply
Did template is understood to all/
Do everybody know about such planning?
Did this planning is conveyed to all department

Any action taken against short fall in supply against requirement.


Did daily study about GAP in supply and demand happen?

Have you used the system to achieve the KPI's?


Export is reduceding or not.

Have all the details related to breakdown are being filled by Operations

Have all the details related to Breakdown are being filled by Maintenanc
Did you review breakdowns for previous day ?
What benefit is expected by recording breakdowns? Do you think both
should get involved in recording of Breakdown slips?

Please give us reason why breakdown start time plus job start and finis

What analysis of information about breakdowns captured should be do

Demonstrate how you are doing basic Root Cause Analysis by using th

Have you discussed with your manager on action points based on your
suggestions/message/pending jobs in breakdown slip?
Have you used the system to achieve the KPI's?
What are the actions taken based on issues like spare information, high
resolution of breakdown etc.

Have all the details related to breakdown are being filled by Operations

Have all the details related to Breakdown are being filled by Maintenanc
Did you review breakdowns for previous day ?
What benefit is expected by recording breakdowns? Do you think both
should get involved in recording of Breakdown slips?

Please give us reason why breakdown start time plus job start and finis

What analysis of information about breakdowns captured should be do

Demonstrate how you are doing basic Root Cause Analysis by using th

Have you discussed with your manager on action points based on your
suggestions/message/pending jobs in breakdown slip?
Have you used the system to achieve the KPI's?
What are the actions taken based on issues like spare information, high
resolution of breakdown etc.

Have all the details related to breakdown are being filled by data feedin

Have all the details related to Breakdown are being correctly filled by th
Did you review the data of breakdowns slip before feeding ?
What benefit is expected by recording breakdowns? Do you think both
should get involved in recording of Breakdown slips?

Please give us reason why breakdown start time plus job start and finis

What analysis of information about breakdowns captured should be do

Demonstrate how you are doing basic Root Cause Analysis by using th

Have you used the system to achieve the KPI's?


Have you discussed with your manager on action points based on your
suggestions/message/pending jobs in breakdown slip?
What are the actions taken based on issues like spare information, high
resolution of breakdown etc.

Have all the details related to breakdown are being filled by data feedin

Have all the details related to Breakdown are being correctly filled by th
Did you review the data of breakdowns slip before feeding ?
What benefit is expected by recording breakdowns? Do you think both
should get involved in recording of Breakdown slips?

Please give us reason why breakdown start time plus job start and finis

What analysis of information about breakdowns captured should be do

Demonstrate how you are doing basic Root Cause Analysis by using th

Have you used the system to achieve the KPI's?


Have you discussed with your manager on action points based on your
suggestions/message/pending jobs in breakdown slip?
What are the actions taken based on issues like spare information, high
resolution of breakdown etc.
Whether template is filled completely ?
Whether all the inter departmental jobs are incorporated?

Availability of spares and other critical equipment is done as per job sco
Why do we need to fill the sheet?

Whether all blocks has been completely understood by HOD?


Whether they are aware of how to track the system?
Whether the concerned people planning daily jobs as per Schedule?
Have you used the system to achieve the KPI's?

Whether the information flow became more effective with the template
Has the information helped in taking pro active actions?
Whether template is filled completely ?
Whether all the inter departmental jobs are incorporated?

Availability of spares and other critical equipment is done as per job sco
Why do we need to fill the sheet?
Whether all blocks has been completely understood by HOD?
Whether they are aware of how to track the system?
Whether the concerned people planning daily jobs as per Schedule?
Have you used the system to achieve the KPI's?

Whether the information flow became more effective with the template
Has the information helped in taking pro active actions?
Are you carrying out root cause analysis as per RCA Policy?

Are you maintaning a RCA documentation file? Please show the RCA lo
Does "5 why" format exist and used please show.

What is the need for RCA policy?


Why do we need to Maintain RCA log book. ?
What is the benefit of using 5 Why template ?

Show if any repetitive problem were corrected by using root cause anal
Please provide one example based on last RCA done?

Have you documented the actions and can you link the actions to the im
Are you carrying out root cause analysis as per RCA Policy?

Are you maintaning a RCA documentation file? Please show the RCA lo
Does "5 why" format exist and used please show.
What is the need for RCA policy?
Why do we need to Maintain RCA log book. ?
What is the benefit of using 5 Why template ?

Show if any repetitive problem were corrected by using root cause anal
Please provide one example based on last RCA done?
Have you used the system to achieve the KPI's?

Have you documented the actions and can you link the actions to the im
Whether the Job checking is done as per shut down planning?
Whether the job checking is done by the team formed?
Whether remarks are mentioned against poor quality of jobs?

Whether the team Is aware of importance of job quality checking?


Whether all jobs compered were completely understood ?
Whether they are aware of how to do job checking?
Whether the frequency of equipment failure reduced post light up?
Have you used the system to achieve the KPI's?
Whether Any counter measures taken to avoid critical issues.?

Whether the Job checking is done as per shut down planning?


Whether the job checking is done by the team formed?
Whether remarks are mentioned against poor quality of jobs?
Whether the team Is aware of importance of job quality checking?
Whether all jobs compered were completely understood ?
Whether they are aware of how to do job checking?
Whether the frequency of equipment failure reduced post light up?
Whether Any counter measures taken to avoid critical issues.?
Have you used the system to achieve the KPI's?
Is PM Schedule followed regularly?
Is PM Checklist completely filled by the Engineers?

Is any remarks mentioned against the work done?


Why do we need to follow the PM Plan?

Whether all plans & Checklist has been completely understood by conc
Whether concern people know how to perform PM?
Has the equipment life been improved with this plan?
Has the PM Plan helped in improving MTBF?
Have you used the system to achieve the KPI's?
Is monthly generation plan prepared by the department?
Is monthly production plan of SID taken into account?
Is the plan ready on the first working day of the month?
Why do we need to make the monthly generation plan?

Is the power gneration plan has been completely understood by the con
Whether sponge iron department head was aware of the planning?
Has the overall power generation has increased??

Has the monthly generation plan helped in better weekly and daily pow
Have you used the system to achieve the KPI's?
Was the generation plan on track??
Did meeting start on time? Are all members reached at time?
Is Terms of reference & Agenda is prepared and followed?

Was the necessary pre-work done by participants i.e. Daily work done ,

Do the responsible members understand the importance of daily shutdo


Are all members aware of their roles in the meeting?.

Availability of spares, castable was checked as per the shutdown plan?

Were variances identified and corrective actions recorded in Action Pla

Were actions, responsibilities and due dates assigned on the Action Pla
Have you used the system to achieve the KPI's?

Were the documented action logs is reviewed and points are being clos

Total number of Sys

AUDIT BY

AUDIT DATE

Rating Scale

0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)

Supervisory Actions Required


to Enable Improvement /
Sustain

3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)

1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)

0
(NIL)
1
(PARTIAL)
3
(HIGH)

0
(NIL)

1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)

3
(HIGH)
0
(NIL)

1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)

3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)

1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)

1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
1
(PARTIAL)
3
(HIGH)
1
(PARTIAL)

1
(PARTIAL)
1
(PARTIAL)
1
(PARTIAL)
0
(NIL)
0
(NIL)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
1
(PARTIAL)
1
(PARTIAL)
1
(PARTIAL)
1
(PARTIAL)
0
(NIL)
0
(NIL)
0
(NIL)
0
(NIL)
1
(PARTIAL)
3
(HIGH)

0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)

3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)

3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)

8
18

TOTAL COMPLIANCE
TOTAL UNDERSTANDING
TOTAL USAGE

Taskforce

30-Jan-15

Observed Current Rating for


this category
(Score: 0, 1 or 3)

REMAR

(Key in any remarks which justify the

Basic RCA need

Basic RCA need

root cause analysis is not done by BMS sys


in thei

root cause analysis is not done by BMS sys


in thei

Not Audited
0

Not Audited
0

the team is yet to submit

the team is yet to submit


leak
3

Not A
0

Not A

Not A

Not A

Not A

Not A

not re
0

not re
0

94%
96%
75%

REMARKS

arks which justify the observed rating given to the auditee)

Basic RCA needs to be strengthen

Basic RCA needs to be strengthen

s not done by BMS system and also they have to install separately
in their phase

s not done by BMS system and also they have to install separately
in their phase

s yet to submit the audit for AFBC 2 tube

s yet to submit the audit for AFBC 2 tube


leakage

Not Audited

Not Audited

Not Audited

Not Audited

Not Audited

Not Audited

not required

not required

ACTION PLAN
(Key in the required action that needs to be taken to address issues - th
must be done for System Elements with a yellow or red scores)

N
taken to address issues - this
th a yellow or red scores)

Sr. No.
System Elements
Accountable

Responsible

FREQUENCY

Shift Handover and log


sheet - Phase 1

Sr. Manager / Manager

Shift Incharge (Engineer)

Daily

2
Shift Handover and log
sheet - Phase 2

Sr. Manager / Manager

Shift Incharge (Engineer)


Daily

Line Walk - Phase

General Manager (Maintenance)

Managers

Weekly

Shift I

Sr.

4
Daily Review Meeting

DRM Chairman

All DRM Members


Daily

Power Plant requirement


and fullfillment

AGM (operation)

Electrical HOD

Daily

General Man

Dai
Daily

Electric

Breakdown Slip (Phase 1)

Engineers

AGM (op

Power Plant requirement


and fullfillment

Managers

Breakdown Slip (Phase 2)

Managers

Engineers

Daily

Breakdown Management
System (BMS) - Phase 1

Managers

Engineers

Monday, Wednesday, Friday

GM

Monday, Wednesday, Friday

Shut Down Job Scoping


Phase 1

nd When Required

Managers

10

Engineers

Breakdown Management
System (BMS) - Phase 2

partmental HOD

Monday

Shut Down Job Scoping


Kiln Phase 2

12

Root Cause Analysis Phase 1

Weekly

nager / Manager

As and When Required

Departmental HOD

As and When R

Departmental

GM

11

GM

Shut Down Job Scoping


Phase 1

l - General Manager

10

Job Quality Check Phase 1

en Required

Weekly

Sr.Manager / Manager

14

arge (Engineer)

Root Cause Analysis Phase 2

Weekly

Sr.Manager / Mana

Sectional - General M

13

Sectional - General Manager

Root Cause Analysis Phase 1

ger / Manager

12

Job Quality Check Phase 2

16

Preventive Maintenance
Planning

Daily

rge (Engineer)

As When Required

Shift In charge (Engineer)

As When Require

Shift Incharge (Engin

Sr. Manager / Mana

15

Sr. Manager / Manager

Job Quality Check Phase 1

ger / Manager

14

ired - During
n

harges

Monthly Power
Generation Plan

1st of every month

Shift Incharge (Engineer)

Daily

Shift Incharge (Engine

Sr. Manager / Manage

17

Sr. Manager / Manager

Preventive Maintenance
Planning

rman

16

18

As and When Required - During


Shutdown

Process In charges

DRM Chairman

Shutdown Review
Meeting

Categories

S1:
Compliance

S2:
Understanding

S3:
Usage

S3:
Usage

S1:
Compliance

S2:
Understanding

S3:
Usage

S1:
Compliance

S2:
Understanding

S3:
Usage

S3:
Usage

S1:
Compliance

S2:
Understanding

S3:
Usage

S1:
Compliance

S2:
Understanding

S3:
Usage

S1:
Compliance

S2:
Understanding

S3:
Usage

S1:
Compliance

S1:
Compliance

S2:
Understanding

S3:
Usage

S1:
Compliance

S2:
Understanding

S3:
Usage

S3:
Usage

S1:
Compliance

S2:
Understanding

S3:
Usage

S1:
Compliance

S2:
Understanding

S2:
Understanding

S3:
Usage

S1:
Compliance

S2:
Understanding

S3:
Usage

S1:
Compliance

S2:
Understanding

S2:
Understanding

S3:
Usage

S1:
Compliance

S2:
Understanding

S3:
Usage

S1:
Compliance

S2:
Understanding

S2:
Understanding

S3:
Usage

S1:
Compliance

S2:
Understanding

S3:
Usage

S1:
Compliance

S2:
Understanding

S3:
Usage

S1:
Compliance

S2:
Understanding

S3:
Usage

S1:
Compliance

S1:
Compliance

S2:
Understanding

S3:
Usage

Name of Area / Department being Audited: Operations / Maintenance

Name of Area / Department Manager: Respective Manager

Name of Individuals Audited:

OBSERVATIONS
(Based on ACTUAL observations and Interviews, use the following quest
best represent the level of compliance/understanding/usage of

Whether template is filled completely?


Whether all concerned people have signed the template?
Whether any remark mentioned on the sheet?
Why do we need to fill the sheet?
Whether all blocks has been completely understood by shift incharge?
Whether the complete sheet is understood by the shift incharge?
How shift handover process has been improved?
Have the information flow became more effective with the templates?

Have you used the system to achieve the KPI's?


Has all the information has been shared during shift handover.?
Whether template is filled completely?
Whether all concerned people have signed the template?
Whether any remark mentioned on the sheet?
Why do we need to fill the sheet?
Whether all blocks has been completely understood by shift incharge?
Whether the complete sheet is understood by the shift incharge?
How shift handover process has been improved?
Have the information flow became more effective with the templates?
Have you used the system to achieve the KPI's?
Has all the information has been shared during shift handover.?
Is line walk schedule prepared? Is it done as per schedule.?
Is line walk log sheet is filled properly and reported as on the day?
Is line walk is done properly by the assigned person?
Are all the codes underdstood by the person.?

Is the line walk personnel understood the scope or area where he has t
What is the benfit of doing line walk?
Is line walk log sheet is reviewed by HOD?

Are task has been assigned with its priority?


Have you used the system to achieve the KPI's?
Are all the high priority issues has been closed?
Did meeting start on time? Are all members reached at time?
Is Terms of reference & Agenda is prepared and followed?

Was the necessary pre-work done by participants i.e. Daily Stats sourc
solutions identified prior to meeting commencing?
Is Terms of reference understood by all DRM Members?
Are all members aware of their roles in the meeting?.
Do DRM Members understand the importance of the meeting.?

Were variances identified and corrective actions recorded in Action Pla

Were actions, responsibilities and due dates assigned on the Action Pla
Have you used the system to achieve the KPI's?

Were the documentated action logs is reviewed and points are being cl
Did Template mailed or received on time?

Is generation is so planned that all department have sufficient power to


is there any remark generated against short fall in supply
Did template is understood to all/
Do everybody know about such planning?
Did this planning is conveyed to all department

Any action taken against short fall in supply against requirement.


Did daily study about GAP in supply and demand happen?

Have you used the system to achieve the KPI's?


Export is reduceding or not.

Have all the details related to breakdown are being filled by Operations

Have all the details related to Breakdown are being filled by Maintenanc
Did you review breakdowns for previous day ?
What benefit is expected by recording breakdowns? Do you think both
should get involved in recording of Breakdown slips?

Please give us reason why breakdown start time plus job start and finis

What analysis of information about breakdowns captured should be do

Demonstrate how you are doing basic Root Cause Analysis by using th

Have you discussed with your manager on action points based on your
suggestions/message/pending jobs in breakdown slip?
Have you used the system to achieve the KPI's?
What are the actions taken based on issues like spare information, high
resolution of breakdown etc.

Have all the details related to breakdown are being filled by Operations

Have all the details related to Breakdown are being filled by Maintenanc
Did you review breakdowns for previous day ?
What benefit is expected by recording breakdowns? Do you think both
should get involved in recording of Breakdown slips?

Please give us reason why breakdown start time plus job start and finis

What analysis of information about breakdowns captured should be do

Demonstrate how you are doing basic Root Cause Analysis by using th

Have you discussed with your manager on action points based on your
suggestions/message/pending jobs in breakdown slip?
Have you used the system to achieve the KPI's?
What are the actions taken based on issues like spare information, high
resolution of breakdown etc.

Have all the details related to breakdown are being filled by data feedin

Have all the details related to Breakdown are being correctly filled by th
Did you review the data of breakdowns slip before feeding ?
What benefit is expected by recording breakdowns? Do you think both
should get involved in recording of Breakdown slips?

Please give us reason why breakdown start time plus job start and finis

What analysis of information about breakdowns captured should be do

Demonstrate how you are doing basic Root Cause Analysis by using th
Have you used the system to achieve the KPI's?

Have you discussed with your manager on action points based on your
suggestions/message/pending jobs in breakdown slip?
What are the actions taken based on issues like spare information, high
resolution of breakdown etc.

Have all the details related to breakdown are being filled by data feedin

Have all the details related to Breakdown are being correctly filled by th
Did you review the data of breakdowns slip before feeding ?
What benefit is expected by recording breakdowns? Do you think both
should get involved in recording of Breakdown slips?

Please give us reason why breakdown start time plus job start and finis

What analysis of information about breakdowns captured should be do

Demonstrate how you are doing basic Root Cause Analysis by using th

Have you used the system to achieve the KPI's?


Have you discussed with your manager on action points based on your
suggestions/message/pending jobs in breakdown slip?
What are the actions taken based on issues like spare information, high
resolution of breakdown etc.
Whether template is filled completely ?
Whether all the inter departmental jobs are incorporated?

Availability of spares and other critical equipment is done as per job sco
Why do we need to fill the sheet?
Whether all blocks has been completely understood by HOD?

Whether they are aware of how to track the system?


Whether the concerned people planning daily jobs as per Schedule?
Have you used the system to achieve the KPI's?

Whether the information flow became more effective with the template
Has the information helped in taking pro active actions?
Whether template is filled completely ?
Whether all the inter departmental jobs are incorporated?

Availability of spares and other critical equipment is done as per job sco
Why do we need to fill the sheet?
Whether all blocks has been completely understood by HOD?
Whether they are aware of how to track the system?
Whether the concerned people planning daily jobs as per Schedule?
Have you used the system to achieve the KPI's?

Whether the information flow became more effective with the template
Has the information helped in taking pro active actions?
Are you carrying out root cause analysis as per RCA Policy?

Are you maintaning a RCA documentation file? Please show the RCA lo
Does "5 why" format exist and used please show.
What is the need for RCA policy?

Why do we need to Maintain RCA log book. ?


What is the benefit of using 5 Why template ?

Show if any repetitive problem were corrected by using root cause anal
Please provide one example based on last RCA done?

Have you documented the actions and can you link the actions to the im
Are you carrying out root cause analysis as per RCA Policy?

Are you maintaning a RCA documentation file? Please show the RCA lo
Does "5 why" format exist and used please show.
What is the need for RCA policy?
Why do we need to Maintain RCA log book. ?
What is the benefit of using 5 Why template ?

Show if any repetitive problem were corrected by using root cause anal
Please provide one example based on last RCA done?
Have you used the system to achieve the KPI's?

Have you documented the actions and can you link the actions to the im
Whether the Job checking is done as per shut down planning?
Whether the job checking is done by the team formed?
Whether remarks are mentioned against poor quality of jobs?
Whether the team Is aware of importance of job quality checking?

Whether all jobs compered were completely understood ?


Whether they are aware of how to do job checking?
Whether the frequency of equipment failure reduced post light up?
Have you used the system to achieve the KPI's?
Whether Any counter measures taken to avoid critical issues.?

Whether the Job checking is done as per shut down planning?


Whether the job checking is done by the team formed?
Whether remarks are mentioned against poor quality of jobs?
Whether the team Is aware of importance of job quality checking?
Whether all jobs compered were completely understood ?
Whether they are aware of how to do job checking?
Whether the frequency of equipment failure reduced post light up?
Whether Any counter measures taken to avoid critical issues.?
Have you used the system to achieve the KPI's?
Is PM Schedule followed regularly?
Is PM Checklist completely filled by the Engineers?
Is any remarks mentioned against the work done?

Why do we need to follow the PM Plan?

Whether all plans & Checklist has been completely understood by conc
Whether concern people know how to perform PM?
Has the equipment life been improved with this plan?
Has the PM Plan helped in improving MTBF?
Have you used the system to achieve the KPI's?
Is monthly generation plan prepared by the department?
Is monthly production plan of SID taken into account?
Is the plan ready on the first working day of the month?
Why do we need to make the monthly generation plan?

Is the power gneration plan has been completely understood by the con
Whether sponge iron department head was aware of the planning?
Has the overall power generation has increased??

Has the monthly generation plan helped in better weekly and daily pow
Have you used the system to achieve the KPI's?
Was the generation plan on track??
Did meeting start on time? Are all members reached at time?
Is Terms of reference & Agenda is prepared and followed?

Was the necessary pre-work done by participants i.e. Daily work done ,

Do the responsible members understand the importance of daily shutdo


Are all members aware of their roles in the meeting?.

Availability of spares, castable was checked as per the shutdown plan?

Were variances identified and corrective actions recorded in Action Pla

Were actions, responsibilities and due dates assigned on the Action Pla
Have you used the system to achieve the KPI's?

Were the documented action logs is reviewed and points are being clos

Total number of Sys

AUDIT BY

AUDIT DATE

Rating Scale

0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)

Supervisory Actions Required


to Enable Improvement /
Sustain

3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)

1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)

0
(NIL)
1
(PARTIAL)
3
(HIGH)

0
(NIL)

1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)

3
(HIGH)
0
(NIL)

1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)

3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)

1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)

3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
1
(PARTIAL)
3
(HIGH)
1
(PARTIAL)
1
(PARTIAL)

1
(PARTIAL)
1
(PARTIAL)
0
(NIL)
0
(NIL)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
1
(PARTIAL)
1
(PARTIAL)
1
(PARTIAL)
1
(PARTIAL)
0
(NIL)
0
(NIL)
0
(NIL)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)

1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)

0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)

3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)

8
18

TOTAL COMPLIANCE
TOTAL UNDERSTANDING
TOTAL USAGE

Taskforce

7-Feb-15

Observed Current Rating for


this category
(Score: 0, 1 or 3)

REMAR

(Key in any remarks which justify the

not a
0

analysis should be done

100 tph shut donw is in progress but sheet

Not Audited
0

the team is yet to submit


leak
1

the team is yet to submit


leak
1

Not A
0

Not A

Not A

Not A

Not A

not re
0

not re
0

93%
93%
73%

REMARKS

arks which justify the observed rating given to the auditee)

not audited

one

in progress but sheet is not prepared yet

s yet to submit the audit for AFBC 2 tube


leakage

s yet to submit the audit for AFBC 2 tube


leakage

Not Audited

Not Audited

Not Audited

Not Audited

Not Audited

not required

not required

ACTION PLAN
(Key in the required action that needs to be taken to address issues - th
must be done for System Elements with a yellow or red scores)

Parito chart should be prepared

there must be use of general shut down planning sheet

N
taken to address issues - this
th a yellow or red scores)

g sheet

Sr. No.
System Elements
Accountable

Responsible

FREQUENCY

Shift Handover and log


sheet - Phase 1

Sr. Manager / Manager

Shift Incharge (Engineer)

Daily

2
Shift Handover and log
sheet - Phase 2

Sr. Manager / Manager

Shift Incharge (Engineer)


Daily

Line Walk - Phase

General Manager (Maintenance)

Managers

Weekly

Shift I

Sr.

4
Daily Review Meeting

DRM Chairman

All DRM Members


Daily

Power Plant requirement


and fullfillment

AGM (operation)

Electrical HOD

Daily

General Man

Dai
Daily

Electric

Breakdown Slip (Phase 1)

Engineers

AGM (op

Power Plant requirement


and fullfillment

Managers

Breakdown Slip (Phase 2)

Managers

Engineers

Daily

Breakdown Management
System (BMS) - Phase 1

Managers

Engineers

Monday, Wednesday, Friday

GM

Monday, Wednesday, Friday

Shut Down Job Scoping


Phase 1

nd When Required

Managers

10

Engineers

Breakdown Management
System (BMS) - Phase 2

partmental HOD

Monday

Shut Down Job Scoping


Kiln Phase 2

12

Root Cause Analysis Phase 1

Weekly

nager / Manager

As and When Required

Departmental HOD

As and When R

Departmental

GM

11

GM

Shut Down Job Scoping


Phase 1

l - General Manager

10

Job Quality Check Phase 1

en Required

Weekly

Sr.Manager / Manager

14

arge (Engineer)

Root Cause Analysis Phase 2

Weekly

Sr.Manager / Mana

Sectional - General M

13

Sectional - General Manager

Root Cause Analysis Phase 1

ger / Manager

12

Job Quality Check Phase 2

16

Preventive Maintenance
Planning

Daily

rge (Engineer)

As When Required

Shift In charge (Engineer)

As When Require

Shift Incharge (Engin

Sr. Manager / Mana

15

Sr. Manager / Manager

Job Quality Check Phase 1

ger / Manager

14

ired - During
n

harges

Monthly Power
Generation Plan

1st of every month

Shift Incharge (Engineer)

Daily

Shift Incharge (Engine

Sr. Manager / Manage

17

Sr. Manager / Manager

Preventive Maintenance
Planning

rman

16

18

As and When Required - During


Shutdown

Process In charges

DRM Chairman

Shutdown Review
Meeting

Categories

S1:
Compliance

S2:
Understanding

S3:
Usage

S3:
Usage

S1:
Compliance

S2:
Understanding

S3:
Usage

S1:
Compliance

S2:
Understanding

S3:
Usage

S3:
Usage

S1:
Compliance

S2:
Understanding

S3:
Usage

S1:
Compliance

S2:
Understanding

S3:
Usage

S1:
Compliance

S2:
Understanding

S3:
Usage

S1:
Compliance

S1:
Compliance

S2:
Understanding

S3:
Usage

S1:
Compliance

S2:
Understanding

S3:
Usage

S3:
Usage

S1:
Compliance

S2:
Understanding

S3:
Usage

S1:
Compliance

S2:
Understanding

S2:
Understanding

S3:
Usage

S1:
Compliance

S2:
Understanding

S3:
Usage

S1:
Compliance

S2:
Understanding

S2:
Understanding

S3:
Usage

S1:
Compliance

S2:
Understanding

S3:
Usage

S1:
Compliance

S2:
Understanding

S2:
Understanding

S3:
Usage

S1:
Compliance

S2:
Understanding

S3:
Usage

S1:
Compliance

S2:
Understanding

S3:
Usage

S1:
Compliance

S2:
Understanding

S3:
Usage

S1:
Compliance

S1:
Compliance

S2:
Understanding

S3:
Usage

Name of Area / Department being Audited: Operations / Maintenance

Name of Area / Department Manager: Respective Manager

Name of Individuals Audited:

OBSERVATIONS
(Based on ACTUAL observations and Interviews, use the following quest
best represent the level of compliance/understanding/usage of

Whether template is filled completely?


Whether all concerned people have signed the template?
Whether any remark mentioned on the sheet?
Why do we need to fill the sheet?
Whether all blocks has been completely understood by shift incharge?
Whether the complete sheet is understood by the shift incharge?
How shift handover process has been improved?
Have the information flow became more effective with the templates?

Have you used the system to achieve the KPI's?


Has all the information has been shared during shift handover.?
Whether template is filled completely?
Whether all concerned people have signed the template?
Whether any remark mentioned on the sheet?
Why do we need to fill the sheet?
Whether all blocks has been completely understood by shift incharge?
Whether the complete sheet is understood by the shift incharge?
How shift handover process has been improved?
Have the information flow became more effective with the templates?
Have you used the system to achieve the KPI's?
Has all the information has been shared during shift handover.?
Is line walk schedule prepared? Is it done as per schedule.?
Is line walk log sheet is filled properly and reported as on the day?
Is line walk is done properly by the assigned person?
Are all the codes underdstood by the person.?

Is the line walk personnel understood the scope or area where he has t
What is the benfit of doing line walk?
Is line walk log sheet is reviewed by HOD?

Are task has been assigned with its priority?


Have you used the system to achieve the KPI's?
Are all the high priority issues has been closed?
Did meeting start on time? Are all members reached at time?
Is Terms of reference & Agenda is prepared and followed?

Was the necessary pre-work done by participants i.e. Daily Stats sourc
solutions identified prior to meeting commencing?
Is Terms of reference understood by all DRM Members?
Are all members aware of their roles in the meeting?.
Do DRM Members understand the importance of the meeting.?

Were variances identified and corrective actions recorded in Action Pla

Were actions, responsibilities and due dates assigned on the Action Pla
Have you used the system to achieve the KPI's?

Were the documentated action logs is reviewed and points are being cl
Did Template mailed or received on time?

Is generation is so planned that all department have sufficient power to


is there any remark generated against short fall in supply
Did template is understood to all/
Do everybody know about such planning?
Did this planning is conveyed to all department

Any action taken against short fall in supply against requirement.


Did daily study about GAP in supply and demand happen?

Have you used the system to achieve the KPI's?


Export is reduceding or not.

Have all the details related to breakdown are being filled by Operations

Have all the details related to Breakdown are being filled by Maintenanc
Did you review breakdowns for previous day ?
What benefit is expected by recording breakdowns? Do you think both
should get involved in recording of Breakdown slips?

Please give us reason why breakdown start time plus job start and finis

What analysis of information about breakdowns captured should be do

Demonstrate how you are doing basic Root Cause Analysis by using th

Have you discussed with your manager on action points based on your
suggestions/message/pending jobs in breakdown slip?
Have you used the system to achieve the KPI's?
What are the actions taken based on issues like spare information, high
resolution of breakdown etc.

Have all the details related to breakdown are being filled by Operations

Have all the details related to Breakdown are being filled by Maintenanc
Did you review breakdowns for previous day ?
What benefit is expected by recording breakdowns? Do you think both
should get involved in recording of Breakdown slips?

Please give us reason why breakdown start time plus job start and finis

What analysis of information about breakdowns captured should be do

Demonstrate how you are doing basic Root Cause Analysis by using th

Have you discussed with your manager on action points based on your
suggestions/message/pending jobs in breakdown slip?
Have you used the system to achieve the KPI's?
What are the actions taken based on issues like spare information, high
resolution of breakdown etc.

Have all the details related to breakdown are being filled by data feedin

Have all the details related to Breakdown are being correctly filled by th
Did you review the data of breakdowns slip before feeding ?
What benefit is expected by recording breakdowns? Do you think both
should get involved in recording of Breakdown slips?

Please give us reason why breakdown start time plus job start and finis

What analysis of information about breakdowns captured should be do

Demonstrate how you are doing basic Root Cause Analysis by using th
Have you used the system to achieve the KPI's?

Have you discussed with your manager on action points based on your
suggestions/message/pending jobs in breakdown slip?
What are the actions taken based on issues like spare information, high
resolution of breakdown etc.

Have all the details related to breakdown are being filled by data feedin

Have all the details related to Breakdown are being correctly filled by th
Did you review the data of breakdowns slip before feeding ?
What benefit is expected by recording breakdowns? Do you think both
should get involved in recording of Breakdown slips?

Please give us reason why breakdown start time plus job start and finis

What analysis of information about breakdowns captured should be do

Demonstrate how you are doing basic Root Cause Analysis by using th

Have you used the system to achieve the KPI's?


Have you discussed with your manager on action points based on your
suggestions/message/pending jobs in breakdown slip?
What are the actions taken based on issues like spare information, high
resolution of breakdown etc.
Whether template is filled completely ?
Whether all the inter departmental jobs are incorporated?

Availability of spares and other critical equipment is done as per job sco
Why do we need to fill the sheet?
Whether all blocks has been completely understood by HOD?

Whether they are aware of how to track the system?


Whether the concerned people planning daily jobs as per Schedule?
Have you used the system to achieve the KPI's?

Whether the information flow became more effective with the template
Has the information helped in taking pro active actions?
Whether template is filled completely ?
Whether all the inter departmental jobs are incorporated?

Availability of spares and other critical equipment is done as per job sco
Why do we need to fill the sheet?
Whether all blocks has been completely understood by HOD?
Whether they are aware of how to track the system?
Whether the concerned people planning daily jobs as per Schedule?
Have you used the system to achieve the KPI's?

Whether the information flow became more effective with the template
Has the information helped in taking pro active actions?
Are you carrying out root cause analysis as per RCA Policy?

Are you maintaning a RCA documentation file? Please show the RCA lo
Does "5 why" format exist and used please show.
What is the need for RCA policy?

Why do we need to Maintain RCA log book. ?


What is the benefit of using 5 Why template ?

Show if any repetitive problem were corrected by using root cause anal
Please provide one example based on last RCA done?

Have you documented the actions and can you link the actions to the im
Are you carrying out root cause analysis as per RCA Policy?

Are you maintaning a RCA documentation file? Please show the RCA lo
Does "5 why" format exist and used please show.
What is the need for RCA policy?
Why do we need to Maintain RCA log book. ?
What is the benefit of using 5 Why template ?

Show if any repetitive problem were corrected by using root cause anal
Please provide one example based on last RCA done?
Have you used the system to achieve the KPI's?

Have you documented the actions and can you link the actions to the im
Whether the Job checking is done as per shut down planning?
Whether the job checking is done by the team formed?
Whether remarks are mentioned against poor quality of jobs?
Whether the team Is aware of importance of job quality checking?

Whether all jobs compered were completely understood ?


Whether they are aware of how to do job checking?
Whether the frequency of equipment failure reduced post light up?
Have you used the system to achieve the KPI's?
Whether Any counter measures taken to avoid critical issues.?

Whether the Job checking is done as per shut down planning?


Whether the job checking is done by the team formed?
Whether remarks are mentioned against poor quality of jobs?
Whether the team Is aware of importance of job quality checking?
Whether all jobs compered were completely understood ?
Whether they are aware of how to do job checking?
Whether the frequency of equipment failure reduced post light up?
Whether Any counter measures taken to avoid critical issues.?
Have you used the system to achieve the KPI's?
Is PM Schedule followed regularly?
Is PM Checklist completely filled by the Engineers?
Is any remarks mentioned against the work done?

Why do we need to follow the PM Plan?

Whether all plans & Checklist has been completely understood by conc
Whether concern people know how to perform PM?
Has the equipment life been improved with this plan?
Has the PM Plan helped in improving MTBF?
Have you used the system to achieve the KPI's?
Is monthly generation plan prepared by the department?
Is monthly production plan of SID taken into account?
Is the plan ready on the first working day of the month?
Why do we need to make the monthly generation plan?

Is the power gneration plan has been completely understood by the con
Whether sponge iron department head was aware of the planning?
Has the overall power generation has increased??

Has the monthly generation plan helped in better weekly and daily pow
Have you used the system to achieve the KPI's?
Was the generation plan on track??
Did meeting start on time? Are all members reached at time?
Is Terms of reference & Agenda is prepared and followed?

Was the necessary pre-work done by participants i.e. Daily work done ,

Do the responsible members understand the importance of daily shutdo


Are all members aware of their roles in the meeting?.

Availability of spares, castable was checked as per the shutdown plan?

Were variances identified and corrective actions recorded in Action Pla

Were actions, responsibilities and due dates assigned on the Action Pla
Have you used the system to achieve the KPI's?

Were the documented action logs is reviewed and points are being clos

Total number of Sys

AUDIT BY

AUDIT DATE

Rating Scale

0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)

Supervisory Actions Required


to Enable Improvement /
Sustain

3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)

1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)

0
(NIL)
1
(PARTIAL)
3
(HIGH)

0
(NIL)

1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)

3
(HIGH)
0
(NIL)

1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)

3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)

1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)

3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
1
(PARTIAL)
3
(HIGH)
1
(PARTIAL)
1
(PARTIAL)

1
(PARTIAL)
1
(PARTIAL)
0
(NIL)
0
(NIL)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
1
(PARTIAL)
1
(PARTIAL)
1
(PARTIAL)
1
(PARTIAL)
0
(NIL)
0
(NIL)
0
(NIL)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)

1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)

0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)

3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)

8
18

TOTAL COMPLIANCE
TOTAL UNDERSTANDING
TOTAL USAGE

Taskforce

14-Feb-15

Observed Current Rating for


this category
(Score: 0, 1 or 3)

REMAR

(Key in any remarks which justify the

Some data is not with full description along


1

AS compliance mode is little bit low this we


be increased as unfilled section should be fi
1

Not audited
0

Not Audited
0

RCA for AFBC 2 is prepared


member and
3

RCA for AFBC 2 is prepared


member and
3

Not A
0

Not A
0

Not A
0

Not A
0

Not A
0

not re
0

not re
0

93%
100%
80%

REMARKS

arks which justify the observed rating given to the auditee)

h full description along with job end time

e is little bit low this week due to unfilled of section so usage can
ed section should be filled to do proper analysis

C 2 is prepared and it is reviewed by all MAT


member and Renoir group

C 2 is prepared and it is reviewed by all MAT


member and Renoir group

Not Audited

Not Audited

Not Audited

Not Audited

Not Audited

not required

not required

ACTION PLAN
(Key in the required action that needs to be taken to address issues - th
must be done for System Elements with a yellow or red scores)

so it must be updated with job end time so it will be easy for analysis and also break down
register help in making chart which can give description of equipment went majorly through
shut down

Chart is prepared by project udaan team and it is noted that to d


anlaysis few job have to be deleted.

there must be use of general shut down planning sheet

Usage is high because decision taken is based on RCA and hence usa
is now fully achiedved for this section.

N
taken to address issues - this
th a yellow or red scores)

sy for analysis and also break down


n of equipment went majorly through

am and it is noted that to do

g sheet

ased on RCA and hence usage

Sr. No.
System Elements
Accountable

Responsible

FREQUENCY

Shift Handover and log


sheet - Phase 1

Sr. Manager / Manager

Shift Incharge (Engineer)

Daily

2
Shift Handover and log
sheet - Phase 2

Sr. Manager / Manager

Shift Incharge (Engineer)


Daily

Line Walk - Phase

General Manager (Maintenance)

Managers

Weekly

Shift I

Sr.

4
Daily Review Meeting

DRM Chairman

All DRM Members


Daily

Power Plant requirement


and fullfillment

AGM (operation)

Electrical HOD

Daily

General Man

Dai
Daily

Electric

Breakdown Slip (Phase 1)

Engineers

AGM (op

Power Plant requirement


and fullfillment

Managers

Breakdown Slip (Phase 2)

Managers

Engineers

Daily

Breakdown Management
System (BMS) - Phase 1

Managers

Engineers

Monday, Wednesday, Friday

GM

Monday, Wednesday, Friday

Shut Down Job Scoping


Phase 1

nd When Required

Managers

10

Engineers

Breakdown Management
System (BMS) - Phase 2

partmental HOD

Monday

Shut Down Job Scoping


Kiln Phase 2

12

Root Cause Analysis Phase 1

Weekly

nager / Manager

As and When Required

Departmental HOD

As and When R

Departmental

GM

11

GM

Shut Down Job Scoping


Phase 1

l - General Manager

10

Job Quality Check Phase 1

en Required

Weekly

Sr.Manager / Manager

14

arge (Engineer)

Root Cause Analysis Phase 2

Weekly

Sr.Manager / Mana

Sectional - General M

13

Sectional - General Manager

Root Cause Analysis Phase 1

ger / Manager

12

Job Quality Check Phase 2

16

Preventive Maintenance
Planning

Daily

rge (Engineer)

As When Required

Shift In charge (Engineer)

As When Require

Shift Incharge (Engin

Sr. Manager / Mana

15

Sr. Manager / Manager

Job Quality Check Phase 1

ger / Manager

14

ired - During
n

harges

Monthly Power
Generation Plan

1st of every month

Shift Incharge (Engineer)

Daily

Shift Incharge (Engine

Sr. Manager / Manage

17

Sr. Manager / Manager

Preventive Maintenance
Planning

rman

16

18

As and When Required - During


Shutdown

Process In charges

DRM Chairman

Shutdown Review
Meeting

Categories

S1:
Compliance

S2:
Understanding

S3:
Usage

S3:
Usage

S1:
Compliance

S2:
Understanding

S3:
Usage

S1:
Compliance

S2:
Understanding

S3:
Usage

S3:
Usage

S1:
Compliance

S2:
Understanding

S3:
Usage

S1:
Compliance

S2:
Understanding

S3:
Usage

S1:
Compliance

S2:
Understanding

S3:
Usage

S1:
Compliance

S1:
Compliance

S2:
Understanding

S3:
Usage

S1:
Compliance

S2:
Understanding

S3:
Usage

S3:
Usage

S1:
Compliance

S2:
Understanding

S3:
Usage

S1:
Compliance

S2:
Understanding

S2:
Understanding

S3:
Usage

S1:
Compliance

S2:
Understanding

S3:
Usage

S1:
Compliance

S2:
Understanding

S2:
Understanding

S3:
Usage

S1:
Compliance

S2:
Understanding

S3:
Usage

S1:
Compliance

S2:
Understanding

S2:
Understanding

S3:
Usage

S1:
Compliance

S2:
Understanding

S3:
Usage

S1:
Compliance

S2:
Understanding

S3:
Usage

S1:
Compliance

S2:
Understanding

S3:
Usage

S1:
Compliance

S1:
Compliance

S2:
Understanding

S3:
Usage

Name of Area / Department being Audited: Operations / Maintenance

Name of Area / Department Manager: Respective Manager

Name of Individuals Audited:

OBSERVATIONS
(Based on ACTUAL observations and Interviews, use the following quest
best represent the level of compliance/understanding/usage of

Whether template is filled completely?


Whether all concerned people have signed the template?
Whether any remark mentioned on the sheet?
Why do we need to fill the sheet?
Whether all blocks has been completely understood by shift incharge?
Whether the complete sheet is understood by the shift incharge?
How shift handover process has been improved?
Have the information flow became more effective with the templates?

Have you used the system to achieve the KPI's?


Has all the information has been shared during shift handover.?
Whether template is filled completely?
Whether all concerned people have signed the template?
Whether any remark mentioned on the sheet?
Why do we need to fill the sheet?
Whether all blocks has been completely understood by shift incharge?
Whether the complete sheet is understood by the shift incharge?
How shift handover process has been improved?
Have the information flow became more effective with the templates?
Have you used the system to achieve the KPI's?
Has all the information has been shared during shift handover.?
Is line walk schedule prepared? Is it done as per schedule.?
Is line walk log sheet is filled properly and reported as on the day?
Is line walk is done properly by the assigned person?
Are all the codes underdstood by the person.?

Is the line walk personnel understood the scope or area where he has t
What is the benfit of doing line walk?
Is line walk log sheet is reviewed by HOD?

Are task has been assigned with its priority?


Have you used the system to achieve the KPI's?
Are all the high priority issues has been closed?
Did meeting start on time? Are all members reached at time?
Is Terms of reference & Agenda is prepared and followed?

Was the necessary pre-work done by participants i.e. Daily Stats sourc
solutions identified prior to meeting commencing?
Is Terms of reference understood by all DRM Members?
Are all members aware of their roles in the meeting?.
Do DRM Members understand the importance of the meeting.?

Were variances identified and corrective actions recorded in Action Pla

Were actions, responsibilities and due dates assigned on the Action Pla
Have you used the system to achieve the KPI's?

Were the documentated action logs is reviewed and points are being cl
Did Template mailed or received on time?

Is generation is so planned that all department have sufficient power to


is there any remark generated against short fall in supply
Did template is understood to all/
Do everybody know about such planning?
Did this planning is conveyed to all department

Any action taken against short fall in supply against requirement.


Did daily study about GAP in supply and demand happen?

Have you used the system to achieve the KPI's?


Export is reduceding or not.

Have all the details related to breakdown are being filled by Operations

Have all the details related to Breakdown are being filled by Maintenanc
Did you review breakdowns for previous day ?
What benefit is expected by recording breakdowns? Do you think both
should get involved in recording of Breakdown slips?

Please give us reason why breakdown start time plus job start and finis

What analysis of information about breakdowns captured should be do

Demonstrate how you are doing basic Root Cause Analysis by using th

Have you discussed with your manager on action points based on your
suggestions/message/pending jobs in breakdown slip?
Have you used the system to achieve the KPI's?
What are the actions taken based on issues like spare information, high
resolution of breakdown etc.

Have all the details related to breakdown are being filled by Operations

Have all the details related to Breakdown are being filled by Maintenanc
Did you review breakdowns for previous day ?
What benefit is expected by recording breakdowns? Do you think both
should get involved in recording of Breakdown slips?

Please give us reason why breakdown start time plus job start and finis

What analysis of information about breakdowns captured should be do

Demonstrate how you are doing basic Root Cause Analysis by using th

Have you discussed with your manager on action points based on your
suggestions/message/pending jobs in breakdown slip?
Have you used the system to achieve the KPI's?
What are the actions taken based on issues like spare information, high
resolution of breakdown etc.

Have all the details related to breakdown are being filled by data feedin

Have all the details related to Breakdown are being correctly filled by th
Did you review the data of breakdowns slip before feeding ?
What benefit is expected by recording breakdowns? Do you think both
should get involved in recording of Breakdown slips?

Please give us reason why breakdown start time plus job start and finis

What analysis of information about breakdowns captured should be do

Demonstrate how you are doing basic Root Cause Analysis by using th
Have you used the system to achieve the KPI's?

Have you discussed with your manager on action points based on your
suggestions/message/pending jobs in breakdown slip?
What are the actions taken based on issues like spare information, high
resolution of breakdown etc.

Have all the details related to breakdown are being filled by data feedin

Have all the details related to Breakdown are being correctly filled by th
Did you review the data of breakdowns slip before feeding ?
What benefit is expected by recording breakdowns? Do you think both
should get involved in recording of Breakdown slips?

Please give us reason why breakdown start time plus job start and finis

What analysis of information about breakdowns captured should be do

Demonstrate how you are doing basic Root Cause Analysis by using th

Have you used the system to achieve the KPI's?


Have you discussed with your manager on action points based on your
suggestions/message/pending jobs in breakdown slip?
What are the actions taken based on issues like spare information, high
resolution of breakdown etc.
Whether template is filled completely ?
Whether all the inter departmental jobs are incorporated?

Availability of spares and other critical equipment is done as per job sco
Why do we need to fill the sheet?
Whether all blocks has been completely understood by HOD?

Whether they are aware of how to track the system?


Whether the concerned people planning daily jobs as per Schedule?
Have you used the system to achieve the KPI's?

Whether the information flow became more effective with the template
Has the information helped in taking pro active actions?
Whether template is filled completely ?
Whether all the inter departmental jobs are incorporated?

Availability of spares and other critical equipment is done as per job sco
Why do we need to fill the sheet?
Whether all blocks has been completely understood by HOD?
Whether they are aware of how to track the system?
Whether the concerned people planning daily jobs as per Schedule?
Have you used the system to achieve the KPI's?

Whether the information flow became more effective with the template
Has the information helped in taking pro active actions?
Are you carrying out root cause analysis as per RCA Policy?

Are you maintaning a RCA documentation file? Please show the RCA lo
Does "5 why" format exist and used please show.
What is the need for RCA policy?

Why do we need to Maintain RCA log book. ?


What is the benefit of using 5 Why template ?

Show if any repetitive problem were corrected by using root cause anal
Please provide one example based on last RCA done?

Have you documented the actions and can you link the actions to the im
Are you carrying out root cause analysis as per RCA Policy?

Are you maintaning a RCA documentation file? Please show the RCA lo
Does "5 why" format exist and used please show.
What is the need for RCA policy?
Why do we need to Maintain RCA log book. ?
What is the benefit of using 5 Why template ?

Show if any repetitive problem were corrected by using root cause anal
Please provide one example based on last RCA done?
Have you used the system to achieve the KPI's?

Have you documented the actions and can you link the actions to the im
Whether the Job checking is done as per shut down planning?
Whether the job checking is done by the team formed?
Whether remarks are mentioned against poor quality of jobs?
Whether the team Is aware of importance of job quality checking?

Whether all jobs compered were completely understood ?


Whether they are aware of how to do job checking?
Whether the frequency of equipment failure reduced post light up?
Have you used the system to achieve the KPI's?
Whether Any counter measures taken to avoid critical issues.?

Whether the Job checking is done as per shut down planning?


Whether the job checking is done by the team formed?
Whether remarks are mentioned against poor quality of jobs?
Whether the team Is aware of importance of job quality checking?
Whether all jobs compered were completely understood ?
Whether they are aware of how to do job checking?
Whether the frequency of equipment failure reduced post light up?
Whether Any counter measures taken to avoid critical issues.?
Have you used the system to achieve the KPI's?
Is PM Schedule followed regularly?
Is PM Checklist completely filled by the Engineers?
Is any remarks mentioned against the work done?

Why do we need to follow the PM Plan?

Whether all plans & Checklist has been completely understood by conc
Whether concern people know how to perform PM?
Has the equipment life been improved with this plan?
Has the PM Plan helped in improving MTBF?
Have you used the system to achieve the KPI's?
Is monthly generation plan prepared by the department?
Is monthly production plan of SID taken into account?
Is the plan ready on the first working day of the month?
Why do we need to make the monthly generation plan?

Is the power gneration plan has been completely understood by the con
Whether sponge iron department head was aware of the planning?
Has the overall power generation has increased??

Has the monthly generation plan helped in better weekly and daily pow
Have you used the system to achieve the KPI's?
Was the generation plan on track??
Did meeting start on time? Are all members reached at time?
Is Terms of reference & Agenda is prepared and followed?

Was the necessary pre-work done by participants i.e. Daily work done ,

Do the responsible members understand the importance of daily shutdo


Are all members aware of their roles in the meeting?.

Availability of spares, castable was checked as per the shutdown plan?

Were variances identified and corrective actions recorded in Action Pla

Were actions, responsibilities and due dates assigned on the Action Pla
Have you used the system to achieve the KPI's?

Were the documented action logs is reviewed and points are being clos

Total number of Sys

AUDIT BY

AUDIT DATE

Rating Scale

0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)

Supervisory Actions Required


to Enable Improvement /
Sustain

3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)

1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)

0
(NIL)
1
(PARTIAL)
3
(HIGH)

0
(NIL)

1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)

3
(HIGH)
0
(NIL)

1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)

3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)

1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)

3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
1
(PARTIAL)
3
(HIGH)
1
(PARTIAL)
1
(PARTIAL)

1
(PARTIAL)
1
(PARTIAL)
0
(NIL)
0
(NIL)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
1
(PARTIAL)
1
(PARTIAL)
1
(PARTIAL)
1
(PARTIAL)
0
(NIL)
0
(NIL)
0
(NIL)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)

1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)

0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)

3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)

9
18

TOTAL COMPLIANCE
TOTAL UNDERSTANDING
TOTAL USAGE

Taskforce

21-Feb-15

Observed Current Rating for


this category
(Score: 0, 1 or 3)

REMAR

(Key in any remarks which justify the

not a

not a
3

some job is not mention like esp tripping


1

Not audited
0

Not Audited
0

not au
0

not au
0

Not A
0

Not A
0

Not A
0

Not A
0

Not A
0

not au
0

not au
0

93%
100%
85%

REMARKS

arks which justify the observed rating given to the auditee)

not audited

not audited

on like esp tripping

not audited

not audited

Not Audited

Not Audited

Not Audited

Not Audited

Not Audited

not audited

not audited

ACTION PLAN
(Key in the required action that needs to be taken to address issues - th
must be done for System Elements with a yellow or red scores)

N
taken to address issues - this
th a yellow or red scores)

Sr. No.
System Elements
Accountable

Responsible

FREQUENCY

Shift Handover and log


sheet - Phase 1

Sr. Manager / Manager

Shift Incharge (Engineer)

Daily

2
Shift Handover and log
sheet - Phase 2

Sr. Manager / Manager

Shift Incharge (Engineer)


Daily

Line Walk - Phase

General Manager (Maintenance)

Managers

Weekly

Shift I

Sr.

4
Daily Review Meeting

DRM Chairman

All DRM Members


Daily

Power Plant requirement


and fullfillment

AGM (operation)

Electrical HOD

Daily

General Man

Dai
Daily

Electric

Breakdown Slip (Phase 1)

Engineers

AGM (op

Power Plant requirement


and fullfillment

Managers

Breakdown Slip (Phase 2)

Managers

Engineers

Daily

Breakdown Management
System (BMS) - Phase 1

Managers

Engineers

Monday, Wednesday, Friday

Managers

10

Shut Down Job Scoping


Phase 1

GM

When Required

Monday, Wednesday, Friday

Engineers

Breakdown Management
System (BMS) - Phase 2

rtmental HOD

Monday,

Shut Down Job Scoping


Kiln Phase 2

GM

12

Root Cause Analysis Phase 1

eneral Manager

eekly

As and When Required

Departmental HOD

11

er / Manager

Shut Down Job Scoping


Phase 1

As and When Requi

Departmental HO

GM

10

equired

(Engineer)

Root Cause Analysis Phase 2

Weekly

Sr.Manager / Manager

Weekly

Sr.Manager / Manager

Sectional - General Mana

13

Sectional - General Manager

Root Cause Analysis Phase 1

/ Manager

12

(Engineer)

Job Quality Check Phase 2

As When Required

Shift In charge (Engineer)

As When Required

Shift Incharge (Engineer)

Sr. Manager / Manager

15

Sr. Manager / Manager

Job Quality Check Phase 1

/ Manager

14

- During

es

Monthly Power
Generation Plan

1st of every month

Shift Incharge (Engineer)

Daily

Shift Incharge (Engineer)

Sr. Manager / Manager

17

Sr. Manager / Manager

Preventive Maintenance
Planning

16

18

As and When Required - During


Shutdown

Process In charges

DRM Chairman

Shutdown Review
Meeting

Categories

S1:
Compliance

S2:
Understanding

S3:
Usage

S3:
Usage

S1:
Compliance

S2:
Understanding

S3:
Usage

S1:
Compliance

S2:
Understanding

S3:
Usage

S3:
Usage

S1:
Compliance

S2:
Understanding

S3:
Usage

S1:
Compliance

S2:
Understanding

S3:
Usage

S1:
Compliance

S2:
Understanding

S3:
Usage

S1:
Compliance

S1:
Compliance

S2:
Understanding

S3:
Usage

S1:
Compliance

S2:
Understanding

S3:
Usage

S3:
Usage

S1:
Compliance

S2:
Understanding

S3:
Usage

S1:
Compliance

S2:
Understanding

S2:
Understanding

S3:
Usage

S1:
Compliance

S2:
Understanding

S3:
Usage

S1:
Compliance

S2:
Understanding

S3:
Usage

S1:
Compliance

S2:
Understanding

S3:
Usage

S1:
Compliance

S2:
Understanding

S3:
Usage

S1:
Compliance

S2:
Understanding

S3:
Usage

S1:
Compliance

S1:
Compliance

S2:
Understanding

S3:
Usage

S1:
Compliance

S2:
Understanding

S3:
Usage

S1:
Compliance

S1:
Compliance

S2:
Understanding

S3:
Usage

Name of Area / Department being Audited: Operations / Maintenance

Name of Area / Department Manager: Respective Manager

Name of Individuals Audited:

OBSERVATIONS
(Based on ACTUAL observations and Interviews, use the following quest
best represent the level of compliance/understanding/usage of

Whether template is filled completely?


Whether all concerned people have signed the template?
Whether any remark mentioned on the sheet?
Why do we need to fill the sheet?
Whether all blocks has been completely understood by shift incharge?
Whether the complete sheet is understood by the shift incharge?
How shift handover process has been improved?
Have the information flow became more effective with the templates?

Have you used the system to achieve the KPI's?


Has all the information has been shared during shift handover.?
Whether template is filled completely?
Whether all concerned people have signed the template?
Whether any remark mentioned on the sheet?
Why do we need to fill the sheet?
Whether all blocks has been completely understood by shift incharge?
Whether the complete sheet is understood by the shift incharge?
How shift handover process has been improved?
Have the information flow became more effective with the templates?
Have you used the system to achieve the KPI's?
Has all the information has been shared during shift handover.?
Is line walk schedule prepared? Is it done as per schedule.?
Is line walk log sheet is filled properly and reported as on the day?
Is line walk is done properly by the assigned person?
Are all the codes underdstood by the person.?

Is the line walk personnel understood the scope or area where he has t
What is the benfit of doing line walk?
Is line walk log sheet is reviewed by HOD?

Are task has been assigned with its priority?


Have you used the system to achieve the KPI's?
Are all the high priority issues has been closed?
Did meeting start on time? Are all members reached at time?
Is Terms of reference & Agenda is prepared and followed?

Was the necessary pre-work done by participants i.e. Daily Stats sourc
solutions identified prior to meeting commencing?
Is Terms of reference understood by all DRM Members?
Are all members aware of their roles in the meeting?.
Do DRM Members understand the importance of the meeting.?

Were variances identified and corrective actions recorded in Action Pla

Were actions, responsibilities and due dates assigned on the Action Pla
Have you used the system to achieve the KPI's?

Were the documentated action logs is reviewed and points are being cl
Did Template mailed or received on time?

Is generation is so planned that all department have sufficient power to


is there any remark generated against short fall in supply
Did template is understood to all/
Do everybody know about such planning?
Did this planning is conveyed to all department

Any action taken against short fall in supply against requirement.


Did daily study about GAP in supply and demand happen?

Have you used the system to achieve the KPI's?


Export is reduceding or not.

Have all the details related to breakdown are being filled by Operations

Have all the details related to Breakdown are being filled by Maintenanc
Did you review breakdowns for previous day ?
What benefit is expected by recording breakdowns? Do you think both
should get involved in recording of Breakdown slips?

Please give us reason why breakdown start time plus job start and finis

What analysis of information about breakdowns captured should be do

Demonstrate how you are doing basic Root Cause Analysis by using th

Have you discussed with your manager on action points based on your
suggestions/message/pending jobs in breakdown slip?
Have you used the system to achieve the KPI's?
What are the actions taken based on issues like spare information, high
resolution of breakdown etc.

Have all the details related to breakdown are being filled by Operations

Have all the details related to Breakdown are being filled by Maintenanc
Did you review breakdowns for previous day ?
What benefit is expected by recording breakdowns? Do you think both
should get involved in recording of Breakdown slips?

Please give us reason why breakdown start time plus job start and finis

What analysis of information about breakdowns captured should be do

Demonstrate how you are doing basic Root Cause Analysis by using th

Have you discussed with your manager on action points based on your
suggestions/message/pending jobs in breakdown slip?
Have you used the system to achieve the KPI's?
What are the actions taken based on issues like spare information, high
resolution of breakdown etc.

Have all the details related to breakdown are being filled by data feedin

Have all the details related to Breakdown are being correctly filled by th
Did you review the data of breakdowns slip before feeding ?
What benefit is expected by recording breakdowns? Do you think both
should get involved in recording of Breakdown slips?

Please give us reason why breakdown start time plus job start and finis

What analysis of information about breakdowns captured should be do

Demonstrate how you are doing basic Root Cause Analysis by using th

Have you used the system to achieve the KPI's?


Have you discussed with your manager on action points based on your
suggestions/message/pending jobs in breakdown slip?
What are the actions taken based on issues like spare information, high
resolution of breakdown etc.

Have all the details related to breakdown are being filled by data feedin

Have all the details related to Breakdown are being correctly filled by th
Did you review the data of breakdowns slip before feeding ?
What benefit is expected by recording breakdowns? Do you think both
should get involved in recording of Breakdown slips?

Please give us reason why breakdown start time plus job start and finis

What analysis of information about breakdowns captured should be do

Demonstrate how you are doing basic Root Cause Analysis by using th

Have you used the system to achieve the KPI's?


Have you discussed with your manager on action points based on your
suggestions/message/pending jobs in breakdown slip?
What are the actions taken based on issues like spare information, high
resolution of breakdown etc.
Whether template is filled completely ?
Whether all the inter departmental jobs are incorporated?

Availability of spares and other critical equipment is done as per job sco
Why do we need to fill the sheet?

Whether all blocks has been completely understood by HOD?


Whether they are aware of how to track the system?
Whether the concerned people planning daily jobs as per Schedule?
Have you used the system to achieve the KPI's?

Whether the information flow became more effective with the template
Has the information helped in taking pro active actions?
Whether template is filled completely ?
Whether all the inter departmental jobs are incorporated?

Availability of spares and other critical equipment is done as per job sco
Why do we need to fill the sheet?
Whether all blocks has been completely understood by HOD?
Whether they are aware of how to track the system?
Whether the concerned people planning daily jobs as per Schedule?
Have you used the system to achieve the KPI's?

Whether the information flow became more effective with the template
Has the information helped in taking pro active actions?
Are you carrying out root cause analysis as per RCA Policy?

Are you maintaning a RCA documentation file? Please show the RCA lo
Does "5 why" format exist and used please show.

What is the need for RCA policy?


Why do we need to Maintain RCA log book. ?
What is the benefit of using 5 Why template ?

Show if any repetitive problem were corrected by using root cause anal
Please provide one example based on last RCA done?

Have you documented the actions and can you link the actions to the im
Are you carrying out root cause analysis as per RCA Policy?

Are you maintaning a RCA documentation file? Please show the RCA lo
Does "5 why" format exist and used please show.
What is the need for RCA policy?
Why do we need to Maintain RCA log book. ?
What is the benefit of using 5 Why template ?

Show if any repetitive problem were corrected by using root cause anal
Please provide one example based on last RCA done?
Have you used the system to achieve the KPI's?

Have you documented the actions and can you link the actions to the im
Whether the Job checking is done as per shut down planning?
Whether the job checking is done by the team formed?
Whether remarks are mentioned against poor quality of jobs?

Whether the team Is aware of importance of job quality checking?


Whether all jobs compered were completely understood ?
Whether they are aware of how to do job checking?
Whether the frequency of equipment failure reduced post light up?
Have you used the system to achieve the KPI's?
Whether Any counter measures taken to avoid critical issues.?

Whether the Job checking is done as per shut down planning?


Whether the job checking is done by the team formed?
Whether remarks are mentioned against poor quality of jobs?
Whether the team Is aware of importance of job quality checking?
Whether all jobs compered were completely understood ?
Whether they are aware of how to do job checking?
Whether the frequency of equipment failure reduced post light up?
Whether Any counter measures taken to avoid critical issues.?
Have you used the system to achieve the KPI's?
Is PM Schedule followed regularly?
Is PM Checklist completely filled by the Engineers?

Is any remarks mentioned against the work done?


Why do we need to follow the PM Plan?

Whether all plans & Checklist has been completely understood by conc
Whether concern people know how to perform PM?
Has the equipment life been improved with this plan?
Has the PM Plan helped in improving MTBF?
Have you used the system to achieve the KPI's?
Is monthly generation plan prepared by the department?
Is monthly production plan of SID taken into account?
Is the plan ready on the first working day of the month?
Why do we need to make the monthly generation plan?

Is the power gneration plan has been completely understood by the con
Whether sponge iron department head was aware of the planning?
Has the overall power generation has increased??

Has the monthly generation plan helped in better weekly and daily pow
Have you used the system to achieve the KPI's?
Was the generation plan on track??
Did meeting start on time? Are all members reached at time?
Is Terms of reference & Agenda is prepared and followed?

Was the necessary pre-work done by participants i.e. Daily work done ,

Do the responsible members understand the importance of daily shutdo


Are all members aware of their roles in the meeting?.

Availability of spares, castable was checked as per the shutdown plan?

Were variances identified and corrective actions recorded in Action Pla

Were actions, responsibilities and due dates assigned on the Action Pla
Have you used the system to achieve the KPI's?

Were the documented action logs is reviewed and points are being clos

Total number of Sys

AUDIT BY

AUDIT DATE

Rating Scale

0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)

Supervisory Actions Required


to Enable Improvement /
Sustain

3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)

1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)

0
(NIL)
1
(PARTIAL)
3
(HIGH)

0
(NIL)

1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)

3
(HIGH)
0
(NIL)

1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)

3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)

1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)

1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
1
(PARTIAL)
3
(HIGH)
1
(PARTIAL)

1
(PARTIAL)
1
(PARTIAL)
1
(PARTIAL)
0
(NIL)
0
(NIL)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
1
(PARTIAL)
1
(PARTIAL)
1
(PARTIAL)
1
(PARTIAL)
0
(NIL)
0
(NIL)
0
(NIL)
0
(NIL)
1
(PARTIAL)
3
(HIGH)

0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)

3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)

3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)

10

TOTAL COMPLIANCE

18

TOTAL UNDERSTANDING
TOTAL USAGE

Taskforce

27-Feb-15

Observed Current Rating for


this category
(Score: 0, 1 or 3)

REMAR

(Key in any remarks which justify the

Some job is not filled w


1

as compliance is not upto at extent s

as compliance is not upto at extent s

92%
100%
92%

REMARKS

arks which justify the observed rating given to the auditee)

Some job is not filled with complete infromation.

e is not upto at extent so usage mark will ultimately go down

e is not upto at extent so usage mark will ultimately go down

ACTION PLAN
(Key in the required action that needs to be taken to address issues - th
must be done for System Elements with a yellow or red scores)

Marking done around that job and it will soon get completed and tomorrow on
more audit of BMS of phase 1 will be done

it will again audited tomorrow

it will again audited tomorrow

N
taken to address issues - this
th a yellow or red scores)

get completed and tomorrow once


e 1 will be done

omorrow

omorrow

Sr. No.
System Elements
Accountable

Responsible

FREQUENCY

Shift Handover and log


sheet - Phase 1

Sr. Manager / Manager

Shift Incharge (Engineer)

Daily

2
Shift Handover and log
sheet - Phase 2

Sr. Manager / Manager

Shift Incharge (Engineer)


Daily

Line Walk - Phase

General Manager (Maintenance)

Managers

Weekly

Shift I

Sr.

4
Daily Review Meeting

DRM Chairman

All DRM Members


Daily

Power Plant requirement


and fullfillment

AGM (operation)

Electrical HOD

Daily

General Man

Dai
Daily

Electric

Breakdown Slip (Phase 1)

Engineers

AGM (op

Power Plant requirement


and fullfillment

Managers

Breakdown Slip (Phase 2)

Managers

Engineers

Daily

Breakdown Management
System (BMS) - Phase 1

Managers

Engineers

Monday, Wednesday, Friday

GM

Monday, Wednesday, Friday

Shut Down Job Scoping


Phase 1

nd When Required

Managers

10

Engineers

Breakdown Management
System (BMS) - Phase 2

partmental HOD

Monday

Shut Down Job Scoping


Kiln Phase 2

12

Root Cause Analysis Phase 1

Weekly

nager / Manager

As and When Required

Departmental HOD

As and When R

Departmental

GM

11

GM

Shut Down Job Scoping


Phase 1

l - General Manager

10

Job Quality Check Phase 1

en Required

Weekly

Sr.Manager / Manager

14

arge (Engineer)

Root Cause Analysis Phase 2

Weekly

Sr.Manager / Mana

Sectional - General M

13

Sectional - General Manager

Root Cause Analysis Phase 1

ger / Manager

12

Job Quality Check Phase 2

16

Preventive Maintenance
Planning

Daily

rge (Engineer)

As When Required

Shift In charge (Engineer)

As When Require

Shift Incharge (Engin

Sr. Manager / Mana

15

Sr. Manager / Manager

Job Quality Check Phase 1

ger / Manager

14

ired - During
n

harges

Monthly Power
Generation Plan

1st of every month

Shift Incharge (Engineer)

Daily

Shift Incharge (Engine

Sr. Manager / Manage

17

Sr. Manager / Manager

Preventive Maintenance
Planning

rman

16

18

As and When Required - During


Shutdown

Process In charges

DRM Chairman

Shutdown Review
Meeting

Categories

S1:
Compliance

S2:
Understanding

S3:
Usage

S3:
Usage

S1:
Compliance

S2:
Understanding

S3:
Usage

S1:
Compliance

S2:
Understanding

S3:
Usage

S3:
Usage

S1:
Compliance

S2:
Understanding

S3:
Usage

S1:
Compliance

S2:
Understanding

S3:
Usage

S1:
Compliance

S2:
Understanding

S3:
Usage

S1:
Compliance

S1:
Compliance

S2:
Understanding

S3:
Usage

S1:
Compliance

S2:
Understanding

S3:
Usage

S3:
Usage

S1:
Compliance

S2:
Understanding

S3:
Usage

S1:
Compliance

S2:
Understanding

S2:
Understanding

S3:
Usage

S1:
Compliance

S2:
Understanding

S3:
Usage

S1:
Compliance

S2:
Understanding

S2:
Understanding

S3:
Usage

S1:
Compliance

S2:
Understanding

S3:
Usage

S1:
Compliance

S2:
Understanding

S2:
Understanding

S3:
Usage

S1:
Compliance

S2:
Understanding

S3:
Usage

S1:
Compliance

S2:
Understanding

S3:
Usage

S1:
Compliance

S2:
Understanding

S3:
Usage

S1:
Compliance

S1:
Compliance

S2:
Understanding

S3:
Usage

Name of Area / Department being Audited: Operations / Maintenance

Name of Area / Department Manager: Respective Manager

Name of Individuals Audited:

OBSERVATIONS
(Based on ACTUAL observations and Interviews, use the following quest
best represent the level of compliance/understanding/usage of

Whether template is filled completely?


Whether all concerned people have signed the template?
Whether any remark mentioned on the sheet?
Why do we need to fill the sheet?
Whether all blocks has been completely understood by shift incharge?
Whether the complete sheet is understood by the shift incharge?
How shift handover process has been improved?
Have the information flow became more effective with the templates?

Have you used the system to achieve the KPI's?


Has all the information has been shared during shift handover.?
Whether template is filled completely?
Whether all concerned people have signed the template?
Whether any remark mentioned on the sheet?
Why do we need to fill the sheet?
Whether all blocks has been completely understood by shift incharge?
Whether the complete sheet is understood by the shift incharge?
How shift handover process has been improved?
Have the information flow became more effective with the templates?
Have you used the system to achieve the KPI's?
Has all the information has been shared during shift handover.?
Is line walk schedule prepared? Is it done as per schedule.?
Is line walk log sheet is filled properly and reported as on the day?
Is line walk is done properly by the assigned person?
Are all the codes underdstood by the person.?

Is the line walk personnel understood the scope or area where he has t
What is the benfit of doing line walk?
Is line walk log sheet is reviewed by HOD?

Are task has been assigned with its priority?


Have you used the system to achieve the KPI's?
Are all the high priority issues has been closed?
Did meeting start on time? Are all members reached at time?
Is Terms of reference & Agenda is prepared and followed?

Was the necessary pre-work done by participants i.e. Daily Stats sourc
solutions identified prior to meeting commencing?
Is Terms of reference understood by all DRM Members?
Are all members aware of their roles in the meeting?.
Do DRM Members understand the importance of the meeting.?

Were variances identified and corrective actions recorded in Action Pla

Were actions, responsibilities and due dates assigned on the Action Pla
Have you used the system to achieve the KPI's?

Were the documentated action logs is reviewed and points are being cl
Did Template mailed or received on time?

Is generation is so planned that all department have sufficient power to


is there any remark generated against short fall in supply
Did template is understood to all/
Do everybody know about such planning?
Did this planning is conveyed to all department

Any action taken against short fall in supply against requirement.


Did daily study about GAP in supply and demand happen?

Have you used the system to achieve the KPI's?


Export is reduceding or not.

Have all the details related to breakdown are being filled by Operations

Have all the details related to Breakdown are being filled by Maintenanc
Did you review breakdowns for previous day ?
What benefit is expected by recording breakdowns? Do you think both
should get involved in recording of Breakdown slips?

Please give us reason why breakdown start time plus job start and finis

What analysis of information about breakdowns captured should be do

Demonstrate how you are doing basic Root Cause Analysis by using th

Have you discussed with your manager on action points based on your
suggestions/message/pending jobs in breakdown slip?
Have you used the system to achieve the KPI's?
What are the actions taken based on issues like spare information, high
resolution of breakdown etc.

Have all the details related to breakdown are being filled by Operations

Have all the details related to Breakdown are being filled by Maintenanc
Did you review breakdowns for previous day ?
What benefit is expected by recording breakdowns? Do you think both
should get involved in recording of Breakdown slips?

Please give us reason why breakdown start time plus job start and finis

What analysis of information about breakdowns captured should be do

Demonstrate how you are doing basic Root Cause Analysis by using th

Have you discussed with your manager on action points based on your
suggestions/message/pending jobs in breakdown slip?
Have you used the system to achieve the KPI's?
What are the actions taken based on issues like spare information, high
resolution of breakdown etc.

Have all the details related to breakdown are being filled by data feedin

Have all the details related to Breakdown are being correctly filled by th
Did you review the data of breakdowns slip before feeding ?
What benefit is expected by recording breakdowns? Do you think both
should get involved in recording of Breakdown slips?

Please give us reason why breakdown start time plus job start and finis

What analysis of information about breakdowns captured should be do

Demonstrate how you are doing basic Root Cause Analysis by using th
Have you used the system to achieve the KPI's?

Have you discussed with your manager on action points based on your
suggestions/message/pending jobs in breakdown slip?
What are the actions taken based on issues like spare information, high
resolution of breakdown etc.

Have all the details related to breakdown are being filled by data feedin

Have all the details related to Breakdown are being correctly filled by th
Did you review the data of breakdowns slip before feeding ?
What benefit is expected by recording breakdowns? Do you think both
should get involved in recording of Breakdown slips?

Please give us reason why breakdown start time plus job start and finis

What analysis of information about breakdowns captured should be do

Demonstrate how you are doing basic Root Cause Analysis by using th

Have you used the system to achieve the KPI's?


Have you discussed with your manager on action points based on your
suggestions/message/pending jobs in breakdown slip?
What are the actions taken based on issues like spare information, high
resolution of breakdown etc.
Whether template is filled completely ?
Whether all the inter departmental jobs are incorporated?

Availability of spares and other critical equipment is done as per job sco
Why do we need to fill the sheet?
Whether all blocks has been completely understood by HOD?

Whether they are aware of how to track the system?


Whether the concerned people planning daily jobs as per Schedule?
Have you used the system to achieve the KPI's?

Whether the information flow became more effective with the template
Has the information helped in taking pro active actions?
Whether template is filled completely ?
Whether all the inter departmental jobs are incorporated?

Availability of spares and other critical equipment is done as per job sco
Why do we need to fill the sheet?
Whether all blocks has been completely understood by HOD?
Whether they are aware of how to track the system?
Whether the concerned people planning daily jobs as per Schedule?
Have you used the system to achieve the KPI's?

Whether the information flow became more effective with the template
Has the information helped in taking pro active actions?
Are you carrying out root cause analysis as per RCA Policy?

Are you maintaning a RCA documentation file? Please show the RCA lo
Does "5 why" format exist and used please show.
What is the need for RCA policy?

Why do we need to Maintain RCA log book. ?


What is the benefit of using 5 Why template ?

Show if any repetitive problem were corrected by using root cause anal
Please provide one example based on last RCA done?

Have you documented the actions and can you link the actions to the im
Are you carrying out root cause analysis as per RCA Policy?

Are you maintaning a RCA documentation file? Please show the RCA lo
Does "5 why" format exist and used please show.
What is the need for RCA policy?
Why do we need to Maintain RCA log book. ?
What is the benefit of using 5 Why template ?

Show if any repetitive problem were corrected by using root cause anal
Please provide one example based on last RCA done?
Have you used the system to achieve the KPI's?

Have you documented the actions and can you link the actions to the im
Whether the Job checking is done as per shut down planning?
Whether the job checking is done by the team formed?
Whether remarks are mentioned against poor quality of jobs?
Whether the team Is aware of importance of job quality checking?

Whether all jobs compered were completely understood ?


Whether they are aware of how to do job checking?
Whether the frequency of equipment failure reduced post light up?
Have you used the system to achieve the KPI's?
Whether Any counter measures taken to avoid critical issues.?

Whether the Job checking is done as per shut down planning?


Whether the job checking is done by the team formed?
Whether remarks are mentioned against poor quality of jobs?
Whether the team Is aware of importance of job quality checking?
Whether all jobs compered were completely understood ?
Whether they are aware of how to do job checking?
Whether the frequency of equipment failure reduced post light up?
Whether Any counter measures taken to avoid critical issues.?
Have you used the system to achieve the KPI's?
Is PM Schedule followed regularly?
Is PM Checklist completely filled by the Engineers?
Is any remarks mentioned against the work done?

Why do we need to follow the PM Plan?

Whether all plans & Checklist has been completely understood by conc
Whether concern people know how to perform PM?
Has the equipment life been improved with this plan?
Has the PM Plan helped in improving MTBF?
Have you used the system to achieve the KPI's?
Is monthly generation plan prepared by the department?
Is monthly production plan of SID taken into account?
Is the plan ready on the first working day of the month?
Why do we need to make the monthly generation plan?

Is the power gneration plan has been completely understood by the con
Whether sponge iron department head was aware of the planning?
Has the overall power generation has increased??

Has the monthly generation plan helped in better weekly and daily pow
Have you used the system to achieve the KPI's?
Was the generation plan on track??
Did meeting start on time? Are all members reached at time?
Is Terms of reference & Agenda is prepared and followed?

Was the necessary pre-work done by participants i.e. Daily work done ,

Do the responsible members understand the importance of daily shutdo


Are all members aware of their roles in the meeting?.

Availability of spares, castable was checked as per the shutdown plan?

Were variances identified and corrective actions recorded in Action Pla

Were actions, responsibilities and due dates assigned on the Action Pla
Have you used the system to achieve the KPI's?

Were the documented action logs is reviewed and points are being clos

Total number of Sys

AUDIT BY

AUDIT DATE

Rating Scale

0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)

Supervisory Actions Required


to Enable Improvement /
Sustain

3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)

1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)

0
(NIL)
1
(PARTIAL)
3
(HIGH)

0
(NIL)

1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)

3
(HIGH)
0
(NIL)

1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)

3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)

1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)

3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
1
(PARTIAL)
3
(HIGH)
1
(PARTIAL)
1
(PARTIAL)

1
(PARTIAL)
1
(PARTIAL)
0
(NIL)
0
(NIL)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
1
(PARTIAL)
1
(PARTIAL)
1
(PARTIAL)
1
(PARTIAL)
0
(NIL)
0
(NIL)
0
(NIL)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)

1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)

0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)

3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)

5
18

TOTAL COMPLIANCE
TOTAL UNDERSTANDING
TOTAL USAGE

Taskforce

5-Mar-15

Observed Current Rating for


this category
(Score: 0, 1 or 3)

REMAR

(Key in any remarks which justify the

As break down slip for po

Approval was

some data as not properly filled so

some job is
1

usage is low due to low compliance


1

95%
100%
79%

REMARKS

arks which justify the observed rating given to the auditee)

break down slip for power cylinder is completed

Approval was not done yet.

as not properly filled so break down analysis usage is low

some job is not fulfilled

ow compliance

ACTION PLAN
(Key in the required action that needs to be taken to address issues - th
must be done for System Elements with a yellow or red scores)

approval should be done as soon as possible.

N
taken to address issues - this
th a yellow or red scores)

oon as possible.

Sr. No.
System Elements
Accountable

Responsible

FREQUENCY

Shift Handover and log


sheet - Phase 1

Sr. Manager / Manager

Shift Incharge (Engineer)

Daily

2
Shift Handover and log
sheet - Phase 2

Sr. Manager / Manager

Shift Incharge (Engineer)


Daily

Line Walk - Phase

General Manager (Maintenance)

Managers

Weekly

Shift I

Sr.

4
Daily Review Meeting

DRM Chairman

All DRM Members


Daily

Power Plant requirement


and fullfillment

AGM (operation)

Electrical HOD

Daily

General Man

Dai
Daily

Electric

Breakdown Slip (Phase 1)

Engineers

AGM (op

Power Plant requirement


and fullfillment

Managers

Breakdown Slip (Phase 2)

Managers

Engineers

Daily

Breakdown Management
System (BMS) - Phase 1

Managers

Engineers

Monday, Wednesday, Friday

GM

Monday, Wednesday, Friday

Shut Down Job Scoping


Phase 1

nd When Required

Managers

10

Engineers

Breakdown Management
System (BMS) - Phase 2

partmental HOD

Monday

Shut Down Job Scoping


Kiln Phase 2

12

Root Cause Analysis Phase 1

Weekly

nager / Manager

As and When Required

Departmental HOD

As and When R

Departmental

GM

11

GM

Shut Down Job Scoping


Phase 1

l - General Manager

10

Job Quality Check Phase 1

en Required

Weekly

Sr.Manager / Manager

14

arge (Engineer)

Root Cause Analysis Phase 2

Weekly

Sr.Manager / Mana

Sectional - General M

13

Sectional - General Manager

Root Cause Analysis Phase 1

ger / Manager

12

Job Quality Check Phase 2

16

Preventive Maintenance
Planning

Daily

rge (Engineer)

As When Required

Shift In charge (Engineer)

As When Require

Shift Incharge (Engin

Sr. Manager / Mana

15

Sr. Manager / Manager

Job Quality Check Phase 1

ger / Manager

14

ired - During
n

harges

Monthly Power
Generation Plan

1st of every month

Shift Incharge (Engineer)

Daily

Shift Incharge (Engine

Sr. Manager / Manage

17

Sr. Manager / Manager

Preventive Maintenance
Planning

rman

16

18

As and When Required - During


Shutdown

Process In charges

DRM Chairman

Shutdown Review
Meeting

Categories

S1:
Compliance

S2:
Understanding

S3:
Usage

S3:
Usage

S1:
Compliance

S2:
Understanding

S3:
Usage

S1:
Compliance

S2:
Understanding

S3:
Usage

S3:
Usage

S1:
Compliance

S2:
Understanding

S3:
Usage

S1:
Compliance

S2:
Understanding

S3:
Usage

S1:
Compliance

S2:
Understanding

S3:
Usage

S1:
Compliance

S1:
Compliance

S2:
Understanding

S3:
Usage

S1:
Compliance

S2:
Understanding

S3:
Usage

S3:
Usage

S1:
Compliance

S2:
Understanding

S3:
Usage

S1:
Compliance

S2:
Understanding

S2:
Understanding

S3:
Usage

S1:
Compliance

S2:
Understanding

S3:
Usage

S1:
Compliance

S2:
Understanding

S2:
Understanding

S3:
Usage

S1:
Compliance

S2:
Understanding

S3:
Usage

S1:
Compliance

S2:
Understanding

S2:
Understanding

S3:
Usage

S1:
Compliance

S2:
Understanding

S3:
Usage

S1:
Compliance

S2:
Understanding

S3:
Usage

S1:
Compliance

S2:
Understanding

S3:
Usage

S1:
Compliance

S1:
Compliance

S2:
Understanding

S3:
Usage

Name of Area / Department being Audited: Operations / Maintenance

Name of Area / Department Manager: Respective Manager

Name of Individuals Audited:

OBSERVATIONS
(Based on ACTUAL observations and Interviews, use the following quest
best represent the level of compliance/understanding/usage of

Whether template is filled completely?


Whether all concerned people have signed the template?
Whether any remark mentioned on the sheet?
Why do we need to fill the sheet?
Whether all blocks has been completely understood by shift incharge?
Whether the complete sheet is understood by the shift incharge?
How shift handover process has been improved?
Have the information flow became more effective with the templates?

Have you used the system to achieve the KPI's?


Has all the information has been shared during shift handover.?
Whether template is filled completely?
Whether all concerned people have signed the template?
Whether any remark mentioned on the sheet?
Why do we need to fill the sheet?
Whether all blocks has been completely understood by shift incharge?
Whether the complete sheet is understood by the shift incharge?
How shift handover process has been improved?
Have the information flow became more effective with the templates?
Have you used the system to achieve the KPI's?
Has all the information has been shared during shift handover.?
Is line walk schedule prepared? Is it done as per schedule.?
Is line walk log sheet is filled properly and reported as on the day?
Is line walk is done properly by the assigned person?
Are all the codes underdstood by the person.?

Is the line walk personnel understood the scope or area where he has t
What is the benfit of doing line walk?
Is line walk log sheet is reviewed by HOD?

Are task has been assigned with its priority?


Have you used the system to achieve the KPI's?
Are all the high priority issues has been closed?
Did meeting start on time? Are all members reached at time?
Is Terms of reference & Agenda is prepared and followed?

Was the necessary pre-work done by participants i.e. Daily Stats sourc
solutions identified prior to meeting commencing?
Is Terms of reference understood by all DRM Members?
Are all members aware of their roles in the meeting?.
Do DRM Members understand the importance of the meeting.?

Were variances identified and corrective actions recorded in Action Pla

Were actions, responsibilities and due dates assigned on the Action Pla
Have you used the system to achieve the KPI's?

Were the documentated action logs is reviewed and points are being cl
Did Template mailed or received on time?

Is generation is so planned that all department have sufficient power to


is there any remark generated against short fall in supply
Did template is understood to all/
Do everybody know about such planning?
Did this planning is conveyed to all department

Any action taken against short fall in supply against requirement.


Did daily study about GAP in supply and demand happen?

Have you used the system to achieve the KPI's?


Export is reduceding or not.

Have all the details related to breakdown are being filled by Operations

Have all the details related to Breakdown are being filled by Maintenanc
Did you review breakdowns for previous day ?
What benefit is expected by recording breakdowns? Do you think both
should get involved in recording of Breakdown slips?

Please give us reason why breakdown start time plus job start and finis

What analysis of information about breakdowns captured should be do

Demonstrate how you are doing basic Root Cause Analysis by using th

Have you discussed with your manager on action points based on your
suggestions/message/pending jobs in breakdown slip?
Have you used the system to achieve the KPI's?
What are the actions taken based on issues like spare information, high
resolution of breakdown etc.

Have all the details related to breakdown are being filled by Operations

Have all the details related to Breakdown are being filled by Maintenanc
Did you review breakdowns for previous day ?
What benefit is expected by recording breakdowns? Do you think both
should get involved in recording of Breakdown slips?

Please give us reason why breakdown start time plus job start and finis

What analysis of information about breakdowns captured should be do

Demonstrate how you are doing basic Root Cause Analysis by using th

Have you discussed with your manager on action points based on your
suggestions/message/pending jobs in breakdown slip?
Have you used the system to achieve the KPI's?
What are the actions taken based on issues like spare information, high
resolution of breakdown etc.

Have all the details related to breakdown are being filled by data feedin

Have all the details related to Breakdown are being correctly filled by th
Did you review the data of breakdowns slip before feeding ?
What benefit is expected by recording breakdowns? Do you think both
should get involved in recording of Breakdown slips?

Please give us reason why breakdown start time plus job start and finis

What analysis of information about breakdowns captured should be do

Demonstrate how you are doing basic Root Cause Analysis by using th
Have you used the system to achieve the KPI's?

Have you discussed with your manager on action points based on your
suggestions/message/pending jobs in breakdown slip?
What are the actions taken based on issues like spare information, high
resolution of breakdown etc.

Have all the details related to breakdown are being filled by data feedin

Have all the details related to Breakdown are being correctly filled by th
Did you review the data of breakdowns slip before feeding ?
What benefit is expected by recording breakdowns? Do you think both
should get involved in recording of Breakdown slips?

Please give us reason why breakdown start time plus job start and finis

What analysis of information about breakdowns captured should be do

Demonstrate how you are doing basic Root Cause Analysis by using th

Have you used the system to achieve the KPI's?


Have you discussed with your manager on action points based on your
suggestions/message/pending jobs in breakdown slip?
What are the actions taken based on issues like spare information, high
resolution of breakdown etc.
Whether template is filled completely ?
Whether all the inter departmental jobs are incorporated?

Availability of spares and other critical equipment is done as per job sco
Why do we need to fill the sheet?
Whether all blocks has been completely understood by HOD?

Whether they are aware of how to track the system?


Whether the concerned people planning daily jobs as per Schedule?
Have you used the system to achieve the KPI's?

Whether the information flow became more effective with the template
Has the information helped in taking pro active actions?
Whether template is filled completely ?
Whether all the inter departmental jobs are incorporated?

Availability of spares and other critical equipment is done as per job sco
Why do we need to fill the sheet?
Whether all blocks has been completely understood by HOD?
Whether they are aware of how to track the system?
Whether the concerned people planning daily jobs as per Schedule?
Have you used the system to achieve the KPI's?

Whether the information flow became more effective with the template
Has the information helped in taking pro active actions?
Are you carrying out root cause analysis as per RCA Policy?

Are you maintaning a RCA documentation file? Please show the RCA lo
Does "5 why" format exist and used please show.
What is the need for RCA policy?

Why do we need to Maintain RCA log book. ?


What is the benefit of using 5 Why template ?

Show if any repetitive problem were corrected by using root cause anal
Please provide one example based on last RCA done?

Have you documented the actions and can you link the actions to the im
Are you carrying out root cause analysis as per RCA Policy?

Are you maintaning a RCA documentation file? Please show the RCA lo
Does "5 why" format exist and used please show.
What is the need for RCA policy?
Why do we need to Maintain RCA log book. ?
What is the benefit of using 5 Why template ?

Show if any repetitive problem were corrected by using root cause anal
Please provide one example based on last RCA done?
Have you used the system to achieve the KPI's?

Have you documented the actions and can you link the actions to the im
Whether the Job checking is done as per shut down planning?
Whether the job checking is done by the team formed?
Whether remarks are mentioned against poor quality of jobs?
Whether the team Is aware of importance of job quality checking?

Whether all jobs compered were completely understood ?


Whether they are aware of how to do job checking?
Whether the frequency of equipment failure reduced post light up?
Have you used the system to achieve the KPI's?
Whether Any counter measures taken to avoid critical issues.?

Whether the Job checking is done as per shut down planning?


Whether the job checking is done by the team formed?
Whether remarks are mentioned against poor quality of jobs?
Whether the team Is aware of importance of job quality checking?
Whether all jobs compered were completely understood ?
Whether they are aware of how to do job checking?
Whether the frequency of equipment failure reduced post light up?
Whether Any counter measures taken to avoid critical issues.?
Have you used the system to achieve the KPI's?
Is PM Schedule followed regularly?
Is PM Checklist completely filled by the Engineers?
Is any remarks mentioned against the work done?

Why do we need to follow the PM Plan?

Whether all plans & Checklist has been completely understood by conc
Whether concern people know how to perform PM?
Has the equipment life been improved with this plan?
Has the PM Plan helped in improving MTBF?
Have you used the system to achieve the KPI's?
Is monthly generation plan prepared by the department?
Is monthly production plan of SID taken into account?
Is the plan ready on the first working day of the month?
Why do we need to make the monthly generation plan?

Is the power gneration plan has been completely understood by the con
Whether sponge iron department head was aware of the planning?
Has the overall power generation has increased??

Has the monthly generation plan helped in better weekly and daily pow
Have you used the system to achieve the KPI's?
Was the generation plan on track??
Did meeting start on time? Are all members reached at time?
Is Terms of reference & Agenda is prepared and followed?

Was the necessary pre-work done by participants i.e. Daily work done ,

Do the responsible members understand the importance of daily shutdo


Are all members aware of their roles in the meeting?.

Availability of spares, castable was checked as per the shutdown plan?

Were variances identified and corrective actions recorded in Action Pla

Were actions, responsibilities and due dates assigned on the Action Pla
Have you used the system to achieve the KPI's?

Were the documented action logs is reviewed and points are being clos

Total number of Sys

AUDIT BY

AUDIT DATE

Rating Scale

0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)

Supervisory Actions Required


to Enable Improvement /
Sustain

3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)

1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)

0
(NIL)
1
(PARTIAL)
3
(HIGH)

0
(NIL)

1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)

3
(HIGH)
0
(NIL)

1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)

3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)

1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)

3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
1
(PARTIAL)
3
(HIGH)
1
(PARTIAL)
1
(PARTIAL)

1
(PARTIAL)
1
(PARTIAL)
0
(NIL)
0
(NIL)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
1
(PARTIAL)
1
(PARTIAL)
1
(PARTIAL)
1
(PARTIAL)
0
(NIL)
0
(NIL)
0
(NIL)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)

1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)

0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)

3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)

7
18

TOTAL COMPLIANCE
TOTAL UNDERSTANDING
TOTAL USAGE

Taskforce

14-Mar-15

Observed Current Rating for


this category
(Score: 0, 1 or 3)

REMAR

(Key in any remarks which justify the

Few job is not mentioned with time


1

There is no due date


3

Not a
0

Not a
0

one job have involvemnet of only mechanic


boiler is in running condition.But it is not me
1

one job have involvemnet of only mechanic


boiler is in running condition.But it is not me
1

Compliance mode is low be


of 100 TPH (APH)
1

shut down tracking is do


compliance mode due to una
folder to a
1

shut down tracking is do


compliance mode due to una
folder to a
1

88%
94%
82%

REMARKS

arks which justify the observed rating given to the auditee)

entioned with time

ere is no due date for any not started job

Not audited

Not audited

mnet of only mechanical and instrument will check it when the


ondition.But it is not mentioned in WHrb # 2 sheet.

mnet of only mechanical and instrument will check it when the


ondition.But it is not mentioned in WHrb # 2 sheet.

mode is low because Job status is not filled


00 TPH (APH) by any department

n tracking is done but there is little fall in


mode due to unavailability of common server
folder to all at once.

n tracking is done but there is little fall in


mode due to unavailability of common server
folder to all at once.

ACTION PLAN
(Key in the required action that needs to be taken to address issues - th
must be done for System Elements with a yellow or red scores)

information is conveyed to the mat member in MAT meeting an


action taken and summary chart is updated

Information is conveyed to all sectional HOD and it will be discussed in DRM


meeting on Monday

Information is conveyed to all sectional HOD and it will be discussed in DRM


meeting on Monday

message is conveyed to all department in DRM


meeting

information is conveyed to IT department and they to


us it can`t be solved.So today in DRM it is decided to
fill it in night also.

information is conveyed to IT department and they to


us it can`t be solved.So today in DRM it is decided to
fill it in night also.

N
taken to address issues - this
th a yellow or red scores)

ember in MAT meeting and


chart is updated

d it will be discussed in DRM

department in DRM

epartment and they told


n DRM it is decided to
also.

Sr. No.
System Elements
Accountable

Responsible

FREQUENCY

Shift Handover and log


sheet - Phase 1

Sr. Manager / Manager

Shift Incharge (Engineer)

Daily

2
Shift Handover and log
sheet - Phase 2

Sr. Manager / Manager

Shift Incharge (Engineer)


Daily

Line Walk - Phase

General Manager (Maintenance)

Managers

Weekly

Shift I

Sr.

4
Daily Review Meeting

DRM Chairman

All DRM Members


Daily

Power Plant requirement


and fullfillment

AGM (operation)

Electrical HOD

Daily

General Man

Dai
Daily

Electric

Breakdown Slip (Phase 1)

Engineers

AGM (op

Power Plant requirement


and fullfillment

Managers

Breakdown Slip (Phase 2)

Managers

Engineers

Daily

Breakdown Management
System (BMS) - Phase 1

Managers

Engineers

Monday, Wednesday, Friday

GM

Monday, Wednesday, Friday

Shut Down Job Scoping


Phase 1

nd When Required

Managers

10

Engineers

Breakdown Management
System (BMS) - Phase 2

partmental HOD

Monday

Shut Down Job Scoping


Kiln Phase 2

12

Root Cause Analysis Phase 1

Weekly

nager / Manager

As and When Required

Departmental HOD

As and When R

Departmental

GM

11

GM

Shut Down Job Scoping


Phase 1

l - General Manager

10

Job Quality Check Phase 1

en Required

Weekly

Sr.Manager / Manager

14

arge (Engineer)

Root Cause Analysis Phase 2

Weekly

Sr.Manager / Mana

Sectional - General M

13

Sectional - General Manager

Root Cause Analysis Phase 1

ger / Manager

12

Job Quality Check Phase 2

16

Preventive Maintenance
Planning

Daily

rge (Engineer)

As When Required

Shift In charge (Engineer)

As When Require

Shift Incharge (Engin

Sr. Manager / Mana

15

Sr. Manager / Manager

Job Quality Check Phase 1

ger / Manager

14

ired - During
n

harges

Monthly Power
Generation Plan

1st of every month

Shift Incharge (Engineer)

Daily

Shift Incharge (Engine

Sr. Manager / Manage

17

Sr. Manager / Manager

Preventive Maintenance
Planning

rman

16

18

As and When Required - During


Shutdown

Process In charges

DRM Chairman

Shutdown Review
Meeting

Categories

S1:
Compliance

S2:
Understanding

S3:
Usage

S3:
Usage

S1:
Compliance

S2:
Understanding

S3:
Usage

S1:
Compliance

S2:
Understanding

S3:
Usage

S3:
Usage

S1:
Compliance

S2:
Understanding

S3:
Usage

S1:
Compliance

S2:
Understanding

S3:
Usage

S1:
Compliance

S2:
Understanding

S3:
Usage

S1:
Compliance

S1:
Compliance

S2:
Understanding

S3:
Usage

S1:
Compliance

S2:
Understanding

S3:
Usage

S3:
Usage

S1:
Compliance

S2:
Understanding

S3:
Usage

S1:
Compliance

S2:
Understanding

S2:
Understanding

S3:
Usage

S1:
Compliance

S2:
Understanding

S3:
Usage

S1:
Compliance

S2:
Understanding

S2:
Understanding

S3:
Usage

S1:
Compliance

S2:
Understanding

S3:
Usage

S1:
Compliance

S2:
Understanding

S2:
Understanding

S3:
Usage

S1:
Compliance

S2:
Understanding

S3:
Usage

S1:
Compliance

S2:
Understanding

S3:
Usage

S1:
Compliance

S2:
Understanding

S3:
Usage

S1:
Compliance

S1:
Compliance

S2:
Understanding

S3:
Usage

Name of Area / Department being Audited: Operations / Maintenance

Name of Area / Department Manager: Respective Manager

Name of Individuals Audited:

OBSERVATIONS
(Based on ACTUAL observations and Interviews, use the following quest
best represent the level of compliance/understanding/usage of

Whether template is filled completely?


Whether all concerned people have signed the template?
Whether any remark mentioned on the sheet?
Why do we need to fill the sheet?
Whether all blocks has been completely understood by shift incharge?
Whether the complete sheet is understood by the shift incharge?
How shift handover process has been improved?
Have the information flow became more effective with the templates?

Have you used the system to achieve the KPI's?


Has all the information has been shared during shift handover.?
Whether template is filled completely?
Whether all concerned people have signed the template?
Whether any remark mentioned on the sheet?
Why do we need to fill the sheet?
Whether all blocks has been completely understood by shift incharge?
Whether the complete sheet is understood by the shift incharge?
How shift handover process has been improved?
Have the information flow became more effective with the templates?
Have you used the system to achieve the KPI's?
Has all the information has been shared during shift handover.?
Is line walk schedule prepared? Is it done as per schedule.?
Is line walk log sheet is filled properly and reported as on the day?
Is line walk is done properly by the assigned person?
Are all the codes underdstood by the person.?

Is the line walk personnel understood the scope or area where he has t
What is the benfit of doing line walk?
Is line walk log sheet is reviewed by HOD?

Are task has been assigned with its priority?


Have you used the system to achieve the KPI's?
Are all the high priority issues has been closed?
Did meeting start on time? Are all members reached at time?
Is Terms of reference & Agenda is prepared and followed?

Was the necessary pre-work done by participants i.e. Daily Stats sourc
solutions identified prior to meeting commencing?
Is Terms of reference understood by all DRM Members?
Are all members aware of their roles in the meeting?.
Do DRM Members understand the importance of the meeting.?

Were variances identified and corrective actions recorded in Action Pla

Were actions, responsibilities and due dates assigned on the Action Pla
Have you used the system to achieve the KPI's?

Were the documentated action logs is reviewed and points are being cl
Did Template mailed or received on time?

Is generation is so planned that all department have sufficient power to


is there any remark generated against short fall in supply
Did template is understood to all/
Do everybody know about such planning?
Did this planning is conveyed to all department

Any action taken against short fall in supply against requirement.


Did daily study about GAP in supply and demand happen?

Have you used the system to achieve the KPI's?


Export is reduceding or not.

Have all the details related to breakdown are being filled by Operations

Have all the details related to Breakdown are being filled by Maintenanc
Did you review breakdowns for previous day ?
What benefit is expected by recording breakdowns? Do you think both
should get involved in recording of Breakdown slips?

Please give us reason why breakdown start time plus job start and finis

What analysis of information about breakdowns captured should be do

Demonstrate how you are doing basic Root Cause Analysis by using th

Have you discussed with your manager on action points based on your
suggestions/message/pending jobs in breakdown slip?
Have you used the system to achieve the KPI's?
What are the actions taken based on issues like spare information, high
resolution of breakdown etc.

Have all the details related to breakdown are being filled by Operations

Have all the details related to Breakdown are being filled by Maintenanc
Did you review breakdowns for previous day ?
What benefit is expected by recording breakdowns? Do you think both
should get involved in recording of Breakdown slips?

Please give us reason why breakdown start time plus job start and finis

What analysis of information about breakdowns captured should be do

Demonstrate how you are doing basic Root Cause Analysis by using th

Have you discussed with your manager on action points based on your
suggestions/message/pending jobs in breakdown slip?
Have you used the system to achieve the KPI's?
What are the actions taken based on issues like spare information, high
resolution of breakdown etc.

Have all the details related to breakdown are being filled by data feedin

Have all the details related to Breakdown are being correctly filled by th
Did you review the data of breakdowns slip before feeding ?
What benefit is expected by recording breakdowns? Do you think both
should get involved in recording of Breakdown slips?

Please give us reason why breakdown start time plus job start and finis

What analysis of information about breakdowns captured should be do

Demonstrate how you are doing basic Root Cause Analysis by using th
Have you used the system to achieve the KPI's?

Have you discussed with your manager on action points based on your
suggestions/message/pending jobs in breakdown slip?
What are the actions taken based on issues like spare information, high
resolution of breakdown etc.

Have all the details related to breakdown are being filled by data feedin

Have all the details related to Breakdown are being correctly filled by th
Did you review the data of breakdowns slip before feeding ?
What benefit is expected by recording breakdowns? Do you think both
should get involved in recording of Breakdown slips?

Please give us reason why breakdown start time plus job start and finis

What analysis of information about breakdowns captured should be do

Demonstrate how you are doing basic Root Cause Analysis by using th

Have you used the system to achieve the KPI's?


Have you discussed with your manager on action points based on your
suggestions/message/pending jobs in breakdown slip?
What are the actions taken based on issues like spare information, high
resolution of breakdown etc.
Whether template is filled completely ?
Whether all the inter departmental jobs are incorporated?

Availability of spares and other critical equipment is done as per job sco
Why do we need to fill the sheet?
Whether all blocks has been completely understood by HOD?

Whether they are aware of how to track the system?


Whether the concerned people planning daily jobs as per Schedule?
Have you used the system to achieve the KPI's?

Whether the information flow became more effective with the template
Has the information helped in taking pro active actions?
Whether template is filled completely ?
Whether all the inter departmental jobs are incorporated?

Availability of spares and other critical equipment is done as per job sco
Why do we need to fill the sheet?
Whether all blocks has been completely understood by HOD?
Whether they are aware of how to track the system?
Whether the concerned people planning daily jobs as per Schedule?
Have you used the system to achieve the KPI's?

Whether the information flow became more effective with the template
Has the information helped in taking pro active actions?
Are you carrying out root cause analysis as per RCA Policy?

Are you maintaning a RCA documentation file? Please show the RCA lo
Does "5 why" format exist and used please show.
What is the need for RCA policy?

Why do we need to Maintain RCA log book. ?


What is the benefit of using 5 Why template ?

Show if any repetitive problem were corrected by using root cause anal
Please provide one example based on last RCA done?

Have you documented the actions and can you link the actions to the im
Are you carrying out root cause analysis as per RCA Policy?

Are you maintaning a RCA documentation file? Please show the RCA lo
Does "5 why" format exist and used please show.
What is the need for RCA policy?
Why do we need to Maintain RCA log book. ?
What is the benefit of using 5 Why template ?

Show if any repetitive problem were corrected by using root cause anal
Please provide one example based on last RCA done?
Have you used the system to achieve the KPI's?

Have you documented the actions and can you link the actions to the im
Whether the Job checking is done as per shut down planning?
Whether the job checking is done by the team formed?
Whether remarks are mentioned against poor quality of jobs?
Whether the team Is aware of importance of job quality checking?

Whether all jobs compered were completely understood ?


Whether they are aware of how to do job checking?
Whether the frequency of equipment failure reduced post light up?
Have you used the system to achieve the KPI's?
Whether Any counter measures taken to avoid critical issues.?

Whether the Job checking is done as per shut down planning?


Whether the job checking is done by the team formed?
Whether remarks are mentioned against poor quality of jobs?
Whether the team Is aware of importance of job quality checking?
Whether all jobs compered were completely understood ?
Whether they are aware of how to do job checking?
Whether the frequency of equipment failure reduced post light up?
Whether Any counter measures taken to avoid critical issues.?
Have you used the system to achieve the KPI's?
Is PM Schedule followed regularly?
Is PM Checklist completely filled by the Engineers?
Is any remarks mentioned against the work done?

Why do we need to follow the PM Plan?

Whether all plans & Checklist has been completely understood by conc
Whether concern people know how to perform PM?
Has the equipment life been improved with this plan?
Has the PM Plan helped in improving MTBF?
Have you used the system to achieve the KPI's?
Is monthly generation plan prepared by the department?
Is monthly production plan of SID taken into account?
Is the plan ready on the first working day of the month?
Why do we need to make the monthly generation plan?

Is the power gneration plan has been completely understood by the con
Whether sponge iron department head was aware of the planning?
Has the overall power generation has increased??

Has the monthly generation plan helped in better weekly and daily pow
Have you used the system to achieve the KPI's?
Was the generation plan on track??
Did meeting start on time? Are all members reached at time?
Is Terms of reference & Agenda is prepared and followed?

Was the necessary pre-work done by participants i.e. Daily work done ,

Do the responsible members understand the importance of daily shutdo


Are all members aware of their roles in the meeting?.

Availability of spares, castable was checked as per the shutdown plan?

Were variances identified and corrective actions recorded in Action Pla

Were actions, responsibilities and due dates assigned on the Action Pla
Have you used the system to achieve the KPI's?

Were the documented action logs is reviewed and points are being clos

Total number of Sys

AUDIT BY

AUDIT DATE

Rating Scale

0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)

Supervisory Actions Required


to Enable Improvement /
Sustain

3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)

1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)

0
(NIL)
1
(PARTIAL)
3
(HIGH)

0
(NIL)

1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)

3
(HIGH)
0
(NIL)

1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)

3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)

1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)

3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
1
(PARTIAL)
3
(HIGH)
1
(PARTIAL)
1
(PARTIAL)

1
(PARTIAL)
1
(PARTIAL)
0
(NIL)
0
(NIL)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
1
(PARTIAL)
1
(PARTIAL)
1
(PARTIAL)
1
(PARTIAL)
0
(NIL)
0
(NIL)
0
(NIL)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)

1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)

0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)

3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)

7
18

TOTAL COMPLIANCE
TOTAL UNDERSTANDING
TOTAL USAGE

Taskforce

21-Mar-15

Observed Current Rating for


this category
(Score: 0, 1 or 3)

REMAR

(Key in any remarks which justify the

usgae is down little because shee


today and it is installed online
3

Break down have some software issue and

Not required
0

Not required
0

Not re
0

Not re
0

Not re
0

Not re
0

Not Re
0

there is too much problem


3

Not re
0

as whole planning is finished


delay in internal job du
1

as whole planning is finished


delay in internal job du
1

94%
88%
82%

REMARKS

arks which justify the observed rating given to the auditee)

ittle because sheet of the month march is submitted


is installed online but job is already noted down.

me software issue and formula issue

Not required

Not required

Not required

Not required

Not Required

much problem in filling this sby all at once

Not required

nning is finished as per schedule but there is


n internal job due to crane unavailibilty

nning is finished as per schedule but there is


n internal job due to crane unavailibilty

ACTION PLAN
(Key in the required action that needs to be taken to address issues - th
must be done for System Elements with a yellow or red scores)

from today onwards line walk job is submitted in online sharing


dolder of udaan and in this sheet each line walker will note the
job.

job.

so scheduling is done and in night shift it is filled by


shift inchagre

N
taken to address issues - this
th a yellow or red scores)

submitted in online sharing


ch line walker will note the

night shift it is filled by


gre

Sr. No.
System Elements
Accountable

Responsible

FREQUENCY

Shift Handover and log


sheet - Phase 1

Sr. Manager / Manager

Shift Incharge (Engineer)

Daily

2
Shift Handover and log
sheet - Phase 2

Sr. Manager / Manager

Shift Incharge (Engineer)


Daily

Line Walk - Phase

General Manager (Maintenance)

Managers

Weekly

Shift I

Sr.

4
Daily Review Meeting

DRM Chairman

All DRM Members


Daily

Power Plant requirement


and fullfillment

AGM (operation)

Electrical HOD

Daily

General Man

Dai
Daily

Electric

Breakdown Slip (Phase 1)

Engineers

AGM (op

Power Plant requirement


and fullfillment

Managers

Breakdown Slip (Phase 2)

Managers

Engineers

Daily

Breakdown Management
System (BMS) - Phase 1

Managers

Engineers

Monday, Wednesday, Friday

GM

Monday, Wednesday, Friday

Shut Down Job Scoping


Phase 1

nd When Required

Managers

10

Engineers

Breakdown Management
System (BMS) - Phase 2

partmental HOD

Monday

Shut Down Job Scoping


Kiln Phase 2

12

Root Cause Analysis Phase 1

Weekly

nager / Manager

As and When Required

Departmental HOD

As and When R

Departmental

GM

11

GM

Shut Down Job Scoping


Phase 1

l - General Manager

10

Job Quality Check Phase 1

en Required

Weekly

Sr.Manager / Manager

14

arge (Engineer)

Root Cause Analysis Phase 2

Weekly

Sr.Manager / Mana

Sectional - General M

13

Sectional - General Manager

Root Cause Analysis Phase 1

ger / Manager

12

Job Quality Check Phase 2

16

Preventive Maintenance
Planning

Daily

rge (Engineer)

As When Required

Shift In charge (Engineer)

As When Require

Shift Incharge (Engin

Sr. Manager / Mana

15

Sr. Manager / Manager

Job Quality Check Phase 1

ger / Manager

14

ired - During
n

harges

Monthly Power
Generation Plan

1st of every month

Shift Incharge (Engineer)

Daily

Shift Incharge (Engine

Sr. Manager / Manage

17

Sr. Manager / Manager

Preventive Maintenance
Planning

rman

16

18

As and When Required - During


Shutdown

Process In charges

DRM Chairman

Shutdown Review
Meeting

Categories

S1:
Compliance

S2:
Understanding

S3:
Usage

S3:
Usage

S1:
Compliance

S2:
Understanding

S3:
Usage

S1:
Compliance

S2:
Understanding

S3:
Usage

S3:
Usage

S1:
Compliance

S2:
Understanding

S3:
Usage

S1:
Compliance

S2:
Understanding

S3:
Usage

S1:
Compliance

S2:
Understanding

S3:
Usage

S1:
Compliance

S1:
Compliance

S2:
Understanding

S3:
Usage

S1:
Compliance

S2:
Understanding

S3:
Usage

S3:
Usage

S1:
Compliance

S2:
Understanding

S3:
Usage

S1:
Compliance

S2:
Understanding

S2:
Understanding

S3:
Usage

S1:
Compliance

S2:
Understanding

S3:
Usage

S1:
Compliance

S2:
Understanding

S2:
Understanding

S3:
Usage

S1:
Compliance

S2:
Understanding

S3:
Usage

S1:
Compliance

S2:
Understanding

S2:
Understanding

S3:
Usage

S1:
Compliance

S2:
Understanding

S3:
Usage

S1:
Compliance

S2:
Understanding

S3:
Usage

S1:
Compliance

S2:
Understanding

S3:
Usage

S1:
Compliance

S1:
Compliance

S2:
Understanding

S3:
Usage

Name of Area / Department being Audited: Operations / Maintenance

Name of Area / Department Manager: Respective Manager

Name of Individuals Audited:

OBSERVATIONS
(Based on ACTUAL observations and Interviews, use the following quest
best represent the level of compliance/understanding/usage of

Whether template is filled completely?


Whether all concerned people have signed the template?
Whether any remark mentioned on the sheet?
Why do we need to fill the sheet?
Whether all blocks has been completely understood by shift incharge?
Whether the complete sheet is understood by the shift incharge?
How shift handover process has been improved?
Have the information flow became more effective with the templates?

Have you used the system to achieve the KPI's?


Has all the information has been shared during shift handover.?
Whether template is filled completely?
Whether all concerned people have signed the template?
Whether any remark mentioned on the sheet?
Why do we need to fill the sheet?
Whether all blocks has been completely understood by shift incharge?
Whether the complete sheet is understood by the shift incharge?
How shift handover process has been improved?
Have the information flow became more effective with the templates?
Have you used the system to achieve the KPI's?
Has all the information has been shared during shift handover.?
Is line walk schedule prepared? Is it done as per schedule.?
Is line walk log sheet is filled properly and reported as on the day?
Is line walk is done properly by the assigned person?
Are all the codes underdstood by the person.?

Is the line walk personnel understood the scope or area where he has t
What is the benfit of doing line walk?
Is line walk log sheet is reviewed by HOD?

Are task has been assigned with its priority?


Have you used the system to achieve the KPI's?
Are all the high priority issues has been closed?
Did meeting start on time? Are all members reached at time?
Is Terms of reference & Agenda is prepared and followed?

Was the necessary pre-work done by participants i.e. Daily Stats sourc
solutions identified prior to meeting commencing?
Is Terms of reference understood by all DRM Members?
Are all members aware of their roles in the meeting?.
Do DRM Members understand the importance of the meeting.?

Were variances identified and corrective actions recorded in Action Pla

Were actions, responsibilities and due dates assigned on the Action Pla
Have you used the system to achieve the KPI's?

Were the documentated action logs is reviewed and points are being cl
Did Template mailed or received on time?

Is generation is so planned that all department have sufficient power to


is there any remark generated against short fall in supply
Did template is understood to all/
Do everybody know about such planning?
Did this planning is conveyed to all department

Any action taken against short fall in supply against requirement.


Did daily study about GAP in supply and demand happen?

Have you used the system to achieve the KPI's?


Export is reduceding or not.

Have all the details related to breakdown are being filled by Operations

Have all the details related to Breakdown are being filled by Maintenanc
Did you review breakdowns for previous day ?
What benefit is expected by recording breakdowns? Do you think both
should get involved in recording of Breakdown slips?

Please give us reason why breakdown start time plus job start and finis

What analysis of information about breakdowns captured should be do

Demonstrate how you are doing basic Root Cause Analysis by using th

Have you discussed with your manager on action points based on your
suggestions/message/pending jobs in breakdown slip?
Have you used the system to achieve the KPI's?
What are the actions taken based on issues like spare information, high
resolution of breakdown etc.

Have all the details related to breakdown are being filled by Operations

Have all the details related to Breakdown are being filled by Maintenanc
Did you review breakdowns for previous day ?
What benefit is expected by recording breakdowns? Do you think both
should get involved in recording of Breakdown slips?

Please give us reason why breakdown start time plus job start and finis

What analysis of information about breakdowns captured should be do

Demonstrate how you are doing basic Root Cause Analysis by using th

Have you discussed with your manager on action points based on your
suggestions/message/pending jobs in breakdown slip?
Have you used the system to achieve the KPI's?
What are the actions taken based on issues like spare information, high
resolution of breakdown etc.

Have all the details related to breakdown are being filled by data feedin

Have all the details related to Breakdown are being correctly filled by th
Did you review the data of breakdowns slip before feeding ?
What benefit is expected by recording breakdowns? Do you think both
should get involved in recording of Breakdown slips?

Please give us reason why breakdown start time plus job start and finis

What analysis of information about breakdowns captured should be do

Demonstrate how you are doing basic Root Cause Analysis by using th
Have you used the system to achieve the KPI's?

Have you discussed with your manager on action points based on your
suggestions/message/pending jobs in breakdown slip?
What are the actions taken based on issues like spare information, high
resolution of breakdown etc.

Have all the details related to breakdown are being filled by data feedin

Have all the details related to Breakdown are being correctly filled by th
Did you review the data of breakdowns slip before feeding ?
What benefit is expected by recording breakdowns? Do you think both
should get involved in recording of Breakdown slips?

Please give us reason why breakdown start time plus job start and finis

What analysis of information about breakdowns captured should be do

Demonstrate how you are doing basic Root Cause Analysis by using th

Have you used the system to achieve the KPI's?


Have you discussed with your manager on action points based on your
suggestions/message/pending jobs in breakdown slip?
What are the actions taken based on issues like spare information, high
resolution of breakdown etc.
Whether template is filled completely ?
Whether all the inter departmental jobs are incorporated?

Availability of spares and other critical equipment is done as per job sco
Why do we need to fill the sheet?
Whether all blocks has been completely understood by HOD?

Whether they are aware of how to track the system?


Whether the concerned people planning daily jobs as per Schedule?
Have you used the system to achieve the KPI's?

Whether the information flow became more effective with the template
Has the information helped in taking pro active actions?
Whether template is filled completely ?
Whether all the inter departmental jobs are incorporated?

Availability of spares and other critical equipment is done as per job sco
Why do we need to fill the sheet?
Whether all blocks has been completely understood by HOD?
Whether they are aware of how to track the system?
Whether the concerned people planning daily jobs as per Schedule?
Have you used the system to achieve the KPI's?

Whether the information flow became more effective with the template
Has the information helped in taking pro active actions?
Are you carrying out root cause analysis as per RCA Policy?

Are you maintaning a RCA documentation file? Please show the RCA lo
Does "5 why" format exist and used please show.
What is the need for RCA policy?

Why do we need to Maintain RCA log book. ?


What is the benefit of using 5 Why template ?

Show if any repetitive problem were corrected by using root cause anal
Please provide one example based on last RCA done?

Have you documented the actions and can you link the actions to the im
Are you carrying out root cause analysis as per RCA Policy?

Are you maintaning a RCA documentation file? Please show the RCA lo
Does "5 why" format exist and used please show.
What is the need for RCA policy?
Why do we need to Maintain RCA log book. ?
What is the benefit of using 5 Why template ?

Show if any repetitive problem were corrected by using root cause anal
Please provide one example based on last RCA done?
Have you used the system to achieve the KPI's?

Have you documented the actions and can you link the actions to the im
Whether the Job checking is done as per shut down planning?
Whether the job checking is done by the team formed?
Whether remarks are mentioned against poor quality of jobs?
Whether the team Is aware of importance of job quality checking?

Whether all jobs compered were completely understood ?


Whether they are aware of how to do job checking?
Whether the frequency of equipment failure reduced post light up?
Have you used the system to achieve the KPI's?
Whether Any counter measures taken to avoid critical issues.?

Whether the Job checking is done as per shut down planning?


Whether the job checking is done by the team formed?
Whether remarks are mentioned against poor quality of jobs?
Whether the team Is aware of importance of job quality checking?
Whether all jobs compered were completely understood ?
Whether they are aware of how to do job checking?
Whether the frequency of equipment failure reduced post light up?
Whether Any counter measures taken to avoid critical issues.?
Have you used the system to achieve the KPI's?
Is PM Schedule followed regularly?
Is PM Checklist completely filled by the Engineers?
Is any remarks mentioned against the work done?

Why do we need to follow the PM Plan?

Whether all plans & Checklist has been completely understood by conc
Whether concern people know how to perform PM?
Has the equipment life been improved with this plan?
Has the PM Plan helped in improving MTBF?
Have you used the system to achieve the KPI's?
Is monthly generation plan prepared by the department?
Is monthly production plan of SID taken into account?
Is the plan ready on the first working day of the month?
Why do we need to make the monthly generation plan?

Is the power gneration plan has been completely understood by the con
Whether sponge iron department head was aware of the planning?
Has the overall power generation has increased??

Has the monthly generation plan helped in better weekly and daily pow
Have you used the system to achieve the KPI's?
Was the generation plan on track??
Did meeting start on time? Are all members reached at time?
Is Terms of reference & Agenda is prepared and followed?

Was the necessary pre-work done by participants i.e. Daily work done ,

Do the responsible members understand the importance of daily shutdo


Are all members aware of their roles in the meeting?.

Availability of spares, castable was checked as per the shutdown plan?

Were variances identified and corrective actions recorded in Action Pla

Were actions, responsibilities and due dates assigned on the Action Pla
Have you used the system to achieve the KPI's?

Were the documented action logs is reviewed and points are being clos

Total number of Sys

AUDIT BY

AUDIT DATE

Rating Scale

0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)

Supervisory Actions Required


to Enable Improvement /
Sustain

3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)

1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)

0
(NIL)
1
(PARTIAL)
3
(HIGH)

0
(NIL)

1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)

3
(HIGH)
0
(NIL)

1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)

3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)

1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)

3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
1
(PARTIAL)
3
(HIGH)
1
(PARTIAL)
1
(PARTIAL)

1
(PARTIAL)
1
(PARTIAL)
0
(NIL)
0
(NIL)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
1
(PARTIAL)
1
(PARTIAL)
1
(PARTIAL)
1
(PARTIAL)
0
(NIL)
0
(NIL)
0
(NIL)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)

1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)

0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)

3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)

7
18

TOTAL COMPLIANCE
TOTAL UNDERSTANDING
TOTAL USAGE

Taskforce

27-Mar-15

Observed Current Rating for


this category
(Score: 0, 1 or 3)

REMAR

(Key in any remarks which justify the

Due date is not av


3

.
3

due to kiln shut down power short


is done w
1

Not a

Not a
0

Not a
0

usage is little because training is

usage is little because training is

usage is low because software issue is ther


formula
1

Not required
0

Not re
0

Not re
0

Not Re
0

No proper remark mentione


and Feb
1

Not re
0

Not a
3

Not a
3

Schedule of light up is of 4 -04-2015 but po


down review meeting it was clear and henc
include more job if required
1

Usage is normal because job is planned to

88%
94%
82%

REMARKS

arks which justify the observed rating given to the auditee)

Due date is not available of some job

down power shortage is there and export agreement


is done with SMS

Not audited

Not audited

Not audited

tle because training is yet not provided for MAT member

tle because training is yet not provided for MAT member

e software issue is there due to which some job havenot proper

Not required

Not required

Not Required

emark mentioned & sheet is deleted of Jan


and Feb month

Not required

Not audited

Not audited

s of 4 -04-2015 but power plant plan is of 1-04-2015.after shut


it was clear and hence more day available to Power plant to
quired

ause job is planned to finish with in short duration

ACTION PLAN
(Key in the required action that needs to be taken to address issues - th
must be done for System Elements with a yellow or red scores)

Kiln shut down

On Thursday this week training is scheduled

On Thursday this week training is scheduled

Duplicate sheet need to be prepared in excel 2013 which will


submitted to Salil Palia Sir on 02-04-2015.

Information to IT department is conveyed but no actio


I provided from IT department

From SID side and Power Side sheet need to be exchanged by email to each
other.

Planning pattern is follow and as per schedule job is finishing

N
taken to address issues - this
th a yellow or red scores)

ng is scheduled

ng is scheduled

n excel 2013 which will


015.

conveyed but no action


department

e exchanged by email to each

ob is finishing

Sr. No.
System Elements
Accountable

Responsible

FREQUENCY

Shift Handover and log


sheet - Phase 1

Sr. Manager / Manager

Shift Incharge (Engineer)

Daily

2
Shift Handover and log
sheet - Phase 2

Sr. Manager / Manager

Shift Incharge (Engineer)


Daily

Line Walk - Phase

General Manager (Maintenance)

Managers

Weekly

Shift I

Sr.

4
Daily Review Meeting

DRM Chairman

All DRM Members


Daily

Power Plant requirement


and fullfillment

AGM (operation)

Electrical HOD

Daily

General Man

Dai
Daily

Electric

Breakdown Slip (Phase 1)

Engineers

AGM (op

Power Plant requirement


and fullfillment

Managers

Breakdown Slip (Phase 2)

Managers

Engineers

Daily

Breakdown Management
System (BMS) - Phase 1

Managers

Engineers

Monday, Wednesday, Friday

GM

Monday, Wednesday, Friday

Shut Down Job Scoping


Phase 1

nd When Required

Managers

10

Engineers

Breakdown Management
System (BMS) - Phase 2

partmental HOD

Monday

Shut Down Job Scoping


Kiln Phase 2

12

Root Cause Analysis Phase 1

Weekly

nager / Manager

As and When Required

Departmental HOD

As and When R

Departmental

GM

11

GM

Shut Down Job Scoping


Phase 1

l - General Manager

10

Job Quality Check Phase 1

en Required

Weekly

Sr.Manager / Manager

14

arge (Engineer)

Root Cause Analysis Phase 2

Weekly

Sr.Manager / Mana

Sectional - General M

13

Sectional - General Manager

Root Cause Analysis Phase 1

ger / Manager

12

Job Quality Check Phase 2

16

Preventive Maintenance
Planning

Daily

rge (Engineer)

As When Required

Shift In charge (Engineer)

As When Require

Shift Incharge (Engin

Sr. Manager / Mana

15

Sr. Manager / Manager

Job Quality Check Phase 1

ger / Manager

14

ired - During
n

arges

Monthly Power
Generation Plan

1st of every month

Shift Incharge (Engineer)

Daily

Shift Incharge (Engine

Sr. Manager / Manage

17

Sr. Manager / Manager

Preventive Maintenance
Planning

man

16

18

As and When Required - During


Shutdown

Process In charges

DRM Chairman

Shutdown Review
Meeting

Categories

S1:
Compliance

S2:
Understanding

S3:
Usage

S3:
Usage

S1:
Compliance

S2:
Understanding

S3:
Usage

S1:
Compliance

S2:
Understanding

S3:
Usage

S3:
Usage

S1:
Compliance

S2:
Understanding

S3:
Usage

S1:
Compliance

S2:
Understanding

S3:
Usage

S1:
Compliance

S2:
Understanding

S3:
Usage

S1:
Compliance

S1:
Compliance

S2:
Understanding

S3:
Usage

S1:
Compliance

S2:
Understanding

S3:
Usage

S3:
Usage

S1:
Compliance

S2:
Understanding

S3:
Usage

S1:
Compliance

S2:
Understanding

S2:
Understanding

S3:
Usage

S1:
Compliance

S2:
Understanding

S3:
Usage

S1:
Compliance

S2:
Understanding

S2:
Understanding

S3:
Usage

S1:
Compliance

S2:
Understanding

S3:
Usage

S1:
Compliance

S2:
Understanding

S2:
Understanding

S3:
Usage

S1:
Compliance

S2:
Understanding

S3:
Usage

S1:
Compliance

S2:
Understanding

S3:
Usage

S1:
Compliance

S2:
Understanding

S3:
Usage

S1:
Compliance

S1:
Compliance

S2:
Understanding

S3:
Usage

Name of Area / Department being Audited: Operations / Maintenance

Name of Area / Department Manager: Respective Manager

Name of Individuals Audited:

OBSERVATIONS
(Based on ACTUAL observations and Interviews, use the following quest
best represent the level of compliance/understanding/usage of

Whether template is filled completely?


Whether all concerned people have signed the template?
Whether any remark mentioned on the sheet?
Why do we need to fill the sheet?
Whether all blocks has been completely understood by shift incharge?
Whether the complete sheet is understood by the shift incharge?
How shift handover process has been improved?
Have the information flow became more effective with the templates?

Have you used the system to achieve the KPI's?


Has all the information has been shared during shift handover.?
Whether template is filled completely?
Whether all concerned people have signed the template?
Whether any remark mentioned on the sheet?
Why do we need to fill the sheet?
Whether all blocks has been completely understood by shift incharge?
Whether the complete sheet is understood by the shift incharge?
How shift handover process has been improved?
Have the information flow became more effective with the templates?
Have you used the system to achieve the KPI's?
Has all the information has been shared during shift handover.?
Is line walk schedule prepared? Is it done as per schedule.?
Is line walk log sheet is filled properly and reported as on the day?
Is line walk is done properly by the assigned person?
Are all the codes underdstood by the person.?

Is the line walk personnel understood the scope or area where he has t
What is the benfit of doing line walk?
Is line walk log sheet is reviewed by HOD?

Are task has been assigned with its priority?


Have you used the system to achieve the KPI's?
Are all the high priority issues has been closed?
Did meeting start on time? Are all members reached at time?
Is Terms of reference & Agenda is prepared and followed?

Was the necessary pre-work done by participants i.e. Daily Stats sourc
solutions identified prior to meeting commencing?
Is Terms of reference understood by all DRM Members?
Are all members aware of their roles in the meeting?.
Do DRM Members understand the importance of the meeting.?

Were variances identified and corrective actions recorded in Action Pla

Were actions, responsibilities and due dates assigned on the Action Pla
Have you used the system to achieve the KPI's?

Were the documentated action logs is reviewed and points are being cl
Did Template mailed or received on time?

Is generation is so planned that all department have sufficient power to


is there any remark generated against short fall in supply
Did template is understood to all/
Do everybody know about such planning?
Did this planning is conveyed to all department

Any action taken against short fall in supply against requirement.


Did daily study about GAP in supply and demand happen?

Have you used the system to achieve the KPI's?


Export is reduceding or not.

Have all the details related to breakdown are being filled by Operations

Have all the details related to Breakdown are being filled by Maintenanc
Did you review breakdowns for previous day ?
What benefit is expected by recording breakdowns? Do you think both
should get involved in recording of Breakdown slips?

Please give us reason why breakdown start time plus job start and finis

What analysis of information about breakdowns captured should be do

Demonstrate how you are doing basic Root Cause Analysis by using th

Have you discussed with your manager on action points based on your
suggestions/message/pending jobs in breakdown slip?
Have you used the system to achieve the KPI's?
What are the actions taken based on issues like spare information, high
resolution of breakdown etc.

Have all the details related to breakdown are being filled by Operations

Have all the details related to Breakdown are being filled by Maintenanc
Did you review breakdowns for previous day ?
What benefit is expected by recording breakdowns? Do you think both
should get involved in recording of Breakdown slips?

Please give us reason why breakdown start time plus job start and finis

What analysis of information about breakdowns captured should be do

Demonstrate how you are doing basic Root Cause Analysis by using th

Have you discussed with your manager on action points based on your
suggestions/message/pending jobs in breakdown slip?
Have you used the system to achieve the KPI's?
What are the actions taken based on issues like spare information, high
resolution of breakdown etc.

Have all the details related to breakdown are being filled by data feedin

Have all the details related to Breakdown are being correctly filled by th
Did you review the data of breakdowns slip before feeding ?
What benefit is expected by recording breakdowns? Do you think both
should get involved in recording of Breakdown slips?

Please give us reason why breakdown start time plus job start and finis

What analysis of information about breakdowns captured should be do

Demonstrate how you are doing basic Root Cause Analysis by using th
Have you used the system to achieve the KPI's?

Have you discussed with your manager on action points based on your
suggestions/message/pending jobs in breakdown slip?
What are the actions taken based on issues like spare information, high
resolution of breakdown etc.

Have all the details related to breakdown are being filled by data feedin

Have all the details related to Breakdown are being correctly filled by th
Did you review the data of breakdowns slip before feeding ?
What benefit is expected by recording breakdowns? Do you think both
should get involved in recording of Breakdown slips?

Please give us reason why breakdown start time plus job start and finis

What analysis of information about breakdowns captured should be do

Demonstrate how you are doing basic Root Cause Analysis by using th

Have you used the system to achieve the KPI's?


Have you discussed with your manager on action points based on your
suggestions/message/pending jobs in breakdown slip?
What are the actions taken based on issues like spare information, high
resolution of breakdown etc.
Whether template is filled completely ?
Whether all the inter departmental jobs are incorporated?

Availability of spares and other critical equipment is done as per job sco
Why do we need to fill the sheet?
Whether all blocks has been completely understood by HOD?

Whether they are aware of how to track the system?


Whether the concerned people planning daily jobs as per Schedule?
Have you used the system to achieve the KPI's?

Whether the information flow became more effective with the template
Has the information helped in taking pro active actions?
Whether template is filled completely ?
Whether all the inter departmental jobs are incorporated?

Availability of spares and other critical equipment is done as per job sco
Why do we need to fill the sheet?
Whether all blocks has been completely understood by HOD?
Whether they are aware of how to track the system?
Whether the concerned people planning daily jobs as per Schedule?
Have you used the system to achieve the KPI's?

Whether the information flow became more effective with the template
Has the information helped in taking pro active actions?
Are you carrying out root cause analysis as per RCA Policy?

Are you maintaning a RCA documentation file? Please show the RCA lo
Does "5 why" format exist and used please show.
What is the need for RCA policy?

Why do we need to Maintain RCA log book. ?


What is the benefit of using 5 Why template ?

Show if any repetitive problem were corrected by using root cause anal
Please provide one example based on last RCA done?

Have you documented the actions and can you link the actions to the im
Are you carrying out root cause analysis as per RCA Policy?

Are you maintaning a RCA documentation file? Please show the RCA lo
Does "5 why" format exist and used please show.
What is the need for RCA policy?
Why do we need to Maintain RCA log book. ?
What is the benefit of using 5 Why template ?

Show if any repetitive problem were corrected by using root cause anal
Please provide one example based on last RCA done?
Have you used the system to achieve the KPI's?

Have you documented the actions and can you link the actions to the im
Whether the Job checking is done as per shut down planning?
Whether the job checking is done by the team formed?
Whether remarks are mentioned against poor quality of jobs?
Whether the team Is aware of importance of job quality checking?

Whether all jobs compered were completely understood ?


Whether they are aware of how to do job checking?
Whether the frequency of equipment failure reduced post light up?
Have you used the system to achieve the KPI's?
Whether Any counter measures taken to avoid critical issues.?

Whether the Job checking is done as per shut down planning?


Whether the job checking is done by the team formed?
Whether remarks are mentioned against poor quality of jobs?
Whether the team Is aware of importance of job quality checking?
Whether all jobs compered were completely understood ?
Whether they are aware of how to do job checking?
Whether the frequency of equipment failure reduced post light up?
Whether Any counter measures taken to avoid critical issues.?
Have you used the system to achieve the KPI's?
Is PM Schedule followed regularly?
Is PM Checklist completely filled by the Engineers?
Is any remarks mentioned against the work done?

Why do we need to follow the PM Plan?

Whether all plans & Checklist has been completely understood by conc
Whether concern people know how to perform PM?
Has the equipment life been improved with this plan?
Has the PM Plan helped in improving MTBF?
Have you used the system to achieve the KPI's?
Is monthly generation plan prepared by the department?
Is monthly production plan of SID taken into account?
Is the plan ready on the first working day of the month?
Why do we need to make the monthly generation plan?

Is the power gneration plan has been completely understood by the con
Whether sponge iron department head was aware of the planning?
Has the overall power generation has increased??

Has the monthly generation plan helped in better weekly and daily pow
Have you used the system to achieve the KPI's?
Was the generation plan on track??
Did meeting start on time? Are all members reached at time?
Is Terms of reference & Agenda is prepared and followed?

Was the necessary pre-work done by participants i.e. Daily work done ,

Do the responsible members understand the importance of daily shutdo


Are all members aware of their roles in the meeting?.

Availability of spares, castable was checked as per the shutdown plan?

Were variances identified and corrective actions recorded in Action Pla

Were actions, responsibilities and due dates assigned on the Action Pla
Have you used the system to achieve the KPI's?

Were the documented action logs is reviewed and points are being clos

Total number of Sys

AUDIT BY

AUDIT DATE

Rating Scale

0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)

Supervisory Actions Required


to Enable Improvement /
Sustain

3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)

1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)

0
(NIL)
1
(PARTIAL)
3
(HIGH)

0
(NIL)

1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)

3
(HIGH)
0
(NIL)

1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)

3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)

1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)

3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
1
(PARTIAL)
3
(HIGH)
1
(PARTIAL)
1
(PARTIAL)

1
(PARTIAL)
1
(PARTIAL)
0
(NIL)
0
(NIL)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
1
(PARTIAL)
1
(PARTIAL)
1
(PARTIAL)
1
(PARTIAL)
0
(NIL)
0
(NIL)
0
(NIL)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)

1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)

0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)

3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)

10

TOTAL COMPLIANCE

18

TOTAL UNDERSTANDING
TOTAL USAGE

Taskforce

2-Apr-15

Observed Current Rating for


this category
(Score: 0, 1 or 3)

REMAR

(Key in any remarks which justify the

Not Audited
0

Not a

Not a
0

Not a
0

Analysis is not

Analysis is not

Not required
0

Not re
0

Not re
0

Not Re
0

Sheet is sub
3

Clearance given to the SID


ligh
3

Clearance given to the SID


ligh
3

Temperature sca
1

92%
92%
83%

REMARKS

arks which justify the observed rating given to the auditee)

Not audited

Not audited

Not audited

Analysis is not done Properly

Analysis is not done Properly

Not required

Not required

Not Required

Sheet is submitted lately

ven to the SID from Power Plant side to do


light up.

ven to the SID from Power Plant side to do


light up.

emperature scanner is delayed.

ACTION PLAN
(Key in the required action that needs to be taken to address issues - th
must be done for System Elements with a yellow or red scores)

Analysis is done on monthly basis by MAT member.But training ism not given t
MAT member yet due to PM checklist submission work.

Analysis is done on monthly basis by MAT member.But training ism not given t
MAT member yet due to PM checklist submission work.

N
taken to address issues - this
th a yellow or red scores)

mber.But training ism not given to


klist submission work.

Sr. No.
System Elements
Accountable

Responsible

FREQUENCY

Shift Handover and log


sheet - Phase 1

Sr. Manager / Manager

Shift Incharge (Engineer)

Daily

2
Shift Handover and log
sheet - Phase 2

Sr. Manager / Manager

Shift Incharge (Engineer)


Daily

Line Walk - Phase

General Manager (Maintenance)

Managers

Weekly

Shift I

Sr.

4
Daily Review Meeting

DRM Chairman

All DRM Members


Daily

Power Plant requirement


and fullfillment

AGM (operation)

Electrical HOD

Daily

General Man

Dai
Daily

Electric

Breakdown Slip (Phase 1)

Engineers

AGM (op

Power Plant requirement


and fullfillment

Managers

Breakdown Slip (Phase 2)

Managers

Engineers

Daily

Breakdown Management
System (BMS) - Phase 1

Managers

Engineers

Monday, Wednesday, Friday

GM

Monday, Wednesday, Friday

Shut Down Job Scoping


Phase 1

nd When Required

Managers

10

Engineers

Breakdown Management
System (BMS) - Phase 2

partmental HOD

Monday

Shut Down Job Scoping


Kiln Phase 2

12

Root Cause Analysis Phase 1

Weekly

nager / Manager

As and When Required

Departmental HOD

As and When R

Departmental

GM

11

GM

Shut Down Job Scoping


Phase 1

l - General Manager

10

Job Quality Check Phase 1

en Required

Weekly

Sr.Manager / Manager

14

arge (Engineer)

Root Cause Analysis Phase 2

Weekly

Sr.Manager / Mana

Sectional - General M

13

Sectional - General Manager

Root Cause Analysis Phase 1

ger / Manager

12

Job Quality Check Phase 2

16

Preventive Maintenance
Planning

Daily

rge (Engineer)

As When Required

Shift In charge (Engineer)

As When Require

Shift Incharge (Engin

Sr. Manager / Mana

15

Sr. Manager / Manager

Job Quality Check Phase 1

ger / Manager

14

ired - During
n

arges

Monthly Power
Generation Plan

1st of every month

Shift Incharge (Engineer)

Daily

Shift Incharge (Engine

Sr. Manager / Manage

17

Sr. Manager / Manager

Preventive Maintenance
Planning

man

16

18

As and When Required - During


Shutdown

Process In charges

DRM Chairman

Shutdown Review
Meeting

Categories

S1:
Compliance

S2:
Understanding

S3:
Usage

S3:
Usage

S1:
Compliance

S2:
Understanding

S3:
Usage

S1:
Compliance

S2:
Understanding

S3:
Usage

S3:
Usage

S1:
Compliance

S2:
Understanding

S3:
Usage

S1:
Compliance

S2:
Understanding

S3:
Usage

S1:
Compliance

S2:
Understanding

S3:
Usage

S1:
Compliance

S1:
Compliance

S2:
Understanding

S3:
Usage

S1:
Compliance

S2:
Understanding

S3:
Usage

S3:
Usage

S1:
Compliance

S2:
Understanding

S3:
Usage

S1:
Compliance

S2:
Understanding

S2:
Understanding

S3:
Usage

S1:
Compliance

S2:
Understanding

S3:
Usage

S1:
Compliance

S2:
Understanding

S2:
Understanding

S3:
Usage

S1:
Compliance

S2:
Understanding

S3:
Usage

S1:
Compliance

S2:
Understanding

S2:
Understanding

S3:
Usage

S1:
Compliance

S2:
Understanding

S3:
Usage

S1:
Compliance

S2:
Understanding

S3:
Usage

S1:
Compliance

S2:
Understanding

S3:
Usage

S1:
Compliance

S1:
Compliance

S2:
Understanding

S3:
Usage

Name of Area / Department being Audited: Operations / Maintenance

Name of Area / Department Manager: Respective Manager

Name of Individuals Audited:

OBSERVATIONS
(Based on ACTUAL observations and Interviews, use the following quest
best represent the level of compliance/understanding/usage of

Whether template is filled completely?


Whether all concerned people have signed the template?
Whether any remark mentioned on the sheet?
Why do we need to fill the sheet?
Whether all blocks has been completely understood by shift incharge?
Whether the complete sheet is understood by the shift incharge?
How shift handover process has been improved?
Have the information flow became more effective with the templates?

Have you used the system to achieve the KPI's?


Has all the information has been shared during shift handover.?
Whether template is filled completely?
Whether all concerned people have signed the template?
Whether any remark mentioned on the sheet?
Why do we need to fill the sheet?
Whether all blocks has been completely understood by shift incharge?
Whether the complete sheet is understood by the shift incharge?
How shift handover process has been improved?
Have the information flow became more effective with the templates?
Have you used the system to achieve the KPI's?
Has all the information has been shared during shift handover.?
Is line walk schedule prepared? Is it done as per schedule.?
Is line walk log sheet is filled properly and reported as on the day?
Is line walk is done properly by the assigned person?
Are all the codes underdstood by the person.?

Is the line walk personnel understood the scope or area where he has t
What is the benfit of doing line walk?
Is line walk log sheet is reviewed by HOD?

Are task has been assigned with its priority?


Have you used the system to achieve the KPI's?
Are all the high priority issues has been closed?
Did meeting start on time? Are all members reached at time?
Is Terms of reference & Agenda is prepared and followed?

Was the necessary pre-work done by participants i.e. Daily Stats sourc
solutions identified prior to meeting commencing?
Is Terms of reference understood by all DRM Members?
Are all members aware of their roles in the meeting?.
Do DRM Members understand the importance of the meeting.?

Were variances identified and corrective actions recorded in Action Pla

Were actions, responsibilities and due dates assigned on the Action Pla
Have you used the system to achieve the KPI's?

Were the documentated action logs is reviewed and points are being cl
Did Template mailed or received on time?

Is generation is so planned that all department have sufficient power to


is there any remark generated against short fall in supply
Did template is understood to all/
Do everybody know about such planning?
Did this planning is conveyed to all department

Any action taken against short fall in supply against requirement.


Did daily study about GAP in supply and demand happen?

Have you used the system to achieve the KPI's?


Export is reduceding or not.

Have all the details related to breakdown are being filled by Operations

Have all the details related to Breakdown are being filled by Maintenanc
Did you review breakdowns for previous day ?
What benefit is expected by recording breakdowns? Do you think both
should get involved in recording of Breakdown slips?

Please give us reason why breakdown start time plus job start and finis

What analysis of information about breakdowns captured should be do

Demonstrate how you are doing basic Root Cause Analysis by using th

Have you discussed with your manager on action points based on your
suggestions/message/pending jobs in breakdown slip?
Have you used the system to achieve the KPI's?
What are the actions taken based on issues like spare information, high
resolution of breakdown etc.

Have all the details related to breakdown are being filled by Operations

Have all the details related to Breakdown are being filled by Maintenanc
Did you review breakdowns for previous day ?
What benefit is expected by recording breakdowns? Do you think both
should get involved in recording of Breakdown slips?

Please give us reason why breakdown start time plus job start and finis

What analysis of information about breakdowns captured should be do

Demonstrate how you are doing basic Root Cause Analysis by using th

Have you discussed with your manager on action points based on your
suggestions/message/pending jobs in breakdown slip?
Have you used the system to achieve the KPI's?
What are the actions taken based on issues like spare information, high
resolution of breakdown etc.

Have all the details related to breakdown are being filled by data feedin

Have all the details related to Breakdown are being correctly filled by th
Did you review the data of breakdowns slip before feeding ?
What benefit is expected by recording breakdowns? Do you think both
should get involved in recording of Breakdown slips?

Please give us reason why breakdown start time plus job start and finis

What analysis of information about breakdowns captured should be do

Demonstrate how you are doing basic Root Cause Analysis by using th
Have you used the system to achieve the KPI's?

Have you discussed with your manager on action points based on your
suggestions/message/pending jobs in breakdown slip?
What are the actions taken based on issues like spare information, high
resolution of breakdown etc.

Have all the details related to breakdown are being filled by data feedin

Have all the details related to Breakdown are being correctly filled by th
Did you review the data of breakdowns slip before feeding ?
What benefit is expected by recording breakdowns? Do you think both
should get involved in recording of Breakdown slips?

Please give us reason why breakdown start time plus job start and finis

What analysis of information about breakdowns captured should be do

Demonstrate how you are doing basic Root Cause Analysis by using th

Have you used the system to achieve the KPI's?


Have you discussed with your manager on action points based on your
suggestions/message/pending jobs in breakdown slip?
What are the actions taken based on issues like spare information, high
resolution of breakdown etc.
Whether template is filled completely ?
Whether all the inter departmental jobs are incorporated?

Availability of spares and other critical equipment is done as per job sco
Why do we need to fill the sheet?
Whether all blocks has been completely understood by HOD?

Whether they are aware of how to track the system?


Whether the concerned people planning daily jobs as per Schedule?
Have you used the system to achieve the KPI's?

Whether the information flow became more effective with the template
Has the information helped in taking pro active actions?
Whether template is filled completely ?
Whether all the inter departmental jobs are incorporated?

Availability of spares and other critical equipment is done as per job sco
Why do we need to fill the sheet?
Whether all blocks has been completely understood by HOD?
Whether they are aware of how to track the system?
Whether the concerned people planning daily jobs as per Schedule?
Have you used the system to achieve the KPI's?

Whether the information flow became more effective with the template
Has the information helped in taking pro active actions?
Are you carrying out root cause analysis as per RCA Policy?

Are you maintaning a RCA documentation file? Please show the RCA lo
Does "5 why" format exist and used please show.
What is the need for RCA policy?

Why do we need to Maintain RCA log book. ?


What is the benefit of using 5 Why template ?

Show if any repetitive problem were corrected by using root cause anal
Please provide one example based on last RCA done?

Have you documented the actions and can you link the actions to the im
Are you carrying out root cause analysis as per RCA Policy?

Are you maintaning a RCA documentation file? Please show the RCA lo
Does "5 why" format exist and used please show.
What is the need for RCA policy?
Why do we need to Maintain RCA log book. ?
What is the benefit of using 5 Why template ?

Show if any repetitive problem were corrected by using root cause anal
Please provide one example based on last RCA done?
Have you used the system to achieve the KPI's?

Have you documented the actions and can you link the actions to the im
Whether the Job checking is done as per shut down planning?
Whether the job checking is done by the team formed?
Whether remarks are mentioned against poor quality of jobs?
Whether the team Is aware of importance of job quality checking?

Whether all jobs compered were completely understood ?


Whether they are aware of how to do job checking?
Whether the frequency of equipment failure reduced post light up?
Have you used the system to achieve the KPI's?
Whether Any counter measures taken to avoid critical issues.?

Whether the Job checking is done as per shut down planning?


Whether the job checking is done by the team formed?
Whether remarks are mentioned against poor quality of jobs?
Whether the team Is aware of importance of job quality checking?
Whether all jobs compered were completely understood ?
Whether they are aware of how to do job checking?
Whether the frequency of equipment failure reduced post light up?
Whether Any counter measures taken to avoid critical issues.?
Have you used the system to achieve the KPI's?
Is PM Schedule followed regularly?
Is PM Checklist completely filled by the Engineers?
Is any remarks mentioned against the work done?

Why do we need to follow the PM Plan?

Whether all plans & Checklist has been completely understood by conc
Whether concern people know how to perform PM?
Has the equipment life been improved with this plan?
Has the PM Plan helped in improving MTBF?
Have you used the system to achieve the KPI's?
Is monthly generation plan prepared by the department?
Is monthly production plan of SID taken into account?
Is the plan ready on the first working day of the month?
Why do we need to make the monthly generation plan?

Is the power gneration plan has been completely understood by the con
Whether sponge iron department head was aware of the planning?
Has the overall power generation has increased??

Has the monthly generation plan helped in better weekly and daily pow
Have you used the system to achieve the KPI's?
Was the generation plan on track??
Did meeting start on time? Are all members reached at time?
Is Terms of reference & Agenda is prepared and followed?

Was the necessary pre-work done by participants i.e. Daily work done ,

Do the responsible members understand the importance of daily shutdo


Are all members aware of their roles in the meeting?.

Availability of spares, castable was checked as per the shutdown plan?

Were variances identified and corrective actions recorded in Action Pla

Were actions, responsibilities and due dates assigned on the Action Pla
Have you used the system to achieve the KPI's?

Were the documented action logs is reviewed and points are being clos

Total number of Sys

AUDIT BY

AUDIT DATE

Rating Scale

0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)

Supervisory Actions Required


to Enable Improvement /
Sustain

3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)

1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)

0
(NIL)
1
(PARTIAL)
3
(HIGH)

0
(NIL)

1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)

3
(HIGH)
0
(NIL)

1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)

3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)

1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)

3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
1
(PARTIAL)
3
(HIGH)
1
(PARTIAL)
1
(PARTIAL)

1
(PARTIAL)
1
(PARTIAL)
0
(NIL)
0
(NIL)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
1
(PARTIAL)
1
(PARTIAL)
1
(PARTIAL)
1
(PARTIAL)
0
(NIL)
0
(NIL)
0
(NIL)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)

1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)

0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)

3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)

9
18

TOTAL COMPLIANCE
TOTAL UNDERSTANDING
TOTAL USAGE

Taskforce

11-Apr-15

Observed Current Rating for


this category
(Score: 0, 1 or 3)

REMAR

(Key in any remarks which justify the

CT make up running status is not m


1

As CT make and other drivce infrom


is not upto full extent

As CT make and other drivce infrom


is not upto full extent
1

Export is no
1

Root cause is not


1

Root cause is not


1

Root cause ana


1

Root Cause as not mentione


so usage is low because without knowing
1

Not A
0

Not A
0

Not A
0

Not A
0

Not A
0

Not A
0

Not A
0

Not A
0

Not Re
0

Not Re
0

Not Re
0

85%
93%
78%

REMARKS

arks which justify the observed rating given to the auditee)

ning status is not mentioned

other drivce infromation is not mentioned so usage


tent

other drivce infromation is not mentioned so usage


tent

Export is not minimized

Root cause is not mentioned properly

Root cause is not mentioned properly

Root cause analysis is not clear

Cause as not mentioned properly for a particular job


cause without knowing the reason corrective action cant be taken

Not Audited

Not Audited

Not Audited

Not Audited

Not Audited

Not Audited

Not Audited

Not Audited

Not Required

Not Required

Not Required

ACTION PLAN
(Key in the required action that needs to be taken to address issues - th
must be done for System Elements with a yellow or red scores)

Issue raised in DRM and correction is made

Issue is raised in DRM meeting and action taken to improve the


usgae

Issue is raised in DRM meeting and action taken to improve the


usgae

Export should be minimized

Audit taken and physical check up of CO analyser is done and issue raised in D
to respective department.

Audit taken and physical check up of CO analyser is done and issue raised in D
to respective department.

Training is again given to Shift Incarge and he is fully convinced.

Issue will be discussed in Monday DRM meeting and corrective action then will
fixed.

N
taken to address issues - this
th a yellow or red scores)

made

ction taken to improve the

er is done and issue raised in DRM


tment.

and he is fully convinced.

g and corrective action then will be

Sr. No.
System Elements
Accountable

Responsible

FREQUENCY

Shift Handover and log


sheet - Phase 1

Sr. Manager / Manager

Shift Incharge (Engineer)

Daily

2
Shift Handover and log
sheet - Phase 2

Sr. Manager / Manager

Shift Incharge (Engineer)


Daily

Line Walk - Phase

General Manager (Maintenance)

Managers

Weekly

Shift I

Sr.

4
Daily Review Meeting

DRM Chairman

All DRM Members


Daily

Power Plant requirement


and fullfillment

AGM (operation)

Electrical HOD

Daily

General Man

Daily
Daily

Electrical

Breakdown Slip (Phase 1)

Engineers

AGM (oper

Power Plant requirement


and fullfillment

Managers

Breakdown Slip (Phase 2)

Managers

Engineers

Daily

Breakdown Management
System (BMS) - Phase 1

Managers

Engineers

onday, Wednesday, Friday

Engineers

ental HOD

Monday, Wed

Managers

Shut Down Job Scoping

10

Monday, Wednesday, Friday

Breakdown Management
System (BMS) - Phase 2

en Required

Engi

Breakdown Management
System (BMS) - Phase 1

Mana

ly

Manager

Shut Down Job Scoping


Kiln Phase 2

As and When Required

Departmental HOD

As and When Required

Departmental HOD

GM

11

GM

Shut Down Job Scoping


Phase 1

ral Manager

10

ired

Weekly

Sr.Manager / Manager

gineer)

Root Cause Analysis Phase 2

Weekly

Sr.Manager / Manager

Sectional - General Manager

13

Sectional - General Manager

Root Cause Analysis Phase 1

nager

12

Shift Incharge (Engineer)


As When Required

Shift In charge (Engineer)


As When Required

gineer)

Job Quality Check Phase 2

Sr. Manager / Manager

15

Sr. Manager / Manager

Job Quality Check Phase 1

nager

14

Shift Incharge (Engineer)

Monthly Power
Generation Plan

Sr. Manager / Manager

Shift Incharge (Engineer)

Daily

Sr. Manager / Manager

17

1st of every month

Preventive Maintenance
Planning

uring

16

18

As and When Required - During


Shutdown

Process In charges

DRM Chairman

Shutdown Review
Meeting

Categories

S1:
Compliance

S2:
Understanding

S3:
Usage

S3:
Usage

S1:
Compliance

S2:
Understanding

S3:
Usage

S1:
Compliance

S2:
Understanding

S3:
Usage

S3:
Usage

S1:
Compliance

S2:
Understanding

S3:
Usage

S1:
Compliance

S2:
Understanding

S2:
Understanding

S3:
Usage

S1:
Compliance

S2:
Understanding

S3:
Usage

S1:
Compliance

S2:
Understanding

S3:
Usage

S1:
Compliance

S2:
Understanding

S3:
Usage

S1:
Compliance

S2:
Understanding

S3:
Usage

S1:
Compliance

S2:
Understanding

S3:
Usage

S1:
Compliance

S2:
Understanding

S3:
Usage

S1:
Compliance

S1:
Compliance

S2:
Understanding

S3:
Usage

S1:
Compliance

S2:
Understanding

S3:
Usage

S1:
Compliance

S1:
Compliance

S2:
Understanding

S3:
Usage

S1:
Compliance

S2:
Understanding

S3:
Usage

S1:
Compliance

S1:
Compliance

S2:
Understanding

S3:
Usage

S1:
Compliance

S2:
Understanding

S3:
Usage

S1:
Compliance

S1:
Compliance

S2:
Understanding

S3:
Usage

Name of Area / Department being Audited: Operations / Maintenance

Name of Area / Department Manager: Respective Manager

Name of Individuals Audited:

OBSERVATIONS
(Based on ACTUAL observations and Interviews, use the following quest
best represent the level of compliance/understanding/usage of

Whether template is filled completely?


Whether all concerned people have signed the template?
Whether any remark mentioned on the sheet?
Why do we need to fill the sheet?
Whether all blocks has been completely understood by shift incharge?
Whether the complete sheet is understood by the shift incharge?
How shift handover process has been improved?
Have the information flow became more effective with the templates?

Have you used the system to achieve the KPI's?


Has all the information has been shared during shift handover.?
Whether template is filled completely?
Whether all concerned people have signed the template?
Whether any remark mentioned on the sheet?
Why do we need to fill the sheet?
Whether all blocks has been completely understood by shift incharge?
Whether the complete sheet is understood by the shift incharge?
How shift handover process has been improved?
Have the information flow became more effective with the templates?
Have you used the system to achieve the KPI's?
Has all the information has been shared during shift handover.?
Is line walk schedule prepared? Is it done as per schedule.?
Is line walk log sheet is filled properly and reported as on the day?
Is line walk is done properly by the assigned person?
Are all the codes underdstood by the person.?

Is the line walk personnel understood the scope or area where he has t
What is the benfit of doing line walk?
Is line walk log sheet is reviewed by HOD?

Are task has been assigned with its priority?


Have you used the system to achieve the KPI's?
Are all the high priority issues has been closed?
Did meeting start on time? Are all members reached at time?
Is Terms of reference & Agenda is prepared and followed?

Was the necessary pre-work done by participants i.e. Daily Stats sourc
solutions identified prior to meeting commencing?
Is Terms of reference understood by all DRM Members?
Are all members aware of their roles in the meeting?.
Do DRM Members understand the importance of the meeting.?

Were variances identified and corrective actions recorded in Action Pla

Were actions, responsibilities and due dates assigned on the Action Pla
Have you used the system to achieve the KPI's?

Were the documentated action logs is reviewed and points are being cl
Did Template mailed or received on time?

Is generation is so planned that all department have sufficient power to


is there any remark generated against short fall in supply
Did template is understood to all/
Do everybody know about such planning?

Did this planning is conveyed to all department


Any action taken against short fall in supply against requirement.
Did daily study about GAP in supply and demand happen?

Have you used the system to achieve the KPI's?


Export is reduceding or not.

Have all the details related to breakdown are being filled by Operations

Have all the details related to Breakdown are being filled by Maintenanc
Did you review breakdowns for previous day ?
What benefit is expected by recording breakdowns? Do you think both
should get involved in recording of Breakdown slips?

Please give us reason why breakdown start time plus job start and finis

What analysis of information about breakdowns captured should be do

Demonstrate how you are doing basic Root Cause Analysis by using th

Have you discussed with your manager on action points based on your
suggestions/message/pending jobs in breakdown slip?
Have you used the system to achieve the KPI's?
What are the actions taken based on issues like spare information, high
resolution of breakdown etc.

Have all the details related to breakdown are being filled by Operations

Have all the details related to Breakdown are being filled by Maintenanc
Did you review breakdowns for previous day ?
What benefit is expected by recording breakdowns? Do you think both
should get involved in recording of Breakdown slips?

Please give us reason why breakdown start time plus job start and finis

What analysis of information about breakdowns captured should be do

Demonstrate how you are doing basic Root Cause Analysis by using th

Have you discussed with your manager on action points based on your
suggestions/message/pending jobs in breakdown slip?
Have you used the system to achieve the KPI's?
What are the actions taken based on issues like spare information, high
resolution of breakdown etc.

Have all the details related to breakdown are being filled by data feedin

Have all the details related to Breakdown are being correctly filled by th
Did you review the data of breakdowns slip before feeding ?
What benefit is expected by recording breakdowns? Do you think both
should get involved in recording of Breakdown slips?

Please give us reason why breakdown start time plus job start and finis

What analysis of information about breakdowns captured should be do

Demonstrate how you are doing basic Root Cause Analysis by using th

Have you used the system to achieve the KPI's?


Have you discussed with your manager on action points based on your
suggestions/message/pending jobs in breakdown slip?
What are the actions taken based on issues like spare information, high
resolution of breakdown etc.

Have all the details related to breakdown are being filled by data feedin

Have all the details related to Breakdown are being correctly filled by th
Did you review the data of breakdowns slip before feeding ?
What benefit is expected by recording breakdowns? Do you think both
should get involved in recording of Breakdown slips?

Please give us reason why breakdown start time plus job start and finis

What analysis of information about breakdowns captured should be do

Demonstrate how you are doing basic Root Cause Analysis by using th

Have you used the system to achieve the KPI's?


Have you discussed with your manager on action points based on your
suggestions/message/pending jobs in breakdown slip?
What are the actions taken based on issues like spare information, high
resolution of breakdown etc.
Whether template is filled completely ?
Whether all the inter departmental jobs are incorporated?

Availability of spares and other critical equipment is done as per job sco

Why do we need to fill the sheet?


Whether all blocks has been completely understood by HOD?
Whether they are aware of how to track the system?
Whether the concerned people planning daily jobs as per Schedule?
Have you used the system to achieve the KPI's?

Whether the information flow became more effective with the template
Has the information helped in taking pro active actions?
Whether template is filled completely ?
Whether all the inter departmental jobs are incorporated?

Availability of spares and other critical equipment is done as per job sco
Why do we need to fill the sheet?
Whether all blocks has been completely understood by HOD?
Whether they are aware of how to track the system?
Whether the concerned people planning daily jobs as per Schedule?
Have you used the system to achieve the KPI's?

Whether the information flow became more effective with the template
Has the information helped in taking pro active actions?
Are you carrying out root cause analysis as per RCA Policy?

Are you maintaning a RCA documentation file? Please show the RCA lo

Does "5 why" format exist and used please show.


What is the need for RCA policy?
Why do we need to Maintain RCA log book. ?
What is the benefit of using 5 Why template ?

Show if any repetitive problem were corrected by using root cause anal
Please provide one example based on last RCA done?

Have you documented the actions and can you link the actions to the im
Are you carrying out root cause analysis as per RCA Policy?

Are you maintaning a RCA documentation file? Please show the RCA lo
Does "5 why" format exist and used please show.
What is the need for RCA policy?
Why do we need to Maintain RCA log book. ?
What is the benefit of using 5 Why template ?

Show if any repetitive problem were corrected by using root cause anal
Please provide one example based on last RCA done?
Have you used the system to achieve the KPI's?

Have you documented the actions and can you link the actions to the im
Whether the Job checking is done as per shut down planning?
Whether the job checking is done by the team formed?

Whether remarks are mentioned against poor quality of jobs?


Whether the team Is aware of importance of job quality checking?
Whether all jobs compered were completely understood ?
Whether they are aware of how to do job checking?
Whether the frequency of equipment failure reduced post light up?
Have you used the system to achieve the KPI's?
Whether Any counter measures taken to avoid critical issues.?

Whether the Job checking is done as per shut down planning?


Whether the job checking is done by the team formed?
Whether remarks are mentioned against poor quality of jobs?
Whether the team Is aware of importance of job quality checking?
Whether all jobs compered were completely understood ?
Whether they are aware of how to do job checking?
Whether the frequency of equipment failure reduced post light up?
Whether Any counter measures taken to avoid critical issues.?
Have you used the system to achieve the KPI's?
Is PM Schedule followed regularly?

Is PM Checklist completely filled by the Engineers?


Is any remarks mentioned against the work done?
Why do we need to follow the PM Plan?

Whether all plans & Checklist has been completely understood by conc
Whether concern people know how to perform PM?
Has the equipment life been improved with this plan?
Has the PM Plan helped in improving MTBF?
Have you used the system to achieve the KPI's?
Is monthly generation plan prepared by the department?
Is monthly production plan of SID taken into account?
Is the plan ready on the first working day of the month?
Why do we need to make the monthly generation plan?

Is the power gneration plan has been completely understood by the con
Whether sponge iron department head was aware of the planning?
Has the overall power generation has increased??

Has the monthly generation plan helped in better weekly and daily pow
Have you used the system to achieve the KPI's?
Was the generation plan on track??
Did meeting start on time? Are all members reached at time?

Is Terms of reference & Agenda is prepared and followed?

Was the necessary pre-work done by participants i.e. Daily work done ,

Do the responsible members understand the importance of daily shutdo


Are all members aware of their roles in the meeting?.

Availability of spares, castable was checked as per the shutdown plan?

Were variances identified and corrective actions recorded in Action Pla

Were actions, responsibilities and due dates assigned on the Action Pla
Have you used the system to achieve the KPI's?

Were the documented action logs is reviewed and points are being clos

Total number of Sys

AUDIT BY

AUDIT DATE

Rating Scale

0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)

Supervisory Actions Required


to Enable Improvement /
Sustain

3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)

1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)

3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)

0
(NIL)

1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)

3
(HIGH)

0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)

3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)

0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)

0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
1
(PARTIAL)
3
(HIGH)

1
(PARTIAL)
1
(PARTIAL)
1
(PARTIAL)
1
(PARTIAL)
0
(NIL)
0
(NIL)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
1
(PARTIAL)
1
(PARTIAL)
1
(PARTIAL)
1
(PARTIAL)
0
(NIL)
0
(NIL)
0
(NIL)
0
(NIL)
1
(PARTIAL)

3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)

1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)

1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)

8
18

TOTAL COMPLIANCE
TOTAL UNDERSTANDING
TOTAL USAGE

Taskforce

18-Apr-15

Observed Current Rating for


this category
(Score: 0, 1 or 3)

REMAR

(Key in any remarks which justify the

DRM is installed
3

Export is li
1

Not A

Break down slip number is


1

Training is no

Not A

Not Re
0

Not Re
0

Not Re
0

For ACWP PUM


3

Not Re
0

Not Re
0

Not Re
0

Sheet is not filled co


1

Sheet is not filled co


1

Not A
0

Not A

Not A
0

93%
93%
87%

REMARKS

arks which justify the observed rating given to the auditee)

DRM is installed on online server

Export is little bit high.

Not Audited

k down slip number is not filled on break down slip

Training is not Schedule yet

Not Audited

Not Required

Not Required

Not Required

For ACWP PUMP RCA is done

Not Required

Not Required

Not Required

heet is not filled completely for few job

heet is not filled completely for few job

Not Audited

Not Audited

Not Audited

ACTION PLAN
(Key in the required action that needs to be taken to address issues - th
must be done for System Elements with a yellow or red scores)

N
taken to address issues - this
th a yellow or red scores)

Sr. No.
System Elements
Accountable

Responsible

FREQUENCY

Shift Handover and log


sheet - Phase 1

Sr. Manager / Manager

Shift Incharge (Engineer)

Daily

2
Shift Handover and log
sheet - Phase 2

Sr. Manager / Manager

Shift Incharge (Engineer)


Daily

Line Walk - Phase

General Manager (Maintenance)

Managers

Weekly

Shift I

Sr.

4
Daily Review Meeting

DRM Chairman

All DRM Members


Daily

Power Plant requirement


and fullfillment

AGM (operation)

Electrical HOD

Daily

General Man

Daily
Daily

Electrical

Breakdown Slip (Phase 1)

Engineers

AGM (oper

Power Plant requirement


and fullfillment

Managers

Breakdown Slip (Phase 2)

Managers

Engineers

Daily

Breakdown Management
System (BMS) - Phase 1

Managers

Engineers

onday, Wednesday, Friday

Engineers

ental HOD

Monday, Wed

Managers

Shut Down Job Scoping

10

Monday, Wednesday, Friday

Breakdown Management
System (BMS) - Phase 2

en Required

Engi

Breakdown Management
System (BMS) - Phase 1

Mana

ly

Manager

Shut Down Job Scoping


Kiln Phase 2

As and When Required

Departmental HOD

As and When Required

Departmental HOD

GM

11

GM

Shut Down Job Scoping


Phase 1

ral Manager

10

ired

Weekly

Sr.Manager / Manager

gineer)

Root Cause Analysis Phase 2

Weekly

Sr.Manager / Manager

Sectional - General Manager

13

Sectional - General Manager

Root Cause Analysis Phase 1

nager

12

Shift Incharge (Engineer)


As When Required

Shift In charge (Engineer)


As When Required

gineer)

Job Quality Check Phase 2

Sr. Manager / Manager

15

Sr. Manager / Manager

Job Quality Check Phase 1

nager

14

Shift Incharge (Engineer)

Monthly Power
Generation Plan

Sr. Manager / Manager

Shift Incharge (Engineer)

Daily

Sr. Manager / Manager

17

1st of every month

Preventive Maintenance
Planning

uring

16

18

As and When Required - During


Shutdown

Process In charges

DRM Chairman

Shutdown Review
Meeting

Categories

S1:
Compliance

S2:
Understanding

S3:
Usage

S3:
Usage

S1:
Compliance

S2:
Understanding

S3:
Usage

S1:
Compliance

S2:
Understanding

S3:
Usage

S3:
Usage

S1:
Compliance

S2:
Understanding

S3:
Usage

S1:
Compliance

S2:
Understanding

S2:
Understanding

S3:
Usage

S1:
Compliance

S2:
Understanding

S3:
Usage

S1:
Compliance

S2:
Understanding

S3:
Usage

S1:
Compliance

S2:
Understanding

S3:
Usage

S1:
Compliance

S2:
Understanding

S3:
Usage

S1:
Compliance

S2:
Understanding

S3:
Usage

S1:
Compliance

S2:
Understanding

S3:
Usage

S1:
Compliance

S1:
Compliance

S2:
Understanding

S3:
Usage

S1:
Compliance

S2:
Understanding

S3:
Usage

S1:
Compliance

S1:
Compliance

S2:
Understanding

S3:
Usage

S1:
Compliance

S2:
Understanding

S3:
Usage

S1:
Compliance

S1:
Compliance

S2:
Understanding

S3:
Usage

S1:
Compliance

S2:
Understanding

S3:
Usage

S1:
Compliance

S1:
Compliance

S2:
Understanding

S3:
Usage

Name of Area / Department being Audited: Operations / Maintenance

Name of Area / Department Manager: Respective Manager

Name of Individuals Audited: Sabyasachhi Sahu

OBSERVATIONS
(Based on ACTUAL observations and Interviews, use the following quest
best represent the level of compliance/understanding/usage of

Whether template is filled completely?


Whether all concerned people have signed the template?
Whether any remark mentioned on the sheet?
Why do we need to fill the sheet?
Whether all blocks has been completely understood by shift incharge?
Whether the complete sheet is understood by the shift incharge?
How shift handover process has been improved?
Have the information flow became more effective with the templates?

Have you used the system to achieve the KPI's?


Has all the information has been shared during shift handover.?
Whether template is filled completely?
Whether all concerned people have signed the template?
Whether any remark mentioned on the sheet?
Why do we need to fill the sheet?
Whether all blocks has been completely understood by shift incharge?
Whether the complete sheet is understood by the shift incharge?
How shift handover process has been improved?
Have the information flow became more effective with the templates?
Have you used the system to achieve the KPI's?
Has all the information has been shared during shift handover.?
Is line walk schedule prepared? Is it done as per schedule.?
Is line walk log sheet is filled properly and reported as on the day?
Is line walk is done properly by the assigned person?
Are all the codes underdstood by the person.?

Is the line walk personnel understood the scope or area where he has t
What is the benfit of doing line walk?
Is line walk log sheet is reviewed by HOD?

Are task has been assigned with its priority?


Have you used the system to achieve the KPI's?
Are all the high priority issues has been closed?
Did meeting start on time? Are all members reached at time?
Is Terms of reference & Agenda is prepared and followed?

Was the necessary pre-work done by participants i.e. Daily Stats sourc
solutions identified prior to meeting commencing?
Is Terms of reference understood by all DRM Members?
Are all members aware of their roles in the meeting?.
Do DRM Members understand the importance of the meeting.?

Were variances identified and corrective actions recorded in Action Pla

Were actions, responsibilities and due dates assigned on the Action Pla
Have you used the system to achieve the KPI's?

Were the documentated action logs is reviewed and points are being cl
Did Template mailed or received on time?

Is generation is so planned that all department have sufficient power to


is there any remark generated against short fall in supply
Did template is understood to all/
Do everybody know about such planning?

Did this planning is conveyed to all department


Any action taken against short fall in supply against requirement.
Did daily study about GAP in supply and demand happen?

Have you used the system to achieve the KPI's?


Export is reduceding or not.

Have all the details related to breakdown are being filled by Operations

Have all the details related to Breakdown are being filled by Maintenanc
Did you review breakdowns for previous day ?
What benefit is expected by recording breakdowns? Do you think both
should get involved in recording of Breakdown slips?

Please give us reason why breakdown start time plus job start and finis

What analysis of information about breakdowns captured should be do

Demonstrate how you are doing basic Root Cause Analysis by using th

Have you discussed with your manager on action points based on your
suggestions/message/pending jobs in breakdown slip?
Have you used the system to achieve the KPI's?
What are the actions taken based on issues like spare information, high
resolution of breakdown etc.

Have all the details related to breakdown are being filled by Operations

Have all the details related to Breakdown are being filled by Maintenanc
Did you review breakdowns for previous day ?
What benefit is expected by recording breakdowns? Do you think both
should get involved in recording of Breakdown slips?

Please give us reason why breakdown start time plus job start and finis

What analysis of information about breakdowns captured should be do

Demonstrate how you are doing basic Root Cause Analysis by using th

Have you discussed with your manager on action points based on your
suggestions/message/pending jobs in breakdown slip?
Have you used the system to achieve the KPI's?
What are the actions taken based on issues like spare information, high
resolution of breakdown etc.

Have all the details related to breakdown are being filled by data feedin

Have all the details related to Breakdown are being correctly filled by th
Did you review the data of breakdowns slip before feeding ?
What benefit is expected by recording breakdowns? Do you think both
should get involved in recording of Breakdown slips?

Please give us reason why breakdown start time plus job start and finis

What analysis of information about breakdowns captured should be do

Demonstrate how you are doing basic Root Cause Analysis by using th

Have you used the system to achieve the KPI's?


Have you discussed with your manager on action points based on your
suggestions/message/pending jobs in breakdown slip?
What are the actions taken based on issues like spare information, high
resolution of breakdown etc.

Have all the details related to breakdown are being filled by data feedin

Have all the details related to Breakdown are being correctly filled by th
Did you review the data of breakdowns slip before feeding ?
What benefit is expected by recording breakdowns? Do you think both
should get involved in recording of Breakdown slips?

Please give us reason why breakdown start time plus job start and finis

What analysis of information about breakdowns captured should be do

Demonstrate how you are doing basic Root Cause Analysis by using th

Have you used the system to achieve the KPI's?


Have you discussed with your manager on action points based on your
suggestions/message/pending jobs in breakdown slip?
What are the actions taken based on issues like spare information, high
resolution of breakdown etc.
Whether template is filled completely ?
Whether all the inter departmental jobs are incorporated?

Availability of spares and other critical equipment is done as per job sco

Why do we need to fill the sheet?


Whether all blocks has been completely understood by HOD?
Whether they are aware of how to track the system?
Whether the concerned people planning daily jobs as per Schedule?
Have you used the system to achieve the KPI's?

Whether the information flow became more effective with the template
Has the information helped in taking pro active actions?
Whether template is filled completely ?
Whether all the inter departmental jobs are incorporated?

Availability of spares and other critical equipment is done as per job sco
Why do we need to fill the sheet?
Whether all blocks has been completely understood by HOD?
Whether they are aware of how to track the system?
Whether the concerned people planning daily jobs as per Schedule?
Have you used the system to achieve the KPI's?

Whether the information flow became more effective with the template
Has the information helped in taking pro active actions?
Are you carrying out root cause analysis as per RCA Policy?

Are you maintaning a RCA documentation file? Please show the RCA lo

Does "5 why" format exist and used please show.


What is the need for RCA policy?
Why do we need to Maintain RCA log book. ?
What is the benefit of using 5 Why template ?

Show if any repetitive problem were corrected by using root cause anal
Please provide one example based on last RCA done?

Have you documented the actions and can you link the actions to the im
Are you carrying out root cause analysis as per RCA Policy?

Are you maintaning a RCA documentation file? Please show the RCA lo
Does "5 why" format exist and used please show.
What is the need for RCA policy?
Why do we need to Maintain RCA log book. ?
What is the benefit of using 5 Why template ?

Show if any repetitive problem were corrected by using root cause anal
Please provide one example based on last RCA done?
Have you used the system to achieve the KPI's?

Have you documented the actions and can you link the actions to the im
Whether the Job checking is done as per shut down planning?
Whether the job checking is done by the team formed?

Whether remarks are mentioned against poor quality of jobs?


Whether the team Is aware of importance of job quality checking?
Whether all jobs compered were completely understood ?
Whether they are aware of how to do job checking?
Whether the frequency of equipment failure reduced post light up?
Have you used the system to achieve the KPI's?
Whether Any counter measures taken to avoid critical issues.?

Whether the Job checking is done as per shut down planning?


Whether the job checking is done by the team formed?
Whether remarks are mentioned against poor quality of jobs?
Whether the team Is aware of importance of job quality checking?
Whether all jobs compered were completely understood ?
Whether they are aware of how to do job checking?
Whether the frequency of equipment failure reduced post light up?
Whether Any counter measures taken to avoid critical issues.?
Have you used the system to achieve the KPI's?
Is PM Schedule followed regularly?

Is PM Checklist completely filled by the Engineers?


Is any remarks mentioned against the work done?
Why do we need to follow the PM Plan?

Whether all plans & Checklist has been completely understood by conc
Whether concern people know how to perform PM?
Has the equipment life been improved with this plan?
Has the PM Plan helped in improving MTBF?
Have you used the system to achieve the KPI's?
Is monthly generation plan prepared by the department?
Is monthly production plan of SID taken into account?
Is the plan ready on the first working day of the month?
Why do we need to make the monthly generation plan?

Is the power gneration plan has been completely understood by the con
Whether sponge iron department head was aware of the planning?
Has the overall power generation has increased??

Has the monthly generation plan helped in better weekly and daily pow
Have you used the system to achieve the KPI's?
Was the generation plan on track??
Did meeting start on time? Are all members reached at time?

Is Terms of reference & Agenda is prepared and followed?

Was the necessary pre-work done by participants i.e. Daily work done ,

Do the responsible members understand the importance of daily shutdo


Are all members aware of their roles in the meeting?.

Availability of spares, castable was checked as per the shutdown plan?

Were variances identified and corrective actions recorded in Action Pla

Were actions, responsibilities and due dates assigned on the Action Pla
Have you used the system to achieve the KPI's?

Were the documented action logs is reviewed and points are being clos

Total number of Sys

AUDIT BY

AUDIT DATE

Rating Scale

0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)

Supervisory Actions Required


to Enable Improvement /
Sustain

3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)

1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)

3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)

0
(NIL)

1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)

3
(HIGH)

0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)

3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)

0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)

0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
1
(PARTIAL)
3
(HIGH)

1
(PARTIAL)
1
(PARTIAL)
1
(PARTIAL)
1
(PARTIAL)
0
(NIL)
0
(NIL)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
1
(PARTIAL)
1
(PARTIAL)
1
(PARTIAL)
1
(PARTIAL)
0
(NIL)
0
(NIL)
0
(NIL)
0
(NIL)
1
(PARTIAL)

3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)

1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)

1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)

5
18

TOTAL COMPLIANCE
TOTAL UNDERSTANDING
TOTAL USAGE

Taskforce

25-Apr-15

Observed Current Rating for


this category
(Score: 0, 1 or 3)

REMAR

(Key in any remarks which justify the

Some box is left unfilled


1

As already intimation given to the s


so it is hiting his understnading
1

Analysis is not done fo

Analysis is not done fo

Not Re

RCA policy is not


1

RCA for ACW


3

Not Re

Not Re

Not Re

PM Not updataed by Mech on 24


1

PM Not updataed by Mech on 24


1

Usage is totally depend on compliance mod


1

Not Re

Not Re

Not Re

90%
90%
85%

REMARKS

arks which justify the observed rating given to the auditee)

unfilled

ation given to the shift incharge but complaince is low


understnading

Analysis is not done for the month of MARCH

Analysis is not done for the month of MARCH

Not Required

CA policy is not in common server

RCA for ACWP - 2 is revised

Not Required

Not Required

Not Required

aed by Mech on 24.04.15 due to folder not opened.

aed by Mech on 24.04.15 due to folder not opened.

nd on compliance mode

Not Required

Not Required

Not Required

ACTION PLAN
(Key in the required action that needs to be taken to address issues - th
must be done for System Elements with a yellow or red scores)

Intimation and instruction given to Shift Incharge

Instruction given to the Sectional Hod and he instruct the Shift


Incharge.

Folder is not working in many PC so action must be taken to


improve it and it is conveyed to IT department.

Folder is not working in many PC so action must be taken to


improve it and it is conveyed to IT department.

N
taken to address issues - this
th a yellow or red scores)

t Incharge

and he instruct the Shift

o action must be taken to


d to IT department.

Sr. No.
System Elements
Accountable

Responsible

FREQUENCY

Shift Handover and log


sheet - Phase 1

Sr. Manager / Manager

Shift Incharge (Engineer)

Daily

2
Shift Handover and log
sheet - Phase 2

Sr. Manager / Manager

Shift Incharge (Engineer)


Daily

Line Walk - Phase

General Manager (Maintenance)

Managers

Weekly

Shift I

Sr.

4
Daily Review Meeting

DRM Chairman

All DRM Members


Daily

Power Plant requirement


and fullfillment

AGM (operation)

Electrical HOD

Daily

General Man

Daily
Daily

Electrical

Breakdown Slip (Phase 1)

Engineers

AGM (oper

Power Plant requirement


and fullfillment

Managers

Breakdown Slip (Phase 2)

Managers

Engineers

Daily

Breakdown Management
System (BMS) - Phase 1

Managers

Engineers

onday, Wednesday, Friday

Engineers

ental HOD

Monday, Wed

Managers

Shut Down Job Scoping

10

Monday, Wednesday, Friday

Breakdown Management
System (BMS) - Phase 2

en Required

Engi

Breakdown Management
System (BMS) - Phase 1

Mana

ly

Manager

Shut Down Job Scoping


Kiln Phase 2

As and When Required

Departmental HOD

As and When Required

Departmental HOD

GM

11

GM

Shut Down Job Scoping


Phase 1

ral Manager

10

ired

Weekly

Sr.Manager / Manager

gineer)

Root Cause Analysis Phase 2

Weekly

Sr.Manager / Manager

Sectional - General Manager

13

Sectional - General Manager

Root Cause Analysis Phase 1

nager

12

Shift Incharge (Engineer)


As When Required

Shift In charge (Engineer)


As When Required

gineer)

Job Quality Check Phase 2

Sr. Manager / Manager

15

Sr. Manager / Manager

Job Quality Check Phase 1

nager

14

Shift Incharge (Engineer)

Monthly Power
Generation Plan

Sr. Manager / Manager

Shift Incharge (Engineer)

Daily

Sr. Manager / Manager

17

1st of every month

Preventive Maintenance
Planning

uring

16

18

As and When Required - During


Shutdown

Process In charges

DRM Chairman

Shutdown Review
Meeting

Categories

S1:
Compliance

S2:
Understanding

S3:
Usage

S3:
Usage

S1:
Compliance

S2:
Understanding

S3:
Usage

S1:
Compliance

S2:
Understanding

S3:
Usage

S3:
Usage

S1:
Compliance

S2:
Understanding

S3:
Usage

S1:
Compliance

S2:
Understanding

S2:
Understanding

S3:
Usage

S1:
Compliance

S2:
Understanding

S3:
Usage

S1:
Compliance

S2:
Understanding

S3:
Usage

S1:
Compliance

S2:
Understanding

S3:
Usage

S1:
Compliance

S2:
Understanding

S3:
Usage

S1:
Compliance

S2:
Understanding

S3:
Usage

S1:
Compliance

S2:
Understanding

S3:
Usage

S1:
Compliance

S1:
Compliance

S2:
Understanding

S3:
Usage

S1:
Compliance

S2:
Understanding

S3:
Usage

S1:
Compliance

S1:
Compliance

S2:
Understanding

S3:
Usage

S1:
Compliance

S2:
Understanding

S3:
Usage

S1:
Compliance

S1:
Compliance

S2:
Understanding

S3:
Usage

S1:
Compliance

S2:
Understanding

S3:
Usage

S1:
Compliance

S1:
Compliance

S2:
Understanding

S3:
Usage

Name of Area / Department being Audited: Operations / Maintenance

Name of Area / Department Manager: Respective Manager

Name of Individuals Audited:Shashiikant Sharma

OBSERVATIONS
(Based on ACTUAL observations and Interviews, use the following quest
best represent the level of compliance/understanding/usage of

Whether template is filled completely?


Whether all concerned people have signed the template?
Whether any remark mentioned on the sheet?
Why do we need to fill the sheet?
Whether all blocks has been completely understood by shift incharge?
Whether the complete sheet is understood by the shift incharge?
How shift handover process has been improved?
Have the information flow became more effective with the templates?

Have you used the system to achieve the KPI's?


Has all the information has been shared during shift handover.?
Whether template is filled completely?
Whether all concerned people have signed the template?
Whether any remark mentioned on the sheet?
Why do we need to fill the sheet?
Whether all blocks has been completely understood by shift incharge?
Whether the complete sheet is understood by the shift incharge?
How shift handover process has been improved?
Have the information flow became more effective with the templates?
Have you used the system to achieve the KPI's?
Has all the information has been shared during shift handover.?
Is line walk schedule prepared? Is it done as per schedule.?
Is line walk log sheet is filled properly and reported as on the day?
Is line walk is done properly by the assigned person?
Are all the codes underdstood by the person.?

Is the line walk personnel understood the scope or area where he has t
What is the benfit of doing line walk?
Is line walk log sheet is reviewed by HOD?

Are task has been assigned with its priority?


Have you used the system to achieve the KPI's?
Are all the high priority issues has been closed?
Did meeting start on time? Are all members reached at time?
Is Terms of reference & Agenda is prepared and followed?

Was the necessary pre-work done by participants i.e. Daily Stats sourc
solutions identified prior to meeting commencing?
Is Terms of reference understood by all DRM Members?
Are all members aware of their roles in the meeting?.
Do DRM Members understand the importance of the meeting.?

Were variances identified and corrective actions recorded in Action Pla

Were actions, responsibilities and due dates assigned on the Action Pla
Have you used the system to achieve the KPI's?

Were the documentated action logs is reviewed and points are being cl
Did Template mailed or received on time?

Is generation is so planned that all department have sufficient power to


is there any remark generated against short fall in supply
Did template is understood to all/
Do everybody know about such planning?

Did this planning is conveyed to all department


Any action taken against short fall in supply against requirement.
Did daily study about GAP in supply and demand happen?

Have you used the system to achieve the KPI's?


Export is reduceding or not.

Have all the details related to breakdown are being filled by Operations

Have all the details related to Breakdown are being filled by Maintenanc
Did you review breakdowns for previous day ?
What benefit is expected by recording breakdowns? Do you think both
should get involved in recording of Breakdown slips?

Please give us reason why breakdown start time plus job start and finis

What analysis of information about breakdowns captured should be do

Demonstrate how you are doing basic Root Cause Analysis by using th

Have you discussed with your manager on action points based on your
suggestions/message/pending jobs in breakdown slip?
Have you used the system to achieve the KPI's?
What are the actions taken based on issues like spare information, high
resolution of breakdown etc.

Have all the details related to breakdown are being filled by Operations

Have all the details related to Breakdown are being filled by Maintenanc
Did you review breakdowns for previous day ?
What benefit is expected by recording breakdowns? Do you think both
should get involved in recording of Breakdown slips?

Please give us reason why breakdown start time plus job start and finis

What analysis of information about breakdowns captured should be do

Demonstrate how you are doing basic Root Cause Analysis by using th

Have you discussed with your manager on action points based on your
suggestions/message/pending jobs in breakdown slip?
Have you used the system to achieve the KPI's?
What are the actions taken based on issues like spare information, high
resolution of breakdown etc.

Have all the details related to breakdown are being filled by data feedin

Have all the details related to Breakdown are being correctly filled by th
Did you review the data of breakdowns slip before feeding ?
What benefit is expected by recording breakdowns? Do you think both
should get involved in recording of Breakdown slips?

Please give us reason why breakdown start time plus job start and finis

What analysis of information about breakdowns captured should be do

Demonstrate how you are doing basic Root Cause Analysis by using th

Have you used the system to achieve the KPI's?


Have you discussed with your manager on action points based on your
suggestions/message/pending jobs in breakdown slip?
What are the actions taken based on issues like spare information, high
resolution of breakdown etc.

Have all the details related to breakdown are being filled by data feedin

Have all the details related to Breakdown are being correctly filled by th
Did you review the data of breakdowns slip before feeding ?
What benefit is expected by recording breakdowns? Do you think both
should get involved in recording of Breakdown slips?

Please give us reason why breakdown start time plus job start and finis

What analysis of information about breakdowns captured should be do

Demonstrate how you are doing basic Root Cause Analysis by using th

Have you used the system to achieve the KPI's?


Have you discussed with your manager on action points based on your
suggestions/message/pending jobs in breakdown slip?
What are the actions taken based on issues like spare information, high
resolution of breakdown etc.
Whether template is filled completely ?
Whether all the inter departmental jobs are incorporated?

Availability of spares and other critical equipment is done as per job sco

Why do we need to fill the sheet?


Whether all blocks has been completely understood by HOD?
Whether they are aware of how to track the system?
Whether the concerned people planning daily jobs as per Schedule?
Have you used the system to achieve the KPI's?

Whether the information flow became more effective with the template
Has the information helped in taking pro active actions?
Whether template is filled completely ?
Whether all the inter departmental jobs are incorporated?

Availability of spares and other critical equipment is done as per job sco
Why do we need to fill the sheet?
Whether all blocks has been completely understood by HOD?
Whether they are aware of how to track the system?
Whether the concerned people planning daily jobs as per Schedule?
Have you used the system to achieve the KPI's?

Whether the information flow became more effective with the template
Has the information helped in taking pro active actions?
Are you carrying out root cause analysis as per RCA Policy?

Are you maintaning a RCA documentation file? Please show the RCA lo

Does "5 why" format exist and used please show.


What is the need for RCA policy?
Why do we need to Maintain RCA log book. ?
What is the benefit of using 5 Why template ?

Show if any repetitive problem were corrected by using root cause anal
Please provide one example based on last RCA done?

Have you documented the actions and can you link the actions to the im
Are you carrying out root cause analysis as per RCA Policy?

Are you maintaning a RCA documentation file? Please show the RCA lo
Does "5 why" format exist and used please show.
What is the need for RCA policy?
Why do we need to Maintain RCA log book. ?
What is the benefit of using 5 Why template ?

Show if any repetitive problem were corrected by using root cause anal
Please provide one example based on last RCA done?
Have you used the system to achieve the KPI's?

Have you documented the actions and can you link the actions to the im
Whether the Job checking is done as per shut down planning?
Whether the job checking is done by the team formed?

Whether remarks are mentioned against poor quality of jobs?


Whether the team Is aware of importance of job quality checking?
Whether all jobs compered were completely understood ?
Whether they are aware of how to do job checking?
Whether the frequency of equipment failure reduced post light up?
Have you used the system to achieve the KPI's?
Whether Any counter measures taken to avoid critical issues.?

Whether the Job checking is done as per shut down planning?


Whether the job checking is done by the team formed?
Whether remarks are mentioned against poor quality of jobs?
Whether the team Is aware of importance of job quality checking?
Whether all jobs compered were completely understood ?
Whether they are aware of how to do job checking?
Whether the frequency of equipment failure reduced post light up?
Whether Any counter measures taken to avoid critical issues.?
Have you used the system to achieve the KPI's?
Is PM Schedule followed regularly?

Is PM Checklist completely filled by the Engineers?


Is any remarks mentioned against the work done?
Why do we need to follow the PM Plan?

Whether all plans & Checklist has been completely understood by conc
Whether concern people know how to perform PM?
Has the equipment life been improved with this plan?
Has the PM Plan helped in improving MTBF?
Have you used the system to achieve the KPI's?
Is monthly generation plan prepared by the department?
Is monthly production plan of SID taken into account?
Is the plan ready on the first working day of the month?
Why do we need to make the monthly generation plan?

Is the power gneration plan has been completely understood by the con
Whether sponge iron department head was aware of the planning?
Has the overall power generation has increased??

Has the monthly generation plan helped in better weekly and daily pow
Have you used the system to achieve the KPI's?
Was the generation plan on track??
Did meeting start on time? Are all members reached at time?

Is Terms of reference & Agenda is prepared and followed?

Was the necessary pre-work done by participants i.e. Daily work done ,

Do the responsible members understand the importance of daily shutdo


Are all members aware of their roles in the meeting?.

Availability of spares, castable was checked as per the shutdown plan?

Were variances identified and corrective actions recorded in Action Pla

Were actions, responsibilities and due dates assigned on the Action Pla
Have you used the system to achieve the KPI's?

Were the documented action logs is reviewed and points are being clos

Total number of Sys

AUDIT BY

AUDIT DATE

Rating Scale

0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)

Supervisory Actions Required


to Enable Improvement /
Sustain

3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)

1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)

3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)

0
(NIL)

1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)

3
(HIGH)

0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)

3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)

0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)

0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
1
(PARTIAL)
3
(HIGH)

1
(PARTIAL)
1
(PARTIAL)
1
(PARTIAL)
1
(PARTIAL)
0
(NIL)
0
(NIL)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
1
(PARTIAL)
1
(PARTIAL)
1
(PARTIAL)
1
(PARTIAL)
0
(NIL)
0
(NIL)
0
(NIL)
0
(NIL)
1
(PARTIAL)

3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)

1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)

1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)

9
18

TOTAL COMPLIANCE
TOTAL UNDERSTANDING
TOTAL USAGE

Taskforce

2-May-15

Observed Current Rating for


this category
(Score: 0, 1 or 3)

REMAR

(Key in any remarks which justify the

lube oil stock is


1

Lube Oil stock is not mentione


not conveyed to

Lube Oil stock is not mentione


not conveyed to
1

Export
1

Not A

box like standard and actula parameter is n


given an dalso information about it conveye
1

Not A
0

93%
93%
85%

REMARKS

arks which justify the observed rating given to the auditee)

lube oil stock is not mentioned

k is not mentioned hence inforamtion about it is


not conveyed to the shift incharge

k is not mentioned hence inforamtion about it is


not conveyed to the shift incharge

Export is high

Not Audited

d actula parameter is not understand completely so training is


mation about it conveyed to the HOD in MAT meeting

Not Audited

ACTION PLAN
(Key in the required action that needs to be taken to address issues - th
must be done for System Elements with a yellow or red scores)

intimation is given to the Sectinal HOD

To achieve KPI all inforamtion should be mentioned in Shi


Handover and log sheet and shift inchagre is intimated.

To achieve KPI all inforamtion should be mentioned in Shi


Handover and log sheet and shift inchagre is intimated.

Export need to minimized

So some parameter need to be revised which will done in next week.

N
taken to address issues - this
th a yellow or red scores)

e Sectinal HOD

uld be mentioned in Shift


t inchagre is intimated.

nimized

will done in next week.

Sr. No.
System Elements
Accountable

Responsible

FREQUENCY

Shift Handover and log


sheet - Phase 1

Sr. Manager / Manager

Shift Incharge (Engineer)

Daily

2
Shift Handover and log
sheet - Phase 2

Sr. Manager / Manager

Shift Incharge (Engineer)


Daily

Line Walk - Phase

General Manager (Maintenance)

Managers

Weekly

Shift I

Sr.

4
Daily Review Meeting

DRM Chairman

All DRM Members


Daily

Power Plant requirement


and fullfillment

AGM (operation)

Electrical HOD

Daily

General Man

Daily
Daily

Electrical

Breakdown Slip (Phase 1)

Engineers

AGM (oper

Power Plant requirement


and fullfillment

Managers

Breakdown Slip (Phase 2)

Managers

Engineers

Daily

Breakdown Management
System (BMS) - Phase 1

Managers

Engineers

onday, Wednesday, Friday

Engineers

ental HOD

Monday, Wed

Managers

Shut Down Job Scoping

10

Monday, Wednesday, Friday

Breakdown Management
System (BMS) - Phase 2

en Required

Engi

Breakdown Management
System (BMS) - Phase 1

Mana

ly

Manager

Shut Down Job Scoping


Kiln Phase 2

As and When Required

Departmental HOD

As and When Required

Departmental HOD

GM

11

GM

Shut Down Job Scoping


Phase 1

ral Manager

10

ired

Weekly

Sr.Manager / Manager

gineer)

Root Cause Analysis Phase 2

Weekly

Sr.Manager / Manager

Sectional - General Manager

13

Sectional - General Manager

Root Cause Analysis Phase 1

nager

12

Shift Incharge (Engineer)


As When Required

Shift In charge (Engineer)


As When Required

gineer)

Job Quality Check Phase 2

Sr. Manager / Manager

15

Sr. Manager / Manager

Job Quality Check Phase 1

nager

14

Shift Incharge (Engineer)

Monthly Power
Generation Plan

Sr. Manager / Manager

Shift Incharge (Engineer)

Daily

Sr. Manager / Manager

17

1st of every month

Preventive Maintenance
Planning

uring

16

18

As and When Required - During


Shutdown

Process In charges

DRM Chairman

Shutdown Review
Meeting

Categories

S1:
Compliance

S2:
Understanding

S3:
Usage

S3:
Usage

S1:
Compliance

S2:
Understanding

S3:
Usage

S1:
Compliance

S2:
Understanding

S3:
Usage

S3:
Usage

S1:
Compliance

S2:
Understanding

S3:
Usage

S1:
Compliance

S2:
Understanding

S2:
Understanding

S3:
Usage

S1:
Compliance

S2:
Understanding

S3:
Usage

S1:
Compliance

S2:
Understanding

S3:
Usage

S1:
Compliance

S2:
Understanding

S3:
Usage

S1:
Compliance

S2:
Understanding

S3:
Usage

S1:
Compliance

S2:
Understanding

S3:
Usage

S1:
Compliance

S2:
Understanding

S3:
Usage

S1:
Compliance

S1:
Compliance

S2:
Understanding

S3:
Usage

S1:
Compliance

S2:
Understanding

S3:
Usage

S1:
Compliance

S1:
Compliance

S2:
Understanding

S3:
Usage

S1:
Compliance

S2:
Understanding

S3:
Usage

S1:
Compliance

S1:
Compliance

S2:
Understanding

S3:
Usage

S1:
Compliance

S2:
Understanding

S3:
Usage

S1:
Compliance

S1:
Compliance

S2:
Understanding

S3:
Usage

Name of Area / Department being Audited: Operations / Maintenance

Name of Area / Department Manager: Respective Manager

Name of Individuals Audited:Shashiikant Sharma

OBSERVATIONS
(Based on ACTUAL observations and Interviews, use the following quest
best represent the level of compliance/understanding/usage of

Whether template is filled completely?


Whether all concerned people have signed the template?
Whether any remark mentioned on the sheet?
Why do we need to fill the sheet?
Whether all blocks has been completely understood by shift incharge?
Whether the complete sheet is understood by the shift incharge?
How shift handover process has been improved?
Have the information flow became more effective with the templates?

Have you used the system to achieve the KPI's?


Has all the information has been shared during shift handover.?
Whether template is filled completely?
Whether all concerned people have signed the template?
Whether any remark mentioned on the sheet?
Why do we need to fill the sheet?
Whether all blocks has been completely understood by shift incharge?
Whether the complete sheet is understood by the shift incharge?
How shift handover process has been improved?
Have the information flow became more effective with the templates?
Have you used the system to achieve the KPI's?
Has all the information has been shared during shift handover.?
Is line walk schedule prepared? Is it done as per schedule.?
Is line walk log sheet is filled properly and reported as on the day?
Is line walk is done properly by the assigned person?
Are all the codes underdstood by the person.?

Is the line walk personnel understood the scope or area where he has t
What is the benfit of doing line walk?
Is line walk log sheet is reviewed by HOD?

Are task has been assigned with its priority?


Have you used the system to achieve the KPI's?
Are all the high priority issues has been closed?
Did meeting start on time? Are all members reached at time?
Is Terms of reference & Agenda is prepared and followed?

Was the necessary pre-work done by participants i.e. Daily Stats sourc
solutions identified prior to meeting commencing?
Is Terms of reference understood by all DRM Members?
Are all members aware of their roles in the meeting?.
Do DRM Members understand the importance of the meeting.?

Were variances identified and corrective actions recorded in Action Pla

Were actions, responsibilities and due dates assigned on the Action Pla
Have you used the system to achieve the KPI's?

Were the documentated action logs is reviewed and points are being cl
Did Template mailed or received on time?

Is generation is so planned that all department have sufficient power to


is there any remark generated against short fall in supply
Did template is understood to all/
Do everybody know about such planning?

Did this planning is conveyed to all department


Any action taken against short fall in supply against requirement.
Did daily study about GAP in supply and demand happen?

Have you used the system to achieve the KPI's?


Export is reduceding or not.

Have all the details related to breakdown are being filled by Operations

Have all the details related to Breakdown are being filled by Maintenanc
Did you review breakdowns for previous day ?
What benefit is expected by recording breakdowns? Do you think both
should get involved in recording of Breakdown slips?

Please give us reason why breakdown start time plus job start and finis

What analysis of information about breakdowns captured should be do

Demonstrate how you are doing basic Root Cause Analysis by using th

Have you discussed with your manager on action points based on your
suggestions/message/pending jobs in breakdown slip?
Have you used the system to achieve the KPI's?
What are the actions taken based on issues like spare information, high
resolution of breakdown etc.

Have all the details related to breakdown are being filled by Operations

Have all the details related to Breakdown are being filled by Maintenanc
Did you review breakdowns for previous day ?
What benefit is expected by recording breakdowns? Do you think both
should get involved in recording of Breakdown slips?

Please give us reason why breakdown start time plus job start and finis

What analysis of information about breakdowns captured should be do

Demonstrate how you are doing basic Root Cause Analysis by using th

Have you discussed with your manager on action points based on your
suggestions/message/pending jobs in breakdown slip?
Have you used the system to achieve the KPI's?
What are the actions taken based on issues like spare information, high
resolution of breakdown etc.

Have all the details related to breakdown are being filled by data feedin

Have all the details related to Breakdown are being correctly filled by th
Did you review the data of breakdowns slip before feeding ?
What benefit is expected by recording breakdowns? Do you think both
should get involved in recording of Breakdown slips?

Please give us reason why breakdown start time plus job start and finis

What analysis of information about breakdowns captured should be do

Demonstrate how you are doing basic Root Cause Analysis by using th

Have you used the system to achieve the KPI's?


Have you discussed with your manager on action points based on your
suggestions/message/pending jobs in breakdown slip?
What are the actions taken based on issues like spare information, high
resolution of breakdown etc.

Have all the details related to breakdown are being filled by data feedin

Have all the details related to Breakdown are being correctly filled by th
Did you review the data of breakdowns slip before feeding ?
What benefit is expected by recording breakdowns? Do you think both
should get involved in recording of Breakdown slips?

Please give us reason why breakdown start time plus job start and finis

What analysis of information about breakdowns captured should be do

Demonstrate how you are doing basic Root Cause Analysis by using th

Have you used the system to achieve the KPI's?


Have you discussed with your manager on action points based on your
suggestions/message/pending jobs in breakdown slip?
What are the actions taken based on issues like spare information, high
resolution of breakdown etc.
Whether template is filled completely ?
Whether all the inter departmental jobs are incorporated?

Availability of spares and other critical equipment is done as per job sco

Why do we need to fill the sheet?


Whether all blocks has been completely understood by HOD?
Whether they are aware of how to track the system?
Whether the concerned people planning daily jobs as per Schedule?
Have you used the system to achieve the KPI's?

Whether the information flow became more effective with the template
Has the information helped in taking pro active actions?
Whether template is filled completely ?
Whether all the inter departmental jobs are incorporated?

Availability of spares and other critical equipment is done as per job sco
Why do we need to fill the sheet?
Whether all blocks has been completely understood by HOD?
Whether they are aware of how to track the system?
Whether the concerned people planning daily jobs as per Schedule?
Have you used the system to achieve the KPI's?

Whether the information flow became more effective with the template
Has the information helped in taking pro active actions?
Are you carrying out root cause analysis as per RCA Policy?

Are you maintaning a RCA documentation file? Please show the RCA lo

Does "5 why" format exist and used please show.


What is the need for RCA policy?
Why do we need to Maintain RCA log book. ?
What is the benefit of using 5 Why template ?

Show if any repetitive problem were corrected by using root cause anal
Please provide one example based on last RCA done?

Have you documented the actions and can you link the actions to the im
Are you carrying out root cause analysis as per RCA Policy?

Are you maintaning a RCA documentation file? Please show the RCA lo
Does "5 why" format exist and used please show.
What is the need for RCA policy?
Why do we need to Maintain RCA log book. ?
What is the benefit of using 5 Why template ?

Show if any repetitive problem were corrected by using root cause anal
Please provide one example based on last RCA done?
Have you used the system to achieve the KPI's?

Have you documented the actions and can you link the actions to the im
Whether the Job checking is done as per shut down planning?
Whether the job checking is done by the team formed?

Whether remarks are mentioned against poor quality of jobs?


Whether the team Is aware of importance of job quality checking?
Whether all jobs compered were completely understood ?
Whether they are aware of how to do job checking?
Whether the frequency of equipment failure reduced post light up?
Have you used the system to achieve the KPI's?
Whether Any counter measures taken to avoid critical issues.?

Whether the Job checking is done as per shut down planning?


Whether the job checking is done by the team formed?
Whether remarks are mentioned against poor quality of jobs?
Whether the team Is aware of importance of job quality checking?
Whether all jobs compered were completely understood ?
Whether they are aware of how to do job checking?
Whether the frequency of equipment failure reduced post light up?
Whether Any counter measures taken to avoid critical issues.?
Have you used the system to achieve the KPI's?
Is PM Schedule followed regularly?

Is PM Checklist completely filled by the Engineers?


Is any remarks mentioned against the work done?
Why do we need to follow the PM Plan?

Whether all plans & Checklist has been completely understood by conc
Whether concern people know how to perform PM?
Has the equipment life been improved with this plan?
Has the PM Plan helped in improving MTBF?
Have you used the system to achieve the KPI's?
Is monthly generation plan prepared by the department?
Is monthly production plan of SID taken into account?
Is the plan ready on the first working day of the month?
Why do we need to make the monthly generation plan?

Is the power gneration plan has been completely understood by the con
Whether sponge iron department head was aware of the planning?
Has the overall power generation has increased??

Has the monthly generation plan helped in better weekly and daily pow
Have you used the system to achieve the KPI's?
Was the generation plan on track??
Did meeting start on time? Are all members reached at time?

Is Terms of reference & Agenda is prepared and followed?

Was the necessary pre-work done by participants i.e. Daily work done ,

Do the responsible members understand the importance of daily shutdo


Are all members aware of their roles in the meeting?.

Availability of spares, castable was checked as per the shutdown plan?

Were variances identified and corrective actions recorded in Action Pla

Were actions, responsibilities and due dates assigned on the Action Pla
Have you used the system to achieve the KPI's?

Were the documented action logs is reviewed and points are being clos

Total number of Sys

AUDIT BY

AUDIT DATE

Rating Scale

0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)

Supervisory Actions Required


to Enable Improvement /
Sustain

3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)

1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)

3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)

0
(NIL)

1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)

3
(HIGH)

0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)

3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)

0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)

0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
1
(PARTIAL)
3
(HIGH)

1
(PARTIAL)
1
(PARTIAL)
1
(PARTIAL)
1
(PARTIAL)
0
(NIL)
0
(NIL)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
1
(PARTIAL)
1
(PARTIAL)
1
(PARTIAL)
1
(PARTIAL)
0
(NIL)
0
(NIL)
0
(NIL)
0
(NIL)
1
(PARTIAL)

3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)

1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)

1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)

8
18

TOTAL COMPLIANCE
TOTAL UNDERSTANDING
TOTAL USAGE

Taskforce

9-May-15

Observed Current Rating for


this category
(Score: 0, 1 or 3)

REMAR

(Key in any remarks which justify the

Line Walk Summary sheet is not u


of folder in o
1

Few line walk


1

Few job of operation

Few job of operation


1

Export is no
1

Not A
0

Not Re

Not A
0

93%
93%
87%

REMARKS

arks which justify the observed rating given to the auditee)

mary sheet is not updated due to problem in opening


of folder in online server

Few line walk is not covered

ew job of operation dept is not finished

ew job of operation dept is not finished

Export is not minimized

Not Audited

Not Required

Not Audited

ACTION PLAN
(Key in the required action that needs to be taken to address issues - th
must be done for System Elements with a yellow or red scores)

intimation is given to the Sectinal HOD

To achieve KPI all inforamtion should be mentioned in Shi


Handover and log sheet and shift inchagre is intimated.

To achieve KPI all inforamtion should be mentioned in Shi


Handover and log sheet and shift inchagre is intimated.

Intimation is given to the HOD and IT department

Intimation is given to the HOD

Intimation about it is given to the Sectional HOD

Intimation about it is given to the Sectional HOD

Export need to minimized for it we are planning more in precis


way so that there is less gap in plan vs actual

ABP is revised so it is in progress

N
taken to address issues - this
th a yellow or red scores)

e Sectinal HOD

uld be mentioned in Shift


t inchagre is intimated.

D and IT department

o the HOD

the Sectional HOD

the Sectional HOD

e planning more in precise


p in plan vs actual

n progress

Sr. No.
System Elements
Accountable

Responsible

FREQUENCY

Shift Handover and log


sheet - Phase 1

Sr. Manager / Manager

Shift Incharge (Engineer)

Daily

2
Shift Handover and log
sheet - Phase 2

Sr. Manager / Manager

Shift Incharge (Engineer)


Daily

Line Walk - Phase

General Manager (Maintenance)

Managers

Weekly

Shift I

Sr.

4
Daily Review Meeting

DRM Chairman

All DRM Members


Daily

Power Plant requirement


and fullfillment

AGM (operation)

Electrical HOD

Daily

General Man

Dai
Daily

Electric

Breakdown Slip (Phase 1)

Engineers

AGM (op

Power Plant requirement


and fullfillment

Managers

Breakdown Slip (Phase 2)

Managers

Engineers

Daily

Breakdown Management
System (BMS) - Phase 1

Managers

Engineers

Monday, Wednesday, Friday

GM

Monday, Wednesday, Friday

Shut Down Job Scoping


Phase 1

nd When Required

Managers

10

Engineers

Breakdown Management
System (BMS) - Phase 2

partmental HOD

Monday

Shut Down Job Scoping


Kiln Phase 2

12

Root Cause Analysis Phase 1

Weekly

nager / Manager

As and When Required

Departmental HOD

As and When R

Departmental

GM

11

GM

Shut Down Job Scoping


Phase 1

l - General Manager

10

Job Quality Check Phase 1

en Required

Weekly

Sr.Manager / Manager

14

arge (Engineer)

Root Cause Analysis Phase 2

Weekly

Sr.Manager / Mana

Sectional - General M

13

Sectional - General Manager

Root Cause Analysis Phase 1

ger / Manager

12

Job Quality Check Phase 2

16

Preventive Maintenance
Planning

Daily

rge (Engineer)

As When Required

Shift In charge (Engineer)

As When Require

Shift Incharge (Engin

Sr. Manager / Mana

15

Sr. Manager / Manager

Job Quality Check Phase 1

ger / Manager

14

ired - During
n

harges

Monthly Power
Generation Plan

1st of every month

Shift Incharge (Engineer)

Daily

Shift Incharge (Engine

Sr. Manager / Manage

17

Sr. Manager / Manager

Preventive Maintenance
Planning

rman

16

18

As and When Required - During


Shutdown

Process In charges

DRM Chairman

Shutdown Review
Meeting

Categories

S1:
Compliance

S2:
Understanding

S3:
Usage

S3:
Usage

S1:
Compliance

S2:
Understanding

S3:
Usage

S1:
Compliance

S2:
Understanding

S3:
Usage

S3:
Usage

S1:
Compliance

S2:
Understanding

S3:
Usage

S1:
Compliance

S2:
Understanding

S3:
Usage

S1:
Compliance

S2:
Understanding

S3:
Usage

S1:
Compliance

S1:
Compliance

S2:
Understanding

S3:
Usage

S1:
Compliance

S2:
Understanding

S3:
Usage

S3:
Usage

S1:
Compliance

S2:
Understanding

S3:
Usage

S1:
Compliance

S2:
Understanding

S2:
Understanding

S3:
Usage

S1:
Compliance

S2:
Understanding

S3:
Usage

S1:
Compliance

S2:
Understanding

S2:
Understanding

S3:
Usage

S1:
Compliance

S2:
Understanding

S3:
Usage

S1:
Compliance

S2:
Understanding

S2:
Understanding

S3:
Usage

S1:
Compliance

S2:
Understanding

S3:
Usage

S1:
Compliance

S2:
Understanding

S3:
Usage

S1:
Compliance

S2:
Understanding

S3:
Usage

S1:
Compliance

S1:
Compliance

S2:
Understanding

S3:
Usage

Name of Area / Department being Audited: Operations / Maintenance

Name of Area / Department Manager: Respective Manager

Name of Individuals Audited:

OBSERVATIONS
(Based on ACTUAL observations and Interviews, use the following quest
best represent the level of compliance/understanding/usage of

Whether template is filled completely?


Whether all concerned people have signed the template?
Whether any remark mentioned on the sheet?
Why do we need to fill the sheet?
Whether all blocks has been completely understood by shift incharge?
Whether the complete sheet is understood by the shift incharge?
How shift handover process has been improved?
Have the information flow became more effective with the templates?

Have you used the system to achieve the KPI's?


Has all the information has been shared during shift handover.?
Whether template is filled completely?
Whether all concerned people have signed the template?
Whether any remark mentioned on the sheet?
Why do we need to fill the sheet?
Whether all blocks has been completely understood by shift incharge?
Whether the complete sheet is understood by the shift incharge?
How shift handover process has been improved?
Have the information flow became more effective with the templates?
Have you used the system to achieve the KPI's?
Has all the information has been shared during shift handover.?
Is line walk schedule prepared? Is it done as per schedule.?
Is line walk log sheet is filled properly and reported as on the day?
Is line walk is done properly by the assigned person?
Are all the codes underdstood by the person.?

Is the line walk personnel understood the scope or area where he has t
What is the benfit of doing line walk?
Is line walk log sheet is reviewed by HOD?

Are task has been assigned with its priority?


Have you used the system to achieve the KPI's?
Are all the high priority issues has been closed?
Did meeting start on time? Are all members reached at time?
Is Terms of reference & Agenda is prepared and followed?

Was the necessary pre-work done by participants i.e. Daily Stats sourc
solutions identified prior to meeting commencing?
Is Terms of reference understood by all DRM Members?
Are all members aware of their roles in the meeting?.
Do DRM Members understand the importance of the meeting.?

Were variances identified and corrective actions recorded in Action Pla

Were actions, responsibilities and due dates assigned on the Action Pla
Have you used the system to achieve the KPI's?

Were the documentated action logs is reviewed and points are being cl
Did Template mailed or received on time?

Is generation is so planned that all department have sufficient power to


is there any remark generated against short fall in supply
Did template is understood to all/
Do everybody know about such planning?
Did this planning is conveyed to all department

Any action taken against short fall in supply against requirement.


Did daily study about GAP in supply and demand happen?

Have you used the system to achieve the KPI's?


Export is reduceding or not.

Have all the details related to breakdown are being filled by Operations

Have all the details related to Breakdown are being filled by Maintenanc
Did you review breakdowns for previous day ?
What benefit is expected by recording breakdowns? Do you think both
should get involved in recording of Breakdown slips?

Please give us reason why breakdown start time plus job start and finis

What analysis of information about breakdowns captured should be do

Demonstrate how you are doing basic Root Cause Analysis by using th

Have you discussed with your manager on action points based on your
suggestions/message/pending jobs in breakdown slip?
Have you used the system to achieve the KPI's?
What are the actions taken based on issues like spare information, high
resolution of breakdown etc.

Have all the details related to breakdown are being filled by Operations

Have all the details related to Breakdown are being filled by Maintenanc
Did you review breakdowns for previous day ?
What benefit is expected by recording breakdowns? Do you think both
should get involved in recording of Breakdown slips?

Please give us reason why breakdown start time plus job start and finis

What analysis of information about breakdowns captured should be do

Demonstrate how you are doing basic Root Cause Analysis by using th

Have you discussed with your manager on action points based on your
suggestions/message/pending jobs in breakdown slip?
Have you used the system to achieve the KPI's?
What are the actions taken based on issues like spare information, high
resolution of breakdown etc.

Have all the details related to breakdown are being filled by data feedin

Have all the details related to Breakdown are being correctly filled by th
Did you review the data of breakdowns slip before feeding ?
What benefit is expected by recording breakdowns? Do you think both
should get involved in recording of Breakdown slips?

Please give us reason why breakdown start time plus job start and finis

What analysis of information about breakdowns captured should be do

Demonstrate how you are doing basic Root Cause Analysis by using th
Have you used the system to achieve the KPI's?

Have you discussed with your manager on action points based on your
suggestions/message/pending jobs in breakdown slip?
What are the actions taken based on issues like spare information, high
resolution of breakdown etc.

Have all the details related to breakdown are being filled by data feedin

Have all the details related to Breakdown are being correctly filled by th
Did you review the data of breakdowns slip before feeding ?
What benefit is expected by recording breakdowns? Do you think both
should get involved in recording of Breakdown slips?

Please give us reason why breakdown start time plus job start and finis

What analysis of information about breakdowns captured should be do

Demonstrate how you are doing basic Root Cause Analysis by using th

Have you used the system to achieve the KPI's?


Have you discussed with your manager on action points based on your
suggestions/message/pending jobs in breakdown slip?
What are the actions taken based on issues like spare information, high
resolution of breakdown etc.
Whether template is filled completely ?
Whether all the inter departmental jobs are incorporated?

Availability of spares and other critical equipment is done as per job sco
Why do we need to fill the sheet?
Whether all blocks has been completely understood by HOD?

Whether they are aware of how to track the system?


Whether the concerned people planning daily jobs as per Schedule?
Have you used the system to achieve the KPI's?

Whether the information flow became more effective with the template
Has the information helped in taking pro active actions?
Whether template is filled completely ?
Whether all the inter departmental jobs are incorporated?

Availability of spares and other critical equipment is done as per job sco
Why do we need to fill the sheet?
Whether all blocks has been completely understood by HOD?
Whether they are aware of how to track the system?
Whether the concerned people planning daily jobs as per Schedule?
Have you used the system to achieve the KPI's?

Whether the information flow became more effective with the template
Has the information helped in taking pro active actions?
Are you carrying out root cause analysis as per RCA Policy?

Are you maintaning a RCA documentation file? Please show the RCA lo
Does "5 why" format exist and used please show.
What is the need for RCA policy?

Why do we need to Maintain RCA log book. ?


What is the benefit of using 5 Why template ?

Show if any repetitive problem were corrected by using root cause anal
Please provide one example based on last RCA done?

Have you documented the actions and can you link the actions to the im
Are you carrying out root cause analysis as per RCA Policy?

Are you maintaning a RCA documentation file? Please show the RCA lo
Does "5 why" format exist and used please show.
What is the need for RCA policy?
Why do we need to Maintain RCA log book. ?
What is the benefit of using 5 Why template ?

Show if any repetitive problem were corrected by using root cause anal
Please provide one example based on last RCA done?
Have you used the system to achieve the KPI's?

Have you documented the actions and can you link the actions to the im
Whether the Job checking is done as per shut down planning?
Whether the job checking is done by the team formed?
Whether remarks are mentioned against poor quality of jobs?
Whether the team Is aware of importance of job quality checking?

Whether all jobs compered were completely understood ?


Whether they are aware of how to do job checking?
Whether the frequency of equipment failure reduced post light up?
Have you used the system to achieve the KPI's?
Whether Any counter measures taken to avoid critical issues.?

Whether the Job checking is done as per shut down planning?


Whether the job checking is done by the team formed?
Whether remarks are mentioned against poor quality of jobs?
Whether the team Is aware of importance of job quality checking?
Whether all jobs compered were completely understood ?
Whether they are aware of how to do job checking?
Whether the frequency of equipment failure reduced post light up?
Whether Any counter measures taken to avoid critical issues.?
Have you used the system to achieve the KPI's?
Is PM Schedule followed regularly?
Is PM Checklist completely filled by the Engineers?
Is any remarks mentioned against the work done?

Why do we need to follow the PM Plan?

Whether all plans & Checklist has been completely understood by conc
Whether concern people know how to perform PM?
Has the equipment life been improved with this plan?
Has the PM Plan helped in improving MTBF?
Have you used the system to achieve the KPI's?
Is monthly generation plan prepared by the department?
Is monthly production plan of SID taken into account?
Is the plan ready on the first working day of the month?
Why do we need to make the monthly generation plan?

Is the power gneration plan has been completely understood by the con
Whether sponge iron department head was aware of the planning?
Has the overall power generation has increased??

Has the monthly generation plan helped in better weekly and daily pow
Have you used the system to achieve the KPI's?
Was the generation plan on track??
Did meeting start on time? Are all members reached at time?
Is Terms of reference & Agenda is prepared and followed?

Was the necessary pre-work done by participants i.e. Daily work done ,

Do the responsible members understand the importance of daily shutdo


Are all members aware of their roles in the meeting?.

Availability of spares, castable was checked as per the shutdown plan?

Were variances identified and corrective actions recorded in Action Pla

Were actions, responsibilities and due dates assigned on the Action Pla
Have you used the system to achieve the KPI's?

Were the documented action logs is reviewed and points are being clos

Total number of Sys

AUDIT BY

AUDIT DATE

Rating Scale

0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)

Supervisory Actions Required


to Enable Improvement /
Sustain

3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)

1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)

0
(NIL)
1
(PARTIAL)
3
(HIGH)

0
(NIL)

1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)

3
(HIGH)
0
(NIL)

1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)

3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)

1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)

3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
1
(PARTIAL)
3
(HIGH)
1
(PARTIAL)
1
(PARTIAL)

1
(PARTIAL)
1
(PARTIAL)
0
(NIL)
0
(NIL)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
1
(PARTIAL)
1
(PARTIAL)
1
(PARTIAL)
1
(PARTIAL)
0
(NIL)
0
(NIL)
0
(NIL)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)

1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)

0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)

3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)

8
18

TOTAL COMPLIANCE
TOTAL UNDERSTANDING
TOTAL USAGE

Taskforce

16-May-15

Observed Current Rating for


this category
(Score: 0, 1 or 3)

REMAR

(Key in any remarks which justify the

Line walk of DM plant is less done


for DM plant is not completed.S
3

.
3

Not a
0

Not a
0

usage is low because software issue is ther


formulaNwe Excel sheet have to be prepare
1

No t audited
0

Not audited
0

Black Out RCA is


1

Black Out RCA is


1

Not re
0

Not re
0

Not Re
0

Not re
0

Not a
0

Not a
0

87%
93%
80%

REMARKS

arks which justify the observed rating given to the auditee)

plant is less done and also 50% of job is of line walk


s not completed.So compliance and usage is less

Not audited

Not audited

e software issue is there due to which some job havenot proper


eet have to be prepared

ack Out RCA is not submiteed yet

ack Out RCA is not submiteed yet

Not required

Not required

Not Required

Not required

Not audited

Not audited

ACTION PLAN
(Key in the required action that needs to be taken to address issues - th
must be done for System Elements with a yellow or red scores)

Intimation is given to MR. Nishatn Bajpai Sir in MAT meeting.

Kiln shut down

On Thursday this week training is scheduled

On Thursday this week training is scheduled

Sheet wil be submitted to palia sir on 22-05-2015

N
taken to address issues - this
th a yellow or red scores)

ajpai Sir in MAT meeting.

ng is scheduled

ng is scheduled

22-05-2015

Sr. No.
System Elements
Accountable

Responsible

FREQUENCY

Shift Handover and log


sheet - Phase 1

Sr. Manager / Manager

Shift Incharge (Engineer)

Daily

2
Shift Handover and log
sheet - Phase 2

Sr. Manager / Manager

Shift Incharge (Engineer)


Daily

Line Walk - Phase

General Manager (Maintenance)

Managers

Weekly

Shift I

Sr.

4
Daily Review Meeting

DRM Chairman

All DRM Members


Daily

Power Plant requirement


and fullfillment

AGM (operation)

Electrical HOD

Daily

General Man

Dai
Daily

Electric

Breakdown Slip (Phase 1)

Engineers

AGM (op

Power Plant requirement


and fullfillment

Managers

Breakdown Slip (Phase 2)

Managers

Engineers

Daily

Breakdown Management
System (BMS) - Phase 1

Managers

Engineers

Monday, Wednesday, Friday

GM

Monday, Wednesday, Friday

Shut Down Job Scoping


Phase 1

nd When Required

Managers

10

Engineers

Breakdown Management
System (BMS) - Phase 2

partmental HOD

Monday

Shut Down Job Scoping


Kiln Phase 2

12

Root Cause Analysis Phase 1

Weekly

nager / Manager

As and When Required

Departmental HOD

As and When R

Departmental

GM

11

GM

Shut Down Job Scoping


Phase 1

l - General Manager

10

Job Quality Check Phase 1

en Required

Weekly

Sr.Manager / Manager

14

arge (Engineer)

Root Cause Analysis Phase 2

Weekly

Sr.Manager / Mana

Sectional - General M

13

Sectional - General Manager

Root Cause Analysis Phase 1

ger / Manager

12

Job Quality Check Phase 2

16

Preventive Maintenance
Planning

Daily

rge (Engineer)

As When Required

Shift In charge (Engineer)

As When Require

Shift Incharge (Engin

Sr. Manager / Mana

15

Sr. Manager / Manager

Job Quality Check Phase 1

ger / Manager

14

ired - During
n

harges

Monthly Power
Generation Plan

1st of every month

Shift Incharge (Engineer)

Daily

Shift Incharge (Engine

Sr. Manager / Manage

17

Sr. Manager / Manager

Preventive Maintenance
Planning

rman

16

18

As and When Required - During


Shutdown

Process In charges

DRM Chairman

Shutdown Review
Meeting

Categories

S1:
Compliance

S2:
Understanding

S3:
Usage

S3:
Usage

S1:
Compliance

S2:
Understanding

S3:
Usage

S1:
Compliance

S2:
Understanding

S3:
Usage

S3:
Usage

S1:
Compliance

S2:
Understanding

S3:
Usage

S1:
Compliance

S2:
Understanding

S3:
Usage

S1:
Compliance

S2:
Understanding

S3:
Usage

S1:
Compliance

S1:
Compliance

S2:
Understanding

S3:
Usage

S1:
Compliance

S2:
Understanding

S3:
Usage

S3:
Usage

S1:
Compliance

S2:
Understanding

S3:
Usage

S1:
Compliance

S2:
Understanding

S2:
Understanding

S3:
Usage

S1:
Compliance

S2:
Understanding

S3:
Usage

S1:
Compliance

S2:
Understanding

S2:
Understanding

S3:
Usage

S1:
Compliance

S2:
Understanding

S3:
Usage

S1:
Compliance

S2:
Understanding

S2:
Understanding

S3:
Usage

S1:
Compliance

S2:
Understanding

S3:
Usage

S1:
Compliance

S2:
Understanding

S3:
Usage

S1:
Compliance

S2:
Understanding

S3:
Usage

S1:
Compliance

S1:
Compliance

S2:
Understanding

S3:
Usage

Name of Area / Department being Audited: Operations / Maintenance

Name of Area / Department Manager: Respective Manager

Name of Individuals Audited:

OBSERVATIONS
(Based on ACTUAL observations and Interviews, use the following quest
best represent the level of compliance/understanding/usage of

Whether template is filled completely?


Whether all concerned people have signed the template?
Whether any remark mentioned on the sheet?
Why do we need to fill the sheet?
Whether all blocks has been completely understood by shift incharge?
Whether the complete sheet is understood by the shift incharge?
How shift handover process has been improved?
Have the information flow became more effective with the templates?

Have you used the system to achieve the KPI's?


Has all the information has been shared during shift handover.?
Whether template is filled completely?
Whether all concerned people have signed the template?
Whether any remark mentioned on the sheet?
Why do we need to fill the sheet?
Whether all blocks has been completely understood by shift incharge?
Whether the complete sheet is understood by the shift incharge?
How shift handover process has been improved?
Have the information flow became more effective with the templates?
Have you used the system to achieve the KPI's?
Has all the information has been shared during shift handover.?
Is line walk schedule prepared? Is it done as per schedule.?
Is line walk log sheet is filled properly and reported as on the day?
Is line walk is done properly by the assigned person?
Are all the codes underdstood by the person.?

Is the line walk personnel understood the scope or area where he has t
What is the benfit of doing line walk?
Is line walk log sheet is reviewed by HOD?

Are task has been assigned with its priority?


Have you used the system to achieve the KPI's?
Are all the high priority issues has been closed?
Did meeting start on time? Are all members reached at time?
Is Terms of reference & Agenda is prepared and followed?

Was the necessary pre-work done by participants i.e. Daily Stats sourc
solutions identified prior to meeting commencing?
Is Terms of reference understood by all DRM Members?
Are all members aware of their roles in the meeting?.
Do DRM Members understand the importance of the meeting.?

Were variances identified and corrective actions recorded in Action Pla

Were actions, responsibilities and due dates assigned on the Action Pla
Have you used the system to achieve the KPI's?

Were the documentated action logs is reviewed and points are being cl
Did Template mailed or received on time?

Is generation is so planned that all department have sufficient power to


is there any remark generated against short fall in supply
Did template is understood to all/
Do everybody know about such planning?
Did this planning is conveyed to all department

Any action taken against short fall in supply against requirement.


Did daily study about GAP in supply and demand happen?

Have you used the system to achieve the KPI's?


Export is reduceding or not.

Have all the details related to breakdown are being filled by Operations

Have all the details related to Breakdown are being filled by Maintenanc
Did you review breakdowns for previous day ?
What benefit is expected by recording breakdowns? Do you think both
should get involved in recording of Breakdown slips?

Please give us reason why breakdown start time plus job start and finis

What analysis of information about breakdowns captured should be do

Demonstrate how you are doing basic Root Cause Analysis by using th

Have you discussed with your manager on action points based on your
suggestions/message/pending jobs in breakdown slip?
Have you used the system to achieve the KPI's?
What are the actions taken based on issues like spare information, high
resolution of breakdown etc.

Have all the details related to breakdown are being filled by Operations

Have all the details related to Breakdown are being filled by Maintenanc
Did you review breakdowns for previous day ?
What benefit is expected by recording breakdowns? Do you think both
should get involved in recording of Breakdown slips?

Please give us reason why breakdown start time plus job start and finis

What analysis of information about breakdowns captured should be do

Demonstrate how you are doing basic Root Cause Analysis by using th

Have you discussed with your manager on action points based on your
suggestions/message/pending jobs in breakdown slip?
Have you used the system to achieve the KPI's?
What are the actions taken based on issues like spare information, high
resolution of breakdown etc.

Have all the details related to breakdown are being filled by data feedin

Have all the details related to Breakdown are being correctly filled by th
Did you review the data of breakdowns slip before feeding ?
What benefit is expected by recording breakdowns? Do you think both
should get involved in recording of Breakdown slips?

Please give us reason why breakdown start time plus job start and finis

What analysis of information about breakdowns captured should be do

Demonstrate how you are doing basic Root Cause Analysis by using th
Have you used the system to achieve the KPI's?

Have you discussed with your manager on action points based on your
suggestions/message/pending jobs in breakdown slip?
What are the actions taken based on issues like spare information, high
resolution of breakdown etc.

Have all the details related to breakdown are being filled by data feedin

Have all the details related to Breakdown are being correctly filled by th
Did you review the data of breakdowns slip before feeding ?
What benefit is expected by recording breakdowns? Do you think both
should get involved in recording of Breakdown slips?

Please give us reason why breakdown start time plus job start and finis

What analysis of information about breakdowns captured should be do

Demonstrate how you are doing basic Root Cause Analysis by using th

Have you used the system to achieve the KPI's?


Have you discussed with your manager on action points based on your
suggestions/message/pending jobs in breakdown slip?
What are the actions taken based on issues like spare information, high
resolution of breakdown etc.
Whether template is filled completely ?
Whether all the inter departmental jobs are incorporated?

Availability of spares and other critical equipment is done as per job sco
Why do we need to fill the sheet?
Whether all blocks has been completely understood by HOD?

Whether they are aware of how to track the system?


Whether the concerned people planning daily jobs as per Schedule?
Have you used the system to achieve the KPI's?

Whether the information flow became more effective with the template
Has the information helped in taking pro active actions?
Whether template is filled completely ?
Whether all the inter departmental jobs are incorporated?

Availability of spares and other critical equipment is done as per job sco
Why do we need to fill the sheet?
Whether all blocks has been completely understood by HOD?
Whether they are aware of how to track the system?
Whether the concerned people planning daily jobs as per Schedule?
Have you used the system to achieve the KPI's?

Whether the information flow became more effective with the template
Has the information helped in taking pro active actions?
Are you carrying out root cause analysis as per RCA Policy?

Are you maintaning a RCA documentation file? Please show the RCA lo
Does "5 why" format exist and used please show.
What is the need for RCA policy?

Why do we need to Maintain RCA log book. ?


What is the benefit of using 5 Why template ?

Show if any repetitive problem were corrected by using root cause anal
Please provide one example based on last RCA done?

Have you documented the actions and can you link the actions to the im
Are you carrying out root cause analysis as per RCA Policy?

Are you maintaning a RCA documentation file? Please show the RCA lo
Does "5 why" format exist and used please show.
What is the need for RCA policy?
Why do we need to Maintain RCA log book. ?
What is the benefit of using 5 Why template ?

Show if any repetitive problem were corrected by using root cause anal
Please provide one example based on last RCA done?
Have you used the system to achieve the KPI's?

Have you documented the actions and can you link the actions to the im
Whether the Job checking is done as per shut down planning?
Whether the job checking is done by the team formed?
Whether remarks are mentioned against poor quality of jobs?
Whether the team Is aware of importance of job quality checking?

Whether all jobs compered were completely understood ?


Whether they are aware of how to do job checking?
Whether the frequency of equipment failure reduced post light up?
Have you used the system to achieve the KPI's?
Whether Any counter measures taken to avoid critical issues.?

Whether the Job checking is done as per shut down planning?


Whether the job checking is done by the team formed?
Whether remarks are mentioned against poor quality of jobs?
Whether the team Is aware of importance of job quality checking?
Whether all jobs compered were completely understood ?
Whether they are aware of how to do job checking?
Whether the frequency of equipment failure reduced post light up?
Whether Any counter measures taken to avoid critical issues.?
Have you used the system to achieve the KPI's?
Is PM Schedule followed regularly?
Is PM Checklist completely filled by the Engineers?
Is any remarks mentioned against the work done?

Why do we need to follow the PM Plan?

Whether all plans & Checklist has been completely understood by conc
Whether concern people know how to perform PM?
Has the equipment life been improved with this plan?
Has the PM Plan helped in improving MTBF?
Have you used the system to achieve the KPI's?
Is monthly generation plan prepared by the department?
Is monthly production plan of SID taken into account?
Is the plan ready on the first working day of the month?
Why do we need to make the monthly generation plan?

Is the power gneration plan has been completely understood by the con
Whether sponge iron department head was aware of the planning?
Has the overall power generation has increased??

Has the monthly generation plan helped in better weekly and daily pow
Have you used the system to achieve the KPI's?
Was the generation plan on track??
Did meeting start on time? Are all members reached at time?
Is Terms of reference & Agenda is prepared and followed?

Was the necessary pre-work done by participants i.e. Daily work done ,

Do the responsible members understand the importance of daily shutdo


Are all members aware of their roles in the meeting?.

Availability of spares, castable was checked as per the shutdown plan?

Were variances identified and corrective actions recorded in Action Pla

Were actions, responsibilities and due dates assigned on the Action Pla
Have you used the system to achieve the KPI's?

Were the documented action logs is reviewed and points are being clos

Total number of Sys

AUDIT BY

AUDIT DATE

Rating Scale

0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)

Supervisory Actions Required


to Enable Improvement /
Sustain

3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)

1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)

0
(NIL)
1
(PARTIAL)
3
(HIGH)

0
(NIL)

1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)

3
(HIGH)
0
(NIL)

1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)

3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)

1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)

3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
1
(PARTIAL)
3
(HIGH)
1
(PARTIAL)
1
(PARTIAL)

1
(PARTIAL)
1
(PARTIAL)
0
(NIL)
0
(NIL)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
1
(PARTIAL)
1
(PARTIAL)
1
(PARTIAL)
1
(PARTIAL)
0
(NIL)
0
(NIL)
0
(NIL)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)

1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)

0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)

3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)
0
(NIL)
1
(PARTIAL)
3
(HIGH)

7
18

TOTAL COMPLIANCE
TOTAL UNDERSTANDING
TOTAL USAGE

Shashikant Sharma and Vishal

16-May-15

Observed Current Rating for


this category
(Score: 0, 1 or 3)

REMAR

(Key in any remarks which justify the

13th june sheet was not signed by


1

.
3

end time was not mentioned in s


1

some job is not correctely feed w


because of this mistake
1

Not re
0

Not re
0

Not Re
0

Not a
0

Not a
0

88%
100%
88%

REMARKS

arks which justify the observed rating given to the auditee)

was not signed by the HOD

ot mentioned in sheet

correctely feed with end time so usage is low


mistake

Not required

Not required

Not Required

Not audited

Not audited

ACTION PLAN
(Key in the required action that needs to be taken to address issues - th
must be done for System Elements with a yellow or red scores)

N
taken to address issues - this
th a yellow or red scores)