APOLLO TRICOAT TUBES LTD

CODE DESCRIPTION FQY Mill -1 FQY Mill -2 FQY Mill-3 FQY Mill-4
RM001 Material not available. 1 60 1 10 2 220 2 55
RM002 Material not slitted./under size strip/strip damage 4 60 3 80 14 310 3 50
RM003 Material not shifted. Crane busy 2 40 0 0 0 0 6 125
RM004 Quality problem in material/ZINC PEEL OFF 1 80 0 0 0 0 0 0
1-RAW MATERIAL 8 240 4 90 16 530 11 230
PR001 Size problem. 2 50 1 20 2 50 0 0
PR002 Welding roll problem. 1 20 1 10 0 0 0 0
PR003 Bend problem. 2 45 0 0 2 340 0 0
PR004 Impeder problem. 5 135 11 285 1 30 5 70
PR005 Work coill change. 3 60 0 0 10 220 2 25
PR006 Roll mark problem. 0 0 0 0 0 0 0 0
PR007 Accumulator strip fold 0 0 2 35 0 0 0 0
PR008 Fin replacement./ TIGHTENING 0 0 0 0 2 55 1 10
PR009 Edge/Joint press/Strip problem 22 260 13 210 72 730 21 267
PR010 Welding joint broken/Joint delay. 8 110 6 110 8 160 8 90
PR011 Tool change. 0 0 0 0 3 65 0 0
PR012 T.H bearing broken. 1 20 7 150 1 20 0 0
PR013 bearing change (forming, Sizing) 4 110 11 250 5 130 0 0
PR014 Bundle pocket full. 0 0 0 0 3 30 3 85
PR015 Misc production/Rinkle problem/over lap prob. 57 1205 15 150 27 340 27 320
2-PRODUCTION 105 2015 67 1220 136 2170 67 867
E001 Uncoiler. 2 20 1 25 1 35 1 40
E002 Pinch roller moter. 0 0 0 0 0 0 0 0
E003 Turn table moter. 0 0 0 0 0 0 0 0
E004 Forming motor . 0 0 0 0 0 0 0 0
E005 Sizing motor. 0 0 0 0 0 0 0 0
E006 Cut off problem. 3 90 32 7235 10 300 28 915
E007 Run out motor. 0 0 6 60 10 115 3 100
E008 H.F welder tripped. 0 0 1 10 13 145 2 40
E009 Zinc wire system tripped. 9 85 8 40 25 305 26 235
E010 Welding m/c, end shear m/c problem. 0 0 0 0 0 0 0 0
E011 Misc electrical/mill stop/PLC TRIP 13 340 4 45 9 140 5 415
E012 Over speed. 0 0 0 0 0 0 0 0
3-ELECTRICAL 27 535 52 7415 68 1040 65 1745
M001 Uncoiler./MISC 2 20 1 25 0 0 1 10
M002 Pinch roll. 0 0 0 0 0 0 0 0
M003 Accumulator. 0 0 0 0 0 0 0 0
M004 Stamping roll/Its guide roll. 0 0 3 100 1 35 1 5
M005 Propeller shaft./Roll shaft Change or fitted 0 0 1 110 2 25 1 20
M006 Roll shaft broken 0 0 4 130 0 0 0 0
M007 Forming stands./SIZING STAND /Misc. prob. 8 295 3 260 6 190 2 340
M008 Weld roll assemblly replacement/work. 0 0 0 0 0 0 2 135
M009 Impeder assembly/Tool post holder. 0 0 0 0 0 0 0 0
M010 Measuring wheel. 0 0 0 0 0 0 0 0
M011 Cut off problem. 3 40 4 130 4 55 6 150
M012 Run out conveyor. 4 245 3 55 7 110 5 95
M013 Sizing top -1 bearing broken./ TH 0 0 0 0 1 145 0 0
M014 Square assembly bearing broken./Gear Box 1 30 0 0 0 0 0 0
M015 coolant pump problem 0 0 0 0 0 0 0 0
4-MECHANICAL 18 630 19 810 21 560 18 755
U001 Coolent Prob (Elect) 0 0 0 0 0 0 1 15
U001 Coolent problem.(Mech.) 0 0 0 0 0 0 0 0
U002 Generator problem. 0 0 0 0 0 0 0 0
U003 Crane problem. / busy/handling 13 220 0 0 1 60 3 35
U004 Cooling tower. 0 0 1 5 0 0 0 0
U005 Air problem. 3 45 2 20 0 0 2 90
5-UTILITIES 16 265 3 25 1 60 6 140
P001 Power failure. 1 65 2 25 2 75 2 80
P002 Power change over. 0 0 0 0 0 0 0 0
6-POWER 1 65 2 25 2 75 2 80
OT002 Manpower delay 0 0 2 35 0 0 0 0
OT003 Starting delay. 1 50 1 20 0 0 0 0
OT004 Roll change. 3 470 3 395 11 2235 5 1010
OT005 Clamps change. 0 0 0 0 2 100 3 145
OT006 Cold saw blade change. 2 10 20 230 40 555 11 165
OT007 Store material delay. 0 0 0 0 0 0 1 25
OT008 Scheduled Maintenance/INVENTORY/ P.M 25 14005 2 1120 3 1340 9 2075
OT009 Zinc wire change. 0 0 0 0 0 0 0 0
OT010 Programme change / GAUGE CHANGE 0 0 0 0 0 0 0 0
OT011 Screen problem (Q.C), Miscellaneous 0 0 0 0 0 0 2 35
OT012 No Plannig 2 1440 4 2590 5 2675 4 2040
7-OTHERS 33 15975 32 4390 61 6905 35 5495

TOTAL Breakdown >>>>>>>>>>>>>>>>>> 208 19725 179 13975 305 11340 204 9312
Err:520
Total Available Time (min.) 23040 24480 24480 24480
Total running time in MIN 3315 10505 13140 15168
Break Down % 86% 57% 46% 38%

Mill Efficiency % 14% 43% 54% 62%

MILL-1 MILL-2 MILL-3 MILL-4

DESCRIPTION FQY FQY FQY FQY FQY FQY FQY FQY
ROLL CHANGE 3 470 3 395 11 2235 5 1010
RAW MATERIAL 8 240 4 90 16 530 11 230
PRODUCTION 105 2015 67 1220 136 2170 67 867
ELECTRICAL 27 535 52 7415 68 1040 65 1745
MACHANICAL 18 630 19 810 21 560 18 755
UTILITIES 16 265 3 25 1 60 6 140
POWER 1 65 2 25 2 75 2 80
OTHERS 30 15505 29 3995 50 4670 30 4485
Total 208 19725 179 13975 305 11340 204 9312
 TUBE MILL -1 BREAK DOWN REPORT
APL APOLLO TUBES LTD
BREAK DOWN REPORT

CODE DESCRIPTION 29/01/2021 30/01/2021 31/01/2021

CUMU.FQY CUMU. TIME FQY (NOS) B/D (MIN) FQY (NOS) B/D (MIN) FQY (NOS) B/D (MIN)
1-RAW MATERIAL
RM001 Material not available. 1 60
RM002 Material not slitted./under size strip/strip damage 4 60
RM003 Material not shifted. Crane busy 2 40
RM004 Quality problem in material/ZINC PEEL OFF 1 80
2-PRODUCTION 8 240 0 0 0 0 0 0
PR001 Size problem. 2 50
PR002 Welding roll problem. 1 20
PR003 Bend problem. 2 45
PR004 Impeder problem. 5 135
PR005 Work coill change. 3 60
PR006 Roll mark problem. 0 0
PR007 Accumulator strip fold 0 0
PR008 Fin replacement./ TIGHTENING 0 0
PR009 Edge/Joint press/Strip problem 22 260 1 10
PR010 Welding joint broken/Joint delay. 8 110
PR011 Tool change. 0 0
PR012 T.H bearing broken. 1 20
PR013 bearing change (forming, Sizing) 4 110 1 25
PR014 Bundle pocket full/CRANE BUSY. 0 0
PR015 Misc production/Rinkle problem/over lap prob. 57 1205 7 300
3-ELECTRICAL 105 2015 9 335 0 0 0 0
E001 Uncoiler. 2 20
E002 Pinch roller moter. 0 0
E003 Turn table moter. 0 0
E004 Forming motor . 0 0
E005 Sizing motor. 0 0
E006 Cut off problem. 3 90
E007 Run out motor. 0 0
E008 H.F welder tripped. 0 0
E009 Zinc wire system tripped./SPRAY GUN 9 85
E010 Welding m/c, end shear m/c problem. 0 0
E011 Misc electrical/mill stop/PLC TRIP 13 340 1 5
E012 Over speed. 0 0
4-MECHANICAL 27 535 1 5 0 0 0 0
M001 Uncoiler./MISC 2 20
M002 Pinch roll. 0 0
M003 Accumulator. 0 0
M004 Stamping roll/Its guide roll. 0 0
M005 Propeller shaft./Roll shaft Change or fitted 0 0
M006 Roll shaft broken 0 0
M007 Forming stands./SIZING STAND /Misc. prob. 8 295
M008 Weld roll assemblly replacement/work. 0 0
M009 Impeder assembly/Tool post holder. 0 0
M010 Measuring wheel. 0 0
M011 Cut off problem. 3 40
M012 Run out conveyor. 4 245
M013 Sizing top -1 bearing broken./ TH 0 0
M014 Square assembly bearing broken./Gear Box 1 30
M015 coolant pump problem 0 0
5-UTILITIES 18 630 0 0 0 0 0 0
U001 Coolent Prob (Elect) 0 0
U001 Coolent problem.(Mech.) 0 0
U002 Generator problem. 0 0
U003 Crane problem. / busy/handling 13 220
U004 Cooling tower. 0 0
U005 Air problem. 3 45
6-POWER 16 265 0 0 0 0 0 0
P001 Power failure. 1 65
P002 Power change over. 0 0
7-OTHERS 1 65 0 0 0 0 0 0
OT002 Manpower delay 0 0
OT003 Starting delay. 1 50
OT004 Roll change. 3 470 2 260
OT005 Clamps change. 0 0
OT006 Alpha blade change 2 10
OT007 Store material delay. 0 0
OT008 Scheduled Maintenance/INVENTORY/ P.M 25 14005
OT009 Zinc wire change. 0 0
OT010 Programme change / GAUGE CHANGE 0 0
OT011 Screen problem (Q.C), Miscellaneous 0 0
OT012 No Planning 2 1440
33 15975 2 260 0 0 0 0
0 0
208 19725 12 600 0 0 0 0
TUBE MILL-01-Break Down Time(min.)
0 0
Total Available Time (min.) 23040
Utilitiy Time(min.) 3315 600 0 0
Total no of stoppage NOS 208 12 0 0

19255 #DIV/0! #DIV/0! #DIV/0!

Full change
ROLL CHANGE 470 3
GAUGE CHANGE 0 0
SPRAY GUN 85 9
TOOL CHANGE 0 0
RAW MATERIAL 240 8
ELECTRICAL 450 18
MACHINICAL 630 18
OTHERS 17850 152
19725 208
 TUBE MILL -2 BREAK DOWN REPORT
APL APOLLO TUBES LTD
BREAK DOWN REPORT

CODE DESCRIPTION
1-RAW MATERIAL
RM001 Material not available.
RM002 Material not slitted./under size strip/strip damage
RM003 Material not shifted. Crane busy
RM004 Quality problem in material/ZINC PEEL OFF
2-PRODUCTION
PR001 Size problem.
PR002 Welding roll problem.
PR003 Bend problem.
PR004 Impeder problem.
PR005 Work coill change.
PR006 Roll mark problem.
PR007 Accumulator strip fold
PR008 Fin replacement./ TIGHTENING
PR009 Edge/Joint press/Strip problem
PR010 Welding joint broken/Joint delay.
PR011 Tool change.
PR012 T.H bearing broken.
PR013 bearing change (forming, Sizing)
PR014 Bundle pocket full/CRANE BUSY.
PR015 Misc production/Rinkle problem/over lap prob.
3-ELECTRICAL
E001 Uncoiler.
E002 Pinch roller moter.
E003 Turn table moter.
E004 Forming motor .
E005 Sizing motor.
E006 Cut off problem.
E007 Run out motor.
E008 H.F welder tripped.
E009 Zinc wire system tripped./SPRAY GUN
E010 Welding m/c, end shear m/c problem.
E011 Misc electrical/mill stop/PLC TRIP
E012 Over speed.
4-MECHANICAL
M001 Uncoiler./MISC
M002 Pinch roll.
M003 Accumulator.
M004 Stamping roll/Its guide roll.
M005 Propeller shaft./Roll shaft Change or fitted
M006 Roll shaft broken
M007 Forming stands./SIZING STAND /Misc. prob.
M008 Weld roll assemblly replacement/work.
M009 Impeder assembly/Tool post holder.
M010 Measuring wheel.
M011 Cut off problem.
M012 Run out conveyor.
M013 Sizing top -1 bearing broken./ TH
M014 Square assembly bearing broken./Gear Box
M015 coolant pump problem
5-UTILITIES
U001 Coolent Prob (Elect)
U001 Coolent problem.(Mech.)
U002 Generator problem.
U003 Crane problem. / busy/handling
U004 Cooling tower.
U005 Air problem.
6-POWER
P001 Power failure.
P002 Power change over.
7-OTHERS
OT002 Manpower delay
OT003 Starting delay.
OT004 Roll change.
OT005 Clamps change.
OT006 Cold saw blade change.
OT007 Store material delay.
OT008 Scheduled Maintenance/INVENTORY/ P.M
OT009 Zinc wire change.
OT010 Programme change / GAUGE CHANGE
OT011 Screen problem (Q.C), Miscellaneous
OT012 No Planning

TUBE MILL-02-Break Down Time(min.)

Total Available Time (min.)
Utilitiy Time(min.)
Total no of stoppage NOS
ROLL CHANGE
GAUGE CHANGE
SPRAY GUN
TOOL CHANGE
RAW MATERIAL
ELECTRICAL
MACHINICAL
OTHERS
 29/01/2021 30/01/2021 31/01/2021
COMU.FQY COMU. TIME FQY (NOS) B/D (MIN) FQY (NOS) B/D (MIN) FQY (NOS) B/D (MIN)
1 10
3 80
0 0
0 0
4 90 0 0 0 0 0 0
1 20
1 10
0 0
11 285
0 0
0 0
2 35
0 0
13 210
6 110
0 0
7 150
11 250
0 0
15 150
67 1220 0 0 0 0 0 0
1 25
0 0
0 0
0 0
0 0
32 7235
6 60
1 10
8 40
0 0
4 45
0 0
52 7415 0 0 0 0 0 0
1 25
0 0
0 0
 3 100
1 110
4 130
3 260
0 0
0 0
0 0
4 130
3 55
0 0
0 0
0 0
19 810 0 0 0 0 0 0
0 0
0 0
0 0
0 0
1 5
2 20
3 25 0 0 0 0 0 0
2 25
0 0
2 25 0 0 0 0 0 0
2 35
1 20
3 395
0 0
20 230
0 0
2 1120
0 0
0 0
0 0
4 2590 2 1150
32 4390 2 1150 0 0 0 0
0 0
179 13975 2 1150 0 0 0 0
0 0
24480

10505 1150 0 0
179 2 0 0

13580 #DIV/0! #DIV/0! #DIV/0!

 Full change
395 3
0 0
40 8
0 0
90 4
7375 44
810 19
5265 101
13975 179
 TUBE MILL -3 BREAK DOWN REPORT
APL APOLLO TUBES LTD
BREAK DOWN REPORT

CODE DESCRIPTION
COMU.FQY
1-RAW MATERIAL
RM001 Material not available. 2
RM002 Material not slitted./under size strip/strip damage 14
RM003 Material not shifted. Crane busy 0
RM004 Quality problem in material/ZINC PEEL OFF 0
2-PRODUCTION 16
PR001 Size problem. 2
PR002 Welding roll problem. 0
PR003 Bend problem. 2
PR004 Impeder problem. 1
PR005 Work coill change. 10
PR006 Roll mark problem. 0
PR007 Accumulator strip fold 0
PR008 Fin replacement./ TIGHTENING 2
PR009 Edge/Joint press/Strip problem 72
PR010 Welding joint broken/Joint delay. 8
PR011 Tool change. 3
PR012 T.H bearing broken. 1
PR013 bearing change (forming, Sizing) 5
PR014 Bundle pocket full/CRANE BUSY. 3
PR015 Misc production/Rinkle problem/over lap prob. 27
3-ELECTRICAL 131
E001 Uncoiler. 1
E002 Pinch roller moter. 0
E003 Turn table moter. 0
E004 Forming motor . 0
E005 Sizing motor. 0
E006 Cut off problem. 10
E007 Run out motor. 10
E008 H.F welder tripped. 13
E009 Zinc wire system tripped./SPRAY GUN 25
E010 Welding m/c, end shear m/c problem. 0
E011 Misc electrical/mill stop/PLC TRIP 9
E012 Over speed. 0
4-MECHANICAL 68
M001 Uncoiler./MISC 0
M002 Pinch roll. 0
M003 Accumulator. 0
M004 Stamping roll/Its guide roll. 1
M005 Propeller shaft./Roll shaft Change or fitted 2
M006 Roll shaft broken 0
M007 Forming stands./SIZING STAND /Misc. prob. 6
M008 Weld roll assemblly replacement/work. 0
M009 Impeder assembly/Tool post holder. 0
M010 Measuring wheel. 0
M011 Cut off problem. 4
M012 Run out conveyor. 7
M013 Sizing top -1 bearing broken./ TH 1
M014 Square assembly bearing broken./Gear Box 0
M015 coolant pump problem 0
5-UTILITIES 21
U001 Coolent Prob (Elect) 0
U001 Coolent problem.(Mech.) 0
U002 Generator problem. 0
U003 Crane problem. / busy/handling 1
U004 Cooling tower. 0
U005 Air problem. 0
6-POWER 1
P001 Power failure. 2
P002 Power change over. 0
7-OTHERS 2
OT002 Manpower delay 0
OT003 Starting delay. 0
OT004 Roll change. 11
OT005 Clamps change. 2
OT006 Cold saw blade change. 40
OT007 Store material delay. 0
OT008 Scheduled Maintenance/INVENTORY/ P.M 3
OT009 Zinc wire change. 0
OT010 Programme change / GAUGE CHANGE 0
OT011 Screen problem (Q.C), Miscellaneous 0
OT012 No Planning 5
61
0
300
TUBE MILL-03-Break Down Time(min.)
0
Total Available Time (min.)
Utilitiy Time(min.)
Total no of stoppage NOS

9105
ROLL CHANGE 2235
GAUGE CHANGE 0
SPRAY GUN 305
TOOL CHANGE 65
RAW MATERIAL 530
ELECTRICAL 735
MACHINICAL 560
OTHERS 6910
11340
 29/01/2021 30/01/2021 31/01/2021
COMU. TIME FQY (NOS) B/D (MIN) FQY (NOS) B/D (MIN) FQY (NOS) B/D (MIN)
220
310
0
0
530 0 0 0 0 0 0
50
0
340
30
220
0
0
55
730
160
65
20
130
30
340
2170 0 0 0 0 0 0
35
0
0
0
0
300
115
145
305
0
140
0
1040 0 0 0 0 0 0
0
0
0
 35
25
0
190
0
0
0
55
110
145
0
0
560 0 0 0 0 0 0
0
0
0
60
0
0
60 0 0 0 0 0 0
75
0
75 0 0 0 0 0 0
0
0
2235
100
555
0
1340
0
0
0
2675 2 910
6905 2 910 0 0 0 0
0
11340 2 910 0 0 0 0
0
24480

13140 910 0 0
300 2 0 0

#DIV/0! #DIV/0! #DIV/0!

Full change
11
0
25
3
16
43
21
181
300
 TUBE MILL -3 BREAK DOWN REPORT
APL APOLLO TUBES LTD
BREAK DOWN REPORT

CODE DESCRIPTION
COMU.FQY COMU. TIME
1-RAW MATERIAL
RM001 Material not available. 2 55
RM002 Material not slitted./under size strip/strip damage 3 50
RM003 Material not shifted. Crane busy 6 125
RM004 Quality problem in material/ZINC PEEL OFF 0 0
2-PRODUCTION 11 230
PR001 Size problem. 0 0
PR002 Welding roll problem. 0 0
PR003 Bend problem. 0 0
PR004 Impeder problem. 5 70
PR005 Work coill change. 2 25
PR006 Roll mark problem. 0 0
PR007 Accumulator strip fold 0 0
PR008 Fin replacement./ TIGHTENING 1 10
PR009 Edge/Joint press/Strip problem 21 267
PR010 Welding joint broken/Joint delay. 8 90
PR011 Tool change. 0 0
PR012 T.H bearing broken. 0 0
PR013 bearing change 0 0
PR014 Bundle pocket full/CRANE BUSY. 3 85
PR015 Misc production/Rinkle problem/over lap prob. 27 320
3-ELECTRICAL 67 867
E001 Uncoiler. 1 40
E002 Pinch roller moter. 0 0
E003 Turn table moter. 0 0
E004 Forming motor . 0 0
E005 Sizing motor. 0 0
E006 Cut off problem. 28 915
E007 Run out motor. 3 100
E008 H.F welder tripped. 2 40
E009 Zinc wire system tripped./SPRAY GUN 26 235
E010 Welding m/c, end shear m/c problem. 0 0
E011 Misc electrical/mill stop/PLC TRIP/ Crane Electrical 5 415
E012 Over speed. 0 0
4-MECHANICAL 65 1745
M001 Uncoiler./MISC 1 10
M002 Pinch roll. 0 0
M003 Accumulator. 0 0
M004 Stamping roll/Its guide roll. 1 5
M005 Propeller shaft./Roll shaft Change or fitted 1 20
M006 Roll shaft broken 0 0
M007 Forming stands./SIZING STAND /Misc. prob. 2 340
M008 Weld roll assemblly replacement/work. 2 135
M009 Impeder assembly/Tool post holder. 0 0
M010 Measuring wheel. 0 0
M011 Cut off problem. 6 150
M012 Run out conveyor. 5 95
M013 Sizing top -1 bearing broken./ TH 0 0
M014 Square assembly bearing broken./Gear Box 0 0
M015 coolant pump problem 0 0
5-UTILITIES 18 755
U001 Coolent Prob (Elect) 1 15
U001 Coolent problem.(Mech.) 0 0
U002 Generator problem. 0 0
U003 Crane problem. / busy/handling 3 35
U004 Cooling tower. 0 0
U005 Air problem. 2 90
6-POWER 6 140
P001 Power failure. 2 80
P002 Power change over. 0 0
7-OTHERS 2 80
OT002 Manpower delay 0 0
OT003 Starting delay. 0 0
OT004 Roll change. 5 1010
OT005 Clamps change. 3 145
OT006 Cold saw blade change. 11 165
OT007 Store material delay. 1 25
OT008 Scheduled Maintenance/INVENTORY/ P.M 9 2075
OT009 Zinc wire change. 0 0
OT010 Programme change / GAUGE CHANGE 0 0
OT011 Screen problem (Q.C), Miscellaneous 2 35
OT012 No Planning 4 2040
35 5495
0 0
204 9312
TUBE MILL-03-Break Down Time(min.)
0 0
Total Available Time (min.) 24480
Utilitiy Time(min.) 15168

Total no of stoppage NOS 204

8302
 Full change
ROLL CHANGE 1010 5
GAUGE CHANGE 0 0
SPRAY GUN 235 26
TOOL CHANGE 0 0
RAW MATERIAL 230 11
ELECTRICAL 1510 39
MACHINICAL 755 18
OTHERS 5572 105
9312 204
 29/01/2021 30/01/2021 31/01/2021
FQY (NOS) B/D (MIN) FQY (NOS) B/D (MIN) FQY (NOS) B/D (MIN)

0 0 0 0 0 0

0 0 0 0 0 0

2 50

1 10

3 60 0 0 0 0
1 20

1 20 0 0 0 0

0 0 0 0 0 0

0 0 0 0 0 0

1 300
1 300 0 0 0 0

5 380 0 0 0 0

380 0 0
5 0 0

#DIV/0! #DIV/0! #DIV/0!