BSRM Mill

DAILY PRODUCTION REPORT

DATE:1/4/2019
BILLET CHARGED BILLET ROLLED HOT OUT MISS ROLL FINISH PRODUCT

SHIFT NO. OF NO. OF COBBLE CHOPPING TOTAL PRODUCT NO. OF PRODUCT

LOT NUMBER BILLET SIZE WEIGHT WEIGHT NO. OF BILLETS WEIGHT % PRODUCT SIZE YIELD %
BILLETS BILLETS NUMBERS WEIGHT % NUMBERS WEIGHT % WEIGHT % GRADE BUNDLES WEIGHT**

SML#001 279.0 160x160x12000 672.931 279.0 672.931 0.0 0.000 0.00 0.0 0.000 0.00 0.0 0.000 0.00 0.000 0.00 D.Bar 10 mm 500W 169 668.436 99.33
SHIFT - C
0 0.0 0 0.000 0.0 0.0 0.000 0.0 0.0 0.000 0 0 0.000

SML#001 199.0 160x160x12000 479.976 196.0 472.740 2.0 4.824 1.01 1.0 2.412 0.51 0.0 0.000 0.00 2.412 0.51 D.Bar 10 mm 500W 118 466.457 98.17
SHIFT - A
ML-DEC-18-2-1 8.0 130x130x12000 12.585 7.0 11.012 1.0 1.573 12.50 0.0 0.000 0.00 0.0 0.000 0.00 0.000 0.00 Angle 25x25x3mm G-345 7 10.930 99.26

ML-DEC-18-2-1 143.0 130x130x12000 224.953 136.0 213.942 3.0 4.719 2.10 0.0 0.000 0.00 4.0 6.292 2.86 6.292 2.86 Angle 25x25x3mm G-345 112 209.324 95.05
SHIFT - B
0 0 0.0 0.0 0.000 0.0 0.0 0.000 0 0 0.000

TOTAL 629 1,390.445 618.0 1,370.625 6.0 11.116 0.80 1.0 2.412 0.17 4.0 6.292 0.46 8.704 0.631 406 1,355.147 98.25

Sl. No. PARTICULARS SHIFT- C SHIFT- A SHIFT- B TOTAL BREAKDOWN DETAILS

a TOTAL TIME 360 480 480 1320 Delay Booking Head DURATION (mins) REASON OF BREAKDOWN

b TOTAL AVAILABLE TIME 290 347 472 1109 PDB 70 Continuously gost rolling alarm fault came & furnace pusher delta position alarm

c EFFECTIVE MILL RUNNING TIME (b-q) 290 272 335 897

d MILL EFFICIENCY (c÷b%) 100.00 78.39 70.97 80.88

e TOTAL PRODUCTION IN MT 668.436 477.387 209.324 1355.147

f AVG. PRODUCTION PER HOUR (e÷b) 138.297 82.545 26.609 73.317

g PRODUCTIVITY (e÷c) 138.297 105.306 37.491 90.645

h ROLLING MILL SPEED M/S (STAND#20) 10.800 11.550 12.300 11.550

C Shift
i OIL CONSUMPTION IN LITERS 0 0 0 0

j OIL CONSUMPTION PER TON (i÷e) 0.000 0.000 0.000 0.000

3
k GAS CONSUMPTION IN M 18,267 15,729 5,814 39,811

l GAS CONSUMPTION PER TON (k÷e) 27.33 32.95 27.78 29.377

m PDB POWER CONSUMPTION IN KWH 52,920 39,600 31,320 123,840

n DG POWER CONSUMPTION IN KWH 0

o TOTAL (PDB +DG) POWER CONSUMPTION IN KWH 52,920 39,600 31,320 123,840

p POWER CONSUMPTION PER TON (o÷e) 79.17 82.95 149.62 91.38

q BREAK DOWN TIME IN MINUTES SHIFT- C SHIFT- A SHIFT- B TOTAL DOWN TIME % PDB 78 Voltage fluctuation of PDB with bar that time 5th,8th,9th,20th st. roll changed

q1 MECHANICAL (Target 3%) 0.0 0.0 5.0 5.0 0.45 Process 75 Section changed from Rebar-2X16 mm to <25X25X3 mm That time 6th,12th,13th,14th,15th,16th,17th,18th,19th,20th roll changed

q2 ELECTRICAL (Target 2%) 0.0 0.0 28.0 28.0 2.52 Plant Shutdown 55 9th,10th,11th,12th st. clamp change.RDM,F/mill water Actuator valve adjusted.

OPERATION DELAY (Target 2.6%) 0.0 0.0 85.0 85.0 7.66

A Shift

q3-1
PRODUC-
TION
q3 q3-2 PROCESS DELAY (Target 5.9%) 0.0 75.0 19.0 94.0 8.48
( TARGET
8.8%)
q3-3 WORKSHOP (Target 0.3%) 0.0 0.0 0.0 0.0 0.00

q4-1 BILLETS DEFECT (Target 0.1%) 0.0 0.0 0.0 0.0 0.00
QUALITY
q4
(0.2%)
q4-2 QUALITY SAMPLING (Target 0.1%) 0.0 0.0 0.0 0.0 0.00

q5 TOTAL DOWN TIME (Target 14%) 0.0 75.0 137.0 212.0 19.12 Operation 52 During carryover cycle one bar displace & RDM entry problem(9min);Bar discharging problem at cooling bed(22min);sizing issue 19th st. pass changed(21min)

r1 HOLIDAY TIME 0.0 0.0 0.0 0.0 0.00 Mech 5 Cold shear grease unit fault
THESE ARE
NOT
r2 PDB DOWN TIME 70.0 78.0 0.0 148.0 11.21 Elect. 28 Cold shear grease unit fault(6min);bar miss counting at extraction trolly(7min);Bar miss counting at extraction trolly(15min);
B Shift

CONSIDERD
r
IN
AVAILABLE r3 MILL COMMISSIONING 0.0 0.0 0.0 0.0 0.00 Process 19 9th-16th st. sampling & mill checking(11min);F/MILL checking & sampling(8min)
TIME
r4 SHUTDOWN TIME 0.0 55.0 8.0 63.0 4.77 Plant Shutdown 8 Slow rolling due to tying 2work done by specialist

s. TOTAL 70.0 133.0 8.0 211.0 15.98 Operation 33 Bar didn't enter 20th st.
SIGNATURE
 BSRM Mill
DAILY PRODUCTION REPORT
DATE:2/4/2019
BILLET CHARGED BILLET ROLLED HOT OUT MISS ROLL FINISH PRODUCT

SHIFT NO. OF NO. OF COBBLE CHOPPING TOTAL PRODUCT NO. OF PRODUCT

LOT NUMBER BILLET SIZE WEIGHT WEIGHT NO. OF BILLETS WEIGHT % PRODUCT SIZE YIELD %
BILLETS BILLETS NUMBERS WEIGHT % NUMBERS WEIGHT % WEIGHT % GRADE BUNDLES WEIGHT**

ML-DEC-18-2-1 157.0 130x130x12000 246.977 152.0 239.111 3.0 4.719 1.91 0.0 0.000 0.00 2.0 3.146 1.30 3.146 1.30 Angle 25x25x3mm G-345 124 229.025 94.54
SHIFT - C
0 0.0 0 0.000 0.0 0.0 0.000 0.0 0.0 0.000 0 0 0.000

ML-DEC-18-2-1 103.0 130x130x12000 162.029 102.0 160.456 1.0 1.573 0.97 0.0 0.000 0.00 0.0 0.000 0.00 0.000 0.00 Angle 25x25x3mm G-345 84 152.811 95.24
SHIFT - A
ML-DEC-18-2-1 119.0 130x130x12000 187.199 119.0 187.199 0.0 0.000 0.00 0.0 0.000 0.00 0.0 0.000 0.00 0.000 0.00 Angle 25x25x4mm G-345 96 184.086 98.34

ML-DEC-18-2-1 10.0 130x130x12000 15.731 10.0 15.731 0.0 0.000 0.00 0.0 0.000 0.00 0.0 0.000 0.00 0.000 0.00 Angle 25x25x4mm G-345 8 15.494 98.49
SHIFT - B
ML-DEC-18-2-1 223.0 130x130x12000 350.962 221.0 347.814 2.0 3.148 0.90 0.0 0.000 0.00 0.0 0.000 0.00 0.000 0.00 Angle 25x25x4mm G-345 179 334.110 96.06

TOTAL 612 962.898 604.0 950.312 6.0 9.440 0.98 0.0 0.000 0.00 2.0 3.146 0.33 3.146 0.330 491 915.526 96.02

Sl. No. PARTICULARS SHIFT- C SHIFT- A SHIFT- B TOTAL BREAKDOWN DETAILS

a TOTAL TIME 480 480 480 1440 Delay Booking Head DURATION (mins) REASON OF BREAKDOWN

b TOTAL AVAILABLE TIME 480 480 450 1410 Process 8 Mill checking & sampling.

c EFFECTIVE MILL RUNNING TIME (b-q) 354 430 368 1152 Process 40 16th st. roll, 15th,17th,18th,19th st. pass change & looper actuator adjust.

d MILL EFFICIENCY (c÷b%) 73.75 89.58 81.78 81.70 Operation 10 Bar not entry 16th st.

e TOTAL PRODUCTION IN MT 229.025 336.897 349.604 915.526 Process 15 Sizing problem.Mill check.

f AVG. PRODUCTION PER HOUR (e÷b) 28.628 42.112 46.614 38.959 Operation 10 Sizing problem.Mill check.

g PRODUCTIVITY (e÷c) 38.818 47.009 57.001 47.684 Mech 9 Bar hit at apron & stuck with comb

h ROLLING MILL SPEED M/S (STAND#20) 12.300 12.150 12.000 12.150 Process 5 18th st. guide adjusted due to leg difference.

C Shift
i OIL CONSUMPTION IN LITERS 0 0 0 0 Mech 7 Stacker area stopper-3 adjusted.

j OIL CONSUMPTION PER TON (i÷e) 0.000 0.000 0.000 0.000 Operation 12 Bar not entry 20th st.
3
k GAS CONSUMPTION IN M 7,618 10,598 11,793 30,009 Operation 10 Bar stuck at RDM due to bar over lap.

l GAS CONSUMPTION PER TON (k÷e) 33.26 31.46 33.73 32.778

m PDB POWER CONSUMPTION IN KWH 33,840 39,960 39,600 113,400

n DG POWER CONSUMPTION IN KWH 0

o TOTAL (PDB +DG) POWER CONSUMPTION IN KWH 33,840 39,960 39,600 113,400

p POWER CONSUMPTION PER TON (o÷e) 147.76 118.61 113.27 123.86

q BREAK DOWN TIME IN MINUTES SHIFT- C SHIFT- A SHIFT- B TOTAL DOWN TIME % Mech 5 Bar jam at RDM.

q1 MECHANICAL (Target 3%) 16.0 5.0 9.0 30.0 2.13 Process 40 Section changed from <25*25*4mm to <25*25*4mm. 16th,15th,17th,18th,19th st. pass changed.

q2 ELECTRICAL (Target 2%) 0.0 5.0 9.0 14.0 0.99 Elect. 5 Stopper -2 synchronization fault.

OPERATION DELAY (Target 2.6%) 42.0 0.0 20.0 62.0 4.40

A Shift

q3-1
PRODUC-
TION
q3 q3-2 PROCESS DELAY (Target 5.9%) 68.0 40.0 44.0 152.0 10.78
( TARGET
8.8%)
q3-3 WORKSHOP (Target 0.3%) 0.0 0.0 0.0 0.0 0.00

q4-1 BILLETS DEFECT (Target 0.1%) 0.0 0.0 0.0 0.0 0.00
QUALITY
q4
(0.2%)
q4-2 QUALITY SAMPLING (Target 0.1%) 0.0 0.0 0.0 0.0 0.00

q5 TOTAL DOWN TIME (Target 14%) 126.0 50.0 82.0 258.0 18.30 Mech 9 Cold shear grease unit fault

r1 HOLIDAY TIME 0.0 0.0 0.0 0.0 0.00 Elect. 9 Cold shear grease unit fault
THESE ARE
NOT
r2 PDB DOWN TIME 0.0 0.0 0.0 0.0 0.00 20th st. guide changed & sampling ,mill checking
B Shift

CONSIDERD Process 14
r
IN
AVAILABLE r3 MILL COMMISSIONING 0.0 0.0 0.0 0.0 0.00 Operation 20
Sizing problem(10 min);Sizing problem(10 min);
TIME
r4 SHUTDOWN TIME 0.0 0.0 30.0 30.0 2.08 Process 30
17th,18th,19th st. pass changed

s. TOTAL 0.0 0.0 30.0 30.0 2.08 Plant Shutdown 30

Mill stopped due to badweather
 BSRM Mill
DAILY PRODUCTION REPORT
DATE:3/4/2019
BILLET CHARGED BILLET ROLLED HOT OUT MISS ROLL FINISH PRODUCT

SHIFT NO. OF NO. OF COBBLE CHOPPING TOTAL PRODUCT NO. OF PRODUCT

LOT NUMBER BILLET SIZE WEIGHT WEIGHT NO. OF BILLETS WEIGHT % PRODUCT SIZE YIELD %
BILLETS BILLETS NUMBERS WEIGHT % NUMBERS WEIGHT % WEIGHT % GRADE BUNDLES WEIGHT**

ML-DEC-18-2-1 243.0 130x130x12000 382.438 243.0 382.438 0.0 0.000 0.00 0.0 0.000 0.00 0.0 0.000 0.00 0.000 0.00 Angle 25x25x4mm G-345 201 372.176 97.32
SHIFT - C
ML-JAN-19-1-1 61.0 130x130x12000 97.203 61.0 97.203 0.0 0.000 0.00 0.0 0.000 0.00 0.0 0.000 0.00 0.000 0.00 Angle 25x25x4mm G-345 51 94.799 97.53

ML-JAN-19-1-1 107.0 130x130x12000 170.503 107.0 170.503 0.0 0.000 0.00 0.0 0.000 0.00 0.0 0.000 0.00 0.000 0.00 Angle 25x25x4mm G-345 91 167.980 98.52
SHIFT - A
SML#001 110.0 160x160x12000 265.104 108.0 260.284 1.0 2.410 0.91 1.0 2.410 0.92 0.0 0.000 0.00 2.410 0.92 D. BAR 20mm 500W 68 255.860 97.40

SML#001 303.0 160x160x12000 730.242 300.0 723.012 2.0 4.820 0.66 1.0 2.410 0.33 0.0 0.000 0.00 2.410 0.33 D. BAR 20mm 500W 185 715.478 98.63
SHIFT - B
HOTOUT 12.0 160x160x12000 29.087 12.0 29.087 0.0 0.000 0.00 0.0 0.000 0.00 0.0 0.000 0.00 0.000 0.00 D. BAR 20mm 500W 7 27.258 93.71

TOTAL 836 1,674.578 831.0 1,662.528 3.0 7.230 0.43 2.0 4.820 0.29 0.0 0.000 0.00 4.820 0.29 603 1,633.551 97.97

Sl. No. PARTICULARS SHIFT- C SHIFT- A SHIFT- B TOTAL BREAKDOWN DETAILS

a TOTAL TIME 480 480 480 1440 Delay Booking Head DURATION (mins) REASON OF BREAKDOWN

b TOTAL AVAILABLE TIME 480 395 480 1355 No Delay

c EFFECTIVE MILL RUNNING TIME (b-q) 480 315 412 1207

d MILL EFFICIENCY (c÷b%) 100.00 79.75 85.83 89.08

e TOTAL PRODUCTION IN MT 466.975 423.840 742.736 1633.551

f AVG. PRODUCTION PER HOUR (e÷b) 58.372 64.381 92.842 72.334

g PRODUCTIVITY (e÷c) 58.372 80.731 108.165 81.204

h ROLLING MILL SPEED M/S (STAND#20) 12.300 12.650 13.000 12.650

C Shift
i OIL CONSUMPTION IN LITERS 0 0 0 0

j OIL CONSUMPTION PER TON (i÷e) 0.000 0.000 0.000 0.000

3
k GAS CONSUMPTION IN M 13,101 15,767 22,367 51,235

l GAS CONSUMPTION PER TON (k÷e) 28.06 37.20 30.11 31.364

m PDB POWER CONSUMPTION IN KWH 0

n DG POWER CONSUMPTION IN KWH 46,440 40,680 58,680 145,800

o TOTAL (PDB +DG) POWER CONSUMPTION IN KWH 46,440 40,680 58,680 145,800

p POWER CONSUMPTION PER TON (o÷e) 99.45 95.98 79.01 89.25

q BREAK DOWN TIME IN MINUTES SHIFT- C SHIFT- A SHIFT- B TOTAL DOWN TIME % Process 80 Section changed <25*25*4mm to Re-Bar 20mm. 11th,12th,15th,16th,17th,18th,19th,20th st. roll changed.

q1 MECHANICAL (Target 3%) 0.0 0.0 59.0 59.0 4.35 PDB 85 Power tripped in whole mill with bar due to PDB. 2nd,4th,5th st. roll changed.

q2 ELECTRICAL (Target 2%) 0.0 0.0 5.0 5.0 0.37

OPERATION DELAY (Target 2.6%) 0.0 0.0 0.0 0.0 0.00

A Shift

q3-1
PRODUC-
TION
q3 q3-2 PROCESS DELAY (Target 5.9%) 0.0 80.0 4.0 84.0 6.20
( TARGET
8.8%)
q3-3 WORKSHOP (Target 0.3%) 0.0 0.0 0.0 0.0 0.00

q4-1 BILLETS DEFECT (Target 0.1%) 0.0 0.0 0.0 0.0 0.00
QUALITY
q4
(0.2%)
q4-2 QUALITY SAMPLING (Target 0.1%) 0.0 0.0 0.0 0.0 0.00

q5 TOTAL DOWN TIME (Target 14%) 0.0 80.0 68.0 148.0 10.92 Process 4 17th & 19th st. looper disable,20th st. REG changed & F/MILL sampling

r1 HOLIDAY TIME 0.0 0.0 0.0 0.0 0.00 Elect. 5 11th st. motor delayed alarm
THESE ARE
NOT
r2 PDB DOWN TIME 0.0 85.0 0.0 85.0 5.90 FEA fixed chain & liftable chain fallen down
B Shift

CONSIDERD Mech 59
r
IN
AVAILABLE r3 MILL COMMISSIONING 0.0 0.0 0.0 0.0 0.00
TIME
r4 SHUTDOWN TIME 0.0 0.0 0.0 0.0 0.00

s. TOTAL 0.0 85.0 0.0 85.0 5.90

 BSRM Mill
DAILY PRODUCTION REPORT
DATE:4/4/2019
BILLET CHARGED BILLET ROLLED HOT OUT MISS ROLL FINISH PRODUCT

SHIFT NO. OF NO. OF COBBLE CHOPPING TOTAL PRODUCT PRODUCT NO. OF PRODUCT
LOT NUMBER BILLET SIZE WEIGHT WEIGHT NO. OF BILLETS WEIGHT % YIELD %
BILLETS BILLETS NUMBERS WEIGHT % NUMBERS WEIGHT % WEIGHT % SIZE GRADE BUNDLES WEIGHT**

SML#001 369.0 160x160x12000 889.305 369.0 889.305 0.0 0.000 0.00 0.0 0.000 0.00 0.0 0.000 0.00 0.000 0.00 D. BAR 20mm 500W 230 879.079 98.85
SHIFT - C
0 0.0 0 0.000 0.0 0.0 0.000 0.0 0.0 0.000 0 0 0.000

SML#001 377.0 160x160x12000 908.585 377.0 908.585 0.0 0.000 0.00 0.0 0.000 0.00 0.0 0.000 0.00 0.000 0.00 D. BAR 20mm 500W 236 896.277 98.65
SHIFT - A
0 0.0 0 0.000 0.0 0.0 0.000 0.0 0.0 0.000 0 0 0.000

SML#001 156.0 160x160x12000 375.966 155.5 374.761 0.0 0.000 0.00 0.0 0.000 0.00 0.5 1.205 0.32 1.205 0.32 D. BAR 20mm 500W 97 367.770 97.82
SHIFT - B
0 0 0.0 0.0 0.000 0.0 0.0 0.000 0 0 0.000

TOTAL 902 2,173.856 901.5 2,172.651 0.0 0.000 0.00 0.0 0.000 0.00 0.5 1.205 0.06 1.205 0.055 563 2,143.126 98.59

Sl. No. PARTICULARS SHIFT- C SHIFT- A SHIFT- B TOTAL BREAKDOWN DETAILS

a TOTAL TIME 480 480 480 1440 Delay Booking Head DURATION (mins) REASON OF BREAKDOWN

b TOTAL AVAILABLE TIME 480 480 226 1186 Process 3 18th,20th st. REG changed and hot sampling done at I-Mill and F-mill

c EFFECTIVE MILL RUNNING TIME (b-q) 472 477 200 1149 Mech 5 First tie of bundle torn then bar displaced at roller table

d MILL EFFICIENCY (c÷b%) 98.33 99.38 88.50 96.88

e TOTAL PRODUCTION IN MT 879.079 896.277 367.770 2143.126

f AVG. PRODUCTION PER HOUR (e÷b) 109.885 112.035 97.638 108.421

g PRODUCTIVITY (e÷c) 111.747 112.739 110.331 111.913

h ROLLING MILL SPEED M/S (STAND#20) 13.000 13.000 13.000 13.000

C Shift
i OIL CONSUMPTION IN LITERS 0 0 0 0

j OIL CONSUMPTION PER TON (i÷e) 0.000 0.000 0.000 0.000

3
k GAS CONSUMPTION IN M 26,190 26,954 13,998 67,143

l GAS CONSUMPTION PER TON (k÷e) 29.79 30.07 38.06 31.329

m PDB POWER CONSUMPTION IN KWH 65,880 68,040 35,640 169,560

n DG POWER CONSUMPTION IN KWH 0

o TOTAL (PDB +DG) POWER CONSUMPTION IN KWH 65,880 68,040 35,640 169,560

p POWER CONSUMPTION PER TON (o÷e) 74.94 75.91 96.91 79.12

q BREAK DOWN TIME IN MINUTES SHIFT- C SHIFT- A SHIFT- B TOTAL DOWN TIME % Process 3 17th,20th st. REG changed & 9th-17th st. hot sampling done.

q1 MECHANICAL (Target 3%) 5.0 0.0 0.0 5.0 0.42

q2 ELECTRICAL (Target 2%) 0.0 0.0 0.0 0.0 0.00

OPERATION DELAY (Target 2.6%) 0.0 0.0 0.0 0.0 0.00

A Shift

q3-1
PRODUC-
TION
q3 q3-2 PROCESS DELAY (Target 5.9%) 3.0 3.0 26.0 32.0 2.70
( TARGET
8.8%)
q3-3 WORKSHOP (Target 0.3%) 0.0 0.0 0.0 0.0 0.00

q4-1 BILLETS DEFECT (Target 0.1%) 0.0 0.0 0.0 0.0 0.00
QUALITY
q4
(0.2%)
q4-2 QUALITY SAMPLING (Target 0.1%) 0.0 0.0 0.0 0.0 0.00

q5 TOTAL DOWN TIME (Target 14%) 8.0 3.0 26.0 37.0 3.12 Process 26 9th,10th,11th,12th,16th,17th st. roll &15th,18th,20th st. pass,19th st. twister change.

r1 HOLIDAY TIME 0.0 0.0 0.0 0.0 0.00 Plant Shutdown 254 11th st. motor tripped then motor replace & 8th st. change
THESE ARE
NOT
r2 PDB DOWN TIME 0.0 0.0 0.0 0.0 0.00
B Shift

CONSIDERD
r
IN
AVAILABLE r3 MILL COMMISSIONING 0.0 0.0 0.0 0.0 0.00
TIME
r4 SHUTDOWN TIME 0.0 0.0 254.0 254.0 17.64

s. TOTAL 0.0 0.0 254.0 254.0 17.64

SIGNATURE
 BSRM Mill
DAILY PRODUCTION REPORT
DATE:5/4/2019
BILLET CHARGED BILLET ROLLED HOT OUT MISS ROLL FINISH PRODUCT

SHIFT NO. OF NO. OF COBBLE CHOPPING TOTAL PRODUCT PRODUCT NO. OF PRODUCT
LOT NUMBER BILLET SIZE WEIGHT WEIGHT NO. OF BILLETS WEIGHT % YIELD %
BILLETS BILLETS NUMBERS WEIGHT % NUMBERS WEIGHT % WEIGHT % SIZE GRADE BUNDLES WEIGHT**

SML#001 83.0 160x160x12000 200.033 83.0 200.033 0.0 0.000 0.00 0.0 0.000 0.00 0.0 0.000 0.00 0.000 0.00 D. BAR 20mm 500W 52 199.529 99.75

SHIFT - C STM#001 224.0 160x160x12000 537.660 224.0 537.660 0.0 0.000 0.00 0.0 0.000 0.00 0.0 0.000 0.00 0.000 0.00 D. BAR 20mm 500W 136 526.413 97.91

BIS#001 66.0 160x160x12000 157.414 66.0 157.414 0.0 0.000 0.00 0.0 0.000 0.00 0.0 0.000 0.00 0.000 0.00 D. BAR 20mm 500W 40 156.186 99.22

BIS#001 177.0 160x160x12000 422.156 174.0 415.000 2.0 4.770 1.13 1.0 2.385 0.57 0.0 0.000 0.00 2.385 0.57 D. BAR 20mm 500W 104 409.713 98.16
SHIFT - A
BIS#001 161.0 160x160x12000 383.969 161.0 383.969 0.0 0.000 0.00 0.0 0.000 0.00 0.0 0.000 0.00 0.000 0.00 D. BAR 20mm 500W 96 378.209 98.50

BIS#001 375.0 160x160x12000 894.338 375.0 894.338 0.0 0.000 0.00 0.0 0.000 0.00 0.0 0.000 0.00 0.000 0.00 D. BAR 20mm 500W 225 881.111 98.52
SHIFT - B
0 0 0.0 0.0 0.000 0.0 0.0 0.000 0 0 0.000

TOTAL 1086 2,595.570 1,083.0 2,588.415 2.0 4.770 0.18 1.0 2.385 0.09 0.0 0.000 0.00 2.385 0.092 653 2,551.161 98.47

Sl. No. PARTICULARS SHIFT- C SHIFT- A SHIFT- B TOTAL BREAKDOWN DETAILS

a TOTAL TIME 480 480 480 1440 Delay Booking Head DURATION (mins) REASON OF BREAKDOWN

b TOTAL AVAILABLE TIME 475 428 480 1383 Plant Shutdown 5 Previous shift BD continued

c EFFECTIVE MILL RUNNING TIME (b-q) 475 428 480 1383

d MILL EFFICIENCY (c÷b%) 100.00 100.00 100.00 100.00

e TOTAL PRODUCTION IN MT 882.128 787.922 881.111 2551.161

f AVG. PRODUCTION PER HOUR (e÷b) 111.427 110.456 110.139 110.679

g PRODUCTIVITY (e÷c) 111.427 110.456 110.139 110.679

h ROLLING MILL SPEED M/S (STAND#20) 13.000 13.000 13.000 13.000

C Shift
i OIL CONSUMPTION IN LITERS 0 0 0 0

j OIL CONSUMPTION PER TON (i÷e) 0.000 0.000 0.000 0.000

k GAS CONSUMPTION IN M3 25,303 23,872 25,670 74,844

l GAS CONSUMPTION PER TON (k÷e) 28.68 30.30 29.13 29.337

m PDB POWER CONSUMPTION IN KWH 64,440 61,560 66,600 192,600

n DG POWER CONSUMPTION IN KWH 0

o TOTAL (PDB +DG) POWER CONSUMPTION IN KWH 64,440 61,560 66,600 192,600

p POWER CONSUMPTION PER TON (o÷e) 73.05 78.13 75.59 75.50

q BREAK DOWN TIME IN MINUTES SHIFT- C SHIFT- A SHIFT- B TOTAL DOWN TIME % PDB 52 R/Mill motor off with bar due to PDB. that time, 3rd,5th,8th,11th,16th,17th st. Roll & 15th,18th st. Pass changed

q1 MECHANICAL (Target 3%) 0.0 0.0 0.0 0.0 0.00

q2 ELECTRICAL (Target 2%) 0.0 0.0 0.0 0.0 0.00

OPERATION DELAY (Target 2.6%) 0.0 0.0 0.0 0.0 0.00

A Shift

q3-1
PRODUC-
TION
q3 q3-2 PROCESS DELAY (Target 5.9%) 0.0 0.0 0.0 0.0 0.00
( TARGET
8.8%)
q3-3 WORKSHOP (Target 0.3%) 0.0 0.0 0.0 0.0 0.00

q4-1 BILLETS DEFECT (Target 0.1%) 0.0 0.0 0.0 0.0 0.00
QUALITY
q4
(0.2%)
q4-2 QUALITY SAMPLING (Target 0.1%) 0.0 0.0 0.0 0.0 0.00

q5 TOTAL DOWN TIME (Target 14%) 0.0 0.0 0.0 0.0 0.00 No Delay

r1 HOLIDAY TIME 0.0 0.0 0.0 0.0 0.00

THESE ARE
NOT
r2 PDB DOWN TIME 0.0 52.0 0.0 52.0 3.61
B Shift

CONSIDERD
r
IN
AVAILABLE r3 MILL COMMISSIONING 0.0 0.0 0.0 0.0 0.00
TIME
r4 SHUTDOWN TIME 5.0 0.0 0.0 5.0 0.35

s. TOTAL 5.0 52.0 0.0 57.0 3.96

SIGNATURE
 BSRM Mill
DAILY PRODUCTION REPORT
DATE:6/4/2019
BILLET CHARGED BILLET ROLLED HOT OUT MISS ROLL FINISH PRODUCT

SHIFT COBBLE CHOPPING TOTAL

NO. OF NO. OF PRODUCT NO. OF PRODUCT
LOT NUMBER BILLET SIZE WEIGHT WEIGHT NO. OF BILLETS WEIGHT % PRODUCT SIZE YIELD %
BILLETS BILLETS NUMBERS WEIGHT % NUMBERS WEIGHT % WEIGHT % GRADE BUNDLES WEIGHT**

BIS#001 382.0 160x160x12000 911.032 379.0 903.877 2.0 4.770 0.52 0.0 0.000 0.00 1.0 2.385 0.26 2.385 0.26 D. BAR 20mm 500W 227 892.868 98.52
SHIFT - C
0 0.0 0 0.000 0.0 0.0 0.000 0.0 0.0 0.000 0 0 0.000

BIS#001 199.0 160x160x12000 474.595 199.0 474.595 0.0 0.000 0.00 0.0 0.000 0.00 0.0 0.000 0.00 0.000 0.00 D. BAR 20mm 500W 123 468.516 98.72
SHIFT - A
0 0.0 0 0.000 0.0 0.0 0.000 0.0 0.0 0.000 0 0 0.000

SML#012 114.0 160x160x12000 264.162 109.0 252.576 4.0 9.269 3.51 1.0 2.317 0.91 0.0 0.000 0.00 2.317 0.91 Channel 125x65x6mm G-345 142 238.617 93.61
SHIFT - B
0 0 0.0 0.0 0.000 0.0 0.0 0.000 0 0 0.000

TOTAL 695 1,649.789 687.0 1,631.048 6.0 14.039 0.85 1.0 2.317 0.14 1.0 2.385 0.15 4.702 0.287 492 1,600.001 97.81

Sl. No. PARTICULARS SHIFT- C SHIFT- A SHIFT- B TOTAL BREAKDOWN DETAILS

a TOTAL TIME 480 480 480 1440 Delay Booking Head DURATION (mins) REASON OF BREAKDOWN

b TOTAL AVAILABLE TIME 480 358 380 1218 Operation 1 Bar stucked at 20th st. delivery

c EFFECTIVE MILL RUNNING TIME (b-q) 479 251 257 987

d MILL EFFICIENCY (c÷b%) 99.79 70.11 67.63 81.03

e TOTAL PRODUCTION IN MT 892.868 468.516 238.617 1600.001

f AVG. PRODUCTION PER HOUR (e÷b) 111.609 78.522 37.676 78.818

g PRODUCTIVITY (e÷c) 111.842 111.996 55.708 97.264

h ROLLING MILL SPEED M/S (STAND#20) 13.000 13.000 2.100 9.367

C Shift
i OIL CONSUMPTION IN LITERS 0 0 0 0

j OIL CONSUMPTION PER TON (i÷e) 0.000 0.000 0.000 0.000

k GAS CONSUMPTION IN M3 26,530 13,456 8,331 48,317

l GAS CONSUMPTION PER TON (k÷e) 29.71 28.72 34.91 30.198

m PDB POWER CONSUMPTION IN KWH 68,400 38,520 23,040 129,960

n DG POWER CONSUMPTION IN KWH 0

o TOTAL (PDB +DG) POWER CONSUMPTION IN KWH 68,400 38,520 23,040 129,960

p POWER CONSUMPTION PER TON (o÷e) 76.61 82.22 96.56 81.22

q BREAK DOWN TIME IN MINUTES SHIFT- C SHIFT- A SHIFT- B TOTAL DOWN TIME % Process 17 Previous shift B/D continued and at that time 20th st. stand changed.

q1 MECHANICAL (Target 3%) 0.0 0.0 23.0 23.0 1.89 Process 90 Section changed from Rebar 20mm to [125*65*6 mm.3rd,5th,6th,7th,9th,11th,13th,14th,15th,17th,18th st. roll changed

q2 ELECTRICAL (Target 2%) 0.0 0.0 10.0 10.0 0.82 Plant Shutdown 122 Plant shutdown due to 15th st. motor changed and 12th st. spindle changed

OPERATION DELAY (Target 2.6%) 1.0 0.0 54.0 55.0 4.52

A Shift

q3-1
PRODUC-
TION
q3 q3-2 PROCESS DELAY (Target 5.9%) 0.0 107.0 36.0 143.0 11.74
( TARGET
8.8%)
q3-3 WORKSHOP (Target 0.3%) 0.0 0.0 0.0 0.0 0.00

q4-1 BILLETS DEFECT (Target 0.1%) 0.0 0.0 0.0 0.0 0.00
QUALITY
q4
(0.2%)
q4-2 QUALITY SAMPLING (Target 0.1%) 0.0 0.0 0.0 0.0 0.00

q5 TOTAL DOWN TIME (Target 14%) 1.0 107.0 123.0 231.0 18.97 Plant Shutdown 100 Section change from D- 20mm to [125x65mm.

r1 HOLIDAY TIME 0.0 0.0 0.0 0.0 0.00 Process 36 Finish product come at scratch mark web bottom(16min);Finish product come at scratch mark then 19th st. scrapar grinding(20min)
THESE ARE
NOT
r2 PDB DOWN TIME 0.0 0.0 0.0 0.0 0.00 Bar bend at cooling bed due to cooling bed water spray did'nt ok(14min);Tying machine fault(5min);Shear-01 nozzle gap adjusted(4min)
B Shift

CONSIDERD Mech 23
r
IN
AVAILABLE r3 MILL COMMISSIONING 0.0 0.0 0.0 0.0 0.00 Operation 14
Bar bend at cooling bed due to cooling bed water spray did'nt ok(14min);
TIME
r4 SHUTDOWN TIME 0.0 122.0 100.0 222.0 15.42 Elect. 10
Last layer didn't cut at cold shear.

s. TOTAL 0.0 122.0 100.0 222.0 15.42 Operation 40

7th st. motor tripped due to motor over current.
SIGNATURE
 BSRM Mill
DAILY PRODUCTION REPORT
DATE:7/4/2019
BILLET CHARGED BILLET ROLLED HOT OUT MISS ROLL FINISH PRODUCT

SHIFT NO. OF NO. OF COBBLE CHOPPING TOTAL PRODUCT NO. OF PRODUCT

LOT NUMBER BILLET SIZE WEIGHT WEIGHT NO. OF BILLETS WEIGHT % PRODUCT SIZE YIELD %
BILLETS BILLETS NUMBERS WEIGHT % NUMBERS WEIGHT % WEIGHT % GRADE BUNDLES WEIGHT**

SML#012 131.0 160x160x12000 303.555 127.0 294.286 3.0 6.952 2.29 1.0 2.317 0.78 0.0 0.000 0.00 2.317 0.78Channel 125x65x6mm G-345 170 286.291 96.52
SHIFT - C
SML#013 21.0 160x160x12000 50.860 20.0 48.438 1.0 2.422 4.76 0.0 0.000 0.00 0.0 0.000 0.00 0.000 0.00Channel 125x65x6mm G-345 29 47.318 97.69

SML#012 103.0 160x160x12000 238.673 101.0 234.038 1.0 2.317 0.97 1.0 2.317 0.98 0.0 0.000 0.00 2.317 0.98Channel 125x65x6mm G-345 138 227.821 96.39
SHIFT - A
SML#012 33.0 160x160x12000 76.468 30.0 69.516 2.0 4.634 6.06 0.0 0.000 0.00 1.0 2.317 3.23 2.317 3.23 D. Bar 25mm 500W 18 66.250 92.23

SML#012 55.0 160x160x12000 127.447 55.0 127.447 0.0 0.000 0.00 0.0 0.000 0.00 0.0 0.000 0.00 0.000 0.00 D. Bar 25mm 500W 35 127.306 99.89
SHIFT - B
SML#001 154.0 160x160x12000 371.180 154.0 371.180 0.0 0.000 0.00 0.0 0.000 0.00 0.0 0.000 0.00 0.000 0.00 D. Bar 25mm 500W 101 363.613 97.96

TOTAL 497 1,168.182 487.0 1,144.905 7.0 16.325 1.40 2.0 4.634 0.40 1.0 2.317 0.20 6.952 0.60 491 1,118.599 97.11

Sl. No. PARTICULARS SHIFT- C SHIFT- A SHIFT- B TOTAL BREAKDOWN DETAILS

a TOTAL TIME 480 480 480 1440 Delay Booking Head DURATION (mins) REASON OF BREAKDOWN

b TOTAL AVAILABLE TIME 446 363 286 1095 Mech 66 Bar stucked at 9th st. entry funnel due to shear-1 heat cut not separate properly

c EFFECTIVE MILL RUNNING TIME (b-q) 313 245 276 834 Process 20 17th st. roll and 15th st. pass changed

d MILL EFFICIENCY (c÷b%) 70.18 67.49 96.50 76.16 Plant Shutdown 25 Production stopped for bad weather

e TOTAL PRODUCTION IN MT 333.609 294.071 490.919 1118.599 Elect. 4 Bar counter miss at C-B

f AVG. PRODUCTION PER HOUR (e÷b) 44.880 48.607 102.990 61.293 Plant Shutdown 9 Slow rolling due to special Billet

g PRODUCTIVITY (e÷c) 63.951 72.017 106.722 80.475 Mech 13 Both tying machine fault

h ROLLING MILL SPEED M/S (STAND#20) 2.100 5.200 8.300 5.200 Operation 30 Stacker operator mistake

C Shift
i OIL CONSUMPTION IN LITERS 0 0 0 0

j OIL CONSUMPTION PER TON (i÷e) 0.000 0.000 0.000 0.000

3
k GAS CONSUMPTION IN M 11,700 9,693 16,642 38,035

l GAS CONSUMPTION PER TON (k÷e) 35.07 32.96 33.90 34.002

m PDB POWER CONSUMPTION IN KWH 25,200 25,200 37,800 88,200

n DG POWER CONSUMPTION IN KWH 0

o TOTAL (PDB +DG) POWER CONSUMPTION IN KWH 25,200 25,200 37,800 88,200

p POWER CONSUMPTION PER TON (o÷e) 75.54 85.69 77.00 78.85

q BREAK DOWN TIME IN MINUTES SHIFT- C SHIFT- A SHIFT- B TOTAL DOWN TIME % Process 25 13th,14th st. pass & 15th,17th st. roll changed extra time required due to 13th st. roll screw down device O/P problem

q1 MECHANICAL (Target 3%) 79.0 6.0 0.0 85.0 7.76 Workshop 6 Extra time required due to 13th st. roll screw down device O/P problem

q2 ELECTRICAL (Target 2%) 4.0 0.0 0.0 4.0 0.37 Mech 6 Extra time required due to 13th st. roll screw down device O/P problem

OPERATION DELAY (Target 2.6%) 30.0 0.0 0.0 30.0 2.74 PDB 68 Mill off with bar due to PDB voltage fluctuation at that time 17th st. roll changed
A Shift

q3-1
PRODUC-
TION
q3 q3-2 PROCESS DELAY (Target 5.9%) 20.0 106.0 10.0 136.0 12.42 Process 11 17th st. roll changed
( TARGET
8.8%)
q3-3 WORKSHOP (Target 0.3%) 0.0 6.0 0.0 6.0 0.55 Process 70 Section changed from [125*65 mm to D-25mm,at that time 2nd,3rd,4th,5th,6th,7th,8th,9th,10th,11th,12th,15th,16th,17th,18th st. roll changed

q4-1 BILLETS DEFECT (Target 0.1%) 0.0 0.0 0.0 0.0 0.00 Plant Shutdown 31 Extra time required due to 12th st. motor check by expert
QUALITY
q4
(0.2%) 18th st. motor damage
q4-2 QUALITY SAMPLING (Target 0.1%) 0.0 0.0 0.0 0.0 0.00 Plant Shutdown 18

q5 TOTAL DOWN TIME (Target 14%) 133.0 118.0 10.0 261.0 23.84 Plant Shutdown 194 18th st. motor maintenance done and drive checking.

r1 HOLIDAY TIME 0.0 0.0 0.0 0.0 0.00 Process 7 18th st. pass change.
THESE ARE
NOT
r2 PDB DOWN TIME 0.0 68.0 0.0 68.0 4.72 Looper disable & cutting adjusted.
B Shift

CONSIDERD Process 3
r
IN
AVAILABLE r3 MILL COMMISSIONING 0.0 0.0 0.0 0.0 0.00
TIME
r4 SHUTDOWN TIME 34.0 49.0 194.0 277.0 19.24

s. TOTAL 34.0 117.0 194.0 345.0 23.96

SIGNATURE
 BSRM Mill
DAILY PRODUCTION REPORT
DATE:8/4/2019
BILLET CHARGED BILLET ROLLED HOT OUT MISS ROLL FINISH PRODUCT

SHIFT NO. OF NO. OF COBBLE CHOPPING TOTAL PRODUCT PRODUCT NO. OF PRODUCT
LOT NUMBER BILLET SIZE WEIGHT WEIGHT NO. OF BILLETS WEIGHT % YIELD %
BILLETS BILLETS NUMBERS WEIGHT % NUMBERS WEIGHT % WEIGHT % SIZE GRADE BUNDLES WEIGHT**

SML#001 357.0 160x160x12000 860.463 355.0 855.642 2.0 4.821 0.56 0.0 0.000 0.00 0.0 0.000 0.00 0.000 0.00 D. Bar 25mm 500W 221 831.929 97.23
SHIFT - C
0 0.0 0 0.000 0.0 0.0 0.000 0.0 0.0 0.000 0 0 0.000

SML#001 289.0 160x160x12000 696.565 289.0 696.565 0.0 0.000 0.00 0.0 0.000 0.00 0.0 0.000 0.00 0.000 0.00 D. Bar 25mm 500W 181 682.793 98.02
SHIFT - A
HOTOUT 9.0 160x160x12000 21.185 6.0 14.123 2.0 4.708 22.22 1.0 2.354 14.29 0.0 0.000 0.00 2.354 14.29 D. Bar 25mm 500W 4 12.024 72.97

SML#001 134.0 160x160x12000 322.975 131.0 315.744 2.0 4.821 1.49 0.0 0.000 0.00 1.0 2.410 0.76 2.410 0.76 D. Bar 25mm 500W 82 307.712 96.72

SHIFT - B HOTOUT 10.0 160x160x12000 23.539 10.0 23.539 0.0 0.000 0.00 0.0 0.000 0.00 0.0 0.000 0.00 0.000 0.00 D. Bar 25mm 500W 6 22.512 95.64

STM#001 217.0 160x160x12000 520.692 217.0 520.692 0.0 0.000 0.00 0.0 0.000 0.00 0.0 0.000 0.00 0.000 0.00 D. Bar 25mm 500W 135 504.728 96.93

TOTAL 1016 2,445.418 1,008.0 2,426.305 6.0 14.349 0.59 1.0 2.354 0.10 1.0 2.410 0.10 4.764 0.196 629 2,361.698 97.15

Sl. No. PARTICULARS SHIFT- C SHIFT- A SHIFT- B TOTAL BREAKDOWN DETAILS

a TOTAL TIME 480 480 480 1440 Delay Booking Head DURATION (mins) REASON OF BREAKDOWN

b TOTAL AVAILABLE TIME 480 416 454 1350 Process 15 17th,18th st. pass and 18th st. REG changed and hot sampling done at 15th,16th st.

c EFFECTIVE MILL RUNNING TIME (b-q) 455 385 449 1289 Elect. 5 Billet not forwarding properly at mill entry roller table

d MILL EFFICIENCY (c÷b%) 94.79 92.55 98.90 95.48 Mech 5 Billet not forwarding properly at mill entry roller table

e TOTAL PRODUCTION IN MT 831.929 694.817 834.952 2361.698

f AVG. PRODUCTION PER HOUR (e÷b) 103.991 100.214 110.346 104.964

g PRODUCTIVITY (e÷c) 109.705 108.283 111.575 109.932

h ROLLING MILL SPEED M/S (STAND#20) 8.300 8.300 8.300 8.300

OIL CONSUMPTION IN LITERS 0 C Shift

i 0 0 0

j OIL CONSUMPTION PER TON (i÷e) 0.000 0.000 0.000 0.000

k GAS CONSUMPTION IN M3 26,125 22,548 25,148 73,820

l GAS CONSUMPTION PER TON (k÷e) 31.40 32.45 30.12 31.257

m PDB POWER CONSUMPTION IN KWH 56,160 50,760 56,160 163,080

n DG POWER CONSUMPTION IN KWH 0

o TOTAL (PDB +DG) POWER CONSUMPTION IN KWH 56,160 50,760 56,160 163,080

p POWER CONSUMPTION PER TON (o÷e) 67.51 73.06 67.26 69.05

q BREAK DOWN TIME IN MINUTES SHIFT- C SHIFT- A SHIFT- B TOTAL DOWN TIME % Process 9 18th st. roll changed

q1 MECHANICAL (Target 3%) 5.0 9.0 0.0 14.0 1.04 Mech 5 Furnace peelbar backward proxymity miss

q2 ELECTRICAL (Target 2%) 5.0 0.0 0.0 5.0 0.37 Mech 1 Furnace peelbar backward proxymity miss

OPERATION DELAY (Target 2.6%) 0.0 0.0 0.0 0.0 0.00 Mech 3 Furnace peelbar backward proxymity miss
A Shift

q3-1
PRODUC-
TION
q3 q3-2 PROCESS DELAY (Target 5.9%) 15.0 22.0 5.0 42.0 3.11 Process 13 18th st. pass & 17th st. roll changed
( TARGET
8.8%)
q3-3 WORKSHOP (Target 0.3%) 0.0 0.0 0.0 0.0 0.00 PDB 64 Voltage fluctuation 16th,18th,15th st. pass changed

q4-1 BILLETS DEFECT (Target 0.1%) 0.0 0.0 0.0 0.0 0.00
QUALITY
q4
(0.2%)
q4-2 QUALITY SAMPLING (Target 0.1%) 0.0 0.0 0.0 0.0 0.00

q5 TOTAL DOWN TIME (Target 14%) 25.0 31.0 5.0 61.0 4.52 PDB 12 Previous shift breakdown continue PDB power failure.

r1 HOLIDAY TIME 0.0 0.0 0.0 0.0 0.00 PDB 14 18th st. motor tripped with bar due to voltage fluctuation of PDB.
THESE ARE
NOT
r2 PDB DOWN TIME 0.0 64.0 26.0 90.0 6.25 18th st. pass change.
B Shift

CONSIDERD Process 5
r
IN
AVAILABLE r3 MILL COMMISSIONING 0.0 0.0 0.0 0.0 0.00
TIME
r4 SHUTDOWN TIME 0.0 0.0 0.0 0.0 0.00

s. TOTAL 0.0 64.0 26.0 90.0 6.25

SIGNATURE
 BSRM Mill
DAILY PRODUCTION REPORT
DATE:9/4/2019
BILLET CHARGED BILLET ROLLED HOT OUT MISS ROLL FINISH PRODUCT

SHIFT NO. OF NO. OF COBBLE CHOPPING TOTAL PRODUCT PRODUCT NO. OF PRODUCT
LOT NUMBER BILLET SIZE WEIGHT WEIGHT NO. OF BILLETS WEIGHT % YIELD %
BILLETS BILLETS NUMBERS WEIGHT % NUMBERS WEIGHT % WEIGHT % SIZE GRADE BUNDLES WEIGHT**

SML#001 365.0 160x160x12000 879.745 365.0 879.745 0.0 0.000 0.00 0.0 0.000 0.00 0.0 0.000 0.00 0.000 0.00 D. Bar 25mm 500W 228 859.351 97.68
SHIFT - C
0 0.0 0 0.000 0.0 0.0 0.000 0.0 0.0 0.000 0 0 0.000

SML#001 201.0 160x160x12000 484.462 198.0 477.231 2.0 4.821 1.00 1.0 2.410 0.50 0.0 0.000 0.00 2.410 0.50 D. Bar 25mm 500W 125 469.321 97.85

SHIFT - A SML#002 4.0 160x160x12000 9.645 4.0 9.645 0.0 0.000 0.00 0.0 0.000 0.00 0.0 0.000 0.00 0.000 0.00 D. Bar 25mm 500W 3 8.446 87.57

SML#002 5.0 160x160x12000 12.056 5.0 12.056 0.0 0.000 0.00 0.0 0.000 0.00 0.0 0.000 0.00 0.000 0.00Channel 100x50x5mm G-345 4 6.449 53.49

SML#002 187.0 160x160x12000 450.906 186.0 448.494 1.0 2.411 0.53 0.0 0.000 0.00 0.0 0.000 0.00 0.000 0.00Channel 100x50x5mm G-345 256 437.428 97.53
SHIFT - B
0 0 0.0 0.0 0.000 0.0 0.0 0.000 0 0 0.000

TOTAL 762 1,836.814 758.0 1,827.172 3.0 7.232 0.39 1.0 2.410 0.13 0.0 0.000 0.00 2.410 0.132 616 1,780.995 97.34

Sl. No. PARTICULARS SHIFT- C SHIFT- A SHIFT- B TOTAL BREAKDOWN DETAILS

a TOTAL TIME 480 480 480 1440 Delay Booking Head DURATION (mins) REASON OF BREAKDOWN

b TOTAL AVAILABLE TIME 480 420 445 1345 Process 18 10th st. Roll & 17th,18th st. pass also 18th st. REG changed. 15th,16th st. hot sampling done.

c EFFECTIVE MILL RUNNING TIME (b-q) 452 284 366 1102 Elect. 3 Stacker pocket motor tripped

d MILL EFFICIENCY (c÷b%) 94.17 67.62 82.25 81.93 Process 7 18th st. pass & guide changed.

e TOTAL PRODUCTION IN MT 859.351 484.216 437.428 1780.995

f AVG. PRODUCTION PER HOUR (e÷b) 107.419 69.174 58.979 79.450

g PRODUCTIVITY (e÷c) 114.073 102.299 71.710 96.969

h ROLLING MILL SPEED M/S (STAND#20) 8.500 5.725 2.950 5.725

OIL CONSUMPTION IN LITERS 0 C Shift

i 0 0 0

j OIL CONSUMPTION PER TON (i÷e) 0.000 0.000 0.000 0.000

k GAS CONSUMPTION IN M3 26,960 16,724 11,717 55,401

l GAS CONSUMPTION PER TON (k÷e) 31.37 34.54 26.79 31.107

m PDB POWER CONSUMPTION IN KWH 57,600 38,520 31,320 127,440

n DG POWER CONSUMPTION IN KWH 0

o TOTAL (PDB +DG) POWER CONSUMPTION IN KWH 57,600 38,520 31,320 127,440

p POWER CONSUMPTION PER TON (o÷e) 67.03 79.55 71.60 71.56

q BREAK DOWN TIME IN MINUTES SHIFT- C SHIFT- A SHIFT- B TOTAL DOWN TIME % Process 12 17th,18th st. pass & 18th st. entry guide changed

q1 MECHANICAL (Target 3%) 0.0 10.0 4.0 14.0 1.04 PDB 60 Voltage fluctuation,at that time 1st,5th st. motor tripped

q2 ELECTRICAL (Target 2%) 3.0 0.0 0.0 3.0 0.22 Process 100 Section changed from D-25mm to [100*50 mm, at that time 3rd,4th,5th,6th,7th,8th,9th,10th,11th,12th,13th,14th,15th,16th,17th,18th st. roll changed

OPERATION DELAY (Target 2.6%) 0.0 14.0 5.0 19.0 1.41 Mech 10 Delay more due to 6th st. clamp problem & 1st st. entry funnel adjustment
A Shift

q3-1
PRODUC-
TION
q3 q3-2 PROCESS DELAY (Target 5.9%) 25.0 112.0 70.0 207.0 15.39 Operation 14 Sizing issue
( TARGET
8.8%)
q3-3 WORKSHOP (Target 0.3%) 0.0 0.0 0.0 0.0 0.00

q4-1 BILLETS DEFECT (Target 0.1%) 0.0 0.0 0.0 0.0 0.00
QUALITY
q4
(0.2%)
q4-2 QUALITY SAMPLING (Target 0.1%) 0.0 0.0 0.0 0.0 0.00

q5 TOTAL DOWN TIME (Target 14%) 28.0 136.0 79.0 243.0 18.07 Operation 5 18th st. delivery tight.

r1 HOLIDAY TIME 0.0 0.0 0.0 0.0 0.00 Process 23 17th st. pass change due to embossing mark on pass(18min);17th st. pass change due to embossing mark on pass(5min)
THESE ARE
NOT Mill check pass grinding due to chips embossing on pass(16min);Chips clear from 15th st. delivery & delivery adjusted(8min);17th st. pass
r2 PDB DOWN TIME 0.0 60.0 0.0 60.0 4.17
B Shift

CONSIDERD Process 34 grinding(10min)

r
IN
AVAILABLE r3 MILL COMMISSIONING 0.0 0.0 0.0 0.0 0.00 Plant Shutdown 35
Bad weather,17th st. roll changed(20min);Bad weather,17th st. pass grinding(15min)
TIME
r4 SHUTDOWN TIME 0.0 0.0 35.0 35.0 2.43 Mech 4
Bar tailend not discharge due to kicker off.

s. TOTAL 0.0 60.0 35.0 95.0 6.60 Process 13

17th st. pass change.
SIGNATURE
 BSRM Mill
DAILY PRODUCTION REPORT
DATE:10/4/2019
BILLET CHARGED BILLET ROLLED HOT OUT MISS ROLL FINISH PRODUCT

SHIFT COBBLE CHOPPING TOTAL

NO. OF NO. OF PRODUCT NO. OF PRODUCT
LOT NUMBER BILLET SIZE WEIGHT WEIGHT NO. OF BILLETS WEIGHT % PRODUCT SIZE YIELD %
BILLETS BILLETS NUMBERS WEIGHT % NUMBERS WEIGHT % WEIGHT % GRADE BUNDLES WEIGHT**

SML#002 157.0 160x160x12000 378.568 155.0 373.745 1.0 2.411 0.64 0.0 0.000 0.00 1.0 2.411 0.64 2.411 0.64 Channel 100x50x5mm G-345 210 367.412 97.68
SHIFT - C
0 0.0 0 0.000 0.0 0.0 0.000 0.0 0.0 0.000 0 0 0.000

SML#002 192.0 160x160x12000 462.962 189.0 455.728 3.0 7.234 1.56 0.0 0.000 0.00 0.0 0.000 0.00 0.000 0.00 Channel 100x50x5mm G-345 256 445.566 97.77
SHIFT - A
0 0.0 0 0.000 0.0 0.0 0.000 0.0 0.0 0.000 0 0 0.000

SML#002 45.0 160x160x12000 108.507 45.0 108.507 0.0 0.000 0.00 0.0 0.000 0.00 0.0 0.000 0.00 0.000 0.00 Channel 100x50x5mm G-345 64 108.213 99.73

SHIFT - B HOTOUT 6.0 160x160x12000 14.462 6.0 14.462 0.0 0.000 0.00 0.0 0.000 0.00 0.0 0.000 0.00 0.000 0.00 Channel 100x50x5mm G-345 8 13.703 94.75

SML#002 17.0 160x160x12000 40.991 13.5 32.552 2.0 4.823 11.76 0.0 0.000 0.00 1.5 3.617 10.00 3.617 10.00 D. Bar 10mm 500W 9 31.409 86.84

TOTAL 417 1,005.489 408.5 984.994 6.0 14.468 1.44 0.0 0.000 0.00 2.5 6.028 0.61 6.028 0.608 547 966.303 97.51

Sl. No. PARTICULARS SHIFT- C SHIFT- A SHIFT- B TOTAL BREAKDOWN DETAILS

a TOTAL TIME 480 480 480 1440 Delay Booking Head DURATION (mins) REASON OF BREAKDOWN

b TOTAL AVAILABLE TIME 455 480 232 1167 Process 10 14th,17th st. pass grinding

c EFFECTIVE MILL RUNNING TIME (b-q) 305 355 137 797 Plant Shutdown 25 Bad weather that time, 13th,14th,15ht,17th st. pass changed.

d MILL EFFICIENCY (c÷b%) 67.03 73.96 59.05 68.29 Operation 140 Bar stuck at Sh-02 due to bar up ward from 14th st. delivery.

e TOTAL PRODUCTION IN MT 367.412 445.566 153.325 966.303

f AVG. PRODUCTION PER HOUR (e÷b) 48.450 55.696 39.653 49.681

g PRODUCTIVITY (e÷c) 72.278 75.307 67.150 72.746

h ROLLING MILL SPEED M/S (STAND#20) 2.950 2.950 7.825 4.575

C Shift
i OIL CONSUMPTION IN LITERS 0 0 0 0

j OIL CONSUMPTION PER TON (i÷e) 0.000 0.000 0.000 0.000

3
k GAS CONSUMPTION IN M 12,315 13,953 6,229 32,496

l GAS CONSUMPTION PER TON (k÷e) 33.52 31.31 40.63 33.630

m PDB POWER CONSUMPTION IN KWH 27,360 32,040 18,000 77,400

n DG POWER CONSUMPTION IN KWH 0

o TOTAL (PDB +DG) POWER CONSUMPTION IN KWH 27,360 32,040 18,000 77,400

p POWER CONSUMPTION PER TON (o÷e) 74.47 71.91 117.40 80.10

q BREAK DOWN TIME IN MINUTES SHIFT- C SHIFT- A SHIFT- B TOTAL DOWN TIME % Process 10 17th st. pass grinding

q1 MECHANICAL (Target 3%) 0.0 0.0 0.0 0.0 0.00 Process 9 15th,17th st. pass changed

q2 ELECTRICAL (Target 2%) 0.0 0.0 5.0 5.0 0.43 Process 21 15th,17th st. pass changed

OPERATION DELAY (Target 2.6%) 140.0 0.0 0.0 140.0 12.00 Process 20 14th st. pass change due to left side grooving mark came
A Shift

q3-1
PRODUC-
TION
q3 q3-2 PROCESS DELAY (Target 5.9%) 10.0 125.0 90.0 225.0 19.28 Process 5 17th st. pass grinding
( TARGET
8.8%)
q3-3 WORKSHOP (Target 0.3%) 0.0 0.0 0.0 0.0 0.00 Process 20 15th st. roll & 17th st. pass changed & 14th st. bottom scriper grinding

q4-1 BILLETS DEFECT (Target 0.1%) 0.0 0.0 0.0 0.0 0.00 Process 20 18th st. roll changed
QUALITY
q4
(0.2%)
q4-2 QUALITY SAMPLING (Target 0.1%) 0.0 0.0 0.0 0.0 0.00 Process 20 17th st. pass changed

q5 TOTAL DOWN TIME (Target 14%) 150.0 125.0 95.0 370.0 31.71 Process 90 Section changed from [100X50 mm to Rebar-4X10mm That time 1st,3rd,4th,5th,6th,7th,8th,9th,10th,11th,12th,14th,15th,16th,17th,18th,19th,20th st. roll changed

r1 HOLIDAY TIME 0.0 0.0 0.0 0.0 0.00 Elect. 5 19th st. drive fault and checking
THESE ARE
NOT
r2 PDB DOWN TIME 0.0 0.0 0.0 0.0 0.00 12th st. motor flash due to over current, motor changed,at that time 17th st. roll changed for bigger roll dia
B Shift

CONSIDERD Plant Shutdown 248

r
IN
AVAILABLE r3 MILL COMMISSIONING 0.0 0.0 0.0 0.0 0.00
TIME
r4 SHUTDOWN TIME 25.0 0.0 248.0 273.0 18.96

s. TOTAL 25.0 0.0 248.0 273.0 18.96

SIGNATURE
 BSRM Mill
DAILY PRODUCTION REPORT
DATE:11/4/2019
BILLET CHARGED BILLET ROLLED HOT OUT MISS ROLL FINISH PRODUCT

SHIFT NO. OF NO. OF COBBLE CHOPPING TOTAL PRODUCT NO. OF PRODUCT

LOT NUMBER BILLET SIZE WEIGHT WEIGHT NO. OF BILLETS WEIGHT % PRODUCT SIZE YIELD %
BILLETS BILLETS NUMBERS WEIGHT % NUMBERS WEIGHT % WEIGHT % GRADE BUNDLES WEIGHT**

SML#002 185.0 160x160x12000 446.083 185.0 446.083 0.0 0.000 0.00 0.0 0.000 0.00 0.0 0.000 0.00 0.000 0.00 D. Bar 10mm 500W 117 438.254 98.24
SHIFT - C
BIS#001 178.0 160x160x12000 424.920 177.0 422.533 1.0 2.387 0.56 0.0 0.000 0.00 0.0 0.000 0.00 0.000 0.00 D. Bar 10mm 500W 105 412.573 97.64

BIS#001 196.0 160x160x12000 467.889 196.0 467.889 0.0 0.000 0.00 0.0 0.000 0.00 0.0 0.000 0.00 0.000 0.00 D. Bar 10mm 500W 119 459.127 98.13
SHIFT - A
BIS#002 6.0 160x160x6000 7.106 6.0 7.106 0.0 0.000 0.00 0.0 0.000 0.00 0.0 0.000 0.00 0.000 0.00 D. Bar 10mm 500W 2 6.740 94.85

BIS#002 115.0 160x160x6000 136.191 110.5 130.862 0.0 0.000 0.00 0.0 0.000 0.00 4.5 5.329 3.91 5.329 3.91 D. Bar 10mm 500W 33 122.847 90.20
SHIFT - B
0 0 0.0 0.0 0.000 0.0 0.0 0.000 0 0 0.000

TOTAL 680 1,482.189 674.5 1,474.472 1.0 2.387 0.16 0.0 0.000 0.00 4.5 5.329 0.36 5.329 0.360 376 1,439.541 97.28

Sl. No. PARTICULARS SHIFT- C SHIFT- A SHIFT- B TOTAL BREAKDOWN DETAILS

a TOTAL TIME 480 480 480 1440 Delay Booking Head DURATION (mins) REASON OF BREAKDOWN

b TOTAL AVAILABLE TIME 480 270 190 940 Process 3 Mill checked

c EFFECTIVE MILL RUNNING TIME (b-q) 477 264 116 857

d MILL EFFICIENCY (c÷b%) 99.38 97.78 61.05 91.17

e TOTAL PRODUCTION IN MT 850.827 465.867 122.847 1439.541

f AVG. PRODUCTION PER HOUR (e÷b) 106.353 103.526 38.794 91.886

g PRODUCTIVITY (e÷c) 12.700 12.700 12.700 100.785

h ROLLING MILL SPEED M/S (STAND#20) 0.000 0.000 0.000 0.000

C Shift
i OIL CONSUMPTION IN LITERS 0 0 0 0

j OIL CONSUMPTION PER TON (i÷e) 0.000 0.000 0.000 0.000

3
k GAS CONSUMPTION IN M 25,394 14,377 7,051 46,822

l GAS CONSUMPTION PER TON (k÷e) 29.85 30.86 57.39 32.526

m PDB POWER CONSUMPTION IN KWH 68,760 46,080 27,360 142,200

n DG POWER CONSUMPTION IN KWH 0

o TOTAL (PDB +DG) POWER CONSUMPTION IN KWH 68,760 46,080 27,360 142,200

p POWER CONSUMPTION PER TON (o÷e) 80.82 98.91 222.72 98.78

q BREAK DOWN TIME IN MINUTES SHIFT- C SHIFT- A SHIFT- B TOTAL DOWN TIME % Process 6 20th st. REG changed & I/MILL,F/MILL sampling

q1 MECHANICAL (Target 3%) 0.0 0.0 0.0 0.0 0.00 Plant Shutdown 210 Double billet discharge from furnace more times that time 18th st. roll & 14th,15th,17th st. pass changed,19th st. twister changed

q2 ELECTRICAL (Target 2%) 0.0 0.0 0.0 0.0 0.00

OPERATION DELAY (Target 2.6%) 0.0 0.0 0.0 0.0 0.00

A Shift

q3-1
PRODUC-
TION
q3 q3-2 PROCESS DELAY (Target 5.9%) 3.0 6.0 0.0 9.0 0.96
( TARGET
8.8%)
q3-3 WORKSHOP (Target 0.3%) 0.0 0.0 0.0 0.0 0.00

q4-1 BILLETS DEFECT (Target 0.1%) 0.0 0.0 74.0 74.0 7.87
QUALITY
q4
(0.2%)
q4-2 QUALITY SAMPLING (Target 0.1%) 0.0 0.0 0.0 0.0 0.00

q5 TOTAL DOWN TIME (Target 14%) 3.0 6.0 74.0 83.0 8.83 Plant Shutdown 120 Billet discharging problem for 6meter bille

r1 HOLIDAY TIME 0.0 0.0 0.0 0.0 0.00 Billet Defect 18 Bar not entry 19th st. due to deffective billet
THESE ARE
NOT
r2 PDB DOWN TIME 0.0 0.0 0.0 0.0 0.00
B Shift

CONSIDERD Plant Shutdown 120 Billet discharging problem for 6meter billet
r
IN
AVAILABLE r3 MILL COMMISSIONING 0.0 0.0 0.0 0.0 0.00 Billet Defect 25 Bar tear 18th st. delivery due to deffective billet that time 18th st. roll changed
TIME
r4 SHUTDOWN TIME 0.0 210.0 290.0 500.0 34.72 Plant Shutdown 50 Billet discharging problem for 6meter billet
s. TOTAL 0.0 210.0 290.0 500.0 34.72 Billet Defect 31 Bar stuck at QTB due to deffective billet
SIGNATURE
 BSRM Mill
DAILY PRODUCTION REPORT
DATE:12/4/2019
BILLET CHARGED BILLET ROLLED HOT OUT MISS ROLL FINISH PRODUCT

SHIFT NO. OF NO. OF COBBLE CHOPPING TOTAL PRODUCT NO. OF PRODUCT

LOT NUMBER BILLET SIZE WEIGHT WEIGHT NO. OF BILLETS WEIGHT % PRODUCT SIZE YIELD %
BILLETS BILLETS NUMBERS WEIGHT % NUMBERS WEIGHT % WEIGHT % GRADE BUNDLES WEIGHT**

BIS#002 129.0 160x160x6000 152.771 124.0 146.849 0.0 0.000 0.00 0.0 0.000 0.00 5.0 5.921 3.88 5.921 3.88 D. Bar 10mm 500W 39 149.484 97.85
SHIFT - C
BIS#001 135.0 160x160x12000 322.271 135.0 322.271 0.0 0.000 0.00 0.0 0.000 0.00 0.0 0.000 0.00 0.000 0.00 D. Bar 10mm 500W 84 313.862 97.39

BIS#001 225.0 160x160x12000 537.118 225.0 537.118 0.0 0.000 0.00 0.0 0.000 0.00 0.0 0.000 0.00 0.000 0.00 D. Bar 10mm 500W 142 529.402 98.56
SHIFT - A
BIS#001 125.0 160x160x12000 298.563 125.0 298.563 0.0 0.000 0.00 0.0 0.000 0.00 0.0 0.000 0.00 0.000 0.00 D. Bar 10mm 500W 78 291.731 97.71

BIS#001 319.0 160x160x12000 761.932 314.0 749.989 3.0 7.166 0.94 0.0 0.000 0.00 2.0 4.777 0.63 4.777 0.63 D. Bar 10mm 500W 190 736.120 97.53
SHIFT - B
0 0 0.0 0.0 0.000 0.0 0.0 0.000 0 0 0.000

TOTAL 933 2,072.653 923.0 2,054.789 3.0 7.166 0.35 0.0 0.000 0.00 7.0 10.698 0.52 10.698 0.518 533 2,020.599 97.83

Sl. No. PARTICULARS SHIFT- C SHIFT- A SHIFT- B TOTAL BREAKDOWN DETAILS

a TOTAL TIME 480 480 480 1440 Delay Booking Head DURATION (mins) REASON OF BREAKDOWN

b TOTAL AVAILABLE TIME 385 480 480 1345 Plant Shutdown 18 6 meter double billet discharging from furnace 6 times

c EFFECTIVE MILL RUNNING TIME (b-q) 260 467 419 1146 Billet Defect 49 5th st. delivery came out with bar due to deffective billet

d MILL EFFICIENCY (c÷b%) 67.53 97.29 87.29 85.20 Plant Shutdown 77 6 meter double billet discharging from furnace

e TOTAL PRODUCTION IN MT 463.346 821.133 736.120 2020.599 Billet Defect 24 Bar stuck at QTB due to deffective billet

f AVG. PRODUCTION PER HOUR (e÷b) 72.210 102.642 92.015 90.138 Billet Defect 44 Bar stuck at QTB due to deffective billet then 18th,20th st. roll changed

g PRODUCTIVITY (e÷c) 106.926 105.499 105.411 105.791 Elect. 8 15th st. motor cooling water leak

h ROLLING MILL SPEED M/S (STAND#20) 12.700 12.700 12.700 12.700

C Shift
i OIL CONSUMPTION IN LITERS 0 0 0 0

j OIL CONSUMPTION PER TON (i÷e) 0.000 0.000 0.000 0.000

3
k GAS CONSUMPTION IN M 14,866 24,056 23,290 62,212

l GAS CONSUMPTION PER TON (k÷e) 32.08 29.30 31.64 30.789

m PDB POWER CONSUMPTION IN KWH 48,240 65,520 61,560 175,320

n DG POWER CONSUMPTION IN KWH 0

o TOTAL (PDB +DG) POWER CONSUMPTION IN KWH 48,240 65,520 61,560 175,320

p POWER CONSUMPTION PER TON (o÷e) 104.11 79.79 83.63 86.77

q BREAK DOWN TIME IN MINUTES SHIFT- C SHIFT- A SHIFT- B TOTAL DOWN TIME % Elect. 5 Previous shift breakdown continue 15th st. motor cooling water leakage.

q1 MECHANICAL (Target 3%) 0.0 0.0 23.0 23.0 1.71 Process 3 Mill checking.

q2 ELECTRICAL (Target 2%) 8.0 5.0 0.0 13.0 0.97 Process 5 20th st. REG change & sampling.

OPERATION DELAY (Target 2.6%) 0.0 0.0 7.0 7.0 0.52

A Shift

q3-1
PRODUC-
TION
q3 q3-2 PROCESS DELAY (Target 5.9%) 0.0 8.0 31.0 39.0 2.90
( TARGET
8.8%)
q3-3 WORKSHOP (Target 0.3%) 0.0 0.0 0.0 0.0 0.00

q4-1 BILLETS DEFECT (Target 0.1%) 117.0 0.0 0.0 117.0 8.70
QUALITY
q4
(0.2%)
q4-2 QUALITY SAMPLING (Target 0.1%) 0.0 0.0 0.0 0.0 0.00

q5 TOTAL DOWN TIME (Target 14%) 125.0 13.0 61.0 199.0 14.80 Process 24 9th,11th,18h st. roll & 14th,15th,17th st. pass changed & 17th,20th st. REG changed,I/MILL,F/MILL hot sampling

r1 HOLIDAY TIME 0.0 0.0 0.0 0.0 0.00 Mech 23 Bar stuck at after shear 3 nozzle due to bottom plate displace
THESE ARE
NOT
r2 PDB DOWN TIME 0.0 0.0 0.0 0.0 0.00
B Shift

CONSIDERD Operation 7 Bar not entry 19th st. right side due to bad slitting for 17th st. e/guide loose
r
IN
AVAILABLE r3 MILL COMMISSIONING 0.0 0.0 0.0 0.0 0.00 Process 7 At that time 18th st. roll changed
TIME
r4 SHUTDOWN TIME 95.0 0.0 0.0 95.0 6.60

s. TOTAL 95.0 0.0 0.0 95.0 6.60

SIGNATURE
 BSRM Mill
DAILY PRODUCTION REPORT
DATE:13/4/2019
BILLET CHARGED BILLET ROLLED HOT OUT MISS ROLL FINISH PRODUCT

SHIFT NO. OF NO. OF COBBLE CHOPPING TOTAL PRODUCT NO. OF PRODUCT

LOT NUMBER BILLET SIZE WEIGHT WEIGHT NO. OF BILLETS WEIGHT % PRODUCT SIZE YIELD %
BILLETS BILLETS NUMBERS WEIGHT % NUMBERS WEIGHT % WEIGHT % GRADE BUNDLES WEIGHT**

BIS#001 219.0 160x160x12000 523.082 219.0 523.082 0.0 0.000 0.00 0.0 0.000 0.00 0.0 0.000 0.00 0.000 0.00 D. Bar 10mm 500W 132 513.573 98.18
SHIFT - C
ML-JAN-19-1-1 208.0 130x130x12000 331.641 208.0 331.641 0.0 0.000 0.00 0.0 0.000 0.00 0.0 0.000 0.00 0.000 0.00 D. Bar 10mm 500W 84 322.561 97.26

ML-JAN-19-1-1 424.0 130x130x12000 676.038 422.0 672.849 0.0 0.000 0.00 0.0 0.000 0.00 2.0 3.189 0.47 3.189 0.47 D. Bar 10mm 500W 172 655.671 96.99
SHIFT - A
0 0.0 0 0.000 0.0 0.0 0.000 0.0 0.0 0.000 0 0 0.000

ML-JAN-19-1-1 501.0 130x130x12000 798.809 497.0 792.432 2.0 3.189 0.40 0.0 0.000 0.00 2.0 3.189 0.40 3.189 0.40 D. Bar 10mm 500W 202 774.260 97.32
SHIFT - B
HOTOUT 4.0 130x130x12000 6.378 4.0 6.378 0.0 0.000 0.00 0.0 0.000 0.00 0.0 0.000 0.00 0.000 0.00 D. Bar 10mm 500W 1 3.848 60.34

TOTAL 1356 2,335.948 1,350.0 2,326.382 2.0 3.189 0.14 0.0 0.000 0.00 4.0 6.378 0.27 6.378 0.273 591 2,269.913 97.31

Sl. No. PARTICULARS SHIFT- C SHIFT- A SHIFT- B TOTAL BREAKDOWN DETAILS

a TOTAL TIME 480 480 480 1440 Delay Booking Head DURATION (mins) REASON OF BREAKDOWN

b TOTAL AVAILABLE TIME 480 480 460 1420 Elect. 2 Three 130 billet came from charging machine to roller table.

c EFFECTIVE MILL RUNNING TIME (b-q) 471 393 453 1317 Mech 2 Three 130 billet came from charging machine to roller table.

d MILL EFFICIENCY (c÷b%) 98.13 81.88 98.48 92.75 Process 3 F/M,I/M hot sampling done. 20th st. REG changed.

e TOTAL PRODUCTION IN MT 836.134 655.671 778.108 2269.913 Process 2 Billet charged from to 160*160*12m to 130*130*12m

f AVG. PRODUCTION PER HOUR (e÷b) 104.517 81.959 101.492 95.912

g PRODUCTIVITY (e÷c) 106.514 100.102 103.061 103.413

h ROLLING MILL SPEED M/S (STAND#20) 12.700 12.700 12.700 12.700

C Shift
i OIL CONSUMPTION IN LITERS 0 0 0 0

j OIL CONSUMPTION PER TON (i÷e) 0.000 0.000 0.000 0.000

3
k GAS CONSUMPTION IN M 24,588 19,435 25,980 70,003

l GAS CONSUMPTION PER TON (k÷e) 29.41 29.64 33.39 30.840

m PDB POWER CONSUMPTION IN KWH 67,320 56,880 63,360 187,560

n DG POWER CONSUMPTION IN KWH 0

o TOTAL (PDB +DG) POWER CONSUMPTION IN KWH 67,320 56,880 63,360 187,560

p POWER CONSUMPTION PER TON (o÷e) 80.51 86.75 81.43 82.63

q BREAK DOWN TIME IN MINUTES SHIFT- C SHIFT- A SHIFT- B TOTAL DOWN TIME % Process 25 14th,15th,17th st. pass & 12th,16th,18th,20th st. roll, 19th st. twister,17th st. MDR change

q1 MECHANICAL (Target 3%) 2.0 0.0 0.0 2.0 0.14 Operation 7 Bar excess loop between 11th,12th st.

q2 ELECTRICAL (Target 2%) 2.0 0.0 0.0 2.0 0.14 Operation 16 Bar fault at 18th st. delivery then S#18 roll change.

OPERATION DELAY (Target 2.6%) 0.0 52.0 7.0 59.0 4.15 Operation 29 Hot out billet charging delay at charging bed.
A Shift

q3-1
PRODUC-
TION
q3 q3-2 PROCESS DELAY (Target 5.9%) 5.0 35.0 0.0 40.0 2.82 Process 10 F/mill check & F/mill sampling that time 18th st. roll change.
( TARGET
8.8%)
q3-3 WORKSHOP (Target 0.3%) 0.0 0.0 0.0 0.0 0.00

q4-1 BILLETS DEFECT (Target 0.1%) 0.0 0.0 0.0 0.0 0.00
QUALITY
q4
(0.2%)
q4-2 QUALITY SAMPLING (Target 0.1%) 0.0 0.0 0.0 0.0 0.00

q5 TOTAL DOWN TIME (Target 14%) 9.0 87.0 7.0 103.0 7.25 Operation 7 Bar came out from 19th st. delivery due to twister pipe was open (L-side )

r1 HOLIDAY TIME 0.0 0.0 0.0 0.0 0.00 Plant Shutdown 20 Production stopped due to bad weather that time 20th st. REG changed
THESE ARE
NOT
r2 PDB DOWN TIME 0.0 0.0 0.0 0.0 0.00
B Shift

CONSIDERD
r
IN
AVAILABLE r3 MILL COMMISSIONING 0.0 0.0 0.0 0.0 0.00
TIME
r4 SHUTDOWN TIME 0.0 0.0 20.0 20.0 1.39

s. TOTAL 0.0 0.0 20.0 20.0 1.39

SIGNATURE
 BSRM Mill
DAILY PRODUCTION REPORT
DATE:14/4/2019
BILLET CHARGED BILLET ROLLED HOT OUT MISS ROLL FINISH PRODUCT

SHIFT COBBLE CHOPPING TOTAL

NO. OF NO. OF PRODUCT NO. OF PRODUCT
LOT NUMBER BILLET SIZE WEIGHT WEIGHT NO. OF BILLETS WEIGHT % PRODUCT SIZE YIELD %
BILLETS BILLETS NUMBERS WEIGHT % NUMBERS WEIGHT % WEIGHT % GRADE BUNDLES WEIGHT**

ML-JAN-19-1-1 512.0 130x130x12000 816.348 512.0 816.348 0.0 0.000 0.00 0.0 0.000 0.00 0.0 0.000 0.00 0.000 0.00 D. Bar 10mm 500W 211 804.259 98.52
SHIFT - C
0 0.0 0 0.000 0.0 0.0 0.000 0.0 0.0 0.000 0 0 0.000

ML-JAN-19-1-1 195.0 130x130x12000 310.914 191.0 304.536 2.0 3.189 1.03 0.0 0.000 0.00 2.0 3.189 1.04 3.189 1.04 D. Bar 10mm 500W 78 297.387 96.64

SHIFT - A BIS#017 48.0 160x160x11000 106.295 48.0 106.295 0.0 0.000 0.00 0.0 0.000 0.00 0.0 0.000 0.00 0.000 0.00 D. Bar 10mm 500W 27 105.802 99.54

BIS#015 125.0 160x160x12000 297.420 122.5 291.472 1.0 2.379 0.80 1.5 3.569 1.21 0.0 0.000 0.00 3.569 1.21 D. Bar 10mm 500W 74 287.073 97.30

BIS#017 258.0 160x160x11000 571.333 258.0 571.333 0.0 0.000 0.00 0.0 0.000 0.00 0.0 0.000 0.00 0.000 0.00 D. Bar 10mm 500W 143 557.849 97.64

SHIFT - B ML-JAN-19-1-1 95.0 130x130x12000 151.543 95.0 151.543 0.0 0.000 0.00 0.0 0.000 0.00 0.0 0.000 0.00 0.000 0.00 D. Bar 10mm 500W 40 149.603 98.72

HOTOUT 11.0 160x160x12000 26.513 11.0 26.513 0.0 0.000 0.00 0.0 0.000 0.00 0.0 0.000 0.00 0.000 0.00 D. Bar 10mm 500W 6 23.044 86.92

TOTAL 1244 2,280.366 1,237.5 2,268.040 3.0 5.568 0.24 1.5 3.569 0.16 2.0 3.189 0.14 6.758 0.297 579 2,225.017 97.81

Sl. No. PARTICULARS SHIFT- C SHIFT- A SHIFT- B TOTAL BREAKDOWN DETAILS

a TOTAL TIME 480 480 480 1440 Delay Booking Head DURATION (mins) REASON OF BREAKDOWN

b TOTAL AVAILABLE TIME 480 415 480 1375 Process 18 11th,18th st. roll & 15th,17th st. pass changed. 15th,17th st. hot sampling done.

c EFFECTIVE MILL RUNNING TIME (b-q) 462 396 429 1287

d MILL EFFICIENCY (c÷b%) 96.25 95.42 89.38 93.60

e TOTAL PRODUCTION IN MT 804.259 690.262 730.496 2225.017

f AVG. PRODUCTION PER HOUR (e÷b) 100.532 99.797 91.312 97.092

g PRODUCTIVITY (e÷c) 104.449 104.585 102.167 103.730

h ROLLING MILL SPEED M/S (STAND#20) 12.700 12.700 12.700 12.700

C Shift
i OIL CONSUMPTION IN LITERS 0 0 0 0

j OIL CONSUMPTION PER TON (i÷e) 0.000 0.000 0.000 0.000

k GAS CONSUMPTION IN M3 24,231 20,594 22,238 67,063

l GAS CONSUMPTION PER TON (k÷e) 30.13 29.84 30.44 30.141

m PDB POWER CONSUMPTION IN KWH 66,240 58,680 61,560 186,480

n DG POWER CONSUMPTION IN KWH 0

o TOTAL (PDB +DG) POWER CONSUMPTION IN KWH 66,240 58,680 61,560 186,480

p POWER CONSUMPTION PER TON (o÷e) 82.36 85.01 84.27 83.81

q BREAK DOWN TIME IN MINUTES SHIFT- C SHIFT- A SHIFT- B TOTAL DOWN TIME % Operation 7 Bar not entered in 18th st. due to 18th st. MDR fall down.

q1 MECHANICAL (Target 3%) 0.0 0.0 0.0 0.0 0.00 Process 5 20th st. REG change & sampling

q2 ELECTRICAL (Target 2%) 0.0 0.0 48.0 48.0 3.49 Process 3 Billet change from 130mm to 160mm

OPERATION DELAY (Target 2.6%) 0.0 7.0 0.0 7.0 0.51 PDB 65 Voltage fluctuation from PDB.3rd,5th,9th,10th,14th st. change.
A Shift

q3-1
PRODUC-
TION
q3 q3-2 PROCESS DELAY (Target 5.9%) 18.0 8.0 3.0 29.0 2.11 Billet Defect 4 Chips checking for deffective billet(NS)
( TARGET
8.8%)
q3-3 WORKSHOP (Target 0.3%) 0.0 0.0 0.0 0.0 0.00

q4-1 BILLETS DEFECT (Target 0.1%) 0.0 4.0 0.0 4.0 0.29
QUALITY
q4
(0.2%)
q4-2 QUALITY SAMPLING (Target 0.1%) 0.0 0.0 0.0 0.0 0.00

q5 TOTAL DOWN TIME (Target 14%) 18.0 19.0 51.0 88.0 6.40 Process 3 Billet changed 160X160X12 mm to 130X130X12 mm

r1 HOLIDAY TIME 0.0 0.0 0.0 0.0 0.00 Elect. 48 Cold disapearing stopper cable damaged that time 18th,20th st. roll and 15th,17th st. pass changed 17th st. REG 19th st. twister changed
THESE ARE
NOT
r2 PDB DOWN TIME 0.0 65.0 0.0 65.0 4.51
B Shift

CONSIDERD
r
IN
AVAILABLE r3 MILL COMMISSIONING 0.0 0.0 0.0 0.0 0.00
TIME
r4 SHUTDOWN TIME 0.0 0.0 0.0 0.0 0.00

s. TOTAL 0.0 65.0 0.0 65.0 4.51

SIGNATURE
 BSRM Mill
DAILY PRODUCTION REPORT
DATE:15/4/2019
BILLET CHARGED BILLET ROLLED HOT OUT MISS ROLL FINISH PRODUCT

SHIFT NO. OF NO. OF COBBLE CHOPPING TOTAL PRODUCT PRODUCT NO. OF PRODUCT
LOT NUMBER BILLET SIZE WEIGHT WEIGHT NO. OF BILLETS WEIGHT % YIELD %
BILLETS BILLETS NUMBERS WEIGHT % NUMBERS WEIGHT % WEIGHT % SIZE GRADE BUNDLES WEIGHT**

ML-JAN-19-1-1 475.0 130x130x12000 757.715 467.0 744.954 5.0 7.976 1.05 0.0 0.000 0.00 3.0 4.786 0.64 4.786 0.64 D. Bar 10mm 500W 192 732.623 97.72
SHIFT - C
0 0.0 0 0.000 0.0 0.0 0.000 0.0 0.0 0.000 0 0 0.000

ML-JAN-19-1-1 210.0 130x130x12000 334.990 207.0 330.204 2.0 3.190 0.95 0.0 0.000 0.00 1.0 1.595 0.48 1.595 0.48 D. Bar 10mm 500W 85 325.251 98.03
SHIFT - A
ML-JAN-19-1-1 248.0 130x130x12000 395.706 248.0 395.706 0.0 0.000 0.00 0.0 0.000 0.00 0.0 0.000 0.00 0.000 0.00 D. Bar 10mm 500W 100 381.782 96.48

ML-JAN-19-1-1 446.0 130x130x12000 711.633 439.0 700.464 4.0 6.382 0.90 0.0 0.000 0.00 3.0 4.787 0.68 4.787 0.68 D. Bar 10mm 500W 180 687.894 97.54
SHIFT - B
HOTOUT 26.0 130x130x12000 41.429 26.0 41.429 0.0 0.000 0.00 0.0 0.000 0.00 0.0 0.000 0.00 0.000 0.00 D. Bar 10mm 500W 10 37.832 91.32

TOTAL 1405 2,241.473 1,387.0 2,212.757 11.0 17.549 0.78 0.0 0.000 0.00 7.0 11.168 0.50 11.168 0.502 567 2,165.382 97.37

Sl. No. PARTICULARS SHIFT- C SHIFT- A SHIFT- B TOTAL BREAKDOWN DETAILS

a TOTAL TIME 480 480 480 1440 Delay Booking Head DURATION (mins) REASON OF BREAKDOWN

b TOTAL AVAILABLE TIME 480 480 480 1440 Billet Defect 24 Deffective billet stuck at F/mill.20th st. REG change.

c EFFECTIVE MILL RUNNING TIME (b-q) 430 425 424 1279 Process 6 Sampling.

d MILL EFFICIENCY (c÷b%) 89.58 88.54 88.33 88.82 Operation 19 Bar stuck with extraction trolley due to operation mistake.

e TOTAL PRODUCTION IN MT 732.623 707.033 725.726 2165.382 Operation 1 Bar not entry 19th st.

f AVG. PRODUCTION PER HOUR (e÷b) 91.578 88.379 90.716 90.224

g PRODUCTIVITY (e÷c) 102.226 99.816 102.697 101.582

h ROLLING MILL SPEED M/S (STAND#20) 12.700 12.700 12.700 12.700

C Shift
i OIL CONSUMPTION IN LITERS 0 0 0 0

j OIL CONSUMPTION PER TON (i÷e) 0.000 0.000 0.000 0.000

3
k GAS CONSUMPTION IN M 22,998 23,496 22,450 68,945

l GAS CONSUMPTION PER TON (k÷e) 31.39 33.23 30.94 31.840

m PDB POWER CONSUMPTION IN KWH 60,480 59,760 59,400 179,640

n DG POWER CONSUMPTION IN KWH 0

o TOTAL (PDB +DG) POWER CONSUMPTION IN KWH 60,480 59,760 59,400 179,640

p POWER CONSUMPTION PER TON (o÷e) 82.55 84.52 81.85 82.96

q BREAK DOWN TIME IN MINUTES SHIFT- C SHIFT- A SHIFT- B TOTAL DOWN TIME % Operation 10 Previous shift breakdown continued bar didn't enter 19th st.

q1 MECHANICAL (Target 3%) 0.0 0.0 6.0 6.0 0.42 Process 30 At that time 7th,8th,16th,18th st. roll & 15th,17th st. pass changed,19th st. twister ,17th st. MDR,20th st. REG changed

q2 ELECTRICAL (Target 2%) 0.0 0.0 0.0 0.0 0.00 Process 15 Hot out billet charging delay at charging bed

OPERATION DELAY (Target 2.6%) 20.0 10.0 0.0 30.0 2.08

A Shift

q3-1
PRODUC-
TION
q3 q3-2 PROCESS DELAY (Target 5.9%) 6.0 45.0 14.0 65.0 4.51
( TARGET
8.8%)
q3-3 WORKSHOP (Target 0.3%) 0.0 0.0 0.0 0.0 0.00

q4-1 BILLETS DEFECT (Target 0.1%) 24.0 0.0 36.0 60.0 4.17
QUALITY
q4
(0.2%)
q4-2 QUALITY SAMPLING (Target 0.1%) 0.0 0.0 0.0 0.0 0.00

q5 TOTAL DOWN TIME (Target 14%) 50.0 55.0 56.0 161.0 11.18 Process 4 20th st. REG changed and Hot sampling done at I-and Fmill

r1 HOLIDAY TIME 0.0 0.0 0.0 0.0 0.00 Billet Defect 36 Bar fault between 18th,19ht,20th st. due to deffective billet, at that time 11th,12th,14th,18th st. roll changed 15th,17th st. pass changed
THESE ARE
NOT
r2 PDB DOWN TIME 0.0 0.0 0.0 0.0 0.00 17th st. REG and 19th st. twister changed Hot sampling done at I and F-mill
B Shift

CONSIDERD Process 10
r
IN
AVAILABLE r3 MILL COMMISSIONING 0.0 0.0 0.0 0.0 0.00 Mech 6
Bar not forward at mill entry R-T
TIME
r4 SHUTDOWN TIME 0.0 0.0 0.0 0.0 0.00

s. TOTAL 0.0 0.0 0.0 0.0 0.00

SIGNATURE
 BSRM Mill
DAILY PRODUCTION REPORT
DATE:16/4/2019
BILLET CHARGED BILLET ROLLED HOT OUT MISS ROLL FINISH PRODUCT

SHIFT NO. OF NO. OF COBBLE CHOPPING TOTAL PRODUCT PRODUCT NO. OF PRODUCT
LOT NUMBER BILLET SIZE WEIGHT WEIGHT NO. OF BILLETS WEIGHT % YIELD %
BILLETS BILLETS NUMBERS WEIGHT % NUMBERS WEIGHT % WEIGHT % SIZE GRADE BUNDLES WEIGHT**

ML-JAN-19-1-1 510.0 130x130x12000 813.751 508.0 810.560 2.0 3.191 0.39 0.0 0.000 0.00 0.0 0.000 0.00 0.000 0.00 D. Bar 10mm 500W 207 790.765 97.56
SHIFT - C
0 0.0 0 0.000 0.0 0.0 0.000 0.0 0.0 0.000 0 0 0.000

ML-JAN-19-1-1 43.0 130x130x12000 68.610 43.0 68.610 0.0 0.000 0.00 0.0 0.000 0.00 0.0 0.000 0.00 0.000 0.00 D. Bar 10mm 500W 18 67.127 97.84

SHIFT - A BIS#001 160.0 160x160x12000 382.536 150.0 358.628 4.0 9.563 2.50 0.0 0.000 0.00 6.0 14.345 3.85 14.345 3.85 D. Bar 10mm 500W 90 350.072 93.86

BIS#001 21.0 160x160x12000 50.161 21.0 50.161 0.0 0.000 0.00 0.0 0.000 0.00 0.0 0.000 0.00 0.000 0.00 D. Bar 10mm 500W 13 49.409 98.50

BIS#001 333.0 160x160x12000 795.410 333.0 795.410 0.0 0.000 0.00 0.0 0.000 0.00 0.0 0.000 0.00 0.000 0.00 D. Bar 10mm 500W 198 779.003 97.94
SHIFT - B
BIS#015 25.0 160x160x12000 59.600 24.0 57.216 1.0 2.384 4.00 0.0 0.000 0.00 0.0 0.000 0.00 0.000 0.00 D. Bar 10mm 500W 14 55.000 96.13

TOTAL 1092 2,170.069 1,079.0 2,140.585 7.0 15.139 0.70 0.0 0.000 0.00 6.0 14.345 0.67 14.345 0.67 540 2,091.376 97.05

Sl. No. PARTICULARS SHIFT- C SHIFT- A SHIFT- B TOTAL BREAKDOWN DETAILS

a TOTAL TIME 480 480 480 1440 Delay Booking Head DURATION (mins) REASON OF BREAKDOWN

b TOTAL AVAILABLE TIME 480 480 480 1440 Process 12 20th st. roll changed due to pass broken,I/MILL,F/MILL sampling

c EFFECTIVE MILL RUNNING TIME (b-q) 461 270 469 1200 Process 3 20th st. REG changed due to chips

d MILL EFFICIENCY (c÷b%) 96.04 56.25 97.71 83.33 Elect. 4 Stacker area rotating trolly lever not down

e TOTAL PRODUCTION IN MT 790.765 466.608 834.003 2091.376

f AVG. PRODUCTION PER HOUR (e÷b) 98.846 58.326 104.250 87.141

g PRODUCTIVITY (e÷c) 102.920 103.691 106.695 104.569

h ROLLING MILL SPEED M/S (STAND#20) 12.700 12.700 12.700 12.700

C Shift
i OIL CONSUMPTION IN LITERS 0 0 0 0

j OIL CONSUMPTION PER TON (i÷e) 0.000 0.000 0.000 0.000

3
k GAS CONSUMPTION IN M 25,088 16,231 25,287 66,607

l GAS CONSUMPTION PER TON (k÷e) 31.73 34.79 30.32 31.848

m PDB POWER CONSUMPTION IN KWH 65,520 44,640 70,200 180,360

n DG POWER CONSUMPTION IN KWH 0

o TOTAL (PDB +DG) POWER CONSUMPTION IN KWH 65,520 44,640 70,200 180,360

p POWER CONSUMPTION PER TON (o÷e) 82.86 95.67 84.17 86.24

q BREAK DOWN TIME IN MINUTES SHIFT- C SHIFT- A SHIFT- B TOTAL DOWN TIME % Process 48 10th st. roll change,20th st. REG change & Sampling(21min);14th,15th,17th st. pass,19th st. twister change(27min)

q1 MECHANICAL (Target 3%) 0.0 0.0 3.0 3.0 0.21 Operation 20 Bar not entry 19th st. due to bad slitting.18th st. roll change.(10min) ;Bar not entry 20th st. due to bad slitting(10min)

q2 ELECTRICAL (Target 2%) 4.0 0.0 8.0 12.0 0.83 Process 15 19th st. roll change.

OPERATION DELAY (Target 2.6%) 0.0 147.0 0.0 147.0 10.21 Operation 22 Bar not entry 19th st. due to bad slitting.18th st. roll change.
A Shift

q3-1
PRODUC-
TION
q3 q3-2 PROCESS DELAY (Target 5.9%) 15.0 63.0 0.0 78.0 5.42 Operation 30 Bar stuck at 18th st. looper right side.
( TARGET
8.8%)
q3-3 WORKSHOP (Target 0.3%) 0.0 0.0 0.0 0.0 0.00 Operation 30 Bar stuck at 18th st. looper right side

q4-1 BILLETS DEFECT (Target 0.1%) 0.0 0.0 0.0 0.0 0.00 Operation 40 Bar stuck at 18th st. looper then 18th st. MSL roll gap & 17th st. roll cross adjust.
QUALITY
q4
(0.2%) 1st st. water line adjust.
q4-2 QUALITY SAMPLING (Target 0.1%) 0.0 0.0 0.0 0.0 0.00 Operation 5

q5 TOTAL DOWN TIME (Target 14%) 19.0 210.0 11.0 240.0 16.67 Elect. 8 11th st. motor delayed alarm due to over temperature

r1 HOLIDAY TIME 0.0 0.0 0.0 0.0 0.00 Mech 3 Tying machine fault.
THESE ARE
NOT
r2 PDB DOWN TIME 0.0 0.0 0.0 0.0 0.00
B Shift

CONSIDERD
r
IN
AVAILABLE r3 MILL COMMISSIONING 0.0 0.0 0.0 0.0 0.00
TIME
r4 SHUTDOWN TIME 0.0 0.0 0.0 0.0 0.00

s. TOTAL 0.0 0.0 0.0 0.0 0.00

SIGNATURE
 BSRM Mill
DAILY PRODUCTION REPORT
DATE:17/4/2019
BILLET CHARGED BILLET ROLLED HOT OUT MISS ROLL FINISH PRODUCT

SHIFT NO. OF NO. OF COBBLE CHOPPING TOTAL PRODUCT PRODUCT NO. OF PRODUCT
LOT NUMBER BILLET SIZE WEIGHT WEIGHT NO. OF BILLETS WEIGHT % YIELD %
BILLETS BILLETS NUMBERS WEIGHT % NUMBERS WEIGHT % WEIGHT % SIZE GRADE BUNDLES WEIGHT**

BIS#001 360.0 160x160x12000 859.903 360.0 859.903 0.0 0.000 0.00 0.0 0.000 0.00 0.0 0.000 0.00 0.000 0.00 D. Bar 10mm 500W 221 845.442 98.32
SHIFT - C
0 0.0 0 0.000 0.0 0.0 0.000 0.0 0.0 0.000 0 0 0.000

BIS#001 246.0 160x160x12000 587.601 240.0 573.269 6.0 14.332 2.44 0.0 0.000 0.00 0.0 0.000 0.00 0.000 0.00 D. Bar 10mm 500W 150 561.682 97.98
SHIFT - A
BIS#001 24.0 160x160x12000 57.414 24.0 57.414 0.0 0.000 0.00 0.0 0.000 0.00 0.0 0.000 0.00 0.000 0.00 D. Bar 10mm 500W 15 56.553 98.50

BIS#001 341.0 160x160x12000 815.761 341.0 815.761 0.0 0.000 0.00 0.0 0.000 0.00 0.0 0.000 0.00 0.000 0.00 D. Bar 10mm 500W 210 804.957 98.68

SHIFT - B BIS#015 13.0 160x160x12000 31.010 13.0 31.010 0.0 0.000 0.00 0.0 0.000 0.00 0.0 0.000 0.00 0.000 0.00 D. Bar 10mm 500W 7 26.050 84.00

HOTOUT 7.0 160x160x12000 16.731 7.0 16.731 0.0 0.000 0.00 0.0 0.000 0.00 0.0 0.000 0.00 0.000 0.00 D. Bar 10mm 500W 5 17.099 102.20

TOTAL 991 2,368.420 985.0 2,354.088 6.0 14.332 0.61 0.0 0.000 0.00 0.0 0.000 0.00 0.000 0.00 608 2,311.783 98.20

Sl. No. PARTICULARS SHIFT- C SHIFT- A SHIFT- B TOTAL BREAKDOWN DETAILS

a TOTAL TIME 480 480 480 1440 Delay Booking Head DURATION (mins) REASON OF BREAKDOWN

b TOTAL AVAILABLE TIME 480 480 480 1440 Process 3 Hot sampling done at I and F-mill and 20th st. REG changed

c EFFECTIVE MILL RUNNING TIME (b-q) 477 360 476 1313

d MILL EFFICIENCY (c÷b%) 99.38 75.00 99.17 91.18

e TOTAL PRODUCTION IN MT 845.442 618.235 848.106 2311.783

f AVG. PRODUCTION PER HOUR (e÷b) 105.680 77.279 106.013 96.324

g PRODUCTIVITY (e÷c) 106.345 103.039 106.904 105.641

h ROLLING MILL SPEED M/S (STAND#20) 12.700 12.700 12.700 12.700

i OIL CONSUMPTION IN LITERS 0 0 0 0 C Shift

j OIL CONSUMPTION PER TON (i÷e) 0.000 0.000 0.000 0.000

k GAS CONSUMPTION IN M3 24,604 19,419 25,557 69,580

l GAS CONSUMPTION PER TON (k÷e) 29.10 31.41 30.13 30.098

m PDB POWER CONSUMPTION IN KWH 70,560 54,720 69,480 194,760

n DG POWER CONSUMPTION IN KWH 0

o TOTAL (PDB +DG) POWER CONSUMPTION IN KWH 70,560 54,720 69,480 194,760

p POWER CONSUMPTION PER TON (o÷e) 83.46 88.51 81.92 84.25

q BREAK DOWN TIME IN MINUTES SHIFT- C SHIFT- A SHIFT- B TOTAL DOWN TIME % Operation 10 18th st. entry guide funnel fall down

q1 MECHANICAL (Target 3%) 0.0 0.0 0.0 0.0 0.00 Process 35 9th,11th,12th,16th,18th,20th st. roll & 14th,15th,17th st. pass also 19th st. twister guide changed. Hot sampling done.

q2 ELECTRICAL (Target 2%) 0.0 0.0 0.0 0.0 0.00 Operation 30 18th st. delivery knockout with bar that time, S#18 roll changed.

OPERATION DELAY (Target 2.6%) 0.0 55.0 0.0 55.0 3.82 Operation 15 Bar stuck at 18th st. looper.
A Shift

q3-1
PRODUC-
TION
q3 q3-2 PROCESS DELAY (Target 5.9%) 3.0 65.0 4.0 72.0 5.00 Process 15 17th st. roll changed.
( TARGET
8.8%)
q3-3 WORKSHOP (Target 0.3%) 0.0 0.0 0.0 0.0 0.00 Process 15 F/M checked.

q4-1 BILLETS DEFECT (Target 0.1%) 0.0 0.0 0.0 0.0 0.00
QUALITY
q4
(0.2%)
q4-2 QUALITY SAMPLING (Target 0.1%) 0.0 0.0 0.0 0.0 0.00

q5 TOTAL DOWN TIME (Target 14%) 3.0 120.0 4.0 127.0 8.82 Process 4 9th to 16th st. sampling & 20th st. REG changed

r1 HOLIDAY TIME 0.0 0.0 0.0 0.0 0.00

THESE ARE
NOT
r2 PDB DOWN TIME 0.0 0.0 0.0 0.0 0.00
B Shift

CONSIDERD
r
IN
AVAILABLE r3 MILL COMMISSIONING 0.0 0.0 0.0 0.0 0.00
TIME
r4 SHUTDOWN TIME 0.0 0.0 0.0 0.0 0.00

s. TOTAL 0.0 0.0 0.0 0.0 0.00

SIGNATURE
 BSRM Mill
DAILY PRODUCTION REPORT
DATE:18/4/2019
BILLET CHARGED BILLET ROLLED HOT OUT MISS ROLL FINISH PRODUCT

SHIFT NO. OF NO. OF COBBLE CHOPPING TOTAL PRODUCT PRODUCT NO. OF PRODUCT
LOT NUMBER BILLET SIZE WEIGHT WEIGHT NO. OF BILLETS WEIGHT % YIELD %
BILLETS BILLETS NUMBERS WEIGHT % NUMBERS WEIGHT % WEIGHT % SIZE GRADE BUNDLES WEIGHT**

BIS#001 57.0 160x160x12000 136.359 57.0 136.359 0.0 0.000 0.00 0.0 0.000 0.00 0.0 0.000 0.00 0.000 0.00 D. Bar 10mm 500W 36 136.108 99.82
SHIFT - C
SML#001 286.0 160x160x12000 689.332 283.0 682.101 3.0 7.231 1.05 0.0 0.000 0.00 0.0 0.000 0.00 0.000 0.00 D. Bar 10mm 500W 178 671.167 98.40

SML#001 194.0 160x160x12000 467.589 194.0 467.589 0.0 0.000 0.00 0.0 0.000 0.00 0.0 0.000 0.00 0.000 0.00 D. Bar 10mm 500W 121 455.639 97.44
SHIFT - A
ML-JAN-19-1-1 6.0 130x130x12000 9.580 5.0 7.983 0.0 0.000 0.00 0.0 0.000 0.00 1.0 1.597 16.67 1.597 16.67 Sq. Bar 12mm SG-415 5 0.000 0.00

ML-JAN-19-1-1 4.0 130x130x12000 6.387 4.0 6.387 0.0 0.000 0.00 0.0 0.000 0.00 0.0 0.000 0.00 0.000 0.00 D. Bar 22mm 500W 1 3.861 60.45

SHIFT - B BIS#001 50.0 160x160x12000 119.420 50.0 119.420 0.0 0.000 0.00 0.0 0.000 0.00 0.0 0.000 0.00 0.000 0.00 D. Bar 22mm 500W 31 121.139 101.44

SML#010 174.0 160x160x12000 422.484 174.0 422.484 0.0 0.000 0.00 0.0 0.000 0.00 0.0 0.000 0.00 0.000 0.00 D. Bar 22mm 500W 104 409.616 96.95

TOTAL 771 1,851.149 767.0 1,842.322 3.0 7.231 0.39 0.0 0.000 0.00 1.0 1.597 0.09 1.597 0.09 476 1,797.530 97.48

Sl. No. PARTICULARS SHIFT- C SHIFT- A SHIFT- B TOTAL BREAKDOWN DETAILS

a TOTAL TIME 480 480 480 1440 Delay Booking Head DURATION (mins) REASON OF BREAKDOWN

b TOTAL AVAILABLE TIME 480 401 480 1361 Process 6 20th st. REG changed ,I/MILL,F/MILL sampling

c EFFECTIVE MILL RUNNING TIME (b-q) 460 275 320 1055 Elect. 11 Double billet discharge from furnace

d MILL EFFICIENCY (c÷b%) 95.83 68.58 66.67 77.52 Process 3 Mill checking

e TOTAL PRODUCTION IN MT 807.275 455.639 534.616 1797.530

f AVG. PRODUCTION PER HOUR (e÷b) 100.909 68.175 66.827 79.245

g PRODUCTIVITY (e÷c) 105.297 99.412 100.241 102.229

h ROLLING MILL SPEED M/S (STAND#20) 12.700 11.025 9.500 11.075

i OIL CONSUMPTION IN LITERS 0 0 0 0 C Shift

j OIL CONSUMPTION PER TON (i÷e) 0.000 0.000 0.000 0.000

k GAS CONSUMPTION IN M3 24,836 15,225 17,063 57,124

l GAS CONSUMPTION PER TON (k÷e) 30.77 33.41 31.92 31.779

m PDB POWER CONSUMPTION IN KWH 68,040 45,720 45,720 159,480

n DG POWER CONSUMPTION IN KWH 0

o TOTAL (PDB +DG) POWER CONSUMPTION IN KWH 68,040 45,720 45,720 159,480

p POWER CONSUMPTION PER TON (o÷e) 84.28 100.34 85.52 88.72

q BREAK DOWN TIME IN MINUTES SHIFT- C SHIFT- A SHIFT- B TOTAL DOWN TIME % Process 90 Section change of D- 4x10mm to SQ-3x12mm.

q1 MECHANICAL (Target 3%) 0.0 25.0 0.0 25.0 1.84 Mech 25 4th st. hydraulic line damage.

q2 ELECTRICAL (Target 2%) 11.0 11.0 0.0 22.0 1.62 Plant Shutdown 15 Bar came out from 20th st. due to modification for SQ- 3x12mm

OPERATION DELAY (Target 2.6%) 0.0 0.0 0.0 0.0 0.00 Elect. 11 R/mill 5th,7th st. carbon brush open.
A Shift

q3-1
PRODUC-
TION
q3
( TARGET q3-2 PROCESS DELAY (Target 5.9%) 9.0 90.0 150.0 249.0 18.30 Plant Shutdown 64 Production slow due to modification for SQ-3x12.
8.8%)
q3-3 WORKSHOP (Target 0.3%) 0.0 0.0 10.0 10.0 0.73

q4-1 BILLETS DEFECT (Target 0.1%) 0.0 0.0 0.0 0.0 0.00
QUALITY
q4
(0.2%)
q4-2 QUALITY SAMPLING (Target 0.1%) 0.0 0.0 0.0 0.0 0.00

q5 TOTAL DOWN TIME (Target 14%) 20.0 126.0 160.0 306.0 22.48 Process 140 Section changed from SQ bar 3*12mm to Re-bar 22mm.At that time,15th,16th,19th,20th st. roll changed

r1 HOLIDAY TIME 0.0 0.0 0.0 0.0 0.00 Workshop 10 Extra time due to 19th st. latch hole jam.
THESE ARE
NOT
r2 PDB DOWN TIME 0.0 0.0 0.0 0.0 0.00 20th st. pass changed with E/guide.
B Shift

CONSIDERD Process 10
r
IN
AVAILABLE r3 MILL COMMISSIONING 0.0 0.0 0.0 0.0 0.00
TIME
r4 SHUTDOWN TIME 0.0 79.0 0.0 79.0 5.49

s. TOTAL 0.0 79.0 0.0 79.0 5.49

SIGNATURE
 BSRM Mill
DAILY PRODUCTION REPORT
DATE:19/4/2019
BILLET CHARGED BILLET ROLLED HOT OUT MISS ROLL FINISH PRODUCT

SHIFT NO. OF NO. OF COBBLE CHOPPING TOTAL PRODUCT PRODUCT NO. OF PRODUCT
LOT NUMBER BILLET SIZE WEIGHT WEIGHT NO. OF BILLETS WEIGHT % YIELD %
BILLETS BILLETS NUMBERS WEIGHT % NUMBERS WEIGHT % WEIGHT % SIZE GRADE BUNDLES WEIGHT**

BIS#001 329.0 160x160x12000 785.780 326.0 778.615 1.0 2.388 0.30 2.0 4.777 0.61 0.0 0.000 0.00 4.777 0.61 D. Bar 22mm 500W 197 765.554 97.72
SHIFT - C
0 0.0 0 0.000 0.0 0.0 0.000 0.0 0.0 0.000 0 0 0.000

BIS#001 115.0 160x160x12000 274.665 115.0 274.665 0.0 0.000 0.00 0.0 0.000 0.00 0.0 0.000 0.00 0.000 0.00 D. Bar 22mm 500W 70 269.761 98.21

SHIFT - A BIS#001 52.0 160x160x12000 124.196 52.0 124.196 0.0 0.000 0.00 0.0 0.000 0.00 0.0 0.000 0.00 0.000 0.00 Sq. Bar 12 mm SG-415 61 120.221 96.80

SML#010 78.0 160x160x12000 189.389 76.0 184.533 1.0 2.428 1.28 0.0 0.000 0.00 1.0 2.428 1.30 2.428 1.30 Sq. Bar 12 mm SG-415 88 179.478 96.00

SML#010 337.0 160x160x12000 818.260 335.0 813.403 2.0 4.856 0.59 0.0 0.000 0.00 0.0 0.000 0.00 0.000 0.00 Sq. Bar 12 mm SG-415 391 798.647 98.19
SHIFT - B
0 0 0.0 0.0 0.000 0.0 0.0 0.000 0 0 0.000

TOTAL 911 2,192.290 904.0 2,175.413 4.0 9.673 0.44 2.0 4.777 0.22 1.0 2.428 0.111 7.205 0.330 807 2,133.661 97.76

Sl. No. PARTICULARS SHIFT- C SHIFT- A SHIFT- B TOTAL BREAKDOWN DETAILS

a TOTAL TIME 480 480 480 1440 Delay Booking Head DURATION (mins) REASON OF BREAKDOWN

b TOTAL AVAILABLE TIME 465 430 469 1364 Process 10 19th,20th st. pass change.

c EFFECTIVE MILL RUNNING TIME (b-q) 448 358 440 1246 Process 7 20th st. pass change.

d MILL EFFICIENCY (c÷b%) 96.34 83.26 93.82 91.35 PDB 15 Voltage fluctuation with bar.

e TOTAL PRODUCTION IN MT 765.554 569.460 798.647 2133.661

f AVG. PRODUCTION PER HOUR (e÷b) 98.781 79.460 102.172 93.856

g PRODUCTIVITY (e÷c) 102.530 95.440 108.906 102.745

h ROLLING MILL SPEED M/S (STAND#20) 9.500 9.425 9.350 9.425

i OIL CONSUMPTION IN LITERS 0 0 8,712 8,712 C Shift

j OIL CONSUMPTION PER TON (i÷e) 0.000 0.000 10.908 4.083

3
k GAS CONSUMPTION IN M 23,483 17,238 12,156 52,876

l GAS CONSUMPTION PER TON (k÷e) 30.67 30.27 15.22 24.782

m PDB POWER CONSUMPTION IN KWH 57,960 46,440 58,680 163,080

n DG POWER CONSUMPTION IN KWH 0

o TOTAL (PDB +DG) POWER CONSUMPTION IN KWH 57,960 46,440 58,680 163,080

p POWER CONSUMPTION PER TON (o÷e) 75.71 81.55 73.47 76.43

q BREAK DOWN TIME IN MINUTES SHIFT- C SHIFT- A SHIFT- B TOTAL DOWN TIME % PDB 50 Previous shift break down continued for PDB;3rd,5rh st. roll changed

q1 MECHANICAL (Target 3%) 0.0 2.0 0.0 2.0 0.15 Process 70 Section changed from D- 22mm to SQ-12*12 mm, at that time 6th,7th,8th,9th,11th,12th,15th,16th,17th,18th,19th,20th st. roll changed

q2 ELECTRICAL (Target 2%) 0.0 0.0 0.0 0.0 0.00 Mech 2 Cold shear last layer forwarding problem

OPERATION DELAY (Target 2.6%) 0.0 0.0 0.0 0.0 0.00

A Shift

q3-1
PRODUC-
TION
q3 q3-2 PROCESS DELAY (Target 5.9%) 17.0 70.0 29.0 116.0 8.50
( TARGET
8.8%)
q3-3 WORKSHOP (Target 0.3%) 0.0 0.0 0.0 0.0 0.00

q4-1 BILLETS DEFECT (Target 0.1%) 0.0 0.0 0.0 0.0 0.00
QUALITY
q4
(0.2%)
q4-2 QUALITY SAMPLING (Target 0.1%) 0.0 0.0 0.0 0.0 0.00

q5 TOTAL DOWN TIME (Target 14%) 17.0 72.0 29.0 118.0 8.65 Process 3 9th st. to 16th st. hot sampling done.

r1 HOLIDAY TIME 0.0 0.0 0.0 0.0 0.00 Process 12 19th & 20th st. pass changed.
THESE ARE
NOT
r2 PDB DOWN TIME 15.0 50.0 0.0 65.0 4.51 Furnace off due to gas pressure low.
B Shift

CONSIDERD Plant Shutdown 11

r
IN
AVAILABLE r3 MILL COMMISSIONING 0.0 0.0 0.0 0.0 0.00 Process 14
19th & 20th st. pass changed.
TIME
r4 SHUTDOWN TIME 0.0 0.0 11.0 11.0 0.76

s. TOTAL 15.0 50.0 11.0 76.0 5.28

SIGNATURE
 BSRM Mill
DAILY PRODUCTION REPORT
DATE:20/4/2019
BILLET CHARGED BILLET ROLLED HOT OUT MISS ROLL FINISH PRODUCT

SHIFT NO. OF NO. OF COBBLE CHOPPING TOTAL PRODUCT PRODUCT NO. OF PRODUCT
LOT NUMBER BILLET SIZE WEIGHT WEIGHT NO. OF BILLETS WEIGHT % YIELD %
BILLETS BILLETS NUMBERS WEIGHT % NUMBERS WEIGHT % WEIGHT % SIZE GRADE BUNDLES WEIGHT**

SML#010 290.0 160x160x12000 704.140 290.0 704.140 0.0 0.000 0.00 0.0 0.000 0.00 0.0 0.000 0.00 0.000 0.00 Sq. Bar 12 mm SG-415 338 690.355 98.04
SHIFT - C
SML#001 61.0 160x160x12000 147.026 61.0 147.026 0.0 0.000 0.00 0.0 0.000 0.00 0.0 0.000 0.00 0.000 0.00 Sq. Bar 12 mm SG-415 72 146.939 99.94

SML#001 128.0 160x160x12000 308.515 128.0 308.515 0.0 0.000 0.00 0.0 0.000 0.00 0.0 0.000 0.00 0.000 0.00 Sq. Bar 12 mm SG-415 151 308.732 100.07
SHIFT - A
ML-JAN-19-1-1 34.0 130x130x12000 54.247 34.0 54.247 0.0 0.000 0.00 0.0 0.000 0.00 0.0 0.000 0.00 0.000 0.00 Sq. Bar 12mm SG-415 27 53.738 99.06

ML-JAN-19-1-1 279.0 130x130x12000 445.142 276.0 440.355 2.0 3.191 0.72 0.0 0.000 0.00 1.0 1.595 0.36 1.595 0.36 D. Bar 08mm 500W 114 431.756 97.69
SHIFT - B
0 0 0.0 0.0 0.000 0.0 0.0 0.000 0 0 0.000

TOTAL 792 1,659.070 789.0 1,654.283 2.0 3.191 0.19 0.0 0.000 0.00 1.0 1.595 0.10 1.595 0.096 702 1,631.520 98.53

Sl. No. PARTICULARS SHIFT- C SHIFT- A SHIFT- B TOTAL BREAKDOWN DETAILS

a TOTAL TIME 480 480 480 1440 Delay Booking Head DURATION (mins) REASON OF BREAKDOWN

b TOTAL AVAILABLE TIME 480 210 400 1090 Process 15 15th,19th,20th st. pass change.

c EFFECTIVE MILL RUNNING TIME (b-q) 465 210 390 1065

d MILL EFFICIENCY (c÷b%) 96.88 100.00 97.50 97.71

e TOTAL PRODUCTION IN MT 837.294 362.470 431.756 1631.520

f AVG. PRODUCTION PER HOUR (e÷b) 104.662 103.563 64.763 89.808

g PRODUCTIVITY (e÷c) 108.038 103.563 66.424 91.917

h ROLLING MILL SPEED M/S (STAND#20) 9.350 11.175 13.000 11.175

C Shift
i OIL CONSUMPTION IN LITERS 0 0 0 0

j OIL CONSUMPTION PER TON (i÷e) 0.000 0.000 0.000 0.000

3
k GAS CONSUMPTION IN M 24,947 10,336 12,184 47,467

l GAS CONSUMPTION PER TON (k÷e) 29.80 28.52 28.22 29.094

m PDB POWER CONSUMPTION IN KWH 60,120 27,000 48,240 135,360

n DG POWER CONSUMPTION IN KWH 0

o TOTAL (PDB +DG) POWER CONSUMPTION IN KWH 60,120 27,000 48,240 135,360

p POWER CONSUMPTION PER TON (o÷e) 71.80 74.49 111.73 82.97

PDB power shutdown and that time section changed from SQ- 12mm to D-8mm.At that time 5th,7th,8th,9th,10th,11th,12th,16th,17th,18th,19th,20th st. roll & 15th st.
q BREAK DOWN TIME IN MINUTES SHIFT- C SHIFT- A SHIFT- B TOTAL DOWN TIME % PDB 270
pass changed
q1 MECHANICAL (Target 3%) 0.0 0.0 0.0 0.0 0.00

q2 ELECTRICAL (Target 2%) 0.0 0.0 5.0 5.0 0.46

A Shift

q3-1 OPERATION DELAY (Target 2.6%) 0.0 0.0 5.0 5.0 0.46
PRODUC-
TION
q3 q3-2 PROCESS DELAY (Target 5.9%) 15.0 0.0 0.0 15.0 1.38
( TARGET
8.8%)
q3-3 WORKSHOP (Target 0.3%) 0.0 0.0 0.0 0.0 0.00

q4-1 BILLETS DEFECT (Target 0.1%) 0.0 0.0 0.0 0.0 0.00
QUALITY
q4
(0.2%)
q4-2 QUALITY SAMPLING (Target 0.1%) 0.0 0.0 0.0 0.0 0.00

q5 TOTAL DOWN TIME (Target 14%) 15.0 0.0 10.0 25.0 2.29 PDB 80 Previous shift delay continue due to PDB.

r1 HOLIDAY TIME 0.0 0.0 0.0 0.0 0.00 Operation 5 Bar Stuck at 18th st. looper
THESE ARE
NOT
r2 PDB DOWN TIME 0.0 270.0 80.0 350.0 24.31 Mill entry R/T section -01 motor drive fault.
B Shift

CONSIDERD Elect. 5
r
IN
AVAILABLE r3 MILL COMMISSIONING 0.0 0.0 0.0 0.0 0.00
TIME
r4 SHUTDOWN TIME 0.0 0.0 0.0 0.0 0.00

s. TOTAL 0.0 270.0 80.0 350.0 24.31

SIGNATURE