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Performance Review- Feb17

Barun Banerjee

Presentation to GM(WB)
[10-03-2017]
TSL Board Tata Steel Slide 2

MoM of Jan Review


Complian
2 QSE
ce

2.1 QSE to strive for achieving ABP target Chief QSE Info

All areas (working as well as non-working) of both mines to be checked


Manager Survey and
out for any unsafe slope/strata and a comprehensive report to be given
2.2
to GM (WB). Corrective action to be taken by mines accordingly.
Planning Next Review Complied
Head Operations
(pending point)

QSE wage cost found to be too high even after the transfer of some of
2.3 its equipment and manpower to QAB. Current year manpower found to Chief QSE Next Review A/C
be higher than last years. To be cross checked. (pending point)

PR to be done for outsourcing of QSE outpit dump lifting. QSE to


2.4
provide water supply in the area
Chief QSE Next Review Done

High OB production and low RC production at QSE to be analyzed and


2.5 Chief QSE Next Review
explanation for the same to be provided
Tata Steel Slide

Performance Overview
Quarry-SE Feb16 (Feb17) FY'17- Till Month
KPI UOM Act AOP Act Gap AOP Act Gap
Raw Coal- Total Ton 2.34 1.82 2.45 +0.63 22.58 19.08 -3.49

Raw Coal- High wall Ton 0 0.42 0.27 -0.15 4.54 2.44 -2.11
Seam Mix Compliance-AOP/
% 37/93 85-90 56/79 -29/-6 85-90 83/74 -2/-11
Revised
OB Cum 6.38 8.40 7.76 -0.64 97.66 85.93 -14.27
Re-handling+ Eco Dump+ HW
% 51 45 37 -8 45 23 -22
Loose
Excavator Availability % 83 82 85.4 +3.4 82 86.4 +4.4

Excavator Productivity Cum/Hr 647 640 602 -38 629 593 -36

Excavator Utilization % 67 61 55.6 -5.4 63 55.2 -8

Ex Run Hrs/ Ex - OB Hrs 6.23 6.5 6.15 -0.35 6.5 6.18 -0.3

RD Availability % 80 81 83.2 +2.2 79 81.14 +2

RD Productivity Cum/Hr 125 150 174 +24 139 161 +22

RD Utilization% % 48 50 45.9 -4 55 41.8 -13

RD Run Hrs/RD/ Day-OB Hrs 5.43 6 5.4 -0.6 6 5.45 -0.5

RD Load/ Trip Ton 83 82.5 80.2 -2.3 82.5 81.7 -0.8


TSL Board Tata Steel Slide 4

High-wall Highwall Plan Highwall Actual

XI X IX VIII VII VI XI X IX VIII VII VI Dif


Ma Ma
y 43300 43300 y 13550 13550 -29750

Jun 11701 33969 45670 Jun 16689 16689 -28981

Jul 45670 45670 Jul 36690 36690 -8980


Au Au
g 45670 45670 g 10855 4030 14885 -30785
Se Se
p 12514 33156 45670 p 23625 23625 -22045

Oct 45670 45670 Oct 38445 1785 40230 -5440


No No
v 3716 41954 45670 v 13290 13290 -32380

Dec Quarry-SE
7940 39730 47670 Feb17
Dec Cum.
(FY'17- Till
14755 Month)
14755 -32915

Jan KPI
47670 UOM
AOP
47670 Act
Jan Gap AOP
9590 33363 Act 42953Gap
-4717
Raw Coal- Total Ton 41670 26170 14510 454330 243827 210503
Feb 15578 26092 41670 Feb 22198 1476 3486
27160 -14510
HWM availability % 70 62 8 70 41 29 -
Utilization 10013 13619
% 45433
60 38 22 60 13781 72 24382 12
21050
15578 81702 43446 8 7 77269 0 0 0 22198 11066 9 72744 7 3
Idle Hrs. 60 202 142 540 1035 495
Planned Maint. Hrs. 72 106 34 720 698 22
Unplanned B/Down Hrs. 108 96 12 1080 3440 2430
MTBF Hrs. 40 31 9 40 25.4 14.6
MTTR Hrs. 20 40 20 20 50 30
Seam Compliance Tata Steel Slide 5

Seam-wise Coal AOP February


Compliance- AOP AOP Actual Dif
XI 15578 22198 6620
X 26092 26875 783
IX 0 0 0
VIII 60000 83576 23576
VII 0 110716 110716
VI 0 1425 1425
V 80000 0 -80000
181670 244790 63120

AOP Nov '16 Dec'16 Jan17 Feb17 Total


AOP Actual Dif AOP Actual Dif AOP Actual Dif AOP Actual Dif AOP Actual Dif
XI 0 12290 12290 0 0 0 0 0 0 15578 22198 6620 73578 118439 44861
X 35000 13205 -21795 52940 91205 38265 47670 29740 -17930 26092 26875 783 292682 242035 -50647
IX 3716 0 -3716 39730 25150 -14580 36046 11360 -24686 0 0 0 145239 107656 -37583
VIII 41954 0 -41954 0 0 0 0 106430 106430 60000 83576 23576 395490 367210 -28280
VII 115008 15050 -99958 20000 14755 -5245 0 33363 33363 0 110716 110716 646205 463670 -182535
VI 34622 44145 9523 80000 2490 -77510 69255 26070 -43185 0 1425 1425 454405 434865 -19540
V 0 21420 21420 20000 12085 -7915 5000 0 -5000 80000 0 -80000 250000 174245 -75755

230300 106110 -124190 212670 145685 -66985 157971 206963 48992


181670 244790 63120 2257599 1908120 -349479
TSL Board Tata Steel Slide 6
AOP February
Bench-wise AOP Actual Dif
OB XI 0 90202 90202
Compliance X 0 135400 135400
IX 0 35288 35288
VIII 0 33643 33643
VII 125000 68256 -56744
VI 0 349 349
V 337378 123061 -214317
Loose 77680 289994 212314
Old Dump 300000 0 -300000
HW Re. 0 0 0
840058 776193 -63865

OB-
Nov Dec Jan Feb Total
AOP
AOP Actual Dif AOP Actual Dif AOP Actual Dif AOP Actual Dif AOP Actual Dif
XI 0 105700 105700 0 13011 13011 0 120114 120114 0 90202 90202 243000 1272027 1029027
X 60000 422098 362098 89278 561045 471767 0 96556 96556 0 135400 135400 1223194 1924713 701519
IX 0 0 0 200000 103829 -96171 57030 164685 107655 0 35288 35288 501262 437247 -64015
VIII 0 0 0 0 0 77973 69073 -8900 0 33643 33643 234111 108953 -125158
VII 0 0 0 0 0 0 66437 66437 125000 68256 -56744 778270 454015 -324255
VI 200000 75725 -124275 113649 10933 -102716 0 65761 65761 0 349 349 980321 1072148 91827
V 65000 157540 92540 200000 102068 -97932 300000 64854 -235146 337378 123061 -214317 1447138 1331116 -116022
Loose 54600 242620 188020 101292 68660 -32632 73081 218156 145075 77680 289994 212314 908427 1769909 861482
Old
Dump 320000 0 -320000 320000 56433 -263567 320000 0 -320000 300000 0 -300000 2730000 130211
HW Re. 0 0 0 0 0 0 0 0 0 0 0 720000 92753 -627247
699600 1003683 304083 1024219 915979 -108240 828084 865636 37552 840058 776193 -63865 9765723 8593092 1427158
Raw Coal Over-burden

Oct16 Feb17 Oct16 Feb17


Plan Actual Dif Plan Actual Dif
XI SE 0 22198 22198 XI SE 0 90202 90202
X SE 0 26875 26875 X SE 140000 135400 -4600
IX SE 0 0 0 IX SE 0 35288 35288
VIII SE 45670 83576 37906 VIII SE 0 33643 33643
VII SE 180000 110716 -69284 VII SE 0 68256 68256
VI SE 0 1425 1425 VI SE 75000 349 -74651
V SE 0 0 0 V SE 0 123061 123061
225670 244790 19120 Loose 70000 289994 219994
Old Dump/Outpit 320000 0 -320000
641120 776193 135073

Raw Coal Over-burden

Aug'16 Dec'16 Aug'16 Dec'16


Plan Actual Dif Plan Actual Dif
XI SE 0 0 0 XI SE 0 13011 13011
X SE 9500 91205 81705 X SE 0 561045 561045
IX SE 9650 25150 15500 IX SE 0 103829 103829
VIII SE 83352 0 -83352 VIII SE 45000 0 -45000
VII SE 110670 14755 -95915 VII SE 270000 0 -270000
VI SE 0 2490 2490 VI SE 0 10933 10933
V SE 0 12085 12085 V SE 0 102068 102068
213172 145685 -67487 Loose 202920 68660 -134260
Old Dump/Outpit 250000 56433 -193567
Sep'16 Jan'17 767920 915979 148059
Plan Actual Dif
XI SE 0 0 0 Sep'16 Jan'17
X SE 0 29740 29740 Plan Actual Dif
IX SE 0 11360 11360 XI SE 0 120114 120114
VIII SE 54514 106430 51916 X SE 150000 96556 -53444
VII SE 163156 33363 -129793 IX SE 0 164685 164685
VI SE 0 26070 26070 VIII SE 0 69073 69073
V SE 0 0 0 VII SE 183270 66437 -116833
217670 206963 -10707 VI SE 40531 65761 25230
V SE 50000 64854 14854
Loose 221199 218156 -3043
Old Dump 250000 0 -250000
895000 865636 -29364
Area Wise Compliance (OB) : Apr17- Feb17
XI OB X OB IX OB VIII OB

Plan Actual Dif Plan Actual Dif Plan Actual Dif Plan Actual Dif

Ashpond Area
Air Strip Existing Face
Bathantand Existing Face 0 0 0 353916 439359 85443 191315 89600 -101715 81138 6237 -74901
Rabidas Tola Existing

Face
Bathantand Ext Face 243000 1309377 1066377 430000 968457 538457 52917 107224 54307 75000 102716 27716
Rabidas Tola Ext Face 439278 519998 80720 257030 199973 -57057 77973 0 -77973
Highwall OB+ Loose

243000 1309377 1066377 1223194 1927814 704620 501262 396797 -104465 234111 108953 -125158

Rehandling/ Coal
VII OB VI OB V OB Old / Eco Dump
Shifting

Plan Actual Dif Plan Actual Dif Plan Actual Dif Plan Actual Dif Plan Actual Dif
25457 23887
Ashpond Area 0 254572
2
284760 523631
1

Air Strip Existing 40114 35916


0 179128 179128 760308 652378 630717 -21661
Face 1 7
- -
Bathantand - 38864
443270 226246 75554 31309 225000 0 22500
Existing Face 217024 9
5 0
- -
Rabidas Tola 19053
0 19053 285000 0 28500
Existing Face 1
1 0
Bathantand Ext
210000 150709 -59291 0 74700 74700
Face
Rabidas Tola Ext -
125000 0
Face 125000
-
Highwall OB+Loose 2730000 73778 1628427 1900808 272381
Area Wise Compliance (Coal) : Apr-Feb17

XI Coal X Coal IX Coal VIII Coal

Plan Actual Dif Plan Actual Dif Plan Actual Dif Plan Actual Dif
Ashpond Area
Air Strip Existing Face 0 3770 3770
Bathantand Existing Face 106480 81010 -25470 56097 71146 15049 163352 173434 10082
Rabidas Tola Existing

Face
Bathantand Ext Face 58000 96241 38241 24500 64930 40430 9650 25150 15500 72000 96840 24840
Rabidas Tola Ext Face 80000 96095 16095 36046 11360 -24686 60000 82100 22100
Highwall Coal 15578 0 -15578 81702 0 -81702 43446 22198 -21248 100138 11066 -89072

73578 96241 22663 292682 242035 -50647 145239 129854 -15385 395490 367210 -28280

VII Coal VI Coal V Coal

Plan Actual Dif Plan Actual Dif Plan Actual Dif


Ashpond Area 17529 170246 152717 100000 101405 1405
Air Strip Existing Face 0 56485 56485 125730 189695 63965 90000 72840 -17160
Bathantand Existing
350008 160376 -189632 149255 3940 -145315 35000 0 -35000
Face
Rabidas Tola Existing
84622 0 -84622 25000 0 -25000
Face
Bathantand Ext Face 160000 107230 -52770
Rabidas Tola Ext Face
Highwall Coal 136197 137819 1622 77269 72744 -4525
646205 461910 -184295 454405 436625 -17780 250000 174245 -75755
Area Wise Compliance Area Wise Compliance (OB) :
(Coal) : Apr-Feb17 Apr17- Feb17

Summary Summary
Plan Actual Dif Plan Actual Dif
Ashpond Area 117529 271651 154122 Ashpond Area 284760 778203 493443
Air Strip Existing Air Strip Existing
215730 322790 107060 1053519 1570153 516634
Face Face
Bathantand Bathantand
860192 489906 -370286 1683288 836996 -846292
Existing Face Existing Face
Rabidas Tola Rabidas Tola
475531 0 -475531
Existing Face
109622 0 -109622 Existing Face
Bathantand Ext
Bathantand Ext 1010917 2713183 1702266
324150 390391 66241 Face
Face
Rabidas Tola Ext
Rabidas Tola Ext 899281 719971 -179310
176046 189555 13509 Face
Face
Highwall OB+
Highwall Coal 454330 243827 -210503 4358427 1974586 -2383841
Loose
2257599 1908120 -349479
9765723 8593092 -1172631
Plan : March17

Coal Mar OB Mar P


XI 0 Outpit Dump 0
XI SUB 10000 Solid +Rehand 700000
X 10000 Highwall
IX 30000 150000
Rehandling
IX + VIII 0 Total Projected 850000
VIII 100000 Total Planned
VII 50000 844080
AOP
VI 0
V 20000
Total Mines 220000
HIGHWALL VII 30000
Total Projected 250000
Total Planned
244248
AOP

RT
BT
AS
TSL Board Tata Steel Slide 13

Excavators- Feb-17

Feb-17

Total OB Productivi
GOD Sch UnSch Avail Avail Run No. of
Downti Util% CuM Run ty MTBF MTTR
Hours Maint Maint Hrs % Hours Failures
me Hours (Cum/Hr
Ex-01 672 9 44.5 53.5 618.5 92.0 492.9 79.7 217865 365.7 614 2 246 22.3

Ex-02 672 1.5 34.5 36 636.0 94.6 232.8 36.6 110740 222.8 523 4 58 8.6

Ex-03 672 27 69.66 96.66 575.3 85.6 380.3 66.1 115325 202.9 601 9 42 7.7

Ex-05 672 281.8 9.58 291.38 380.6 56.6 300.7 79.0 172660 290.7 617 4 75 2.4

PL-01 672 19.6 60.08 79.68 592.3 88.1 318 53.7 135243 215.7 661 18 18 3.3
PL-02 672 18 13.6 31.6
640.4 95.3 189 29.5 24360 46.2 527 14 17 1.0
3443.
4032 356.9 231.92 588.82 85.4 1913.7 55.6 776193 1344 602 51 34 4.5
2
TSL Board Tata Steel Slide 14

Productivity and Run Hours OB Feb17

Rear Dumpers Excavators


RD Run Productivity Cycle Average No. of RDs RD Nos. RD Run Hrs/ Productivit
Trips Cum Ex Run Hrs
Hrs (Cum/Hr) Time Deployed deployed Shift y (Cum/Hr)
XI OB+
2608 91280 853.3 107 19.6 5.3 179 4.77 190.6 479
Outpit
16642
X OB 4755 1065.6 156 13.4 4.3 189 5.64 278.9 597
5
IX OB 1686 59010 355.8 166 12.7 3.9 66 5.39 101.5 581
VIII
941 32935 182.3 181 11.6 4.1 33 5.52 51.4 641
OB/Shale
15970
VII OB 4563 889.6 180 11.7 4.5 158 5.63 252.7 632
5
VI OB
11151
V OB 3186 415.6 268 7.8 2.2 74 5.62 189.8 588
0
Loose/ 15725
4493 685.8 229 9.2 3.4 122 5.62 248.8 632
Dev/Hwall 5
Coal
474 16590 110.7 150 14.0 3.0 24 4.61 31.7 523
Shifting
4558.7 174 12.0 3.8 845 5.39 1345.4 591

Excl Running
Maint 602
RD Utilization% FY17

KPI YTD FY'17 Plan Actual


100 100

90 90
Good
80 80

70 70

60 60
RD Utilization (%)

55

RD Utilization (%)
50 50
41.8
40 40

30 30

20 20

10 10

0 0

15
RD Availability% FY17

100 100
KPI YTD FY'17 Plan Actual
90 90
81.14
80
79 Good 80

70 70

60 60
RD Availability (%)

RD Availability (%)
50 50

40 40

30 30

20 20

10 10

0 0

16
RD Productivity FY17

200 200

180 180
161
160 160
139
Good
RD Productivity (Cum/Hr)

140 140

RD Productivity (Cum/Hr)
120 120

100 100

80 80

60 60
KPI YTD FY'17 Plan Actual
40 40

20 20

0 0

17
Ex Utilization FY17

80 80
KPI YTD FY'17 Plan Act

70 70
63 Good
60 60
55.2

50 50
Ex Utilization (%)

40 40

Ex Utilization (%)
30 30

20 20

10 10

0 0

18
Ex Availability% FY17

100 100
KPI YTD FY'17 Plan Actual
90 86.3 90
82
80 Good 80

70 70

60 60
Ex Availability (%)

50 50

Ex Availability (%)
40 40

30 30

20 20

10 10

0 0

19
Ex Productivity FY17

700 700
KPI YTD FY'17 Plan Actual
629
593 Good
600 600
Ex Productivity (Cum/Hr)

Ex Productivity (Cum/Hr)
500 500

400 400

300 300

200 200

100 100

0 0

20
Drill Utilization FY17

50 50
KPI YTD FY'17 Plan Act
45 45

40 40
Good
35 35
Drill Utilization (%)

29.41
30 30

Drill Utilization (%)


25 25
21
20 20

15 15

10 10
OB Face
5 constraint 5

0 0

21
Drill Availability% FY17

100 KPI YTD FY'17 Plan Act 100


90.8
90 90

80 80
73.0
Good
70 70

60 60
Ex Availability (%)

Drill Availability (%)


50 50

40 40

30 30

20 20

10 10

0 0

22
End of Presentation

23
Hourly RD Availability- Feb17

2nd 10th 11th 12th 13th 14th 15th 16th 17th 18th 19th 20th 21st 22nd 23rd 24th
1st Hr 3rd Hr 4th Hr 5th Hr 6th Hr 7th Hr 8th Hr 9th Hr
Hr Hr Hr Hr Hr Hr Hr Hr Hr Hr Hr Hr Hr Hr Hr Hr
5.00- 6.00- 7.00- 8.00- 9.00- 10.00- 11.00- 12.00- 1.00- 2.00- 3.00- 4.00- 5.00- 6.00- 7.00- 8.00- 9.00- 10.00- 11.00- 12:00- 1:00- 2:00- 3:00- 4:00-
6.00A 7.00A 8.00A 9.00A 10.00 11.00 12.00 1.00P 2.00P 3.00P 4.00P 5.00P 6.00P 7.00P 8.00P 9.00P 10.00 11.00 12.00 1:00A 2:00A 3:00A 4:00A 5:00A
M M M M AM AM PM M M M M M M M M M PM PM AM M M M M M

1st 2 3.5 3.67 4 3.75 4.5 5 5 4 5 6.5 5.5 4 4 5 4 2 2.5 2.5 3.5 3 2 3 2

2nd 1 3 3 3 3 3.5 2.5 2 4 5 5 6.5 7.5 5 6 4 3 2.5 2 2.25 3.5 3 3 3

3rd 3 4.5 6.5 7.5 9 6.25 6.75 6 3 4.5 5 5 4 4 5 5 2 2 2 3 3 3.5 3 3

4th 3 3.5 5 5.17 5 4.5 5.5 7 5 6.75 9.5 10 10.25 7.5 5.5 5 3 3.5 4 4 3 3 3 3

5th 4 5 7 5.5 5.75 6 6 7 3 3.5 4 5.25 3.25 3 2.5 2 3 3.5 3.5 3 3 3 3 3

6th 2 3 3.5 3.5 3.5 3.5 7.5 8.75 4 3.5 6 7 6.25 8.25 5.75 4 2 2 3.25 3 3 2 2 2

7th 3 3 5 6 6 5.5 6 5 1 2 2 3 2.5 2 2 2 1 2 4 3.5 1 1 1 1

B 8th 1 2.5 3 2.25 2.5 2.5 4 4.75 4 4 6 5.5 4.5 6 5.5 4.5 3 3 3 3 2 2 2 2

r 9th 5.5 6 6 6 5 4 4.5 5 6 6.75 8 8.25 6.75 7 7.75 6 7 6.5 6.5 5.5 5.75 5 5.5 6

e 10th 4 6 5.5 5 4.5 4.5 4 2 3 5 5.75 5 5.5 6.5 7 5 4 4 4 4 3 3 5.5 6

a 11th 3 4 4.5 5 3.5 4 4 4 3 2.75 3 4 3.75 4.5 2.5 2 3 4 5 5 5 4 3 3

k 12th 3 4 4.75 4.5 3.5 3.5 2.75 3 1 1.5 1.5 2.5 3 2.5 2.5 3.25 1 1 1 1.5 1.5 1 1 1.25

D 13th 3 4.5 4.5 4.25 3.75 4.5 6.5 8 4 5 5.5 5 5 4.5 5.5 3 1 1 1.5 1 0.5 1.5 1.5 0

o 14th 2 2.25 3.5 5.75 4.25 6.5 7 6 4 4.5 5.5 5 4.5 2.75 1.25 2 0 0 0 0 0 0.5 0 1

w 15th 1 1.75 2.25 4 4 3.5 4.5 5.75 4 5 5 6 4.5 5 4 4 5 5 5 4.75 4 4 4


24
4
1st and Last load- Feb
Average 1st Loadtime Average Last Loadtime

Date A B C A B C

1st 05:37:00 14:00:00 21:52:00 12:32:00 20:33:00 04:34:00

2nd 05:42:00 14:10:00 21:56:00 12:32:00 20:26:00 04:32:00

3rd 05:49:00 14:01:00 21:45:00 12:36:00 20:34:00 04:32:00

4th 05:40:00 13:54:00 21:55:00 12:32:00 20:28:00 04:33:00

5th 05:52:00 13:53:00 22:01:00 12:31:00 20:34:00 04:33:00

6th 06:00:00 15:20:00 21:55:00 12:30:00 20:33:00 04:35:00

7th 05:15:00 14:00:00 21:42:00 12:29:00 20:35:00 04:35:00

8th 05:59:00 14:20:00 21:35:00 12:36:00 20:36:00 04:45:00

9th 05:45:00 13:50:00 21:37:00 12:35:00 20:35:00 04:42:00

10th 05:25:00 14:05:00 21:44:00 12:31:00 20:34:00 04:30:00

11th 05:48:00 14:15:00 21:48:00 12:25:00 20:34:00 04:45:00

12th 05:51:00 14:21:00 21:40:00 12:30:00 20:32:00 04:27:00

13th 05:49:00 14:38:00 21:51:00 12:35:00 20:34:00 04:31:00

14th 05:50:00 14:27:00 21:47:00 12:33:00 20:36:00 04:30:00

15th 05:48:00 13:56:00 21:24:00 12:35:00 20:34:00 04:31:00

16th 05:49:00 14:04:00 21:46:00 12:36:00 20:34:00 04:22:00 25


Major Stoppages/ Delays Bench-wise
X OB& Highwall/Loose/ Old
XI OB IX OB VIII S VII OB VI OB V OB CS
RT Dump
Marching 13.50 16.1 6.8 3 13.3 7.9 5 6.9 72.50
Face Pb/Toe In Face/ Faults 6 10.5 1.5 2 20.00
Ex-02 Idle: Face Pb/ Mat Pb/ Uneven Face 276 276.00
Sidecasting/ Edge Cleaning 53.3 17.8 13 6.5 16.5 1 7.5 115.60
Face congestion/ Space Constraint 6 6.00
Cable Handling/ Field Sw Sftg 12 12.00
HEMM B/d or entangled in face/ road/
1.5 4.67 6.17
Blasted Material on Road
Face height more/ Rising Face 5 2 7.00
Boulder Handling/ Excess boulders in face 9.5 8 3 3 6 1 30.50
Face Preparation 10.32 3.5 5 1.5 3.5 13.75 1 0.5 39.07
Material Shortage 11.75 7.5 2.5 8.5 25 12 67.25
Hoisting/Digging Slow/poor- PL 4 4 8.00
Narrow Face/ Face Congestion 8.5 8 16.50
Training of Mining Assoc. 0.00
Unsafe Cond- Boulder/ DYsliding/ N
4.5 3 3 10.50
Highwall
No Power-Ex-02/ Cable Pb/Tripping 2.5 2.50
Development Jobs/Ramp Makng 16.9 3.7 6 1.3 7.5 2 4 3.3 14 58.70
Approach Road/Ramp Pb/ Road
Making/high Gradient of ramp/ Narrow 8.25 1.75 1 11.00
Road width
RD/ Ex Manpower Shortage 2 3 5.00
RD Shortage 10 3 13.00
Ramp, Road Skiddy/Watery Face 25.1 25.10
Compact/Hard to dig/Unblasted material 6 3 3 12.00
Dust Pb 5 1.75 2 2 4.75 15.50
Diesel Shortage 1 8.25 3 7 19.25
Union Meeting/ Gm Meeting/ Canteen Pb
2.5 2.50
etc
Poor illumination/ Light Pb 3 3.00

450.27 99.10 42.80 8.80 60 2 102.92 34.05 54.65 854.64


26
Stoppages/ Delays: Excavator wise
Ex-01 Ex-02 Ex-03 Ex-04 Ex-05 PL
Marching 19.5 12.8 12.9 7.7 13.4 6.2 72.5
Face Pb/Toe In Face/ Faults 6 6 8 20
Ex-02 Idle: Face Pb/ Mat Pb/ Uneven Face 276 276
Sidecasting/ Edge Cleaning 36.5 55.2 3 1.5 13.4 6 116
Face congestion/ Space Constraint 6 6
Cable Handling/ Field Sw Sftg 12 12
HEMM B/d or entangled in face/ road/ Blasted Material
4.67 1.5 6.17
on Road
Face height more/ Rising Face 7 7
Boulder Handling/ Excess boulders in face 6 9.5 6 9 30.5
Face Preparation 8.5 10.32 13.75 4.5 2 39.1
Material Shortage 18 10.75 29.5 2.5 6.5 67.3
Hoisting/Digging Slow/poor- PL 8 8
Narrow Face/ Face Congestion 5 8.5 3 16.5
Unsafe Cond- Boulder/ DYsliding/ N Highwall 4.5 3 3 10.5
No Power-Ex-02/ Cable Pb/Tripping 2.5 2.5
Development Jobs/Ramp Makng 5 16.9 13.1 6.7 17 58.7
Approach Road/Ramp Pb/ Road Making/high Gradient
4.25 3.75 3 11
of ramp/ Narrow Road width
RD/ Ex Manpower Shortage 2 3 5
RD Shortage 10 3 13
Ramp, Road Skiddy/Watery Face 9 16.1 25.1
Compact/Hard to dig/Unblasted material 3 3 6 12
Dust Pb 4.75 5 2 3.75 15.5
Diesel Shortage 19.25 19.3
Union Meeting/ Gm Meeting/ Canteen Pb etc 2.5 2.5
Poor illumination/ Light Pb 3 3
130.2 450.5 110.1 9 64 90.7 855
27
Delay
Blasting Delays Time
(Min)
1st Feb 1:35 PM 35
2nd Feb 1:30 PM 30
3rd Feb 1:30 PM 30
4th Feb 1:30 PM 30
5th Feb 1:25 PM 25
6th Feb 2:45 PM 105
7th Feb 1:40 PM 40
8th Feb 1:35 PM 35
9th Feb 1:30 PM 30
10th Feb 1:45 PM 45
11th Feb 1:45 PM 45
12th Feb 2:20 PM 80
13th Feb 2:00 PM 60
14th Feb 2:10 PM 70
15th Feb 1:45 PM 45
16th Feb 2:00 PM 60
17th Feb N.B. 0
18th Feb 1:45 PM 45 28
Load Hauled per trip
OB Coa
Averag Averag
Date A B C
e
A B
l C
e
1st 78.70 80.20 80.03 79.64 74.76
75.25 74.26
2nd 75.59 82.24 79.62 79.22 75.15
73.84 75.48 76.12
3rd 77.52 75.42 73.16 75.37 69.67
70.35 69.67 68.99
4th 80.15 79.89 80.85 80.30 67.33
67.4 72.01 62.57
5th 81.45 73.25
80.8 78.93 84.63 71.75 71.8 76.21
6th 79.04 71.19
71.84 80.64 84.65 69.92 71.93 70.72
7th 78.39 73.62
77.59 75.68 81.91 74.31 73.48 73.06
8th 82.61 69.34
84.7 81 82.13 75.26 65.63 67.12
9th 80.94 63.16 76.96 61.25 67.12
82.58 80.15 80.08
10th 76.16 72.15
78.55 73.89 76.04 73.67 67.69 75.08
11th 78.60 69.68
79.57 72.59 83.63 67.71 69.7 71.63
12th 77.98 68.70
76.36 77.17 80.42 74.14 68.12 63.84
13th 80.72 69.36
81.2 77.3 83.8 73.3 66.2 68.6
14th 81.0 83.0 80.0 81.31 70.2 73.9 72.3 72.15

15th 77.8 83.2 81.0 80.67 74.9 70.4 66.3 70.51

16th 81.5 81.8 82.4 81.89 74.1 65.1 73.5 70.94


29
17th 79.9 78.2 83.8 80.65 75.3 75.7 65.6 72.17
TSL Board Tata Steel Slide 30
Burz Pump No-1 Burz Pump No-2
Pump Run Hours

A B C A B C
1st 7 6 12.9 1st 7 6 12.9
2nd 7 3 6 15.4 2nd 6 6 12.3
3rd 2 2 6 9.2 3rd 7 3 6 15.8
4th 6 5 6 16.8 4th 6 2 6 14.2
5th 3.8 5.5 6 15.3 5th 0.4 5.5 6 11.9
6th 2 5 4.4 11.4 6th 1.2 4.9 4.4 10.5
7th 1.2 2.4 0 3.6 7th 2.1 4.8 5.4 12.3
8th 0.0 0.0 0.0 0 8th 5.3 5.8 6.2 17.3
9th 0.0 2.3 0.0 2.3 9th 3.5 2.2 6.1 11.8
10th 1.1 4.4 6.1 11.6 10th 3.7 3.8 6.1 13.6
11th 1.7 4.1 6.5 12.3 11th 1 3.2 6.4 10.6
12th 3.9 3.5 2.3 9.7 12th 0.3 3.4 4.2 7.9
13th 1.7 1.7 13th 0
14th 0 14th 2 2.1
15th 0 15th 1 4 4.5
16th 0 16th 1 0.7
0
17th 0 17th
18th 0 18th 0
19th 0 19th 0
20th 0.0 2.5 1.1 3.6 20th 0
21st 1.90 3.10 5.80 10.8 21st 0.00 0.00 0.00 0
22nd 4.60 4.20 5.70 14.5 22nd 0
23rd 2.10 2.1 23rd 0
24th 1.30 1.3 24th 0
25th 0 25th 0
26th 0 26th 0
27th 0 27th 1.00 1
28th 3.00 2.20 5.2 28th 2.50 2.5
45.4 48.5 65.8 159.7 45.30 41.7 74.9 161.9

Daily 1.6 1.7 2.4 5.7 1.6 1.5 2.7 5.8


TSL Board Tata Steel Slide 31

Excavator Manpower deployed OB Coal

A B C A B C

1st 4 4 3 0 0 1

2nd 2 3 2 1 0 1

3rd 3 3 3 1 1 1

4th 3 3 3 1 1 1

5th 2 3 3 2 1 1

6th 3 4 3 1 1 1

7th 3 3 3 1 1 1

8th 3 3 3 1 2 1

9th 3 3 3 1 1 1

10th 3 3 3 1 1 1

11th 2 4 2 1 1 1

12th 4 4 3 1 1 1

13th 4 2 3 1 2 1

14th 3 3 3 1 1 1

15th 4 2 2 1 2 1

16th 2 3 2 1 1 1
Excavator Run Hrs/ Manshift (Hrs)
Variance: 0.35+Hrs

Target 6.5 Hrs


Face Constraints

Material shortage
Downtime
HEMM

6.15 Loss

0.25 0.08 0.02 0

R1 R2
Rear Dumper Run Hrs/ Manshift:
Face Pb/ Material
HEMM Downtime

Target 6 Hrs
Shortage

5.40
Loss

0.49 0.11 0.00


TSL Board Tata Steel Slide 33

Breakdown Loss of Excavators & RDs

1st 2nd 3rd 4th 5th 6th 7th 8th 9th 10th 11th 12th 13th 14th 15th
TOTAL NO OF RD Operator deployed 45 37 45 35 21 25 30 32 40 38 46 35 31 45 35
B/D occurance of RD 17 14 17 15 13 18 9 13 14 16 11 10 16 14 10
Total loss due to RD switch 5.61 4.62 5.61 4.95 4.29 5.94 2.97 4.29 4.62 5.28 3.63 3.3 5.28 4.62 3.3
Total down time loss in RD due to Ex 12.75 10.5 5.64 0 0.66 0 0 10 0 35.32 1 0 2.33 0 0
Total EX operator deployed in daily 13 9 7 7 6 7 9 8 11 10 10 0 10 11 8
Total RD operator deployed in daily 45 37 45 35 21 25 30 32 40 38 46 35 31 45 35
Total loss of hours of ex down in which Ex operator deployed 9.25 11 1.41 0 0.33 0 0 2.92 0.25 10.83 1.5 0 2.33 1 0

Loss per men per shift in RD 0.12 0.12 0.12 0.14 0.20 0.24 0.10 0.13 0.12 0.14 0.08 0.09 0.17 0.10 0.09
Loss per men per shift due to Ex 0.71 1.22 0.20 0.00 0.06 0.00 0.00 0.37 0.02 1.08 0.15 0.10 0.23 0.09 0.00
Total loss per man shift in RD 0.84 1.35 0.33 0.14 0.26 0.24 0.10 0.50 0.14 1.22 0.23 0.35 0.40 0.19 0.09
Total loss per manshift Ex 0.71 1.22 0.20 0.00 0.06 0.00 0.00 0.37 0.02 1.08 0.15 0.25 0.23 0.09 0.00

16t
h 17th 18th 19th 20th 21st 22nd 23rd 24th 25th 26th 27th 28th Feb'17

TOTAL NO OF RD Operator deployed 35 39 45 44 47 41 30 35 37 34 32 29 42 Hds

B/D occurance of RD 16 17 29 25 34 17 13 14 14 13 9 11 11 No
5.2
Total loss due to RD switch 8 5.61 9.57 8.25 11.22 5.61 4.29 4.62 4.62 4.29 2.97 3.63 3.63 hrs

Total down time loss in RD due to Ex 0 0 11 7.5 2 0 3 0 0 16 0 6 0 hrs

Total EX operator deployed in daily 8 8 12 11 11 8 8 7 8 8 10 10 11 Hds

Total RD operator deployed in daily 35 39 45 44 47 41 30 35 37 34 32 29 42 Hds

Total loss of hours of ex down in which Ex operator deployed 0 0 7.95 6.08 1.32 1.25 1.5 4 0.83 8 7.5 12 1.5 hrs


0.1
Loss per men per shift in RD 5 0.14 0.21 0.19 0.24 0.14 0.14 0.13 0.12 0.13 0.09 0.13 0.09 hrs
Tata Steel Slide

Excavator Productivity (Cum/Hr)


Variance: 35 Cum/Hr

Development Jobs

Coal Shifting Loss


Long Marching
602

18 18 2 0
R1 R5 R6
R2 R3 R4

AOP
R1: Frequent Development Jobs/ Side casting for face opening/ widening/ Road Prep/ Face
Prep
R2: Long Marching of Excavators : 72.5 Hrs
R3: Shifting of coal 32 Hrs @ 474 CuM / Hr Loss Calc
TSL Board Tata Steel Slide 35

Excavator Productivity

UOM Fig.
Total OB Cum 776193
Excavator Run Hours - OB ( For productivity) Hrs 1289.4
Productivity Cum/Hr 602

(1) Marching- Long Hrs 72.5


Pdvty w.o. (1) Cum/Hr 638

(2) Development Jobs/ Sidecasting/ Face Preparation Hrs 78.5


Pdvty w.o. (2) Cum/Hr 641
Pdvty w.o. (1) & (2) Cum/Hr 682

(3) Coal Shifting Loss Hrs 5.78


Pdvty w.o. (3) Cum/Hr 605
Pdvty w.o. (1) (2)& (3) Cum/Hr 685

(4) Ramp Skiddy/ Watery Face Hrs 25.1


Pdvty w.o. (3) Cum/Hr 614
Pdvty w.o. (1) (2)& (3)(4) Cum/Hr 701
TSL Board Tata Steel Slide 36

High-wall
Q-SEB : High Wall Outage Feb17

Total GODs Hours = 672 Hrs

Avail. Hour(Contr.) = 431Hrs Down Hours = 241 Hrs


( 64.1 % ) (35.9% )

Hour (Opn.)= 207.5 Hrs. (30.9 %)

Planned Outage = 117.5Hrs Unplanned Outage = 123.5 Hrs


(48.8% ) (51.2% )
HIGH WALL MINER AVAILABILITY - FEB 17)

Availability (%) Category 1 Plan Actual Availability (%)


Better
100 100

57.4 64.1
80 70
70 70 70 70 70 70 70 70 70 70 70 80
61
60
35 41 41 60
40 25 60.1 16 40
20 46.9 20
0 0
FY'17(P) FY'17(A) May'16 Jun'16 Jul'16 Aug'16
13.9
Sep'16 Oct'16 Nov'16 Dec'16 Jan'17 Feb'17 Mar'17

Causes for Deviation(s) Feb17 Plan Actual Gap


1. Augur Pedestal head Bolt Broken
Availability(in%) 70 64.1 -5.9

Action Plan Responsibility Target Date

Corrective Action CBL Immediate


Periodic Checking started

Preventive Action:
Periodic Checking
HIGH WALL MINER MTBF - FEB 17)
Bette

31
62.4
60 60 60
82
14 40 40 40 40 MTBF
MTBF 25 25 25 25 17 21
7 11 12
3
17 22.8 Category 1 Plan
FY'17(P) FY'17(A) May'16 Jun'16 July'16 Aug'16 Sep'16 Oct'16 Nov'16 Dec'16 Jan'17 Feb'17 Mar'17

Causes for Deviation(s)


Plan Actual Gap
1. Belly Chain Problem -1 time
2 Augur Pedestal bolt broken - 2 time
3 Communication Cable Damage 2 Time MTBF 40 21 -19
4 Pump Problem 2 Time
5 Safety & EMS-3

Action Plan Responsibility Target Date


Immediate Action
1. Periodic checking of pedestal bolts status started CBL Immediate
DAY WISE AVAILABILITY OF HIGH WALL FEB 17

30

Hours

20

24 24 24 24 24 24 24 24
10 19
16 16 16 16 15
13 12 13
9 10 9
8 8 8 7
6
4 3 4
0

40
Summary of B/Downs of High wall Feb17

Sl. Description Hrs


No.
1 Mechanical/ Push Beam 49
2 Others/Hydraulic 16
3 Mechanical/Coal Conveyor 15
4 Others/Misc/safety& env. 43.5
5

41
High Wall Performance Analysis Feb17

Hrs
Coal Conveyor; 12%
Hydraulic; 13% Push Beam; 40%

Misc; 35%

300 100%
H
250 75% 100%
o 88% 80%
u 200
60%
r
150 40% Total Down time
s =123.5 Hrs 40%
100
49 44
50 16 15 20%
0 0%
Push Beam Other&EMS Hydraulic Coal conveyor

42
B/Down Frequency Of High Wall - Feb17

10 120.0
100.0
90.0 100.0
8
Frequency Nos.

80.0
6 80.0
6 60.0 Total No. of B/down
= 10 Times 60.0 %
4
40.0
2
2 1 1 20.0

0 0.0
Misc/safety/env Push Beam Coal Conveyor Hydraulic

43
High-wall Coal Production from May to Feb17 ( Tonne)

Potential loss
Due to Idle Hrs.
Potential loss Target
Due to B/D

TPH
Actual Feb=131
243827 Avg=123
164870

41438
4195 0
R1 R2 R3

Quarry-SE Feb17 Cum. (FY'17- Till Month)


KPI UOM AOP Act Gap AOP Act Gap
Idle Hrs. 60 202 142 540 1035 495
Planned Maint. Hrs. 72 106 34 720 698 22
Unplanned B/Down Hrs. 108 96 12 1080 3440 2430
B/D Hours Of High Wall - May16 to Feb17

B/D Hrs BD Cum%


120 1600
1391 99
95 97 98 1400
100 89 92
84 1200
80 74
1000
61
60 800
40 600
40 466
342 400
20 173
96 90 62 200
51 45
0 0
700

45
B/D Frequency Of High Wall - May16 to Feb17

120 1600
1391 B/D Hrs %Cumm. 100
97 99 1400
100 92
87
80 1200
80 75
69 1000
57
60 700 800

40 600
40 466
342 400
20
20 173
96 90 200
62 51 45 24
0 0

46
47
TSL Board Tata Steel Slide 48

OB Shortfall

Actual
Seam Plan (Solid+ Dif Reasons
Loose)
Delay in Approach road
XI 175000 90202 -84798
preparation
X 100000 21612 -78388
Bathantand Loose Handled: 158112 CuM
VIII 0 191755 191755
for approach road preparation
VII 85000 68256 -16744
Total 360000 371825 11825
X 150000 160821 10821 Delay in settlement of Rabidas
IX 50000 60024 10024 Tola; Against Plan of 1st
VIII 40000 0 -40000 Dec17, it was settled on 20
Rabidas Tola Jan17; Delay in top bench
VII 150000 0 -150000 movement slowed down
advancement of lower seams
Total 390000 220845 -169155
VI 0 349 349
Air Strip
V 90000 123061 33061
Total 90000 123410 33410
Plan Actual Dif ( Actual - Plan)
OB- OB- OB-
CuM/ Ton Coal S/R Coal S/R Coal S/R
Solid Solid Solid
Ashpond Area 284760 117529 2.42 778203 271651 2.86 493443 154122 0.44

Air Strip Existing


Face+ Rabidas Tola 1529050 325352 4.70 1570153 322790 4.86 41103 -2562 0.16
Existing Face

Bathantand
1683288 860192 1.96 836996 489906 1.71 -846292 -370286 -0.25
Existing Face
Bathantand Ext
1010917 324150 3.12 2713183 390391 6.95 1702266 66241 3.83
Face
Rabidas Tola Ext
899281 176046 5.11 719971 189555 3.80 -179310 13509 -1.31
Face
5407296 1803269 3.00 6618506 1664293 3.98 1211210 -138976 0.98

49
TSL Board Tata Steel Slide 50

OB Shortfall

Actual
Seam Plan (Solid+ Dif Reasons
Loose)
Delay in Approach road
XI 175000 90202 -84798
preparation
X 100000 21612 -78388
Bathantand Loose Handled: 158112 CuM
VIII 0 191755 191755
for approach road preparation
VII 85000 68256 -16744
Total 360000 371825 11825
X 150000 160821 10821 Delay in settlement of Rabidas
IX 50000 60024 10024 Tola; Against Plan of 1st
VIII 40000 0 -40000 Dec17, it was settled on 20
Rabidas Tola Jan17; Delay in top bench
VII 150000 0 -150000 movement slowed down
advancement of lower seams
Total 390000 220845 -169155
VI 0 349 349
Air Strip
V 90000 123061 33061
Total 90000 123410 33410