Input And Production

Monitoring Department

February 2024
 Content
01 Objective

02 Reform implantation

03 Customer satisfaction

04 Business performances

05 Monitoring and evaluation results of

production units

06 Problem encountered and solution

 Input production monitoring department services

 Measure the Material

Data analytics give
 Material supply for consumption
 Monitoring works production units the recommendation
production units and on production units production units
delivery products BOQ for each products to
and aggregate check the profitability and
for the projects cursers ,asphalt reduce the wastage
plant
 Objectives

 Each production unit can achieve required standard

(production target), optimum utilization of resources and also
minimize cost by controlling raw material consumption for
products and reduced the wastage. INPUT AND
PRODUCTION
 Ensure the delivery of different products MONITORING
produced at input production center at the DEPEARTEMENT
intended time and in accordance to customer
request

 Affording different Inputs for

maximizing productivity
Reform implantation implemented key
01 performance index (KPI)
And the results on 100%
 Digitalization
 Change tools implementation

Implemented Kaizen
02
Applied enterpriser recourse planning(ERP)

Implemented enterpriser
03 recourse planning(ERP)

Implemented ISO 04
 Health and Safety management

Change tools Environmental management system

implementation

Quality management system

 Work order status
We have 572 work orders in number and 362 works on
physical last eight-month 249 work order are complete
and 230 are delivered and 101 works on progress and 221
not stared due to lack of raw material, some of are to give
reagents works and we are lose 496,755,747.39 ETB due
fa e r

to not started these orders.

n

11%
ti s m
io
sa s to
ct
Cu

Delivery ETB 76M

19%
On progress ETB 132M

Not starts ETB 497M 70%

The Finished products not delivered to production units Material Delivered to projects using vehicle's
Item work
Product Quantity Production unit Date
No order
Revenues From vehicles
1 A4 Size frame WP-12 12 pcs wood production u. 2016
4,500,000.00
2 First Aid kit Box WP-12 24 pcs wood production u. 2016
3 Dual purpose cupboard N. A 6 pcs wood production u. 2016
4,000,000.00
3,811,007.78
4 Dual purpose cupboard N. A 4 pcs wood production u. 2016
5 File Cabinet N. A 5 pcs wood production u. 2015
3,500,000.00
6 Wooden door N. A 5 pcs wood production u. 2016

metal production u
3,000,000.00
1 Double bunk metal bed MP-164 4 pcs metal production u. 2016
2 Shoe polish shade MP-103 1 pc metal production u. 2016
2,500,000.00
3 Traffic sign stand N. A 10 pcs metal production u. 2016
4 Fire extinguisher MP-214 24 pcs metal production u. 2016 1,894,069.27
2,000,000.00

Alum. Production 1,346,378.54

u. 1,500,000.00
1,187,031.36
1 Aluminum. Door AP-318 11 pcs Alum. Production u. 2015

19%
2 Aluminum Door AP-215 12 pcs Alum.. Production u. 2016 1,000,000.00
1,348,409.38
3 Aluminum Slide window N. A 30 pcs Alum.. Production u. 2016
4 Aluminum. Kerketo N. A 80 pcs Alum.. Production u. 2016 500,000.00

Traffic sign P.U

-
1 ECC Finishing TS-222 10 pcs Traffic sign P.U 2016 october November december January February

70%
2 Circular sign N.A 5 pcs Traffic sign P.U 2016
3 Head office (facility) TS-303 30 pcs Traffic sign P.U 2016
 Next month those products will be delivered to customer
 Input material delivery and material consumption to production units
1. For Concrete production product units’ total material cost on this month was 42,471,930 ETB used

2. For wood production units 'total materials cost on this month was 319,525.22 ETB used

3. For metal production product units’ total material cost on this month was 434,988.22 ETB used.

4. For traffic sign & road making units total material cost on this month was 16,073 ETB used.

5. For flexi flume unit’s total material cost on this month was 55,115 ETB used

 Totally on February month, for all production units the material cost was 43,297,631.44 ETB used

19%

70%
 Input material consumption of production units
production units Cost of material Financial Execution total cost for production
1 prefab
 Overall material
33,652,547.50 69,096,339.70 49%
2 Aluminum 0 0.00 0%
consumption of the
3 ready mix concrete 17,129,987.76 26,727,672.59 64% production units are
4 HCB 1,852,846.36 2,619,935.75 71% good
5 wood production 37,729.86 233,550.01 16%
6 metal production 161,210.10 1,091,097.72 15%
7 flexi flume 88,233.50 1,018,468.00 9%
8 gypsum production 0.00 0.00 0%
9 traffic sign 15,203.13 0.00 0%
10 checkered block 0.00 0 0%
Total 52,937,758.22 100,787,063.77 53%
69,096,339.70

Input material consumption of production units

19% Cost of material

Financial Execution
33652548

26,727,672.59

70%
17129988

2,619,935.75

1,091,097.72

1,018,468.00
233,550.01
1852846

161210

88234
37730

15203
0.00

0.00

0.00

0.00
0

0
prefab A LU ready mix concrete HCB w ood production metal production flexi flume gyps um production traffic s ign checkerd block
 Financial performances
The Financial plan of the department on this
month 131.8M
Financial execution of the month 120.9M ETB
That is 92% achieve of the plan of the month.
this compare to the previsions month
execution19.3M ETB its increased by 620% Financial Execution
80,000,000.00

70,000,000.00 69,087,343.70
60,000,000.00

50,000,000.00

40,000,000.00

30,000,000.00
26,727,672.59
20,000,000.00

10,000,000.00 1,091,097.72 1,018,468.00 13,585,799.45

2,619,935.75 233,550.01 2,338,689.60 461,799.25 3,811,007.78
0.00 0.00 0.00 0.00 0.00
 Physical performances

The physical plan of the department on this

month 159,803.50 items are produced.
Physical execution of the month 56,291.21
That is 35% achieve of the plan of the month.

Physical Execution
50000
45000 45183
40000
35000
30000
25000
20000
15000
10000
7531
5000
1912 2900 2009 4200
0 0 80 0 8 0 99 168
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Monitoring and Evaluation Results of department

0 02 03 04 05
1

working days Works

and over time Material physical &
Ideal hours consumption financial without work
execution order
execution
 1. Ideal hours in production 1. The prefab production units lack optimal hours.

units working
2. The ready mix concrete production units lack optimal hours
3. Felix flume production units on this month all working hours are use
hours of
appropriately
production units month Ideal hours working hours
4. 184 hours this month, no items were produced in the aluminum production units
1 prefab 184 0 184

0 02 03 04
due to a shortage of raw materials.
2 Aluminum 184 184 0
5. Metal production units It’s advisable if supply of Raw material is Provide as fast
3 ready mix concrete 184 0 184 as possible as to achieve the plan to be perform.28hr loss hours in this production
4 HCB

5 wood production
1 184

184
44

112
140

72
center.
6. The HCB production unit lost 44 hours of work since there were no pumice raw
6 metal production 184 28 156 materials available, and every day, manufacturing begins after 4:30 due to

7 flexi flume 184 0 184 product pickup at that time. And two At the some time machine missed up & all
four machine are not working if always works two machine.
8 gypsum production 184 184 0
7. Wood production center there is 112 ideal hours in this production units on the
9 traffic sign 184 152 32
given month there is two products are coming from ECC Finishing these are 42.7
10 Checkered block 184 184 0
m2 of laminated MDF kitchen Cabinet and 20 m2 of laminated MDF file cabinet.
And also the raw material of these products are covered by the owner due to lack
of raw material.
8. Due to sub-contractor problem checkered block and gypsum production ideal
hours 184
9. Traffic sin and road making production units 152 hours are lost as a result of the
scotch light and aluminum sheet scarcity.
 2. working days and over time execution
overtime  The prefab production unit physically produce 405 pc of elements on
execution working days execution
Saturday afternoon and Sunday (over time work). Also financially they
production units physical execution physical execution TOTAL
execute 14,904,565.67 ETB.
prefab 405 1,507.00 1912

0 02 03 04
 Ready mix concrete production units the overtime execution 563.58meter
Aluminum 0 0 0
cube different grade of concrete produced executed 5,217,394.19 ETB and
ready mix concrete 563.58 2,335.93 2899.51

1
working day production 2335.95-meter cube different grade of concrete
HCB 7,100.00 38,083.00 45183
produced 21,510,278.40 ETB on this month.
wood production 0 0 0
metal production 312 1697 2009  HCB production units overtime production is 7,100 different size HCB are
flexi flume 0 4200 4200
executed 545,959.2 ETB and working day production 38,083 different size
gypsum production 0 0 0 HCB produced executed 2,073,976.55 ETB.
traffic sign 0 8 8
paving block 0 0 0  Metal production units the anchor nut production in overtime 312 pcs and
executed 175,344.00 ETB and working day production of different
elements 1697 executed from this 915,753.72 ETB.
3. Material consumption production units The production units have good total material consumption costs.
total cost for Comparing it to the selling price
production units Cost of material Financial Execution
production
 Prefab production center the material cost are 49% of the
1 prefab 33,652,547.50 69,096,339.70 49%
2 Aluminum 0 0.00 0%
selling prices
3

4
ready mix concrete
HCB 0
17,129,987.76
1,852,846.36
26,727,672.59
2,619,935.75 02 64%

71% 03
selling prices
04
 Ready mix concrete production material cost are 64% of the

1
5 wood production 37,729.86 233,550.01 16%
6 metal production 161,210.10 1,091,097.72
 Wood production units material cost are 16% of the selling
15%
7 flexi flume 88,233.50 1,018,468.00 9% prices
8 gypsum production 0.00 0.00 0%
 Metal production units material cost are 15% of the selling
9 traffic sign 15,203.13 0.00 0%
10 checkered block 0.00 0 0%
prices
Total 52,937,758.22 100,787,063.77 53%  Flexi flume production units material cost 9% of the selling
prices
 HCB production units material cost 71% of selling prices
 Traffic sign and road making production units produced 8pcs
different elements about without work order so that 15,203.15
ETB loss for material.
 Physical & financial execution  The monthly physical goal for the prefab production unit is 1578

Physical Financial
pieces, however because they might be generating 1912 pieces of
production units Physical plan PP VS PE Financial plan FP VS FE
Execution Execution prefab elements and 202 curb stones, they only meet 121% of the
1 prefab 1,578.00 1912 121% 41,664,233.00 69,087,343.70 166% plan. Additionally, although their monthly budget was 41,664,233
2 Aluminum 1,056.00 0 0% 16,754,871.00 0.00 0% ETB, they could have executed 69,087,343.70 ETB, resulting in a

0 02
ready mix 166% success rate.
3 2094.4 138% 5,448,131.00 26,727,672.59 491%
concrete 2,899.51
4 HCB 105,330.90 45,183.00 43% 12,404,210.00 2,619,935.75 21%  The ready mix concrete production unit typically produces m3

5 wood production
1 202
79.70
39% 3,955,450.00 233,550.01 6%
2899.51 different classes of ready mix throughout this reporting
month. 1411.71 m3 of them are internal, while 1487.8 m3 are
6 metal production 5,148.00 2,009.00 39% 4,364,296.00 1,091,097.72 25% external. Achieve the financial and physical goals at 100% in
7 flexi flume 4,166.70 4,200.00 101% 439,398.00 1,018,468.00 232% general. And between the general production and external and
gypsum internal consumption have 56.66 m3 (2%) difference. This
8 23,000.00 0.00 0% 1,660,736.00 0.00 0%
production difference is the first standard mix design and currently concrete
9 traffic sign 740 8 1% 2,847,261.00 0.00 0% consumption rate difference
10 checkered block 16,487.50 0.00 0% 946,237.00 0 0%
Total 159,803.50 56,291.21 35% 90,484,823.00 100,778,067.77 111%  Flexi flume production units they execute in percentage as 101%
and 232% physically and financially respectively as per plan.
Physical plan was 4166.67 and financial plan was 439,398.00ETB. .
Canvas Production is not available, because there is no demand for
this element.
 Physical & Financial Execution CPC

 The metal production units the expected Physical execution for this month was 5148 pcs and they achieve 2009 Pcs and expected financial execution was
4,364,296.00birr and they achieve 1,091,097.72 birr When expressed in percentage they executed 39% and 25% physically and financially respectively; because of this
we could have lose 3,273,198.28 ETB. The metal production units as known there are Products which has to be produced continuously without any gap which is used for
Building construction input elements such: - as Anchor Nut, Barrel, Wedge and plate but, there is shortage of Raw material as to produce as per plan.

0 02
 HCB production units achieve 43% and 21% of the plan, respectively, with a physical and financial plan of 105,330 pcs and 12,404,210birr, and 45,183 goods and

1
2,619,935.75ETB for implementation. The reasons for the execution are minimal; just two of the four HCB machines are in use for the entire month.
 Wood's financial development for the month is extremely poor in comparison to their plan, which calls for 233,550.01 birr to be executed but 3,955,450 birr in total,
meaning that 5.905% of the plan can be achieved and 94.095% of losses can occur.
 Units for producing aluminum Due to a shortage of aluminum accessory slide connectors, L-connectors, horizontal frames, L & T profiles, rubber gaskets, hinges, and
roller doubles, there is no production this month. Due to these factors, 16,754,871 ETB is lost.
 Due to subcontractor issues, the gypsum and checkered block production units aren't producing any money this month, resulting in a loss of 2,606,973.70 ETB.

Physical Execution
Financial Execution vs plan

69,087,343.70
50000
Financial plan Financial Execution
45000 45183
40000

41,664,233.00
35000

30000

26,727,672.59
25000

16,754,871.00

12,404,210.00
20000

5,448,131.00

4,364,296.00
3,955,450.00
2,619,935.75

2,847,261.00
1,091,097.72

1,018,468.00

1,660,736.00
15000

233,550.01

946,237.00
439,398.00
10000
4200
2009

0.00

0.00

0.00

0.00
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ALU ready mix concrete HCB wood production metal production flexi flume gypsum production traffic sign checkerd block
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 Material consumption production units
The production units have good total material consumption costs Comparing it to the selling price

 Prefab production center the material cost are 49% of the selling prices
 Ready mix concrete production material cost are 64% of the selling prices
 Wood production units material cost are 16% of the selling prices
0
 Metal production units material cost are 15% of the selling prices
 Flexi flume production units material cost 9% of the selling prices
02
1
 HCB production units material cost 71% of selling prices
 Traffic sign and road making production units produced 8pcs different elements about without work order so that
15,203.15 ETB loss for material.
Material consumption production units
69,096,339.70

26,727,672.59
33652548

17129988

2,619,935.75 Cost of material

1,091,097.72

1,018,468.00
Financial Execution

233,550.01
1852846

161210

88234
37730

15203
0.00

0.00

0.00

0.00
0

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Works without work orders

Products Quantity Generally, due to this the production

0
Traffic sign and road
making
015,203.15
2 ETB center losses 24,194.58 ETB for
material cost . And man power

1
1 Rectangle traffic sign
2 Rectangular scotch
1(1*1.5)m
4(2*0.9)m
machinery cost are losses for this these
products.

3 Rectangular scotch 1(0.9*0.66)m Without a work order, production units

4 Rectangular scotch 2 (1*0.5)m did not produce the products. because
wood product production of works without payment cause
8,991.43 ETB bankruptcy(loss) of the production
center
centers.
1 Circular table top 12(80)cm
2 Coffee holder (rockobot) 1(107*61*50)cm
TOTAL 21
 Works without work orders
Production unit product description unit size Quantity

Rectangle traffic sign pcs 1m*1.5m 1

0 02
Rectangular scotch pcs 2m*0.9 4

1 Rectangular scotch pcs 1m*0.5m 2

Traffic sign production unit Rectangular scotch pcs 0.9m*0.66m 1

circular table top pcs 0.68m 12

Wood production unit coffee holder (recobot) pcs 1.07*0.61*0.5m 1

Generally, due to this the production center losses 24,194.58 ETB for material cost . And man power
machinery cost are losses for this these products.

Without a work order, production units did not produce the products. because of works without payment cause
bankruptcy(loss) of the production centers.
 Aggregate crusher production

Physical plan vs Execution

16,000.00

14,000.00
0 02 13760

1
12,000.00
11479.28 11479.28 11180 11479.28

10,000.00

8,000.00

6880 6880 6880

6,000.00 6020 6020

4,000.00
3103.3
1968.6
2,000.00
690 250.88 1517.97

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Physical plan Physical Execution

 Aggregate crusher production
1. Jinka Mender Project Whereas the Average physical performance according to the plan is 10.7%. On the other hand, an Average Financial also performance also 29.267%. In the reporting month,

production Affect due to Lack Machinery (excavator &Loader),Mitanaces (mantle)and Right off way for quarry site .

2. Salayish-Omo Project Whereas the physical financial performance according to the plan is 0%. In the reporting month, no production due to Programmable Logic Controller (Plc) case ,Machinery

0
Shortage ,Shortage of electrode
02
3. Yabelo Bypass & Airfild Project Whereas the physical performance according to the plan is 15.03%. On the other hand, the financial performance also 69.67%. In the reporting month, Due To these

1
reasons the physical performances is low Shortage Machinery affect the production, Maintenance problem production, Connection and network is not available for Communication.

4. Alaba-Angacha-Wato Project The performance with regard to physical and financial plan in the month is 0% and 0% respectively. No Production Due to Ramp failures, Shortage Machinery

5. Adama-Awash Project Whereas the Average physical performance 2.675% & financial performance was 34.8%. In the reporting month,. Challenges Encountered Roter (Sand Maker),

mechanical(meso crusher) Maintenance , Different oil Supply and Fuel Problem

6. Dulecha- Awash Project Whereas the physical performance according to the plan is 0%.On the other hand, the financial performance also 0%. In the reporting month. due to these Shortage of

Machinery, Fuel Shortage and Bearing problem

7. Awash-Arba Project Whereas the physical performance according to the plan is 0%.On the other hand, the financial performance also 0%. In the reporting month. The production affected by Shortage

of Machinery and Fuel Shortage.

8. Mile-Galafi Overlay Project Whereas the physical performance according to the plan is 4.81%. On the other hand, the financial performance also 11.65%. In the reporting month, production Affect

due Shortage fuel, Lack Machinery (Dump truck) and Conveyor Maintenance

9. Gishen Junction Project the physical performance according to the plan is 0%.On the other hand, the financial performance also 0%. In the reporting month, no production due to Machinery

(Loader, Excavator &Dump truck) and rollers

10. Megech Dam the physical performance according to the plan is 0%.On the other hand, the financial performance also 0%. Due to these reasons Cone Crusher unit Defect , PLC, Aggregate Load cell

Calibration Problem, Concrete mixing Reduction Gear defect .

 Sand maker

 The metal production units the expected Physical execution Asphalt production
for this month was 5148 pcs and they achieve 2009 Pcs and
expected financial execution was 4,364,296.00birr and they

0 02
achieve 1,091,097.72 birr When expressed in percentage they  This reporting month the production of asphalt is low its compare that the plan of the
executed 39% and 25% physically and financially
month financial plan 15,151,564.80 and the physical plan 82,560 meter cube of
respectively; because of this we could have lose 3,273,198.28

1
ETB. The metal production units as known there are Products asphalt produce about the financial execution is 3,338,689.60 this is 22% of the
which has to be produced continuously without any gap plan and physical execution 99.2 this is 0.1% of plan
which is used for Building construction input elements such: -
as Anchor Nut, Barrel, Wedge and plate but, there is shortage
of Raw material as to produce as per plan.

Physical Financial
production Physical Physical PP VS Financial Financial FP VS production units Physical plan
Execution
PP VS PE Financial plan
Execution
FP VS FE
units plan Execution PE plan Execution FE 1 Jinka mender 13,760 0 0% 2,525,260.80 0 0%
36,173,606. 2 Yabelo bypass 13,760 0 0% 2,525,260.80 0 0%
1Jinka mender 8,600 0 0% 0 0%
4 Alaba-Angacha-
3 13,760 0 0% 2,525,260.80 0 0%
Wato
36,173,606.
2Yabelo bypass 8,600 0 0% 0 0% 4 Adama-awash 13,760 99.2 0.70% 2,525,260.80 3,338,689.60 132.20%
4 5 Dulecha- Awash 13,760 0 0% 2,525,260.80 0 0%
36,173,606. 6 Mile Galafi overlay 13,760 0 0% 2,525,260.80 0 0%
3Adama-awash 8,600 0 0% 0 0%
4 22.03
Total 82,560 99.2 0.10% 15,151,564 3,338,689.6
36,173,606. %
4Mile Galafi 8,600 167.927 2.00% 461,799.25 1.28%
4
144,694,425
Total 34,400 167.927 0.49% 461,799.25 0.32%
.
Problem Encountered on
production units

Lack of raw Material Solution

 Purchasing progress
Sub-contractor problem
 Working using available material
Lack of market demand  Some material supply by customer
 It was possible to use the existing
Issues Maintenance (critical),
material and workers
Material exchange problem,
Shortage machinery and
 Right off way problem
 The ways forward

 Emphasizing timely input supplier  Quality improvement  Reducing rework and wastage

 educing production delivery time

 Using ERP and KPI  Reducing production delivery time
,
Recommendation
 The suppling of raw material is very important to achieve their physical and financial plan

 Measurement issue, raw material shortage and machinery maintenance shall be given a critical attention to keep the

productivity of each production unit at theInternal Stakeholder

expected External Stakeholder
level and lack man Priority Stakeholder
power on metal and HCB give attention.

 Use annual leaves for staff in production units to minimize resource loss in the event of a lack of raw materials.
Stakeholder Name
 Every machine in HCB is working towards achieving the plan.

 Computerize machines starts works to solve the shortage of anchor nut production in metal production units.
Stakeholder Name
 The products are delivered to the customer by all production units in accordance with the work order the following month.

 Prefab concreters amended their BOQs using current production quantity.

 Without a work order, production units did not produce the products
 INPUT AND PRODUCTON
MONITORING CONTROL
DEPARTEMNT

THANK
YOU
BELAY WEKGARI
+251-91390-2064