1.
Steel & Mining Conference | 1
Sensitivity: Internal (C3)
C&I Monthly Report
July-2022

2.
Steel & Mining Conference | 1
Sensitivity: Internal (C3)
• Highlights:
 Lowest Inventory ( ₹ 18,55,102 )
 Improvement project done- 5 No’s
 Safety Improvement-
1. Turbine drain MOV DR-01&02 successfully operation done from DCS in auto & manual mode
2. Digital display provided for measuring Raw water pond level
 For Equipment reliability-
1. Boiler fill pump current provided in DCS
2. Alarm provided on annunciator if HPBP opened > 2%
• Lowlights:
 GPS Clock faulty

3.
Steel & Mining Conference | 1
Sensitivity: Internal (C3)
Notification Compliance
Apr-21 May-21 Jun-21 Jul-21 Aug-21 Sep-21 Oct-21 Nov-21 Dec-21 Jan-22 Feb-22 Mar-22 Apr-22 May-22 Jun-22 Jul-22
Total Generated 90 123 116 162 166 174 85 70 91 68 72 123 78 81 86 135
Completed 86 117 105 152 154 158 78 66 88 66 69 110 67 76 82 128
Pending 4 6 11 10 12 16 7 4 3 2 3 13 11 5 4 7
%Compliance 95.5 95.12% 90.51% 93.80% 92.77% 90.75% 91.76% 94.28% 96.70% 97.05% 95.83% 89.40% 85.89% 93.82% 95.34% 94.81%
0
20
40
60
80
100
120
140
160
180
200
Apr/21 May/21 Jun/21 Jul/21 Aug/21 Sep/21 Oct/21 Nov/21 Dec/21 Jan/22 Feb/22 Mar/22 Apr/22 May/22 Jun/22 Jul/22
Total Generated Completed Pending

4.
Steel & Mining Conference | 1
Sensitivity: Internal (C3)
Defects Action Plan
Notification date Order Notification Notification type System status Description Target Date Status
28.07.2022 11642811 Z0 OSNO LOADER INST INSTALATION & FAB. 06.08.2022
28.07.2022 11642771 Z1 OSNO Chillerunit A/B flow switch checki req. Code Creation u/p
22.07.2022 11639821 Z0 OSNO GPS CLOCK NOT RUNNING 30.10.2022 PR 2200000289
14.07.2022 11636542 Z1 OSNO
PA FAN#B NDE SIDE VIB PRB CHECK
REQ
12.07.2022 11635945 Z0 OSNO Boiler LHS hydrastp sensor leakage 25.12.2022 PR 2500002514
12.07.2022 11635668 Z1 OSNO CT Sump level checking req. PR UNDER APPROVAL
02.07.2022 11632834 Z0 OSNO
DM PLANT BLOW DOWN CONDUCTIVITY
SENSOR
PR UNDER APPROVAL
14.06.2022 11623129 Z1 OSNO DESPRHTR SD#02 TUNNING REQ
03.06.2022 11618845 ZR OSNO OSTS RCA of Boiler tripped on druml level low ZR task pending
13.05.2022 11609860 Z1 OSNO CHILLER#1 ALARM RESET KEY NOT
WORK
20.7.2022 PO 4400055133 vendor not reply
08-04-2022 11593767 Z1 OSNO DM-DM plant stream-B nt strt in automode deliv: 20.09.2021, Overdue materials, GRN issue,
under QC, diaphragm wrong supplied, New
Diaphragm dispatched
06-04-2022 11593046 Z1 OSNO DM-CT FT flow not match from PLC to field Reading showing in local PR U/P
29-03-2022 11588319 Z0 OSNO Portable o2 analyzer checking req. 30.08.2022 PO: 4100117580 Deliv.23.07.2022
29-03-2022 11587941 z0 OSNO RFID TAG NOT RUNNING CHP
OPERATOR
08.08.2022 SIV done materials MWH
16-03-2022 11582570 Z1 OSNO Chiller A cond. line TG not available 15.012.2022 PR 2500002514
16-03-2022 11582572 Z1 OSNO Chiller A chilled water line TG NA 15.012.2022 PR 2500002514
16-03-2022 11582575 Z1 OSNO Chiller B cond. line o/l PG not work 15.012.2022 PR 2500002514
16-03-2022 11582573 Z1 OSNO Chiller B chiled water line TG NA 15.012.2022 PR 2500002514

5.
Steel & Mining Conference | 1
Sensitivity: Internal (C3)
Defects Action Plan
Notification date Order Notification Notification type System status Description Target Date Status
16-03-2022 11582571 Z1 OSNO Chiller B cond. line TG not available 15.012.2022 PR 2500002514
20220206 11567532 Z1 OSNO DM-H2So4 manual level gauge not working
PO awaited PR done 2500002089,
20220119 11558167 Z0 ATCO NOPR FLOWMETER TO BE CHECK PSF
PO awaited PR done 2500002371
20220110 11567282 Z0 OSNO Na Analyser Activition Error at DMP 10.09.2022 PO 4100117577 Deliv.27.08.2022
20220102 11567019 Z4 OSNO MOT LEVEL TX iNSTALLATION AT TBN
Service engg visited but txr not running, he will check again,
material return to vendor
20220102
11524781 Z1 OSNO FA SILO DIFF BETWN PLC & FIELD
TR u/p
20211114 11525744 Z1 OSNO SWAS CBD SILICA ANLYSR NOT OK 28.08.2022 PO 5100032805, deliv done, wrong material dispatch
27-08-2021 11486083 Z1 OSNO BLR BLOWDOWN SILICA NAN ON SWAS Repeated- 11525744
20210826 11485684 Z0 OSNO
MILL B FEEDER I/L GATE LIMIT ROD
DAMAGE
06-08-2022 M/M support required for welding
31-07-2021 11472581 Z0 NOPR ORAS ESP FIELD TEM LED SCANNER N/W PO 4400060927 Delv 25.06.2022, review deliv date: 15/07/2022
20-07-2021 11467843 Z1 OSNO MS SILICA ANALYSER SWAS VALUE
WRONG
28.08.2022 PO 5100032805, deliv done wrong material dispatch
20210719 11466601 Z0 OSNO turbine lub oil dp gauge checking work
PO awaited PR 2500002067
29.06.2021 11458376 ZP OSNO DS PLC CHECKING Upgradation required, Will integrate with Honeywell DCS
11448793 ZP OSNO BCN-3 IR SENSOR CHECKING PO awaited PR- 2500002291
20210527 11444944 Z1 OSNO SBA-A XV 337A AIR LEAKEGE
deliv: 20.09.2021, Overdue materials, GRN issue, under QC,
diaphragm wrong supplied, New Diaphragm dispatched
03-05-2021 95528494 11437319 Z0 NOPR ORAS ammonia tank pressure txr checking work PO 4400046945 DELIV 20.10.2021, Overdue PO
26.04.2021 11433632 Z0 NOPR ORAS ammonia level txr checking work Awaited for tank empty
09-11-2020 11327974 Z0 OSNO DM-SAC-B air vent air diaphragm leakage
PO 4100116027
deliv: 20.09.2021, Overdue materials, GRN issue, under QC,
diaphragm wrong supplied, New Diaphragm dispatched
06-02-2020 11159385 Z1 OSNO DM-XV 341 SBA-A air vent air leakage deliv: 20.09.2021, Overdue materials, GRN issue, under QC,
diaphragm wrong supplied, New Diaphragm dispatched
28-11-2019 11121224 Z1 OSNO CHP, PLC UPGRADATION REQUIRED Up gradation required

6.
Steel & Mining Conference | 1
Sensitivity: Internal (C3)
PM Compliance
Apr-21 May-21 Jun-21 Jul-21 Aug-21 Sep-21 Oct-21 Nov-21 Dec-21 Jan-22 Feb-22 Mar-22 Apr-22 May-22 Jun-22 Jul-22
Total Generated 126 114 140 112 142 114 134 132 142 113 136 124 130 117 142 113
Completed 126 114 140 112 142 114 134 132 142 113 136 124 130 117 142 113
Pending 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0
%Compliance 100% 100% 100% 100% 100% 100% 100% 100% 100% 100% 100% 100% 100% 100% 100% 100%
0
20
40
60
80
100
120
140
160
Apr/21 May/21 Jun/21 Jul/21 Aug/21 Sep/21 Oct/21 Nov/21 Dec/21 Jan/22 Feb/22 Mar/22 Apr/22 May/22 Jun/22 Jul/22
Total Generated Completed

7.
Steel & Mining Conference | 1
Sensitivity: Internal (C3)
Inventory Analysis
Month Inventory NMI SMI NMI consumption SMI Consumption Total Consumption
Apr-21 ₹ 27,34,448.00 ₹ 6,10,429.00 ₹ 7,46,826.00 ₹ 54,784.00 ₹ 39,031.00 ₹ 7,27,182.30
May-21 ₹ 29,73,000.00 ₹ 8,92,115.00 ₹ 6,24,000.00 ₹ 2,71,876.60 ₹ 2,22,868.20 ₹ 7,99,563.60
Jun-21 ₹ 26,07,778.00 ₹ 5,85,510.00 ₹ 6,48,234.00 ₹ 0.00 ₹ 1,37,263.00 ₹ 8,82,642.20
Jul-21 ₹ 29,68,492.00 ₹ 4,43,508.00 ₹ 12,71,686.00 ₹ 21,453.05 ₹ 0.00 ₹ 5,09,067.98
Aug-21 ₹ 35,25,212.00 ₹ 6,14,658.00 ₹ 6,69,229.00 ₹ 0.00 ₹ 5,54,583.00 ₹ 11,67,475.74
Sep-21 ₹ 28,86,481.00 ₹ 6,88,886.00 ₹ 1,14,646.00 ₹ 92,205.00 ₹ 0.00 ₹ 13,33,182.44
Oct-21 ₹ 33,37,031.00 ₹ 5,96,681.00 ₹ 1,94,398.00 ₹ 8,746.00 ₹ 62,300.00 ₹ 8,25,868.00
Nov-21 ₹ 34,58,587.00 ₹ 5,87,935.00 ₹ 1,32,098.00 ₹ 29,100.00 ₹ 0.00 ₹ 8,61,852.44
Dec-21 ₹ 30,78,136.00 ₹ 5,58,835.00 ₹ 7,09,765.00 ₹ 0.00 ₹ 0.00 ₹ 8,36,750.39
Jan-22 ₹ 29,56,928.00 ₹ 5,85,908.00 ₹ 7,29,487.00 ₹ 9,153.20 ₹ 1,14,488.00 ₹ 4,75,682.09
Feb-22 ₹ 26,68,415.00 ₹ 5,79,754.87 ₹ 6,14,999.00 ₹ 1,39,188.62 ₹ 24,032.90 ₹ 4,43,924.00
Mar-22 ₹ 25,03,520.00 ₹ 4,40,566.00 ₹ 5,90,966.00 ₹ 58,524.58 ₹ 19,630.00 ₹ 6,55,766.00
Apr-22 ₹ 22,52,090.89 ₹ 10,00,488.84 ₹ 3,79,043.20 ₹ 510.00 ₹ 1,71,528.00 ₹ 3,15,603.73
May-22 ₹ 20,23,120.00 ₹ 3,56,054.00 ₹ 6,41,757.00 ₹ 1,82,907.00 ₹ 3,19,879.00 ₹ 13,94,121.54
Jun-22 ₹ 14,12,877.46 ₹ 3,79,966.36 ₹ 4,78,074.44 ₹ 0.00 ₹ 1,42,965.00
₹ 280706
SRN ₹ 331000
Tot. Con. ₹ - 50600
Jul-22 ₹ 16,47,411.00 ₹ 3,79,967.00 ₹ 4,24,174.00 ₹ 2.00 ₹ 74,587.66 ₹ 3,89,652.26
Aug-22 ₹ 18,55,102.00 ₹ 4,03,233.36 ₹ 3,55,233.38
S. No Inventory Indicators Stock Value %
1 Consumable Spare ₹ 2,23,267.83 12.40
2 Emergency Spare ₹ 4,56,323.79 25.34
3 Obsolete ₹ 1,62,712.68 9.04
4 Missing from MWH ₹ 1,46,000.00 8.11
5 Standby Spare ₹ 2,88,618.21 16.03
6 To be consume ₹ 1,35,716.00 7.54
7 To be transfer ₹ 3,88,127.67 21.55
Approx Inventory Value ₹ 18,00,766.18
Consumable
Spare
12%
Emergency
Spare
25%
Obsolete
9%
Missing from
MWH
8%
Standby Spare
16%
To be
consume
8%
To be transfer
22%
Plant Stock- ₹ 1645062
MWH Stock- ₹ 210040

8.
Steel & Mining Conference | 1
Sensitivity: Internal (C3)
Open PR/PO Status
Open PR
Order awaited 73
Services 1
Under release 7
Total 81
Open PO
Aug-22 18
Sep-22 3
Oct-22 11
Nov-22 7
Dec-22 12
Jan-23 3
Mar-23 1
Overdue: Response awaited from Buyer/Vendor 18
Total 73
Central PR request raised 30

9.
Steel & Mining Conference | 1
Sensitivity: Internal (C3)
Kaizen Implementation
0
1
2
3
4
5
6
7
Apr/21 May/21 Jun/21 Jul/21 Aug/21 Sep/21 Oct/21 Nov/21 Dec/21 Jan/22 Feb/22 Mar/22 Apr/22 May/22 Jun/22 Jul/22
Apr/21 May/21 Jun/21 Jul/21 Aug/21 Sep/21 Oct/21 Nov/21 Dec/21 Jan/22 Feb/22 Mar/22 Apr/22 May/22 Jun/22 Jul/22
Kaizen 0 4 4 5 3 6 6 2 4 5 5 4 4 6 5 5
Vertical Unit SBU FIP ID/ Kaizen ID Project Title/ Kaizen Title
CPP Zawar C&I CPP/ZWR/KZN/202223/0085 Master fuel trip generate if all ESP field trip
CPP Zawar C&I CPP/ZWR/KZN/202223/0087 Boiler fill pump current in DCS
CPP Zawar C&I CPP/ZWR/KZN/202223/0086 Alarm on Annunciator if HPBP opened > 2%
CPP Zawar C&I CPP/ZWR/KZN/202223/0088 New Access control installation
CPP Zawar C&I CPP/ZWR/KZN/202223/0089 Raw water pond LED installation for level display

10.
Steel & Mining Conference | 1
Sensitivity: Internal (C3)
Kaizen Pics
Raw Water Pond LED
HPBP Open > 2 %
Boiler Fill Pump Current

11.
Steel & Mining Conference | 1
Sensitivity: Internal (C3)
Training July-2022
Sr. No. Topic Trainer Attendies Duration Man Hrs Status
1 Knowledge About 10 line LED Update Sandeep Sharma 10 No's 1 Hrs 10 Completed
2 Knowledge About SWAS Analyser Amit Meena 10 No's 1 Hrs 10 Completed
3 Knowledge About Fire Alarm system Sandeep Sharma 10 No's 1 Hrs 10 Completed
4 Knowledge About Control Valve Shivram Meena 10 No's 1 Hrs 10 Completed
Technical Training

12.
Steel & Mining Conference | 1
Sensitivity: Internal (C3)
Way Forward
 CO detector for Hg Analyser
 LHS cable interlocking with belt
 PLC SMPS healthy indication on PLC graphics
 Ammonia Signal in DCS
 MOT level transmitter installation

13.
Steel & Mining Conference | 1
Sensitivity: Internal (C3)