Sheet1

ROLLING MILL PLANT EFFECIENCY

CCMROLLING MILLLENGTH3.043LENGTH3.043TOTALTOTALNUMBERS PRODUCED99561660INWARD90455545NUMBERS PASSED90455545PASSED84432516 NUMBERS FAILED9106115FAILED62329

ThusCCM EFFICIENCY83%CCM WASTAGE17%

AS IS SITUATIONTO BE SITUATIONPresent Achieved CapacityFull capacityThus only 516 pieces processedIf total 545 pieces processed

Now,Rolling Mill production capacityLENGTH3.043LENGTH3.043TOTALTOTALPASSED84432516Total pieces90455545Billet size 0.0367840.0363Billet size 0.0367840.0363Steel Density7.857.85Steel Density7.857.85

Front and back end wastageTonnage achieved24.2553696123.10056147.355929625.987896129.654525155.642421

billet weight avg tonswastage in tons(4 cuts)0.2850.0056568147.35592962.9247825353

Thus actual production achieved144.4311470647Less production as per actual11.2112739353Thus rolling mill plant effeciency93%Rolling mill wastage percentage7%

PLANT CAPACITY UTILLIZATIONRolling Mill Production DetailsMaximum capacity tons produced 1 hour3510.00666975one shift BILLETS420120.0800372 shifts BILLETS840240.160074achieved144.4311470647CAPACITY UTILLIZATION60%

UNDER UTILLIZATION40%To Improvise the situation ,1)The wastage % in rolling mill has to controlled and bring down to 5 % and less2)The wastage % in CCM has to controlled and bring down to 5-8 % and less

Sheet2

ROLLING MILL PLANT EFFECIENCY

CCMROLLING MILLLENGTH3.0434LENGTH3.0434TOTALTOTALNUMBERS PRODUCED995610660INWARD90455545NUMBERS PASSED904550545PASSED84432516 NUMBERS FAILED91060115FAILED62329

ThusCCM EFFICIENCY83%CCM WASTAGE17%

AS IS SITUATIONTO BE SITUATIONPresent Achieved CapacityFull capacityThus only 516 pieces processedIf total 545 pieces processed

Now,Rolling Mill production capacityLENGTH3.043LENGTH3.043TOTALTOTALPASSED84432516Total pieces90455545Billet size 0.0367840.0363Billet size 0.0367840.0363Steel Density7.857.85Steel Density7.857.85

Front and back end wastageTonnage achieved24.2553696123.10056147.355929625.987896129.654525155.642421

billet weight avg tonswastage in tons(4 cuts)0.2850.0056568147.35592962.9247825353

Thus actual production achieved144.4311470647Less production as per actual5.3617088647Thus rolling mill plant effeciency93%Rolling mill wastage percentage7%

PLANT CAPACITY UTILLIZATIONRolling Mill Production Details

1 BILLET JOURNEY = 158 SECONDS2.6333333333minsThus in One Hour22.784810126623Maximum capacity

produced 1 hour3610.2925746one shift BILLETS432123.51089522 shifts BILLETS864247.0217904achieved144.4311470647CAPACITY UTILLIZATION58%

UNDER UTILLIZATION42%To Improvise the situation ,1)The wastage % in rolling mill has to controlled and bring down to 5 % and less2)The wastage % in CCM has to controlled and bring down to 5-8 % and less

Sheet3Machine Time Calculation

FOR 4 METER Billet productionFOR 3 METER Billet productionspeeddistance/timespeeddistance/time

2.384/time2.383/timetime1.6806722689time1.26050420171.68minutes1.26minutesminsecminsec1601601.68x1.26xX75.6Secondsx100.8secondsThus on an average CCM takes 95 to 100 seconds for 4 meter billet productionThus on an average CCM takes 70 to 75seconds for 3 meter billet productionlets take average time97secondslets take average time72secondsTravel time from CCM to rolling mill 80secondsFirst 6 pass time in rolling mill38secondsNext 3 pass time in rollin mill27secondsNext 5 pass time in rolling Mill65secondsNext balance passes in rolling Mill to cooling bed 14seconds

Total rolling mill operational time for 1st billet144secondsFrom next Billet the Operational time will reduce by 40SecondsActual operating time of billet104seconds

Thus one Billet require1.73minutein rolling mill to convert into bars

In 1 hour no of billets processed34.6153846154

Thus average billet rolled per hour35Billets

Sheet4

1000000ROLLING MILL PLANT EFFECIENCY2000001000000350000CCMROLLING MILL650000LENGTH3.0434LENGTH3.0434TOTALTOTALNUMBERS PRODUCED910910INWARD873873NUMBERS PASSED873873PASSED855855 NUMBERS FAILED3737FAILED1818

ThusCCM EFFICIENCY96%CCM WASTAGE4%

AS IS SITUATIONTO BE SITUATIONPresent Achieved CapacityFull capacityThus only 855 pieces processedIf total 873 pieces processed

Now,Rolling Mill production capacityLENGTH43LENGTH43TOTALTOTALPASSED8550855Total pieces8730873Billet size 0.04840.0363Billet size 0.04840.0363Steel Density7.857.85Steel Density7.857.85

Front and back end wastageTonnage achieved324.84870324.8487331.687620331.68762

billet weight avg tonswastage in tons(4 cuts)0.2850.0056568324.84876.447733776

Thus actual production achieved318.400966224Less production as per actual13.286653776Thus rolling mill plant effeciency96%Rolling mill wastage percentage4%

PLANT CAPACITY UTILLIZATIONRolling Mill Production Details

1 BILLET AVG JOURNEY TIME = 100 SECONDS1.6666666667BILLETS Thus in One Hour3636Maximum capacitytonnage(4 meter) Billets produced 1 hour3613.67784one shift BILLETS432164.134082 shifts BILLETS864328.26816achieved318.400966224CAPACITY UTILLIZATION97%

UNDER UTILLIZATION3%To Improvise the situation ,1)The wastage % in rolling mill has to controlled and bring down to 5 % and less2)The wastage % in CCM has to controlled and bring down to 5-8 % and less

Sheet5FINAL DISCOUNTED PRICE ON AMCS.noDESCRIPTIONPRODUCT UNIT PRICEQTYAMC 20% PER YRTOTAL AMC FOR 5 YRS1ST YR FREE 2015-2016ARGS REBAR+ CAD DETAILING100000012000001000000

BSPECIAL DISCOUNT FOR SUNVIK35%ON TOTAL AMC FOR 5 YRS( APPLICABLE FROM 2016 TO 2021)350000

CA-B650000

DSERVICE TAX 14%91000

EGRAND TOTAL(C+D)741000