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Plant KRA Review on 27/28 December
S.No E.Code Name Designation
1 1387 Sanat Kumar Bhatt Senior General Manager (Producti
Performance Planning and Assesment for the Quarter Jan-Mar 2012Name : Anup Kumar
Designation: DGM - HR
S No KRA KPI
Identification & proposal of new guest House
1 Identification and separation of low performers from executive and workman category2 Study of optimum Manpower requirement in various functions/departments in workmen grade. Priority to be given to Technical functions in the mill3 Draft placement of workmen in Grade structure , as already discussed
4
5 Associate with PBOPlus in setting out KRA/KPIs of various functions departments including HR (HO and Kashipur) and conducting periodical review of status of progress6 Sourcing and recruitment drive of it is in different technical departments7 Facilitate implementation annual performance appraisal system for 2012-2013 for executives8 expoeditious completion of relocating company's guest house at kashipur and improvements in canteen
9
Shree Shyam Pulp & Board Mills Ltd.
Review 1 - (DATE)
Initiatives/Action 0/1
1. Advertise in local papers20-Jan-13
15-Feb-13
3. Finalise recruitments
28-Feb-13
31-Jan-13
Stores Personnel overhaul50% in January and 50% by 15th Feb. 2013
25-Jan-131. Creation of Calendar
3. Implement by schedule 100% compliance
15-Feb-13
Steps to achieve the Initiative/Action
Measures/Performance
Indicator
Recruitments(Non- executives)
Within 30 days on board
2. Conduct interviews with dept heads
Identification of low performing employees
1.Consultation with Dept heads and finalisation
2. Execution for separation of 50% nos out of list of low performers
31 March 2013 (10% in Jan. 20% in Feb. and 20% in March)
Manage exit of 15 employees in Store department and their
replacement.
Planning of Foundation day celebration on 22nd & 23rd Feb.
2. Inform all shareholders of the same
Proposal for improvement of Factory Canteen
Identification & proposal of new guest House 31-Mar-13
Identification and separation of low performers from executive and workman categoryStudy of optimum Manpower requirement in various functions/departments in workmen grade. Priority to be given to Technical functions in the mill
Draft placement of workmen in Grade structure , as already discussed
Associate with PBOPlus in setting out KRA/KPIs of various functions departments including HR (HO and Kashipur) and conducting periodical review of status of progressSourcing and recruitment drive of it is in different technical departments
Facilitate implementation annual performance appraisal system for 2012-2013 for executivesexpoeditious completion of relocating company's guest house at kashipur and improvements in canteen
Achieving the executive manpower strength , recommended by PBOPlus
, by expeditious deployment of newly recruited engineer/engineer
trainee in slotted regular assignment and segregating the existing
executives by name
send status reports on 1,2,3,4,6, in march
Shree Shyam Pulp & Board Mills Ltd.
Emp. Code: Ed. Qual.Department:
Review 1 - (DATE)
Feedback Weightage
L-5 L-4 L-3 L-2 L-1
50% in January and 50% by 15th Feb. 2013
Suggested KPI for Jan-Mar
Target Date(To be given under column L3)
Shree Shyam Pulp & Board Mills Ltd.Annexure I
%age/ Level Achieved
Actual Performance (By
Appraiser)Perfromance
score
Shree Shyam Pulp & Board Mills Ltd.
Performance Planning and Assesment for the Quarter Jan-Mar 2012Name : Anup Kumar
Designation: DGM - HR
S No KRA KPI
1 Job Performance Monitoring Performance of Engineer
Training of Engineer Trainees
2 Management of Trainees
Promotion/Upgradation of Engineers
3 Training
4 Security
5 KRA/KPI MonitoringCompliance to commitments made by personnel at Plant via KPI sheets
Assignment of dept to Engineers/Trainees
Growth of Executives in Organisation
Duty Roster of Security personnel
6 QC Officers
Shree Shyam Pulp & Board Mills Ltd.
Review 1 - (DATE)
Initiatives/Action 0/1
3.Monitor Performance
Steps to achieve the Initiative/Action
Measures/Performance
Indicator
In association with HODs monitor the performance according to a
template and schedule , the performance of all Engineers below
the grade of Deputy Manager
1. Create criteria and template of performa after discussion with HODs
2. Inform all shareholders of performance monitoring process
4. Create list of High Performers and Low Performers and create an action
plan to address them
Monitoring the Training Program for and the progress made in the
same by Engineer trainees
1. Create formalised training program template to be followed on a departmental level for the training of engineer trainees by their HODs
2. Monitor the compliance to the template
3. Maintain record of Special Projects assigned to Trainees along with completion dates and grade of
work
5. Flag high performers and low performers
6. Create reward program and remedial program ,as the case may
be
4.Finalise with all Shareholders
3. Roll out action plan
Compliance to commitments made by personnel at Plant via KPI sheets
Based on evaluation / acquisition of requisite learning by them during
training period
1. Create criteria for evaluation of Engineers/trainees.
2. Evaluate the learning and training period performance according to
criteria
3. Assign personnel based on findings
4.Meet with HODs to ensure that their needs are being met by the
correct candidate
5. Assign personnel and monitor progress on a weekly basis for 3
months.
Promote Engineers or upgrade their responsibilities based on an
evaluation of Job Performance
1. Create criteria for evaluation of Engineers/trainees.
2. Evaluate performance in consultation with HODs
3. Create proposal list of Engineers to be promoted with corresponding
reward
Identify training inputs required for executives keeping in view
their potential
1. Consult with HODs to identify department and grade specific training inputs for executives
2. Create action plan for training modules along the suggestions
made by HODs
Provide HR concurrence to duty roster of Security personnel
prepared by GM ( Vigilance and Security) in accordance to
company guidelines
1. Collect KRA/KPI sheets of Plant personnel for Jan-March
2. Review the same for quality of KPI commitments made
3. Review faulty KPIs with concerned personnel and PBOPlus to rectify
during monthly reviews
4.Follow up with defaulters and commitments due in close future to
ensure compliance
5. Flagging of Low performers and high performers and corresponding action to be taken. Create SOP for
the same.
Shree Shyam Pulp & Board Mills Ltd.
Emp. Code: Ed. Qual.Department:
Review 1 - (DATE)
Feedback Weightage
L-5 L-4 L-3 L-2 L-1
Suggested KPI for Jan-Mar
Target Date(To be given under column L3)
Shree Shyam Pulp & Board Mills Ltd.Annexure I
%age/ Level Achieved
Actual Performance (By
Appraiser)Perfromance
score
Shree Shyam Pulp & Board Mills Ltd.
Performance Planning and Assesment for the Quarter Oct - Dec, 12
Name :Shiv Kumar Singh
Designation: Manager
S NoKRA KPI Initiatives/Action
1
2
3
4
Signature of App
To reduce the number of breakdowns
TO REDUCE THE BREAKDOWN
REPLACE AND REPAIR OLD AND DEFECTIVE SWITCHGEARS.
TO REDUCE THE BURNING OF MOTORS
PREPARED A MAINTENACE SCHEDULE, AND RUN THE
MAINTENANCE PROGRAM ACCORDING TO THE SCHEDULE.
MOTORS OF 3000 RPM IN 3 MTHS., 1500 RPM IN 6 MTHS, 1000 RPM IN 9 MTHS AND 750
RPM IN 12 MTHS IS TO BE OVERHAULED.
Reduce Production Loss due to Electrical
Failures
TO REDUE THE BREAKDOWN COMING
DUE TO OVER TEMPERATURE.
CHECKING AND RECORD MAINTENANCE OF THE
TEMPERATURE OF 6MW TG, 2MW TG, TRANSFORMERS, ESP,
ACBS, CABLE JOINTS.
Provide continuous power
PROJECT WORK IN 16MW TG AND 110 TPH
BOILER
PROPER CO-ORDINATION WITH CONTRACTORS, PROCESS
DEPARTMENT.
Reduce the electrical maintenance cost
Shree Shyam Pulp & Board Mills Ltd.
Performance Planning and Assesment for the Quarter Jan-Mar 2013
Name :Shiv Kumar Singh
Designation: Manager
S NoKRA KPI Initiatives/Action
1 To reduce the number of breakdowns
To reduce the breakdown
Replace and repair old defective switchgears
Motors of 3000 RPMin 3 mnths., 1500 RPM in 6 mnths, 1000 RPMin 9 mnths and 750
RPM in 12 mnths is to be overhauled
2
3
Inventory Management
Reduce Production Loss due to Electrical
Failures
Provide continuous power
Project work in 16MW TG and 110 TPH boiler
Reduce the electrical maintenance cost
Shree Shyam Pulp & Board Mills Ltd.
Review 1 - 26 Dec 20120/1 Feedback
Plan, Execute,Audit Machine Hours per year
1
Plan, Execute,Audit
1
Done
Plan, Execute,Audit
0
Plan, Execute,Audit Tonnes per year
1
Plan,Do,Check0
Number of 0 ( Red Buttons) 2Number of 1 (Green Buttons) 3
Total number of Activities 5Achievement Percentage 60
Steps to achieve the Initiative/Action
Measures/Performance Indicator
10 ACBs repaired.
Planned 14 Actual 26
Planned 15 and Actual 12
Done. Record to be checked
Planned 9 jobs. Completed 6 jobs
Shree Shyam Pulp & Board Mills Ltd.
Review 2
0/1
10 % reduction over Oct-Dec (20 hrs ) Jan: 21 hrs ( 16 hrs due to transformer breakdown)
28-Jan-13
5-Feb-13
5-Feb-13
8-Feb-13
report by 5th of next month
28-Jan-13
2. Raise all PR's According to Calendar
Steps to achieve the Initiative/Action
Measures/Performance Indicator
Estimated Financial Impact
Actual Financial Impact
1.Create a full plan month wise listing the
equipment to be replaced with by-date.
2. Identify obsolete and irreperable equipment
3. Proposal for disposal and replacement list.
5. No of equipments to be repaired
6. Track breakdown hours
1. Finalise PM schedule monthwise and Zone
wise with all stakeholders
First Week of every Subsequent Month
First Week of every Subsequent Month
100% compliance to Plan
15-Mar-13
15-Nov-12
15-Nov-12
100% compliance to Plan
100% compliance to Plan
10 % reduction in stores value
10-Feb-13
Update Final PR list 10-Feb-13
Number of 0 ( Red Buttons)
3. Create comparison report for before and
after changes. Breakdown hrs before replacement vs After.
4. Track breakdown hours with Why Why
Completion of 3 pending jobs from Oct to Dec
1.All Purchase Requisitions to be placed
with Expected Date of Delivery linked to
schedule
2. Number of Purchase orders to be placed.
3.Number of Equipments to be received
monthwise
4. Erection and commissiong of all
equipments
Finalise ROL/ROQ of spares
Number of 1 (Green Buttons)Total number of ActivitiesAchievement Percentage
Shree Shyam Pulp & Board Mills Ltd.
Emp. Code: 1212 Ed. Qual.Department: Electrical
Review 1 - 26 Dec 2012 Data by RameshTarget Date(To be given under column L3)
Suggested KPI for Jan-Mar L-5 L-4 L-3
October
New KPI to be prepapred by making a full plan month wise listing the respective parts to be repaired/replaced.
New KPI to be prepapred by making a full plan month wise listing the respective parts to be repaired/replaced.
Shree Shyam Pulp & Board Mills Ltd.
Emp. Code: 1212 Ed. Qual.Department: Electrical
Review 2Target Date(To be given under column L3)
Feedback Suggested KPI for April-JuneL-5 L-4
Jan: 21 hrs ( 16 hrs due to transformer breakdown)
Done.
Being done.
Being done.
Being done.
NOT DONE. 8 Feb-2013
NOT DONE. 8 Feb-2013
Awaiting Material
Shree Shyam Pulp & Board Mills Ltd.Annexure I
Target Date(To be given under column L3)Weightage
L-2 L-1
%age/ Level Achieved
Actual Performance (By
Appraiser)
Perfromance score
Shree Shyam Pulp & Board Mills Ltd.Annexure I
Target Date(To be given under column L3)Weightage
L-3 L-2 L-1
%age/ Level Achieved
Actual Performance (By
Appraiser)
Perfromance score
Shree Shyam Pulp & Board Mills Ltd.
Perfromance Planning and Assesment for the Quarter Oct - Dec, 12Name : Vijai Veer PrakashDesignation: Head ( Fire and Safety )
S No KRA KPI
1Number of Accidents
2 Training Fulfillment of Training Calendar
1.1 Critical Accidents ( Death/ Loss more than 25 Lakhs)
1.2 Major Accidents ( Absent more than 3 Days)
1.3 Minor Accidents ( Absent for less than 3 days or no absence )
Formation of Advisory Panel on Safet
2 Inspection Timely Submission of Reports
Signature of Appraisee:
Shree Shyam Pulp & Board Mills Ltd.
Perfromance Planning and Assesment for the Quarter Jan-Mar 2013Name : Vijai Veer PrakashDesignation: Head ( Fire and Safety )
S No KRA KPI
1 Maintenance and Repair Old Cooling TowerCD # 2Machine #3 Paper Godown Gate
2 Installations Water Hydrant pipelines with hydrant 3 Personnel Conctractor's workers are working un
Shree Shyam Pulp & Board Mills Ltd.
Perfromance Planning and Assesment for the Quarter Oct - Dec, 12
Review 1 - 26 Dec 2012
Initiatives/Action0/1 Feedback
Date
1
Measures/Performance
Indicator
Suggested KPI for Jan-Mar
Training programs 30 Mins in duration for 4 Hazardous Depts.
Records maintained from 16 July 2012 until date
1)PowerPlant 1,3,4,5 - Total workman = 64
2) Pulp Mill ( CD, Chlorine Yard Total Workman = 15, Washer) - Total
workman = 38
3) Recovery Boiler - Total number of Workman = 23
1
Date 1
Daily inspections of all depts 1
3
3
4) Yard Total Number of Workman = 15
Central Safety Committee to be formed
MOMs available and all records. Meetings every 3 months.
%Reduction in number of accidents/ incidents of negligence
70% of all suggestions are implemented since May 2012. 5 instances of major accident reduced to 1 ( As on Date )
Next KPI :Initiatives to identify Hazardous areas and implement Safety measures.
Next KPI : Identify at risk workers and compile list , so as to be effectively train them in Safety measaures.
Number of 1 (Green Buttons)
Total number of Activities
100
Shree Shyam Pulp & Board Mills Ltd.
Perfromance Planning and Assesment for the Quarter Jan-Mar 2013
Review 2
Initiatives/Action
0/1
PVC Sheets of roof cooling towers are 1-MarFour supports of conveyor CD #2 are 15-Mar-13Are shaking loose, resulting in a safe 28-Feb-13Sufficient number of water hydrants v 28-Feb-13Corrective action to be taken against 28-Feb-13
Achievement Percentage
Measures/Performance
Indicator
Estimated Financial Impact
Actual Financial Impact
Number of 0 ( Red Buttons)
Number of 1 (Green Buttons)
Total number of Activities
Achievement Percentage
Shree Shyam Pulp & Board Mills Ltd.
Emp. Code: Ed. Qual.Department:
Target Date(To be given under column L3)
L-5 L-4 L-3 L-2 L-1
25-Dec-12
17-Nov-12
31-Oct-12
18-Dec-12
29-Nov-12
24-Nov-12
24-Oct-12
6-Dec-12
8-Nov-12
12-Oct-12
2-Oct-12
24-Oct-12
Shree Shyam Pulp & Board Mills Ltd.
Emp. Code: Ed. Qual.Department:
Feedback Target Date(To be given under column L3)
L-5 L-4 L-3
Suggested KPI for April-June
Shree Shyam Pulp & Board Mills Ltd.Annexure I
Weightage %age/ Level
Achieved
Actual Performance (By
Appraiser)Perfromance
score
Shree Shyam Pulp & Board Mills Ltd.Annexure I
Target Date(To be given under column L3)
Weightage L-2 L-1
%age/ Level Achieved
Actual Performance (By Apprais
er)
Perfromance score
Shree Shyam Pulp & Board Mills Ltd.
Perfromance Planning and Assesment for the Quarter Oct - Dec, 12Name : Mohammad Mazharul HaqueDesignation: Production Manager
KRAKPI
1Production ( Shared with Senior)
2
x%OTIF- ( Assigned to senior )
x
x x
3
5
Timely Completion
6
Timely Completion
7 Project AssignedTimely Completion
9 Project Assigned
Timely Completion
Target Production acheivement ( Shared with Senior)
Cost of production ( Shared with Senior)
Target cost of production ( Shared with Senior)
Employee Engagement Index ( Assigned to senior )
Project Assigned (Quality Improvement )
Project Assigned ( Quality Imporvement )
11 Project Assigned
Timely Completion
Signature of Appraisee:
Shree Shyam Pulp & Board Mills Ltd.
Performance Planning and Assesment for the Quarter Jan-Mar 2013Name : Mohammad Mazharul Haque
Designation: Production Manager
KRA
KPI
1
Production Target
Target Production Achievement for Line 3
Jan: 1650 TFeb: 1500 TMar: 1650 T
2Cost of production
Reduction of Power Consumprtion
3% OTIF
4 Employee Engagement
Shree Shyam Pulp & Board Mills Ltd.
Review 1 - 27 Dec 2012
Initiatives/Action 0/1
1
Date 1
x x
x x
Date
1
Date
1
Date
1
Date
1
Overall Measures/Perform
ance Indicator
New Ceramic top fitted on four chamber wire flat boxes
New ceramic top fitted on low vacuum boxes
Wire manifold area cleaning provision made
Holley Roll Shift toward slice 20 mm
Paper deckle on pope reel increased to 291 cm
Vacuum Pump nash taken and operated
Date
1
0Number of 0 ( Red Buttons) 1
Number of 1 (Green Buttons) 7Total number of Activities 8Achievement Percentage 87.5
Shree Shyam Pulp & Board Mills Ltd.
One ball floatation provided in wire seal fit
Review 1
Initiatives/Action Steps to Achieve initiative 0/1
25-Jan-13
20-Jan-13
3. Changing of dryer siphon . At first boiler shut
1. Create work schedule 25-Jan-13
5-Feb-13
Measures/Performance
Indicator
100% compliance to Target
1. Cleaning of Manifold 4 times a month
100% Compliance to schedule
1. Compile schedule and finalise with all shareholders
2. Implement measures according to plan
3. Track performance after implementation
2. Cleaning of entire system once a month by boilout
100% Compliance to schedule
1. Compile schedule and finalise with all shareholders
2. Implement measures according to plan
3. Track performance after implementation
2. Confirm possession of all required parts and materials
3. Track performance after implementation
4. RCC beam to be repaired 28-Feb-13
1. Inform Civil dept of issue 5-Feb-132. Fix work schedule with Civil 8-Feb-13
15-Feb-13
100% compliance
5. Track performance after repair.
31-Jan-13
20-Jan-13
Number of 0 ( Red Buttons)Number of 1 (Green Buttons)
Total number of ActivitiesAchievement Percentage
3.Ensure indent of all required materials and spares
4. Implement activities according to plan
10 % reduction over last 6 months avg
1. Compile baseline date for previous six months of power
consumption
2. Create action plan for change of vacuum pump and cleaning
3. Implemeant activities as per schedule
4. Track performance through monthly report
100% compliance to Plan
100 % compliance to weekly Plan
Shree Shyam Pulp & Board Mills Ltd.
Emp. Code:Department:
Review 1 - 27 Dec 2012
Feedback Suggested KPI for Jan-Mar Target Date(To be given under column L3)
L-5
Data to be validated
x
x
Completed in Sept/Oct 2012. Drag
load on wire is reduced. Increasing
the wire life.
Next KPI: To monitor the power consumption saving of
Oct- Dec. With baseline of Sept consumption.
Consumption numbers to be taken from Mr Rajiv Pande.
Should be cleaned every 5 days.
Machine needs downtime of 2-3 hrs
of downtime. Formation of slime leads to breakages. No formal schedule
in place for cleaning. Done only on basis
of estimation of slime formation.
Next KPI : Formal schedule of cleaning to be formed and
follwed in Jan-March.
Improvement in Tear Factor ( 36- 37 to 38 ). Runability of
machine improved.
Next KPI : Figures to be procured from lab indicating
increased performance in terms of runability and tear
factor, etc. Till Sept : 288- 289 .
Currently : 291 ( Max possible) . Increased
production.
Next KPI : Production data to be submitted with exact
figure of increase.
Shaft problems in PM 3. Addressed by
usage of Vauum Pump nash. Increase
in production . Runability increase.
Shree Shyam Pulp & Board Mills Ltd.
Emp. Code:
Runability affected due to fluctuation in water level in seal fit.
Production-
Sept: 1534 Oct : 1802 Nov :
1599 Dec ( till date ) : 1384 Challenges to
be addressed:Availability of felt at the right time as a priority.
Fans introduced in Hood System to
combat condensation due to
winter season. Finishing Loss
(Currently): 6% ; Target ( Jan-March) :
5.5%
Next KPI : Listing of initiatives that will lead to reduction in finishing loss. Flow meter to be requested for Steam and
Power Consumption monitoring. Quality control of
helpers to be ensured to reduce finishing loss via incentives and training.
Department:Review 1
Actual Financial Impact Feedback
Being done.
Being done.
Being done.
Estimated Financial Impact
TPM initiatives to be outlined in consultation with PBOPlus . To be establish timelines and responsibility centers
Oct-Dec : 5070 TAvg PD: 55.1 TPD
As on 29-JanJan: 1577 T
Avg PD: 56.32 TPD
Schedule made with Mech Foreman.
Schedule made on 22 Jan. Detailed activity wise plan to be
made with timelines.
Made without timelines as linked to boiler shutdown.
To be compiled.
Yes
To be made .Not done as yet since it is linked to boiler
shutdown.
Cleaning and pump change done.
Reduction in breakages to be tracked
OTIF reports to be plotted for Planned versus Actual.
Shree Shyam Pulp & Board Mills Ltd.
720 Ed. Qual. Post Graduate Diploma in Pulp and Paper technologyPaper M/C 3
Target Date(To be given under column L3)Weightage
L-4 L-3 L-2 L-1
x x x x x
x x x x x
4-Jul-12
Sept, Oct
25-Aug-12
August
18-Sep-12
Sept
Shree Shyam Pulp & Board Mills Ltd.
720 Ed. Qual. Post Graduate Diploma in Pulp and Paper technology
Paper M/C 3
Target Date(To be given under column L3)
L-5 L-4 L-3 L-2
Suggested KPI for April-June
Shree Shyam Pulp & Board Mills Ltd.Annexure I
Post Graduate Diploma in Pulp and Paper technology
x x x
x x x
%age/ Level Achieved
Actual Performance (By
Appraiser)Perfromance
score
Drag load on wire reduced
Breakage for slime reduced
Surface properties of paper increased
Finish deckle increased
M/C runability improved
Shree Shyam Pulp & Board Mills Ltd.Annexure I
Post Graduate Diploma in Pulp and Paper technology
Vacuum fluctuation on wire reduced
Target Date(To be given under column L3)
Weightage
L-1
%age/ Level Achieved
Actual Performance (By Apprais
er)
Perfromance score
Shree Shyam Pulp & Board Mills Ltd.
Perfromance Planning and Assesment for the Quarter Oct - Dec, 12Name : JN Tiwari
Designation: Head Pulp Production
S No KRA KPI
1 Pulp Production
2 Cost of production Target cost of production
3434.60 MT/month(Avg. of Jan-Oct 2012) to be increased as per plan
3 Delivery to internal Customer %OTIF4 Employee Engagement Employee Engagement Index
Signature of Appraisee:
Shree Shyam Pulp & Board Mills Ltd.
Perfromance Planning and Assesment for the Quarter Jan-Mar 2013Name : JN Tiwari
Designation: DGM Recovery
S No KRA KPI
1 Production Achievement Traget Production Achievement
2 Cost of production
Steam consumption
Power Consumption
Chemicals In effluent
3 % OTIF4 Employee Engagement Index
3
Reduction in effluent discharge from cauticizing pit to zero effluent
Reduction in furnace oil consumption
4
Shree Shyam Pulp & Board Mills Ltd.
Review 1 - 26 Dec 2012
Initiatives/Action 0/1
N/A
2) Timely change C.D. throat. Plan fulfillment %
1
NA
Saving of Caustic by 2%
INR per metric tonne1
Steam Consumption
1
Steps to achieve the Initiative/Action
Measures/Performance
Indicator
1) Using cooking aid along with Caustic (Uniform cooking,
Unbleached Brightness will be improved and bleach chemical will
be reduced)
1) Adding Cooking Aid 5MT/month (Cost of cooking Aid – Rs 150/Kg)
Metric tonnes per month
2) Changing C.D. Throat after six months(Cost of C.D. throat Rs 6 Lacs;
cost of Maintenance -Rs 25000/month)
3) Increase of Pulp Production by approximately 17MT/day.
Increase in metric tonnes per day
1) Cost of Caustic 40000/MT 2) Caustic consumption reduced by 2% 3) INR 30.8
lacs per month
1) Cost of steam - INR 1000/MT 2) Saving of Steam - INR 19.25 Lacs per month Net Saving - 41.3
lacs per month
% NA% 0
1
3
4
75
Shree Shyam Pulp & Board Mills Ltd.
Review 2
Initiatives/Action 0/1
Number of 0 ( Red Buttons)
Number of 1 (Green Buttons)
Total number of Activities
Achievement Percentage
Steps to achieve the Initiative/Action
Measures/Performance
Indicator
SCBL from evaporators to ensure 50% conc min
Cleaning of evaporator bodies of 1,2,3rde twice a month
Firing liquor conc to ensure at 60-61% conc min
Checking of firing liquor sample in each shift for solids conc
15-Feb-13
31-Jan-13
31-Jan-13
Reduction in steam consumption 30-Jan-13
No color water to go into drain
Ensure complete combustion of BL fired in the bioler
Recovery boiler secondary air dampers to be set to get 150 mmWC wind box pressure at 13 Tons/Hr air flow and ensure all the primary and
secondary air ports cleaned
Ensure 40 Tons of WL production daily maintaining all the thickners
load in normal condition
Ensure 24 hrs running of lime mud filter and timely removal of mud
from all the thickners
Take all the water from causticizing pit to LMW-2
Reduce Furnace oil consumption from 46 TPM to 40 TPM
Maintain high solid conc of firing liquor and reduce oil consumption
during soot blowing
SHE-Proper segregation of BL spillage water and condensate and
keep the recovery boiler ground floor area fully cleared
Gland cooling water to be taken separately to the main drain and colored water to the recovery pit
Clear water entering the system to be prevented
All the condensate line and water spillage to be taken to clear water
I dentify the non working steam traps and get them in proper
working order
Monitor weekly the consumption of steam with reasons for variance
Identify points of unrequired power consumption
Reduction of 10 Units/ Ton of WL
Reduce chemical discharge down to standard levels
Number of 0 ( Red Buttons)
Number of 1 (Green Buttons)
Total number of Activities
Achievement Percentage
Shree Shyam Pulp & Board Mills Ltd.
Emp. Code:Department:
Review 1 - 26 Dec 2012
Feedback Target Date(To be given under column L3)
L-5 L-43850 3900
Suggested KPI for Jan-MarSept : 3273.59
MT/month Oct: 3961.48
MT/Month Nov: 3590.17
MT/Month Currently : Nil
cooking aid ( since Oct)
Challenges to be Addressed : Difficult to
manage performance of
cooking aid because of
quality. Hence not enforced. When Paper machines
run dry , this measure will be
encouraged.
Difficult to manage
performance of cooking aid because of
quality. Hence not enforced. When Paper
machines run dry , this
measure will be encouraged.
Challenges to be addressed:Cost of
chemicals is rising. Caustic
consumption has risen . Steam and
power consumption has
also risen.Maintenance is not properly done by the dept
itself. Maintenance
previously outsorced. Throat
has to come by 18-Jan-2013 else
Pulp mill performance will
deteriorate.
Next KPI : Caustic
Consumption to be 38% in Jan-March against
39.5% (Current). Reduction in
Chlorine consumption to
10% against 10.7% (Current)Next KPI : Target
of Steam Consumption : 2.5 Ton/Ton of Pulp against 3 Tons/Ton of
Pulp at presentNext KPI: PHE has to be
employed. In order to use it,soft water
supply required. This is a Cross-
Functional initiative with PowerPlant.
Shree Shyam Pulp & Board Mills Ltd.
Emp. Code:Department:
Review 2
Feedback
Being done in Jan. Currently 48-49%.
Next KPI : Add an initiative in Oct- Dec about
reduction in chemicals going
into effluent treatment
Estimated Financial Impact
Actual Financial Impact
Suggested KPI for April-Jun
Being done in Jan. Currently is 58-59%. This is due to economiser leakage. Will
be completed by end of Feb.
Done
Done
Being Done
Not Done. Will be done by 20-Feb-2013
Currently 120mmWC. Air tuning being done to ensure that it reaches
150mmWC at 12.5 T/hr
Currently 40-41.5 tons of WL . Being done as per schedule
Being done. Drain will be closed. As a result Pulp mill will receive more water to better the quality of washing being
done there.
Identification complete. Awaiting first shut opportunity.
Require flowmeter. PR raised, installation in April
Done. Currently Zero color water in drain.
Shree Shyam Pulp & Board Mills Ltd.
Ed. Qual.Production ( Pulp )
Target Date(To be given under column L3) Weightage
L-3 L-2 L-14000
%age/ Level Achieved
Actual Performance (By
Appraiser)
Shree Shyam Pulp & Board Mills Ltd.
Ed. Qual.Production ( Pulp )
Target Date(To be given under column L3) Weightage
L-5 L-4 L-3 L-2 L-1
Shree Shyam Pulp & Board Mills Ltd.Annexure I
Perfromance score
Shree Shyam Pulp & Board Mills Ltd.Annexure I
%age/ Level Achieved
Actual Performance (By Appraise
r)
Perfromance score
Shree Shyam Pulp & Board Mills Ltd.
Perfromance Planning and Assesment for the Quarter Oct - Dec, 12Name : V.K.THARADDesignation: GM
S No KRA KPI
1 Target Production acheivement
SCBL Production to be increased
2 Target cost of production
Increase in WL production by 25% ( from 854 ton to 1068 Ton per
month ave.)
Increase in Steam generation by 20%(from 9797 tons/month to 11760
tons/month)
Increase in power generation in 1.9 MWTG Set by 25% (from 361752
KWH/Month to 452200 KWH/month)
Reduce Furnace Oil consumption from 46 Ton/month to 39Tons/month (15%)
x x
x x
Signature of Appraisee:
Shree Shyam Pulp & Board Mills Ltd.
Performance Planning and Assesment for the Quarter Jan-Mar 2013Name : V.K.THARADDesignation: GM
S No KRA KPI
%OTIF ( To be assigned to his Senior - Head )
Employee Engagement Index ( To be assigned to his Senior )
1 Production Target Production achievement
Boiler Breakdown
2 Cost of Production Target cost of production
5S
3 %OTIF Weekly
4 Employee Engagement Index
Shree Shyam Pulp & Board Mills Ltd.
Initiatives/Action 0/1
Date
1
Date
1
Increase evaporator feed rate Date
1
Increase plant availability Date
1
Date
1
Reduce dependability on FO Firing at >60% conc Date0
Oil burner cleaning and checking Burner nozzle cleaning frequently Date
1
Review 1 - 26 Dec 2012
Steps to achieve the Initiative/Action
Measures/Performance
Indicator
Reduce Recovery boiler down time from 16% to 6%
Effective soot bowing & regular air port cleaning.
Increase Liquor firing rate from 6Ton/Hr to 8 Tons/Hr dry solids.
Effective soot bowing & regular air port cleaning.
Body cleaning, PHE Cleaning, Precooler in circuit continuously.
Soot Blowing,air port cleaning,firing liq conc.
90 % steam generation to be supplied to 1.9 MWTG Set.
LP Steam PRDS controller to be set on auto mode.
x x x
x x x
0
6
7
85.71
Shree Shyam Pulp & Board Mills Ltd.
Review 2
Initiatives/Action 0/1
Number of 0 ( Red Buttons)
Number of 1 (Green Buttons)
Total number of Activities
Achievement Percentage
Steps to achieve the Initiative/Action
Measures/Performance
Indicator
Tuesdays
15-Jan-13
31-Jan-13
12/1/2013
Maintain the Achieved Targets of 1200 TPM of WL
100% compliance to Target
% cost saving over Oct - Dec
Zero repeat of Oct 2012 boiler breadown till the major
modification of the boiler 1.Reduction of Boiler Pressure from
42 - 36 kgs/ cm2100% compliance
to Target
Reduce Effluent Discharge from Evaporator Plant
From 30 m3/hr to 10 m3/hr from 1-
Feb-2013
1. Monitor weekly and file report with number of instances of excess
discharge and analysis of reasons for the same.
2. Recirculation of vacuum pump sealing water and pre-cooler water
3. Recirculation of Gland Cooling Water
1 % reduction over avg of Oct - Dec
Sit with all stakeholders to arrive at correct steam cons nos
Reduce Furnace Oil consumption from 46 Ton/month to 41.5Tons/month (10%)
10% reduction and Cost Saving
Detailed Plan
28-Feb-13
15-Jan-13
2. Implementation of measures
28-Feb-13
1. Implementation Plan for 5S 31-Jan-13
2. Implementation of measures
12-Jan-13
2. Weekly report
1 Program
12-Jan-13
2. Training Program as per plan 100% Compliance
Conc of black liquor to be increased from 10-Jan-2013
2 % increase( 61% from 59% and Cost
Saving
Firing of the same to be increased to 7.5 T/hr from 7 T/hr from 15-Jan-
2013
5.8% increase in Production and
Cost Saving
The drive to improve level of insulation in the plant needs to be
increased
1. Identification and rectification plan of steam losses.
100% Compliance to Plan
SHE- Proper segregation, housekeeping. FIFO
100% compliance to Plan
100 % compliance to weekly plan
1. Not done in the past. Finalise weekly plan with PPC ( Vivek
Shrotriya)
10% variance over plan allowed
Training program for PHE Maintenance
1. Training programme schedule finalisation
Number of 0 ( Red Buttons)
Number of 1 (Green Buttons)
Total number of Activities
Achievement Percentage
Shree Shyam Pulp & Board Mills Ltd.
Emp. Code: 1344Department: Chemical recovery
Feedback Target Date(To be given under column L3)
L-5 L-4
Review 1 - 26 Dec 2012
Suggested KPI for Jan-Mar
WL Production Oct : 1104 T Nov : 1047 T. De-bottlenecking of turbines to reduce Recovery Boiler downtime ( From 6 MW to 2 MW )
Next KPI : Steps to be taken to ensure that there is no repitition of major boiler breakdown as happened in Oct (?) 2012 till the major modification of the boiler
Current Firing Rate : 7- 7.5 T/hr. Firing Rate ( July ) : 6 T/hr
Earlier WBL feed rate : 60 m3/hr Current ( Oct-Dec) : 75 m3/hr. Estimated prod inc is 25%.
New KPI : Training program for PHE Maintenance leading to savings in coal due to reduced steam consumption.( % cost saving )
Oct: 12573 T/Month Nov:11410 T/MonthNew Initiative implemented.Recovery boiler runabiliity is increased by linking it's power to the turbine.
Oct : 42 T/Month
Nov : 41.2 T/Month
Conc of black liquor to be increased., Firing of
the same to be increased. Further
reduction is difficult. But attempts are
being made.The drive to improve level of insulation in
the plant needs to be increased.Detailed
plan to be added as a new KPI
New KPI related to SHE- Proper segregation,
housekeeping. FIFO
x x
x x
Shree Shyam Pulp & Board Mills Ltd.
Emp. Code: 1344Department: Chemical recovery
Review 2
FeedbackEstimated Financial Impact
Actual Financial Impact
Suggested KPI for April-June
Currently running at 36kgs/cm2
Currently running at 10 m3/hr. By 15 feb will be zero m3/hr. Savings in fresh water consumption. Zero wastage of fresh water although consumption itself may reduce from 10m3/hr currently to 5 m3/hr
As on 15-Feb the weekly reports will be filed. No instances of excess discharge.
Done.
Done.
Steam/Power consumption nos have been gotten for Jan. Oct-Dec will be compiled by 8 Feb 2013
Jan: 1050 TPM (Power breakdown twice in month leading to lower production. 1 Jan - 11 hrs 22 Jan-12 hrs. Fire in cables and transformer respectively). 11/18 Jan lower paper production.
4-5% reduction in
Power Generation
Jan: 40 TPMFeb (Expected) : 39 TPM. Savings of INR 45000 per ton of furnace oil.
Currently 60% . Economiser leakage slowed down progress. By end of month will reach 61%
Currently 7.5 T/hr . Will be maintained till March.
Identification of area is done. Proposal and plan of work complete. Contractor called in. Lack of funds .
Done.
Done.
Not done. 10-Feb plan will be finalised after meeting.
Plan made. External training personnel to be brought in. Awaiting commitment of time from that side.
Savings will be reflected in
Steam Generation and Furnace
Oil consumption
Reduction in Loss of
Production by 5.8%
Shree Shyam Pulp & Board Mills Ltd.
Ed. Qual. PG DIPLOMA (PULP & PAPER)
Target Date(To be given under column L3)Weightage
L-3 L-2 L-1
1/10/2012-31/12/2012
1/10/2012-31/12/2012
1/10/2012-31/12/2012
1/10/2012-31/12/2012
1/10/2012-31/12/2012
1/10/2012-31/12/2012
1/10/2012-31/12/2012
%age/ Level Achieved
x x x x x
x x x x x
Shree Shyam Pulp & Board Mills Ltd.
Ed. Qual. PG DIPLOMA (PULP & PAPER)
Target Date(To be given under column L3)
L-5 L-4 L-3 L-2 L-1
Currently running at 10 m3/hr. By 15 feb will be zero m3/hr. Savings in fresh water consumption. Zero wastage of fresh water although consumption itself may reduce from 10m3/hr currently to 5 m3/hr
Steam/Power consumption nos have been gotten for Jan. Oct-Dec will be compiled by 8 Feb 2013
Currently 60% . Economiser leakage slowed down progress. By end of month will reach 61%
Identification of area is done. Proposal and plan of work complete. Contractor called in. Lack of funds .
Plan made. External training personnel to be brought in. Awaiting commitment of time from that side.
Shree Shyam Pulp & Board Mills Ltd.Annexure I
Actual Performance (By
Appraiser)Perfromance
score
x x
x x
Shree Shyam Pulp & Board Mills Ltd.Annexure I
Weightage %age/ Level
Achieved
Actual Performance (By Apprais
er)
Perfromance score
Currently running at 10 m3/hr. By 15 feb will be zero m3/hr. Savings in fresh water consumption. Zero wastage of fresh water although consumption itself may reduce from 10m3/hr currently to 5 m3/hr
Shree Shyam Pulp & Board Mills Ltd.
Perfromance Planning and Assesment for the Quarter Oct - Dec, 12
Name :S.K.Pant
Designation: DGM Project
S NoKRA/Equipment KPI Initiatives/Action
Weighted average of value of projects completed on timePAPER MACHINE #3
PAPER MACHINE #4
VERTICAL DIGESTER
ROTARY DIGESTER
220TPD BLEACH PLANT
FINALIZATION OF SCHEDULE, FINALIZATION OF BOM & ORDER
PLACEMENT
FINALIZATION OF SCHEDULE, FINALIZATION OF BOM & ORDER
PLACEMENT
COMMISSIONING OF VERTICAL DIGESTER IN 1ST WEEK OF NOV.
COMMISSIONING OF ROTARY DIGESTER
DOUBLE WET WASHING FOR CD#1&2
REVISED DRAWING FINALIZATION, BOM FINALIZATION
BOM & SCHEDULE FINALIZATION, CONTRACTOR FOR MECH. WORK
FINALIZATION
ODL PLANT
CLO2
Weighted average of value of projects completed within budgets
Credit management and payments
Vendor satisfaction
Signature of Appraisee:
DRAWINGS & BOM FINALIZATION, SCHEDULING WORK IS UNDER
PROGRESS
CONSULTANT FOR DRAWING & DETAIL ENGINEERING FINALIZATION
Shree Shyam Pulp & Board Mills Ltd.
Performance Planning and Assesment for the Quarter Jan-mar 2013
Name :S.K.Pant
Designation: DGM Project
S No
KRA/Equipment KPI Initiatives/Action
1 PAPER MACHINE #3Weighted average of
value of projects completed on time
Bottlenecks Identified by Nayyar for PM3/4. Which calls for additional
investments. After the factoring of President and Nayyar, de-bottlenecking is a priority.
PAPER MACHINE #4
220TPD BLEACH PLANT
Bottlenecks Identified by Nayyar for PM3/4. Which calls for additional
investments. After the factoring of President and Nayyar, de-bottlenecking is a priority.
DOUBLE WET WASHING FOR CD#1&2
Number of activities to be completed by 31 Jan 2013 ( CD 1 )
Number of activities to be completed by 15 Mar 2013 ( CD 2 )
Number of activities to be completed by 31 Mar 2013
ODL PLANT
CLO2
110 TPD
CLO2 Planned Project Cost
3 Credit management and paymentsCash flow requirements
4 Vendor satisfaction
Fornightly meeting with vendors
Signature of Appraisee:
Number of activities to be completed by 31 Mar 2013
Number of activities to be completed by 31 Mar 2013
DOUBLE WET WASHING FOR CD#1&2
Planned Project Cost Vs Actual Project Cost
Clearance of Vendor Bills within 3 days of receipt.
Shree Shyam Pulp & Board Mills Ltd.
Review 1 - 26 Dec 2012
0/1 Feedback
DATE N/A
DATE N/A
PLAN,EXECUTE,AUDIT DATE 1
PLAN,EXECUTE,AUDIT DATE 1
DATE 0
DATE 1
Steps to achieve the Initiative/Action
Measures/Performance Indicator
MONITORING THE MECH. WORK PROGRESS ON DAILY BASIS AND
FINALIZATION OF APPROCHFLOW SYSTEM DRAWINGS
SS Material not received as per plan. Requisition given in Nov. Order yet to be placed. Challenges to
be addressed: Bottlenecks Identified by Nayyar for PM3/4.
Which calls for additional investments.
After the factoring of President and Nayyar, de-bottlenecking is a
priority.
FABRICATION WORK IS ALMOST COMPLETED AND DRAWINGS ARE
FINALTotal fabrication done.
SS remaining.
MONITORING OF CIVIL & MECH. WORK ON DAILY BASIS, WEEKLY REVIEW WITH TEAM MEMBERS
Underwent major modification in interest of improved layout. Not critical so not coming in
way of other project delays. Will be
completed by 31 Jan ( CD 1) and 15 Mar ( CD
2 )
MONITORING OF GANTRY PLATE ERRECTION & AGITATOR WORK ON REGULAR BASIS & WEEKLY REVIEW
OF PROJECT
Trusses completed as per revised plan
( 17 Nov ).
DATE 0
DATE 0
Number of 0 ( Red Buttons) 3Number of 1 (Green Buttons) 3
Total number of Activities 6Achievement Percentage 50
DRAWING & DETAIL ENGINEERING WORK IS GOING ON
Dismantling and shifting of pipeline completed.
Civil works delayed. Pipeline marterial required , delayed.
INQUIRY PLACEMENT WORK IS GOING ON
Pant and Saini to finalise the schedule
based on data provided by the
consultants.
Shree Shyam Pulp & Board Mills Ltd.
Review 2
0/1
20-Jan-13
2. Finalise implementation schedule 25-Jan-13
25-Jan-13
Steps to achieve the Initiative/Action
Measures/Performance Indicator
Estimated Financial Impact
1. Submission and Approval of the de-bottlenecking plan.
3. Number of activities to be completed by 31 Mar 2013
2. Finalise implementation schedule
Completed in Oct-Nov
Completed in Oct-Nov
Number
Date
Completed in Oct-Dec
Completed before Oct-Dec
Number
Date
1. Submission and Approval of the de-bottlenecking plan.
3. Number of activities to be completed by 31 Mar 2013
1. Number of Purchase Requisitions to be placed
2. Number of Purchase orders to be placed.
3.Number of Equipments to be received
4. Erection and commissioning of all equipments
5. Weekly follow up meeting with purchase/Vendors
Number of occasions where follow up scheduled but not
completed. ( Records to be kept )
1. Number of Purchase Requisitions to be placed
2. Number of Purchase orders to be placed.
3.Number of Equipments to be received
4. Erection and commissioning of all equipments
5. Weekly follow up meeting with purchase/Vendors
Number of occasions where follow up scheduled but not
completed. ( Records to be kept )
1 Finalise implementation schedule
2. Finalise implementation schedule
1. Finalise P&I 20-Jan-132. Create work schedule 28-Feb-13
3. Implement according to schedule 100% compliance
28-Feb-13
10-Mar-13
% Variance ( 10 % over Planned )
Approx cost of INR 5.42 crores
15-Feb-13
% Variance ( 10 % over Planned )
Number of 0 ( Red Buttons)Number of 1 (Green Buttons)
Total number of ActivitiesAchievement Percentage
2. Number of Purchase Requisitions to be Finalised and Sent
3. Purchase orders to be placed by 31 Mar
4. Number of Equipments to be received and erected by 31 Mar
1. Receipt of Information from consultant
Number Days after receipt from Consultant
1. Clear all pending bills of vendors ( For CD 1)
2. Release of Payments to Vendors ( For CD 1)
3. Total actual cost Vs Original Planned Cost
NOTE : CD 2 to start after completion of CD 1
Finalise monthly cash flow requirements based on
implementation schedule
Monthly monitoring of Actual Vs Planned Cashflow
Number of occasions where Vendor Bills not cleared within 3
days
Record of all meetings with vendors and documentation of all issues
raised by them Number of occasions where was
not held( against schedule.)
Shree Shyam Pulp & Board Mills Ltd.
Emp. Code:Department:
Suggested KPI for Jan-Mar Target Date(To be given under column L3)
L-5
Acknowledgement of all Communications sent from Plant to HO with tentative
timelines. Work biforcation between the project team
members. Challenges to be addressed:Workshop tools
if not available will be outsourced to maintain
compliance with timeline.
Shree Shyam Pulp & Board Mills Ltd.
Emp. Code:Department:
Review 2
Actual Financial Impact Feedback
Done. 24-Jan-2013Get specific activities from SK Pant
that are being overseen bby RK Verma
Being Done. To be finished by 5-Feb-2013.
Multiple activities waiting for material. Not received.
Being Done. To be finished by 5-Feb-2013
Done. 24-Jan-2013
Erection completed for most items.
Being Done. To be finished by 5-Feb-2013.
Multiple activities waiting for material. Not received.
Being Done. To be finished by 5-Feb-2013
Not done as yet. Estimated completion at 8 Feb 2013. Material
not received.
Updated in 24-Dec-2013. Blow tank material only new addition to list.
Being done. To be given on 5-Feb-2013
Records being kept. All previous communications to be updated to
record format bby 10-Feb-2013
Redrawing on 14-Jan-2013. Mech has passed onto Civil. Civil design
under progress. To be passed by 2-Feb-2013
PO for 8 out of 27 items created. 19 still pending.
List completed and submitted. Equipment still pending.
Records being kept. All previous communications to be updated to
record format bby 10-Feb-2013
All Required PR filed.
Received 1 Dec 2012 - 28 Jan 2013. Corresponding PRs have been generated.
To be done by 10-Feb-2013
To be finalised on 2-Feb-2013
Being done.
All vendors go through Delhi
All vendors go through Delhi
Redrawing on 14-Jan-2013. Mech has passed onto Civil. Civil design
Perfromance Planning and Assesment for the Quarter Oct - Dec, 12Name : RAJEEV PANDE
Designation: DGM ELECTRICAL
S No KRA
1 Reduction of Unplanned shut down/ Break down
2 Improvement in Grid Power Factor
2 Improvement in Grid Power Factor
3 Timely completion of projects of different areas and section
Signature of Appraisee:
Shree Shyam Pulp & Board Mills Ltd.
Performance Planning and Assesment for the Quarter Jan - Mar 2013Name : RAJEEV PANDE
Designation: DGM ELECTRICAL
S No KRA
1 Unplanned Breakdowns
2 Under the Mill Survival Plan to provide reliable power to ETP
3 Improve information sharing and documenting system
4 Timely completion of all expansion projects
5 Cross Functional Intiatives
Shree Shyam Pulp & Board Mills Ltd.
KPI Initiatives/Action
0.93(existing) to 0.97 Adding 1000kvar capacitors
10% reduction ( present 10.45 Hrs to 9.30 Hrs per month) - For paper machines
Increasing critical equipments route checking
Scheduled Preventive maintenance of critical
equipment having no stand-by , will be increased.
To identify route cause of break down and prevent re-occurance.
0.93(existing) to 0.97 Adding 1000kvar capacitors
Shree Shyam Pulp & Board Mills Ltd.
As per set targets by project team under the guidance of president
Proper co-ordination with entire project team, purchase and
vendors
Daily monitoring of work progress
KPI Initiatives/Action
Reduction in Unplanned Breakdowns
Implementation Plan of measures
Root -Cause and Why-Why Analysis of Downtime in Oct-Dec
No. of activities completed monthwise
Preventive Maintenance Schedule
No Downtime due to lack of Critical Spares
Zero loss due to machine failure
Record of Breakdown of Equipments whose preventive
maintenance already done.
New 11 KV distribution system commission
To provide reliable and constant power to the ETP for the better
performance from TG.
Ensure all ongoing projects to make sure there are no surprises .Expand horizontally to include Instrumentation and some elements of Civil.
Integration of Preventive maintenance system in IT systems
To discuss with Mr Anoop Srivastva for facility and options
avalable in REMCO
Daily monitoring of work progress
Awarding erection job to well equipped and professional
contractor
Identification of 10 Major Causes for Breakdown in consultation
with Mechanical/Electrical/Process
1. Water leakage in roof.
2
Shree Shyam Pulp & Board Mills Ltd.
Review 1 - (DATE)
0/1
Date 1
Date 1
Date 0
Date 1
Date
1
Date
% increase in PGF 1
Steps to achieve the Initiative/Action
Measures/Performance
Indicator
Identifing critical equipments of each section and a format to
devlope for on line checking of critical parameter. The check list to
be filled by electrician daily and verifyed by section engineer.
Off line check list to be devloped for, scheduled preventive maintenance
equipments.
Date to be fixed after consultation with process as per their monthly
planned shut plan.
History records of equipments to be devloped.
A format of why- why analysis to be devloped and analysis of each break
down will be done.
Entry of each break down and analysis in the history record
1000KVAR capacitors will be installed.
Date 1
Date N/A
Date N/A
Date 0
2
6
8
75
Shree Shyam Pulp & Board Mills Ltd.
A format will be developed for weekly monitoring of capacitor's
performance analysis.
Awarding erection job to well equipped and professional
contractorNumber of 0 ( Red
Buttons)
Number of 1 (Green Buttons)
Total number of Activities
Achievement Percentage
Review 2
0/1
12-Jan-13
12-Jan-13
15-Jan-13 1
15-Jan-13 1
20-Jan-13
Steps to achieve the Initiative/Action
Measures/Performance
IndicatorEstimated Financial
ImplactActual Financial
Impact
9 hrs 40 mins for all machines and hrs for
pulp
100 % Compliance to Plan
100% Compliance to Plan
Finalise plan of requirements with all stakeholders.
Ensure availability of spares and consumables
Finalise equipment-wise work under preventive maintenance
31-Mar-13
10-Jan-13
25-Jan-13
28-Feb-13
9-Jan-13
PR to be generated 1 day after approval
To float inquiryPO to be released
Monitor weekly. Format to be finalised.
100% compliance to Plan
History Card to be Maintained. ISO Documents
Number of such cases. Allowed 5%.
1. Costing and scheduling for work to be done.
2. Ensuring availability of materials and parts by raising of PR on time.
3. Implement activities as per schedule
4,. Monitor Performance after installation
Finalisation of Consumption Pattern over the last 3 months data of
Spares
Identifying critical list of spares to be kept in stock. Raising purchase
requisitions.
To prepare Technical Feasibility Report
BOM and estimate to be submitted to the President for approval
Monitor recipt of material Erection and commissioning 28-Feb-13
20-Feb-13
31-Jan-13 Preventive module has not been taken. Along with other modules. To be added to RAMCO. Ravi Tandon to discuss with Amit Gupta
100% Compliance
29-Jan-13 Comparitive statements sent to Purchase on 28 Jan-2013
Offer of SN consultant is with management for their approval
1. Finalise implementation schedule along with estimated cost
2. Number of activities to be completed by 31 Mar 2013
3. Number of Purchase Requisitions to be placed
4. Number of Purchase orders to be placed.
5..Number of Equipments to be received
6. Erection and commissioning of all equipments
7. Monitoring and recording of progress on fortnightly basis
8. Summary of action plan for removing bottlenecks
1. Meeting of all heads to identify the 10 major causes per dept
2. Finalisation of measures to mitigate each major cause from each
individual dept.
1. Formalise plan of work with Civil
2. Indent for material
3. Implementation of Measures by plan
4. Tracking and monitoring of major causes to confirm positive effect of
measures.
3. Implement activity according to schedule
4. Track amount of water leakage over next 6 months
Shree Shyam Pulp & Board Mills Ltd.
Emp. Code:Department: Electrical
Review 1 - (DATE)
Feedback Target Date(To be given under column L3)
L-5 L-4
Confirmed by President
Route checking format has been made.Identification of critical
equipments done. Oct : 4 hrs 15 mins. Nov : 9 hrs 15 mins ( VFD failure
increased figure.) Dec: Exceeded as on date.
Schedule finalised for preventive maintenance for next months. Not currently implemented. Shutdown
schedule from Process Dept required. Major shuts in all depts to be compiled
by Process and Maintenance Dept. Take target of 15% reduction in rewinding of
2900 rpm motors for next quarter.
Oct : 0.95 Nov:0.98 Dec: 0.97 Life cycle cost of capacitor should be
analysed as an Initiative for next quarter. Baseline to be established in Dec 2012 for Cost and Life Cycle Run and number of capacitors changed.
Shree Shyam Pulp & Board Mills Ltd.
Emp. Code:Department: Electrical
Oct : 0.95 Nov:0.98 Dec: 0.97 Life cycle cost of capacitor should be
analysed as an Initiative for next quarter. Baseline to be established in Dec 2012 for Cost and Life Cycle Run and number of capacitors changed.
0% equipment received as per original project plan. Since site is not ready.
Cooling towers have to be shifted but electrical work pending. Challenges to
be addressed:Equipment planning. (Projects): Funds flow for procurement.
Capital used in Revenue.
On 25 Jan , next order to be released to registered contractor.Major contributor
in TPM planning.
Review 2
Feedback Feedback
Jan breakdown is 21 hrs.
Suggested KPI for April-June
On jan-29:Cooling tower is ready for
commissioning. Shut required to finish shift.
0% equipment received as per original project plan. Since site is not ready.
Cooling towers have to be shifted but electrical work pending. Challenges to
be addressed:Equipment planning. (Projects): Funds flow for procurement.
Capital used in Revenue.
Prepared. Will be submitted by 19-Jan- 2013 to President- DONE
To be submitted and finalised on 1/24/2013 - DONE
Memos dispatched to Power Plant and Recovery. However Pulp and Paper
machine will be completed by 26-Jan-2013. NOT DONE - BY 15 Feb
Under process. To be Completed by 26-Jan-2013 - DONE
Under process. To be Completed by 31-Jan-2013. NOT DONE. To be done by 10
Feb
DONE
Done
Done
Done
To be done after commissioning.
DONE
DONE
DONE
DONE
AwaitingAwaiting
Formats already developed by PBOPlus. To be shared with Rajeev Pandey. Abhilash to confirm the same ASAP
through an email to RP with a copy to Manjit Singh.
Regular Items consumption listed.All communications must be recorded. Final consumption database to be
compiled by 22-Jan-2013.
Under process. To be Completed by 26-Jan-2013. DONE.
Awaiting
Preventive module has not been taken. Along with other modules. To be added to RAMCO. Ravi Tandon to discuss with Amit Gupta
Comparitive statements sent to Purchase on 28 Jan-2013
Approval gotten 22-Jan-2013Order Pending with Purchase.
Shree Shyam Pulp & Board Mills Ltd.
Ed. Qual.
Target Date(To be given under column L3)Weightage
L-3 L-2 L-1
1 Oct - 20 Oct
1 Oct - 31 Oct
1 Oct - 31 Dec
1 Oct - 31 Dec
On going
1 Oct - 31 Dec
1 Oct -31 Oct
%age/ Level Achieved
Actual Performance (By
Appraiser)
1 Oct - 15 Nov
Shree Shyam Pulp & Board Mills Ltd.
Ed. Qual.
Target Date(To be given under column L3)
Weightage
L-5 L-4 L-3 L-2 L-1
1 Oct - 20 Oct
1 Oct - 31 Oct
1 Oct - 31 Dec1 Oct - 31 Dec
On going
1 Oct - 31 Dec
1 Oct - 15 Nov
Shree Shyam Pulp & Board Mills Ltd.Annexure I
Perfromance score
Shree Shyam Pulp & Board Mills Ltd.Annexure I
%age/ Level Achieved
Actual Performance (By Apprais
er)
Perfromance score
Shree Shyam Pulp & Board Mills Ltd.
Performance Planning and Assesment for the Quarter Oct - Dec, 12Name : Dalip VermaDesignation: Sr. Manager
S No KRA KPI
1 Breakdown Reduction by 5 %
2 5 % Reduction in Cost
3 Reducing Air Compressor Failure
4
Reduce Breakdowns due to Instrumentation
Reduce instrumentation maintenance cost
Completion of Project of different areas and sections.
4
*NOTE: The individual will get the credit as long as he has done the activity whether the parameter improves or not . If we follow this model , management may not see any benefit. It is better to link to breakdown time saving and cost saving at least for his senior
Signature of Appraisee:
Shree Shyam Pulp & Board Mills Ltd.
Performance Planning and Assesment for the Quarter Jan- Mar 13Name : Dalip VermaDesignation: Sr. Manager
S No KRA KPI
1 Unplanned Breakdowns
Completion of Project of different areas and sections.
5 % Reduction in Unplanned Breakdowns
Inventory Management
3
4 Porject Assigned Listing of all Ongoing Projects
Reducing air leakage in plant. Identify the air leakage & rectify it.
5 Cross Functional Intiatives
Shree Shyam Pulp & Board Mills Ltd.
Review 1 - (DATE)
Initiatives/Action0/1
TPM Listing of all Instruments Date
1
Date
1
TPM Date
0
Date
0
TPM
Date
1
Project Management
Date
NA
Date
NA
Steps to achieve the Initiative/Action
Measures/Performance Indicator
Scheduled preventive maintenance of critical equipment
Analyzing Critical spare Consumption in 3 month & listing
Transmitter Failure to be reduced by providing Knopy & Cover with plastic sheet.
Reducing air leakage in plant. Identify the air leakage & rectify it.
Proper coordation with entire project team, purchase and vendors.
Awarding erection job to well equipped and professional contractor.
Project Management
Date
NA
*NOTE: The individual will get the credit as long as he has done the activity whether the parameter improves or not . If we follow this model , management may not see any benefit. It is better to link to breakdown time saving and cost saving at least for his senior
Number of 0 ( Red Buttons) 2Number of 1 (Green Buttons) 3
Total number of Activities 5Achievement Percentage 60
Shree Shyam Pulp & Board Mills Ltd.
Review 1
Initiatives/Action
0/1
5 % reduction over Oct-Dec
Daily monitoring of work progress.
Steps to achieve the Initiative/Action
Measures/Performance Indicator
12..01.2013
15.01..2013
100 % compliance to Plan
21.01.2013
90% compliance to schedule
28.01.2013
Monitor weekly 100% compliance to Plan
21..01.2013
28.01.2013
Tracking the individual section 100% compliance to Plan
15.01.2013
Project
100% compliance to Plan
100 % compliance to Plan
Root -Cause and Why-Why Analysis of Downtime in Oct-Dec
Implementation Plan of measures
Preventive Maintenance Schedule
Finalise plan of requirements with all
stakeholders.
Ensure availability of spares and consumables
Finalise equipment-wise work under preventive
maintenance
Record of Breakdown of Equipments whose preventive
maintenance already done. Number of such cases. Allowed
5%.
No Downtime due to lack of Critical Spares
Finalisation of Consumption Pattern over the last 3 months data of
Spares
Identifying critical list of spares to be kept in stock
raising purchase requisitions
1. Finalise implementation tracking schedule
1. Finalise implementation schedule along with
estimated cost
2. Number of activities to be completed by 31 Mar
2013
3. Number of Purchase Requisitions to be placed
100 % compliance to Plan
100% compliance to Plan
100 % compliance to Plan
Number of 0 ( Red Buttons)
Number of 1 (Green Buttons)
Total number of ActivitiesAchievement Percentage
4. Number of Purchase orders to be placed.
5..Number of Equipments to be received
6. Erection and commissioning of all
equipments
7. Monitoring and recording of progress on
fortnightly basis % variance over agreed dates as
per plan.
8. Summary of action plan for removing bottlenecks
Identification of 10 Major Causes for Breakdown in
consultation with Mechanical/Electrical/Process
1. Meeting of all heads to identify the 10 major
causes per dept
2. Finalisation of measures to mitigate each major
cause from each individual dept.
3. Implementation of Measures by plan
4. Tracking and monitoring of major causes to confirm
positive effect of measures.
Shree Shyam Pulp & Board Mills Ltd.
Emp. Code:Department:
Review 1 - (DATE)
Feedback Suggested KPI for Jan-Mar Target Date(To be given under column L3)
L-5
NOT INITIATIVES
Breakdown- July+Aug+Sept: 24 hr 15 min Oct+Nov+Dec(Till date ) : 20 hr 55 mins. ( 14.9% reduction)
Next KPI : Further 5% reduction. Materials not being procured. Critical list with date of PR to be compiled and addressed to President.
No equipment was nspected beyond date.
Analysis not complete. However, critical spare listing submitted.
Next KPI : To be completed by 31 Jan.
Data from stores to be submitted .Review pending.
CD - 3 points . Bleach Plant - 1 point. M/C - Regular. PM 3 - To be rectified after all machines are shutdown.Temporary arrangement made. Compressor loading has been dreduced as a result of it.
Next KPI :Flowmeters to be requested and installed
NOT INITIATIVES
*NOTE: The individual will get the credit as long as he has done the activity whether the parameter improves or not . If we follow this model , management may not see any benefit. It is better to link to breakdown time saving and cost saving at least for his senior
Shree Shyam Pulp & Board Mills Ltd.
Emp. Code:Department:
Review 1
Actual Financial Impact Feedback
Next KPI :100% Compliance to Preventive Maintenance Schedule. Number of occurences where Schedule was not followed. Next KPI: Segregation and Storage of Spares.
Suggested KPI for April-June Target Date(To be given under column L3)
L-5 L-4 L-3 L-2
Plan finalised at Dept level. Still to be communiated to all shareholders by 1 - Feb
60% of all spares and consumables , PR raised. Remainder to be completed 7-Feb
Activities have been listed in schedule. Dates to be added. 1-Feb-2013
Costing has been completed. Schedule of work for all ongoing is compiled. Final date to be decided upon release of funds.
In progress. Being done in consultation with President.
Shree Shyam Pulp & Board Mills Ltd.Annexure I
5% Reduction
5 % Reduction
10 % Reduction
%age/ Level Achieved
Actual Performance (By
Appraiser)Perfromance
score
As per set targets by project team under
the guidance of president
Shree Shyam Pulp & Board Mills Ltd.Annexure I
Target Date(To be given under column L3)
Weightage L-1
As per set targets by project team under
the guidance of president
%age/ Level Achieved
Actual Performance (By Apprais
er)
Perfromance score
Shree Shyam Pulp & Board Mills Ltd.
Performance Planning and Assesment for the Quarter Oct - Dec, 12Name : R.K. VermaDesignation: G.M. Production
S NoKRA KPI
1
Production achievement Target Production achievement
2
Cost of production Target cost of production
3
%OTIF-Q Quality
4 Employee Engagement Index
Signature of Appraisee:
Shree Shyam Pulp & Board Mills Ltd.
Performance Planning and Assesment for the Quarter Jan-Mar 2013
Name : R.K. Verma
Designation:G.M. Production
S NoKRA KPI
1Production achievement PM 3 - Project Assigned
* Feed back column to be independently filled by R.K.Verma
regarding work done Oct-Dec.
PM 4 - Project Assigned
2 Cost of production Target cost of production
4 Employee Engagement Index Coordination with all Inter-
Functional Depts
Shree Shyam Pulp & Board Mills Ltd.
Initiatives/Action Steps to achieve the Initiative/Action
Prevent breakage loss due to slime
Cleaning of approach flow system after pressure screen providing cleaning dummy (In head box and its taper
header. 5 No. of dummies fitted to clean the pipe was beyond approach earlier )
Final dummy was fitted on 25 August 2012 ( Earlier breakage because of slime was 18- 20 per day. After
providing this dummy and cleaning the system initial six days has breakage due to slime, as nearly zero. Then
again, we have to clean the system. Time taken to clean the system is almost two and a half hours. Increase in
production of 2.5- 3 tonnes per day.)
Control AKD consumption and avoid intermittent soft size
paper rejection
Change the AKD dosing point at appropriate point. Note: This change we have done in PM-1 and PM- 2 also.
(Earlier AKD and Retention Aid was at interval of 400mm before pressure screen then AKD partially precipitated before mixing up with pulp. Dosing point was given in
accept line dummy of primary c.c. consumption reduced to 2 kg/ton. Also soft size rejection substantially reduced)
In summer season before changing dosing point , AKG consumption was 50 +- 2 kg/hr. After changing dosing
point it has reduced to 45+- 2 kg/hr . Rejection of paper due to soft size paper was almost 10 tonnes/
month/machine. Which has gone down to 0.4 tonnes
Increase the deckle at pope reel to get 380-387 cms deckle
utilization
Adjusting the sealing strip of wire and press felt, making it plain. And other small exercises.(Earlier deckle at pope
reel we used to get 391 cms but because of some reasons , deckle at pope reel has gone down to 386 cms. After
given exercse, we started to get 390-391 cms and utilization upto 387 cms.)
Cleaning of cut reels from side by old cloth
Timely cleaning of dryer fluff accumulated on dryer doctor
Avoid reel damage complaint
Increase the deckle at pope reel to get 380-387 cms deckle
utilizationBefore 28-July 2012, our average deckle utilization was 377.5 and at present we are utilizing at average upto
384.48 cms
Exluding down time we are getting production rate of 2.69
tonnes/hr in PM-3. To be increased to 2.8 tonnes/hr
Timely system cleaning. Guiding machine man to reduce paper reeling time after each break . Keep constant watch
to avoid unwanted breakdown and attend the job as preventive maintenance. (We attended 2 jobs during
boiler breakdown. Ie: Pressroll B/S sleevechange and 2nd press roll change that was causing downtime due to
coupling bolts breaking . We and the team are giving similar attention to avoid such time loss)
Reduce the drag load on wire and increase the wire life
Convince management to invest in ceramic tipped suction box top. (We communicate to the management and procured IBS ceramic tipped top fitted in dry suction
boxes of PM- 3 & 4. Consequently the drive load reduced by 20- 25 amp. The total fitting be completed from 4-July-
2012 to 20-Aug-2012)
Saving power when 20 Tonnes or more order in higher
grammage.
We will stop 160 kw vacuum pump and take 110 kw vacuum pump in operation. (If we get 68 gsm or higher order 20 or more than that we follow the practice and
save the power.)
To avoid creasing complain in sheet order paper
To add 2-3 kg/tn UF Resin in winter season and 1-2 kg/ton in balance months on regular basis. (To use UF Resin
without fail.)
Control the fluff complaint from printer
Sharp cutting of circular knife.(We are always keeping grinded knife on R/W and cutter. So that operation may
change in odd hours also. Keep regular watch on working of rewinder cutter whether they are following or not.)
Proper packaging of reels. (To insert and tighten core plug by hammer .Edge protector quality to check and see
whether packers are tightening or not.Proper stitching of reels by HDP cloth)
Shree Shyam Pulp & Board Mills Ltd.
Initiatives/Action Steps to achieve the Initiative/Action
Preshut Activities
1. Receipt of Vacuum Pump from China ( PO Placed )
3. Overheaed Crane ( Funds to be released )
Factoring Comments of President and Nayyar.
2. Press Frame from China ( Funds to be released by 10 Jan 2013 )
Civil Works
Erection
Commissioning
Preshut Activities
1. Receipt of Vacuum Pump from China ( PO Placed )
Civil Works
Erection
Commissioning
Avoid reel damage complaint
Shifting of all Equipments to Outside
Factoring Comments of President and Nayyar.
2. Press Frame from China ( Funds to be released by 10 Jan 2013 )
Shifting of all Equipments to Outside
Budget To be Provided by Head Office
Coordination Meetings to be done Weekly ( Fridays)
1. Minutes of meeting to be maintained with Pending Issues ,Timelines and Responsibility Centers
1. Record to be kept of all complaints ragrding reel damage, split machine wise with Why Why analysis
2. Ensure proper packaging of reels
13. Track machine complaints over 3 months period
weekly.
Shree Shyam Pulp & Board Mills Ltd.
Review 1 - 26 Dec 2012
0/1 Feedback
1
0
1
1
1
Measures/Performance Indicator
Suggested KPI for Jan-Mar
Log book to be maintained in plant.
Data regarding total breakages due to slime , monthwise ( Oct-Dec) to
be submitted. As well production increase
( PM-3 ).
in 2010 : 26 kg/ton brought down in 2012:
23 kg/ton (In Summers).
Reduction less than 0.4 is not possible.
Reduction achieved due to good climatic
conditions.
1
1
NA
NA
NA
1
0
Increase from 384.48 to 386 ( Max achieved in PM-3 ). President and
Shamim will validate the numbers regarding
Deckle.
Submit data on current achor values for Low
GSM and High GSM. To be attached in Ja-March
KPI along with suggested
imporvements.
Encouraging results. Continued in current
quarter.
Detailed Project schedule for PM-3 and PM-4 completed.
Number of 0 ( Red Buttons) 2
Number of 1 (Green Buttons) 5
Total number of Activities 7
Achievement Percentage 71.43
Shree Shyam Pulp & Board Mills Ltd.
Review 2
0/1 Actual Financial Impact
25-Apr-13
17-Dec-12
2/10/2013 ((60 Days )
16-Jan-13
7-Feb-13
10-Jan-13
Measures/Performance Indicator
Estimated Financial Impact
3/15/2013 (27 Days )
3/25/2013 (30 Days )
21-April-2013 ( 55 Days )
25-Apr-13
25-Apr-13
17-Dec-12
2/10/2013 ((60 Days )
16-Jan-13
7-Feb-13
3/15/2013 (27 Days )
3/25/2013 (30 Days )
21-April-2013 ( 55 Days )
25-Apr-13
Variance against Budgeted Cost Budget prepared and discussed with top management on 25-Jan-2013
% Variance over plan
% Variance pending issues
5th of next month
0% complaint received
Every Tuesday
Number of 0 ( Red Buttons)Number of 1 (Green Buttons)
Total number of ActivitiesAchievement Percentage
Shree Shyam Pulp & Board Mills Ltd.
Emp. Code: 966Department: Paper M/C
Target Date(To be given under column L3)
L-5 L-4 L-3
Shree Shyam Pulp & Board Mills Ltd.
Emp. Code: 966
Department: Paper M/C
Feedback Suggested KPI for April-June Target Date(To be given under column L3)
L-5
Done
Not received.
Funds not released.
Funds not released.
Not Received.
Done.
Budget prepared and discussed with top management on 25-Jan-2013
Being done.
Shree Shyam Pulp & Board Mills Ltd.
Ed. Qual. Pulp and Paper Tech from I.P.T Saharanpur
Target Date(To be given under column L3)Weightage
L-2 L-1
%age/ Level Achieved
Actual Performance (By
Appraiser)
Shree Shyam Pulp & Board Mills Ltd.
Ed. Qual. Pulp and Paper Tech from I.P.T Saharanpur
Target Date(To be given under column L3)Weightage
L-4 L-3 L-2 L-1
Shree Shyam Pulp & Board Mills Ltd.Annexure I
Perfromance score
Shree Shyam Pulp & Board Mills Ltd.Annexure I
%age/ Level Achieved
Actual Performance (By Apprais
er)
Perfromance score
Shree Shyam Pulp & Board Mills Ltd.
Perfromance Planning and Assesment for the Quarter Oct - Dec, 12Name : Pawan Kumar SainiDesignation: Sr. Manager
S NoKRA KPI
1 Reduction of Customer complaints Zero Customer Complaints
2 Loss due to quality problems Zero loss due to quality problems
3 Standardization of Quality norms
4 Improve Quality Enabling Processes
Signature of Appraisee:
Shree Shyam Pulp & Board Mills Ltd.
Performance Planning and Assesment for the Quarter Jan- Mar 2013Name : Pawan Kumar SainiDesignation: Sr. Manager
S No
KRA KPI
1 Zero Customer ComplaintsImprove Quality of Pre-Dispatch and Online Inspection
2 Standardization of Quality norms
3 Improve Quality Enabling Processes
4 Measures to improve Pulp Quality
Efficient working of testing equipment and procure new as per
requirement
Timely alerts on Brightness variation from backend
Timely alerts on Cleanliness from backend
Timely alerts on presence of residual hypo in bleached pulp.
Shree Shyam Pulp & Board Mills Ltd.
Review 1 - 27 Dec 2012
Initiatives/Action 0/1
Analysis of Past Complain
1
0
NA
NA
Reduced time in reporting & testing result1
Number of errors found
0
Analysed the Inventory Of Stock 1
1
Steps to achieve the Initiative/Action
Measures/Performance Indicator
Try to Reduction of Customer Complain of 50%.
Number of Complaints Processed/Analysed
Preventive action to be taken to minimise
complaints.
Generate MIS & Testing Report
To Train Subordinates & Accuracy of The Report
Analysis Of Stock Chemical Consumption On the Basis Of Last Six Month Record
Stock Planning As per Production Plan
Efficient Working Of testing Equipment 1
Number of 0 ( Red Buttons)2
5
Total number of Activities7
Achievement Percentage71
Shree Shyam Pulp & Board Mills Ltd.
Review 1 - 27 Dec 2012
Initiatives/Action 0/1
Identified The External Vendors For Calibration Of
Lab Testing Equipment
Timely Maintenance Of Testing Equipment
Calibration All The Lab Equipment
Number of 1 (Green Buttons)
Steps to achieve the Initiative/Action
Measures/Performance Indicator
To give training and more supervision in Finishing House also to reduce customer complaint
1. Root -Cause and Why-Why Analysis of complaints
received in Oct-Dec
To work along with Mr Vivek Shrotriya for developing weekly MIS on PDI
For improving online inspection shop floor chemists' (at Paper Machines) JDs to be defined by Mr Saini
Ensure all Lab instruments are certified and calibrated.
Find number of errors % wise and subsequent reduction in errors.
1. Timely feedback to Pulp Mill shift-in-charge
2. Corrective action in co-ordination with respective machine In-Charges to avoid
greater losses at Paper MachineGeneral : Ensure clear records in Log Books for compliance of the above
Shree Shyam Pulp & Board Mills Ltd.
Emp. Code:Department:
Review 1 - 27 Dec 2012
Feedback Suggested KPI for Jan-Mar Target Date(To be given under column L3)
L-5Complaints Received : 30 Major Complaints: 1) Shade (1)2) GSM (4)3) Reel damage (6) 4) Rough cutting and dust (4)5) Creasing (4)6) Paper breakage (4) 7) Short size (4)
1)Core pipe resolution through training.2) Checking increase of knifes to reduce rough cutting.
1)Incoming reports are almost immediate but time has reduced from 2 pm to 11 am
Training provided on KRAs but errors remain.
Next KPI : Find number of errors % wise and subsequent reduction in errors.
Shree Shyam Pulp & Board Mills Ltd.
Emp. Code:Department:
Review 1 - 27 Dec 2012
Actual Financial Impact Feedback
Calibration of all equipment done. Done after a year since last check.
Estimated Financial Impact
Get added initiatives from PK Saini after consultation with Manjit Singh
Shree Shyam Pulp & Board Mills Ltd.
1284 Ed. Qual. B. Sc.Quality Control(P.C Lab)
Target Date(To be given under column L3)Weightage
L-4 L-3 L-2 L-1
15 Oct - 31 Dec
15 Oct - 31 Dec
15 Oct - 31 Dec
15 Oct - 31 Dec
Shree Shyam Pulp & Board Mills Ltd.
1284 Ed. Qual. B. Sc.Quality Control(P.C Lab)
Target Date(To be given under column L3)
L-5 L-4 L-3 L-2
Suggested KPI for Jan-Mar
Get added initiatives from PK Saini after consultation with Manjit Singh
Shree Shyam Pulp & Board Mills Ltd.Annexure I
%age/ Level Achieved
Actual Performance (By
Appraiser)Perfromance
score
Shree Shyam Pulp & Board Mills Ltd.Annexure I
Target Date(To be given under column L3)
Weightage L-1
%age/ Level Achieved
Actual Performance (By Apprais
er)
Perfromance score
Shree Shyam Pulp & Board Mills Ltd.
Performance Planning and Assesment for the Quarter Oct- Dec 2012Name : Anoop Kumar Saxena
Designation: General Manager
S No KRA KPI
1 Projects Assigned
2 Projects Assigned
3 Projects Assigned
4 Projects Assigned
To make a system for consumption of RO reject water in wet washing.
To avoid multi discharge of ash from Boiler 3 & make single discharge point. It will reduce the ash
transport cost & Fly ash.
Maintaining of Co-ordination with Boiler-Turbine erector
Coordination with Purchase department and stores for material supply.
Signature of Appraisee:
Shree Shyam Pulp & Board Mills Ltd.
Performance Planning and Assesment for the Quarter Jan-Mar 2013Name : AK Saxena
Designation:
S No KRA KPI
1 Breakdown Reduce boiler breakdown time by 5%
General Manager Projects
2 Projects Assigned
3 Projects Assigned Hydraulic Testing of Boiler
4 Projects Assigned Commissioning of new cooling tower
Coordination with Purchase department and stores for material supply.
5 Projects Assigned FBR Commissioning
6 Projects AssignedTo avoid consumption of fresh water in the vacuum pump and the pre-cooler of the evaporator. for this
to make arrangement for water circulation
Shree Shyam Pulp & Board Mills Ltd.
Initiatives Steps to achieve the Initiative/Action
Plan,Get it done,Check
Plan,Get it done,Check
Meet,Review,Decide,Act
Meet,Review,Decide,Act
Setting up of 250 mtr. of 4" line. All material used from the scrap.
Setting up separate screw conveyor from scrap
Arranging a meeting at 5:30 PM daily to review day's achievement and
plan next day's schedule
Maintainence of coherence in needs & supply by checking bills. Preparing requests and personal Inspections.
Number of 0 ( Red Buttons)Number of 1 (Green Buttons)
Total number of ActivitiesAchievement Percentage
Shree Shyam Pulp & Board Mills Ltd.
Initiatives/Action Steps to achieve the Initiative/Action
Economiser performance
1. Economiser performance to be monitored and reported.
4. Implementation measures for causes of Breakdown
5. Monitoring
No of equipments to be recdFinalise vendor wise schedule of meetings
Weekly coordination meetings. MOM issued on same day
Installation and Procurement
2. Number of activities to be completed by 31 Mar 2013
5..Number of Equipments to be received
6. Erection and commissioning of all equipments
8. Summary of action plan for removing bottlenecks
2. Number of activities to be completed by 31 Mar 2013
2. WHY-WHY analysis of each breakdown in the period of Oct-Dec ( 3 Nos. )
3. Analysis of Planned vs Actual Time of rectifying the problem.
Maintainence of coherence in needs & supply.
Analysis of October -Dec of meetings to be provided in terms of % delay beyond plan.
1. Finalise implementation schedule along with estimated cost
3. Number of Purchase Requisitions to be placed with expected schedule of delivery
4. Number of Purchase orders to be placed.
7. Monitoring and recording of progress on fortnightly basis with areas of concern
1. Finalise implementation schedule along with estimated cost
3. Number of Purchase Requisitions to be placed with expected schedule of delivery
5..Number of Equipments to be received
6. Erection and commissioning of all equipments
8. Summary of action plan for removing bottlenecks
2. Number of activities to be completed by 31 Mar 2013
5..Number of Equipments to be received
6. Erection and commissioning of all equipments
8. Summary of action plan for removing bottlenecks
2. Number of activities to be completed by 31 Mar 2013
5..Number of Equipments to be received
4. Number of Purchase orders to be placed.
7. Monitoring and recording of progress on fortnightly basis with areas of concern
1. Finalise implementation schedule along with estimated cost
3. Number of Purchase Requisitions to be placed with expected schedule of delivery
4. Number of Purchase orders to be placed.
7. Monitoring and recording of progress on fortnightly basis with areas of concern
1. Finalise implementation schedule along with estimated cost
3. Number of Purchase Requisitions to be placed with expected schedule of delivery
4. Number of Purchase orders to be placed.
6. Erection and commissioning of all equipments
8. Summary of action plan for removing bottlenecks
7. Monitoring and recording of progress on fortnightly basis with areas of concern
Shree Shyam Pulp & Board Mills Ltd.
Review 1 - 27 Dec 2012
0/1 Feedback Suggested KPI for Jan-Mar
1
1
1
0
Measures/Performance
Indicator
Number of Delays against date give to
top management Completed in first week of November.
Number of Delays against date give to
Board
Completed in the end of Oct. Saving of 35000 INR /month ( approx) + Benefit of reduction in pollution.
Number of times meeting cancelled or
delayed
Analysis of October and November of meetings to be provided in terms of % delay beyond plan.
Number of times, per month, failed to meet timelines agreed on. No formal record
maintainedNew KPI : Maintain record of communication
New KPI : Hydraulic testing of Boiler by 25 Jan.
New KPI : FBR project to be started by February 15. Detailed listing of major activities and timelines to be provided.
New KPI: New cooling tower to start by Jan 25. Detailed listing of major activities to be given.
New KPI : Economiser performance to be monitored and reported. There should be zero breakdown in boiler due to economiser.
Number of 0 ( Red Buttons) 1Number of 1 (Green Buttons)3
Total number of Activities 4Achievement Percentage 75
Shree Shyam Pulp & Board Mills Ltd.
Review 2
0/1 Actual Financial Impact
31-Jan-13
New KPI: WHY-WHY analysis of each breakdown in the period of Oct-Dec ( 3 Nos. ) . Also the analysis of Planned vs Actual Time of rectifying the problem.
Oct-Dec: Nil ( Except for economiser breakdown)Jan: Nil
Being done. Zero breakdown.
Zero Breakdown.
Zero Breakdown.
Zero Breakdown.
Zero Breakdown.
DoneDoneDone
Done
Done
Done. Awaiting material
Done. Awaiting material
Done. Awaiting material
Done.
Done.
Done.
Done.
Done.
Done.
Done.
Done.
Done.
Done
Done
Done
Done
Done
Done
Done
Shree Shyam Pulp & Board Mills Ltd.Annexure I
B.Tech(Mechanical)
Weightage
100%
100%
100%
100%
%age/ Level Achieved
Actual Performance (By
Appraiser)Perfromance
score
Shree Shyam Pulp & Board Mills Ltd.Annexure I
Target Date(To be given under column L3)
Weightage L-2 L-1
%age/ Level Achieved
Actual Performance (By Apprais
er)
Perfromance score
Shree Shyam Pulp & Board Mills Ltd.
Performance Planning and Assesment for the Quarter Oct - Dec, 12Name : Dr. Sudhir K. Singh ChauhanDesignation: Deputy Manager
S No KRA KPI
1 Plantation as per business plan
2
3
Development of Hi-tech clonal nursery and R&D Centre.
Boundary plantation as per business plan
Boundary plantation at main gate/cycle stand area, ETP & Oxygen tank area.
Seasonal Flowering, Herbal, ornamental plants , Hedge planted and vegetable, new Bore well at Garden and Guest house area
Agriculture crop model and agro forestry crop model
Agriculture crop model and Agro forestry crop model
1) Development of Agricultural - crop model of Sugarcane irrigated by ETP water of the mill
4 Plantation as per business plan FSC –coc certification
Signature of Appraisee:
Shree Shyam Pulp & Board Mills Ltd.
Performance Planning and Assesment for the Quarter Jan-Mar 2013Name : Dr. Sudhir K. Singh ChauhanDesignation: Deputy Manager
S No KRA KPI
2) Intercropping agro forestry model development irrigated by ETP water
1
Development of green belt through pla
Agro forestry models for farmers under
Development of Hi-Tech Clonal Productiob and R&D center ( Nursery)
To promote ETP water and clonal pla
Social & Farm forestry initiatives like promotion of clonal plantation,development of nursery of both Eucalyptus and Bamboo with certif
Maintaing documentation work and crea
Shree Shyam Pulp & Board Mills Ltd.
Review 1 - 27 Dec 2012
Initiatives/Action0/1
Plan,Implement,Check
1Plan,Implement,Check
0Plan,Implement,Check
0
Plan,Implement,Check
1
Steps to achieve the Initiative/Action
Measures/Performance
Indicator
Establishment of Green house, net house , open nursery and CMA for large scale up plantations through farmers and mills. Work will be started of Hi-Tech Clonal Nursery and R&D Centre after sanction of project/budget. Project already has been submitted.
Number of Days delay against annual commitment
Clonal Eucalyptus, Ashoka, Kadam, Silver oak, Gold Mohar, Shisham, Amaltas and Acacia Species for greenery development and balancing environment.
Number of Days delay against annual commitment
Oranamental and flowering plants planted in scrubbed Plastics drums at ETP. Medicinal, ornamental and Flowering plants will be planted accordingly seasons.
Number of Days delay against annual commitment
Model develop for using ETP water as a irrigation for agriculture crop and compare with farmers crop within adjoining mills area
Number of Days delay against annual commitment
Plan,Implement,Check
0Plan,Implement,Check
0
Number of 0 ( Red Buttons) 4Number of 1 (Green Buttons) 2
Total number of Activities 6Achievement Percentage 33
Shree Shyam Pulp & Board Mills Ltd.
Review 2
Initiatives/Action
0/1
Develop Agro- Forestry model with Clonal Eucalyptus and Poplar irrigation by ETP water for demo to farmers. Meeting held with adjoining farmers regarding use of ETP water as a irrigation in crops
Number of Days delay against annual commitment
Preparation of documents for FSC-coc at Kashipur. For Global marketing of our products
Number of Days delay against annual commitment
Steps to achieve the Initiative/Action
Measures/Performance
Indicator
Under this project , SSPBML will be able to rpdouce 6 Lac plants in a year. Of which ,m 4-5 lacs of clonal plants will be distributed/on sale to farmers at a rate of INR 8/ Plant. Nursery generates revenue from this project of approimately 20 Lacs/Yr after meeting the expenses. These plants will cover a green belt of 200-250 hectare area. This plantation shall generate sufficient raw material ( wood pulpp) bas per future requirements within 5-6 years. It will alsp provide a positive impact to prreserve our environment, which is a major challeneg today.
10-Jan2. Get approval 15-Jan-13
5-Feb-13
As per calendar
100% compliance
10-Feb-13
Chemical properties of sugarcane and ither content will be tested from Pant Nagar University and Govt Sugarcane Research center.
28-Feb-13
15-Feb-13
28-Feb-2013 on wards.
1. Development of Gene Bank/CMA/Mini Hedge Garden for coppice shoots for clonal production. Size of Gene bank will be 320 m2.
1. Submit proposal listing costings, benefits and estimated workplan
3.Created detailed calendar with project activities and planned dates for each
4. Indent all required consumables/materials
5.Monitor Receipt of materials
Block and line/boundary plantation of Clonal Eucalyptus , Poplar, and other avenue plants and species
1. Created detailed calendar with project activities and planned dates for each
2. Indent all required consumables/materials
We will prepare data of our sugarcane crop and compile with adjoining farmers' sugarcane crop. We will analyse chemical properties of our sugarcane with GB pant University and sugarcane research center and compare with normal farmer's crop
A meeting will be conducted with the adjoining farmers at the time of harvesting at sugarcane plot.
1. Compilation of Date of Sugarcane crop
2. Analysis of Data as well as Chemical Propoerties of crop
3. Meetings with adjoining farmers
1. Completion of Survey 28-Feb-13
5-Mar-13
10-Mar-13
As per report to be completed by 31-March-2013
Agro forestry intercropping model develop for poplar and Eucalyptus with Sugarcane
1. Submit projected model in form of proposal
2. Create calendar for demonstrations/meetings with farmers
2. Demonstrate plot for adjoining farmers according to date.
Conduct close survey in adjoining villages and feedback will be taken from the farmers then prepare a policy after discussion with management
2. Meetings for discussion with farmers
3. Submission of report listing feedback from farmers and agreements if any
4. Implemenatation of measures listed in report
Social & Farm forestry initiatives like promotion of clonal plantation,development of nursery of both Eucalyptus and Bamboo with certif
20-Feb-13
10-Feb-13
20-Feb-13
5-Mar-13
1. Identification of 10 Farmers for establishing seed nursery of eucalyptus and bamboo.
2. Create calendar for all activities including but not limited to the provision of good quality seeds by the mills and technical guidance to growers free of cost
3. Conduct survey to gauge effectiveness of program
4. Implementation of all CAPA measures gotten from survey
100% Compliance
23-Jan-13
2. Create training calendar 8-Feb-13
100% compliance
Number of 0 ( Red Buttons)Number of 1 (Green Buttons)
Total number of ActivitiesAchievement Percentage
5. Follow through on all initiatives taken by company for enviromental protectionb as per guidelines of MoEF
Implement and prepare documents as per FSC standards and conducting monthly trainings to mills staffs at Kashipur regarding FSC_COC under supervision of President
1. Preparation of documents
3. Carry out training modules as per calendar
Shree Shyam Pulp & Board Mills Ltd.
Emp. Code: 1468Department: Plantation
Review 1 - 27 Dec 2012
Feedback Suggested KPI for Jan-Mar Target Date(To be given under column L3)
L-5 L-4 L-3
Oct - Mar
Oct - Dec
Sept - Feb
Modified proposal submitted in December.
Yield (estimated) : 100 quintals
Shree Shyam Pulp & Board Mills Ltd.
Emp. Code: 1468Department: Plantation
Review 2
Actual Financial Impact Feedback Target Date(To be given under column L3)
L-5
Next KPI: Submission of feasibility report on use of Eucalyptus and Poplar as fuel for boiler.
Dec Onwards
Next KPI : Inform all villagers in surrounding areas of the effluent and that it is not dangerous or harmful.
Next KPI : Agro data required with referenc eto Input, harvest, yield data etc.
Estimated Financial Impact
Suggested KPI for April-Jun
Under this project , SSPBML will be able to rpdouce 6 Lac plants in a year. Of which ,m 4-5 lacs of clonal plants will be distributed/on sale to farmers at a rate of INR 8/ Plant. Nursery generates revenue from this project of approimately 20 Lacs/Yr after meeting the expenses. These plants will cover a green belt of 200-250 hectare area. This plantation shall generate sufficient raw material ( wood pulpp) bas per future requirements within 5-6 years. It will alsp provide a positive impact to prreserve our environment, which is a major challeneg today.Approval of project and release of first installemnt of INR 6 Lac up to 15-Jan-2013 for Gene Bank/CMA/MiniGedge garden.
DonePending
Chemical properties of sugarcane and ither content will be tested from Pant Nagar University and Govt Sugarcane Research center.
Decrease pressure of pollution control board if farmers using our ETP water as an alternative source of irrigation
As per report to be completed by 31-March-2013
Practice will be helpful to obtain various certificates related to environment safety and management ie: ISO EMS 14001(2004) Bank Loan benefits in taxation and other environmental consents with this effort. Our plantation activities will also be helpful to claim carbon credit and FSC certification
Get recognition , value addition and for leg Pre-Assesment was done on 29-Nov-2012 . Final audit has been completed by SSGS auditor on 23-Jan-2013
Shree Shyam Pulp & Board Mills Ltd.Annexure I
Ed. Qual. M.Sc. Ph.D.- Forestry
Target Date(To be given under column L3)Weightage
L-2 L-1
100%
100%
100%
%age/ Level Achieved
Actual Performance (By
Appraiser)Perfromance
score
100%
Shree Shyam Pulp & Board Mills Ltd.Annexure I
Ed. Qual. M.Sc. Ph.D.- Forestry
Target Date(To be given under column L3)
Weightage L-4 L-3 L-2 L-1
%age/ Level Achieved
Approval of project and release of first installemnt of INR 6 Lac up to 15-Jan-2013 for Gene Bank/CMA/MiniGedge garden.
Decrease pressure of pollution control board if farmers using our ETP water as an alternative source of irrigation
Pre-Assesment was done on 29-Nov-2012 . Final audit has been completed by SSGS auditor on 23-Jan-2013
Actual Performance (By Apprais
er)
Perfromance score
Shree Shyam Pulp & Board Mills Ltd.
Perfromance Planning and Assesment for the Quarter Oct - Dec, 12Name : Raman KarirDesignation: Deputy Manager
S No KRA KPI
xx
xx
x %OTIF (To be assigned to senior) x
x Employee Engagement Index ( To be asx
1 Housekeeping of Turbines 5S Score
2 Breakdown Hours Zero Break Down
3 Hydraulic Cylinder leakage Frequency of Leakage
Power Production ( To be assigned to senior)
Cost of Power Production( To be assigned to senior)
Signature of A
Shree Shyam Pulp & Board Mills Ltd.
Performance Planning and Assesment for the Quarter Jan-Mar 2013Name : Raman KarirDesignation: Deputy Manager
S No KRA KPI
1 Power Production
2Cost of Power Production Cost of Consumables
Reduce Hydraulic Cylinder leakage
3 %OTIF4 Employee Engagement Index
Shree Shyam Pulp & Board Mills Ltd.
Review 1 - 27 Dec 2012
Initiatives/Action 0/1
x xx
x xx
x x x
x x x
1-Nov to Dec 2012 5S Score % 1
2. Listing of spares in stockDate 1
INR Lakhs 0
1-Nov to 31 Dec 2012
0
1. Indent of spares 29-Oct-12
02. Review of spares One month ( 30-Nov)
3. Change the cylinder One day ( 1-Dec)
Steps to achieve the Initiative/Action
Measures/Performance
Indicator
1. Proper stacking and segregation
3. Consumption of last six months against budget
Analysis of breakdown in last six months
Breakdown Hours per year
Number of occasions of Leakage per year
4. Monitoring
0
Number of 0 ( Red Buttons) 3Number of 1 (Green Buttons) 2
Total number of Activities 5Achievement Percentage 40
Shree Shyam Pulp & Board Mills Ltd.
Review 2
Initiatives/Action 0/1
Listing of spares in stock
1. Indent of spares2. Review of spares
Steps to achieve the Initiative/Action
Measures/Performance
Indicator
To reduce the consumption of consumables/spares by 10%
1. Finalisation of Consumption Pattern over the last 3 months data
of Spares
2. Identify trends in spares usage and highlight critical items
3.Daily updation of issues,receipts and consumption.
Minimise frequency of leakage by maintaining spares
3. Change the cylinder4. Monitoring
Number of 0 ( Red Buttons)Number of 1 (Green Buttons)
Total number of ActivitiesAchievement Percentage
Shree Shyam Pulp & Board Mills Ltd.
Emp. Code:Department:
Review 1 - 27 Dec 2012
Feedback Suggested KPI for Jan-Mar Target Date(To be given under column L3)
L-5 L-4
x x
x x
x x
x x
Scrap/Obsolete items tobe
removed after re-checking by
concerned dept. Elec,mech etc.
Spares listing to be updated in
subsequent KPI
Next KPI: Daily updation of issues,receipts and
consumption. ( Common for Boiler)
Data not submitted. Next KPI: To reduce the
consumption of consumables/spares by 10%
( Same for boiler )
Failure to make contact with
personnel who have relevant information
Next KPI : Eliminate the leakage from hydraulic
cylinder . Same subpoints/initiatives.
Shree Shyam Pulp & Board Mills Ltd.
Emp. Code:Department:
Review 2
Actual Financial Impact FeedbackEstimated Financial Impact
Suggested KPI for April-Mar
Shree Shyam Pulp & Board Mills Ltd.
1199 Ed. Qual. Inter + Mech Diploma PP/ Turbine
Target Date(To be given under column L3) Weightage
L-3 L-2 L-1
x x x x x x
x x x x x x
x x x x x x
x x x x x x
1 Nov - Dec
1 Nov - Dec
29-Oct
%age/ Level Achieved
Actual Performance (By
Appraiser)
One Month (30 Nov)
One Month (1 Dec)
Shree Shyam Pulp & Board Mills Ltd.
1199 Ed. Qual. Inter + Mech Diploma PP/ Turbine
Target Date(To be given under column L3) Weightage
L-5 L-4 L-3 L-2 L-1
Shree Shyam Pulp & Board Mills Ltd.Annexure I
x
x
x
x
Perfromance score
Shree Shyam Pulp & Board Mills Ltd.Annexure I
%age/ Level Achieved
Actual Performance (By Apprais
er)
Perfromance score
Shree Shyam Pulp & Board Mills Ltd.
Perfromance Planning and Assesment for the Quarter Oct - Dec, 12Name : YOGESH KMR. SAINIDesignation: Deputy Manager
S No KRA KPI
1 Projects Assigned
2 Projects Assigned
3 Any other project assigned Meet timelines
Signature of Appraisee:
Shree Shyam Pulp & Board Mills Ltd.
Perfoemance Planning and Assesment for the Quarter Jan-Mar 2013Name : YOGESH KMR. SAINIDesignation: Deputy Manager
S No KRA KPI
Design of new cooling tower so that online one sump out of 4 may be
cleaned
Co-ordination with FBR boiler errector
Shree Shyam Pulp & Board Mills Ltd.
Review 1 - 27 Dec 2012
Initiatives/Action 0/1 Feedback
Plan,Do,Check Number of days delay
1
Meet,Review, Decide,Act
1
0Number of days delay
Number of 0 ( Red Buttons) 0Number of 1 (Green Buttons) 2
Total number of Activities 2Achievement Percentage 100
JAN-MAR TARGETS TO BE MORE SUBSTANTIVE
Shree Shyam Pulp & Board Mills Ltd.
Review 2
Initiatives/Action 0/1
Steps to achieve the Initiative/Action
Measures/Performance
Indicator
Study of existing and new design, Prepration of drawings, Supervised on site progress.
Arrangement of meeting at 5:30 PM to review day's progress and plan next day's schedule.
Number of occasions of missed timelines
Data to be validated
Steps to achieve the Initiative/Action
Measures/Performance
Indicator
Estimated Financial Impact
Number of 0 ( Red Buttons)Number of 1 (Green Buttons)
Target Date(To be given under column L3) Weightage
L-1
100%
100%
Shree Shyam Pulp & Board Mills Ltd.Annexure I
B.Tech (Chemical)
Target Date(To be given under column L3) Weightage
L-3 L-2 L-1
%age/ Level Achieved
Actual Performance (By
Appraiser)Perfromance
score
%age/ Level Achieved
Actual Performance (By Apprais
er)
Perfromance score
Shree Shyam Pulp & Board Mills Ltd.
Perfromance Planning and Assesment for the Quarter Oct - Dec, 12Name : Manish SrivastavaDesignation: Dy. Manager HR
S No KRA KPI
1 Implement HR Processes Deployment of Right Manpower
2 Implement HR Processes
3 Implement HR Processes Encouragement of employees
4 Classification of Workmen
Initiate Employee Engagement Activity
Grading of Workmen into Grade 8 and Grade 9.
Signature of Appraisee:
Shree Shyam Pulp & Board Mills Ltd.
Performance Planning and Assesment for the Quarter Jan-Mar 2013Name : Sachin Verma/Manish SrivastavaDesignation: Dy. Manager HR
S No KRA KPI
1Employee Satisfaction Index Satisfaction Index
2 Administrative Processes TCEC TCEC %3 Satisfaction of A level Players To be introduced next year4 Satisfaction of other Players To be introduced next year
5 Implement HR Processes Deployment of Right Manpower
6 Implement HR Processes Encouragement of employees
7 Classification of Workmen Grading of Workmen into Grade 8 and Grade 9.
Shree Shyam Pulp & Board Mills Ltd.
Review 1 - 27 Dec 2012
Initiatives/Action 0/1
0
0
0
1
1
0
0
Meet with Dept Heads and finalise.
0
Number of 0 ( Red Buttons) 6Number of 1 (Green Buttons) 2
Total number of Activities 8
Steps to achieve the Initiative/Action
Measures/Performance
Indicator
1. Provide the required Manpower within 30 days
Number of times missed agreed upon
timelines
2. Recruitment of qualified manpower as per job requirements within time
Number of times missed agreed upon
timelines
3. Identify the job description for designated position
Number of times missed agreed upon
timelines
1. Organize and Get together any other activities
Number of times missed agreed upon
timelines
3. Organize different committees including workers & staff
Number of times missed agreed upon
timelines
1. Introduce PMS in phases, in the factory for workmen
Number of times missed agreed upon
timelines
2. Identify the employee training needs and inputs fror the same.
Number of times missed agreed upon
timelines
Achievement Percentage 25
Shree Shyam Pulp & Board Mills Ltd.
Review 2
Initiatives/Action 0/1
%? Measured monthly
Identfication to be done by Jan 31.
Identify 5 categories per month
Steps to achieve the Initiative/Action for Jan-
March
Measures/Performance
Indicator
Implement the reward recognition processes in the Engagement
Activities % (Measured
annually )
Criteria for Employee Awards program and different awards to be finalised for foundation Day
1. Provide the required Manpower within 30 days
2. Recruitment of qualified manpower as per job requirements within time3. Identify the job description for designated position
1. Introduce PMS in phases, in the factory for workmen
Format and processes for workmen appraisal to be firmed up by 31 Mar
2. Identify the employee training needs and inputs fror the same.
Target dates for workman level to be finalised by 31 Jan, for all depts.
Meet with Dept Heads and finalise. 9 Depts to be covered by 31 Mar
Number of 0 ( Red Buttons)Number of 1 (Green Buttons)
Total number of ActivitiesAchievement Percentage
Shree Shyam Pulp & Board Mills Ltd.
Emp. Code:Department:
Review 1 - 27 Dec 2012
Feedback Target Date(To be given under column L3)
L-5 L-4 L-3
1 Oct-31 Dec
1 Oct-31 Dec
1 Oct-31 dec
Suggested steps for Jan-Mar
Data to be provided
Next KPI : Identfication to be done by Jan 31.
Identify 5 categories per month
2 events organisedKaizen committee created. Initiatives received from it.
Next KPI : Implement the reward recognition
processes in the Engagement Activities
Next KPI: Format and processes for workmen
appraisal to be firmed up by 31 Mar
Next KPI : Target dates for workman level to be
finalised by 31 Jan, for all depts.
3 Departments a month.
Next KPI : 9 Depts to be covered by 31 Mar
Next KPI: Criteria for Employee Awards
program and different awards to be finalised
for foundation Day
Shree Shyam Pulp & Board Mills Ltd.
Emp. Code:Department:
Review 2
Actual Financial Impact Feedback Target Date(To be given under column L3)
L-5
Estimated Financial Impact
Suggested KPI for April-Jun
Shree Shyam Pulp & Board Mills Ltd.
Ed. Qual.
Target Date(To be given under column L3) Weightage
L-2 L-1
40% 100%
25% 100%
25% 100%
%age/ Level Achieved
Actual Performance (By
Appraiser)
Shree Shyam Pulp & Board Mills Ltd.
Ed. Qual.
Target Date(To be given under column L3) Weightage
L-4 L-3 L-2 L-1
Shree Shyam Pulp & Board Mills Ltd.Annexure I
Perfromance score
Shree Shyam Pulp & Board Mills Ltd.Annexure I
%age/ Level Achieved
Actual Performance (By Apprais
er)
Perfromance score
Shree Shyam Pulp & Board Mills Ltd.
Perfromance Planning and Assesment for the Quarter Oct - Dec, 12Name : S.Maji
Designation: Manager - Stores
S No KRA KPI
1 Production loss due to materials
2 Loss of materials in storage
3 Customer Satisfaction Internal customer satisfaction index
4 5S Implementation of 5S
Elimination of Production loss due to material
Prevention of Loss of material in stroage
Signature of Appraisee:
Shree Shyam Pulp & Board Mills Ltd.
Performance Planning and Assesment for the Quarter Jan-Mar 2013Name : Ashok Sharma/S.Maji
Designation: Manager - Stores
S No KRA KPI
1 Production loss due to materials Reduction of Production Loss
Timely Lifting of Goods from Local transport
2 Prevention of Loss of material in storage
Elimination of Production loss due to material
Modifications and work in Storage
3 Customer Satisfaction Loss of materials in storage
Internal customer satisfaction index
4 5S Implementation of 5S
Shree Shyam Pulp & Board Mills Ltd.
Review 1 - 27 Dec 2012
Initiatives/Action 0/1
1 Oct-31 Dec
d) Issue Material of FIFO basis
31 Dec-31 Jan
Steps to achieve the Initiative/Action/ Timeline
Measures/Performance
Indicator
a) Classification of items and fixation of ROL/ROQ
Tonnes of Production lost
b) Finalise Critical Items list and placement
c) Increase no of items under ROL from existing 500 to 1000
a) Zero availability in stock of expiry date items
Number of items where shortage was found
b) Finalise plane of usage of shelf life items
c) Reduction of Non-Moving Items by 20 %
a) To provide summary sheet of orders placed to Engg depts on
weekly basis% Satisfaction as per
feedback
b) Sending list of pending PRs to Purchase dept
c) Weekly meeting with internal customers
To be implemented dept wide in Stores.
Shree Shyam Pulp & Board Mills Ltd.
Review 2
Initiatives/Action 0/1
Timely Lifting of Goods from Local transport
31-Mar-13
Bearings, Oil seals and Sleeves to come under purview of 5S in Jan-
Mar
Number of 0 ( Red Buttons)
Number of 1 (Green Buttons)
Total number of Activities
Achievement Percentage
Steps to achieve the Initiative/Action/ Timeline
Measures/Performance
Indicator
Tonnes of Production lost- 5% reduction over
loss for Oct-dec
1. Identifying Materials getting Stocks Out on Daily basis
Daily report to be Submitted
2. Critical Material List to be given to purchase daily
1. Compile list of all obsolete/unusable materials still in
storage
15-Mar-13
31-Jan-13
31-Jan-13
28-Feb-13
Daily Submission
28-Feb-13
15-Mar
7-Mar-13
15-Mar-13
d) Issue Material of FIFO basis 100% compliance
Tuesday
Tuesday
Friday
2. Create an At-Risk Sheet for materials
3. Conduct Monthly Meeting with HODs
last week of every month
1. Create calendar of work with timelines and responsibility centers
2. Create action plan and raise indents
3. Meet with all stakeholders and finalise as well as circulate plan
4. Follow through with plan as per schedule
a) Classification of items and fixation of ROL/ROQ
b) Finalise Critical Items list and placement
c) Increase no of items under ROL from existing 500 to 750
a) Zero availability in stock of expiry date items
b) Finalise plan of usage of shelf life items
c) Reduction of Non-Moving Items by 5 %
% Satisfaction as per feedback
a) To provide summary sheet of orders placed to Engg depts on
weekly basis
b) Sending list of pending PRs to Purchase dept
c) Weekly meeting with internal customers . MoM issued same
day with timelines and responsibility centers
To be implemented dept wide in Stores.
1. Create final implementation plan 31-Jan-13
2. Implementation of all 5S activities 100% Compliance to plans
Number of 0 ( Red Buttons)
Number of 1 (Green Buttons)
Total number of Activities
Achievement Percentage
Shree Shyam Pulp & Board Mills Ltd.
Emp. Code:Department:
Review 1 - 27 Dec 2012
Feedback Target Date(To be given under column L3)
L-5 L-4 L-3
Suggested KPI for Jan-Mar
Resigned hence could
not be reviewed. New
incumbent taken over few
days back
Next KPI : By January end complete ROL/ROQ list for all consumables to be compiled.
Shree Shyam Pulp & Board Mills Ltd.
Emp. Code:Department:
Review 2
Feedback Target Date(To be given under column L3)
L-5
Data for Oct-Dec not compiled. Will be done by 5-Feb 2013
Being done
Being done.
Work has started.
Estimated Financial Impact
Actual Financial Impact
Suggested KPI for April-Jun
Work has started.
Being done but no official record being maintained. All meetings from here on will be recorded and monthly MoM circulated
Will be done by 15-Feb. All work done so far will be updated.
Will be done by 15-Feb
Physical stock taking in prgress. Will be completed on 28 Feb
Physical stock taking in prgress. Will be completed on 28 Feb
Will be completed once physical stock taking is complete. Expiry date items list will be compiled by end of Feb.
Shelf life items list will be compiled by 15-Feb. Plan of usage will be subsequently formed in consultation with all stakeholders.
Non-Moving items list will be compiled after stock taking. ie by 18-FebBeing done
Not Done. Summary sheet will be prepared from now all and updated for Jan by 18-Feb
Not Done. Will be prepared from now all and updated for Jan by 18-Feb
Meetings taking place. But record being maintained.
Not Done. To be submitted by 5-Feb. Only have TPM measures received from Neeraj Singhal so far.
Shree Shyam Pulp & Board Mills Ltd.
Ed. Qual.
Target Date(To be given under column L3) Weightage
L-2 L-1
%age/ Level Achieved
Actual Performance (By
Appraiser)
Shree Shyam Pulp & Board Mills Ltd.
Ed. Qual.
Target Date(To be given under column L3) Weightage
L-4 L-3 L-2 L-1
Being done but no official record being maintained. All meetings from here on will be recorded and monthly MoM circulated
Will be completed once physical stock taking is complete. Expiry date items list will be compiled by end of Feb.
Shelf life items list will be compiled by 15-Feb. Plan of usage will be subsequently formed in consultation with all stakeholders.
Not Done. Summary sheet will be prepared from now all and updated for Jan by 18-Feb
Not Done. To be submitted by 5-Feb. Only have TPM measures received from Neeraj Singhal so far.
Shree Shyam Pulp & Board Mills Ltd.Annexure I
Perfromance score
Shree Shyam Pulp & Board Mills Ltd.Annexure I
%age/ Level Achieved
Actual Performance (By Apprais
er)
Perfromance score
Shree Shyam Pulp & Board Mills Ltd.
Perfromance Planning and Assesment for the Quarter Oct - Dec, 12Name : Khatra Mohan SatapathyDesignation: Manager - Production
S No KRA KPI
1
2 Better product quality Number of occasions quality failed
Target Production acheivement ( To be shared with senior )
To increase production by 5% in P.M/C No. 4 . Carrier rope should be fitted in dryer group no. 3 which is
not there now. For which paper passing is being delayed. M/C should
run with Turbine power so that stoppage due to Hydl. Power Failure
should be avoided.
3
4 Employee Engagement Index
x %OTIF ( To be assigned to senior ) x
Signature of A
Shree Shyam Pulp & Board Mills Ltd.
Performance Planning and Assesment for the Quarter Jan-Mar 2013Name : Khatra Mohan SatapathyDesignation: Manager - Production
S No KRA KPI
1 Target Production Achievement Increase Production by 5 % in PM 4
Target cost of production ( to be shared with senior )
2 Target cost of production Achieve Target Cost
3 Employee Engagement Index Increase Employee engagement
4 %OTIF To be taken up next year
Shree Shyam Pulp & Board Mills Ltd.
Review 1 - 27 Dec 2012
Initiatives/Action 0/1 Feedback
Effective management
0
Plan,Execute,Check Date
1
Plan,Execute,Check
Plan,Execute,Check
Plan,Execute,Check
Steps to achieve the
Initiative/Action
Measures/Performance
Indicator
Plan,Implement,Review
% Increase in production
Production Sept : ? Oct : 1087 Nov : 989.15
Vacuum system should be modified so that M/C speed can be increased.
Vacuum Pressure(earlier)(?) : 150 mmHG Current : 250 mm HG
By providing Consistency reg water in stock line can be minimised
Plan,Implement,Review
Date ( Later on more appropriate measure)
Better smoothness, cluster calendar is to be modified. Cluster roll should
be fitted in bottom side.Date ( Later on more appropriate measure)
To avoid water dripping, mainly in winter season exhaust fans are to be
fitted in both side walls which is affecting quality of paper
Date ( Later on more appropriate measure)
Mainly complaints come to P.M/C regarding variation in GSM and less
smoothness. To avoid both complaints reasons are given above.
Date ( Later on more appropriate measure)
Plan,Execute,Check
x x
Number of 0 ( Red Buttons)Number of 1 (Green Buttons)
Total number of ActivitiesAchievement Percentage
Shree Shyam Pulp & Board Mills Ltd.
Review 2
Initiatives/Action 0/1
Crews of the Machine should be motivated and educated
Plant Head feedback in %
Steps to achieve the
Initiative/Action
Measures/Performance
IndicatorEstimated
Financial Impact
15-Jan-13
31-Jan-13
15-Feb-13
Collect Base Data and set Target INR / T of Paper
25-Jan-13
28-Jan-13
100% Compliance
19-Feb-13
100% Compliance
100% Compliance
1. Establish target Production Value
against last 3 month's value
2.Create detailed action plan
3. Implement all activities by target
date given
1. Collect baseline data for the last 6
months
2. Set target for reduction with
detailed action plan
3. Implement all activities by target
date given and monitor porgress in a
monthly basis
Increase Employee Morale through motivation
1. Create schedule for Motivational
Seminars and Special Initiatives
2. Ensure 100% compliance with
schedule
3. Maintain record of all meetings and initiatives with description of
meeting.
Measure and Track effectiveness of Training of Employees
20-Jan-13
15-Feb-13
1-Mar-13
Number of 0 ( Red Buttons)Number of 1 (Green Buttons)
Total number of ActivitiesAchievement Percentage
.1. Establish Criteria to measure
effectiveness of training to be listed.
2. Create template for Training evaluation
3. Track training scores for all
employees over a 3 months period ,
monthly. Make report of emerging trends.
Shree Shyam Pulp & Board Mills Ltd.
Emp. Code: 1055 Ed. Qual.Department: Production ( Paper Machine )
Review 1 - 27 Dec 2012
Target Date(To be given under column L3)
L-5 L-4 L-3 L-2 L-1
Suggested steps for Jan-Mar
x x x x x
Shree Shyam Pulp & Board Mills Ltd.
Emp. Code: 1055 Ed. Qual.Department: Production ( Paper Machine )
Review 2
Feedback Target Date(To be given under column L3)
L-5 L-4 L-3
Next KPI : Record to be maintained that logs all training and motivation sessions. Criteria to measure effectiveness of training to be listed.
Actual Financial Impact
Suggested KPI for April-Jun
TPM initiatives to be outlined in consultation with PBOPlus . To be establish timelines and responsibility centers
Not yet ready as on 29-Jan-2013. To be followed up on.
Cannot be assessed.Not Done
Not Done
Not Done
Oct - Dec (Act) : 3122 T
Targetted Value ( 5 % increase over 3122 T): 3278 T
Target Date(To be given under column L3) Weightage
L-2 L-1
%age/ Level Achieved
Actual Performance (By Apprais
er)
Perfromance score
Shree Shyam Pulp & Board Mills Ltd.
Perfromance Planning and Assesment for the Quarter Oct - Dec, 12Name : Sanat Kumar BhattDesignation: Line Head
S No KRA KPI
1 Production (To be shared with subordinate )
Finishing Loss
AKD Consumption
2 Target cost of production
Target Production achievement (2280 MT)
Cost of Production ( To be shared with subordinate)
3 %OTIF
4
Signature of Appraisee:
Shree Shyam Pulp & Board Mills Ltd.
Performance Planning and Assesment for the Quarter Jan-Mar 2013Name : Sanat Kumar BhattDesignation: Line Head
KRA KPI
1 Target Production acheivement
Employee Engagement Index
Modifications of Machine/Set-Up
Reduction in finishing loss
2 Project Assigned
3 Training On-The-Job training
Time , Cost, Quality Commissioning of Vacuum
Pump
Shree Shyam Pulp & Board Mills Ltd.
Initiatives/Action
(i) Cleaning with Boil out the system twice in a month and total time required is five hrs
(ii) By Cleaning the Vacuum Pumps with for de-scaling to increase vac. in pressure & wire to reduce breakage at least once in week.
(i)By Improving the housekeeping of finishing area.(ii)Maximum deckle utilization with marketing people.
(iii)To Reduce Quality change frequency by coordinating with marketing people.(iv) 5% Sheet Size order along with Reel Order.
(i)Dosing of Fixing Agent to be increased 50 gm.(ii) Regular Checking the metering pump.
(iii)At the time of M/c shut the line of AKD must be properly flushed.
Cost of Dynacog- 180 Rs/ KgCost of AKD- 30.75 Rs/Kg
Shree Shyam Pulp & Board Mills Ltd.
Initiatives/Action
To reduce the number of bends in LP Steam line in PM 1.
Modifying the crown of Press Rolls in both stages of PM 1 ( Press part ).
Modifying the crown of Press Rolls in both stages of PM 2 ( Press part ).
Hood to be mounted on PM-1 to control water dripping problem.
Maximise deckle utilization with Marketing
Commissioning of One Vacuum Pump .
Monthly meeting with the officers and On Job Training being scheduled every week
Shree Shyam Pulp & Board Mills Ltd.
Review 1 - 26 Dec 2012
0/1 Feedback
Tonnes
1
1
Data to be validated
%
0
gm/T
1
0
Steps to achieve the Initiative/Action
Measures/Performance
IndicatorSuggested Steps for Jan-
Mar
Open and clean the Headbox, Centricleaners and Pressure Screen.Schedule: every month 8 to 15 and
23 to 30
Sept : 1676 TOct: 1473.73 T
Nov:2056 TNo reduction in
downtime due to boil time measures since
this is already a measure in practice
before taking baseline data. Estimated impact of 6-8 hrs of additional
production time of paper.
Next KPI : PM 1 ( Steam Line ) : To reduce the
number of bends in LP Steam line in PM
1.Modifying the crown of Press Rolls in both stages
of PM 1 ( Press part ) . Similar job to be done for
PM-2. Activitity timelines to be given for line laying, crowns and
vacuum pump.
Schedule: Every Monday Cleaning by keeping one stand by.
Next KPI : Requisition of One Vacuum Pump .100
tonnes increase in production per month
PM-1 . 50 Tonnes in PM-2.
Schedule: (i)Check the Finishing house register every week for
finishing loss.(ii) Checking the Ream Weight every
day.
Present : 7% finishing loss. Data from week to
week of finishing loss for Sep-Dec to be
tabulated and trends to be identified. Measures to be taken
to further reduce finishing loss over the next three months to
be added with estimated date of
installation in next KPI. Challenges to be
addressed:Shortage of weight from customer (
four complaints registered)
Schedule: After every 15 days increase as 300-350-400 gm/T
dosing of fixator (Dynacog). (Gain of Rs22)
AKD Consumption, Sept: Oct : 20 kg, Nov : 18.5- 19 Dec: 17.5 kgs ( To be verified with
Mr V.K.Saxena )
NA
0
Number of 0 ( Red Buttons) 3Number of 1 (Green Buttons) 3
Total number of Activities 6Achievement Percentage 50
Shree Shyam Pulp & Board Mills Ltd.
Review 2
0/1 Actual Financial Impact
1. Prepare detailed action plan 28-Jan-13
At a later point , when there is
interdepartmental working. There must be a
jointly arranged target between Powerplant and
PM 1/2. So as to prove that if one machine is
stopped , the remianing are running at capacity
steam pressure.
CNMD: Why can't we anticipate actions to be
taken for imporvements?
Steps to achieve the Initiative/Action
Measures/Performance
IndicatorEstimated Financial
Impact
2-Jan-13
3. Receipt of Materials
1. Prepare detailed action plan 28-Jan-13
15-Feb-13
3. Receipt of Materials
1. Prepare detailed action plan 28-Jan-13
21-Dec-12
3. Receipt of Materials
7-Jan-13
1. Implement measure 5-Jan-132.Track the performance 5-Jan-13
5-Feb-13
Weekly
2. Create Indent list for spares and materials
100% Compliance
4. Implement plan according to calendar
100% Compliance
5. Monitor change in performance on a weekly basis and create
monthly report100%
Compliance Steam pressure no longer incosistent
2. Create Indent list for spares and materials
100% Compliance
4. Implement plan according to calendar
100% Compliance
5. Monitor change in performance on a weekly basis and create
monthly report100%
Compliance
2. Create Indent list for spares and materials
100% Compliance
4. Implement plan according to calendar
5. Monitor change in performance on a weekly basis and create
monthly report100%
Compliance
10 % Reduction in finishing loss
3. Create summary report on reduction figures with suggestions
for further measures
1. Conduct weekly meetings with Marketing in charge ( Vivek
Shrotriya)
100% compliance
1. Prepare detailed action plan 28-Jan-13
2-Jan-13
3. Receipt of Materials
1. Prepare detailed calendar 5-Feb-13
00% compliance
Number of 0 ( Red Buttons)Number of 1 (Green Buttons)
Total number of ActivitiesAchievement Percentage
2. Record meetings and submit monthly proposal for changes and
measures
100 tonnes increase in production per month
PM-1 . 50 Tonnes in PM-2.
2. Create Indent list for spares and materials
100% Compliance
4. Implement plan according to calendar
100% Compliance
5. Monitor change in performance on a weekly basis and create
monthly report100%
Compliance
2. Record MoM for all meetings and submit monthly report for all
measures and suggestions along with timelines and responsibility
centers.
Shree Shyam Pulp & Board Mills Ltd.
Emp. Code: Ed. Qual.Department: Production
Data by Ramesh Target Date(To be given under column L3)
L-5 L-4 L-3 L-2 L-1
Shree Shyam Pulp & Board Mills Ltd.
Emp. Code: Ed. Qual.Department: Production
Feedback Target Date(To be given under column L3)
L-5 L-4 L-3
Suggested KPI for April-Jun
Shree Shyam Pulp & Board Mills Ltd.Annexure I
Weightage
60%
5.60% 30%
23 Kg /T 50%
%age/ Level Achieved
Actual Performance (By
Appraiser)Perfromance
score
67% efficiency ( Currently)
Shree Shyam Pulp & Board Mills Ltd.Annexure I
Target Date(To be given under column L3) Weightage
L-2 L-1
%age/ Level Achieved
Actual Performance (By Apprais
er)
Perfromance score
Shree Shyam Pulp & Board Mills Ltd.
Perfromance Planning and Assesment for the Quarter Oct - Dec, 12Name : V.K.SaxenaDesignation: Manager ( Stock )
S No KRA
Shree Shyam Pulp & Board Mills Ltd.
Performance Planning and Assesment for the Quarter Jan-Mar 2013Name : V.K.SaxenaDesignation: Manager ( Stock )
S No KRA
1 Cost of Production
2 Quality of Paper
Shree Shyam Pulp & Board Mills Ltd.
Perfromance Planning and Assesment for the Quarter Oct - Dec, 12
KPI
Shree Shyam Pulp & Board Mills Ltd.
Performance Planning and Assesment for the Quarter Jan-Mar 2013
KPI
AKD consumption
Ash consumption
Shade Variation
Shree Shyam Pulp & Board Mills Ltd.
Initiatives/Action Steps to achieve the Initiative/Action
Shree Shyam Pulp & Board Mills Ltd.
Initiatives/Action Steps to achieve the Initiative/Action
Decrease consumption of AKD . Currently 23 kg/ton
1. Monitoring the dosage of AKD twice in a shift daily.
Increase Ash consumption
2. Create action plan for all actvities
3. Implementation of measures
Minimise shade variation
2. Create action plan for all actvities
3. Implementation of measures
2. At time of M/C shut the line of AKD must be properly flushed
3. By increasing the dosage of fixator ( Dynacog) 300-350-400 gm/ton
1. Compile baseline data for Oct-Dec
4. Tracking of production machine wise to monitor ash value with
monthly report
1. Compile baseline data for Oct-Dec
4. Tracking of production machine wise to monitor shade variation with
monthly report
Shree Shyam Pulp & Board Mills Ltd.
Review 1 - 26 Dec 2012
0/1 Feedback Suggested KPI for Jan-MarMeasures/Performance Indicator
Number of 0 ( Red Buttons) 1
Number of 1 (Green Buttons) 5
Total number of Activities 6Achievement Percentage 83
Shree Shyam Pulp & Board Mills Ltd.
Review 2
0/1 Actual Financial Impact
Reduction by 1 kg
Measures/Performance Indicator
Estimated Financial Impact
With immediate effect,
Monitor the dosage for 15 days
28-Jan-13
5-Feb-13
100% Compliance
100% Compliance
'B' Value Measurement
28-Jan-13
5-Feb-13
100% Compliance
100% Compliance
Increse from 8-9% to a target of 10%
Shree Shyam Pulp & Board Mills Ltd.
Emp. Code: 1347 Ed. Qual. M.Sc (Chem.)P.G. Diploma in paper & pulp & paper from Saharanpur.Department: Unit-II
Target Date(To be given under column L3) Weightage
L-5 L-4 L-3 L-2 L-1
Shree Shyam Pulp & Board Mills Ltd.
Emp. Code: 1347 Ed. Qual. M.Sc (Chem.)P.G. Diploma in paper & pulp & paper from Saharanpur.Department: Unit-II
Feedback Target Date(To be given under column L3)
Done. Daily dosage monitoring also being recorded
Suggested KPI for Jan-Mar
Prepared for awaiting Shut
Monitoring Dosage
Not done. Will be done by 10-Feb-2013
Being done
Not Done
Will be started and completed by 5-Feb-2013
Shree Shyam Pulp & Board Mills Ltd.Annexure I
M.Sc (Chem.)P.G. Diploma in paper & pulp & paper from Saharanpur.
%age/ Level Achieved
Actual Performance (By
Appraiser)Perfromance
score
Shree Shyam Pulp & Board Mills Ltd.Annexure I
M.Sc (Chem.)P.G. Diploma in paper & pulp & paper from Saharanpur.
Target Date(To be given under column L3) Weightage %age/ Level Achieved
Actual Performance (By Appraise
r)
Perfromance score
Shree Shyam Pulp & Board Mills Ltd.
Perfromance Planning and Assesment for the Quarter Oct - Dec, 12Name : B.P.JainDesignation: G.M. (PRODUCTION)
S No KRA
1 Target Production acheivement
2 Target cost of production
3 %OTIF- Quality
4 Labour Engagement
Shree Shyam Pulp & Board Mills Ltd.
Performance Planning and Assesment for the Quarter Jan-Mar 2013Name : B.P.JainDesignation: G.M. (PRODUCTION)
S No KRA
1 Target Production Achievement
4
2 Target cost of production
3 %OTIF- Quality
4
Shree Shyam Pulp & Board Mills Ltd.
Perfromance Planning and Assesment for the Quarter Oct - Dec, 12
KPI
Cost reduction. Vetting to be done by President and Ramesh Kumar at HO.
Increase machine production by 2.00% *Note : To confirm whether that production has been achieved.
Further improvement in quality of paper
Employee Engagement Index
Shree Shyam Pulp & Board Mills Ltd.
Performance Planning and Assesment for the Quarter Jan-Mar 2013
KPI
Target Production Achievement
Reduce instances of breakage
Paper quality complaints from market must be reduced.
Excess Weight
Smoothness Variation
Reel Joint/Collapsed Core Pipe
Shree Shyam Pulp & Board Mills Ltd.
Initiatives/Action
c)Improve deckle utilization
Steps to achieve the Initiative/Action
a)Maintain vac pumps health in a good condition
1)Checking of its water sealing line at least once in a week and
take corrective actions.
b)Checking of glands packing and if required to be changed
c)Clearing pumps with acid once in one month
b)Increase the frequency of cleaning of all fresh water/backwater filter/showers
a)Minimum once in a week or whenever opportunity of
available
Close liasion with Sh. Samim Khan almost daily
a)Reduce 25 kw per ton of paper in power consuption
b)100kgs steam per ton of paper. c)AKD- 2kg/tn of paper consumption
d)Reduce finishing house related problems 1.Sheet/Yield Size Variation 2.Core Pipe
collapse 3. Rough Edge cutting
c)Holding meeting of all shift incharge initally weekly and then
fortnightly.
a)Reduction specks level in paper.
i)Develope cost consciousness
ii)Maintain production with quality
a)Modification of III rd stage centri-cleaner line
a)Holding meeting up to supervisory level - and discuss the following.
a)Holding regular meeting with finishing house supervisors,and
all shift incharges to avoid finishing house related
complaints and quality and production problems . Holding
once time fortnightly.
Initially weekly and then twice in a month.
iii)To avoid finishing related problems
i) Cost consciousness
ii) Stop wastage
iii) Benefit of regularity and punctuality
iv) Factory discipline etc.etc
Shree Shyam Pulp & Board Mills Ltd.
b) Meeting with workers and Develop.
Initiatives/Action
Improving of machine runability
2. Summary report to be prepared
4. Weekly monitoring of Action Plan
Reduction of Loss due to Breakages
1.Improving Vacuum Pump Health
Steps to achieve the Initiative/Action
Target Production Value of -Jan : 4800 TFeb: 4350 T
March: 3500 T
1. Daily Analysis of reasons for downtime of machine with CAPA
plan
3. Action plan for eliminating causes of reduction involving all concerned
departments
1. Compile/Analyse Breakages Data for 1-15 Jan for all machines
1.Analyse Breakages Weekly and report
2. Identify top 5 reasons for breakages and finalise Action Plan
1.Checking of it's water sealing line at least once in a week and take
corrective actions.
2. Prevent breakage loss due to slime
2.Creation of detailed Action plan
3. Implementation of measures
3. Improve deckle utilization
4. Edge Cutter Nozzle Functioning
5. Fluff related issues
Reduction in Steam and Power Consumption
2.Checking of glands packing and if required to be changed
3.Cleaning pumps with acid once in one month
1. Create Baseline Data for Breakages due to Slime
4. Tracking of breakages due to slime over 3 month period.
Close liasion with Shamim Khan almost daily
1. Improvement of shower water quality
2. Ensure good health of nozzle tip
1. Periodic cleaning in doctors in first two groups of dryers.
Identify areas of high consumption with remedial measures action plan
Monitoring weekly with Responsibility Center and Timelines
to be compiled in Weekly report.
CAPA Analysis
2. Daily Analysis of reasons
3. Summary report to be prepared
5. Weekly monitoring of Action Plan
Ensure GSM control in Products incidences of excess weight( from weigh bridge) going to
customer will be reduced
1. Prepare a detailed action plan for 10 major concern areas
4. Action plan for eliminating causes of reduction involving all concerned
departments
Reduce number of Instances of complaint of Smoothness
Shree Shyam Pulp & Board Mills Ltd.
Review 1 - 26 Dec 2012
0/1 Feedback Suggested KPI for Jan-Mar
% Production rate increase.
1
1
1
1
Measures/Performance Indicator
Maintenance of Log Book should be regularChecked once in a week. Vacuum no longer drops ( Nov- Dec). 1824-> 1833 kg/hr Comparison to Anchor GSM (58) for next quarter. Split % increase according to Low and High GSM in next KPI.
Checked every 15 days.
Exceeding required schedule
% increase in Deckle over previous check
Earlier 257. Current : 259.5. Target : 260.5 (Max)- Steps to achieve this target to come in January-March 2013 KPI. To be submitted - 31 Dec 2012
a) Sept- 792 kw/T consumption. Oct- 714 kw/T. Nov- 793kw/T (To be split in subsequent KPI according to Low and High GSM consumption.) b) Flow meter not functional. Accurate reading N/A. No complaint made at level of President of Steam Flow Meter. c) Sept - 20.87 kg/T paper. Oct- 19.19. Nov- 17.47
Imporvements over baseline data provided.
Fixed time meetings on Tues. No rough edge complaints. No Core pipe complaints. There are two classes of cutters ( Domestic, Imported and Duplex.) . Establish baseline Data for all three concerns. To be submitted by 31 Dec. Improvements over this in next Quarter
1
0
c)Holding meeting of all shift incharge initally weekly and
then fortnightly.
% improvement in database provided regarding problem areas outlined in Challenges
column.
No significant increase in productivity. But initial penetration noted. Personal interaction with
downstream process shareholders required. Presently, only meeting with No.2 in dept. For next quarter go down
to lower levels as observer in meetings
chaired by Shft In-Charges etc. with
workers. Open house for performance measure in April.
Next KPI :Machine's runability must be
improved.
Next KPI: Paper quality complaints from market
must be reduced.
Next KPI : Size and weight was a concern in
production.
Next KPI :Excess Weight in Machine 4- Ensure GSM
control in Products of PM 4 and incidences of excess weight going to customer
will be reduced and database to be created
and improvement shown in next quarter KPI
0
Number of 0 ( Red Buttons) 1
Number of 1 (Green Buttons) 5
Total number of Activities 6Achievement Percentage 83
Shree Shyam Pulp & Board Mills Ltd.
Review 2
0/1 Actual Financial Impact
100% compliance to Plan
Tuesday ( Weekly )
100% compliance to Plan
18-Jan-13
31-Jan-13
Measures/Performance Indicator
Estimated Financial Impact
5% Improvement over Average Runability of the last 3 Months
for all machines.
Number of Activities still pending on a monthly basis -
Not more than 15%
5% Reduction in Breakages over Average number in 1-15
Jan 2013
To be submitted Weekly ( Tuesday) for previous week
Checked every 15 days.
Log book to be maintained.
2-Feb-13
2-Feb-13
100% compliance to Plan
5th of every month
15-Jan-13
100% compliance to Plan
50% reduction in breakages over Baseline data
% increase in Deckle over previous check
Number of instances of breakage due to Edge Cutter
Number of breaks in calendar and rewinder due to fluff
5% over last Quarter ( per ton of paper produced)
25-Jan-13
25-Jan-13
25-Jan-13
31-Jan-13
Every Tuesday
10% Improvement over baseline data of number of complaints provided over 6
months.
10 % Reduction in Number of Complaints of Excess Weight
10% Improvements over baseline data of number of complaints provided over 6
months.
10% Improvements over baseline data of number of complaints provided over 6
months.
Shree Shyam Pulp & Board Mills Ltd.
Emp. Code: 1347 Ed. Qual. M.Sc (Chem.)P.G. Diploma in paper & pulp & paper from Saharanpur.Department: Unit-II
Target Date(To be given under column L3) Weightage
L-5 L-4 L-3 L-2 L-1
Four times in a month.
Minimum two times in
a month
Once in a month
Minimum four times in
a month
On day to day basis
By 31-Oct 2012 100%
October four times . November and December - two times.
100%
a) By 15 November 2012 b) By November end
By 21-November 2012(Material already indented is awaited.)
Shree Shyam Pulp & Board Mills Ltd.
Emp. Code: 1347 Ed. Qual. M.Sc (Chem.)P.G. Diploma in paper & pulp & paper from Saharanpur.Department: Unit-II
October- Four times in a month and November , December - Two times a month
Feedback Target Date(To be given under column L3)
Data to be analysed.
YES
To be prepared by 4-Feb-2013
Done
Suggested KPI for Jan-Mar
As on 29-Jan Jan: 4393 T
Done only on PM-4
Not done as on 29-Jan
To be collected on 30-Jan
To be collected on 30-Jan
Not Done. Will be completed on 4-Feb-2013Not Done. Will be completed on 4-Feb-2013
Not Done. Will be completed on 4-Feb-2013
Will be completed on 8-Feb-2013
Shree Shyam Pulp & Board Mills Ltd.Annexure I
M.Sc (Chem.)P.G. Diploma in paper & pulp & paper from Saharanpur.
%age/ Level Achieved
Actual Performance (By
Appraiser)Perfromance
score
Shree Shyam Pulp & Board Mills Ltd.Annexure I
M.Sc (Chem.)P.G. Diploma in paper & pulp & paper from Saharanpur.
Target Date(To be given under column L3) Weightage %age/ Level Achieved
Actual Performance (By Apprais
er)
Perfromance score
Shree Shyam Pulp & Board Mills Ltd.
Perfromance Planning and Assesment for the Quarter Oct - Dec, 12Name : Yogendra Pratap SinghDesignation: Manager
S No KRA KPI
1 Unplanned Breakdown
2 Plan fulfillment level
3 In time installation
Paper M/C mechanical maintenance unplanned breakdown (OM-
1/2/3/4)
PM- 1,2,3,4 - Preventive + Predictive Maintenance
Project PM- 3,4 . Modification fabrication work
4 Energy Energy Saved
5 Finishing House - PM- 1,2 Reducing finishing loss
Performance enhancement
Weightage x Apraiser's Score
Shree Shyam Pulp & Board Mill Ltd
Performance Planning and Assesment for the quarter: Jan-Mar 2013Name: Yogendra Pratap Singh
Designation:
Note : 1. Attach extra Sheet, if necessary.
Sl No KRA KPI
1 Unplanned Breakdowns
2
10% Reduction in Unplanned Breakdowns
No Downtime due to lack of Critical Spares
Loss of Production due to Machine Failure
Zero Loss of Production due to Machine Failure
3 Project AssignedPM3
New Core Cutter Machine
Maintenance Cost Reduction
4 IT systems to be upgradedImprove information sharing and documenting system
Shree Shyam Pulp & Board Mills Ltd.
Review 1 - (DATE)
Initiatives/Action 0/1
% of available time 0
1
% against plan
1Greasing of gearboxes,pumps etc. Plan fulfillment %
Plan fulfillment %
1
Steps to achieve the Initiative/Action
Measures/Performance
Indicator
To reduce mechanical breakdown time by 2 %
Inventory control better spares management
Reducing downtime of emergency breakdown to maintain health of
M/C by Periodic maintenance of all mechanical equipments
Reduction in Downtime
To improve running condition of all mechanical equipment
Preventive maintenance , proper oiling of bearings
To check installed and running condition of all equipments doctor
blade, frames, stretchers etc.
Proper workforce at hand and proper supervision and guidance for
workplace worker
0
0
Jogger installation ( Sept 2012 ) 1
Number of 0 ( Red Buttons) 2Number of 1 (Green Buttons)4
Total number of Activities 6
Achievement Percentage 67
Shree Shyam Pulp & Board Mill Ltd
Reduction in Power usage and motor breakdown
Lubrication of bearings and gearboxes. Better load control while
M/C run, steam line insulation - Leverage load control
Units of energy Saved per tonne
Rotor of duplex cutter to be changed. It being unbalanced and
not designed well. Knife spares to be maintained.
Reduction in finishing loss in %
% increase in throughput
Initiatives/ActionsReview 1
0/1
20-Jan-13
28-Jan-13
25-Jan-13
25-Jan-13
25-Jan-13
Availability of Critical Spares
28-Jan-13
31-Jan-13
1-Feb-13
Tuesdays
Steps to Achieve Initiatives/Actions
Measures/Performance
Indicator
10 % Reduction in breakdown Hours over Oct-Dec ( 40 hrs for all
four machines per month)
Root -Cause and Why-Why Analysis of Downtime in Oct-Dec
Identify top 10 causes of Breakdown with Plan for CAPA along with
Timelines and Responsibility Centers
No. of activities completed monthwise
100 % Compliance to Plan
Preventive Maintenance Schedule Zone-Wise
100 % Compliance to Plan
1.Finalise plan of requirements with all stakeholders.
2.Ensure availability of spares and consumables
3.Finalise equipment-wise work under preventive maintenance
Monitor weekly. Format to be finalised
100% compliance to Plan
1.Finalisation of Consumption Pattern over the last 3 months data
of Spares
2.Identifying critical list of spares to be kept in stock raising purchase
requisitions
3.PR raised with Timelines of new items
4.Weekly Monitoring of receipt of spares with Procurement along with
issues and Action Plan
Rebuild work 31-Mar-13
Completed
No.
28-Jan-13
No.
30-Jan-13
31-Mar-13
Tuesday
28-Feb-13
15-Jan-13
18-Jan-13
No.
28-Feb-13
Tuesday
1. Finalise implementation schedule along with estimated cost
2. Number of activities to be completed by 31 Mar 2013
3. Number of Purchase Requisitions to be placed
4. Number of Purchase orders to be placed.
5..Number of Equipments to be received
6. Erection and commissioning of all equipments
7. Fortnightly monitoring and recording of progress
% variance over agreed dates as per
plan.
8. Weekly summary of action plan for removing bottlenecks
1. Finalise implementation schedule along with estimated cost
3. Number of Purchase Requisitions to be placed
4. Number of Purchase orders to be placed.
6. Erection and commissioning of core cutter
7. Fortnightly monitoring and recording of progress
% variance over agreed dates as per
plan.
8. Weekly summary of action plan for removing bottlenecks
5% over baseline data of Oct-Dec
Record of Breakdown of Equipments whose preventive maintenance
already done. History Card to be Maintained. ISO
DocumentsNumber of such cases.
Allowed 5%.
Analysis of all Such breakdowns with CAPA
Within 48 hrs of Breakdown
31-Jan-13
10-Feb-13
1. Finalise requirements for PMS system, zone wise
2. Meetings with IT to finalise changes in PMS System
Performance Planning and Assesment for the quarter: 1st Oct to 31st Dec 2012.Name: R.B. Saini
Designation:
Sl No KRA KPI
1 Breakdowns Zero the number of breakdowns
3 Maintenance Reduce the maintenance cost
4 Hydraulic testing of towers Pass in the test
DGM ( Mechanical ) Pulp,Paper and ETP
5 Timely completion of project
6 Timely completion of project
7 CD #1 Blow Tank Work Timely completion of project
8 Timely completion of project
Tower agitator fittings and motor and support agitator works. ( 5
Nos. Towers)
Cross Gantry and Roof Truss fabrication work
CBD and Drive of CD#1 project work
9 Timely completion of project
10 Washer Repairing ( Total 2 Nos. ) Timely completion of project
11 Timely completion of project
12 Timely completion of project
Feeding conveyors of depithers CD#1 ( 1500 mm width in place of
1000 mm conveyor )
Lathe Machine foundation work for Washer
CD#1 Pulper Shifting and feeding conveyor and aqua separator work and its pipe line work
( Project Doubhle wet washing )
Weightage x Apraiser's Score
Shree Shyam Pulp & Board Mill Ltd
Performance Planning and Assesment for the quarter: Jan-Mar 2013Name: R.B. Saini
Designation:
Sl No KRA KPI
1 Unplanned Breakdowns
Assessment Scale 1 - 10 ( 1 being Lowest and 10 Highest)
Note : 1. Attach extra Sheet, if necessary.
DGM ( Mechanical ) Pulp,Paper and ETP
10% Reduction in Unplanned Breakdowns
2
3 Project Assigned
Borewell
No Downtime due to lack of Critical Spares
Loss of Production due to Machine Failure
Zero Loss of Production due to Machine Failure
220TPD Bleach Plant
CD 1 Double Wet Washing
Maintenance Cost Reduction
4 IT systems to be upgraded
6 Cross Functional Intiatives
7Weighted average of value of projects completed within budgetsVERTICAL DIGESTER
ROTARY DIGESTER
Improve information sharing and documenting system
Shree Shyam Pulp & Board Mill Ltd
Initiatives/ActionsReview 1 - 27 Dec 2012
0/1
1
1Date
0
Steps to Achieve Initiatives/Actions
Performance Indicator
% reduction in number of breakdowns compared to base period of previous 12 months
Maintenance INR saved per metric tonne
To complete up to 5/12/12 (Final Testing) after lining
All arrangement for water filling and shifting to other towers
Civil foundation Work of Motor
Date
NADate
NA
Arrangement of Materials
Date
1
Drawings of TussDate
Arrangement of ContractorsDate
Arrangements of Paints
Date
5 % Work Done Civil drawings
Date
1
Mechanical Drawings
Date
Materials Procurement Date
Shifting of B/L pumps foundationsDate
Date
Date
1
To complete up to 31/12/12 (25% work complete)
Civil foundation Work of Agitators
Fabrication work complete. Primer and painting work to
continue.
Note- Erection Work delayed due to civil work
Shifting of Conveyor columns ( 2 Nos. )
Reduction in erection Work (10 days)
Hydraulic Testing and arrangement of CBD
Date1
Civil Foundation work Date NA
Dismantling of exit drive and CBDDate NA
Civil Work
Date
1
Ramp Work DateFlooring Work Date
Belt joining DateHood Coverings Date
Drive Works ( VFD ) Date
1st Washer - 70% complete Deck Wire Change on LatheDate
02nd washer - 50% complete
Date
20% Work Lathe Machine shiftingDate
1Civil Work for Vertical Digester
Date
Activity Chart
1
Fabricate all jobs before erection
Clearance of drawings Materials Procurement
2
Coupling and other fitting arrangements
Reduction in time ( 12 Days ) - 70 % Complete
Inner Support plate welding work complete
Reduction in erection Work ( 15 Days ) - 25% Work Done
Boost up of Civil Work by Day to Day analysis
Proper Coordination with electrical dept to complete the
target
Number of 0 ( Red Buttons)
8
10
80
Shree Shyam Pulp & Board Mill Ltd
Initiatives/ActionsReview 1
0/1
13-Jan-13
18-Jan-13
Number of 1 (Green Buttons)
Total number of Activities
Achievement Percentage
Steps to Achieve Initiatives/Actions
Measures/Performance
Indicator
10 % Reduction in breakdown Hours over
Oct-Dec ( 20 hrs)
Root -Cause and Why-Why Analysis of Downtime in Oct-Dec
Identify top 10 causes of Breakdown with Plan for CAPA along with
Timelines and Responsibility Centers
No. of activities completed monthwise
100 % Compliance to Plan
Availability of Critical Spares
15-Jan-13
18-Jan-13
20-Jan-13
Tuesdays
15-Feb-13
Completed
8 Activities
Completed
Completed
15-Jan-13
Preventive Maintenance Schedule Zone-Wise
100 % Compliance to Plan
1.Finalise plan of requirements with all stakeholders.
2.Ensure availability of spares and consumables
3.Finalise equipment-wise work under preventive maintenance
Monitor weekly. Format to be finalised
100% compliance to Plan
1.Finalisation of Consumption Pattern over the last 3 months data
of Spares
2.Identifying critical list of spares to be kept in stock raising purchase
requisitions
3.PR raised with Timelines of new items
4.Weekly Monitoring of receipt of spares with Procurement along with
issues and Action Plan
New Borewell to replace older one. Shortage of water
1. Finalise implementation schedule along with estimated cost
2. Number of activities to be completed by 31 Mar 2013
3. Number of Purchase Requisitions to be placed
4. Number of Purchase orders to be placed.
5..Number of Equipments to be received
15-Feb-13
28-Feb-13
15-Jan-13
18-Jan-13
No.
28-Feb-13
Tuesday
28-Feb-13
15-Jan-13
18-Jan-13
No.
28-Feb-13
6. Erection and commissioning of all equipments
7. Fortnightly monitoring and recording of progress on fortnightly
basis
% variance over agreed dates as per
plan.
8. Summary of action plan for removing bottlenecks
1. Finalise implementation schedule along with estimated cost
3. Number of Purchase Requisitions to be placed
4. Number of Purchase orders to be placed.
6. Erection and commissioning of core cutter
7. Fortnightly monitoring and recording of progress
% variance over agreed dates as per
plan.
8. Weekly summary of action plan for removing bottlenecks
1. Finalise implementation schedule along with estimated cost
3. Number of Purchase Requisitions to be placed
4. Number of Purchase orders to be placed.
6. Erection and commissioning of core cutter
7. Fortnightly monitoring and recording of progress
% variance over agreed dates as per
plan.
Tuesday
31-Jan-13
10-Feb-13
1. Clear all pending bills of vendors
2. Release of Payments to Vendors
8. Weekly summary of action plan for removing bottlenecks
5% over baseline data of Oct-Dec
Record of Breakdown of Equipments whose preventive maintenance
already done. History Card to be Maintained. ISO
DocumentsNumber of such cases.
Allowed 5%.
Analysis of all Such breakdowns with CAPA
Within 48 hrs of Breakdown
1. Finalise requirements for PMS system, zone wise
2. Meetings with IT to finalise changes in PMS System
Identification of 10 Major Causes for Breakdown in consultation with Mechanical/Electrical/Process
1. Meeting of all heads to identify the 10 major causes per dept
2. Finalisation of measures to mitigate each major cause from each
individual dept.
3. Implementation of Measures by plan
4. Tracking and monitoring of major causes to confirm positive effect of
measures.
Planned Project Cost Vs Actual Project Cost
3. Total actual cost Vs Original Planned Cost
% Variance ( 10 % over Planned )
*NOTE : Bills for ETP environment, 220TPD,CLO2,110TPD, Wet
Washing- expected and will be dispatched on time
Shree Shyam Pulp & Board Mill Ltd Part - I
Emp. Code: 339Department:
Review 1 - 27 Dec 2012
Target
FeedbackL-5 L-4Suggested KPI for Jan-
Mar
Breakdown Hrs.Sept : 30 hrs Oct : 22 hrs Nov : 20 hrs
Next KPI : List of materials to be given
by 31 dec. To be procured to reach a
target of 10 hrs breakdown.
Maintenance Cost (Earlier ) : 12.5 Lacs INR ( Approx because data not avaialable from stores.) Current : 7 Lacks INR
To be completed upto 5 Dec- Done for 3/5 towers. Delay from Civil side. R.N.Jha is the Head. Tower 1 completed as per plan on 30 Nov. Tower 2 and Tower 3 on 1 Dec. Done on 3rd Dec. Tower 4 and 5 to be completed 4 days after civil work
Next KPI : Tower 4 and 5 to be completed 4 days after civil work.
Fabrication work started on 8 Nov 2012
Material Received
Target Completion : 31 Dec ( Status to be updated on 1 Jan )
Fabrication started on 8 Nov as per plan. Materials received on 7 Nov. Job completed on 20 Nov ( 2 Days before plan )
Fabrication work started 8/11/12 (Roof truss)
Crane Gantry Fabrication work 24/11/12
Start Date 05/12/12 - Complete Date 02/01/13
Start Date 7/12/12 - Complete Date 10/01/13
Shree Shyam Pulp & Board Mill Ltd Part - I
Emp. Code: 339Department:
Review 1
Target
Feedback
Done on 14-Jan-2013
Done on 14-Jan-2013
Not Done. To be given on 5-Feb-2013
Estimated Financial Impact
Actual Financial Impact
Suggested KPI for April-Jun 2
Oct:22 hrs Nov: 20 hrsDec: 24 hrs
Jan: 16hrs 30 mins
Done
Done. Follow up reminders also sent.
Done
Done
Done
Not done. To be submitted on 5-Feb-2013
Received
Being Done. Will be completed OTIF/
Within week on completion.No material received. All spares and consumables have been indented. Work awaits arrival of materials.
Done
Done
Done
Done
Done
Done
12- Feb using old blow tank.
Work to begin on 10 Feb 2013. Electrical parts/consumables still pending. Steam Packing and Blow Tank Material still pending. Nut/Bolts still missing.
Format to be taken from Rajiv Pande. Being maintained.
8-Feb-2013 for previous 3 breakdowns.
To be done
To be done.
Oct: 12 lacNov: 8.6 lacDec: 10 lac
Jan:
Vertical - No Pending Bills to vendors
Rotary- No Pending Bills to vendors
Will be submitted after commissioning.
Shree Shyam Pulp & Board Mill Ltd
Ed. Qual. M.Sc. ChemistryMechanical Date of Birth
Target
L-3L-2 L-1
28 Nov - 31 Dec
Weightage(Total 100)
%age/ Level Achieved
Performance Assessment By Appraisee
01/01/13 to 15/01/13 24/12/12 to 5/1/13 20/12/12 to 30/12/12 1/2/13 to 10/2/13
Fabrication work started on 8 Nov 2012
Started 21/12/12- Completed 31/1/13
Started 20/12/12- Completed 31/12/12 Start - 1/1/13 - Complete 31/1/13
Truss Fabrication completed on 20/11/12
Gantry Fabrication completed on 07/12/12
Both washer internal support changed and welded, Also gland sleeve changed. Rest work is to be done on Lathe machine.
Start Date 05/12/12 - Complete Date 02/01/13
Start Date 7/12/12 - Complete Date 10/01/13
Started -5/12/2012Completed - 20/12/12
Signature of Appraisee
Signature of Appraiser
Shree Shyam Pulp & Board Mill Ltd
Ed. Qual. M.Sc. ChemistryMechanical Date of Birth
Target
L-5 L-4L-3
L-2 L-1
Weightage(Total 100)
%age/ Level Achieved
Performance Assessment By Appraisee
No material received. All spares and consumables have been indented. Work awaits arrival of materials.
Shree Shyam Pulp & Board Mill Ltd
Performance Assessment By Appraiser
01/01/13 to 15/01/13 24/12/12 to 5/1/13 20/12/12 to 30/12/12 1/2/13 to 10/2/13
Both washer internal support changed and welded, Also gland sleeve changed. Rest work is to be done on Lathe machine.
Shree Shyam Pulp & Board Mill Ltd
Performance Assessment By Appraiser
Shree Shyam Pulp & Board Mills Ltd.
Performance Planning and Assesment for the Quarter Oct - Dec, 12Name : Satish Kumar Johar
Designation: General Manager
S No KRA KPI
1 Production Achievement Zero Breakdown
2 Cost of production Reduction of Steam Cost
Shree Shyam Pulp & Board Mills Ltd.
Performance Planning and Assesment for the Quarter Jan-Mar 2013Name : Satish Kumar Johar
Designation: General Manager
S No KRA KPI
1 Production Achievement Zero Breakdown
5S
2 Cost of ProductionReduction of Steam Cost
3 %OTIF
4
Reduction of Cost of Power Generation
Employee Engagement Index
Shree Shyam Pulp & Board Mills Ltd.
Review 1 - (DATE)
Initiatives/Action 0/1
1. Identify critical problem Breakdown time % 0
15-Jan NA
3. Identify critical spares 15-Jan NA
15-Jan NA
1
Number of 0 ( Red Buttons) 1
Number of 1 (Green Buttons)1
Steps to achieve the Initiative/Action
Measures/Performance
Indicator
2. Making schedule for preventive maintenance
4. Identify minimum level of spares- ROL/ROQ
Increase consumption of Pith. Present 60 TPD. Target 80 TPD.
Increase in quantity to 80 TPD on a daily basis
Use of RDF. Present 10 TPD. Target 15 TPD
Total number of Activities 2
Achievement Percentage 50
Shree Shyam Pulp & Board Mills Ltd.
Review 2
Initiatives/Action 0/1
1. Identify critical problem 20-Jan-13
20-Jan-13
7-Feb-13
20-Jan-13
Steps to achieve the Initiative/Action
Measures/Performance
Indicator
20% reduction over avg of 3 months
Root -Cause and Why-Why Analysis for TURBINE of Downtime in Oct-Dec
Root -Cause and Why-Why Analysis for BOILER of Downtime in Oct-Dec
Identify 10 Major reasons for Breakdown with CAPA along with
Plan for Implementation
2. Making schedule for preventive maintenance
100% Compliance to Plan
1.Finalise plan/Schedule of requirements with all stakeholders.
31-Jan-13
31-Jan-13
3. Availibility critical spares
20-Jan-13
20-Jan-13
26-Jan-13
Every Tuesday
%5S Score
31-Jan-13
%Reduction
Jan-13
1.Prepare detailed action plan
2.Implement RDF usage measures
3.Monitor performance
15-Jan-13
2.Ensure availability of spares and consumables
3.Finalise equipment-wise work under preventive maintenance
28-Feb-2013 ( Except Long-Delivey Items :
20%)
1.Finalisation of Consumption Pattern for TURBINEover the last 6
months data of Spares
2.Finalisation of Consumption Pattern for BOILER over the last 6
months data of Spares
3.Identifying critical list of spares to be kept in stock raising purchase
requisitions
4.Monitoring of receipt of spares through weekly reports.
Identify areas of 5S for implementation
Use of RDF. Present 10 TPD. Target 15 TPD
Increase consumption of Pith. Present 60 TPD. Target 80 TPD.
INR 21 Lacs saving for Jan-Mar
Identification of Personnel to be Trained
15-Jan-13
Number of 0 ( Red Buttons)Number of 1 (Green Buttons)
Total number of ActivitiesAchievement Percentage
Identification of Training Inputs required
Shree Shyam Pulp & Board Mills Ltd.
Emp. Code:Department:
Review 1 - (DATE)
Feedback Target Date(To be given under column L3)
L-5
7 Lac INR / Month saving
Suggested KPI for Jan-Mar
Breakdown ( Avg : 24) Oct: 25 hrs Nov : 13 hrs
Dec : 34 hrs
Next KPI : 20% reduction of breakdown hours over average of Oct-Dec breakdown hrs.
Fuel substitutes can be investigated.
Dependency on coal reduced.Saving of non-renewable resources.
Next KPI: % reduction to be communicated.
Next KPI : Identification of Personnel to be Trained
WASHER VAT( CHLORINE)WASHER VAT (ALKALI)WASHER VAT (HYPO)-2HYPO-2 SEAL PIT -1 WITH PUMPHYPO-1 SEAL PIT-2 WITH PUMPALKALI SEAL PIT-3 WITH PUMPCHLORINE SEAL PIT-4 WITH PUMP
BALANCE STR. UPTO GANTRY LEVELBALANCE STR. UPTO ROOF LVLEOP REACTOR FDN.
BLOW TANK FDN AT V.DIGESTER
FOUNDATION WORK TOWER CLO2FDN.WORK ODL TOWERFDN.WORK BLOW TANKFDN. WORK REACTOR
EQUIPMENT FOUNDATION(BALANCE 20%)
FOUNDTION AND DRAIN WORK TO FACILITATE THE MECHANISM FOR RECOVERY WASTE WATER RECYCLEING.
Perfromance Planning and Assesment for the Quarter Oct - Dec, 12Name : Energy Conservation CFTKEY: CC - Core Committee ( VK Tharad, Rajeev Pandey, SK Johar, Ranjedra Singh Nayal, RK Verma)
S No Responsibility Center Area of Impact
1 CC Organisation Efficiency
Organisation Efficiency
2 CC + President Organisation Efficiency
3 Rajeev Pandey Organisation Efficiency
Shree Shyam Pulp & Board Mills Ltd.
CC - Core Committee ( VK Tharad, Rajeev Pandey, SK Johar, Ranjedra Singh Nayal, RK Verma)
Initiative Steps to achieve the Initiative Measurable
Task Force Formation
28-Feb-13
Zone Identification
Modification of Lighting System 1. Lighting Audit to be conducted
Meetings to be conducted to finalise members of the Task Force,
Finalisation of criteria for the giving of suggestion as well as reception of
suggestions.Task Force Finalisation for each of the zones by the Individual Zonal
Heads.
Format for Energy Conservation Suggestion/Recommendation
created as first draft
Finalise guidelines for Task force for giving suggestions
Formation of Energy Conservation Policy
Heat loss in pipelines and ducting
Condensate RecoverySteam Losses
Audit of Pumping throughout plant
2. Submission of proposal listing precise measures and estimated savings.
Segregation of Air Lines in Production
Cleaning of Paper Machine backwater , so that it can be recirculated to shower water
Fuel costs in Transportation Equipment
1. Format for evaluation of pump in terms of rating, positioning of valves,
Criteria for Evaluation of Suggestions received
Shree Shyam Pulp & Board Mills Ltd.
Emp. Code:Department:
Status of InitiativeFeedback Target Date(To be given under column L3)