1 EMS Automation and Digitization sanjay chatuevedi sir

2 submercible pump to kamlesh

3 safety theme-confined space entry
4 action on vibes survey ashfaq
5 Corporate maintenance audit
6 contractor assessment sheet vivek singh
7 IE approval sheet
8 hetronic load cell data transfer nitesh
9 Reliability training evaluation.
10 plant performance review corporate.Deepika patel
11 1.Training calendar for 2020 FY.
2.Training module.
3. Training attendance.
4.Question and Answer test.
5 Based on evaluation skill gap matrix
and re-training and evaluation to
enhance skill.
12 Maintenance philosophy training
13 cost saving project update
14 slow moving items from muri
15 disha industry 4.0
16 system grounding webinar
17 shop floor inventory.
18 Achievements and setbacks.
19 online kaizen
20 contract manpower reduction
21 photograph for height pass
22 ZBB sheet of autoshop will be cheked
by vijayant .
23 rolling plan
24 ROI data
25 provision
26 contractor safety management

1 shop floor inventory

2 shift schedule
by 10th june 2020

by 10th june 2020

1st week of sept 2020 4th week of March 2020
by 7th june
by 10th june 2020

9th june 2020

5th june 2020,3.30 pm

3rd june

5th june 2020,11 am

6th june 3.30 pm
4th june
2nd june

22-Jun-20

30-Jun-20

15-Jul-20 arfa mail

by 5th july 2021

by 1st july 2022
 Dharmendra Bhanu Rajesh Rohit
1 RCM
2 shop floor audit by PM pillar
3 motor list for MCSA
4 Ekayan
5 illumination report
6
7
8
9
10
Deepak Pradeep pardeep
 MOVE ORDER
PR RAISED COST COST
RAISED
ACTUAL CONSUMPTION COST
item Pr no pr date pr value po no po date Name
962100023 1.04-20 168000 rohit/rajesh
962100047 4.4.2020 184185 rohit/rajesh
962100204 14.04.20 57820 rohit/rajesh
962100237 15.04.20 125804 rohit/rajesh
962100
 Apr-20
Name Emp code Safety Training/24Hr BBSO/52
Prasmit kumar Parida 106073 1 3
Rohit Pundir 107857 2 4
Rajesh Parida 106793 1 4
Dharmendra Shahu 106840 1 3
Ankit srivastava 106625 2 0
Pradeep kumar yadav 107243 1 0
Deepak Kumar Bishoyi 106997 0 0
Saugata Gupta 108142 2 4
Bhanu Pratap Singh 800106 1 7
Pardeep B 800080 0 0
Manoj Dhakad 8000075 1 4
Premsagar Maurya 107897 1 0
Rajendra Maithili 105964 3 3
Mayanand Kushwaha 108020 1 0
Manoj Dhakad - 2 800075 1 0
Brajesh Dhakad 108040 1 1
19 33
 May-20 Jun-20
Name Emp code Safety Tra BBSO/52 Name Emp code Safety Tra
Prasmit kumar Parida 106073 1 4 Prasmit kumar Parida 106073 0
Rohit Pundir 107857 1 4 Rohit Pundir 107857 1
Rajesh Parida 106793 1 4 Rajesh Parida 106793 0
Dharmendra Shahu 106840 1 4 Dharmendra Shahu 106840 1
Ankit srivastava 106625 1 0 Ankit srivastava 106625 2
Pradeep kumar yadav 107243 1 4 Pradeep kumar yadav 107243 0
Deepak Kumar Bishoyi 106997 0 0 Deepak Kumar Bishoyi 106997 0
Saugata Gupta 108142 1 4 Saugata Gupta 108142 3
Bhanu Pratap Singh 800106 2 4 Bhanu Pratap Singh 800106 0
Pardeep B 800080 1 4 Pardeep B 800080 0
Manoj Dhakad 8000075 1 4 Manoj Dhakad 800075 2
Premsagar Maurya 107897 1 0 Premsagar Maurya 107897 0
Rajendra Maithili 105964 3 4 Rajendra Maithili 105964 1
Mayanand Kushwaha 108020 1 4 Mayanand Kushwaha 108020 2
Manoj Dhakad - 2 800075 1 4 Manoj Dhakad - 2 800163 1
Brajesh Dhakad 108040 1 0 Brajesh Dhakad 108040 0
18 48 13
BBSO/52
5
3
4
1
2
0
0
4
0
4
4
0
5
3
4
0
39
 Rajesh Sayan Rohit
Data need
Sr.No Job
by(Target Date)
2 nd day of every
1 Shop floor inventory
month
2 nd day of every
2 MPR Data
month
Availability √ √ √
MTTR √ √ √
MTBF √ √ √

Breakdown
report,seggregation and √ √ √
analysis
Major breakdown √ √ √
improvemental job. √ √ √
Constraints √ √ √
3 RCA within 48 Hr. √ √ √
2 nd day of every
4 FMECA √ √ √
month
2 nd day of every
5 Risk card √ √ √
month
2 nd day of every
safety
6 month
2 nd day of every
safety MIS
month
2 nd day of every
BBSO , Nearmiss
month
Closure of safety ASAP
observation.
7 AM data
2 nd day of every
Kaizen
month
8 Inventory Mnagement
Actual consumption
PR /Move order
ZBB compliance( PR,Issue
value)

contactor bill /service bill

9
verification and process.

Contract workman
10 attendance verification
and process

11 Provision Data
 Data need to Data need to Data need to
provide every provide every provide every
12 IMS Audit
month to month to month to
Yashwant. Yashwant. Yashwant.

Customer satisfication
13
index
14 Training Record.

Hand /powerTools
16
inspection
Measuring instrument
17 calibration √ √

18 Stationary
19 safety Item
20 House keeping of office √ √ √

21 Lighting maintenance √ √

22 Earth pit maintenance √

23 QCDIPS board updation

Technician Tools
24 √ √
inspection

25 RCCB recod √ √

26 Illumination report √ √

27 Shift schedule

28 Tool Talk (G-shift) Apr-22,Nov-22 May-22,Dec-22 Jun-22,Jan-23

Arc Flash
29 Electrical safety training Protection- LOTOTO
NFPA70
30 HOT Work
31 Work at Height √
32 Confined space
14 PME
15 HPT
Dharmendra Bhanu Pardeep Yashwant shift I/C Prasmit

√ √ √ compile
√ √ √ compile
√ √ √ compile

√ √ √ compile

√ √ √ compile
√ √ √ compile
√ √ √ compile
√ √ √ √
√ √ √
√
√ √ √
√

√ √

√ √

√ √

√
√ √

√
√

√ √

√ √ √

√ √
Data need to Data need to Data need to
provide every provide every provide every
√
month to month to month to
Yashwant. Yashwant. Yashwant.

√
√
√
√ √

√
√
√ √ √ √

compile and
√
keep record
compile and
√
keep record
√
compile and
√ √ keep data √
every month
compile and
√
keep record

√ compile and
keep record
√

July-22,Feb-23 Aug-22,Mar-23 Sep-22 Oct-22

Lightening
Earthing-IS
protection -IS
standard
standard
√

√
√
√
 *PM schedule,compliance.
*PM checksheet. Rohit Rajesh Bhanu

1 PM activity √ √ √

2 Calibration Activity *Schedule,compliance √ √ √

3 Motor overhauling *Schedule,compliance √ √ √

4 FMECA Critical Equipment √ √ √
5 Risk card Critical Equipment √ √ √
6 RCA Breakdown> 2 Hrs & Frequency>2 √ √ √

* List of Activities.
7 HIRA/SWI/SMP/SOP *HIRA √ √ √
*SWI
*SMP
8 Energy Saving. *Energy saving project √ √ √
Energy meter Reading
9 √
Monitoring
*Availability/MTTR/MTBF
*Major jobs executed.
*Major Breakdowns
*Developmental jobs.
*Motor overhauling /failure data
10 MPR data *Major concern √ √ √

*provide spare detail to Yashwant

11 Inventory management * support Yashwant for technical
spec finalisation .

* Electrical safety audit

12 Audit * IMS Audit Data Data Data
* IMEA audit
*Energy Audit
13 CAPEX
Confined Space
HOT Work
Lightening safety √
Safety Training to sub
14
ordinate
 Safety Training to sub
14 Work At Height
ordinate
Earthing-IS standard
Arc Flash Safety √
LOTOTO √
Near Miss
BBSO
15 Safety data Safety Training
Height Pass
PME
16 People development * Technical Training √ √ √
17 WCM pillar activity *AM activity
* Kaizen √ √ √
18 Small Group Activity * Kaizen data updation in oracle
*OIC √ √ √

19 Self development * Behavioural skill √ √ √

*Technical Skill
20 Crossfunctional Activity √ √ √
Dharmendra Sayan Yashwant Prasmit

√ √ √

√
√ √ √
√ √ √
√ √ √

√ √ √

√ √ √ √

*R&M cost( area wise)

√ √ Compile
*Service cost

* Availability of spare.
* Raising PR.
*Move order.
*follow up with purchse.
*GRN clearance
* Vendor development.
* shop floor inventory tracking.
*Central store inventory
tracking.
*Daily consumption tracking.
*ZBB sheet tracking.
( Normal,Addition-A,Add-B)

Data Data Update in IMS √

√
√
√
 √
√

√
√
√
√
√

√ √ √ √
√ √
√ √ √ √
√
√ √ √ √

√ √ √ √

√ √ √ √
1 PM activity Calibration Activity Motor overhauling

FMECA,Risk card,

*PM
Schedule,compliance. *Schedule,complianc *Schedule,complianc
*PM checksheet. e Critical Equipment
e

2
11

12 Audit CAPEX Safety Training to

sub ordinate Safety data

* Electrical safety
audit Confined Space,HOT Near
13 * IMS Audit Work,Lightening Miss,BBSO.PME.Heig
* IMEA audit safety,Work At ht Pass
*Energy Audit Height,Earthing-IS
standard,Arc Flash
Safety,LOTOTO
19 Self development * Behavioural skill
*Technical Skill
20 Crossfunctional Activity
 Energy meter
HIRA/SWI/SMP/SOP Energy Saving. MPR data
Reading Monitoring

RCA
*Availability/
MTTR/MTBF
*Major jobs
Breakdown> 2 Hrs & executed.
Frequency>2 * List of Activities. *Major
*HIRA Breakdowns
*SWI *Energy saving *Developmental
*SMP project jobs.

WCM pillar activity Small Group

People development Self development
Activity
*AM activity

* Kaizen,* Kaizen
* Technical Training data updation in
oracle,*OIC
Inventory
management

*provide spare
detail to
Yashwant
* support
Yashwant for
technical spec
finalisation .
 Pot Room-E&I Goals for FY-22
SNo. Description Weightage Type of Goal

1 Goal#1 To build a strong Safety culture in Smelter E&I with the objective to provide 10 Normal
a safe working environment to employees, contractors and associates:

1.a. Fatality = 0
b. LTIFR less than 0.25,
c. LTISR less than 100,
d. Total Recordable Injury Frequency Rate (TRIFR) less than 1.5.

2.Safety Training: 3 Man-days

1 Day - Training on British Safety Council on Felt Leadership
1 Day - Training on HIRA, MOC, PSSR, PTW
½ Day – Training on Emergency Preparedness plan
½ Day – Training on App. legal requirements, compliance, impacts etc.

3.Safety Intervention/NM/PI/BBSO: 36/Year as per Enablon planning & 1BBSO/Week

for all management cadre
To investigate all FAC/LTI-Reportable/Recordable/High potential Near miss incidence
& to ensure 100% effectiveness.
* Review compliance of all HIRA for all sections of E&I bi annually.
* Ensure implementation of all safety standards in all sections of E&I as per the
guidelines from all Safety Taskforces.
* Compliance of
all safety audit points.
.* No. of observations made by safety officers in their respective areas to be zero.
(unsafe condition, unsafe act, severe safety violations)

2 Goal#2: Implementation of projects and process improvement schemes to achieve 10 Normal

following improved results over FY 21:
1) Review & Revive of Energy Management System for perfect energy monitoring
from one location.
2) To implement energy saving & OIC projects: 2 Nos.
3) Tree plantation to increase the Greening: 5 Trees/person for entire E&I staff: total
500 Trees.
4) Achieve 10% Reduction in Water Consumption & 2% reduction in APC over FY21
(FY21-663MWH target for FY22-650MWH).
5)100% availability of HF & Dust analysers of GTC. Also ensure the 100% remote
data communication with the Server of MPPCB & CPCB
6)10% Reduction of identified waste including e - waste .
7) Impementation of 4 No's of Worlds best maintenance / safety / environment
Practices in the department .

3 Goal#3: Drive Quality and Product Improvement to improve Customer 20 Normal

Satisfaction:
1. Achieve Availability of identified
equipment/Plants:PTA:92%,GTC:96%,Vehicle:96%,CSS:96% POT:98%,Alpsys
and surmec: 99%
2. Zero finished goods return due to weigh scale weight variations at ICM,
Wire Rod.
3. Achieve 5% more CSI number over FY 21 best achieved.
4. To monitor SLA system & to adhere with SLA target score
5. To ensure the regular Customer feedback & to monitor the customer
satishfaction score.
6. Effective & consistance working of PTM central control room.
7. Ensure no fire incident due to electrical fault in GTC,CSS,POT Room and
Duplex server room.
4 Goal#4: To contribute to cash generation as per P&B: 10 Stretched
1.
To achieve Stores Inventory of less than 4 Crs. by Mar-22 in line with
Accenture study (for pot room E&I).
2. Reduce shop floor inventory by 30 % at year end from Rs.0 .4 Crs. to Rs.
0.3 Crs.
3. Reduction in slow moving stores inventory > 2.5 years at the end of
5 Goal#5: To achieve production, COP as per P&B with focus on 2.5% 15 Stretched
improvement in overheads targeted:
1. Support to achieve production: Hot metal: 366,497 tons,Total Cold Metal
378,162 tons.
2. Fixed cost P&B 5.61 Crs – to achieve a Reduction: 15%. Hence target
4.76 Crs.(Stretched Target).
3. Achieve 2% reduction in Electrical Aux power consumption over FY 21.
(FY 21 Actual 552 KWH/T, FY 22 Stretched Target -541 KWH/T)

6 Goal#6: System Implementation & periodic monitoring: 15 Normal

1) 1) Up-gradation of Risk Register, Mitigation Plans & Emergency Response plans of
pot room E&I.
2) Prepare and review the Risk Card for every Supercritical equipment followed by
the critical equipment to avoid any unwanted surprises. To complete for Supercritical
equipment by 30 Sept-21.
3) Achieve savings of 5 Lacs through identified improvement projects (OIC, CYGNUS,
etc.)
4) WCM SA Maturity Self-Assessment Score > 75%
5) BCE Self-Assessment Score > 85%
6) Facilitate implementation of Ekaayan(One ERP) project in Smelter
7) To ensure RCM imlementation for identified critical equipments in E&I
8) Reduction of unpredictable breakdowns (>4 hrs ) by 25%.
9) Achieve 100% PM Compliance as per schedule.
10)Ensure active engagement & participation of all small groups thru Monthly
audit & awards system
11.Weightage for active participation in Safety task force/sub committee and
implementation of the same at department.

7 Goal#7: Implement organizational culture of managers taking accountability for 10 Normal

identification and development of talent:
1) To work on people development and building leaders at all levels; Identify People
successors for critical roles at SH/AH level of the organization. Development
Development of two supervisors/managers working at shifts to take up the role of
next level in one year.(Develop 2 AH by Mar-22).
a. Identify successors for critical roles at SH/AH level of the organization. In time
Review of MDP ( AH ) & feedabck for improvement .
b.Ensure TNI of all members & their compliance.
c. Participation in weekly technical trainings ( 4 mandays / employee )& the
technical training by External Trainer on core competencies once a quarter
organised by HTU.
d.Preparation of IDP and review of the same twice in a year for all employees in his
team.
2)Lifting of 25 % people out of poor skill category thru skill development process
and task force activities .
3) Improvement in Vibes Score by 10%. (Young Talent, Female Employees &
employees under 35 years age) 4) Implementation of SHILIM#4 for cultural
change. The audit report should indicate performance of more than 90% result.
I will develope two engineers/managers for their Career growth from my team
(Professional development of two engineers/managers by name)
8 Goal#8: Strengthen Project Management system to ensure project delivery 10 Normal
as per plan:
1) To ensure implementation of the projects identified and approved in
Capex Plan FY 22, with in time lines and within the planned cash outflow.
(25 Crs. for ALP SYS upgradation & 1 Crs. r for Pot Room. Planned Cash
Flow in FY 22 is Rs. 100 Lacs)
2) Identification of minimum TWO Digitization projects & its
implementation in FY 22:
AA. Energy management system for energy data acquisition, monitoring
& analysis from one location
BB. Common Control Room for PTMs data/parameters acquisition,
monitoring & analysis
Rohit Rajesh Sayan

1.BBSO target
2.Safety Training for self.
3.Safety Traing to sub-ordinate.
4.closure of safety observation.
5.Height Pass.
6.PTW training
7.LOTOTO Training
8.Electrical safety Training
8.1Arc Flash Protection
8.2LOTOTO
8.3Earthing-IS standard
8.4Lightening protection -IS
standard
9.HOT Work
10.Work at Height
11.Confined space
Bhanu Dharmendra Yashwant
Leaves/employee Non-working day
PL 30
Week-off 52
Saturday 26
CL 8
SL 12
PH 10
Total 138
Working Day working day/Month

227 18.9166666666667
 *PM schedule,compliance.
*PM checksheet.
1 1 PM activity 8

2 2 Calibration Activity *Schedule,compliance 9

* List of Activities.
3 3 HIRA/SWI/SMP/SOP *HIRA 10
*SWI
*SMP

4 4 Energy Saving. *Energy saving project

Energy meter Reading

5 5
Monitoring

11

Near Miss
6

7
BBSO
6 Safety data
8
Safety Training
9
Height Pass
10 PME
7 WCM pillar activity *AM activity
12

11

12
Risk card Critical Equipment
13
RCA Breakdown> 2 Hrs & Frequency>2
14

CAPEX 15

16

Confined Space

17

Safety Training to sub ordinate

HOT Work

18
Lightening safety
Work At Height 19

Earthing-IS standard
20
Arc Flash Safety
LOTOTO
* Technical Training
People development
Motor overhauling *Schedule,compliance

FMECA Critical Equipment

Inventory
management

* Electrical safety audit

Audit * IMS Audit
* IMEA audit
*Energy Audit
*Availability/MTTR/MTBF
*Major jobs executed.
*Major Breakdowns
*Developmental jobs.
*Motor overhauling /failure data
MPR data *Major concern

Skill development and

Crossfunctional Contribution in areas apart from
Activity your area.
Self development (at least in different areas of Pot
room)
* Kaizen

Small Group Activity * Kaizen data updation in oracle

*OIC
 Apr-22 Status

Rohit 1.CCR : Level2 system.

1.FAS commissioning ,installation

Rajesh
2.Fire coating of EG room cables.

1.Firewall switch installation and

Sayan configuration.
2.GTC KEP server

Vinay Gupta

Dharmendra
Yashwant
 May-22 Status Jun-22 Status

1.FAS commissioning ,installation 1.Completed.

2.Fire coating of EG room cables. 2.In progress

1.Laboratory data interface with

IT network.

1.Bath burning extension

project.
 Jul-22 Status Aug-22 Status Sep-22 Status Oct-22 Status

1.Anode stem voltage drop: Real

In progress.
time measurement system.

1.installation of HF and dust

Analyser in temporary GTC
chimney.
Nov-22 Status Dec-22 Status Jan-23 Status Feb-23 Status Mar-23 Status