Sspbml- Kra Plant Jan-mar 15-2-13 v7

Plant KRA Review on 27/28 December

S.No E.Code Name Designation

1 1387 Sanat Kumar Bhatt Senior General Manager (Producti

2 1229 Senior Manager(Production)

9 953 Senior Manager (E.T.P)

14 1394 Deputy General Manager (Mechani

15 196 Devendra Agrawal Senior Manager (Mechanical)

16 1388 Chander Pal Singh Manager (Mechanical)

17 965 Manager (Mechanical)

18 1171 Rajeev Pandey Deputy General Manager (Electrica

19 1212 Manager(Electrical)

20 601 Dalip Kumar Verma Senior Manager(Instrumentation)

21 1284 Pawan Singh Saini Senior Manager (Quality Control)

22 1347 General Manager (Mill Developme

23 966 Ramakant Verma General Manager (Mill Developme

24 1476 Head Management Service (Mill D

25 970 Senior Manager (Mill Developmen

Pradyot Kumar Mitra

Anami Saran Srivastava

Suman Kumar Pant

Yogendra Pratap Singh

Shiv Kumar Singh

Bimlendu Prakash Jain

Swarupananda Maji

Vinod Kumar Kesharwani

26 1336 General Manager (Mill Developme

27 1409 Mohd. Gufran Manager (Mill Development)

28 11 Manager IT/ERP (I.T.)

29 1392 Vijai Veer Prakash Manager (Fire & Safety)

30 1373 Dharmendra Singh Manager (Accounts)

31 1326 Ashok Kumar Sharma Manager (Store)

32 756 General Manager (Administration)

Anoop Kumar Saxena

Shamim Ahmed Khan

Manjeet Singh Sandhu


Department GradeDOB

DOJ Qul.

Production G4 1/7/1953 24/04/2012M.SC.

Production G5 8/4/1955 15/10/2011B.Sc

E.T.P. G5 2/12/1947 15/12/2010M.Sc Chemistry

Mechanical G4 16/06/1970 3/5/2012

Mechanical G5 23/02/1967 17/11/2006 B.Tech ( Mech.)

Mechanical G5 20/09/1968 26/04/2012

Mechanical G5 1/10/1958 31/12/2010

Electrical G4 26/01/1972 8/7/2011

Electrical G5 18/01/1972 1/10/2011

Instrumentation G5 12/4/1980 18/04/2009

Quality Control G5 13/12/1952 7/4/2011B.Sc

Mill Development G4 15/07/1950 12/3/2012



Mill Development G5 4/8/1970 25/10/2010B.E, Civil

12th,Diploma Mechanical

BSc,Diploma Mechanical

AMI degree Machanical12th,Diploma Electrical Engg.,Diploma Energy Mannegment12th, Diploma Electrical Engg.

Diploma Instrumantation

M.SC.PG Diploma Pulp & PaperDiploma Pulp & Paper Tech.

B.Tech Chemical Engg.

Mill Development G4 30/06/1967 15/02/2012B. Tech Machanical


I.T. G5 15/06/1969 1/6/2006

Fire & Safety G5 1/12/1953 1/5/2012

Accounts G5 1/7/1976 6/4/2012

Store G5 4/1/1954 15/01/2012M.A

Administration G4 1/3/1979 12/7/2010B.A.

BSc, Diploma Mechanical Engg.B.A.PG Dipoma Computer SoftwereDiploma Electrical Engg,Post graduat deploma in indaction SafetyM.COM, C.A


Pre.Exp. Rating Remarks

22 Yrs. 50

34 Yrs. 33

35 YRs. 38

19 Yrs. 50

15 YEARS LEFT

17 Yrs. NA

67

18 Yrs. 75

10 Yrs. 60

8 Yrs. 60

26 Yrs. 71

10 Yrs. 83

71

12 Yrs. 100

18 Yrs. ?

to be reassed with data from Pande-Provided

Initiatives were Jul - sep only

To be resubmitted as no dates in sheet

21 Yrs 75

9 Yrs. 62

15 YEARS NOT DONE

24 Yrs. 100

8 Yrs. NOT DONE

LEFT

5 Yrs. NA

ONLY JD GIVEN NO INITIATIVE

S.No E.Code Name

1 151

2 813

3 1468

4 1190 Balwinder Singh

5 1199 Raman Karir

6 1500

7 1205 Lalit Singh

8 1477 Shohrab Akmal

9 1202

10 1499 Jeevesh Kumar

11 1292

12 1502 Manish Srivastav

13 118

Radhey Shyam Singh

Vinod Kumar Rana

Dr.Sudhir Kumar Singh Chauhan

Shiv Narayan Khushawaha

Yogesh Kumar Saini

Sachin Kumar Verma

Rajeev Mohan Saxena

Designation Department

Assistant Manager(Pulp Mill) Pulp Mill

Assistant Manager (Stock Preparation) Stock Preparation

Deputy Manager (E.T.P) E.T.P.

Deputy Manager(Power Plant) Power Plant



Assistant Manager(Electrical) Electrical

Assistant Manager (Instrumentation) Instrumentation

Deputy Manager (Mill Development) Mill Development

Assistant Manager (Power Plant) Mill Development

Deputy Manager(Human Resource) Human Resource

Deputy Manager (Human Resource) Human Resource

Assistant Manager (Human Resource) Human Resource

Grade DOB DOJ Qul. Pre.Exp.

G6 1/1/1963 21/10/1999B.Sc

14 YEARS

G6 31/07/1972 27/08/2010B.Sc

18 Yrs.

G6 1/7/1977 30/08/2012MSc,Phd

12 Yrs.

G6 1/4/1958 1/8/2011 34 Yrs.

G6 20/08/1950 16/08/2011 29 Yrs.

G6 2/9/1979 22/10/201212Years

G6 1/3/1984 29/08/2011B.Tech (Electical)

6 Yrs.

G6 4/8/1981 17/09/2012B.Sc

6 Yrs.

G6 21/04/1984 22/08/2011 5 Yrs.

G6 5/2/1980 22/10/201214Years

G6 15/07/1973 1/1/2012 5 Yrs.

G6 18/4/1979 22/10/2012M.L.P.M,L.L.B 7Years

G6 26/03/1965 5/6/2000B.A.L.L.B

16 YEARS

I class Boiler Attendent,Diploma Mechanical Engg12th,Diploma Mechanical Engg.B.E Electrical Engg.Diploma Electronics Engg.

B.Tech Chamical Engg. Spacalization inpulp & paperDiploma Mechanical Engg.B.COM, Manager course HMP, MBA

33

25

100

25

25

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

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


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


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


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


Review 1 - (DATE)


3.Monitor 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.



Review 1 - (DATE)

Feedback Weightage

L-5 L-4 L-3 L-2 L-1







score


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


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


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


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


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



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


100% compliance to Plan

15-Mar-13

15-Nov-12

15-Nov-12



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


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.


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


Target Date(To be given under column L3)Weightage

L-2 L-1



Appraiser)

Perfromance score



L-3 L-2 L-1



Appraiser)

Perfromance score


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:


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


Perfromance Planning and Assesment for the Quarter Oct - Dec, 12

Review 1 - 26 Dec 2012

Initiatives/Action0/1 Feedback

Date

1


Indicator


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


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


Indicator










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



Feedback Target Date(To be given under column L3)

L-5 L-4 L-3

Suggested KPI for April-June


Weightage %age/ Level

Achieved



score



Weightage L-2 L-1


Actual Performance (By Apprais

er)

Perfromance score


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



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




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


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


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


2. Confirm possession of all required parts and materials


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 weekly Plan


Emp. Code:Department:


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.


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.


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.


720 Ed. Qual. Post Graduate Diploma in Pulp and Paper technologyPaper M/C 3


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


720 Ed. Qual. Post Graduate Diploma in Pulp and Paper technology

Paper M/C 3


L-5 L-4 L-3 L-2



Post Graduate Diploma in Pulp and Paper technology

x x x

x x x




score

Drag load on wire reduced

Breakage for slime reduced

Surface properties of paper increased

Finish deckle increased

M/C runability improved


Post Graduate Diploma in Pulp and Paper technology

Vacuum fluctuation on wire reduced


Weightage

L-1



er)

Perfromance score


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



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




N/A

2) Timely change C.D. throat. Plan fulfillment %

1

NA

Saving of Caustic by 2%

INR per metric tonne1

Steam Consumption

1



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


Review 2








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





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.



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



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.


Ed. Qual.Production ( Pulp )

Target Date(To be given under column L3) Weightage

L-3 L-2 L-14000



Appraiser)


Ed. Qual.Production ( Pulp )


L-5 L-4 L-3 L-2 L-1


Perfromance score



Actual Performance (By Appraise

r)

Perfromance score


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



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



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




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


Review 2








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


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 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


Emp. Code: 1344Department: Chemical recovery


L-5 L-4



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


Emp. Code: 1344Department: Chemical recovery

Review 2

FeedbackEstimated Financial Impact



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%


Ed. Qual. PG DIPLOMA (PULP & PAPER)


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


x x x x x

x x x x x


Ed. Qual. PG DIPLOMA (PULP & PAPER)


L-5 L-4 L-3 L-2 L-1


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.




score

x x

x x



Achieved


er)

Perfromance score



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


DRAWINGS & BOM FINALIZATION, SCHEDULING WORK IS UNDER

PROGRESS

CONSULTANT FOR DRAWING & DETAIL ENGINEERING FINALIZATION


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.


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





Planned Project Cost Vs Actual Project Cost

Clearance of Vendor Bills within 3 days of receipt.



0/1 Feedback

DATE N/A

DATE N/A

PLAN,EXECUTE,AUDIT DATE 1

PLAN,EXECUTE,AUDIT DATE 1

DATE 0

DATE 1



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



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.


Review 2

0/1

20-Jan-13

2. Finalise implementation schedule 25-Jan-13

25-Jan-13




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.


1. Number of Purchase Requisitions to be placed



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 )





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




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.)



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.



Review 2


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

under progress. To be passed by 2-Feb-2013

Submitted and updated as on 24 Jan 2013


Emp. Code: 1394 Diploma Mech. Engineering ProductionDepartment: Project


L-4 L-3 L-2 L-1

20% 50%

20% 50%

10%

10%

10%

10% 50%

Ed. Qual.

%age/ Level

Achieved

Actual Performance

(By Appraiser)Perfromance

score

10% 50%

10% 50%


Emp. Code: 1394 Diploma Mech. Engineering ProductionDepartment: Project


Weightage L-5 L-4 L-3 L-2 L-1

Ed. Qual.

Suggested KPI

for April- Jun



er)

Perfromance score


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



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


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


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


Review 1 - (DATE)

0/1

Date 1

Date 1

Date 0

Date 1

Date

1

Date

% increase in PGF 1



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


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)




Review 2

0/1

12-Jan-13

12-Jan-13

15-Jan-13 1

15-Jan-13 1

20-Jan-13



IndicatorEstimated Financial

ImplactActual Financial

Impact

9 hrs 40 mins for all machines and hrs for

pulp

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.


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




5..Number of Equipments to be received


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


Emp. Code:Department: Electrical

Review 1 - (DATE)


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.


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.


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.


Ed. Qual.


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



Appraiser)

1 Oct - 15 Nov


Ed. Qual.


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


Perfromance score



er)

Perfromance score


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



Performance Planning and Assesment for the Quarter Jan- Mar 13Name : Dalip VermaDesignation: Sr. Manager

S No KRA KPI


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.


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



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





Review 1

Initiatives/Action

0/1

5 % reduction over Oct-Dec

Daily monitoring of work progress.



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




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%.


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










6. Erection and commissioning of all

equipments

7. Monitoring and recording of progress on

fortnightly basis % variance over agreed dates as

per plan.


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.


4. Tracking and monitoring of major causes to confirm

positive effect of measures.



Review 1 - (DATE)


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




Review 1


Next KPI :100% Compliance to Preventive Maintenance Schedule. Number of occurences where Schedule was not followed. Next KPI: Segregation and Storage of Spares.


Oct: 10 hrs 55 minsNov: 4 hrs 5 minsDec: 6 hrs 25 mins

Jan:15 Hrs 25 mins

Done.

Not done. Will be completed by 4-Feb-2013

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

Done.

Done. Jan to be complied by 7-Feb-2013

To be sepaatly compiled by 10-Feb-2013

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.


601 Ed. Qual. Diploma Instrumentation Tech.Instrumentation


L-4 L-3 L-2 L-1

01.10.12-31.10.12

01.11.12-10.11.12

01.10.12-31.12.2012

01.10.12-30.11.2012

01.10.12-31.12.2012


601 Ed. Qual. Diploma Instrumentation Tech.Instrumentation

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.


5% Reduction

5 % Reduction

10 % Reduction




score

As per set targets by project team under

the guidance of president



Weightage L-1

As per set targets by project team under

the guidance of president



er)

Perfromance score


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





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


4 Employee Engagement Index Coordination with all Inter-

Functional Depts


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)



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.



0/1 Feedback

1

0

1

1

1



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


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



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




Emp. Code: 966Department: Paper M/C


L-5 L-4 L-3


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.


Ed. Qual. Pulp and Paper Tech from I.P.T Saharanpur


L-2 L-1



Appraiser)


Ed. Qual. Pulp and Paper Tech from I.P.T Saharanpur


L-4 L-3 L-2 L-1


Perfromance score




er)

Perfromance score


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



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.




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



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




Identified The External Vendors For Calibration Of

Lab Testing Equipment

Timely Maintenance Of Testing Equipment

Calibration All The Lab Equipment




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





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.





Calibration of all equipment done. Done after a year since last check.


Get added initiatives from PK Saini after consultation with Manjit Singh


1284 Ed. Qual. B. Sc.Quality Control(P.C Lab)


L-4 L-3 L-2 L-1

15 Oct - 31 Dec

15 Oct - 31 Dec

15 Oct - 31 Dec

15 Oct - 31 Dec


1284 Ed. Qual. B. Sc.Quality Control(P.C Lab)


L-5 L-4 L-3 L-2


Get added initiatives from PK Saini after consultation with Manjit Singh





score



Weightage L-1



er)

Perfromance score


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.



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


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.





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. 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.


3. Number of Purchase Requisitions to be placed with expected schedule of delivery


7. Monitoring and recording of progress on fortnightly basis with areas of concern





0/1 Feedback Suggested KPI for Jan-Mar

1

1

1

0


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



Review 2


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.



Impact

50 % reduction over Oct-Dec

1 Day production PM. 24 hrs. 180

Tons

31-Jan-13

31-Jan-13

5-Feb-13

5-Feb-135-Feb-13

15-Feb-13

15-Oct-13

31-Jan-13

15-Oct-13








By 17th and 2nd of next month



28-Feb-13

31-Jan-13

15-Nov-12

Zero Consumption

30-Jan-13

All inhouse
















Emp. Code: 1336 Ed. Qual. B.Tech(Mechanical)Department: Utility projects


L-5 L-4 L-3 L-2 L-1

10 Oct-6 Nov

6 Oct-8 Nov

1 Oct-Ongoing

1 Oct-Ongoing


Emp. Code: 1284 Ed. Qual. B. Sc.

Department: Quality Control(P.C Lab)


L-5 L-4 L-3


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.

Done.

Done.

Done.

Done.

Done.

Done.

Done.

Done.

Done

Done

Done

Done

Done

Done

Done


B.Tech(Mechanical)

Weightage

100%

100%

100%

100%




score



Weightage L-2 L-1



er)

Perfromance score


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



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




Plan,Implement,Check

1Plan,Implement,Check


0


1



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.


Oranamental and flowering plants planted in scrubbed Plastics drums at ETP. Medicinal, ornamental and Flowering plants will be planted accordingly seasons.


Model develop for using ETP water as a irrigation for agriculture crop and compare with farmers crop within adjoining mills area




0




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


Preparation of documents for FSC-coc at Kashipur. For Global marketing of our products




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



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


Emp. Code: 1468Department: Plantation



L-5 L-4 L-3

Oct - Mar

Oct - Dec

Sept - Feb

Modified proposal submitted in December.

Yield (estimated) : 100 quintals


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.



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


Ed. Qual. M.Sc. Ph.D.- Forestry


L-2 L-1

100%

100%

100%




score

100%


Ed. Qual. M.Sc. Ph.D.- Forestry


Weightage L-4 L-3 L-2 L-1


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


er)

Perfromance score


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


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




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)



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




Review 2


Listing of spares in stock

1. Indent of spares2. Review of spares



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







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.



Review 2

Actual Financial Impact FeedbackEstimated Financial Impact

Suggested KPI for April-Mar


1199 Ed. Qual. Inter + Mech Diploma PP/ Turbine


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



Appraiser)

One Month (30 Nov)

One Month (1 Dec)


1199 Ed. Qual. Inter + Mech Diploma PP/ Turbine


L-5 L-4 L-3 L-2 L-1


x

x

x

x

Perfromance score




er)

Perfromance score


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



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



Initiatives/Action 0/1 Feedback

Plan,Do,Check Number of days delay

1

Meet,Review, Decide,Act

1

0Number of days delay



JAN-MAR TARGETS TO BE MORE SUBSTANTIVE


Review 2




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




Indicator



Emp. Code: 1202 Ed. Qual.Department: Utility Projects



L-5 L-4 L-3 L-2

4 Oct-15 Nov


Emp. Code: 1202 Ed. Qual.Department: Utility Projects

Review 2


L-5 L-4


1 Oct-Ongoing

Daily




B.Tech (Chemical)


L-1

100%

100%


B.Tech (Chemical)


L-3 L-2 L-1




score



er)

Perfromance score


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.



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.




0

0

0

1

1

0

0

Meet with Dept Heads and finalise.

0





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


timelines

3. Identify the job description for designated position


timelines

1. Organize and Get together any other activities


timelines

3. Organize different committees including workers & staff


timelines

1. Introduce PMS in phases, in the factory for workmen


timelines

2. Identify the employee training needs and inputs fror the same.


timelines

Achievement Percentage 25


Review 2


%? Measured monthly

Identfication to be done by Jan 31.

Identify 5 categories per month

Steps to achieve the Initiative/Action for Jan-

March


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







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



Review 2


L-5




Ed. Qual.


L-2 L-1

40% 100%

25% 100%

25% 100%



Appraiser)


Ed. Qual.


L-4 L-3 L-2 L-1


Perfromance score




er)

Perfromance score


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



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




1 Oct-31 Dec

d) Issue Material of FIFO basis

31 Dec-31 Jan

Steps to achieve the Initiative/Action/ Timeline


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.


Review 2


Timely Lifting of Goods from Local transport

31-Mar-13

Bearings, Oil seals and Sleeves to come under purview of 5S in Jan-

Mar





Steps to achieve the Initiative/Action/ Timeline


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









L-5 L-4 L-3


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.



Review 2


L-5

Data for Oct-Dec not compiled. Will be done by 5-Feb 2013

Being done

Being done.

Work has started.




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.


Ed. Qual.


L-2 L-1



Appraiser)


Ed. Qual.


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.


Perfromance score




er)

Perfromance score


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


x %OTIF ( To be assigned to senior ) x

Signature of A


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



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


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


Mainly complaints come to P.M/C regarding variation in GSM and less

smoothness. To avoid both complaints reasons are given above.


Plan,Execute,Check

x x




Review 2


Crews of the Machine should be motivated and educated

Plant Head feedback in %

Steps to achieve the

Initiative/Action


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



.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.


Emp. Code: 1055 Ed. Qual.Department: Production ( Paper Machine )



L-5 L-4 L-3 L-2 L-1

Suggested steps for Jan-Mar

x x x x x


Emp. Code: 1055 Ed. Qual.Department: Production ( Paper Machine )

Review 2


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.



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

Jan: 1250 TFeb: 1030 TMarch : Nil ( Machine 4 closed from 18-Feb )

Not Done


Production ( Paper Machine )

Weightage %age/ Level Achieved



score

xx x x x

x x x x


Production ( Paper Machine )


L-2 L-1



er)

Perfromance score


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


Target Production achievement (2280 MT)

Cost of Production ( To be shared with subordinate)

3 %OTIF

4



Performance Planning and Assesment for the Quarter Jan-Mar 2013Name : Sanat Kumar BhattDesignation: Line Head

KRA KPI


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


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


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



0/1 Feedback

Tonnes

1

1


%

0

gm/T

1

0



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




Review 2


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?




Impact

2-Jan-13

3. Receipt of Materials


15-Feb-13



21-Dec-12


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


100% Compliance


100% Compliance


monthly report100%

Compliance


100% Compliance



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


2-Jan-13


1. Prepare detailed calendar 5-Feb-13

00% compliance



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.


100% Compliance


100% Compliance


monthly report100%

Compliance

2. Record MoM for all meetings and submit monthly report for all

measures and suggestions along with timelines and responsibility

centers.


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


Emp. Code: Ed. Qual.Department: Production


L-5 L-4 L-3



Weightage

60%

5.60% 30%

23 Kg /T 50%




score

67% efficiency ( Currently)



L-2 L-1



er)

Perfromance score


Perfromance Planning and Assesment for the Quarter Oct - Dec, 12Name : V.K.SaxenaDesignation: Manager ( Stock )

S No KRA


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



KPI



KPI

AKD consumption

Ash consumption

Shade Variation



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


Minimise shade variation

2. Create action plan for all actvities


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



0/1 Feedback Suggested KPI for Jan-MarMeasures/Performance Indicator





Review 2


Reduction by 1 kg



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%


Emp. Code: 1347 Ed. Qual. M.Sc (Chem.)P.G. Diploma in paper & pulp & paper from Saharanpur.Department: Unit-II


L-5 L-4 L-3 L-2 L-1




Done. Daily dosage monitoring also being recorded


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


M.Sc (Chem.)P.G. Diploma in paper & pulp & paper from Saharanpur.




score



Target Date(To be given under column L3) Weightage %age/ Level Achieved


r)

Perfromance score


Perfromance Planning and Assesment for the Quarter Oct - Dec, 12Name : B.P.JainDesignation: G.M. (PRODUCTION)

S No KRA



3 %OTIF- Quality

4 Labour Engagement


Performance Planning and Assesment for the Quarter Jan-Mar 2013Name : B.P.JainDesignation: G.M. (PRODUCTION)

S No KRA

1 Target Production Achievement

4


3 %OTIF- Quality

4



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


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


Initiatives/Action

c)Improve deckle utilization


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


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


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. 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



0/1 Feedback Suggested KPI for Jan-Mar

% Production rate increase.

1

1

1

1


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





Review 2



Tuesday ( Weekly )


18-Jan-13

31-Jan-13



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


5th of every month

15-Jan-13


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.




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.)



October- Four times in a month and November , December - Two times a month


Data to be analysed.

YES

To be prepared by 4-Feb-2013

Done


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






score

Target Date(To be given under column L3) Weightage %age/ Level Achieved


er)

Perfromance score


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


2

10% Reduction in Unplanned Breakdowns


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


Review 1 - (DATE)


% of available time 0

1

% against plan

1Greasing of gearboxes,pumps etc. Plan fulfillment %

Plan fulfillment %

1



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





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


Indicator

10 % Reduction in breakdown Hours over Oct-Dec ( 40 hrs for all

four machines per month)


Identify top 10 causes of Breakdown with Plan for CAPA along with

Timelines and Responsibility Centers



Preventive Maintenance Schedule Zone-Wise


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


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







7. Fortnightly monitoring and recording of progress

% variance over agreed dates as per

plan.

8. Weekly summary of action plan for removing bottlenecks




6. Erection and commissioning of core cutter



plan.


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



Review 1 - (DATE)


L-5

Not a Initiative


Sept ( 21 hrs )Oct(26 hrs 15 mins)/Nov(21 hrs+35 hrs) :PM-1:- 2

hrs/6 Hr 15 min/10 hrs /PM-2:6 hrs/ 7 Hr/4 hrs

PM-3 : nil/10 Hr/40hrs( 35 hr due to inavailability of Pinion)

PM-4 : 13hrs/3 hrs/2 hrsCritical holding inventory provided to

stores. To provide PR Details of critical items. Unplanned downtime in total is

low as compared to industry benchmark. however, planned

downtime is excessively high- Steam boiler and market and environment

requirements.No breakdown reported because of oil or grease. Format to be provided for

maintaning records of preventive maintenance done.( Follow the

schedule provided by Rajiv Pandey)

Prepare Preventive maintenance schedule and implement during next

quarter.

Regularly checked but no record being maintained. Frequency of checks to be

logged.

Multi skilling is at its highest in the plant. Full-time value of each worker is

2-3 times as informed by President

Not Changed


Emp. Code: 339Department:

Ampere value constanly monitored. Logs to be maintained about the same.

Record and map the ten highest consumption units in operation. To be reviewed in April. Format to be signed

by Y.P Singh ( Mechanical) and ( Electrical ). After the first review in January, it is possible that the list is

expanded to the top 20 or the top 30 and so on.

Innovative measure taken : Cutter replicated from smaller scale and

applied to line. To add list of initiatives to next KPI where all ongoing projects are listed with expected dates of installation.

Problem areas where housekeeping is an issue to be listed with

measures to mitigate.

Next KPI : Standard of Housekeeping to be improved through proper stacking and segregation of materials.

Review 1

Target

Estimated Financial Impact Feedback

Jan: 30 hrs

Done

Not done: To be submitted by 5 Feb 2013

To be done by : 2/10/2013

Being Done. Will be done by 2 Feb 2013

Being Done

Not Done. Will be done by 5 feb 2013



Done

Done

Done

Done

Awaiting parts.

To be done by 31- March

Will be done by 5-Feb-2013



Done

Done

Not Done . Will be completed by 15-Feb


965 Ed. Qual.Mech


L-4 L-3 L-2 L-1

Shree Shyam Pulp & Board Mill LtdPart - I

Ed. Qual. M.Sc. ChemistryMechanical Date of Birth

Target

L-5 L-4L-3

L-2

Not done: To be submitted by 5 Feb 2013

Being Done. Will be done by 2 Feb 2013



Weightage(Total 100)

Suggested KPI for April-Jun 2

Not Done . Will be completed by 15-Feb


100%

100%

100%



Appraiser)Performance

score

Signature of Appraisee

Signature of Appraiser


L-1


Performance Assessment By Appraisee

Performance Assessment By Appraiser


Perfromance Planning and Assesment for the Quarter Oct - Dec, 12Name : R N Jha


S No KRA KPI

1 Pulp 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



Perfromance Planning and Assesment for the Quarter Jan-Mar 2013Name : R N Jha


S No KRA KPI

1 Production Achievement

CD Production


Cost of Caustic

Cost of Chlorine

Consumption of Steam

Power Consumption

Chemicals in effluent

3 Delivery to Internal Customer

4 Employee Engagement

Soft water supply required followed by commissioning of PHE

5 %OTIF Weekly





N/A

2) Timely change C.D. throat. Plan fulfillment %

1

NA

Saving of Caustic by 2%

INR per metric tonne1

Steam Consumption

1



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


Review 2


Increase in rate of CD Production







Indicator

100% of Machine Demand to be met

Current : 7 T/hrTarget: 7.5 T/hr

Improvement in Wet Washing Big Aqua changed

Change of Small Aqua by old one

On Monday

On Monday

On Monday

Steam Consumption Identify points of Steam Loss 15-Jan-13

20-Jan-13

Reduction of 10 Units

1. Improvement of Pith Separation by installation od depither basket

2% increase over baseline( 18% )

1% Increase in Consistency in Raw

Material over existing value (17-18%)

Within 12 hrs of first opportunity of

shutdown of plant

5%Reduction in Overall Cost per metric

tonne per month

Caustic Consumption to be 38% in Jan-March against 39.5% (Current).

4. Monitor Consumption levels on a week to week basis and report with

reasons for variance.Reduction in Chlorine consumption to 10% against 10.7% (Current)

Target of Steam Consumption : 2.5 Ton/Ton of Pulp against 3 Tons/Ton

of Pulp at present

Implementation plan for remdial action with Responsibility Centers

and Timelines

Installation for softening plant has not arrived. Soft water supply still not received from Recovery team.

Commissioning of PHE

20 hr running so 20 tons per day saving. 1000/mT of steam

Monday

Date

2. Create Action plan for reduction Date

100% compliance

100% Compliance

Complaint redressal from Customer

CAPA Analysis 2 Reports a Month

1. Identify points of high Power Consumption

2. Remedial measures plan to be created

3. Raise indents as per plan for consumables and spares

Project of Soft Water being done by Recovery Boiler Project Team

Within 24 hrs of Soft water supply

Reduction of Steam Consumption ( After Commissioning of PHE)

1 T/Hr reduction in CD

1.Monitor weekly Consumption of Steam with reasons for variance

Reduce Chemical discharge down to Standard Levels

% reduction over avg of last 6 months

1. Identify Standard for Chemical Discharge

3. Finalise Action plan and notify all shareholders


4. Implement strategy and monitor levels on a fortnightly basis.

Supply Pulp within Standard Quality Parameters

Within 24 hrs of complaint

Report every fortnight with Responsibility Centers and

Timelines.

Regular meetings with Internal Team Twice a month

2 Reports a Month

12-Jan-13

2. Weekly report

1. Record of MoM with Issues to be addressed along with timelines and

responsibility centers

100 % compliance to weekly plan

1. Not done in the past. Finalise weekly plan with PPC ( Vivek

Shrotriya)

10% variance over plan allowed

Identification of 10 Major Causes for Breakdown in consultation with Mechanical/Electrical/Process



individual dept.



measures.






Emp. Code: Ed. Qual.Department: Production ( Pulp )



L-5 L-4 L-3 L-2 L-13850 3900 4000

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.


Emp. Code: Ed. Qual.Department: Production ( Pulp )

Review 2


L-5 L-4 L-3

Next KPI : Add an initiative in Oct- Dec about

reduction in chemicals going

into effluent treatment




Increase of 12 TPD per production

Oct: 7.3 T/hrNov: 7.1 T/hrDec: 7.14 T/hr

Jan:7.6 T/hr

Done. 20-21% currently

Will be done on 4-Feb-2013.

Done. No steam loss .

Savings of 20 kg/ ton of bleach

pulp. 40 rs per kg. 145 tons per day

Oct- Dec : 14-15%Jan: 17%

Work done on 25 Dec

Oct: 38.25%Nov:38.92%Dec:39.2%Jan:36.9%

As a result of aqua change and dipither

Oct: 10.74%Nov:9.93%Dec:10.46%

Jan: 10.3%

Oct: 2.71 T Nov: 2.77 TDec : 2.9 T

Jan:2.62 T

Done. No steam loss .

Preventive maintenance being

done.

To be compiled by 10-Feb-2013

To be compiled by 10-Feb-2013

Installation for softening plant has not arrived. Soft water supply still not received from Recovery team.

20 hr running so 20 tons per day saving. 1000/mT of steam

Data unavilable for Oct-Dec. Will be compiled by 10-Feb-2013

Will be compiled by 10-Feb-2013



Oct: 296KW/T of Bleach

Nov: 308 KW/T of Bleach

Dec: 339 KW/T of Bleach

Jan: 311 KW/T of Bleach

Report to be compiled by 5-Feb-

2013





score



L-2 L-1



r)

Perfromance score


Perfromance Planning and Assesment for the Quarter Oct - Dec, 12Name : Mohd. Gufran

Designation: Manager Grade 5

S No KRA KPI

1 Project Assigned PM-4-General Arrangement

2 Project Assigned PM-3- General Arrangement

3 Project Assigned PM -3 - Pope Reel Frame Detailing

4 Project Assigned



Performance Planning and Assesment for the Quarter Jan-Mar 2013Name : Mohd. Gufran

Designation: Manager Grade 5

S No KRA KPI

1 Project AssignedPM-4-General Arrangement

PM- 3 -Preparation of Wire Part Drawing

2 Project Assigned PM -3 - Pope Reel Frame Detailing

3 Project Assigned PM- 3 -Preparation of Wire Part Drawing


Initiatives/Action Steps to achieve the Initiative 0/1

Date

1

Date

1

Date

1

Modified Wire Part System Date

1

Date

0

Date

0

Date1

Date1

Date

1

Date

1



Indicator

Layout preparation PM-4. Approach flow, wirepart, drivers etc ( Backside)

Drives- Couch, FDR, Sue Pickup Roll, Dryers and Calendar Pope Reel

Proposal of Dryer group Uniform Part System and Detailing drawings

Wire part - delay due to material required (M.S. Plates)

Civil Drawing, inspection of fabrication

Pope reel frame detailing wire part drawing ( PM3) - (Backside)

New wire part Section and Detailing drawing of wire part ( In progress)

( delay for dimensional drawing "Binip" received from China)

Layout of drives, Couch , F.D.R , Suc. Pickup roll, Press II and III , dryers ,

Calander, Pope reel

New dryer group - Uniform Part Sytem- Detailing Drawing

Drum Package from China Date

0

Date

0

Date0




Initiatives/Action Steps to achieve the Initiative 0/1

1Monitoring receipt of material 100% Compliance

Submission of dates of Inspection

Balance Part In-House production ( material required)

Existing wire part in out of use it and Fabricated- Machined - Cladding

Review 1 - 27 Dec


Indicator

Wire part - delay due to material required (M.S. Plates)

Identification of Critical Material required with dates

1/15/2013(With YP Singh)

Civil Drawing, inspection of fabrication

(Under VK kesharwani) Record of Inspection and report of the same to be created

Drum Package from ChinaFollow up with vendor 10-Jan-13

1Monitoring receipt of material 100% Compliance

1Monitoring receipt of material 100% compliance

5-Feb-13



Balance Part In-House production ( material required)

Identification of Critical Material required with dates

1/15/2013(YP Singh)

Existing wire part in out of use it and Fabricated- Machined - Cladding

Create detailed action plan for design and fabrication


Emp. Code: 1409 Ed. Qual. Diploma in Mech Engg ( Production) Department: Project


L-5 L-4 L-3 L-2 L-1

Complete as on 20 Oct



Completed as on 16 July

Completed as on 4 September

Completed as on 30 July

Completed as on 10 August

Ongoing from 29 Aug . Estimated to be complete on 8 Jan.

Complete as on 10 Sept



75% fabricated as on 11 Nov + 25 % late due to material required

Requires to totally new design and fabrication.. Estimated time is 45 days from time of beginning of project.


Emp. Code: 1409 Ed. Qual. Diploma in Mech Engg ( Production) Department: Project


L-5 L-4 L-3

Done.Being done. PRs raised. Awaiting material.

Done. On 28-Jan-2013 8-Jan

Done. Awaiting shut to complete work.





DoneAwaiting payment. Dispatch will follow.

DoneBeing done. PRs raised. Awaiting material.

Done. PR/PO raised.


Diploma in Mech Engg ( Production)


Achieved



score


Diploma in Mech Engg ( Production)


Weightage L-2 L-1



r)

Perfromance score


Perfromance Planning and Assesment for the Quarter Oct - Dec, 12Name : S.N Pandey Designation:

S NoKRA KPI

1 Project Assigned

2 Project Assigned

3 Project Assigned

4 Project Assigned Earlier finishing loss was 7.8 %

6


Simple Center of P.M 3. Size Variation

P.M. 3= NO2. Hardly cutting 2- 3 sets in a single flow production

Core cutting machine was cutting rough. Wastage was high

Suggestion for Improvement for Area to be handled by M/C

personnel1 . Increased WID and reduction for

sheet in M1 and 2

2. Cutter of P.M # loading stand modification


Perfromance Planning and Assesment for the Quarter Oct - Dec, 12Name : S.N Pandey Designation:

S No

KRA KPI

1 Production Variation in Production Run

Variation in Production Rate

2 Project Assigned


4 Implementation of 5S




Size Variation 1

1

Quality of Cutting 1

0

Date of Installation N/A

Date of Installation N/A

1

3

4

75



Indicator

Removed press roll . Top bottom and machines overhauled gear box.

Removed drum rolls. Machines , adjusted paper roll

Change in rate of Production

Changed new core cutting M/C with circular knife

Reduced to 5.5/ 6. 0 % by best utilization. Reducing unneccesary

WIP % Change in Finishing

Loss

Presently rolls of 4.0 - 4.5 T may be loaded and has to modify so that 6-7

T rolls may be loaded.

At least 6 new set to be ordered. Also circular knife to be ordered. 50

no. in each size






Review 2


1-Feb-13

By Tuesday

7th of next month

7-Jan-13

% errors noticed

By Tuesday

7th of next month



Indicator

Creation of report that tracks size variation every production run.

1. Create a template listing all machines , production type and

amount of production

2. Track production over 3 month period


3. Monitor weekly and create summary report listing type Quality variance and Number of occurences

of variance

4. Conduct monthly meetings to discuss reports

Tracking of Production rates per day.

1. Create a Template with Start Time, End Time and Production

Value (per day)

2. Track production over 3 month period

3. Monitor monthly and create summary report listing rates of

production , machine wise

4. Conduct monthly meetings to discuss reports

Modification of Cutter to be completed by Mar 31 ( To be handed

over to RK Verma)

Finishing Loss Reduction

% increase in 5S score


( To be handed over to RK Verma)



3. Number of Purchase Requisitions to be placed with Timelines for

expected delivery100% compliance to

Plan

4. Number of Purchase orders to be placed. 100% compliance to

Plan







plan.


No further reduction possible since finishing

loss will only be possible with increase

in demand for high grammage paper









L-5 L-4 L-3

Data to be Validated

Size variation of 3-5 mm. Currently : 1-2 mm . Allowed upto 3mm.

Next KPI: Creation of report that tracks size variation every

production run.

Led to production Improvement. Earlier : 25 TPD Currently : 35 TPD

Next KPI : Tracking of Production rates per day.

Template to be created with Start Time, End Time and

Production Value (per day)

Next KPI : Modification will be completed by 31 Mar of

Cutter.



Review 2


L-5



Done

Dec and Jan avilable. Oct and Nov will be gotten by 5-Feb-2013

Jan report will be due on 5-Feb-2013

Will be done.




Ed. Qual.


L-2 L-1

1.0 - 1.5 % of loss




score

Six variable problem solve. Now ruinning

smooth.

Now cutting 6-7 a shift

Smooth cutting and no loss


Ed. Qual.


Weightage L-4 L-3 L-2 L-1

Dec and Jan avilable. Oct and Nov will be gotten by 5-Feb-2013



er)

Perfromance score


Performance Planning and Assesment for the quarter: 1st Oct to 31st Dec 2012.Name: Anami Saran SrivastavaDesignation: Sr. Manager

Sl No KRA KPI

1 ETP Breakdown Breakdown Hours

2 Optimize dozing of chemicals

3 TrainingTrained Chemist

Trained Officer

4 Charter

All Parameters within limits

Weightage x Appraiser's Score


Performance Planning and Assesment for the Quarter Jan-Mar 2013Name : Anami Saran SrivastavaDesignation: Sr. Manager

S No KRA KPI

1 ETP Breakdown

Assessment Scale 1 - 10 ( 1 being Lowest and 10 Highest)


10 % Reduction in Unplanned Breakdowns ( 40 hrs - 36 hrs )

2 Charter All Parameters within limits



0/1

Initiatives/Action Steps to Achieve Target /Action

Plan, Get it done , Check

0

1Plan the process, Do it , Check Date

1

Plan the process, Do it , Check Date

Generating report as per charter Date

1

a) BOD.

0

Performance Indicator

Implement maintenance schedules

Breakdown Hours per month

Maintain O2 dozing less than 1500 kg

Plan the process, Get it done , Check

Number of hours per month outside the range.

Maintain urea dozing less than 300 kg



Maintain DAP dozing less than 150 kg



a) Trained one chemist for analysis and stabilization of aeration basin

b) Trained one officer for operation of the plant


To meet the prescribed parameters


Number of occasions outside limit per month

b) COD.

0c) Flow of discharge

0

0Number of 0 ( Red Buttons) 5




Intiatives/Action0/1

% reduction

20-Feb-13

100% compliance





d) Specific requirements of colour as per Maha Magh Mela



Steps to Achieve Initiatives/Action



100 % compliance with Preventive Maintenance

Schedule Zone-Wise

1. Finalise plan of requirements with all stakeholders.

Saturday/Sunday once in a month

2. Ensure availability of spares and consumables

3. Finalise equipment-wise work under preventive maintenance

Record of Breakdown of Equipments who's preventive maintenance already done.

Number of such cases. Allowed 5%.

a) BOD.

b) COD.

c) Flow of discharge



To meet the prescribed parameters

Create action plan. Implement measures. Monitor BOD levels against standard


Create action plan. Implement measures. Monitor COD levels against standard


Create action plan. Implement measures. Monitor flow of discharge levels against standard


d) Specific requirements of colour as per Maha Magh Mela

Create action plan. Implement measures. Monitor colour levels against standard




Feedback

Completed in August.

2 occurences of BOD outside limit

Nov : 12 hrs ( instead of planned zero hrs due to clarifier breakdown). Maintenance Records

must be maintained.

Currently: 1000kg/day. BOD: 22-24 ( Should be less than 30 as per Statute)

Currently : 200 kg/day . Risk : BOD will increase . As per law , required level is 450 kg/day

Currently: 100 kg/dayRisk : BOD will increase . As per law , required level is 250 kg/da

Recruited in November. Training ongoing ( 3 Months )

Recruited in April 2012. Earlier as a chemist.Shifted to plant in November. Dual

charge ( Lab duties as well )

2 occurences of COD outside limit


Review 2

Actual : 100 m3 per ton of paper. Earlier initiatives did not give desired results.

Target of < 500 cobalt units. Oct : 600 - 800 Nov: 500-600 Dec (15th ) : 200-250


100%

100%

100%








Emp. Code: - 11 Ed. Qual. :- Bsc (Math & Physics), PGDCA, Network CertificateDepartment: IT/ERP,PPC,MIS,DISPATCH

Target Weightage


Ed. Qual. :- Bsc (Math & Physics), PGDCA, Network Certificate

%age/ Level

Achieved

Actual Performance (By Appraiser)

Perfromance score


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


7 CD #1 Blow Tank Work 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


10 Washer Repairing ( Total 2 Nos. ) 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 )



Performance Planning and Assesment for the quarter: Jan-Mar 2013Name: R.B. Saini

Designation:

Sl No KRA KPI




DGM ( Mechanical ) Pulp,Paper and ETP

10% Reduction in Unplanned Breakdowns

2

3 Project Assigned

Borewell


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


7Weighted average of value of projects completed within budgetsVERTICAL DIGESTER

ROTARY DIGESTER

Improve information sharing and documenting system


Initiatives/ActionsReview 1 - 27 Dec 2012

0/1

1

1Date

0



% 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


8

10

80


Initiatives/ActionsReview 1

0/1

13-Jan-13

18-Jan-13






Indicator

10 % Reduction in breakdown Hours over

Oct-Dec ( 20 hrs)


Identify top 10 causes of Breakdown with Plan for CAPA along with

Timelines and Responsibility Centers



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


1.Finalise plan of requirements with all stakeholders.



Monitor weekly. Format to be finalised


1.Finalisation of Consumption Pattern over the last 3 months data

of Spares


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






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


7. Fortnightly monitoring and recording of progress on fortnightly

basis


plan.








plan.








plan.

Tuesday

31-Jan-13

10-Feb-13

1. Clear all pending bills of vendors

2. Release of Payments to Vendors


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



individual dept.



measures.

Planned Project Cost Vs Actual Project Cost

3. Total actual cost Vs Original Planned Cost


*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



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




Review 1

Target

Feedback

Done on 14-Jan-2013

Done on 14-Jan-2013

Not Done. To be given on 5-Feb-2013



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.



Target

L-3L-2 L-1

28 Nov - 31 Dec




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.



Started -5/12/2012Completed - 20/12/12





Target

L-5 L-4L-3

L-2 L-1




No material received. All spares and consumables have been indented. Work awaits arrival of materials.

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.


Performance Planning and Assesment for the Quarter Oct - Dec, 12Name : Satish Kumar Johar


S No KRA KPI

1 Production Achievement Zero Breakdown

2 Cost of production Reduction of Steam Cost


Performance Planning and Assesment for the Quarter Jan-Mar 2013Name : Satish Kumar Johar


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



Review 1 - (DATE)


1. Identify critical problem Breakdown time % 0

15-Jan NA

3. Identify critical spares 15-Jan NA

15-Jan NA

1


Number of 1 (Green Buttons)1



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




Review 2


1. Identify critical problem 20-Jan-13

20-Jan-13

7-Feb-13

20-Jan-13



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


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



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


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



Identification of Training Inputs required



Review 1 - (DATE)


L-5

7 Lac INR / Month saving


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

Next KPI : Identification of Training Inputs.



Review 2


Done

Being done.


Oct: 25 HrsNov:13 HrsDec:34 hrs ( Planned shutdown)

Jan: Nil

Not applicable due to zero breakdown from Oct-Dec

List of activities done on 15-Jan. Informed all customers,. Dates still pending.

Done.

Nil Consumption

Oct-Dec (Avg): 7 TPD

Done on 15-Jan

Training provided to 6 people.

Done

All spares are available for preventive maintenance

No records maintain. Being done.

To finalise detailed activity plan with responsibility centers and timelines.

Average usage comiing to 12 TPD in Jan against target of 15 TPD

Pith started in December. Dec:67 TPDJan: 94 TPDFeb (Target ) : 94 TPDMar ( Target ): 94 TPD

Input provided to HR Team.Done.


1510 Ed. Qual. B.E.MechPowerplant


L-4 L-3 L-2 L-1

31 Dec - 31 March

31 Dec - 31 March

31 Dec - 31 March

31 Dec - 31 March

31 Dec - 31 March



1510 Ed. Qual. B.E.MechPowerplant


L-5 L-4 L-3 L-2 L-1




Perfromance score



Achieved


Perfromance score


Perfromance Planning and Assesment for the Quarter Oct - Dec, 12Name : P.K.MitraDesignation: Senior Manager

S No KRA KPI

1 Production


3 %OTIF - Quality

4


Target Production achievement



Performance Planning and Assesment for the Quarter Jan-March 2013Name : P.K.MitraDesignation: Senior Manager

S No KRA KPI

1 Production


3 %OTIF - Quality

4On Job Training

5 Project Assigned



Initiatives/Action

Installation Vaccum Pump

To identify points of wastage of power and steam

Steam pressure has to be regulated


Initiatives/Action

Maintenance Schedule for all 4 Vacuum Pumps

Record to be kept of Breakages due to Vacuum Pump

Commissioning of new Vacuum Pump

To identify points of wastage of power and steam

Steam pressure has to be regulated

Finishing Loss

Conducting OJT with the Shift-Incharges and Foremen every week.

To reduce the number of bends in LP steam line in PM-1.

Modifying the crowning of Press Rolls in both stages of PM-1. Crowning has been already done in MG touch roll (Press Roll).



Ordering and Installation of Vaccum Pump to increase efficiency of machine

Closing of all points of loss for power and steam. Date




Date and % Increase in Efficiency of Machine



1.Finalise plan of requirements with all stakeholders. 15-Feb-132.Ensure availability of spares and consumables 100% Compliance to Plan

3.Finalise equipment-wise work under preventive maintenance 28-Feb-13

2-Jan-13

1.Finalise Cost-Benefit Analysis 28-Dec-12

2.Approval of Procurement 3.Finalise Implementation Schedule 31-Jan-13

1.Prepare Action Plan for Diagnostic 2-Feb-13

10-Feb-13

3.Summary report listing points of excess consumption to be made 15-Feb-134.Eliminate trouble points 28-Feb-13

5.Monitor consumption and compare performance 100% Compliance to Plan


2.Baselines for Steam and Power Consumption to be used to compare against identified trouble points

1.Prepare a detailed action plan for 3 major concern areas 2-Feb-132.Daily Analysis of reasons for variation 10-Feb-13

3.Summary report to be prepared 15-Feb-13

28-Feb-13

5.Weekly monitoring of Action Plan 100% Compliance to Plan

5 % Reduction

(ii)Maximise deckle utilization with marketing people.

Conducting OJT with the Shift-Incharges and Foremen every week.

31-Jan-13

1. Finalise implementation schedule along with estimated cost2. Number of activities to be completed by 31 Mar 2013

5..Number of Equipments to be received6. Erection and commissioning of all equipments



PR details dated on 2-Jan-2013



Tracking of data and improvement shown in next

quarter KPI with Oct-Dec for a baseline

4.Action plan for eliminating causes of reduction involving all concerned departments

(i) Hood has been mounted on PM-1 to control water dripping problem. Finishing loss has been reduced to some extent up to date.



% variance over agreed dates as per plan.




0/1 Feedback Target Date(To be given under column L3)

L-5 L-4

1

0

0

213

33


Current Efficiency : 85% Target Efficiency

of Machine after installation of Pump :

92%

Next KPI: Record to be kept of breakages shift

wise due to Vacuum Pump. Maintenance schedule of all four

pumps required as well as installation of new

vacuum pump.

Steam pressure is erratic. Steam power

consumption has to be reduced.

Next KPI : Flow meter for steam pressure required. Purchase order to be filed and installed by January for all three machines. As

well as data for steam pressure to be kept on record. Reduction in

steam pressure per tonne of paper using current

standard as baseline. 3.5 Tonnes (Current)

Next KPI: Condensate system needs to be

modified. Proposal for which to be completed by 30 Jan. Seek approval and create plan in KPI for Jan-

Mar



Review 2

0/1 Actual Financial Impact Feedback

increases the production 100 MT per month in PM-1 and 50 MT in PM-2.

PR approved on 20-Jan Not done as on 29-Jan.





Plan given verbally on 1-Jan-2013. Written

communication to be sent ASAP.

Records being Maintained.

117 breakages due to Vacuum Pump ( As on

Date from 1-Jan )

Not done as on 29-JanNot done as on 29-Jan

Daily meetings being held informally with Viovek Shrotriya and Shamim Ahemed Khan. Message sent on mobile.

3 meetings held in January. Records being kept. Follow up with Mr Mitra to check format of record keeping . Check for imporvements.


Data not compiled for Oct-Dec. To be done.

Only Jan done.

Finishing Loss as on 29-Jan is 6%Dec: 6.6%


Ed. Qual.Production


L-3 L-2 L-1

60%



Appraiser)

67% efficiency ( Currently)


Ed. Qual.Production


L-5 L-4 L-3 L-2 L-1

Daily meetings being held informally with Viovek Shrotriya and Shamim Ahemed Khan. Message sent on mobile.

3 meetings held in January. Records being kept. Follow up with Mr Mitra to check format of record keeping . Check for imporvements.


Perfromance score




r)

Perfromance score


Perfromance Planning and Assesment for the Quarter OCT-DEC'12Name : Shamim Ahmad KhanDesignation: Manager

S No KRA KPI

1 Customer satisfaction* Internal Customer Satisfaction Index

2 % achievement of profit target

3 IT Infrastructure up time/downtime Downtime/ Available hours

4 Service provider satisfaction* Satisfaction of ERP vendor / Partner

Quality of decision making as measured by meeting profit target



Perfromance Planning and Assesment for the Quarter OCT-DEC'12Name : Shamim Ahmad KhanDesignation: Manager

S No KRA KPI

1 Customer satisfaction* Internal Customer Satisfaction Index

2 % achievement of profit target

3 IT Infrastructure up time/downtime Downtime/ Available hours

4 Service provider satisfaction* Satisfaction of ERP vendor / Partner

Quality of decision making as measured by meeting profit target


Intiatives/ActionReview 1 - (DATE)

0/1

% Satisfaction

% Achievement

Maintain all Records as per ISO Data

% Downtime

% Satisfaction



IT- Add 4-5 Plant user on network for Email/ERP/Daily Routine Work &

Trained for System Operation

MIS- Physical Stock Level - RawMaterial/Fuel

Every 15 days Check Phsical Qty with Book Qty - & Generate more MIS for

Management

PPC- Minimize down time for Quality Change, 100% Deckle

Utilization,

Dispatch- Reduce Finish Goods Stock level, Error Free Dispatched,

Achive 100 % FG-Dispatched as per Delivery Schdule & Loading

Minimium Error Based, Monitoring Stock Lavel Item Wise,

Number of 0 ( Red Buttons)Number of 1 (Green Buttons)Total number of ActivitiesAchievement Percentage

Signature of Appraiser:


Intiatives/ActionReview 1 - (DATE)0/1

% Satisfaction1. Create proposal 5-Feb-13

8-Feb-133. System purchase and Install 16-Feb-13

20-Feb-13



IT- Add additional Plant users on network for Email/ERP/Daily Routine

Work & Trained for System Operation

2. Get approval for systems from management

4. User addition and performance tracking of system

% Achievement

100%compliance

% Downtime

% Satisfaction


MIS- Physical Stock Level - RawMaterial/Fuel

Every 15 days Check Phsical Qty with Book Qty - & Generate more MIS for

Management

PPC- Minimize down time for Quality Change, 100% Deckle

Utilization,

Reduce number of times GSM changes per day to reduce

downtime

Dispatch- Reduce Finish Goods Stock level, Error Free Dispatched,

Achive 100 % FG-Dispatched as per Delivery Schdule & Loading

Minimium Error Based, Monitoring Stock Lavel Item Wise,

Maintain all Records as per ISO and FSC Data



Review 1 - (DATE)Target Weightage

FeedbackL-5 L-4 L-3 L-2 L-1

80%

70%

0.1%

70%


On Leave hence not reviewed



Review 1 - (DATE)Target Weightage

Feedback L-5 L-4 L-3 L-2 L-1

80%


On Leave hence not reviewed

70%

0.1%

70%


Ed. Qual. :- Bsc (Math & Physics), PGDCA, Network Certificate


Perfromance score


Perfromance Planning and Assesment for the Quarter Oct - Dec, 12Name : Chandra Pal SinghDesignation: Manager

S No KRA KPI

1 Unplanned breakdowns

Zero unplanned breakdowns

2

3 Project

4 Cd+2 Double Wet Washing

5 Cd Tubes Steam

6 List Of Equipment

7 Rotary Digester

8 Vertical Digester Timely Commisioning of Pumps

Loss of production due to Mechanical Breakdown in Pulp Mill Zero loss of production due to

machine failure within budgets

Timely Completion of Project At Different Areas & Section

Cd+2 Double Wet Washing P.H.12 To 30.11.12

Cd Tubes Steam Consumption & Deduction

Complete Specification Of Equipment

Timely Completion of Dismantling Work



Performance Planning and Assesment for the Quarter Jan-Mar 2013Name : Chandra Pal SinghDesignation: Manager

S No KRA KPI

1 Unplanned breakdowns

Zero unplanned breakdowns

ETP

CD#2

Loss of production due to Mechanical Breakdown in Pulp Mill Zero loss of production due to

machine failure within budgets

CD#1 Double Wet Washing

220 TPD Bleach Plant

ODL

CD#1 Double Wet Washing P.H.12 To 30.11.12

Cd Tubes Steam Cd Tubes Steam Consumption & Reduction


Review 1 - (DATE)


TPM Project

TPM Project

Plan,Execute,Audit Date

Plan,Execute,Audit Date

Reduction In Gland Packging Plan,Execute,Audit Date

Daily Checks Report Plan,Execute,Audit Date

1. Prepare List of Equipment Plan,Execute,Audit Date

2. Specification Of All Equipment Plan,Execute,Audit Date

Dismantilating At Rotary Digester Plan,Execute,Audit Date

Commisioning of All Pumps Plan,Execute,Audit Date



Indicator

Analysis,Root Cause, Solution, Agreement,Implementation,Audit

Hours of Unplanned Breakdowns


Tonnes of Production Lost

Gratuity Plate Of Pipe Line & 30Tom Crane

Increase Life Of CD.Screne & Threat

NOT AVAILABLE


Review 1

Initiatives/Action

0/1

TPM Project

5-Feb-13







Indicator

Actual

Estimated

Impact


10% reduction in Hours of Unplanned Breakdowns ( currently 20 hrs per monthy )

1. Track breakdown for previous 3 months and create report listing suggestions and critical causes

15-Feb-13

20-Feb-13

4. Implement measures 100% Compliance

5. Track performance per month 100% Compliance

TPM Project

5-Feb-13

15-Feb-13

20-Feb-13

100% Compliance

5. Track performance per month 100% CompliancePreventitive Maintenance

28-Jan-13

2. Raise all PR's

Preventitive Maintenance

2. Schedule meeting with conerned dept to discuss recurring problems. Record MoM.

3. Create action plan for changes and suggestions brought up in meeting

Tonnes of Production Lost


1. Track breakdown for previous 3 months and create report listing suggestions and critical causes

2. Schedule for preventive maintenance .

3. Create critical list for spares and materials

4. Implement measures according to calendar

1. Finalise PM schedule monthwise and Zone wise with all stakeholders

According to Calendar

3. Create comparison report for before and after changes.

Breakdown hrs before replacement vs After.




28-Jan-13

2. Raise all PR's

Plan,Execute,Audit 5-Feb

25-Jan

25-Jan

3. Complete projects by Calendar 100% compliance

100% compliance20-Feb

25-Jan

25-Jan


100% compliance

25-Jan

25-Jan

1. Finalise PM schedule monthwise and Zone wise with all stakeholders

According to Calendar

3. Create comparison report for before and after changes.

Breakdown hrs before replacement vs After.




Increase Life Of CD.Screen & Threat

1. Create Calendar for all Project work

2. File Indents for all reauired materials and parts

4. Track performance with monthly report




Pulp mill work completed. Civil work pending till 31-March-2013




100% compliance

Reduction In Gland Packging Plan,Execute,AuditDaily Checks Report Plan,Execute,Audit Daily since Oct


10-Feb-2013 ( Subject to arrival of plate. Repeated indents raised)






Emp. Code: 1388 Ed. Qual. B. Sc.Department: Mech.(Pulp Mill)

Review 1 - (DATE)


L-5 L-4 L-3 L-2

15 Oct- 31 Dec

15 Oct- 31 Dec

15 Oct- 31 Dec

15 Oct- 31 Dec

15 Oct- 31 Dec


Emp. Code: 1388 Ed. Qual. B. Sc.Department: Mech.(Pulp Mill)

Review 1


L-5 L-4 L-3 L-2

Being Done

Estimated Financial

Impact


16 Tons saving PMOct: 34hrsNov:24hrsDec:26 hrs

Jan:17hrs

Bein Done.

Being Done

Done

Being Done

Done

Done

Done

Done

Done

Done

Done

Done

Not done. To be submited by 10 Feb-2013. Waiting for civil work.

Done

Plate has arrived. May have problems.Being done.



L-1




score



Weightage L-1




score


Perfromance Planning and Assesment for the Quarter Jan - Mar 2013Name : OPS ChauhanDesignation: GM - Security and Vigilance

S No KRA KPI

1 Personnel Management

Recruitment of New Personnel

Personnel to be retained during security overhaul

2

Security at Plant

Physical Security

5Waste Material Management



Review 1 - (DATE)


21-Jan-13

23-Jan-13

13-Jan-13

24-Jan-13

28-Feb-13

1. Establish criteria for evaluation 6-Feb-13

15-Feb-13

20-Feb-13



Indicator

Reviewing and establishing new manpower for security at Kashipur

Plant

1. Finalise list of Army Men to be interviewed and contact the same.

2. Conduct Interviews at Delhi with Ex army men

3. Walk in interviews at corporate office/Kashipur

4. Finalise short list and finish recruitment procedures

5. Create report 1 month after recruitment to monitor the

performance of new personnel

Review of personnel to be retained from existing base.

2. Conduct evaluations as per criteria according to schedule

3. Make final recommendations via report

Boundary Walls

20-Jan-13

8-Feb-13

Handling of Hazardous Materials

2-Jan-13

8-Jan-13

Implement measures 10-Jan-13

Improvement in In-Out systems

10-Feb-13

100% compliance

5-Feb-13

Monitoring report to be filed 28-Feb-13

10-Jan-13

1. Identify areas at Kashipur plant without boundary wall

2. Create action plan with indents and manpower requirements

3. Implement measures as per schedule

Hazardous materials like Chlorine , Lime , Caustic and waste paper to

be minimised by identifying instances of concern

Create report listing measures and circulate

Preparing a report proposing changes from existing system

Implementing the measures outlined in above report according to action

plan

Making separate well-identified systems both for permanent and

contract labour

Improving contracts execution system within Mill Area

1. Working closely with Manjit Singh, VP admin, Pradeep Pande, VP

Commerical, Ashok Taneja- VP HR and S.Maji to improve upon

vigilance/tracking of contract labour and stores materials used by them ,

create a report listing action plan.

15-Feb-13

Disposal of Scrap at Kashipur Plant

Scrap removed and disposed of 19-Jan-13

NO INITIATIVES

Implementing the measures outlined in above report according to action

plan


Emp. Code: Ed. Qual. M.Com, C.A.Department:

Review 1 - (DATE)


L-5 L-4 L-3 L-2 L-1

80 Tons of scrap disposed . INR 28/kg


M.Com, C.A.




score


Performance Planning and Assesment for the quarter: 1st Oct to 31st Dec 2012.Name: Vinod Kumar Kesharwani

Designation: Sr. Manager

Sl No KRA KPI

1 Project Assigned

2 Project Assigned

3 Project Assigned Improvement in work quality

4 Project Assigned Cost optimization

Completion of Project in Optimum Time Frame

Improvement in house keeping at civil works area




Performance Planning and Assesment for the quarter: Jan-Mar 2013Name: Vinod Kumar Kesharwani

Designation: Sr. Manager

Sl No KRA KPI

1 Project Assigned16 MW TURBINE

Project Assigned BOILER CONTROL BUILDING


Project AssignedBOILER FOUNDATION(AUXILIARRY)

Project Assigned RCC CHIMNEY

Project AssignedASH SILO

Project AssignedCOAL HANDLING SYSTEM

Project Assigned B.FBR PLANT:-

Project Assigned C. R.O.PLANT

Project Assigned

Project Assigned E. 220 TPD BLEACH WASHER

Project Assigned F. BLOW TANK FDN.

Project AssignedG.ODL PLANT

D.WATER CONSERVATION SYSTEM AT RECOVERY PLANT

Project AssignedH. CLO2 PLANT

Project Assigned I. PM-3 PRESHUT JOB

Project Assigned J. PM-4 PRESHUT JOB

Project Assigned

Project Assigned

K. MAKING USABLE THE SCRAP TMT STEEL

L. BUILDING GARBAGE UTILISATION IN FLOOR BASE ,YARD & ROADS




3. Scheduling of project Date

% 5S Score

Saving in INR

Steps to Achieve Initiative/Action


1. Proper Coordination and Planning

Time and Cost within Plan

2. Submission of bill in time for prompt payment

Number of occasions when bill was late

4. Coordination with Purchase Dept.

Number of Days not interacted

1. To educate the workmen for keeping the site clean for smooth

working

1. Site checking by different site in charge before casting of any

RCC workNumber of times

rejected in one year

2. Checking of building raw material before unloading at site

Number of times rejected in one year

3. Record of Power Card and Cube Testing

Number of times rejected in one year

1. Review the consultant drawing / design

2. In house design Saving in INR

3. Maximum work on labour rate Saving in INR



Review 2


PANEL ROOM AT G.FLOOR

DISTRIBUTION PANEL ROOM

PANEL ROOM AT F.FLOOR

FLOORING WORK

TRANSFORMER AND PANEL ROOM FIXING OF DOORS & WINDOWS

Steps to Achieve Initiative/Action




TURBINE & AUXILIARRY FINAL GROUTING


BRICKWORK & PLASTER(FOR BALANCE 30%WORK)





basis

STRUCTURE UPTO 25 MTR LVL

STR.UPTO 27 MTR LVL

FEED PUMP FOUNDATION

DCS ROOM

BRICKWORK AND PLASTER

FLOORING WORK

PA FAN FOUNDATION

SA FAN FOUNDATION

ROOSTER PUMP FOUNDATION

PAINTING WORK OF CHIMNEYID FAN FOUNDATION








basis








basis

ASH SILO AREA DEVELOPMENT (BALANCE WORK)

CONVEYOR FOUNDATION(BALANCE 50%)

CONTROL BUILING(BALANCE 30 %)

HBL TANK FDN.(BALANCE 15%)

RO BUILDING(BALANCE 15%)RO EQUIPMENT FDN.(5%)RO DRAINS(10%)RO APPROACH (50%)

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.

BALANCE STR. UPTO 14 MTR.(BALANCE 20%)

DISMANTLING WORK (BALANCE 30%)

ODL PLANT BUILDING (FOUNDATION)

GANTRY SUPPORT PEDESTALVACCUM PUMP FDN.CENTICLEANER PIT & PUMPSCENTICLEANER SHED COLUMNPANEL ROOM

PANEL ROOM

DCS ROOM & COMPRESSOR ROOMCENTICLEANER PITMISC FDN.

RO PLANT APPROACH ROADASH SILO ROAD


ABSORBPTION TOWER BUILDING UPTO 4.1 MTR(BALANCE 30%)

ABSORBPTION TOWER BUILDING UPTO 7.9 MTR

ABSORBPTION TOWER UPTO 12.4 MTR

APPOX 4 -5 MT TMT STORED AT YARD TO BE SHORTED OUT AND MAKING IN GOOD CONDITION FOR RCC WORK


Emp. Code: 970 Ed. Qual. M.Sc. ChemistryDepartment: Civil Date of Birth 04.08.1970


Feedback Target

L-5 L-4 L-3 L-2 L-1

1 Oct - 31 Dec 100%

100%

Suggested KPI forr Jan-Mar


Avilability of funds big

constraint. To be reworded

with measureable

targets for each project

Assessment I Total


Emp. Code: 970 Ed. Qual. M.Sc. ChemistryDepartment: Civil Date of Birth 04.08.1970

Review 2

Feedback Target

L-5 L-4 L-3 L-2 L-1

Suggested KPI forr April-Jun



Perfromance Planning and Assesment for the Quarter Oct - Dec, 12Name : Devendra AgarwalDesignation: Sr Manager Mechanical Maintenance

S No KRA KPI

1 Plant availability

2 Spares

3 Recovery Boiler Availability

4 Cost of Production Reduction in cost of production

Signature of A

Minimising the breakdown/downtime for achieving 100% plant availability

Maintaining all the required spares ready in stock

Increasing recovery boiler availability for smooth running


Performance Planning and Assesment for the Quarter Jan-Mar 2013Name : Devendra AgarwalDesignation: Sr Manager Mechanical Maintenance

S No KRA KPI


Review 1 - (DATE)


2)Weekly monitoring and analysis

2)Consumption of norms of spares

3)List of critical spares to be made

Reduction in consumption by 5 %




Indicator

1) Preparing a root chart for all the plant equipments and implementing

strictlyCondition monitoring of running

equipment daily

Number of breakdown hours

1) Prepare a list of all the psares and their inventory position

Timely indenting the required material and follow up

Number of occasions when spares not available for maintenance

Regular checking of all the soot blowers for proper working without

gland leakageReducing soot blower downtime

from 10% to 5% Number of hours recovery boiler not available

To prepare a database of lubricants and bearings consumption

% of Base cost of Lubricants and Bearings in previous 12 months


Review 2





Indicator


Emp. Code: 196 Ed. Qual. B.Sc, B.E(Mech)Department: Chemical Recovery

Review 1 - (DATE)

Feedback Weightage

L-5 L-4 L-3 L-2 L-1

1 Oct - 31 Dec

1 Oct - 31 Dec

1 Oct - 31 Dec

1 Oct - 31 Dec



Resigned hence not reviewed


Emp. Code: 196 Ed. Qual. B.Sc, B.E(Mech)Department: Chemical Recovery

Review 2

Feedback Weightage

L-5 L-4 L-3 L-2 L-1







score


Perfromance Planning and Assesment for the Quarter Oct - Dec, 12Name : Dharmendra SinghDesignation: Manager A/C & Finance

S No KRA KPI

1

2

3Prepare imprest advance statement

4

5 Authorisation in ERP

6

7

8

9

10

11

Fulfill A&F processes and handle exceptions

Monitoring on cash balance & cash forcasting


Prepaired cash flow statement for fund planning



Checking & authorisation of receipt, payment, journal, contra vouchers & cash sheet

Fulfill A&F processes and handle exceptionsFulfill A&F processes and handle exceptions

Maintain relation with Excise, banks ,financial institutions & other govt. deptt.


Liaisoning with excise & other govt. deptt.


Computation of all data related to Excise & Service tax for payment & Return filing.


E-Filing of Excise & Service Tax Return.


Freight, Claim, Salary Advance, Imprest Advance & all other expenses passing.


Working to get "Certificates" from Excise & Customs.

12

All Vendors accounts Reconcilation.

13

14



Performance Planning and Assesment for the Quarter Jan-Mar 2013Name : Dharmendra SinghDesignation: Manager A/C & Finance

S No KRA KPI



Arrangment of Bank & Cash payment for suppliers & others as per Management instructions on plant level.


Provide adequate Guidelines & full co-operation to all team members for smooth working.


Review 1 - (DATE)


Plan/Design,Execute,Check













Indicator

Follow processes as per schedule/calendar/timeline

Number of times failed to meet agreed timelines/SLA






Number of times failed to meet agreed timelines/SLA/




















NO INITIATIVES


Review 2










Indicator


Emp. Code: 1373 Ed. Qual. M.Com, C.A.Department: Accounts

Review 1 - (DATE)


L-5 L-4 L-3 L-2 L-1

Daily

Daily

Daily

Daily

Daily

Monthly

Daily

Does work as per instructions

Monthly/Quarterly/Hlf.Yearly/Annualy

When needed.

Daily


Emp. Code: 1373 Ed. Qual. M.Com, C.A.Department: Accounts

Review 2


L-5 L-4 L-3 L-2 L-1

When needed.

Suggested KPIs for April-Jun


M.Com, C.A.

Weightage

100%

100%

100%

100%

100%

100%

100%

100%

100%

100%

100%




score

100%

100%

100%


M.Com, C.A.


Achieved



score


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


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



Status of InitiativeFeedback Target Date(To be given under column L3)

L-5

Proposal submitted

CFL lights toreplace existing lighting. Possibly LEDs

Consisting of -1) Decription of Existing system and

it's operation2)Description of Proposed system

and it's operation3)Energy Saving Calculations

4)Cost benefits in terms of Annual energy Saving Potential , Annual

cost SavingInvestment,Simple Payback

The plant is to be broken into 5 Zones. Is there to be sub-division within that zone ? On the basis of what? Who is to head each zone?

Insulation

Major costs involved.

a)Low Investment and High Gain b)Low Investment and Low gain

On what basis will priority and and weightage be assigned?- Financial Impact will receive most consideration


1373 Ed. Qual. M.Com, C.A.Accounts


L-4 L-3 L-2 L-1





score


Perfromance Planning and Assesment for the Quarter Oct - Dec, 12Name : Ajay GoelDesignation: Head of Engineering

S No KRA KPI

1

Unplanned Breakdown Zero unplanned Breakdown

2Costs Maintenance Costs within Budgets

3KRA/KPI initiative

4

CFT

5

6

7

8

91011

[email protected]

mailto:[email protected]



Performance Planning and Assesment for the Quarter Jan-Mar 2013Name : Dharmendra SinghDesignation: Manager A/C & Finance

S No KRA KPI


Review 1 - (DATE)


Spares planning

Vendor Development




Indicator

Preventive Maintenance Schedules to be followed with 100% compliance and regularly reviewed and modified

Compliance to preventive maintenance schedule in terms of

Time Cost and Quality

Optimise Repair and Maintenance Cost

Ensure equipment health with major focus on leakages of Black Liquor , Caustic, Acids , Oil, Steam, Air etc

throughout the plant.

Drive the KPIs of Electrical and Mechanical Dept

Oversee energy conservation initiative being driven by Mr Rajeev

Pandey

To follow up recommendations regarding improvements in contract

management from reports generated by S.Maji



Review 2






Indicator


Emp. Code: 1373 Ed. Qual.Department: Accounts

Review 1 - (DATE)


L-5 L-4 L-3 L-2

1) Zone 1 : Raw Material to Pulp : RS Nayal

2) Zone 2: Stock to Finshing House : RK Verma

3) Zone 3 : Power Utilities : SK Johar

4) Zone 4 : Recovery at Balance of the Plant : VK

Tharad5) Overall coordinator : Rajeev Pandey


Emp. Code: 1373 Ed. Qual.Department: Accounts

Review 2


L-5 L-4 L-3 L-2

Suggested KPIs for April-Jun


M.Com, C.A.


L-1

100%

100%

100%

100%

100%

100%

100%

100%100%100%100%




score


M.Com, C.A.


L-1




score

Sspbml- Kra Plant Jan-mar 15-2-13 v7

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Transcript of Sspbml- Kra Plant Jan-mar 15-2-13 v7