Professional Documents
Culture Documents
IMEE ACUBA
2007 (Jan-Aug)
Sectional
Performance
OPERATIONS GROUP
PERFORMANCE SUMMARY
3,500
Grids and Oxides
3,000
Metric Tons of
2,500
2,000
1,500
1,000
500
0
JAN FEB MAR APR MAY JUN JUL AUG
'07 Actual 2,721 2,219 2,871 2,078 2,280 2,092 2,707 2898
'07 Target 3,119 2,185 2,734 1,973 2,283 2,211 3,900 3900
Fill Rate 87.24% 101.56% 105.01% 105.32% 99.87% 94.62% 69% 74%
delays attributed to Improve planning & analysis before as project Planning &
new task (grid implementation of new tasks arises Analysis
screening) tools
% Sulfur Content
2.50
2.00
Percent Sulfur Content
1.50
(%)
1.00
0.50
0.00
J AN FEB MAR APR MAY J UN J UL AUG
80.00
Percent Compliance on
Sulfur Content
60.00
(%)
40.00
20.00
0.00
J AN FEB MAR APR MAY J UN J UL AUG
Reverb
Blast
9 14
8 12
7
10
6
5 8
4 6
3
4
2
1 2
0 0
J F M A M J J A S J F M A M J J A S
Actual 5.79 5.78 5.99 8.38 7.41 5.7 5.64 6.26 6.79 Actual 5.19 4.8 4.36 4.97 5.9 12.3 - 5.07 4.89
Target 5.75 5.75 5.76 5.19 5.19 3.31 5.45 6.09 6.11 Target 6.15 6.06 5.98 1.59 5.19 - 5.31 5.32
5000
4000
3000
2000
1000
Jan Feb Mar Apr May Jun Jul Aug Sept
Actual 2891 3311 3963 2459 3117 2493 2206 3701 4140
Target 3500 3500 3500 3500 3500 2500 2340 3900 4000
Feed requirements for 3,500 tons per month not Status quo until the supply improves
supplied
3
PESO / kg bullion
0
J AN FEB MAR APR MAY J UN J UL AUG SEPT
ACTUAL 2.65 1.87 1.81 2.12 2.33 2.01 2.19 1.92 1.78
TARGET 2.46 2.41 2.5 2.17 1.58 1.5 1.94 1.77 1.78
REVISED
ANALYSIS OF DEVIATION ACTION PLANS TIMETABLE
Opportunities Threats
oImprovement projects thru SPC oUnplanned shutdown of machine and
oMechanization of blast & reverb operation ie. equipment
Feeding activities, clearing activities oInsufficient supply of feed materials
oBenchmarking oNon-approval of Capex
oTechnical trainings abroad oPower failures
oFurther reduction of resource consumption i.e. oMachine design flaws
fuel, chemicals, electricity oNeighbor complaints due to odor and smoke
o4500MT/mo production output emissions
oFull implementation of TPM
3
PESO / MT Pb
0
J AN FEB MAR APR MAY J UN J UL AUG SEPT
ACTUAL 2.48 1.97 2.08 2.28 2.80 3.00 2.42 2.24 2.04
TARGET 2.74 2.72 2.74 2.74 3.12 2.84 2.79 2.48 2.48
100
80
% FILLRATE
60
40
20
0
J AN FEB M AR APR M AY J UN J UL AUG SEPT
REVISED ADDITIONAL
ANALYSIS OF DEVIATION ACTION PLANS RESOURCES
TIMETABLE REQUIRED
REVISED ADDITIONAL
ANALYSIS OF
ACTION PLANS RESOURCES
DEVIATION TIMETABLE REQUIRED
Delay in approval of Awaiting for Installation – dec’ Design meetings
Capex for autoburners autoburners (1 unit 07 with Tech &
for delivery) Engg
Operational – jan
2008
Opportunities Threats
oMechanization of process i.e. skimming, oBreakdown of major equipment like overhead
feeding of materials into kettles, color coding of crane, casting machine, kettles, OES
lead bars, temperature monitoring
100
98
96
94
92
90
Jan Feb Mar Apr May Jun Jul Aug Sept
Availability 92.92 95.22 98.54 95.93 95.08 96.42 97.36 93.23 95.82
Target 95 95 95 95 95 95 95 95 95
Target
August, 2007 PRI 1st Sem QEMS Management Review 30
Objective Target Actual: YTD % Acc
100
95
90
85
80
Jan Feb Mar Apr May Jun July Aug
25,000.00
100
80
20,000.00
60
40 15,000.00
20
0 10,000.00
J F M A M J J A S J F M A M J J A
% Compliance 99.1 97.9 94.9 99.6 100 99.7 95.9 99.2 95.7 Php Savings 21,99318,96116,79817,64120,31421,66720,98521,083
15
10
0
Jan Feb Mar Apr May Jun Jul Aug
100
80
60
40
20
0
Jan Feb Mar Apr May Jun Jul Aug
100
80
60
40
20
0
Jan Feb Mar Apr May Jun Jul Aug Sept
% Compliance 99.2 98.6 97.9 97.2 97.5 97.1 100 100 100
1
PESO / WW Treated
0.8
0.6
0.4
0.2
0
J AN FEB M AR APR M AY J UN J UL AUG
800,000
700,000
600,000
500,000
400,000
gals.
300,000
200,000
100,000
0
J AN FEB M AR APR M AY J UN J UL AUG
300
250
200
150
100
50
0
Jan Feb Mar Apr May June July August
80.00
60.00
40.00
20.00
0.00
J AN FEB MAR APR MAY J UN J UL AUG SEPT
200.00
150.00
100.00
50.00
0.00
J AN FEB MAR APR MAY J UN J UL AUG SEPT
Spares unavailability Ensure 1 unit spare per critical part Complete spares
such as: sets of blades, availability come end
motors, pumps of Sept ‘o7
150.00
Metric Tons
100.00
50.00
0.00
JAN FEB MAR APR MAY JUN JUL AUG
150
Metric Tons
100
50
0
J AN FEB MAR APR MAY J UN J UL AUG
Opportunities Threats
oCapability to treat hazardous lead oNon-utilization of PE separators as
waste from other companies heat source in smelting
oPossible sales of blast slag process(195MT/mo)
oLess treatment and disposal cost oHigh disposal cost
using FESI technology oPossible closure of PRI plant due to
stockpile of wastes
100
80
60
40
20
0
Jan Feb Mar Apr May Jun Jul Aug
% Completed 92 96 83 66 62 78 92 90
100
80
60
40
20
0
Jan Feb Mar Apr May Jun Jul Aug
% Completed 92 96 83 66 62 78 95 100
Opportunities Threats
oHighly available support from oHigh facilities maintenance cost due
Integrated engineering and SBDI to corrosion i.e buidings and grounds
oPoor quality workmanship of
contractors
oUntimely delivery of project
materials and spare parts
INVENTORY ACCURACY
120%
100%
Percentage
80%
60%
40%
20%
0%
JAN FEB MAR APR MAY JUN JUL AUG SEPT
ACT UAL 100% 100% 100% 100% 100% 100% 100% 100% 100%
TARGET 100% 100% 100% 100% 100% 100% 100% 100% 100%
Month
120%
100%
80%
RATE
60%
40%
20%
0%
JAN FEB MAR APR MAY JUN JUL AUG SEPT
ACTUAL 102% 101% 101% 87% 81% 101% 97% 102% 107%
TARGET 100% 100% 100% 100% 100% 100% 100% 100% 100%
Required finished lead from oJust in time delivery. Implemented and sustained
refining was not met Within 24 hrs after
casting
o100% availability of
delivery trucks and
forklift
Strength Weaknesses
oProactive personnel oNo designated signatories in the
oComplete Manning complement absence of LLM and LRR
oSap utilization oHigh LIB
o100% availability of equipment oOpen storage areas
oUse of back up system in case of SAP
breakdown
Opportunities Threats
oAvailability of back up forklift oSlow SAP system
oUse of outside truck scale oQuality issues on flashes in FL bars
oDelay inspection of FL for delivery
oDelay issuance of COA
Domestic/Imported
8,000
6,000
mt 4,000
2,000
-
J an Feb Mar April May J une J uly Aug Sept
Target 07 5,129 3,958 5,579 4,747 5,821 5,170 4,894 5,198 6,632
Actual 07 4,298 4,688 4,737 4,793 5,288 5,398 5,408 5,817 6,293
Fill Rate 84% 118% 85% 101% 91% 104% 111% 112% 95%
Inventory Accuracy
102%
100%
98%
%
96%
94%
92%
JAN FEB MAR APR MAY JUN JULY AUG SEPT
Inventory Accuracy 95% 98% 99% 100% 100% 100% 100% 100% 100%
month
Raw Materials
100%
80%
60%
%
40%
20%
0%
JAN FEB MAR APR MAY JUN JUL AUG SEPT
Raw Materials 79% 89% 84% 83% 76% 83% 90% 88% 73%
month
Opportunities Threats
oMechanization of unloading process oBreakdown of equipment i.e
oDesignated area for IB battery axing forklifts
oSlow hiring system
Electrolysis voltage controller not yet Perform oxide electrolysis August 2007
delivered experimentation (defer Al dross)
(MUC)
Hydro & pyro exp’tation (2nd batch) deferred Continue hydro experimentation September 2007
due to prioritization of grids melting and (LLA)
reverb support activities
No final operational plan Come up with operational September 2007 Capex budget for
yet plan (Smelting/Engg/Tech) (1) bunker storage,
transfer and
control systems;
(2) burner nozzle
replacement; (3)
continuous
emissions
monitoring system
as required by
DENR
There is also a need for extra precaution and additional controls during some
experimentation activities because of the exposure of the engineers to
hazardous emissions especially those concerning new and improved processes.
SUCCESS DRIVERS:
o Established process stability, no parameters beyond control limits
1. Pb in slag
2. TCLP Pb
SUCCESS DRIVERS:
oImproved customer satisfaction feedback mechanism
oFocus on product quality
oIssues that were raised last year were resolved already
oNo negative issues raised from the last survey dated May 26, 2007
SUCCESS DRIVERS:
Established quality controls
Opportunities Threats
oSupport from technical engineers oPoor purchasing system
oSix sigma methodologies oHiring system
oInvolvement in process related oNon-cooperative people
improvement projects oDelay in laboratory relocation
oCustomer feedback mechanism oSafety hazards from
oProfessional development thru experimentation/method development
trainings
oBenchmarking
oTop management support
150
140
130
120
110
100
90
80
70
60
50
Jan Feb Mar A pr May Jun Jul A ug Sept
Coke usage 119 124 116 146 132 97.3 107 114 115
Target
140
130
120
110
100
90
80
70
60
50
40
30
20
10
0
Jan Feb Mar A pr May Jun Jul A ug Sept
Diesel Usage 103 109 107 116 125 133 - 106 115
Target
70
60
50
40
30
20
10
0
J AN FE B M AR AP R M AY J UN J UL AUG
ACT UAL 44 49 59 51 65 66 70 43
T ARGE T 66 66 66 66 66 66 66 66
Optimized Water Usages 1,700 Li./ MT-Output 1,424 Li./ MT-Output 100%
Water Consumption
2,500
2,000
Metric Ton of Output
Cubic Metres per
1,500
1,000
500
0
J AN FEB MAR APR MAY J UN J UL AUG
Reset targets according to revised target production Moving Target based Central Planning’s
volume on SCM’s Central Forecast
Planning REALISTIC
Projection
Optimize use of recycled water from PRF On-going Additional Water
Pumps, Return
Lines, Valves
Re-orientation of all personnel regarding water usage Done and monthly Monthly Meetings,
and conservation reiterated during Orientations,
sectional meetings Trainings,
Seminars,
Workshop
Programs
Upgrade Desulphurization 250 kg. Soda Ash per 229 kilograms 108%
Process Control and Monitoring MT of processed Oxides Reduced consumption
to optimize chemical utilization by 8%
270
240
210
180
Metric Ton Oxides
Kilograms per
150
120
90
60
30
0
JAN FEB MAR APR MAY JUN JUL AUG
'07 Actual 259 229 211 219 225 230 214 220
'07 Target 250 250 250 250 250 250 250 230
Aluminum Consumption
4
Kg / MT Pb
0
J AN FEB MAR AP R MAY J UN J UL AUG SEP T
ACTUAL 1.21 1.26 1.23 1.29 1.29 1.37 1.2 1.15 1.09
TARGET 1.43 1.43 1.43 1.37 1.37 1.37 1.37 1.37 1.37
Kg / MT Pb
2 0.5
Kg / MT Pb
1
0
J F M A M J J A S 0 J F M A M J J A S
ACTUAL 2.58 2.57 2.41 1.81 2.27 2.42 2.06 2.4 2.03 ACTUAL 0.17 0.15 0.15 0.17 0.17 0.17 0.16 0.16 0.07
TARGET 2.86 2.86 2.86 2.50 2.50 2.50 2.50 2.50 2.5 TARGET 0.17 0.17 0.17 0.17 0.17 0.17 0.17 0.17 0.17
70
50
L / MT Pb
30
10
-10
J AN FEB MAR AP R MAY J UN J UL AUG SEP OCT NOV DEC
ACTUAL 44.02 30.00 36.26 34.03 38.60 47.10 40.07 36.9 37.54
TARGET 44.76 44.76 44.76 39.36 39.36 39.36 39.36 39.36 39.36 39.36 39.36 39.36
60.00
50.00
40.00
KWH / MT Pb
30.00
20.00
10.00
0.00
J AN FEB MAR AP R MAY J UN J UL AUG SEP OCT NOV DEC
TARGET 38.00 38.00 38.00 38.00 38.00 38.00 38.00 38.00 38.00 38.00 38.00 38.00
HCL Consumption
Kg / WW Treated
0.02
0.015
0.01
0.005
0
JAN FEB MAR APR MAY JUN
NaOH Consumption
0.02
Kg / WW Treated
0.015
0.01
0.005
0
JAN FEB MAR APR MAY JUN
August, 2007
TARGET 0.00512 0.00512 0.00512 0.00512 0.00512 0.00512
PRI 1st Sem QEMS Management Review 118
ENVIRONMENTAL PERFORMANCE : Highlights
0.015
0.01
0.005
0
JAN FEB MAR APR MAY JUN
Polymer Consumption
0.0002
Kg / WW Treated
0.00016
0.00012
0.00008
0.00004
0
JAN FEB MAR APR MAY JUN
25
20
Metric Ton Output
CubicMeters per
15
10
0
MAR APR MAY J UN J UL AUG SEP OCT NOV DEC
Operate afterburner
continuously at T>700
25
20
15
10
0
JAN FEB MAR APR MAY JUN
BLAST 5 5 10 6 4 7
REVERB 6 5 1 0 4 0
Target
August, 2007 PRI 1st Sem QEMS Management Review 124
Objective: Target Actual
Reduce Smoke Emission 10 53 incidents
Reduce lancing
activities
10
0
JAN FEB MAR APR MAY JUN
Baghouse 5 0 1 2 2 0
30
25
20
15
10
0
JAN FEB MAR APR MAY JUN
Baghouse 7 11 13 4 5 7
oIncidents during sump tank oSemi annual replacement of scrubber dec 2007
draining packing
oInstallation of discharge piping direct to done
sed pit.
oOperation of afterburner oInclusion of after burner operation in
done
not included in furnace restarting procedure.
restarting procedure
(remote occurrence)
10
0
JAN FEB MAR APR MAY JUN
Baghouse 5 0 1 2 2 0
30
25
20
15
10
0
JAN FEB MAR APR MAY JUN
Baghouse 7 11 13 4 5 7
80
60
40
20
PARAMETERS:
SOx, NOx, PM, CO, Pb PRI 1st Sem QEMS Management Review
August, 2007 133
Objective Target Actual
Reduce odor emissions incidence 10
oOdor from other sources oInvestigate odor coming from PVC Aug. 30
PE,scrap plates. And other sources.
10
0
JAN FEB MAR APR MAY JUN JUL AUG
REFINING 2 2 1 1 1 1
Smoke from turning Recruit burner tenders Oct ’07 HRM support
on of HAUCK
burners Install addt’l automatic Dec ’07 kettle availability &
ignition burner at R#7 Eng’g support
Smoke from grid Modify holding kettle dampers Completion by kettle availability &
melting Repair of Refining kettle the end of dec Eng’g support
dampers 07
100
90
80
%compliance
70
60
50
40
30
20
10
0
Pb TDS COD O&G TSS
1st Quarter 100 100 100 100 100
2nd Quarter 100 100 66.7 100 100
3rd Quarter 100 100 100 100 100
4th Quarter
Opportunities Threats
oWorld class RPE custodian center oHigh level of lead exposure of personnel
oAssociated to decontamination operation oManpower shortage
oDeputize safety function
oMultiskilled personnel
oVacuum facilities for all employees
o 1. GHK procedure
o 2. PPE warehouse expansion
o 3. Training of personnel