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Volume Statistics
Actual BP Actual BP BP Actual
2008-09 2009-10 2010-11 2011-12 2011-12 2012-13 April'12 April'12 Wire Rod 127536 148451 160930 177337 168187 181476 Ingot Total 170123 50745 26460 10385 7504 593 15139 517 15656 14728 382 15110
5834 897
9397 1458
11455 1645
12000 3000
11422 3018
15000 6000
1250 500
1010 670
Volume Statistics
350000
300000
250000
100000
50000
Cost of Production
ACTUAL Description CH-1 CH-2 Avg COP Deviation COP Weighted VAL STL COP CH-1 FY 11-12 FY 11-12 and CH-2 FY11-12 BAL v/s VAL 11-Feb 1553 4081 5634 1941 3299 5240 1718 3748 5466 0 -386 -222 1146 2581 3727 102 0 572 1167 1739 -102 -222 0 892 3462
Total variable cost Total fixed cost Net cost S & d cost Other Income
Total COP
5248
5240
5245
3829
1416
4354
96454 11438
71515
99528
10156
Improvement Projects
Increase in Furnace capacity Increasing Plant availability and Utilization Increase in production of Export and Alloy Rod Reduction in CG-2 volume VOLUME INCREASE (1.7 to 2 lacs MT)
Additional NSR
SOP adherence
Achievements in FY 11-12
Ever highest Wire Rod production in a year Ever highest Export Rod production Ever highest EC Capture rate in a year : 168187 MT : 3018 MT : 91%
Thank You
Avg COP Deviation COP COP Description CH-2 Hindalco STL REMARKS Weighted VAL COP CH-1 FY 11-12 FY 11-12 n CH-2 FY11-12 BAL v/s VAL 11-Apr 11-Feb Melt Loss 88 779 382 421 -39 1082 475 Alloying element 606 348 565 -217 50 85 Furnace Oil 859 1196 1002 0 1002 667 2670 Oil rates of Hindalco and STL are Steam 3 0 0 0 not relevant in todays scenerio Power 142 221 176 232 -56 134 529 Less Dross realization -145 -255 -192 -72 -120 0 -297 Total variable cost 1553 1941 1718 1146 572 1933 3462 Manufacturing Exp 1036 1815 1368 1002 366 336 372 Mannpower 1806 1097 1504 571 933 928 287 Administration Exp 278 387 324 418 -94 Packing exp 155 0 89 590 -501 14 Allocated Exp 806 0 463 0 463 Total fixed cost 4081 3299 3748 2581 1167 Rep & maint 0 106 219 Depreciation 0 63 Net cost 5634 5240 5466 3727 1739 1433 892 S & d cost 0 102 -102 Other Income -386 -222 0 -222 0 0 Total COP 5248 5240 5245 3829 1416 3366 4354 Production-wire rod 96454 71515 99528 10156 ingot 7504 AWR 11438 Note In VAL, furnaces are electrically heated and operation is outsourced . No fce oil is used Allocated expenses in CH-1 are of manpower cost of enabling team. In STL, operation and maintenance is out sourced, no packing as use is in house and no consumption of Boron At Hindalco, boron master alloy is not used, mill are 6B which require less maintenance. packing cost is booked in sales. administrative expenses are not booked in WR.Manpower cost is less because of wage structure.
ACTUAL CH-1
In VAL, furnaces are electrically heated and operation is outsourced . No furnace oil is used In STL, operation and maintenance is out sourced, no packing as use is in house and no consumption of Boron At Hindalco, boron master alloy is not used, mill are 6B which require less maintenance. packing cost is booked in sales. Administrative expenses are not booked in WR.Manpower cost is less because of wage structure.