Podcast
Questions and Answers
What indicates the beginning of the Turnaround Time (TAT) in the HR dispatch process?
What indicates the beginning of the Turnaround Time (TAT) in the HR dispatch process?
What is the minimum weight that must be achieved for the process to proceed without needing an invoice?
What is the minimum weight that must be achieved for the process to proceed without needing an invoice?
In the slab dispatch process, where does the weighment occur for direct customers?
In the slab dispatch process, where does the weighment occur for direct customers?
Which activity is performed after the lashing process?
Which activity is performed after the lashing process?
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What is the purpose of the PDIR check in the process flows?
What is the purpose of the PDIR check in the process flows?
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What physical resources are involved in the loading activities?
What physical resources are involved in the loading activities?
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Which of the following is NOT a step mentioned in the gate entry process?
Which of the following is NOT a step mentioned in the gate entry process?
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What is the primary condition to perform weighment for HR coils?
What is the primary condition to perform weighment for HR coils?
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What is the rail coefficient for the TSM plant?
What is the rail coefficient for the TSM plant?
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What is the acceptable vehicle Turn Around Time (TAT) for dispatch activities?
What is the acceptable vehicle Turn Around Time (TAT) for dispatch activities?
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What is the total capacity of steel making per annum for the TSM plant?
What is the total capacity of steel making per annum for the TSM plant?
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Which of the following is NOT part of the product mix at TSM plant?
Which of the following is NOT part of the product mix at TSM plant?
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At which stage does TAT start in the process flow path for CR Dispatch?
At which stage does TAT start in the process flow path for CR Dispatch?
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What is the weight threshold to update in SAP during the dispatch process?
What is the weight threshold to update in SAP during the dispatch process?
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Which of the following activities occurs right after loading in the CR Dispatch process?
Which of the following activities occurs right after loading in the CR Dispatch process?
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Which product has the highest monthly production in the TSM plant's product mix?
Which product has the highest monthly production in the TSM plant's product mix?
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What is the main issue affecting traceability in CR products?
What is the main issue affecting traceability in CR products?
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Which of the following product forms relates to Hot Rolled Pickled and Oiled sheets?
Which of the following product forms relates to Hot Rolled Pickled and Oiled sheets?
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Which plant code corresponds to the Galvanized Plain sheet dispatched to Yard 10?
Which plant code corresponds to the Galvanized Plain sheet dispatched to Yard 10?
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What is the storage capacity of the CRM Yard 10?
What is the storage capacity of the CRM Yard 10?
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What typically happens if the re-weighment of CR products shows a difference greater than 100 kgs?
What typically happens if the re-weighment of CR products shows a difference greater than 100 kgs?
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Which of the following sheets is produced in the 743 plant code lines?
Which of the following sheets is produced in the 743 plant code lines?
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What is a major infrastructural constraint noted within the SMS-1 CR Yard?
What is a major infrastructural constraint noted within the SMS-1 CR Yard?
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What maintenance issue affects crane functionality in the sheds?
What maintenance issue affects crane functionality in the sheds?
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What is the total monthly production capacity of the TSM plant for steel making?
What is the total monthly production capacity of the TSM plant for steel making?
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In which dispatch process does the TAT start at the gate?
In which dispatch process does the TAT start at the gate?
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Which product has the least production capacity in the TSM plant's product mix?
Which product has the least production capacity in the TSM plant's product mix?
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What is the total number of vehicles involved in dispatching activities according to the information provided?
What is the total number of vehicles involved in dispatching activities according to the information provided?
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What condition must be met for an invoice to be generated during the weighment process?
What condition must be met for an invoice to be generated during the weighment process?
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What is the rail coefficient for the TSM plant, indicating transportation efficiency?
What is the rail coefficient for the TSM plant, indicating transportation efficiency?
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Which of the following is a type of refined steel product produced at the TSM plant's facility?
Which of the following is a type of refined steel product produced at the TSM plant's facility?
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During the loading process in CR dispatch, which activity is completed just before lashing?
During the loading process in CR dispatch, which activity is completed just before lashing?
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Which of the following product forms is produced by the CRCA process?
Which of the following product forms is produced by the CRCA process?
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What is the storage capacity of Yard 10?
What is the storage capacity of Yard 10?
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Which plant code is associated with the dispatch of Galvanized Corrugated Sheet?
Which plant code is associated with the dispatch of Galvanized Corrugated Sheet?
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What happens if the re-weighment of CR products shows a difference greater than 100 kgs?
What happens if the re-weighment of CR products shows a difference greater than 100 kgs?
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Which of the following sheets is typically dispatched to Yard 10?
Which of the following sheets is typically dispatched to Yard 10?
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What is the primary cause of traceability issues in CR products?
What is the primary cause of traceability issues in CR products?
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How many loading points for dispatch are available in the SMS-1 CR Yard?
How many loading points for dispatch are available in the SMS-1 CR Yard?
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Which product form does the 742 plant code produce?
Which product form does the 742 plant code produce?
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What step follows after the weighment process in the HR dispatch process?
What step follows after the weighment process in the HR dispatch process?
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In which scenario is an invoice required during slab dispatch?
In which scenario is an invoice required during slab dispatch?
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Which of the following is NOT involved in the vehicle placement and loading activities?
Which of the following is NOT involved in the vehicle placement and loading activities?
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What is the primary action taken during the PDIR check?
What is the primary action taken during the PDIR check?
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During the slab dispatch process, what happens if the weight is below the specified threshold?
During the slab dispatch process, what happens if the weight is below the specified threshold?
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Which stage signifies the end of the turnaround time (TAT) in the dispatch process?
Which stage signifies the end of the turnaround time (TAT) in the dispatch process?
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What is the minimum weight required to skip the invoice generation for slab dispatch?
What is the minimum weight required to skip the invoice generation for slab dispatch?
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What does the term 'HSM Parking' refer to in the process flow?
What does the term 'HSM Parking' refer to in the process flow?
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What must occur for the PDIR check to proceed in the HR dispatch process?
What must occur for the PDIR check to proceed in the HR dispatch process?
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In the slab dispatch process, who is the weighment directed to?
In the slab dispatch process, who is the weighment directed to?
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What happens if the weight is below 100 kg during the HR dispatch process?
What happens if the weight is below 100 kg during the HR dispatch process?
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Which activity directly follows the loading process in slab dispatch?
Which activity directly follows the loading process in slab dispatch?
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What condition must be met during the gate entry process before loading starts?
What condition must be met during the gate entry process before loading starts?
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What does lashing ensure during the loading process?
What does lashing ensure during the loading process?
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What type of products are subject to weighment in dispatch processes?
What type of products are subject to weighment in dispatch processes?
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During the HR dispatch process, what signifies the end of the turnaround time (TAT)?
During the HR dispatch process, what signifies the end of the turnaround time (TAT)?
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Which product form is produced by the 743 plant code lines?
Which product form is produced by the 743 plant code lines?
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What is the storage capacity of the SMS-1 CR Yard?
What is the storage capacity of the SMS-1 CR Yard?
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Which activity is performed after the loading process in CR dispatch?
Which activity is performed after the loading process in CR dispatch?
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What is one of the key constraints noted within the SMS-1 CR Yard?
What is one of the key constraints noted within the SMS-1 CR Yard?
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Which plant code is associated with the Galvalume Sheet?
Which plant code is associated with the Galvalume Sheet?
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What issue primarily affects traceability in CR products?
What issue primarily affects traceability in CR products?
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Which loading point capacity does Yard 10 offer for dispatch?
Which loading point capacity does Yard 10 offer for dispatch?
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What happens if the re-weighment of CR products shows a weight difference greater than 100 kgs?
What happens if the re-weighment of CR products shows a weight difference greater than 100 kgs?
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What is the primary purpose of lashing in the loading process?
What is the primary purpose of lashing in the loading process?
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How is the outbound logistics capacity defined at the TSM plant?
How is the outbound logistics capacity defined at the TSM plant?
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What is indicated by the start of Turnaround Time (TAT) at Gate 2?
What is indicated by the start of Turnaround Time (TAT) at Gate 2?
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Which product has the lowest production volume among the listed products at TSM?
Which product has the lowest production volume among the listed products at TSM?
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What happens if the weight difference during re-weighment exceeds 100 kgs?
What happens if the weight difference during re-weighment exceeds 100 kgs?
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What is the acceptable vehicle Turn Around Time (TAT) during dispatch activities?
What is the acceptable vehicle Turn Around Time (TAT) during dispatch activities?
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Which component is checked after loading in the dispatch process?
Which component is checked after loading in the dispatch process?
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What limit is used to determine if an invoice is required during the billing process?
What limit is used to determine if an invoice is required during the billing process?
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Study Notes
TSM Plant Overview
- Capacity is 4.8 MTPA (Million Tonnes Per Annum)
- Outbound Logistics arm (OBL) handles logistics
- Rail coefficient is 72%
- Monthly dispatch capacity is 440 KT (Kilo Tonnes)
Product Mix
- Production: HR (350 KT), CR (50 KT), Slab (40 KT)
- HR (Hot Rolled) Coil, CRCA Sheet, CR (Cold Rolled) Sheet and HR Plate are dispatched by both rail and road
- Dispatch volume:
- Rail: 310 KT HR Coil, 40 KT CRCA Sheet, 39 KT HR Plate, 1 KT CRCA Sheet, 5 KT HR Plate and 35 KT HR Coil.
- Road: 40 KT HR Coil, 1 KT CRCA Sheet, 5 KT Plate, 35 KT HR Coil
- Dispatch activities involve:
- CRM (Customer Relationship Management) Logistics Park for CR and CR Dispatch
- HSM (Hot Strip Mill) Parking for HR Dispatch
- CRM (Customer Relationship Management) Parking for Slab Dispatch
CRM Logistics Park (CR Dispatch)
- Average turnaround time (TAT) for ~110 vehicles
- Each vehicle will have ~60 vehicles ahead of them
- The process starts at Gate 2 and ends when the vehicle leaves the park.
-
Steps:
- Entering the park
- Loading
- Lashing
- Weighment (only for non CRCA, CTL and HR Slit products)
- PDIR (Pre-Dispatch Inspection Report) check
- Tarpaulin (if applicable)
- Invoice generation
- Weight update in SAP
- Departure from the park.
HSM Parking (HR & Slab Dispatch)
- Process starts at Gate 2 and ends with the vehicle leaving the park.
-
HR Dispatch:
- Loading
- Lashing
- Weighment
- PDIR check
- Invoice generation
- Weight update in SAP
- Departure from the park.
-
Slab Dispatch:
- Loading
- Lashing
- Weighment (of products for direct delivery to customers only)
- PDIR check
- Invoice generation
- Weight update in SAP
- Departure from the park.
Infrastructure CRM Shed-10
- 5 KT storage capacity
- 3 dispatch loading points
- Storage is not just for CRCA, CR, CRFH, HR Slit, PPGL, GL, CCL, etc.
- Used for loading, unloading, shifting, packing and dispatch activities
- Overhead cranes and other machinery for various activities.
- Re-weighment of CR products is done after loading, and if weight difference is more than 100 Kgs, it is sent back to production.
- This process is more frequent for HR Slit and PPGL, which increases TAT
- Traceability issues in CR products are due to intrashifting by production team and failure to update the system/OBL team.
Infrastructure SMS-1 CR Yard
- 12 KT storage capacity
- 9 loading points for dispatch
- Large sheds, each with two overhead cranes.
- One crane is permanently shut down or under maintenance.
Full Form of Products
- CRCA - Cold Rolled Close Annealed
- GP Sheet - Galvanized Plain Sheet
- GL Sheet - Galvalume Sheet
- PPGL - Pre-Painted Galvalume Sheet
- GC Sheet - Galvanized Corrugated Sheet
- HRPO - Hot Rolled Pickled and Oiled
Plant Codes
- 1- 742- HRPO, Pickling line – direct dispatch
- 2- 743- GP1 Line – Galvanized Plain (GP Hard) – to Yard 10
- 3- 742- CRFH - Mill1 and Mill 2 – to SMS yard
- 4- 743- GP2 Line (GL Coil) – to Yard 10
- 5- 743- CTL1, GP Sheet, GC Sheet – to Yard 10
- 6- 742- CR coils, CRFH coils, Mill 3 - to SMS Yard
- 7- 743- CRCA sheet – to SMS Yard
- 8- 742, 743, 744 - PPGL coil, GL coil, CR coil - to Yard 10
- 9- 744 - CCL, Profile - to Yard 10
- 10 - 5kT Yard for direct dispatch by road and rail
- 11- 743- GP3 line, CTL2, GP sheet, GC sheet – to Yard 10
- 12- 756 - IBMD for Filler loading
TSM Overview
- TSM plant has a steel making capacity of 4.8 MTPA
- Outbound Logistics (OBL) and TSM run the plant's logistics
- 72% of products are transported by rail
- The plant produces HR, CR and Slab products
Product Mix
- HR, CR and Slab products are manufactured at TSM
- HR products include HR Coil, Hot Rolled Plate and HR Pickled
- CR products include CRCA sheet, GP Coil, Galume Coil
- Slab products are dispatched directly to customers
Acceptable Vehicle Turn Around Time (TAT)
- TAT for CRM is ~110 vehicles
- TAT for CR Dispatch activities is ~ 60 vehicles
Process Flow Path in CR Dispatch
- CR Dispatch starts at the gate 2
- Products are weighed and re-weighed
- Weight updates are made in SAP
- PDIR is checked
- Lashing, loading, weighing, and tarpaulin activities are done in the shed
- Invoice is generated upon completion of the activities
Process Flow Path in HR Dispatch
- HR Dispatch starts at gate 2
- Products are weighed and re-weighed
- Weight updates are made in SAP
- PDIR is checked
- Lashing, loading, and weighing activities are done in the shed
- Invoice is generated upon completion of the activities
Process Flow Path in Slab Dispatch
- Slab Dispatch starts at gate 2
- Products are weighed and re-weighed
- Weight updates are made in SAP
- PDIR is checked
- Loading and lashing activities are done
- Invoice is generated upon completion of the activities
Plant Codes
- 742 – HRPO, Pickling line – direct dispatch
- 743 – GP1 Line – Galvanized Plain (GP Hard) – to Yard 10
- 742 – CRFH - Mill1 and Mill 2 – to SMS yard
- 743 – GP2 Line (GL Coil) – to Yard 10
- 743 – CTL1, GP Sheet, GC Sheet – to Yard 10
- 742 – CR coils, CRFH coils, Mill 3 - to SMS Yard
- 743 – CRCA sheet – to SMS Yard
- 742, 743, 744 – PPGL coil, GL coil, CR coil - to Yard 10
- 744 – CCL, Profile - to Yard 10
- 5kT Yard for direct dispatch by road and rail
- 743 – GP3 line, CTL2, GP sheet, GC sheet – to Yard 10
- 756 – IBMD for Filler loading
Infrastructure Constraints
- CRM Yard 10 has 5 kT storage capacity with 3 loading points
- SMS-1 CR Yard has 12 kT storage capacity with 9 loading points
- There are storage sheds with O.H cranes used for loading, unloading, shifting, packing, and other activities
- One O.H crane at SMS-1 CR Yard is under permanent shutdown or maintenance
Traceability Issues
- Traceability issues are mainly due to intrashifting and lack of coordination between the production team and the OBL team
- CR products are often reweighed after loading, and if the difference is greater than 100 kg, they are returned to the production team
- This difference in weight is more frequent for HR Slit (Shed 1) and PPGL (Shed 8)
- This process increases the TAT
TSM Plant Overview
- The TSM plant has a 4.8 MTPA steel making capacity.
- 72% of the plant's output is transported by rail.
- The plant produces 440 KT/month of steel.
- The product mix includes HR (350 kT), CR (50 kT), and Slab (40 kT).
Product Mix & Dispatch
- HR products are dispatched by rail and road.
- CRCA sheet is dispatched primarily by rail, with smaller quantities by road.
- CR products are dispatched via CRM and CR dispatch activities.
- Slab products are dispatched directly to customers.
Dispatch Activities
-
CR Dispatch Activities
- Weighment: Applicable for non-CRCA, CTL, and HR Slit products.
- Lashing & Loading: Essential for securing the product.
- PDIR Check: Ensures the proper documentation and load.
-
HR Dispatch Activities
- Weighment: Ensures weight accuracy.
- Lashing & Loading: Secure the product for transportation.
- PDIR Check: Verifies documentation and load security.
-
Slab Dispatch Activities
- Weighment: For Slab products.
- Lashing: Securing the product during transportation.
Infrastructure Overview
-
CRM Logistics Park
- Yard 10 has a 5KT storage capacity and 3 loading points.
- Overseeing cranes handle loading, unloading, shifting, packing.
- Crane utilization is crucial for efficient dispatch.
- Re-weighment is done after loading, with discrepancies above 100 kgs requiring resubmission to the production team.
- Traceability issues arise due to intra shifting by the production team and insufficient system updates.
-
SMS-1 CR Yard
- Offers a 12KT storage capacity and 9 loading points.
- The yard features 2 O.H cranes, but one is often under maintenance.
Infrastructure Constraints
-
CRM Logistics Park & SMS-1 CR Yard
- Large shed sizes impact crane efficiency.
- Maintenance activities on overhead cranes can cause delays.
Product Acronyms and Plant Codes
-
Full Form of Products
- CRCA - Cold Rolled Close Annealed
- GP Sheet - Galvanized Plain Sheet
- GL Sheet - Galvalume Sheet
- PPGL - Pre-Painted Galvalume Sheet
- GC Sheet - Galvanized Corrugated Sheet
- HRPO- Hot Rolled Pickled and Oiled
-
Plant Codes
- 1-742 - HRPO, Pickling Line - direct dispatch
- 2-743 - GP1 Line - Galvanized Plain (GP Hard) - to Yard 10
- 3-742 - CRFH - Mill 1 and Mill 2- to SMS yard
- 4-743 - GP2 Line (GL Coil) - to Yard 10
- 5-743 - CTL1, GP Sheet, GC Sheet - to Yard 10
- 6-742 - CR coils , CRFH coils, Mill 3 - to SMS Yard
- 7-743 - CRCA sheet- to SMS Yard
- 8- 742, 743, 744- PPGL coil, GL coil, CR coil - to Yard 10
- 9-744 - CCL, Profile - to Yard 10
- 10- 5KT Yard for direct dispatch by road and rail
- 11- 743 - GP3 line, CTL2, GP sheet, GC sheet - to Yard 10
- 12- 756 - IBMD for Filler loading
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Description
This quiz explores the operational overview of the TSM plant, focusing on its capacity, product mix, and logistics handling. Test your knowledge on the various dispatch methods and the logistics processes involved in the production of Hot Rolled and Cold Rolled products.
