TSM Steel Plant Overview and Processes
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Questions and Answers

What is the minimum weight required for weighment to be applicable for HR Coil?

  • 100 kg (correct)
  • 150 kg
  • 50 kg
  • 200 kg

    • Which materials fall under the weighment application category?

  • CRCA, HR Slit
  • All types of metals
  • Non CRCA, CTL & HR Slit (correct)
  • HR Plate/Sheet only

    • In the slab dispatch process, what document is associated with the weighment process?

  • Delivery Note
  • Purchase Order
  • Invoice (correct)
  • Sales Order

    • What action occurs if the weighment is below 100 kg for the HR Coil?

    <p>It does not proceed with the process.</p> Signup and view all the answers

    What is the final action before a vehicle departs from CRM Logistics Park?

    <p>PDIR Check</p> Signup and view all the answers

    What is the role of Gate 2 in the process flow?

    <p>It marks the start of TAT.</p> Signup and view all the answers

    What is the first step in the HR Dispatch process after TAT starts?

    <p>Loading</p> Signup and view all the answers

    Which activity directly follows the lashing activity in the dispatch process?

    <p>PDIR Check</p> Signup and view all the answers

    What issue primarily affects traceability in CR products?

    <p>Poor communication between teams</p> Signup and view all the answers

    Which of the following sheets are dispatched to Yard 10?

    <p>PPGL coils and GC sheets</p> Signup and view all the answers

    How many loading points for dispatch are available in SMS-1 CR Yard?

    <p>9</p> Signup and view all the answers

    What is the significance of a weight difference greater than 100 kgs during re-weighment?

    <p>Products are sent back to the production team</p> Signup and view all the answers

    Which plant code corresponds to the Hot Rolled Pickled and Oiled line?

    <p>742</p> Signup and view all the answers

    What is the combined storage capacity of Yard 10?

    <p>5kT</p> Signup and view all the answers

    Which sheet types are produced by the 743 plant code?

    <p>GP Sheet and GP3 line</p> Signup and view all the answers

    What maintenance activity affects O.H crane availability?

    <p>Permanent shutdown for maintenance</p> Signup and view all the answers

    What is the rail coefficient for the TSM plant?

    <p>72%</p> Signup and view all the answers

    Which product has the highest production quantity in the product mix?

    <p>H.R Coil</p> Signup and view all the answers

    What is the approximate number of vehicles involved in the dispatch activities?

    <p>110 vehicles</p> Signup and view all the answers

    What is the purpose of the re-weighment during the process flow of CR Dispatch?

    <p>To update weight in SAP</p> Signup and view all the answers

    Which of the following combines the activities necessary for CRM logistics?

    <p>Loading and Lashing</p> Signup and view all the answers

    What action is taken if the weight is less than or equal to 100 during the dispatch process?

    <p>Use tarpaulin</p> Signup and view all the answers

    What is the overall capacity of steel making for the TSM plant?

    <p>4.8 MTPA</p> Signup and view all the answers

    What represents the acceptable vehicle turnaround time within the dispatch activities?

    <p>Approximately 110 vehicles</p> Signup and view all the answers

    What is the overall monthly production capacity of the TSM plant in KT?

    <p>440 KT/month</p> Signup and view all the answers

    Which product mix includes the highest amount produced in tons?

    <p>H.R Coil (350 kT)</p> Signup and view all the answers

    What is the minimum weight needed for a weighment to be applicable in the process flow?

    <p>100 kg</p> Signup and view all the answers

    Which mode of transport has the highest allocation in the product dispatch activities?

    <p>Rail for HR Coil</p> Signup and view all the answers

    What is the acceptable vehicle turn around time within the dispatch activities?

    <p>110 minutes</p> Signup and view all the answers

    Which step occurs after the invoice is generated in the dispatch process?

    <p>Lashing</p> Signup and view all the answers

    What represents the rail coefficient for the TSM plant?

    <p>72%</p> Signup and view all the answers

    What is the primary impact of not adhering to the acceptable vehicle turn around time?

    <p>Delayed dispatch schedules</p> Signup and view all the answers

    What is the critical weight threshold for weighment in both HR Coil and Slab Dispatch processes?

    <p>100 kg</p> Signup and view all the answers

    In the HR Dispatch process, what task follows the lashing activity?

    <p>Weight Update in SAP</p> Signup and view all the answers

    What happens if the weighment in the Slab Dispatch process is under the specified limit?

    <p>The vehicle must be reweighed</p> Signup and view all the answers

    Which of the following activities is not part of the HR Coil process flow?

    <p>Customer Invoicing</p> Signup and view all the answers

    Which stage in the dispatch process involves a PDIR Check for compliance?

    <p>Before Loading</p> Signup and view all the answers

    What critical information is updated in SAP during the dispatch process?

    <p>Weight Measurements</p> Signup and view all the answers

    Which of the following does not relate to the timing aspect in the dispatch activities?

    <p>Gate 2 Process Flow</p> Signup and view all the answers

    What signifies the end of the load process in CRM Logistics Park?

    <p>Vehicle Departure Confirmation</p> Signup and view all the answers

    Identify the function of Overhead (O.H) cranes in facilities apart from Yard 10.

    <p>Shifting, loading, unloading, and packing activities.</p> Signup and view all the answers

    What is the primary consequence of a weight difference greater than 100 kg during the re-weighment process?

    <p>The product gets redirected back to the production team.</p> Signup and view all the answers

    Which statement accurately describes the storage capabilities of Yard 10?

    <p>It has a storage capacity of 5kT and 3 loading points for dispatch.</p> Signup and view all the answers

    Which product types are dispatched from the 743 plant code?

    <p>Galvanized Plain sheets and Galvanized Corrugated sheets.</p> Signup and view all the answers

    What likely causes traceability issues in Cold Rolled (CR) products?

    <p>Intrashifting by the production team and lack of system updates.</p> Signup and view all the answers

    How many loading points are available for dispatch in the SMS-1 CR Yard?

    <p>9 loading points.</p> Signup and view all the answers

    Which description accurately reflects the maintenance situation of the cranes in the sheds?

    <p>One O.H crane is permanently shut down, affecting operational capacity.</p> Signup and view all the answers

    How are the loading processes in CRM Yard differentiated?

    <p>By associating specific loading points with product types.</p> Signup and view all the answers

    Study Notes

    TSM Overview

    • TSM plant has a steel-making capacity of 4.8 MTPA
    • 72% of the plant’s output is transported by rail
    • The plant produces 440 KT of steel per month

    Product Mix

    • Steel product mix includes: HR (350 kT), CR (50 kT), and Slab (40 kT)
    • HR (Hot-Rolled) products are 310 KT of coil, 40 KT of plate and 39 KT of sheet
    • CR (Cold-Rolled) products are 1 KT of coil, 5 KT of plate, and 35 KT of sheet
    • Different products are transported by both rail and road

    Dispatch Activities

    • The acceptable vehicle turn-around time (TAT) for dispatch is ~110 vehicles
    • There are ~60 vehicles for CRM and CR dispatch activities

    Process Flow Paths

    • The TAT starts at the CRM parking and ends at Gate 2
    • CR dispatch activities include: loading, lashing, weighment, PDIR check, tarpaulin, and invoice
    • HR dispatch activities include: loading, lashing, weighment, PDIR check, and invoice
    • Slab dispatch activities include: loading, lashing, weighment, PDIR check, and invoice

    Infrastructure Constraints

    • Yard 10 has 5kT storage capacity and 3 loading points for dispatch
    • SMS-1 CR Yard has 12kT storage capacity and 9 loading points for dispatch
    • There are O.H cranes in the sheds for various activities, including loading/unloading, shifting, packing.
    • Crane utilization for dispatch is a key factor in operations
    • Re-weighment is necessary after loading, and if there is a difference greater than 100 kgs, the products are sent back to the production team for re-work
    • Traceability issues in CR products are due to intrashifting by the production team, and a lack of coordination with the OBL team.

    TSM (Meramandali) Overview

    • TSM plant has a steel-making capacity of 4.8 MTPA
    • TSM plant has a 440 KT/month outbound logistics (OBL) capacity
    • 72% of the TSM plant's outbound logistics is transported by rail
    • The product mix includes:
      • HR (350 kT)
      • CR (50 kT)
      • Slab (40 kT)

    Product Mix Details

    • HR Coil (310 kT)
      • 40 kT transported by road
      • 39 kT transported by rail
    • HR Plate (1 kT)
      • 5 kT transported by road
      • 35 kT transported by rail
    • CRCA Sheet (40 kT)
      • All transported by rail
    • GP Coil (5 kT)
      • Transported by road
    • Galume Coil (35 kT)
      • Transported by road

    Dispatch Activities and Turnaround Time (TAT)

    • Acceptable TAT for vehicle is ~ 110 vehicles
    • CRM (Customer Relationship Management) logistics park has a TAT of ~ 60 vehicles

    CR Dispatch Process Flow

    • TAT starts at CRM Parking
    • TAT ends at Gate 2
    • Weighment and re-weighment are done at the mill
    • If the weight difference is >= 100 kg, the product is sent back to the production team
    • Lashing and PDIR (Pre Departure Inspection Report) are conducted.
    • Tarpaulins are applied to the product.
    • Products are weighed and loaded.
    • An invoice is generated and the product is dispatched

    HR Dispatch Process Flow

    • TAT starts at HSM (Hot Strip Mill) Parking
    • TAT ends at Gate 2
    • Weighment and re-weighment is done at the mill
    • Lashing and PDIR (Pre Departure Inspection Report) are conducted.
    • Products are weighed and loaded.
    • An invoice is generated and the product is dispatched

    Slab Dispatch Process Flow

    • TAT starts at HSM (Hot Strip Mill) Parking
    • TAT ends at Gate 2
    • Weighment and re-weighment is done at the mill
    • Products are weighed and loaded
    • PDIR is conducted.
    • The product is dispatched directly to the customer
    • An invoice is generated and the product is dispatched

    Infrastructure - CRM Shed-10

    • Shed 10 has a capacity of 5 kT and has 3 loading points for dispatch
    • Shed 10 uses O.H cranes for loading, unloading, shifting, packing and dispatch activities
    • After loading, CR products are re-weighed. If the difference is >100 kg, the product is sent back to the production team. This issue is more prevalent with HR Slit (Shed 1) and PPGL (Shed 8), increasing the TAT.
    • Traceability issue with CR products is primarily due to shifting by the production team and not updating the system or OBL team.

    Infrastructure Constraints - SMS-1 CR Yard

    • Has 12 kT storage capacity and 9 loading points for dispatch.
    • Shed is big, has 2 O.H cranes on one half and 1 O.H crane on the other. One O.H crane is permanently shut down for maintenance.

    Product Abbreviations

    • 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

    • Plant codes allocate specific areas for product processing and storage:
      • Plant Code 1 - 742 - HRPO, Pickling line - direct dispatch
      • Plant Code 2 - 743 - GP1 Line - Galvanized Plain (GP Hard) - to Yard 10
      • Plant Code 3 - 742 - CRFH - Mill1 and Mill 2 - to SMS Yard
      • Plant Code 4 - 743 - GP2 Line (GL Coil) - to Yard 10
      • Plant Code 5 - 743 - CTL1, GP Sheet, GC Sheet - to Yard 10
      • Plant Code 6 - 742 - CR coils, CRFH coils, Mill 3 - to SMS Yard
      • Plant Code 7 - 743 - CRCA sheet - to SMS Yard
      • Plant Code 8 - 742, 743, 744 - PPGL coil, GL coil, CR coil - to Yard 10
      • Plant Code 9 - 744 - CCL, Profile - to Yard 10
      • Plant Code 10 - 5kT Yard for direct dispatch by road and rail
      • Plant Code 11 - 743 - GP3 line, CTL2, GP sheet, GC sheet - to Yard 10
      • Plant Code 12 - 756 - IBMD for Filler loading

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    Description

    This quiz explores the TSM steel plant's capacity, product mix, and dispatch activities. It covers the plant's output distribution, vehicle turnaround times, and individual product dispatch processes for hot-rolled and cold-rolled products. Test your knowledge on each aspect of the plant's operations!

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