Black Breakdown Summery Mill Wise

BREAKDOWN REPORT (BLACK) OF MILL :10-JAN-2016
Code STOPPAGE NATURE & CAUSES MILL-6 MILL-7 MILL-8 MILL-9 MILL-10 MILL-11 MILL-12 MILL-13 MILL-14 MILL-15 TOTAL TOTAL(MIN) TOTAL(HRS)
PO1 Pick-up,Roll mark,Tool mark,problem 20 20
PO2 Size & Pipe bending problem 15 45 60
PO3 Strip fold in forming & finpas section 0
PO4 Joint delay&joint broken 10 30 80 120
PO5 Strip fold in R.L.A. 35 35
PO6 Wrincle problem/Overlap problem 20 20 255 4.25
M1 Decoiler not working 15 15
M2 Propeller shaft,Roll shaft,Block brg.change 15 15
M3 W/R assembly changed 140 140
M4 Coil car problem 0
M5 Power pack problem 0
M6 Impeeder line,Impeeder,Work coil change 0
Fin cut problem(fin cut holder,bogei not ready & plate

M7 lose) 0
M8 Cutting car rai brg change 0
M9 Cutting car problem 20 20
M10 R.O.T. problem 0
M11 Tool post problem, 0
M12 Bundling conveyor & bundling m/c. 0 190 3.17
E1 Decoiler side problem 0
E2 Plant tripped, 0
E3 Elecrical problem(Grinding burn;size,finpass,coc motor 45 300 345
E4 Coil support problem

E5 RLA Problem 0
E6 HF Tripped 40 40
E7 D.C.Moter problem 0
E8 Cutting car problem 0
E9 R.O.T.problem 0
E10 Tool post problem 0
Bundling conveyor & bundling m/c.M,Welding prob.

E11 0 385 6.42
OTH1 Material segrigation 60 60
OTH2 Material Wating 0
OTH3 Man power delay & mill cleaning 40 40 30 15 90 135 30 50 430
Proper roll not available such as welding roll,& profile

OTH4 problem 0
OTH5 crain delay(QC,Not working) 35 240 275
OTH6 Power failure 0
OTH7 Store related such as spare part not available 0

Other delay such as cooling water,gas cylinder &
OTH8 equipment setting 0 765 12.75
SSD1 Cutter change 20 30 30 45 50 45 95 45 360
SSD2 Stamp change, 15 20 35
SSD3 VFR,FF,FS ,THbearing change 115
SSD4 Accumulator Side change 0
SSD5 Spray gun setting, 10 10
SSD6 zinc wire change(coating) 20
SSD7 Welding roll change 55 35 90
SSD8 Impeeder line,Impeeder,Work coil change 40 50 25 115
SSD9 Bogei setting for fin cut & tool change 20 20
SSD10 Tool change & fin change /TH bearing change 5 10 15
SSD11 Decoiler plate setting for small id slit or big id slit coil 0
SSD12 Roll change 330 330
SSD13 Gauge change 45 45 45 55 95 285

Material defect such as edge,width,thikness,chamber
SSD14 problem 0
Mill under shutdown
SSD15 (Operation,Mechanical,Electrical) 0
SSD16 Mill under shutdown due to Manpower Problem 0 1260 21.00
TOTAL 605 0 390 275 375 155 210 305 540 135
PO2 Size & Pipe bending problem 60 20 35 10 125
PO3 Strip fold in forming & finpas section 60 60
PO4 Joint delay&joint broken 20 15 10 65 20 130
PO5 Strip fold in R.L.A. 15 15
M2 Propeller shaft,Roll shaft,Block brg change 0
M3 W/R assembly changed 30 30
M7 Water line problem 40 40
M9 Cutting car problem 10 15 25
M11 Tool post problem, 0
M12 Bundling conveyor & bundling m/c. 0 195 3.25
E2 Plant tripped, 0
Elecrical problem(Grinding burn;size,finpass,coc
E3 motor trip) 0
E4 Coil support problem

E5 RLA Problem 0
E6 HF Tripped 15 70 85
E8 Cutting car problem 30 60 90
E9 R.O.T.problem 0
E10 Tool post problem 0
Bundling conveyor & bundling m/c.M,Welding prob.

E11 0 175 2.92
OTH1 Material segrigation 0
OTH2 Material Wating 140 140
OTH3 Man power delay & mill cleaning 25 40 60 90 75 100 840 1230
Proper roll not available such as welding roll,& profile

OTH4 problem 0
OTH5 crain delay(QC,Not working) 0
OTH7 Store related such as spare part not available 0

Other delay such as cooling water,gas cylinder &
OTH8 equipment setting 0 1370 22.83
SSD1 Cutter change 20 55 15 80 75 30 20 295
SSD3 VFR,FF,FS ,THbearing change

SSD4 Accumulator Side change 0
SSD5 Spray gun setting, 15 70 85
SSD6 zinc wire change(coating) 20 25
SSD7 Welding roll change 90 30 15 60 195
SSD8 Impeeder line,Impeeder,Work coil change 40 40
SSD9 Bogei setting for fin cut & tool change 0
SSD10 Tool change & fin change /TH bearing change 50 50
SSD11 Decoiler plate setting for small id slit or big id slit coil 0
SSD12 Roll change 710 705 1415
SSD13 All roll alingmet 240 220 460
SSD14 Gauge change 80 15 10 65 60 230

Material defect such as edge,width,thikness,chamber
SSD15 problem 0
Mill under shutdown
SSD16 (Operation,Mechanical,Electrical) 0 2825 47.08
TOTAL 1040 920 255 425 400 465 0 300 0 1170
PO1 Pick-up,Roll mark,Tool mark,problem 0
PO3 Strip fold in forming & finpas section 100 25 125
PO5 Strip fold in R.L.A. 0
PO6 Wrincle problem/Overlap problem 0 900 15.00
M1 Decoiler not working 0
M2 Roll bearing broken so change 120 120
M3 Coc coupling change 120 120
M4 W/R assembly changed 0
M7 Impeeder line,Impeeder,Work coil change 20 20
M10 R.O.T. problem 60 60 120
M11 Tool post problem, 0 440 7.33
E2 Plant tripped, 0
E3 HF Tripped 60 40 15 115
E4 D.C.Moter problem 10 10
E5 Cutting car problem 70 70 140
E6 R.O.T.problem 0
E7 Tool post problem 0 265 4.42
OTH1 Material segrigation 20 40 60
OTH2 Material Wating 30 180 120 330
OTH4 crain delay 70 70
OTH6 Store related such as spare part not available 0 1045 17.42
SSD1 Cutter change 35 20 50 45 130 95 60 80 20 535
SSD2 Stamp change, 55 45 25 10 135
SSD3 THbearing change 0
SSD4 Spray gun setting, 40 20 80 140
SSD5 Zinc wire change 40 15 45 100
SSD6 Welding roll change 50 50
SSD8 Bogei setting for fin cut 5 5
SSD9 Tool change 0
SSD10 Fin change 0
SSD12 Gauge change 30 25 85 60 120 35 40 395
SSD13 Material defect such as edge,width,thikness,chamber problem 20 20
SSD14 Mill under shutdown (Operation,Mechanical,Electrical) 0 1745 29.08

TOTAL 625 405 285 325 600 455 660 680 360 0
PO2 Size & Pipe bending problem 70 10 70 60 15 225
PO4 Joint delay&joint broken 35 25 55 40 15 60 230
PO5 Strip fold in R.L.A. 0
M2 Roll bearing,Propeler shaft broken so change 15 15
M3 Gear change( low to high) 30 30
M4 Pipe mouth pressing 70 70
M5 Pinch lever assembly fitting 200 200
M6 Coc wheel change 30 30
M9 Cutting car problem(cutter broken) 85 85
M10 R.O.T. problem 25 30 55
M11 Tool post problem, 30 30 515 8.58
E2 Plant tripped, 0
E3 HF Tripped 30 30
E5 Cutting car problem(cutter broken) 55 65 120
E6 R.O.T.problem 20 35 55
E7 Tool post problem 30 30 235 3.92
OTH1 Material segrigation 45 45
OTH2 Material Wating 65 90 155
OTH3 Man power delay & mill cleaning 35 95 50 120 80 110 105 65 60 720
OTH4 crain delay 40 20 90 30 180
OTH5 Power failure 90 90
SSD3 THbearing change 100 100
SSD4 Spray gun setting, 45 30 70 145
SSD5 Zinc wire change 10 20 30
SSD6 Welding roll change 15 15
SSD9 Tool change 5 5 10 20
SSD10 Fin change 35 35
SSD12 Gauge change 25 85 40 30 100 15 120 415
SSD13 Material defect such as edge,width,thikness,chamber problem 0

TOTAL BREAKDOWN ( MIN ) 355 430 305 470 440 540 765 490 215 0
TOTAL BREAKDOWN ( HRS.) 5.917 7.167 5.083 7.833 7.333 9 12.75 8.167 3.583 24
TOTAL RUNNING ( HRS.) 18.08 16.83 18.92 16.17 16.67 15 11.25 15.83 8.417 0
PO4 Joint delay&joint broken 20 25 30 30 105
PO5 R.L.A Empty 20 20
M2 Roll bearing,Propeler shaft,excel bolt broken so change 20 15 35
M3 Gear change( low to high) 0
M4 Pipe mouth pressing 0
M5 Pinch lever assembly fitting 0
M6 Coc wheel change 0
M9 Cutting car problem(cutter broken) 0
E2 Plant tripped, 0
E3 HF Tripped 0
E5 35 0
E6 R.O.T.problem 0
OTH1 Material segrigation,old coil run 50 50
OTH3 Man power delay & mill cleaning 50 60 230 170 90 600
OTH4 crain delay 0
SSD1 Cutter change 35 55 45 55 25 215
SSD3 TH Roll change & alingment 190 210 400
SSD4 Spray gun setting, 0
SSD7 Impeeder line,Impeeder,Work coil change 20 20
SSD8 Bogei setting for fin cut 0
SSD9 Tool change 0
SSD10 Fin change 0
SSD12 Gauge change 35 130 105 270

TOTAL BREAKDOWN ( HRS.) 2.417 8 9.167 6.417 7.167 7.333 0 0 0
TOTAL RUNNING ( HRS.) 21.58 16 14.83 17.58 16.83 16.67 24 24 12 24

PO2 Size & Pipe bending problem 30 30
PO4 Joint delay&joint broken 35 35
PO5 R.L.A not working 40 30 70
M2 Roll bearing,Propeler shaft,excel bolt broken so change 15 15
M3 Gear change( low to high) 0
M4 Pipe mouth pressing 0
M8 Impeeder line,Impeeder change, Work coil change 15 30 30 75
M9 Cutting car problem(cutter broken) 0
E2 Plant tripped, 0
E3 HF Tripped 20 20
E5 Electrical supply of 45 45
E6 R.O.T.problem 0
OTH1 Material segrigation,old coil run 0
OTH3 Man power delay & mill cleaning 20 30 45 240 60 270 270 270 780 1440 3425
OTH4 crain delay 40 40 80
SSD3 TH Roll change & alingment 0
SSD4 Spray gun setting, 10 10
SSD5 Zinc wire change 10 10
SSD6 Welding roll change 15 30 20 65
SSD7 Impeeder line,Impeeder,Work coil burn 15 15
SSD9 Tool change 0
SSD11 Roll change 420 360 120 900
SSD12 Gauge change 20 15 45 30 110

TOTAL BREAKDOWN ( HRS.) 2 2.083 2.75 11.5 8.5 5.75 6.667 9.667 17.5 24
TOTAL RUNNING ( HRS.) 10 21.92 21.25 12.5 15.5 18.25 17.33 14.33 6.5 0
PO2 Size & Pipe bending problem 40 10 10 60 5 125
PO5 R.L.A strip collapse 130 20 90 90 30 360
M2 Roll bearing,Propeler shaft,excel bolt broken so change 0
M3 R L A tie rod fitting &joint delay 45 45
M4 WELding roll bearing change 30 30
M8 Impeeder line,Impeeder change, Work coil change 0
M9 Cutting car problem(cutter maint. Work) 35 35
M10 R.O.T. problem 5 50 25 80
E2 Plant tripped, 0
E5 Electrical supply of 0
E6 R.O.T.problem 0
OTH4 crain delay 30 30 25 85
SSD1 Cutter change 35 10 25 260 15 130 60 45 580
SSD2 Stamp change, 60 10 10 80
SSD6 Welding roll change 55 25 90 95 265
SSD7 Impeeder line,Impeeder,Work coil burn 35 40 75
SSD9 Tool change 10 15 25
SSD10 Fin change 0
SSD12 Gauge change 210 80 30 45 365
SSD13 Material defect such as edge,width,thikness,chamber problem 35 50 85

TOTAL BREAKDOWN ( HRS.) 5.417 10.25 5.583 12.42 6 10.33 7 6.917 16 0
TOTAL RUNNING ( HRS.) 6.583 13.75 18.42 11.58 6 13.67 17 17.08 8 24

12 HRS 24 HRS 24 HRS 24 HRS 12 HRS 24 HRS 24 HRS 24 HRS 24 HRS 24 HRS
PO2 Size & Pipe bending problem 20 20 70 110
PO3 Strip fold in forming & finpas section 10 60 70
PO5 R.L.A strip collapse 30 30
M3 Fin pass shaft pin broken 60 30 90
M4 WELding roll bearing change 0
M9 Cutting car problem 10 180 190
E1 Decoiler side problem 30 30
E2 Plant tripped, 0
E3 HF Tripped 70 70
E5 Electrical supply of 0
E6 R.O.T.problem 0
OTH3 Man power delay & mill cleaning 120 100 120 30 20 105 20 70 100 685
OTH4 crain delay 10 30 55 95
SSD2 Stamp change, 35 35
SSD3 TH Roll change & alingment 80 40 120
SSD6 Welding roll change 0
SSD7 Impeeder line,Impeeder,Work coil burn 30 45 20 60 45 200
SSD9 Tool change 20 20
SSD11 Roll change 0
SSD12 Gauge change 10 130 20 15 55 45 90 365
SSD14 Mill under shutdown (Operation,Mechanical,Electrical) 720 720 1775 29.58

TOTAL BREAKDOWN ( HRS.) 4.833 5.75 6.833 8.083 2.25 16.58 2.167 6.917 6 0
TOTAL RUNNING ( HRS.) 19.17 18.25 17.17 15.92 9.75 7.417 21.83 17.08 18 24
PO5 R.L.A strip collapse 110 20 130
M3 Fin pass shaft pin broken 0
M5 Bearing broken of FB3 bottom roll block 120 120
M8 Impeeder line,Impeeder change, Work coil change 30 30
M9 Cutting car problem 15 15 10 40
M10 R.O.T. problem 30 30
E1 Decoiler side problem 10 10
E2 Plant tripped, 0
E5 Electrical shutdown and power supply of 115 115 230
E6 R.O.T.problem 0
OTH4 crain delay 40 120 25 75 260
SSD4 Spray gun setting,& problem 80 20 100
SSD7 Impeeder line,Impeeder change,Work coil burn 20 60 80
SSD9 Tool change 10 10
SSD11 Roll change 240 370 390 1000
SSD12 Gauge change 55 20 15 20 130 100 70 410
SSD13 Material defect such as edge,width,thikness,chamber problem 35 35

TOTAL BREAKDOWN ( HRS.) 9.583 10 8.417 8.833 9 6.917 8 10.25 0 16.17
TOTAL RUNNING ( HRS.) 14.42 14 15.58 15.17 3 17.08 16 13.75 24 7.833

PO5 R.L.A strip collapse 0
M5 Bearing broken of FB3 bottom roll block 0
M9 Cutting car problem 0
E1 Decoiler side problem 20 20 40
E2 Plant tripped, 0
E3 HF Tripped 0
E5 Electrical shutdown and power supply of 0
E6 R.O.T.problem 0
OTH1 Material segrigation,old coil run 90 180 165 270 240 945
SSD1 Cutter change 15 60 90 100 265
SSD3 TH block shaft bolt broken 70 70
SSD4 Spray gun setting,& problem 0
SSD7 Impeeder line,Impeeder change,Work coil burn 15 15
SSD9 Tool change 0
SSD10 Fin change 0
SSD12 Gauge change 45 60 55 150 120 130 150 60 770

TOTAL BREAKDOWN ( HRS.) 3.5 8.667 4.25 5.417 0 9.667 10.92 12.5 6.5 8.167
TOTAL RUNNING ( HRS.) 8.5 15.33 7.75 6.583 24 14.33 13.08 11.5 5.5 15.83
12 HRS 12 HRS 12 HRS 12HRS 24 HRS 24 HRS 24 HRS 24 HRS 12HRS 24 HRS
M1 uncoiler not working 270 270
E2 Plant tripped, 0
E3 HF Tripped 0
E6 R.O.T.problem 0
OTH1 Material segrigation,old coil run 30 90 360 480
OTH2 Material Wating 350 200 120 450 300 1420
SSD3 TH block shaft bolt broken 0
SSD4 Spray gun setting,& problem 85 85
SSD5 Zinc wire change 0
SSD7 Impeeder line,Impeeder change,Work coil burn 35 35
SSD9 Tool change 0
SSD10 Fin change 0
SSD12 Gauge change 125 95 30 100 40 25 415
SSD13 Mill alignment & size setting 380 380

TOTAL BREAKDOWN ( HRS.) 0 2.583 5.25 18.92 21.5 8.333 18.17 6.667 16.17 16.42
TOTAL RUNNING ( HRS.) 24 9.417 18.75 5.083 2.5 15.67 5.833 17.33 7.833 7.583
24HRS 12 HRS 24 HRS 24HRS 24 HRS 24 HRS 24 HRS 24 HRS 24HRS 24 HRS
M1 uncoiler not working 20 20 40
M4 Uncoiler mandral bolt broken 30 30
E2 Plant tripped, 0
E3 HF Tripped 20 20
E6 R.O.T.problem 0
OTH1 Material segrigation,old coil run 75 385 300 120 880
OTH4 crain delay 0
SSD1 Cutter change 20 70 80 70 70 85 395
SSD2 Stamp change, 15 15
SSD7 Impeeder line,Impeeder change,Work coil burn 0
SSD9 Tool change 0
SSD10 Fin change 0
SSD12 Gauge change 155 155 110 35 180 190 260 175 1260
SSD13 Mill alignment & size setting 0

TOTAL BREAKDOWN ( HRS.) 3.833 3.417 7.25 6.167 14.08 13 12.08 8.5 0 0
TOTAL RUNNING ( HRS.) 8.167 8.583 16.75 17.83 9.917 11 11.92 15.5 24 24
PO3 Strip fold in forming & finpass section 30 30
PO5 R.L.A strip collapse 30 30 60
M1 uncoiler not working 0
M4 WELding roll bearing broken 20 20
M8 Forming stand 2&4 Roll shaft broken 120 120
M9 Cutting car problem 25 190 30 245
E2 Plant tripped, 0
E3 HF Tripped 0
E6 R.O.T.problem 20 20
OTH1 Material segrigation,old coil run 45 60 240 240 160 850 60 1655
SSD2 Stamp change, 60 40 20 50 170
SSD7 Impeeder line,Impeeder change,Work coil burn 0
SSD9 Tool change 0
SSD12 Gauge change 20 630 70 150 130 100 70 150 1320

TOTAL BREAKDOWN ( HRS.) 3.667 14.33 14.83 5.333 7.833 12.5 12.25 10.17 18.33 4.75
TOTAL RUNNING ( HRS.) 8.333 9.667 9.167 18.67 4.167 11.5 11.75 13.83 5.667 7.25
PO3 Strip fold in forming & finpass section 0
M1 uncoiler not working 20 45 65
M4 WELding roll bearing broken 0
M8 R.L.A shaft problem 40 40
E2 Plant tripped, 0
E3 HF Tripped 0
E5 Electrical power supply of 35 35
E6 R.O.T.problem 0
OTH1 Material segrigation,old coil run 300 140 110 60 1440 180 2230
SSD7 Impeeder line,Impeeder change,Work coil change 20 25 25 70
SSD9 Tool change 0
SSD10 Fin change 0
SSD12 Gauge change 85 310 25 70 200 290 45 1025

TOTAL BREAKDOWN ( HRS.) 11.5 2.833 4.333 11.83 6.417 5.583 13.42 13 24 8.25
TOTAL RUNNING ( HRS.) 0.5 21.17 19.67 12.17 5.583 18.42 10.58 11 0 15.75
PO3 Strip fold in forming & finpass section 40 35 75
PO4 Joint delay&joint broken 95 20 115
PO6 Wrincle problem/Overlap problem 60 40 100 425 7.08
M1 uncoiler not working 0
M2 Roll bearing,Propeler shaft,excel bolt broken so change 60 60
M4 WELding roll bearing broken 0
M8 R.L.A shaft problem 0
E2 Plant tripped, 0
E3 HF Tripped 30 30
E5 Electrical power supply of 0
E6 R.O.T.problem 60 60
OTH3 Man power delay & mill cleaning 240 205 100 30 40 615
SSD1 Cutter change 30 25 40 40 135
SSD2 Stamp change, 0
SSD4 Spray gun setting,& problem 30 25 60 60 175
SSD7 Impeeder line,Impeeder change,Work coil change 60 30 30 20 140
SSD9 Tool change 0
SSD10 Fin change 0
SSD11 Roll change 0
SSD12 Gauge change 240 245 485

TOTAL BREAKDOWN ( HRS.) 10 0 8.417 9 0 0 6.333 5.5 0 0
TOTAL RUNNING ( HRS.) 2 24 15.58 15 24 24 17.67 18.5 24 24


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BREAKDOWN REPORT (BLACK) OF MILL :10-JAN-2016

PO1 Pick-up,Roll mark,Tool mark,problem 20 20

PO2 Size & Pipe bending problem 15 45 60

PO3 Strip fold in forming & finpas section 0

PO4 Joint delay&joint broken 10 30 80 120

PO5 Strip fold in R.L.A. 35 35

PO6 Wrincle problem/Overlap problem 20 20 255 4.25

M1 Decoiler not working 15 15

M2 Propeller shaft,Roll shaft,Block brg.change 15 15

M3 W/R assembly changed 140 140

M4 Coil car problem 0

M5 Power pack problem 0

M6 Impeeder line,Impeeder,Work coil change 0

Fin cut problem(fin cut holder,bogei not ready & plate

M8 Cutting car rai brg change 0

M9 Cutting car problem 20 20

M10 R.O.T. problem 0

M11 Tool post problem, 0

M12 Bundling conveyor & bundling m/c. 0 190 3.17

E1 Decoiler side problem 0

E3 Elecrical problem(Grinding burn;size,finpass,coc motor 45 300 345

E4 Coil support problem

E8 Cutting car problem 0

E10 Tool post problem 0

Bundling conveyor & bundling m/c.M,Welding prob.

OTH1 Material segrigation 60 60

OTH2 Material Wating 0

OTH3 Man power delay & mill cleaning 40 40 30 15 90 135 30 50 430

Proper roll not available such as welding roll,& profile

OTH5 crain delay(QC,Not working) 35 240 275

OTH6 Power failure 0

OTH7 Store related such as spare part not available 0

SSD1 Cutter change 20 30 30 45 50 45 95 45 360

SSD2 Stamp change, 15 20 35

SSD3 VFR,FF,FS ,THbearing change 115

SSD4 Accumulator Side change 0

SSD5 Spray gun setting, 10 10

SSD6 zinc wire change(coating) 20

SSD7 Welding roll change 55 35 90

SSD8 Impeeder line,Impeeder,Work coil change 40 50 25 115

SSD9 Bogei setting for fin cut & tool change 20 20

SSD10 Tool change & fin change /TH bearing change 5 10 15

SSD12 Roll change 330 330

SSD13 Gauge change 45 45 45 55 95 285

SSD16 Mill under shutdown due to Manpower Problem 0 1260 21.00

PO1 Pick-up,Roll mark,Tool mark,problem 20 20

PO2 Size & Pipe bending problem 60 20 35 10 125

PO3 Strip fold in forming & finpas section 60 60

PO4 Joint delay&joint broken 20 15 10 65 20 130

PO5 Strip fold in R.L.A. 15 15

PO6 Wrincle problem/Overlap problem 15 15 365 6.08

M1 Decoiler not working 100 100

M2 Propeller shaft,Roll shaft,Block brg change 0

M3 W/R assembly changed 30 30

M4 Coil car problem 0

M5 Power pack problem 0

M6 Impeeder line,Impeeder,Work coil change 0

M7 Water line problem 40 40

M8 Cutting car rai brg change 0

M9 Cutting car problem 10 15 25

M10 R.O.T. problem 0

M11 Tool post problem, 0

M12 Bundling conveyor & bundling m/c. 0 195 3.25

E1 Decoiler side problem 0