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Plan for Managing In-Plant Logistics Operations of Balasore Alloys Ltd.

In Plant - Movements

Movement of Raw material from Stock yard to briquette plant Movement of briquettes to Bunker Bunker to furnace Furnace to hot metal yard Hot metal yard to sales and material recovery Plant (MRP) Resizing , weighing, bagging, sealing at Sales yard Marking of Finished goods bags / Balasore Alloys logo sticker at Sales Yard Loading finished goods on Trucks for outbound dispatch

In Plant- Location and Movement (Not to scale)


Shakti Chrome ltd./ Briquett e plant
Bunker 1

HMY 2

HMY 1

HMY 4
Bunker 2

Furnace 5 in no. Raw material stack yard

Slag yard
Bunker 3

Material recovery plant HMY 3 &5

Sales yard for finished goods all activity labour managed

HMY: Hot Metal Yard, Bunker feeds raw material to furnace, Blue is raw material movement, Red is hot metal movement, Green is finished goods movement

In Plant- Movement Flow chart


Raw material yard (RM)
Briquette plant (BP)
Bunker 1 to Furnace 1 &2 2 to Furnace 4&5 3 to Furnace no.. 3

Furnaces 1 to 5

Slag yard

Metal recovery plant (MRP)

From Gas cleaning plant (GCP) to waste dump outside the plant

Furnace to hot metal yard 1 to 4

Sales yard Finished Goods (FG)

FG Loaded in trucks for outbound

RM to BP: 4 tipper , 1 loader dedicated + 1 tractor BP to Bunker :5 tipper and 1+1 loader, 1 permanent and 1 case by case basis MRP: 2 tipper dedicated + 1 JCP + 1 excavator + 2 tractor Furnace: 5 special tippers dedicated from furnaces to hot metal yard HMY ( hot metal yard ) : 11 Tractors, shifting finished goods (FG) to sales yard GCP( Gas cleaning plant) : 1 Tractor dumping waste to out in the fields
4

IN Plant Logistics ( Equipments)


Sl.No
1

Particulars

Detail of movement

No. of equip 1 3 1 11

Running Basis / Availability


Per hrs / 8 hrs per day / 200 hrs per month

2 3 4

EXCAVATOR HITACHI 200 OR Anywhere in plant EQUIVALENT 1 NO / ( Volvo 210) PAY LOADER- HM -2021 Z BAR LOADER OR Anywhere in plant EQUIVALENT J C B / 424 BACKHOE LOADER . TRIPPER ( FOR COLD METAL ) :--( GROSS WT 17.000 Mt ) ( ( R/M - 4, SCL - 5, MRP - 2 ). TRIPPER ( FOR HOT METAL ) :-- ( GROSS Wt -17.000 Mt ) ( MODIFIED FOR HOT METAL) TRACTOR HYDRULIC UNLODING SYSTEM.(( F/H -11,MRP - 2,GCP -1,SCL - 1). Anywhere in plant 4 for Raw material / 5 for Briquette plant/ 2 for Material recovery plant 5 for movement of hot metal from furnace to Hot metal yard 11 for finished goods / 2 for metal recovery/ 1 for Gas cleaning plant / 1 for briquitte plant

Per hrs / 19.5 hrs per day / 585 hrs per month Per hrs / 19.5 hrs per day / 585 hrs per month Per Mt / 24 hrs availablity

Per Mt / 24 hrs availablity

5
Per Mt / 9 hrs

15

TRACTOR HYDRULIC UNLODING SYSTEM.

8 am to 5 pm ( 9 Per Mt / 9 hrs hrs ) 6 am to 6 pm (12 Per Mt / 9 hrs hrs )

TRACTOR HYDRULIC UNLODING SYSTEM. R/M: Raw Material , SCL: Shakti Cons LtdBriquette plant , MRP: Material recovery plant, F/H: Finsihed goods handling , GCP : Gas cleaning plant

Excavator (1), JCB (1), Loader (3), Tractors (15), Dumpers (16)

IN Plant Logistics ( Cost Benefit - Excavator Volvo -210, Tata Hyva Dumper, Payloader and Tractor )
Please open and see Finance Models for cost & benefits Deploying New Excavator is beneficial in comparison to cost

Deploying New Payloader is beneficial in comparison to cost

Deploying new Dumper is not beneficial in comparison to cost

Deploying new Tractor is not beneficial in comparison to cost

Sales Yard- Finished goods process


Material brought from Hot metal yard
fines stacked, weighed and packed separately in 50 kg bags

Resizing of the material


One mt jumbo empty plastic bags placed on the trucks for lumps
Jumbo bag is mechanically sewn and a seal is put on each bag ith no. and logo of BAL

Bagging and weighing in 50 kg hesian bags in 8 to 9 groups

50 kg bags are emptied into 1mt jumbo bags


Vehicles leaves for final weighment and then for final destination

Vehicle goes for weighment

Vehicle returns and weight is appropriated

Labour Contractors 2 : Bijon Biswas and A K Mondal supply total labour to sales yard. Total 9 manual weighing scales worked on by 9 labour groups. 1. Resizing and rebreaking the lumps 37 labors 2. Weighing and packing in 50 kg bags and then in one mt bags- 46 labours 3. Loading the trucks 25 labours 4. One ton bag stiching and sealing- 5 labors

Thank You