SSF Plastics Baseline Draft for Review
SSF Plastics Baseline Draft for Review
2 Baseline
2.1 Baseline Period
The baseline period to measure the performance of the project is Oct-23 to Sep-24. The idea behind
considering the said period for baseline is that it takes into account all the improvements done by
SSF prior to the analysis/project start.
Downtime Summary in Hours Nov-23 to Oct-24 (Data Source ERP Data Base- Downtime Machine wise Summary)
Weekly Man Plastic
Total Available Colour Material Mould Power Production Run
Section Off / Auxiliary Machine Power Mould No Plan Others CLD Trial
Hours Hours Change Shortage Change Failure / Process Hours
Holiday Shortage Shortage
EBM 2,10,456 16,432 1,94,024 1,651 144 6,574 2,152 346 1,261 1,817 34,060 2,055 37 9,117 5,661 1,790 1,27,359
IBM 33,672 2,680 30,992 68 4 1,051 53 8 16 181 18,540 223 0 1,038 221 23 9,567
IM 4,54,785 25,168 4,29,617 586 365 4,611 2,322 1,876 942 21,202 1,31,571 1,502 0 14,275 3,273 10,852 2,36,243
ISBM 36,608 2,984 33,624 87 0 916 76 4 626 607 13,363 439 0 1,406 611 144 15,343
Overall 7,35,521 47,264 6,88,257 2,392 512 13,151 4,603 2,234 2,844 23,807 1,97,534 4,219 37 25,836 9,766 12,809 3,88,512
Production Summary in Hours Nov-23 to Oct-24(Data Source ERP Data Base- Production ledger)
Section Total Production Hours Rejection Hours Hold Hours Earned Hours
6,90,000
0.3% 0.1%
1.9% 0.7% 0.3% 0.4%
3.5%
5,90,000
4,90,000
1,90,000
-0.2%
90,000
-10,000
2.3.2 Planned Performance Indicator- EBM
Weekly Man Plastic
Total Available Colour Material Mould Power Production
Section Off / Auxiliary Machine Power Mould No Plan Others CLD Trial Run Hours
Hours Hours Change Short Change Failure / Process
Holiday Short Short
Oct-23 17,856 3,264 14,592 51 12 352 21 1 63 178 3,416 37 - 836 318 58 9,249
Nov-23 17,272 1,264 16,008 102 11 564 141 - 157 144 2,325 125 - 414 564 24 11,437
Dec-23 17,840 1,136 16,704 90 8 633 46 - 98 105 3,008 20 - 782 495 42 11,378
Jan-24 17,848 2,320 15,528 84 10 613 53 31 131 152 958 1 - 764 462 228 12,042
Feb-24 16,648 576 16,072 136 11 508 203 15 105 144 1,932 78 - 754 461 476 11,249
Mar-24 17,856 1,424 16,432 169 24 329 528 - 113 139 2,906 576 - 294 524 108 10,724
Apr-24 17,272 1,464 15,808 180 3 440 254 7 98 148 3,730 311 - 335 547 25 9,731
May-24 18,176 1,896 16,280 137 6 619 130 5 82 130 3,844 75 - 985 406 24 9,835
Jun-24 17,256 264 16,992 86 24 596 420 239 84 156 3,053 568 37 1,210 501 61 9,957
Jul-24 17,840 1,144 16,696 388 13 997 91 2 129 131 2,654 264 - 900 490 115 10,521
Aug-24 17,848 1,104 16,744 121 17 448 99 26 91 78 3,480 - - 1,068 383 346 10,587
Sep-24 16,744 576 16,168 107 6 475 166 20 109 310 2,755 - - 774 510 284 10,651
Grand
2,10,456 16,432 1,94,024 1,651 144 6,574 2,152 346 1,261 1,817 34,060 2,055 37 9,117 5,661 1,790 1,27,359
Total
Production Summary in Hours Nov-23 to Oct-24(Data Source ERP Data Base- Production ledger)
Section Total Production Hours Rejection Hours Hold Hours Earned Hours
2,00,000
0.9% 0.1%
3.4% 1.1% 0.2% 0.6%
0.9%
1,50,000
17.6% 1.1% 0.0%
Hrs
4.7%
2.9% 0.9%
1.3% 1.0% 0.4%
1,00,000
0
2.3.3 Planned Performance Indicator- IBM
Weekly Man Plastic
Total Available Colour Material Mould Power Production
Section Off / Auxiliary Machine Power Mould No Plan Others CLD Trial Run Hours
Hours Hours Change Short Change Failure / Process
Holiday Short Short
Production Summary in Hours Nov-23 to Oct-24(Data Source ERP Data Base- Production ledger)
Section Total Production Hours Rejection Hours Hold Hours Earned Hours
35,000
20,000
15,000
Oct-23 34,960 4,200 30,760 28 6 383 189 54 32 827 10,819 18 - 1,288 320 1,445 15,351
Nov-23 36,712 3,360 33,352 14 8 70 142 6 64 2,298 10,920 326 - 782 167 489 18,066
Dec-23 37,944 2,416 35,528 13 37 507 40 428 102 2,090 9,674 136 - 1,406 194 939 19,963
Jan-24 38,616 4,968 33,648 24 16 578 18 398 76 1,385 12,278 56 - 1,026 292 764 16,736
Feb-24 35,528 336 35,192 16 28 285 117 222 70 1,972 11,868 59 - 1,408 220 1,028 17,898
Mar-24 39,000 2,424 36,576 48 38 214 457 15 58 2,001 14,181 36 - 378 187 757 18,206
Apr-24 38,880 2,736 36,144 53 35 376 117 193 61 1,716 15,749 442 - 164 543 869 15,825
May-24 40,176 2,640 37,536 52 29 232 25 21 51 1,640 18,062 57 - 1,006 152 767 15,440
Jun-24 37,488 - 37,488 82 33 473 778 21 108 1,834 7,372 122 - 2,374 387 802 23,103
Jul-24 38,687 - 38,687 148 46 705 69 391 49 1,808 7,263 127 - 1,597 225 1,145 25,114
Aug-24 38,688 1,272 37,416 45 35 324 82 33 93 1,814 9,515 48 - 1,713 304 619 22,792
Sep-24 38,106 816 37,290 62 53 463 289 94 179 1,818 3,869 75 - 1,133 282 1,227 27,747
Grand
4,54,785 25,168 4,29,617 586 365 4,611 2,322 1,876 942 21,202 1,31,571 1,502 - 14,275 3,273 10,852 2,36,243
Total
Production Summary in Hours Nov-23 to Oct-24(Data Source ERP Data Base- Production ledger)
Section Total Production Hours Rejection Hours Hold Hours Earned Hours
3,00,000
-1,00,000
Note:
No Plan Splitup
A performance loss of -3933 implies that the actual production exceeds the rated production, suggesting the following possibilities:
1. The actual cycle time is shorter than the standard (STD) cycle time.
2. Additional delays have been recorded beyond the expected time."
2.3.5 Planned Performance Indicator- ISBM
Weekly Man Plastic
Total Available Colour Material Mould Power Production
Section Off / Auxiliary Machine Power Mould No Plan Others CLD Trial Run Hours
Hours Hours Change Short Change Failure / Process
Holiday Short Short
Production Summary in Hours Nov-23 to Oct-24(Data Source ERP Data Base- Production ledger)
Section Total Production Hours Rejection Hours Hold Hours Earned Hours
35,000
0.3% 0.0%
30,000 2.7% 0.2% 0.0% 1.9%
1.8%
25,000
Hrs
20,000
39.7% 1.3% 0.0%
15,000 4.2%
1.8% 0.4% 0.5% 0.4% 0.3%
10,000 Planned Performance Index: 44.5%
5,000
0
Baseline & Evaluation Methodology: SSF Plastics
Weekly off / Holidays= Planned weekly off and Holidays (in Hours) * Number of machines
Planned Planned Operating Hours = God Hours – Weekly off/ Holidays (in hrs.)
Performance
Run Hours = Planned Operating Hours – Machine Non-available time Eqpt. (Non-available
Indicator % includes No plan B/D, C/O, Manpower Shortage, PM etc.)
Oct-23 Nov-23 Dec-23 Jan-24 Feb-24 Mar-24 Apr-24 May-24 Jun-24 Jul-24 Aug-24 Sep-24 Average
EBM
IBM
IM
ISBM Data Not Received from head Office
Indirect
Total Direct
Man-Days
Total
731.81 859.68 872.81 847.45 770.92 794.38 761.06 769.32 885.07 956.45 899.22 928.32 839.71
Production MT
Man-days/MT
Automation 1 3,19,742
Engineering 44 2,13,51,839
Finance & Accounts
4 25,68,832
HR & ADMIN 7 40,85,503
IT Department 1 5,00,874
Logistics & Dispatch 7 41,38,086
Marketing 1 4,29,096
Data Not Received
Materials 11 64,98,513
Production 72 3,79,88,861
Quality 28 1,42,58,465
Safety and Security 1 8,24,997
Tool Room 18 88,40,083
Warehouse 6 28,39,184
Total 201 10,46,44,076
No. of
Total Total
Wind Solar IEX Disel Units Production
Month EB Units Units Units for Units/KG
Units Units Units Unit Consumed In Kg
Consumed Production
in Tooling
F= (A+B+
A B C D E G H= F-G
C+D+E)
Oct-23 1010081 298503 0 0 2100 1310684 39321 1271363 7,39,229 1.72
Nov-23 1167843 352397 0 0 1060 1521300 45639 1475661 8,69,280 1.70
Dec-23 871740 650176 0 0 1740 1523656 45710 1477946 8,77,103 1.69
Jan-24 319396 1065553 0 27359 3360 1415668 42470 1373198 8,51,664 1.61
Feb-24 189767 1177084 0 28713 1040 1396604 41898 1354706 7,76,751 1.74
Mar-24 966897 294496 0 232527 2720 1496640 44899 1451741 8,00,639 1.81
Apr-24 601735 379109 0 426780 1800 1409424 42283 1367141 7,63,107 1.79
May-24 19 980436 0 478021 11520 1469996 44100 1425896 7,76,204 1.84
Jun-24 0 1431468 98753 0 8220 1538441 30769 1507672 8,87,902 1.70
Jul-24 2639 1549741 91368 0 4380 1648128 32963 1615165 9,59,717 1.68
Aug-24 539130 723945 106245 239605 4100 1613025 32260 1580764 9,02,756 1.75
Sep-24 119892 1228735 110931 169373 4660 1633591 32672 1600919 9,31,924 1.72
Total 5789138 10131643 407297 1602379 46700 17977157 474983 17502174 10136276 1.73
2.5 Yield
2.6. Cost Parameters
3. Evaluation Methodology
Key Performance Indicators (KPIs) were set and agreed with the SSF Management during the analysis
phase to measure the performance of the project both operationally as well as financially. The
improvements will be evaluated against the Baselines defined in the Baseline section above at the month
ending.
Total financial benefits will be the net of savings from all the categories put together and any outflow of
expenses to achieve these gains. The methodology to calculate the savings in each of the above-mentioned
case is explained below:
5. Exclusions
Renoir Renoir shall not be liable for non-achievement of the target annualized benefits and or the key
milestone to the extent that the computation of the same is influenced, without limitation, by the
following factors (and thus shall be entitled to invoice and be paid its fees in full):
1. Force majeure situations like strike, protests, storm alert, power failure, floods, disease
outbreak, etc.;
2. Drastic change in manpower absenteeism when compared to the baseline, more than 30%.
3. Unavailability of raw material.
4. Unavailability of spare part due to external factors
5. Utilization loss due to annual/unplanned shutdown of the plant
6. Change in management priorities/ scope of the project
7. Change in raw material mix.
8. Dip in demand in the market.
9. Business situations, as decided by the shareholders and/or the board of the client, that are
beyond Renoir’s reasonable control (e.g. sale or closure of a plant).
10. Non implementation of Renoir’s recommendation by SSF Plastics
Agreement & Sign-off
Mr. Sunil Dhawan (MD - SSF) Mr. Pulkit Dhavan (Ops Director, SSF)
Mr. KVR. Subramaniam (CFO, SSF) Mr. V. Baskar (Factory Head SSF)
Mr. Debadatta (EBM Operation Head SSF) Mr. M.N. Srinivas (IM Operation Head SSF)