1.

Savings in lieu of Enhanced Percentage of Prime Quality Coils

Particulars Apr 2022-Dec 2022 Jan 2023-Jun 2023

Ok Coil Percentage 93.84% 95.95%
Total Production 43031 Tons 63102 Tons

Additional saleable material in the period 01.01.2023 – 30.06.2023 due to successful

implementation of project = [{(95.95-93.84) x 63102}/100] Tons = 1331 Tons

Average NSR of GP (Jan 2023-Jun 2023) = INR 66043 per ton

Average NSR of Steel Scrap (Jan 2023-Jun 2023) = INR 37631 per ton
Difference = (66043 – 37631) = INR 28412 per ton

Monetary savings in the period 01.01.2023 – 30.06.2023 due to successful implementation

of project = (1331 x 28412) = INR 3,78,16,372/-……………………………………………………………..….(A)

2. Savings in lieu of Enhanced Productivity

Particulars Apr 2022-Dec 2022 Jan 2023-Jun 2023

Productivity 346 Tons/Day 497 Tons/Day

Number of Days of Line Run in the period 01.01.2023 – 30.06.2023 = 127 Days

Extra production in the period 01.01.2023 – 30.06.2023 due to successful implementation of

project = (497-346) x 127 = 19177 Tons

Average Contribution of GP Coils = INR 16881 per ton

Average Contribution of HR Coils = INR 15495 per ton
Difference between Average Contribution of GP and HR coils = INR 1386 per ton

Monetary savings due to enhancement in productivity in the period 01.01.2023 – 30.06.2023

through successful implementation of project = INR (19177 x 1386)
= INR 2,65,79,322/-………………….(B)

3. Savings in lieu of Reduction in Zinc Consumption

Particulars Apr 2022-Dec 2022 Jan 2023-Jun 2023

Zinc Consumption 24.91 kg/ton 21.35 kg/ton
Total Production 43031 Tons 63102 Tons

Price of Zinc = INR 2,85,000 per ton

Reduction in zinc consumption in the period 01.01.2023 – 30.06.2023 due to successful

implementation of project = (24.91-21.35) x 63102 kg = 224643 kg = 224.64 Tons
 Monetary savings due to reduction in zinc consumption in the period 01.01.2023 –
30.06.2023 through successful implementation of project = INR (285000 x 224.64)
= INR 6,40,22,400/- …………………(C)

4. Savings in lieu of Time Saved due to elimination of manual welding

Particulars Apr 2022-Dec 2022 Jan 2023-Jun 2023

Number of welds 2194 3363
Average Welding Cycle Time 9.75 mins 2.95 mins

Time saved per weld = (9.75-2.95) mins = 6.8 mins

Number of welds (Jan 2023-June 2023) = 3363
Total time saved = (6.8 x 3363) mins = 22868 mins = 381 hours = 15.88 days

Total Production (Jan 2023-June 2023) = 63102 Tons

Duration of line run (Jan 2023-June 2023) = 127 Days
Line Productivity = (63102 / 127) Tons/day = 497 Tons/day

Extra Production in the period 01.01.2023 – 30.06.2023 due to successful implementation of

project = (15.88 x 497) Tons = 7892 Tons

Average Contribution of GP Coils = INR 16881 per ton

Average Contribution of HR Coils = INR 15495 per ton
Difference between Average Contribution of GP and HR coils = INR 1386 per ton

Monetary savings due to elimination of manual welding in the period 01.01.2023 –

30.06.2023 through successful implementation of project = INR (7892 x 1386)
= INR 1,09,38,312/-…………………(D)

5. Savings in lieu of reduction in manual welder personnel deployment

Particulars Apr 2022-Dec 2022 Jan 2023-Jun 2023

Number of manual welding person deployed 04 02

Reduction in manpower = 02
CLC rate of welder = INR 918 per person per day

Monetary savings due to reduction in manpower deployed in the period 01.01.2023 –

30.06.2023 through successful implementation of project = INR (918 x 26 x 2 x 6)
= INR 2,86,416/- …….….……………(E)

6. Cost of Project Implementation

Cost of Wire Feeder Machine = INR 15600/-

Cost of 5 kg Inconel 625 Spool = INR = 32500/-
Total cost of Project Implementation = INR 48100/-…………………………………………..………………(F)
TOTAL SAVINGS IN THE PERIOD 01.01.2023 – 30.06.2023 THROUGH SUCCESSFUL IMPLEMENTATION
OF PROJECT (A+B+C+D+E-F) = INR 13,95,94,722/-