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PHILIPPINE RECYCLERS INC.

2007 QEMS Management Review


August, 2007

IMEE ACUBA
2007 (Jan-Aug)
Sectional
Performance
OPERATIONS GROUP
PERFORMANCE SUMMARY

August, 2007 PRI 1st Sem QEMS Management Review 3


RAW MATERIALS
PREPARATION
PERFORMANCE SUMMARY

August, 2007 PRI 1st Sem QEMS Management Review 4


QUALITY PERFORMANCE : Areas for
Improvement
Objective: Target: Average / Actual: %Acc
Compliance to Fill Rate; Supply grids and oxides 100% 78.73% 78.73%
based on BBM’s utilization and output
requirements
BBM Monthly Output
4,000

3,500
Grids and Oxides

3,000
Metric Tons of

2,500

2,000

1,500

1,000

500

0
JAN FEB MAR APR MAY JUN JUL AUG

JAN FEB MAR APR MAY JUN JUL AUG

'07 Actual 2,721 2,219 2,871 2,078 2,280 2,092 2,707 2898

'07 Target 3,119 2,185 2,734 1,973 2,283 2,211 3,900 3900

Fill Rate 87.24% 101.56% 105.01% 105.32% 99.87% 94.62% 69% 74%

August, 2007 PRI 1st Sem QEMS Management Review 5


Objective: Target: Actual: % Acc
Compliance to Fill Rate; Supply grids and 100% Fill 78.73% 78.73%
oxides based on BBM’s utilization and output Rate
requirements
ANALYSIS OF ACTION PLANS TIMETABLE RESOURCE
DEVIATION S
REQUIRED
Started late in the Commence early in the year but 2008 U.L.A.B.
month of January’07 ensure ULAB availability availability

Scarcity in ULAB SCM-MC concern SCM-MC


supply concern

 Unexpected Improve Autonomous maintenance As per CPM’s Continuous


Machine Downtimes skills schedule of TPM
and delays implementat trainings,
ion seminars,

 delays attributed to Improve planning & analysis before as project Planning &
new task (grid implementation of new tasks arises Analysis
screening) tools

August, 2007 PRI 1st Sem QEMS Management Review 6


Objective: Target: Ave. / Actual %Acc

Compliance to % Sulfur Less than 2% Sulfur 1.92% Sulfur 100%


Content on Oxides Analyses Content
Specifications

% Sulfur Content
2.50

2.00
Percent Sulfur Content

1.50
(%)

1.00

0.50

0.00
J AN FEB MAR APR MAY J UN J UL AUG

JAN FEB MAR APR MAY JUN JUL AUG


'07 Actual 1.26 1.49 1.61 1.31 1.52 1.29 1.7 2.3
'07 Target 2.00 2.00 2.00 2.00 2.00 2.00 2.00 2.00

August, 2007 PRI 1st Sem QEMS Management Review 7


Objective: Target: Average / Actual: %Acc
100% compliance to % Sulfur Zero Exceedances on %S 59.83 % 59.83 %
Content on Oxides Analyses analyses / results

% Compliance on Sulfur Contents


100.00

80.00
Percent Compliance on
Sulfur Content

60.00
(%)

40.00

20.00

0.00
J AN FEB MAR APR MAY J UN J UL AUG

JAN FEB MAR APR MAY JUN JUL AUG


'07 Actual 91.89 83.61 77.16 88.52 80.60 98.39 71.7 38.46
'07 Target 100 100 100 100 100 100 100 100

August, 2007 PRI 1st Sem QEMS Management Review 8


Objective: Target: Actual: %Acc
Compliance to specifications(%S < 100% compliance 59.83 % 59.83 %
or = 2.0%)
ANALYSIS OF DEVIATION ACTION PLANS REVISED ADDITIONAL
TIMETABLE REQUIRED
RESOURCES
Average: Implement manual on-going projects Automation of
%S = 1.92% monitoring measures for process Desulphurization
Although the average is less than the to countercheck controls on processes, Sulfur
results of analyses desulphurization Analyzer, reliable (pH
required compliance, off-shoots beyond
2% are incurred because of analyses & while the processes sensors, pH meters
other experimental necessities needed are undergoing and transmitters), on-
experiments. line process recorders
in 6-σ & SPC projects.
Inaccurate pH readings due to oxide Continuous on-going… Sulfur Analyzer,
build up on sensors during processes Improvement Efforts CapEx & OpEx- accurate (pH sensors,
With Technical and pH meters, and
based projects
Engineering transmitters), on-line
Departments AUG 1-31 process recorders
Although the average is less than the  experiment on Aug to Oct BCM
required compliance, off-shoots beyond soda ash  battery puncher
2% are incurred because of analyses & desulfurization  20Kgal reactor tank
other experimental necessities needed  draining of battery  filter press w/
in 6-σ & SPC projects. acid backwash
 experiment on
lowering moisture
content
Dilution washing
Cake rewashing
August, 2007 PRI 1st Sem QEMS Management Review 9
SWOT ANALYSIS
Strengths Weaknesses
oCompetent personnel oAging workforce
oTeamwork oToo eager to conduct experiments
oStrategically agile resulting to recurring deviations in PDN-
oCan directly support refining by producing procedure.
meltable grids and lugs oReactive maintenance instead of
oCan support blast by producing rails preventive / proactive maintenance
oManagement team exhibits the corporate oNot able to consistently provide
core values customer needs (i.e. %S, %moisture)
oCan perform Autonomous Maintenance oSemi-mechanized operations
oWorking environment needs
improvement i.e. lightings, platform,
GHK,
oLimited workspace due to increasing
Opportunities process
Threats capabilities
oCan directly produce lead bullions oExperiments may be extended longer
oNew employees can pour in new ideas to the oExperiment may yield a “different”
operation result
oManning for 3rd shift may not be
provided on-time

August, 2007 PRI 1st Sem QEMS Management Review 10


SMELTING SECTION
PERFORMANCE SUMMARY

August, 2007 PRI 1st Sem QEMS Management Review 11


QUALITY PERFORMANCE : Areas for Improvement
Objective Target (YTD-Sept) Actual (YTD - Sept) % Acc
Conversion Cost Blast – P5.35/kg Blast – P6.23/kg Blast – 84%
Reverb – P6.18/kg Reverb – P5.33/kg Reverb-100%

Reverb
Blast
9 14

8 12
7
10
6

5 8

4 6
3
4
2

1 2

0 0
J F M A M J J A S J F M A M J J A S
Actual 5.79 5.78 5.99 8.38 7.41 5.7 5.64 6.26 6.79 Actual 5.19 4.8 4.36 4.97 5.9 12.3 - 5.07 4.89
Target 5.75 5.75 5.76 5.19 5.19 3.31 5.45 6.09 6.11 Target 6.15 6.06 5.98 1.59 5.19 - 5.31 5.32

August, 2007 PRI 1st Sem QEMS Management Review 12


Objective Target (yr to date-Sept) Actual (yr to date - % Acc
Sept)

Conversion Cost Blast – P5.35/kg Blast – P6.23/kg Blast – 84%


Reverb – P6.18/kg Reverb – P5.33/kg Reverb-100%

ANALYSIS OF DEVIATION ACTION PLANS REVISED TIMETABLE

Blast: April-May 2007 Redesign feed chute to Done


-Process problem prevent clogging of feed
Drossing at
leadwell which Blast: 25-30 tons On-going
caused 3 production/
shutdowns of the shift
blast
-Coke consumption is
below target of
130kg/MT but the
increase in price offset
the savings

August, 2007 PRI 1st Sem QEMS Management Review 13


Objective Target (YTD) Actual (YTD) % Acc

Furnaces Production Output 3643 MT 3642 MT 94%

5000
4000
3000
2000
1000
Jan Feb Mar Apr May Jun Jul Aug Sept

Actual 2891 3311 3963 2459 3117 2493 2206 3701 4140
Target 3500 3500 3500 3500 3500 2500 2340 3900 4000

August, 2007 PRI 1st Sem QEMS Management Review 14


Objective Target (YTD) Actual (YTD) % Acc
Furnaces Production Output 3643 MT 3642 MT 94%

ANALYSIS OF DEVIATION ACTION PLANS

Feed requirements for 3,500 tons per month not Status quo until the supply improves
supplied

March-May 07 -1day no production/month due to


unavailability of feed materials

August, 2007 PRI 1st Sem QEMS Management Review 15


Objective Target Actual: YTD % Acc

Conversion Cost (APM (yr to date – Sept) P 2.06/kg FL 97%


operations) P 1.92/ kg FL

3
PESO / kg bullion

0
J AN FEB MAR APR MAY J UN J UL AUG SEPT

ACTUAL 2.65 1.87 1.81 2.12 2.33 2.01 2.19 1.92 1.78

TARGET 2.46 2.41 2.5 2.17 1.58 1.5 1.94 1.77 1.78

August, 2007 PRI 1st Sem QEMS Management Review 16


Objective Target Actual: YTD % Acc
Conversion Cost (APM (yr to date – Sept) P 2.06/kg FL 97%
operations) P 1.92/ kg FL

REVISED
ANALYSIS OF DEVIATION ACTION PLANS TIMETABLE

o experiment was done last week


of sept to establish optimum
flowrate setting for naoh for each
feed combination @ both furnaces
-also Last month, experimental
runs have been conducted for the
optimization of soda ash usage by
RMP section with the coordination
of technical section.by this
experiment some adjustment in
our caustic consumption was done
in scrubber operation to comply to
our stack emission.

August, 2007 PRI 1st Sem QEMS Management Review 17


SWOT ANALYSIS
Strengths Weaknesses
oCompetent workforce oFrequent breakdown of machine & equipment
oTechnically competent engineers i.e. loaders, forklifts, hoist, RSF, baghouse,
oStrategically agile roots blower
oHigh Absenteeism rate
oAble to respond to the need of the
customer oHigh LIB
oEstablished new methods i.e. spc projects, oLabor grievances
method development projects oReactive at times
oAvailability of resources i.e. approved capex oLapses in implementation of procedures
oInternal communication system
oInconsistencies in the implementation of GHK
oSmoke and odor emission

Opportunities Threats
oImprovement projects thru SPC oUnplanned shutdown of machine and
oMechanization of blast & reverb operation ie. equipment
Feeding activities, clearing activities oInsufficient supply of feed materials
oBenchmarking oNon-approval of Capex
oTechnical trainings abroad oPower failures
oFurther reduction of resource consumption i.e. oMachine design flaws
fuel, chemicals, electricity oNeighbor complaints due to odor and smoke
o4500MT/mo production output emissions
oFull implementation of TPM

August, 2007 PRI 1st Sem QEMS Management Review 18


REFINING SECTION
PERFORMANCE SUMMARY
(Jan-June, 2007)

August, 2007 PRI 1st Sem QEMS Management Review 19


QUALITY PERFORMANCE : Success(es)

Objective Target Actual % Acc


Conversion Cost P2.72 / MT Pb P2.36 / MT Pb Year-to- 100%
Year-to-date date

3
PESO / MT Pb

0
J AN FEB MAR APR MAY J UN J UL AUG SEPT

ACTUAL 2.48 1.97 2.08 2.28 2.80 3.00 2.42 2.24 2.04

TARGET 2.74 2.72 2.74 2.74 3.12 2.84 2.79 2.48 2.48

August, 2007 PRI 1st Sem QEMS Management Review 20


Objective Target Actual: YTD % Acc
Reduction of Dross Generation 12% 12% 100%
(cumulative)
ACTION PLAN STATUS REVISED RESPONSIBLE
TIMETABLE
1. Dry Dross Expt on-going Jul-Dec ’07 GST
6 sigma project
2. Pellets Dross Expt on-going Jul-Dec ’07 GST
6 sigma project

3.Sulfur Dross Expt being done Jul-Dec ’07 MCA


-use of charcoal to reduce %Pb MSA on dross
-develop Sulfur usage calculator PR-awaiting delivery
-explore use of saw dust instead
of charcoal

4.Aluminizing Dross Expt being done Jul–Dec 07 MCA


-reduce alum usage to reduce
dross
-modify alum usage calculator

August, 2007 PRI 1st Sem QEMS Management Review 21


Objective Target Actual: YTD % Acc
Reduction of Dross Generation 12% 12% 100%
(cumulative)

ACTION PLAN STATUS REVISED RESPONSIBLE


TIMETABLE

5. CN Dross BEING DONE Jul-Dec ’07 BMF


-reduce CN usage
*Standardize: if Sb <
50ppm,
use only 1 bag caustic
instead of 2 bags
6.Tin Dross o some yellow Jul-Dec ’07 BMF
-use all yellow dross for dross
Sb removal processing Still transferred to
smelting chamber
-storage of yellow dross
o boxes for grid
-clearing of alum drosses at
melting will be
dross area
used for storing
yellow dross

August, 2007 PRI 1st Sem QEMS Management Review 22


QUALITY PERFORMANCE : Areas for
Improvement
Objective Target Actual % Acc

Produce Finished Lead required by 100 % 96 % Fillrate 96%


Warehouse for delivery to customers Fillrate Year-to-date

100

80
% FILLRATE

60

40

20

0
J AN FEB M AR APR M AY J UN J UL AUG SEPT

ACTUAL 100 100 100 87 81 100 96 100 100


TARGET 100 100 100 100 100 100 100 100 100

August, 2007 PRI 1st Sem QEMS Management Review 23


Objective Target Actual: YTD % Acc

Produce Finished Lead 100 % Fillrate 96 % Fillrate Year- 96%


required by Warehouse to-date
for delivery to customers

REVISED ADDITIONAL
ANALYSIS OF DEVIATION ACTION PLANS RESOURCES
TIMETABLE REQUIRED

Lack of available *RECOVER June – Dec ‘07


furnace lead due to other sources of
lack of raw materials lead
- scattered lead
- from Slag
- from spilled lead

*Grid melting July ’07 and as Grid feeder


necessary Mech.
skimmer

August, 2007 PRI 1st Sem QEMS Management Review 24


Objective Target Actual % Acc

Improve temp 100% design 75% design 75%


Monitoring capability/ completion (1st sem) completion
Automation of Burners Complete installation
(2nd sem)

REVISED ADDITIONAL
ANALYSIS OF
ACTION PLANS RESOURCES
DEVIATION TIMETABLE REQUIRED
Delay in approval of Awaiting for Installation – dec’ Design meetings
Capex for autoburners autoburners (1 unit 07 with Tech &
for delivery) Engg
Operational – jan
2008

August, 2007 PRI 1st Sem QEMS Management Review 25


Objective Target Actual: YTD % Acc

Predictability of refining 100% model completion 50% model 50%


process completion

ANALYSIS OF DEVIATION ACTION PLANS REVISED


TIMETABLE

Design of a working Completion of the Dec 07


MS Access program is Access program
still on-going

August, 2007 PRI 1st Sem QEMS Management Review 26


SWOT ANALYSIS
Strengths Weaknesses
oCompetent engineers oHigh LIB / with medical issues
oStrategically agile oLimited production workspace / storage areas
oCan readily shift from one type of alloy oSmoke emissions
to the other as required by the customer
oReadily available spares of equipment
i.e. stirrers, lead pumps, combustion
blowers
oCan process other lead aside from
furnace lead that can be refined i.e. Grid
melting
oMulti-tasking personnel i.e. can perform both
refiner/caster job
oImproved processing time by the development
of new refining method i.e. sn/sb removal
oAlloying/mixing program
oRegular assessment of refining system

Opportunities Threats
oMechanization of process i.e. skimming, oBreakdown of major equipment like overhead
feeding of materials into kettles, color coding of crane, casting machine, kettles, OES
lead bars, temperature monitoring

August, 2007 PRI 1st Sem QEMS Management Review 27


OPERATIONS SUPPORT GROUP
PERFORMANCE SUMMARY

August, 2007 PRI 1st Sem QEMS Management Review 28


ENGINEERING/MAINTENANCE
PERFORMANCE SUMMARY

August, 2007 PRI 1st Sem QEMS Management Review 29


QUALITY PERFORMANCE : Success(es)
Objective Target Actual: YTD % Acc
Machine Availability 95% % 100%

100

98

96

94

92
90
Jan Feb Mar Apr May Jun Jul Aug Sept

Availability 92.92 95.22 98.54 95.93 95.08 96.42 97.36 93.23 95.82
Target 95 95 95 95 95 95 95 95 95

Target
August, 2007 PRI 1st Sem QEMS Management Review 30
Objective Target Actual: YTD % Acc

Service Level (R3) Planned 93.89% 100%


Maintenance
90% compliance

100

95

90

85

80
Jan Feb Mar Apr May Jun July Aug

% Compliance 99.12 100.00 98.36 93.62 88.07 96.00 92.72 94.38


Target

August, 2007 PRI 1st Sem QEMS Management Review 31


Objective Target Actual: YTD % Acc

Power Factor Corrector 90% 98.29% 100%

25,000.00
100

80
20,000.00
60

40 15,000.00
20

0 10,000.00
J F M A M J J A S J F M A M J J A

% Compliance 99.1 97.9 94.9 99.6 100 99.7 95.9 99.2 95.7 Php Savings 21,99318,96116,79817,64120,31421,66720,98521,083

August, 2007 PRI 1st Sem QEMS Management Review 32


QUALITY PERFORMANCE : Areas for
Improvement
Objective Target Actual: YTD % Acc
Meantime to Repair (R2) 3 hrs 7.59 hrs 88%

15

10

0
Jan Feb Mar Apr May Jun Jul Aug

# of hrs 2.17 1.58 1.53 2.00 1.85 1.45 2.5 13.1


Target 3 3 3 3 3 3 3 3
Target

August, 2007 PRI 1st Sem QEMS Management Review 33


Objective Target Actual: YTD % Acc
Meantime to Repair (R2) 3 hrs 7.59 hrs 88%

ANALYSIS OF DEVIATION ACTION PLANS REVISED


TIMETABLE
Worn-out of bushing oReplacement of all Sept 2007
on gearbox worn-out bushings
mechanical shaft of oInspection of
shaking table bushings will be
included in the
Long repair time inspection checklist
Provide spare Sept 2007
because of machine fabricated hinges and
fabrication bolts

Insufficient Increase frequency of Sept 2007


lubrication greasing and
lubrication from
monthly to weekly

August, 2007 PRI 1st Sem QEMS Management Review 34


Objective Target Actual: YTD % Acc

Service Level for 80% technically Ave: 71.06% 89%


Maintenance Request (R1) completed

100
80

60
40

20

0
Jan Feb Mar Apr May Jun Jul Aug

% Completed 98.77 99.70 99.50 89.38 69.49 75.21 56.38 74.64


Target

August, 2007 PRI 1st Sem QEMS Management Review 35


Objective Target Actual: YTD % Acc
TPM implementation Autonomous 99.34% 99.34%
Maintenance
100% compliance

100

80
60

40

20

0
Jan Feb Mar Apr May Jun Jul Aug Sept

% Compliance 99.2 98.6 97.9 97.2 97.5 97.1 100 100 100

August, 2007 PRI 1st Sem QEMS Management Review 36


Objective Target Actual: YTD % Acc

TPM implementation Autonomous Maintenance 99.34% 99.34%


100% compliance

ANALYSIS OF DEVIATION ACTION PLANS TIMETABLE

Inconsistency w/ the --Establish TPM sectional October 2007


Production Schedule champions
- TPM program is not -Set-up and confirmation of TPM July – December 2007
properly coordinated w/ activities with Production
Production Planners.
- Establish Basic Equipment
Condition (Stabilizes Failure
Establish CLAIR Standards Intervals)
- Re-training of production - July - September 2007
operatives with focus on CLAIR - August – December 2007
standards.
- Formulation of Standard - October 2007
Checklist including training
- Abnormality Tag Implementaion
- December 2007
- Certification of Operators on
Cleaning Standards.

August, 2007 PRI 1st Sem QEMS Management Review 37


SWOT ANALYSIS
STRENGTHS WEAKNESSES
oCompetent workforce oHigh LIB
oTeamwork oExposure of maintenance personnel
oManpower utilization to pollutants during conversation
oAvailability of critical spares while repairing equipment at high
risk areas
oClearly defined objectives
oInconsistencies in project turnover
oClear distribution of tasks
procedures
oSAP-PM utilization oInconsistency in the dissemination
oIn-house fabrication capability of information regarding the project
or the request
oHigh electricity cost
oInefficiencies in monitoring of
electrical consumption
oInaccurate allocation of sectional
electrical consumption

August, 2007 PRI 1st Sem QEMS Management Review 38


SWOT ANALYSIS
OPPORTUNITIES THREATS
oTraining abroad oLack of support from process owners in TPM
oMechanization of production implementation
processes oLack of concern from process owners
oUse of Bio-diesel regarding use of equipment resulting to
property
damage
oInefficiencies in Purchasing system (lead time,
quality)
oImproper use of heavy equipment
oHigh restoration cost for deteriorated heavy
equipment
oLack of monitoring of production supervisors
during repair of their equipment
oNon-approval of capex i.e. 50HP compressor,
payloader
oContaminated equipment from production
brought to the area

August, 2007 PRI 1st Sem QEMS Management Review 39


BPWM
(SIWM, WWTF, PRF)
PERFORMANCE SUMMARY

August, 2007 PRI 1st Sem QEMS Management Review 40


ENVIRONMENTAL PERFORMANCE :
Success(es)
Objective (SIWM) Target Actual: YTD % Acc
Implement water recycling 250,000 gallons per 356,149 gallons 100%
and minimization month
(Average)

Process Water usage,


in Gallons
800,000
700,000
600,000
500,000
400,000
300,000
200,000
100,000
0
Jan Feb Mar Apr May Jun Jul A ug

Target 2007 Actual

August, 2007 PRI 1st Sem QEMS Management Review 41


ENVIRONMENTAL PERFORMANCE :
Success(es)
Objective (SIWM) Target Actual: YTD % Acc
Generate Revenue from P 168,000 per P 186,811.33 100%
non-lead wastes month (Average)

Sales from Wastes,


in PhP
400,000
350,000
300,000
250,000
200,000
150,000
100,000
50,000
0
Jan Feb Mar Apr May June July Aug

Target 2007 Actual

August, 2007 PRI 1st Sem QEMS Management Review 42


Objective (SIWM) Target Actual: YTD % Acc
Objective : Target Actual : 100%
Support the disposal of 40 MT per month 87.88 MT
Aluminizing dross (Average)

Aluminum Dross Disposal,


in MT
150
130
110
90
70
50
30
10
-10
Jan Feb Mar Apr May June July Aug

Target 2007 Actual

August, 2007 PRI 1st Sem QEMS Management Review 43


Objective (WWTF) Target Actual: YTD % Acc
Conversion Cost P0.26 /GAL WW P0.14 /GAL WW 100%
Treated Treated

1
PESO / WW Treated

0.8

0.6

0.4

0.2

0
J AN FEB M AR APR M AY J UN J UL AUG

ACTUAL 0.13 0.13 0.13 0.13 0.14 0.23 0.13 0.10


TARGET 0.26 0.26 0.26 0.26 0.26 0.26 0.26 0.26

August, 2007 PRI 1st Sem QEMS Management Review 44


Objective (WWTF) Target Actual: YTD % Acc

Recycling of wastewater 250,000 gals. min 266,220 gals. 100%

800,000
700,000
600,000
500,000
400,000
gals.

300,000
200,000
100,000
0
J AN FEB M AR APR M AY J UN J UL AUG

ACTUAL 236,675 136,845 702,698 425,330 711,965 249,650 259,679 196,814


TARGET 250000 250000 250000 250000 250000 250000 250000 250000

August, 2007 PRI 1st Sem QEMS Management Review 45


ENVIRONMENTAL PERFORMANCE : Areas for Improvement

Objective (SIWM) Target Actual: YTD % Acc


Maximize the usage of 15 MT per month 11.97 MT 80%
cheaper internally cut scrap (Average)
iron

Scrap Iron Cutting,


in MT
30
25
20
15
10
5
0
Jan Feb Mar Apr May June July Aug
Target 2007 Actual

August, 2007 PRI 1st Sem QEMS Management Review 46


Objective(SIWM) Target Actual % Acc
Maximize the usage of 15 MT per month 11.97 MT 80%
cheaper internally cut (Average)
scrap iron
ANALYSIS OF DEVIATION ACTION PLANS REVISED ADDITIONAL
TIMETABLE RESOURCES
REQUIRED
 Minimal transfer of Pursue capex approval 2008 PAYLOADER
scrap iron due to for payloader VRC
payloader breakdown

 Scrap iron cutting Relocate cutting On-going Building, concrete


operation at Adjacent operations beside materials, contractor,
lot was stopped contractor’s fabrication approved quotations
because of potential area
fire hazard threat as
per Health and Safety
( april)

 Smelting stopped oContinue cutting of ¼” Temporary area for


iron transfer because thk or more iron holding iron, contractor,
they want to use oSell less than ¼” thk cover
billets (may) iron through bidding
oResume transfer of iron
when smelting gives the
go signal

August, 2007 PRI 1st Sem QEMS Management Review 47


Objective (SIWM) Target Actual: YTD % Acc
Maximize production of Lead 240 MT per month 223 MT 93%
Grids recovery from wastes on three shifts (Average)

Lead Grids Recovery from Wastes,


in MT
350

300

250

200

150

100

50

0
Jan Feb Mar Apr May June July August

Target 2007 Actual

August, 2007 PRI 1st Sem QEMS Management Review 48


QUALITY PERFORMANCE : Success(es)
Objective (PRF) Target Actual: YTD % Acc
Maximize Processing 85 % Process % 100%
Efficiency Efficiency

PRF Process Efficiency


100.00
Process Efficiency

80.00

60.00

40.00

20.00

0.00
J AN FEB MAR APR MAY J UN J UL AUG SEPT

JAN FEB MAR APR MAY JUN JUL AUG SEPT


'07 Actual 85.04 83.48 84.74 84.97 84.50 87.68 85.56 86.14 86.05
'07 Target 85.00 85.00 85.00 85.00 85.00 85.00 85.00 85.00 85

August, 2007 PRI 1st Sem QEMS Management Review 49


QUALITY PERFORMANCE : Areas for
Improvement
Objective (PRF) Target Actual: YTD % Acc
Consistent & Reliable PPP Chips 206 MT-Input of PPP Ave.: MT %
Processing Chips/month

PRF Monthly Input


250.00
Metric Tons of GRPPBK

200.00

150.00

100.00

50.00

0.00
J AN FEB MAR APR MAY J UN J UL AUG SEPT

JAN FEB MAR APR MAY JUN JUL AUG SEPT


'07 Actual 180.74 207.44 236.30 186.00 159.00 195.88 219.14 183.92 185.96
'07 Target 206.00 206.00 206.00 206.00 206.00 206.00 206.00 206.00 206

August, 2007 PRI 1st Sem QEMS Management Review 50


Objective (PRF) Target Actual: YTD % Acc
Consistent & Reliable PPP 206 MT-Input of PPP Ave.:194 MT 94%
Chips Processing Chips/month
ANALYSIS OF ACTION REVISED
DEVIATION PLANS TIMETABLE
Major Breakdowns of Speed-up Spare Unit Fabrication through Acquisition of spare
Granulator Assembly R.T.I. granulator assembly
Consistent follow-ups (with RTI & SCM-MP) by Mid-September
& repetitive inquiries on CER#:07-012 2007 (2 to 3 months
PR#11-550920 duration of
fabrication)

Spares unavailability Ensure 1 unit spare per critical part Complete spares
such as: sets of blades, availability come end
motors, pumps of Sept ‘o7

August, 2007 PRI 1st Sem QEMS Management Review 51


Objective (PRF) Target Actual: YTD % Acc
Consistent & Reliable PGF 175 MT-GRPPBK / Month 166 MT- GRPPBK 94%
Monthly Output

PRF Monthly Output


200.00

150.00
Metric Tons

100.00

50.00

0.00
JAN FEB MAR APR MAY JUN JUL AUG

JAN FEB MAR APR MAY JUN JUL AUG


2007 Actual 153.70 173.18 200.25 158.05 134.35 171.75 187.5 158.43
2007 Target 175.00 175.00 175.00 175.00 175.00 175.00 175.00 175.00

August, 2007 PRI 1st Sem QEMS Management Review 52


Objective (PRF) Target Actual: YTD % Acc
Consistent & Reliable PGF 175 MT-GRPPBK / Month 166 MT- GRPPBK 94%
Monthly Output
ANALYSIS OF ACTION REVISED
DEVIATION PLANS TIMETABLE
Minor breakdowns of Continue TPM applications & Engineering’s Implemented
auxiliary machines, PM (R3/R5) schedule and activities)
equipment & mechanisms

Major Downtime on Speed-up Spare Unit Fabrication by R.T.I. Acquisition by Mid-


Granulator Assembly Consistent follow-ups & repetitive inquiries September 2007
with RTI & SCM-MP (earliest)

August, 2007 PRI 1st Sem QEMS Management Review 53


Objective (PRF) Target Actual: YTD % Acc
100% Fill Rate to PBI-SMPP Deliver 170 MT- 161 MT Delivered 95%
Ground Plastics to
SMPP

PRF's GRPPBK Delivery


200

150
Metric Tons

100

50

0
J AN FEB MAR APR MAY J UN J UL AUG

JAN FEB MAR APR MAY JUN JUL AUG


'07 Actual 141.37 148.98 182.90 125.56 144.82 167.49 174.65 157
'07 Target 170.00 170.00 170.00 170.00 170.00 170.00 170.00 170.00

August, 2007 PRI 1st Sem QEMS Management Review 54


Objective (PRF) Target Actual: YTD % Acc

100% Fill Rate to Deliver 170 MT- 161 MT Delivered 95%


PBI-SMPP Ground Plastics
to SMPP
ANALYSIS OF ACTION REVISED ADDITIONAL RESOURCES
DEVIATION PLANS TIMETABLE REQUIRED

Only 22 deliveries 25 - 7 MT On-going 175 Metric Tons of Ground


for the month of deliveries as SMPP Plastics Output and 25 Trips
August (19-7MT requires from our Trucking
deliveries & 3 haul- Contractor every month.
outs below 7MT)
Note:
157 MT delivered to
SMPP (83%) and 3J
(17%) out of
produced 158.43 MT
Ground Plastics

August, 2007 PRI 1st Sem QEMS Management Review 55


SWOT ANALYSIS(SIWM)
Strengths Weaknesses
oProcess capability improvements thru SPC oLabor intensive
& Six Sigma tools oMostly casuals
oAdded Revenue from selling of wastes oOnly 6 regulars
oFESI technology is capable to meet 5ppm oHuge inventory of wastes
TCLP std on blast slag and PVC tails oUnable to treat wastes due to limited
oAble to recover lead from wastes storage space and no legal disposal site
oInconsistent TCLP results for mid sized and
oversized PVC wastes
oInefficient chemical dispenser
oEfficiency and reliability of FESI process
needs improvement

Opportunities Threats
oCapability to treat hazardous lead oNon-utilization of PE separators as
waste from other companies heat source in smelting
oPossible sales of blast slag process(195MT/mo)
oLess treatment and disposal cost oHigh disposal cost
using FESI technology oPossible closure of PRI plant due to
stockpile of wastes

August, 2007 PRI 1st Sem QEMS Management Review 56


SWOT ANALYSIS(WWTF)
STRENGTHS: WEAKNESSES:
oCompetent personnel oLimited treatment capacity
oLow LIB oHigh R&M cost
oTeamwork oLimited workspace
oCreative oHigh corrosion on steel structures and
oHigh OEE equipment
oStable process oInadequate ventilation system
o100% water recycling for lead grids
recovery
oMaterials are readily available with
acceptable quality
oCompliant to lead in air workarea
OPPORTUNITIES: THREATHS:
oWater recycling in tecnofer, slurrification oLack of awareness of other sections on
process, SCM-MC container and truck water utilization
washing oLong repair time of spares
oIncrease treatment capacity oIncreasing caustic consumption due to
oNew wwtf will reduce operating time ,less Low pH discharge from scrubber & battery
manning, R&M cost breaking process
oSoil erosion at WWTF area
oFlooding

August, 2007 PRI 1st Sem QEMS Management Review 57


SWOT ANALYSIS(PRF)
STRENGTHS: WEAKNESSES:
oExpertise in plastic granulation oCapacity is limited to 175MT/mo
oFree raw materials ground plastics
oEfficient machine operation and oShared forklift and payloader usage
process control oLimited storage / working area
oCost effective operation oLimited to one customer
oLimited to one hauler
oCannot process PHR chips because
of limited capacity
OPPORTUNITIES: THREATHS:
oProcess PHR chips instead of selling to oOperation is dependent on Raw
subcontractor material preparation operation
oSell excess production when PRI oRTI’s long lead time on spares
decides to buy another tecnofer fabrication
oIncrease capacity of PBI from 175 to
240 mt or more due to imported
plastic flakes

August, 2007 PRI 1st Sem QEMS Management Review 58


FACILITIES MANAGEMENT
PERFORMANCE SUMMARY

August, 2007 PRI 1st Sem QEMS Management Review 59


QUALITY PERFORMANCE : Success(es)
Objective Target Actual: YTD % Acc
Service Level for 85% technically 86% 100%
Maintenance Request (R1) completed

100

80

60

40

20

0
Jan Feb Mar Apr May Jun Jul Aug

% Completed 92 96 83 66 62 78 92 90

August, 2007 PRI 1st Sem QEMS Management Review 60


QUALITY PERFORMANCE : Areas for
Improvement
Objective Target Actual: YTD % Acc
Service Level for 95% technically 92% 97%
Maintenance Request (R3) completed

100

80

60

40

20

0
Jan Feb Mar Apr May Jun Jul Aug

% Completed 92 96 83 66 62 78 95 100

August, 2007 PRI 1st Sem QEMS Management Review 61


Objective Target Actual: YTD % Acc
Service Level for Maintenance 85% technically 86% 100%
Request (R1) completed (revised
target for july)
ANALYSIS OF DEVIATION ACTION REVISED
PLANS TIMETABLE
1. PCW Planner is overwhelmed - Additional back-up personnel August 2007
w/ SAP transaction & Project for SAP PM transactions for PCW
Drawing & Cost estimate of Projects
projects - External Services for Drafting
- PCW Planner is the only Works
one who does SAP-PM
confirmations.
2. Delayed confirmation of PCW -Request for new PC & user ID for August 2007
Planner Eng’g Planners
- Limited SAP User ID -Weekly Reconciliation w/ purchasing On-going
- delayed delivery of Materials to update back logs & correct
deficiency.
- Lack of specification on
-Revise project completion
pare parts
target/phase (R1/R3)
- Late releasing of PR
a.Phase 1- notification-order creation
- Partial Delivery of project
-Phase 2-order creation-pr creation
materials
-Phase 3-implementation-completion
- Delayed processing of
Labor

August, 2007 PRI 1st Sem QEMS Management Review 62


FACILITIES PROJECTS : UPDATE
ACTIVITY STATUS
Relocation of Filter Press Done
o Construction of Foundation &
platform
Construction of Foundation for the Done
Expanded
Reverb
Construction of Fence PRIANNEX III Lot Done
Land Development PRI-ANNEX III Lot Waiting for the Awarding of qualified
Contractor
Construction of Deep well # 3 Done
Design and Construction of Lead Waiting for the issuance of BLDG. Permit
Decontamination Facility
a. Construction of New QA/Laboratory
b. Relocation of QA/Laboratory
c. Renovation of R & F Locker Area
d. Construction of Casual Locker Area
e. Construction of Lead Decontamination
Area

August, 2007 PRI 1st Sem QEMS Management Review 63


SWOT ANALYSIS(PRF)
Strengths Weaknesses
oProactive personnel oInconsistency in the dissemination of
oCapable to train CMMS using SAP information regarding the project or
basis the request
oFacilities PM full implementation oLack of resources for facilities
oMRP implementation maintenance i.e sweeper, power
spray, lawn mower

Opportunities Threats
oHighly available support from oHigh facilities maintenance cost due
Integrated engineering and SBDI to corrosion i.e buidings and grounds
oPoor quality workmanship of
contractors
oUntimely delivery of project
materials and spare parts

August, 2007 PRI 1st Sem QEMS Management Review 64


FINISHED LEAD WAREHOUSE
PERFORMANCE SUMMARY

August, 2007 PRI 1st Sem QEMS Management Review 65


•Attained targeted
QUALITY PERFORMANCE
inventory :accuracy
Success(es)
Objective: Target Actual % Acc
Maintain accurate finished lead Inventory=10 100% 100%
inventory- SAP VS. ACTUAL 0% Accuracy

INVENTORY ACCURACY
120%

100%
Percentage

80%

60%

40%

20%

0%
JAN FEB MAR APR MAY JUN JUL AUG SEPT
ACT UAL 100% 100% 100% 100% 100% 100% 100% 100% 100%
TARGET 100% 100% 100% 100% 100% 100% 100% 100% 100%
Month

August, 2007 PRI 1st Sem QEMS Management Review 66


QUALITY PERFORMANCE : Areas for
Improvement
Objective Target Actual % Acc
Supply all PBI LEAD Requirements 100 % 99 % Fillrate 99%
Fillrate Year-to-date

120%
100%
80%
RATE

60%
40%
20%
0%
JAN FEB MAR APR MAY JUN JUL AUG SEPT

ACTUAL 102% 101% 101% 87% 81% 101% 97% 102% 107%
TARGET 100% 100% 100% 100% 100% 100% 100% 100% 100%

August, 2007 PRI 1st Sem QEMS Management Review 67


Objective Target Actual % Acc

Supply all PBI LEAD Requirements 100 % Fillrate 94 % Fillrate 94%


Year-to-date

ANALYSIS OF DEVIATION ACTION PLANS REVISED


TIMETABLE

Required finished lead from oJust in time delivery. Implemented and sustained
refining was not met Within 24 hrs after
casting
o100% availability of
delivery trucks and
forklift

August, 2007 PRI 1st Sem QEMS Management Review 68


SWOT ANALYSIS(PRF)
SWOT ANALYSIS

Strength Weaknesses
oProactive personnel oNo designated signatories in the
oComplete Manning complement absence of LLM and LRR
oSap utilization oHigh LIB
o100% availability of equipment oOpen storage areas
oUse of back up system in case of SAP
breakdown

Opportunities Threats
oAvailability of back up forklift oSlow SAP system
oUse of outside truck scale oQuality issues on flashes in FL bars
oDelay inspection of FL for delivery
oDelay issuance of COA

August, 2007 PRI 1st Sem QEMS Management Review 69


SCM - MATERIAL CONTROL
PERFORMANCE SUMMARY

August, 2007 PRI 1st Sem QEMS Management Review 70


QUALITY PERFORMANCE : Success(es)
Objective: Target: Average / Actual: % Acc
Fill Rate 100% 100% YTD 100% YTD

Domestic/Imported

8,000

6,000

mt 4,000

2,000

-
J an Feb Mar April May J une J uly Aug Sept

Target 07 5,129 3,958 5,579 4,747 5,821 5,170 4,894 5,198 6,632

Actual 07 4,298 4,688 4,737 4,793 5,288 5,398 5,408 5,817 6,293

Fill Rate 84% 118% 85% 101% 91% 104% 111% 112% 95%

August, 2007 PRI 1st Sem QEMS Management Review 71


Objective: Target: Average / Actual: % Acc

Compliance to Fill Rate; Plan , 100% 100% YTD 100% YTD


receive , store issued junk
batteries , scrap material , raw
materials within the plant to
meet internal customer.
ANALYSIS OF DEVIATION ACTION PLANS REVISED ADDITIONAL
TIMETABLE RESOURCES
REQUIRED
 Scarcity in ULAB supply  OMMC new  2007  U.L.A.B. availability
buying strategy
 High Price PB Loc from Vismin
supplier ( Bacolod )  OMMC develop 2007
new PB loc supplier  OMMC concern
with in Luzon area

Payment Issue ( imported ECCO )  inform Treasury

August, 2007 PRI 1st Sem QEMS Management Review 72


Objective: Target: Average / Actual: % Acc
Maintain Accurate inventory 95 % minimum 99 % YTD 100%
Actual versus SAP

Inventory Accuracy

102%
100%
98%
%

96%
94%
92%
JAN FEB MAR APR MAY JUN JULY AUG SEPT

Inventory Accuracy 95% 98% 99% 100% 100% 100% 100% 100% 100%
month

August, 2007 PRI 1st Sem QEMS Management Review 73


QUALITY PERFORMANCE : Areas for
Improvement
Objective: Target: Average / Actual: % Acc

Maintain Accurate inventory 95 % minimum 87% 92%


Actual versus SAP

Raw Materials

100%

80%

60%
%

40%

20%

0%
JAN FEB MAR APR MAY JUN JUL AUG SEPT

Raw Materials 79% 89% 84% 83% 76% 83% 90% 88% 73%

month

August, 2007 PRI 1st Sem QEMS Management Review 74


Objective: Target: Average / Actual: % Acc

Maintain Accurate inventory Actual 95 % minimum


versus SAP
ANALYSIS OF DEVIATION ACTION PLANS REVISED
TIMETABLE
Delayed confirmation of alloying  Confirmation timeliness on-going projects
materials by production (smelting monitoring ( Cut off Time
and refining section )
confirmation )

Delivery without PO Cut off time of generation of PO on-going


for delivery materials

August, 2007 PRI 1st Sem QEMS Management Review 75


SWOT ANALYSIS(PRF)
Strengths Weaknesses
Teamwork oLimited storage space
Warehouse management oInsufficient forklifts
Competent personnel oLimited unloading area
Inventory management oNo roofing for unloading area
which causes delay in unloading
and receiving during rainy season

Opportunities Threats
oMechanization of unloading process oBreakdown of equipment i.e
oDesignated area for IB battery axing forklifts
oSlow hiring system

August, 2007 PRI 1st Sem QEMS Management Review 76


TECHNICAL SECTION
PERFORMANCE SUMMARY

August, 2007 PRI 1st Sem QEMS Management Review 77


Success(es)
HOSHIN PROJECTS
o Design and standardization of grids preparation and
melting project – June 2007 fully turned over to
operations
o Standardized measurement of input and outputs for grids
screen, including establishment of yield
o Established refining requirements, including evaluation and
recommendation on refining gas handling capacity
o Design of oven dryer, storage boxes, grids feeder
o Technical and operational support – logistics, drying, overall
project coordination
o Cost effectiveness study on implementation of grids melting
when expanded reverb is operational already

August, 2007 PRI 1st Sem QEMS Management Review 78


HOSHIN PROJECTS
o Design and use of refining heat recovery
system for drying grids and paste
o For grids melting
o For reverb drier (for implementation 1st week Aug)
o Improvement of refining skimmer design

August, 2007 PRI 1st Sem QEMS Management Review 79


HOSHIN PROJECTS
o Lab scale experimentation
o Oxide and fumes desulfurization
o Hydrometallurgical recovery of Sb from pellet
dross
o Identification, selection and purchase
requisition of instrumentation for BBM
process automation

August, 2007 PRI 1st Sem QEMS Management Review 80


DMP / Technical Support Projects
o Reverb technical support
o Rebricking: Compressive strength and
microstructure of bricks, brick expansion and
expanded arc calculations, brick count
o Smokebox calculations
o Pelletizer design
o U-tube less design (use of hygiene gas to cool blast
furnace gas)

August, 2007 PRI 1st Sem QEMS Management Review 81


DMP / Technical Support Projects
o Validation of free lead recovered from
Aluminizing dross
o Cost effectiveness study on the use of
bunker in the reverb furnace
o Other technical support activities

August, 2007 PRI 1st Sem QEMS Management Review 82


Areas for Improvement
Objective Target Actual %Acc

1.1 Optimization of BBM 100% 75% 75%


process By Aug 2007

ANALYSIS OF DEVIATION ACTION PLANS REVISED / NEW ADDITIONAL


TIMETABLE RESOURCES
REQUIRED

External lab analyses Follow up external lab August 2007


(XRD/XRF/SEM) not yet done analysis (MUC)

Not enough data to get


current yield (4 only)

No documentation of impact Complete documentation August 2007


study (BRB)

Water flowmeters/pressure Follow up instrumentation September 2007


gauges not yet (flowmeters/pressure
delivered/installed gauges) delivery and
installation (BRB)
Battery precrushing final Final design of battery August 2007 Battery precrushing
design not yet completed precrusher (MUC) budget (c/o RMP)

August, 2007 PRI 1st Sem QEMS Management Review 83


Objective Target Actual % Acc

1.2 Design and 100% 99% 99%


standardization of grids By Apr 2007
preparation project
ANALYSIS OF DEVIATION ACTION PLANS REVISED
TIMETABLE
Grids prep and melting Continue technical support Same
operation will operate until end (All)
of July 2007 – Technical support
still needed

August, 2007 PRI 1st Sem QEMS Management Review 84


Objective Target Actual % Acc
2.1 Design and 100% 60% 60%
standardization of By Jul 2007
desulfurization of flue
dust and scrap plates
ANALYSIS OF DEVIATION ACTION PLANS REVISED ADDITIONAL
TIMETABLE RESOURCES
REQUIRED
Characterization / Complete characterization / August 2007
experimentation not yet experimentation (BRB)
completed
Other experiments deferred Verify presence and quantity Aug 2007 –
– waiting for verification of of arsine/stibine (LLA) – qualitative
presence of As/Sb hazardous qualitative and quantitative
gases – no tester yet Sep 2007 – Arsine/stibine tester
quantitative (imported)
(imported)
No final design of gaseous Final design of gaseous August 2007 Budget for gaseous
emissions control yet emissions control (LLA) emissions controls
(c/o RMP)

Waiting for instrumentation September 2007


delivery and installation
(sulfur analyzer)

August, 2007 PRI 1st Sem QEMS Management Review 85


Objective Target Actual % Acc
2.2 Optimization of 100% 43% 43%
desulfurization By Aug 2007
ANALYSIS OF DEVIATION ACTION PLANS REVISED
TIMETABLE

Instrumentation not yet Follow up delivery and installation September 2007


delivered and set-up (BRB)
Experimentation not yet Complete experimentation to validate September 2007
completed which desulfurization methods (acid
draining / oxide washing / dilution /
double desulfurization) are the most
cost effective to implement
(BRB/MUC)

No decision yet if oxide Prioritize battery draining /


washing will still be done, may precrushing over oxide washing due
not be needed if battery is to larger impact on process and more
drained, other options may be cost savings
done also

August, 2007 PRI 1st Sem QEMS Management Review 86


Objective Target Actual % Acc
3.1 Developmental study on Pyrometallurgical 100% 42% 42%
and hydrometallurgical methods of recovering By Sep
Pb, Sb and other recoverable metals from 2007
dross and other wastes
ANALYSIS OF DEVIATION ACTION PLANS REVISED / NEW
TIMETABLE
Other exp’ts deferred – No verification of Verify presence and quantity of Sep 2007
presence of As/Sb hazardous gases yet arsine/stibine (LLA)

Establish any fumes engineering November 2007


controls in pilot plant if these gases
are present (MUC/LLA)

Electrolysis voltage controller not yet Perform oxide electrolysis August 2007
delivered experimentation (defer Al dross)
(MUC)
Hydro & pyro exp’tation (2nd batch) deferred Continue hydro experimentation September 2007
due to prioritization of grids melting and (LLA)
reverb support activities

Complete costing of pyro recovery September 2007


of Sb (LLA)
Defer pyro recovery of Al dross, September 2007
complete costing (high operating
cost) (MUC)

August, 2007 PRI 1st Sem QEMS Management Review 87


Objective Target Actual % Acc
4.1 Use of heat from 100% 100% 100%
refining burner exhaust By May 2007
for drying grids and
paste
ACTION PLANS REVISED / NEW
TIMETABLE
Technical support for fabrication and installation of heat recovery August 2007
system for reverb drier (LLA)

Objective Target Actual % Acc


5.1 Improvement of 100% 95% 95%
current skimmer design By June 2007
for faster skimming in
refining
ANALYSIS OF DEVIATION ACTION PLANS REVISED / NEW
TIMETABLE
Not being used by Discuss feedbacks with supervisors / August 2007
operators consistently, operators / users if there are any to improve
feedback/issues/concerns process (YAB/MUC)
of process owners not
clear

August, 2007 PRI 1st Sem QEMS Management Review 88


Objective (Additional Target Actual % Acc
Priority Project)

Use of Bunker – Cost 100% 75% 75%


effectiveness study and By Aug 2007
operational plan

ANALYSIS OF ACTION PLANS REVISED / NEW ADDITIONAL


DEVIATION TIMETABLE RESOURCES
REQUIRED
Legal requirements not yet Verify legal requirements August 2007
fully verified and controls (env’l and
health and safety)
(YAB/BRB), risk assessment

No final operational plan Come up with operational September 2007 Capex budget for
yet plan (Smelting/Engg/Tech) (1) bunker storage,
transfer and
control systems;
(2) burner nozzle
replacement; (3)
continuous
emissions
monitoring system
as required by
DENR

August, 2007 PRI 1st Sem QEMS Management Review 89


Priority Projects for 2nd Semester
o All Hoshin projects and related activities
o Use of bunker – operational plan
o Technical package for PEZA tax incentives
o Technical package for Japan / Australia
ULAB Importation
o Other new / to be assigned high impact
projects

August, 2007 PRI 1st Sem QEMS Management Review 90


SWOT ANALYSIS
Strengths Weaknesses
oTeamwork within section and with other oPurchasing bottlenecks (projects, and also
sections materials that can be easily bought through
oForesight the internet)
oStrong support system oBudget approval for non-urgent research
oProject planning materials
oPrioritization / decision-making skills oUnstructured design review
oDifficulty in rating the overall
oTechnical capability and experience
accomplishment of projects because of
oDiverse expertise changing priorities and additional activities
oCustomer oriented technical support that arise in the course of the studies
oMalasakit (within section, and for other conducted. These all depend on the
sections) urgency and needs of the production /
oTop management support company at a given time
oPassion and love for work oFinance skills

August, 2007 PRI 1st Sem QEMS Management Review 91


SWOT ANALYSIS
Opportunities Threats
oLearning and growth oEnvironmental and health hazards
oThrough benchmarking with other during experimentation especially
similar and non-similar industries those that involve new processes
oThrough various diverse projects oPossibility of lack of focus and speed
handled due to a large number of projects that
oExcellence in various fields need to be accomplished
oPossibility of miscommunication with
oAvailability of new technology and
contractors because from experience
research materials
some specifications were not exactly
followed during fabrication of some
equipment

August, 2007 PRI 1st Sem QEMS Management Review 92


Overall Assessment and
Conclusion
The QEMS of Technical is sustained which is shown in attainment of most of its
goals and objectives. There is continual improvement in the planning,
implementation and monitoring of projects over the years.

The section’s major strengths are project planning and implementation,


teamwork, technical capability/skills and a strong drive towards excellence.

There is however a need for further improvement in the following areas:


Project monitoring in terms of rating the overall accomplishment of projects
when there are changing priorities and additional activities that arise in the
course of the studies conducted; Finance skills of engineers; and Design
review procedures.

There is also a need for extra precaution and additional controls during some
experimentation activities because of the exposure of the engineers to
hazardous emissions especially those concerning new and improved processes.

Finally, to speed up projects and activities, and to take advantage of the


availability of new technology and research materials, materials requested for
purchase should be delivered in a timely manner.

August, 2007 PRI 1st Sem QEMS Management Review 93


Other Plans of Action
o Expedite hiring of new engineer to absorb some of the
projects and activities, consider hiring OJT’s from Mapua
(YAB, August 2007)
o Further improvement of project monitoring mechanisms
(YAB, December 2007)
o Finance and other technical and non-technical trainings
for engineers (YAB, November 2007)
o Research and document applicable design review
procedures (BRB, MUC, LLA, November 2007)
o Improve engineering controls for hazardous gases
during experimentation (MUC, LLA, November 2007)
o Follow-up other materials requested for purchase, and
credit card for buying research materials and items from
the internet (YAB, August 2007)
o For activities that require a contractor’s job, monitor
and check implementation as often as necessary to
make sure that desired specifications are met (All)

August, 2007 PRI 1st Sem QEMS Management Review 94


QUALITY ASSURANCE
PERFORMANCE SUMMARY

August, 2007 PRI 1st Sem QEMS Management Review 95


QUALITY PERFORMANCE (Successes)
OBJECTIVE TARGET Actual YTD %Acc YTD
Customer Rejection Zero Zero 100%
Internal Rejection Zero Zero 100%
Customer Complaints Zero Zero 100%
Process development o 100% completion of oSPC Phase 2 work 100%
and improvement SPC programs by programs -100%
thru SPC Nov’07 completed
Optimize o 100% o98% Actual 98%
measurement Accomplishment Satisfaction rating
capabilities to serve (based on internal based on External
all testing and external /Internal Customer
requirements of customer Satisfaction
operating units, satisfaction survey) Feedback
process related  External Customer Mechanism
improvement projects Satisfaction Rating – External customer
(R&D, SPC and Six- 100% satisfaction rating –
 Internal Customer 100%
Sigma projects) Satisfaction Rating –
92% Internal Customer
Satisfaction Rating –
89%

August, 2007 PRI 1st Sem QEMS Management Review 96


OBJECTIVE TARGET Actual %Acc

Optimize  Internal Customer Internal 97%


measurement Satisfaction Rating – Customer
capabilities to serve 92% Satisfaction rating
all testing – 89%
requirements of
operating units,
process related
improvement
projects (R&D, SPC
and Six-Sigma
projects)
Internal and External Customer Satisfaction Measurement:
oProduct Quality – based on quality specs
oService Quality
 Response to concerns
 Compliance to analysis time

ANALYSIS OF ACTION PLANS PIC REVISED


DEVIATION TIMETABLE
Refer to 1st Sem LMS Management Review

August, 2007 PRI 1st Sem QEMS Management Review 97


OBJECTIVE TARGET Actual %Acc

Process development o 100% completion oSPC Phase 2 work 100%


and improvement of SPC programs programs -100%
thru SPC by Nov’07 completed

SUCCESS DRIVERS:
o Established process stability, no parameters beyond control limits
1. Pb in slag
2. TCLP Pb

August, 2007 PRI 1st Sem QEMS Management Review 98


OBJECTIVE TARGET Actual %Acc

Optimize o 100% o 98% Actual 100%


measurement Accomplishment Satisfaction rating
capabilities to serve (based on internal based on External
all testing and external /Internal Customer
requirements of customer Satisfaction
operating units, satisfaction Feedback
process related survey) Mechanism
improvement projects  External  External customer
(R&D, SPC and Six- Customer satisfaction rating –
Sigma projects) Satisfaction Rating 90%
– 90%

SUCCESS DRIVERS:
oImproved customer satisfaction feedback mechanism
oFocus on product quality
oIssues that were raised last year were resolved already
oNo negative issues raised from the last survey dated May 26, 2007

August, 2007 PRI 1st Sem QEMS Management Review 99


QUALITY PERFORMANCE (Areas for
Improvement)
OBJECTIVE TARGET Actual %Acc

Process o CpK >= 1.33 o Cpk (Process 81%


development and testing) – 1.14 Achieved
improvement thru o Cpk (Envi testing)
SPC – 1.05

ANALYSIS OF ACTION PLANS PIC REVISED ADDITIONAL


DEVIATION TIMETABL RESOURCES
E REQUIRED

oSample oThe sample must be All QA- oOn- Grinding


homogeneity pulverized thoroughly. LAB going machine
oIndividual shaking of Analysts (Capex
the samples during 2008)
aliquot taking.

August, 2007 PRI 1st Sem QEMS Management Review 100


OBJECTIVE TARGET Actual %Acc

Sustain ISO 17025 o 100% Completion of o 94% completed 94%


Accreditation work programs for
scope extension
(end of June'07)
o Retention of o Activities on-going
Accreditation with
additional scope by
Nov '07
ANALYSIS OF ACTION PLANS PIC REVISED
DEVIATION TIMETABLE
Awaiting delivery of oExpedite delivery of JMD/ July-Oct,
CRM for slag to be CRM MCS 2007
used for the method oCompletion of
validation of Pb in method validation
slag once CRM has been
delivered

August, 2007 PRI 1st Sem QEMS Management Review 101


OBJECTIVE TARGET Actual %Acc

Sustain Quality and o 100% completed by June o 92% 92%


Environmental '07 – web based completed
Management documentation
Systems
ANALYSIS OF ACTION PLANS PIC REVISED
DEVIATION TIMETABL
E

oReview of Assign whole day of Saturday JBE/ROD oOn-going


completeness and for the review of complete-
authenticity of all ness and authenticity of
documents not yet document
completed
oPrioritized
processing of
document revisions

August, 2007 PRI 1st Sem QEMS Management Review 102


ENVIRONMENTAL PERFORMANCE – Success(es)

OBJECTIVE TARGET Actual %Acc

Optimize TCLP testing 100% (requested vs. o 100% 100%


capability on solid analysis done)
waste treatment

SUCCESS DRIVERS:
Established quality controls

ACTION PLANS PIC REVISED ADDITIONAL


TIMETABL RESOURCES
E REQUIRED
Expedite delivery of microwave digester JTD Aug,2007
to speed up analysis of samples

Provide additional hood for JTD / Jan, 2008 Hoods


environmental samples in the new EAB
Laboratory

August, 2007 PRI 1st Sem QEMS Management Review 103


SWOT ANALYSIS
Strengths Weaknesses
oStrategically agile oCompliance with analysis time
oFlexibility in laboratory testing oWork environment due to laboratory space
oDedication of project owners constraints
oTechnically competent QA personnel
oTeam synergy
oHarmonious relationship with other
departments
oMulti-skilled QA personnel
oGood internal communication
oEfficiency in releasing of results
oLMS management system accredited to
ISO 17025
oSPC
oGood laboratory practices
oParticipation in international proficiency
testing
oEstablished regular performance reporting
and monitoring process
oEquipped with state of the art equipment

August, 2007 PRI 1st Sem QEMS Management Review 104


SWOT ANALYSIS

Opportunities Threats
oSupport from technical engineers oPoor purchasing system
oSix sigma methodologies oHiring system
oInvolvement in process related oNon-cooperative people
improvement projects oDelay in laboratory relocation
oCustomer feedback mechanism oSafety hazards from
oProfessional development thru experimentation/method development
trainings
oBenchmarking
oTop management support

August, 2007 PRI 1st Sem QEMS Management Review 105


Resource Consumption

August, 2007 PRI 1st Sem QEMS Management Review 106


Objective (SMELTING) Target (YTD) Ave Actual % Acc

Reduce Coke 135 kg/ton bullion 119 kg/ton 100%


Consumption bullion Reduced consumption by
13%

150
140
130
120
110
100
90
80
70
60
50
Jan Feb Mar A pr May Jun Jul A ug Sept

Coke usage 119 124 116 146 132 97.3 107 114 115
Target

August, 2007 PRI 1st Sem QEMS Management Review 107


Objective (SMELTING) Target (YTD) Ave Actual % Acc

Reduce Diesel 120 li/ton bullion 114 li/ton bullion 100%


Consumption Reduced consumption by
11%

140
130
120
110
100
90
80
70
60
50
40
30
20
10
0
Jan Feb Mar A pr May Jun Jul A ug Sept

Diesel Usage 103 109 107 116 125 133 - 106 115

Target

August, 2007 PRI 1st Sem QEMS Management Review 108


Objective (SMELTING APM) Target Actual YTD % Acc
Optimal Chemical Usage 66 56 100%
Reduced consumption by 15%

Caustic soda Consumption


100
90
80
Kg / MT bullion

70
60
50
40
30
20
10
0
J AN FE B M AR AP R M AY J UN J UL AUG

ACT UAL 44 49 59 51 65 66 70 43

T ARGE T 66 66 66 66 66 66 66 66

August, 2007 PRI 1st Sem QEMS Management Review 109


Objective: (RMP) Target: Ave. / Actual: %Acc

Optimized Water Usages 1,700 Li./ MT-Output 1,424 Li./ MT-Output 100%

Water Consumption
2,500

2,000
Metric Ton of Output
Cubic Metres per

1,500

1,000

500

0
J AN FEB MAR APR MAY J UN J UL AUG

JAN FEB MAR APR MAY JUN JUL AUG


'07 Actual 1,683 1,595 1,555 1,743 1,651 2,003 1702 1081
'07 Target 1,700 1,700 1,700 1,700 1,700 1,700 1700 1700

August, 2007 PRI 1st Sem QEMS Management Review 110


Objective: (RMP) Target: Ave. / Actual: %Acc
Optimized Water Usages 1,700 Li./ MT- 1,424 Li./ MT- 100%
Output Output
ACTION PLANS REVISED ADDITIONAL
TIMETABLE RESOURCES
REQUIRED
Installation of more flow meters to monitor actual water 3rd Quarter of 2007 More Flow Meters
consumption to be installed on
3rd Quarter of 2007

Reset targets according to revised target production Moving Target based Central Planning’s
volume on SCM’s Central Forecast
Planning REALISTIC
Projection
Optimize use of recycled water from PRF On-going Additional Water
Pumps, Return
Lines, Valves

Re-orientation of all personnel regarding water usage Done and monthly Monthly Meetings,
and conservation reiterated during Orientations,
sectional meetings Trainings,
Seminars,
Workshop
Programs

August, 2007 PRI 1st Sem QEMS Management Review 111


Objective: (RMP) Target: Ave. / Actual: %Acc

Upgrade Desulphurization 250 kg. Soda Ash per 229 kilograms 108%
Process Control and Monitoring MT of processed Oxides Reduced consumption
to optimize chemical utilization by 8%

BBM Soda Ash Usage


300

270

240

210

180
Metric Ton Oxides
Kilograms per

150

120

90

60

30

0
JAN FEB MAR APR MAY JUN JUL AUG
'07 Actual 259 229 211 219 225 230 214 220
'07 Target 250 250 250 250 250 250 250 230

August, 2007 PRI 1st Sem QEMS Management Review 112


Objective: (REFINING) Target Actual YTD % Acc
Optimal Chemical Usage 1.37 Kg / MT Kg / MT 100%
Reduced
consumption by 15%

Aluminum Consumption
4
Kg / MT Pb

0
J AN FEB MAR AP R MAY J UN J UL AUG SEP T

ACTUAL 1.21 1.26 1.23 1.29 1.29 1.37 1.2 1.15 1.09

TARGET 1.43 1.43 1.43 1.37 1.37 1.37 1.37 1.37 1.37

August, 2007 PRI 1st Sem QEMS Management Review 113


Objective Target Actual

Optimal Chemical Niter - .17 Kg / MT Niter - .17 Kg / MT


Usage Caustic Soda – 2.50 Kg / Caustic Soda - 2.35 Kg /
MT MT

Caustic Soda Consumption Niter Consumption


1
4
3

Kg / MT Pb
2 0.5
Kg / MT Pb

1
0
J F M A M J J A S 0 J F M A M J J A S

ACTUAL 2.58 2.57 2.41 1.81 2.27 2.42 2.06 2.4 2.03 ACTUAL 0.17 0.15 0.15 0.17 0.17 0.17 0.16 0.16 0.07

TARGET 2.86 2.86 2.86 2.50 2.50 2.50 2.50 2.50 2.5 TARGET 0.17 0.17 0.17 0.17 0.17 0.17 0.17 0.17 0.17

August, 2007 PRI 1st Sem QEMS Management Review 114


ENVIRONMENTAL PERFORMANCE :

Objective Target Actual Ave


Optimize Diesel Usage 39.36 liters / MT 38.11 liters / MT

70

50
L / MT Pb

30

10

-10
J AN FEB MAR AP R MAY J UN J UL AUG SEP OCT NOV DEC

ACTUAL 44.02 30.00 36.26 34.03 38.60 47.10 40.07 36.9 37.54

TARGET 44.76 44.76 44.76 39.36 39.36 39.36 39.36 39.36 39.36 39.36 39.36 39.36

August, 2007 PRI 1st Sem QEMS Management Review 115


Objective Target Actual
Optimize electricity usage 38.00 KWH / MT 33.63 KWH / MT

60.00

50.00

40.00
KWH / MT Pb

30.00

20.00

10.00

0.00
J AN FEB MAR AP R MAY J UN J UL AUG SEP OCT NOV DEC

ACTUAL 17.00 36.47 30.69 35.56 36.88 45.15

TARGET 38.00 38.00 38.00 38.00 38.00 38.00 38.00 38.00 38.00 38.00 38.00 38.00

August, 2007 PRI 1st Sem QEMS Management Review 116


ENVIRONMENTAL PERFORMANCE : Highlights

Objective Target Ave Actual


Optimal Chemical Usage(ww) 0.00660 kgs/WW 0.00476 kgs/WW treated
treated

HCL Consumption
Kg / WW Treated

0.02
0.015
0.01
0.005
0
JAN FEB MAR APR MAY JUN

ACTUAL 0.00498 0.00742 0.00539 0.00468 0.00244 0.00362


TARGET 0.00660 0.00660 0.00660 0.00660 0.00660 0.00660

August, 2007 PRI 1st Sem QEMS Management Review 117


ENVIRONMENTAL PERFORMANCE : Highlights

Objective Target Ave Actual


Optimal Chemical Usage 0.00512 kgs/WW 0.00470 kgs/WW treated
treated

NaOH Consumption
0.02
Kg / WW Treated

0.015
0.01
0.005
0
JAN FEB MAR APR MAY JUN

ACTUAL 0.00437 0.00322 0.00360 0.00435 0.00677 0.00591

August, 2007
TARGET 0.00512 0.00512 0.00512 0.00512 0.00512 0.00512
PRI 1st Sem QEMS Management Review 118
ENVIRONMENTAL PERFORMANCE : Highlights

Objective Target Ave Actual


Optimal Chemical Usage 0.00190 kgs/WW 0.00138 kgs/WW treated
treated

Ferric Sulfate Consumption


0.02
Kg / WW Treated

0.015
0.01
0.005
0
JAN FEB MAR APR MAY JUN

ACTUAL 0.00127 0.00145 0.00156 0.00141 0.00138 0.00120


TARGET 0.00190 0.00190 0.00190 0.00190 0.00190 0.00190
August, 2007 PRI 1st Sem QEMS Management Review 119
ENVIRONMENTAL PERFORMANCE : Highlights

Objective Target Ave Actual


Optimal Chemical Usage 0.00003 kgs/WW 0.00003 kgs/WW treated
treated

Polymer Consumption
0.0002
Kg / WW Treated

0.00016
0.00012
0.00008
0.00004
0
JAN FEB MAR APR MAY JUN

ACTUAL 0.00004 0.00003 0.00004 0.00003 0.00003 0.00003


TARGET 0.00003 0.00003 0.00003 0.00003 0.00003 0.00003
August, 2007 PRI 1st Sem QEMS Management Review 120
Objective: Target: Actual / Average: (148.70%)
Optimize Resource Utilization 22.24 CubicMetres 10.71 CM / MT
per MT-Output per Mo.

PRF Water Usage

25

20
Metric Ton Output
CubicMeters per

15

10

0
MAR APR MAY J UN J UL AUG SEP OCT NOV DEC

MAR APR MAY JUN JUL AUG S EP OCT NOV DEC

2006 Actual 10.42 10.47 10.55 11.41


2006 Target
August, 2007 22.24 22.24 22.24 PRI 1st22.24
Sem QEMS 22.24 22.24
Management Review 22.24 22.24 22.24 22.24
121
Environmental Parameters Monitoring

August, 2007 PRI 1st Sem QEMS Management Review 122


ENVIRONMENTAL PERFORMANCE : Areas for Improvement

Objective Target Actual


Compliance to CO emission 500 >500 mg/NCM
mg/NCM

ANALYSIS OF ACTION PLANS TIMETABLE


DEVIATION

Afterburner set to < Install cooling system in the Done


700°C – to prevent clogging baghouse inlet
of smokebox
Enlarged the short duct Done
connecting the smoke boxes

Operate afterburner
continuously at T>700

Replace LPG burner with April 2008 – CAPEX


diesel burner

Smokebox cleaning Change method of smokebox 3rd week of August 2007


duration is 2 hours daily clearing – use backhoe
August, 2007 PRI 1st Sem QEMS Management Review 123
Objective: Target Actual
Reduce Smoke Emissions 10 53 incidents

SMOKE MONITORING 2007


30

25

20

15

10

0
JAN FEB MAR APR MAY JUN

BLAST 5 5 10 6 4 7
REVERB 6 5 1 0 4 0

Target
August, 2007 PRI 1st Sem QEMS Management Review 124
Objective: Target Actual
Reduce Smoke Emission 10 53 incidents

ANALYSIS OF ACTION PLANS TIMETABLE RESOURCES


DEVIATION REQUIRED

Lancing activities at Reduce moisture January 2008 - Dryer burner @ 2M


reverb furnace content of feed CAPEX BTU/hr -
materials <5%

Reduce lancing
activities

Insufficient capacity of Telescopic hood Sept 30, 2007


thimble baghouse

U-tubeless Dec, 2007

Install hood at lead Mar-Apr, 2008


well area (blast and
reverb)

Revise inlet ducts of Mar-Apr, 2008


blast furnace
baghouse
August, 2007 PRI 1st Sem QEMS Management Review 125
Objective: Reduce Smoke Emission Target Actual
10 53 incidents
ANALYSIS OF ACTION PLANS TIMETABLE RESOURCES
DEVIATION REQUIRED

Insufficient Install telescopic Sept 30, 2007


extraction capacity hood
at blast furnace
Install hood at lead
well (blast and
reverb)

Install U-tubeless On hold by SCM

No extraction hood Install hood and June 2008 - CAPEX Hood


at slag dumping relocate baghouse
area

August, 2007 PRI 1st Sem QEMS Management Review 126


ENVIRONMENTAL PERFORMANCE : Areas for Improvement
Objective Target : Actual :
Reduce smoke emissions incidence 5 2

SMOKE MONITORING 2007

10

0
JAN FEB MAR APR MAY JUN
Baghouse 5 0 1 2 2 0

August, 2007 PRI 1st Sem QEMS Management Review 127


ENVIRONMENTAL PERFORMANCE : Highlights
Objective Target : Actual :
Reduce odor emissions incidence 10 8

ODOR MONITORING 2007

30

25

20

15

10

0
JAN FEB MAR APR MAY JUN
Baghouse 7 11 13 4 5 7

August, 2007 PRI 1st Sem QEMS Management Review 128


Objective Target Actual
Reduce odor emissions incidence 10

ANALYSIS OF DEVIATION ACTION PLANS TIMETABLE RESOURCES


REQUIRED

oOdor from other sources oEvaluate non-met baghouses Nov 1-15

oIncidents during sump tank oSemi annual replacement of scrubber dec 2007
draining packing
oInstallation of discharge piping direct to done
sed pit.
oOperation of afterburner oInclusion of after burner operation in
done
not included in furnace restarting procedure.
restarting procedure
(remote occurrence)

August, 2007 PRI 1st Sem QEMS Management Review 129


ENVIRONMENTAL PERFORMANCE : Areas for Improvement
Objective Target : Actual :
Reduce smoke emissions incidence 5 2

SMOKE MONITORING 2007

10

0
JAN FEB MAR APR MAY JUN
Baghouse 5 0 1 2 2 0

August, 2007 PRI 1st Sem QEMS Management Review 130


ENVIRONMENTAL PERFORMANCE : Highlights
Objective Target : Actual :
Reduce odor emissions incidence 10 8

ODOR MONITORING 2007

30

25

20

15

10

0
JAN FEB MAR APR MAY JUN
Baghouse 7 11 13 4 5 7

August, 2007 PRI 1st Sem QEMS Management Review 131


Legal Requirements Compliance (Jan-June 2007):
 100% Compliance to Pb in air in work area
 Compliance to stack emissions standards
• 100% compliance reverb - Pb, PM, NOx, SOx, CO
• 80% compliance blast - Pb, PM, NOx, SOx
• 100% compliance non met baghouses - Pb, PM, NOx, SOx, CO
 100% compliance to ambient SOx
 100% compliance to noise standards
 75% (average) compliance to ambient Pb

August, 2007 PRI 1st Sem QEMS Management Review 132


Stack Emission Compliance
100

80

60

40

20

0 JAN FEB MAR APR MAY JUN

BLAS T 100 100 80 100 100 100


REVERB 100 100 100 100 100 100
40k baghouse

PARAMETERS:
SOx, NOx, PM, CO, Pb PRI 1st Sem QEMS Management Review
August, 2007 133
Objective Target Actual
Reduce odor emissions incidence 10

ANALYSIS OF DEVIATION ACTION PLANS TIMETABLE RESOURCES


REQUIRED

oOdor from other sources oInvestigate odor coming from PVC Aug. 30
PE,scrap plates. And other sources.

Operation of afterburner not oSemi annual replacement of scrubber dec 2007


included in furnace packing
restarting procedure oInstallation of discharge piping direct to done
(remote occurrence) sed pit.
oInclusion of after burner operation in
done
restarting procedure.

August, 2007 PRI 1st Sem QEMS Management Review 134


Objective Target : Actual :
Reduce smoke emissions incidence 1 8 incidences

SMOKE MONITORING 2007

10

0
JAN FEB MAR APR MAY JUN JUL AUG

REFINING 2 2 1 1 1 1

August, 2007 PRI 1st Sem QEMS Management Review 135


Objective Target : Actual :
Reduce smoke emissions incidence 1 8 incidences

ANALYSIS OF ACTION PLANS TIMETABLE RESOURCES


DEVIATION REQUIRED

Smoke from turning Recruit burner tenders Oct ’07 HRM support
on of HAUCK
burners Install addt’l automatic Dec ’07 kettle availability &
ignition burner at R#7 Eng’g support

Smoke from grid Modify holding kettle dampers Completion by kettle availability &
melting Repair of Refining kettle the end of dec Eng’g support
dampers 07

August, 2007 PRI 1st Sem QEMS Management Review 136


Effluent Compliance

100
90
80
%compliance

70
60
50
40
30
20
10
0
Pb TDS COD O&G TSS
1st Quarter 100 100 100 100 100
2nd Quarter 100 100 66.7 100 100
3rd Quarter 100 100 100 100 100
4th Quarter

August, 2007 PRI 1st Sem QEMS Management Review 137


Objective Target Actual
Effluent Compliance 100 % 96 %

ANALYSIS OF ACTION PLANS TIMETABLE RESOURCES


DEVIATION REQUIRED

Monthly scheduled Ensure that monthly August 2007 Manpower


cleaning of discharge cleaning of discharge resources
pipeline was not pipeline is strictly
consistently done followed.
Increase frequency of
cleaning discharge August 2007
pipeline (2x per month)

August, 2007 PRI 1st Sem QEMS Management Review 138


PRI Programs Update

August, 2007 PRI 1st Sem QEMS Management Review 139


Objective Target Actual
SPC Implementation 100% completion 40%
(Phase 2)

ANALYSIS OF ACTION PLANS REVISED TIMETABLE


DEVIATION

Projects selected do Changed project to blast slag June – October 2007


not describe the %Pb – implementation of
behavior of the procedures on fluxing and
process. slag tapping

August, 2007 PRI 1st Sem QEMS Management Review 140


Recovery Section’s Programs Highlights:

o Improved Good House Keeping Procedures and Practices


o Statistical Process Control implementation
 100% implementation as programmed (phase by phase staging)
 Optimization of processes with the help of Technical Department
 Established desulfurization monitoring procedures
• Total Productive Maintenance implementation
 Autonomous & Planned maintenance schedules and assignments are performed mostly by Recovery
Section’s Trained & Qualified Operators
• Bilis-Ayos (SMED) project
 Modular replacement of Discharge Pumps and Motors
• Implementation of improved visual factory program
• Health and Safety
 Recovery Section has worked to-date (for more than months) incurring less than 0.2 man-hours lost
(accident rate)

August, 2007 PRI 1st Sem QEMS Management Review 141


PRI PROGRAMS UPDATE: smelting

•Pokayoke – restart Sept. 1, 2007


•Improved GHK
Most improved section in GHK for the month of March &
June

August, 2007 PRI 1st Sem QEMS Management Review 142


PRI Programs Update:
• Bilis Ayos update

1. Modular Replacement of Rotary Drier Gear Box Drive.


2. MA-41 Crusher Modular Replacement
3. Rotary Drier Screw Feeder
4. Refining Lead Pump Pipe Pre-heater (Design stage)

August, 2007 PRI 1st Sem QEMS Management Review 143


•Improved GHK
Most improved in GHK (motorpool area) for the month of April

August, 2007 PRI 1st Sem QEMS Management Review 144


PRI Programs Update:
• Improved GHK
Install skylight roofs at WWTF building
Install spare part racks (KANBAN method)
Improvement of WWTF garden
• Bilis Ayos
Install back-up pump for sedimentation pit filter press
• TPM
Epoxy painting of WWTF building trusses and posts
• Laging Ligtas
Installed safety railing at Clarifier 2 tanks
Installed canal covers and repair defective platforms and railing
Installed fire alarm beacon at WWTF area
• Visual factory
Rehab of WWTF and sedimentation pit area signage

August, 2007 PRI 1st Sem QEMS Management Review 145


Conclusion
o The smelting section was able to
achieve production requirements.
However, there are still incidences of
smoke and odor emissions.

August, 2007 PRI 1st Sem QEMS Management Review 146


CONCLUSION:

REFINING SECTION HAS SATISFACTORILY DELIVERED THE


VOLUME OF LEAD AND LEAD ALLOYS REQUIRED BY OUR
CUSTOMER,ALTHOUGH THERE ARE AREAS THE NEED
IMPROVEMENT LIKE HIGH LIB CASES OF PERSONNEL.

August, 2007 PRI 1st Sem QEMS Management Review 147


CONCLUSION:
o Data and SWOT Analysis suggest that the section can handle
greater responsibility like the production of melted grids and
scrap rails. By completing the manpower resources and
developing better maintenance management plans, the section
will be able to deliver consistent output. Likewise, a good
planning and an improved technical understanding of
operations involving battery crushing, separation and
desulfurization will enable the section to give better operation
indices such as lower %S and lower %MC.

o The programs and action plans developed will enable the


section to realize its goal and surpass its current limitations.

August, 2007 PRI 1st Sem QEMS Management Review 148


CONCLUSION:

With the implementation of the TPM and engineering programs,


Engineering / Maintenance Section were able to support production
achieve its targets and contribute to lower conversion cost.

August, 2007 PRI 1st Sem QEMS Management Review 149


The WWTF is highly capable of exceeding the effluent
standards.

August, 2007 PRI 1st Sem QEMS Management Review 150


In general, by product waste management-PRF has
exceeded the requirements of its customer. PRI is a
cost saving operation for RAMCAR operation as a
whole.

August, 2007 PRI 1st Sem QEMS Management Review 151


CONCLUSION
The creation of facilities management has contributed
to the realization of TPM-Planned Maintenance
programs.

August, 2007 PRI 1st Sem QEMS Management Review 152


CONCLUSION
o Prepare policy regarding designated signatories in the
absence of LLM/LRR
o Prepare policy on the protection of FL from contamination

The finished lead warehouse management commits to


exceed customer requirements

August, 2007 PRI 1st Sem QEMS Management Review 153


Conclusion
o We in material control section are in
a right track achieving our goal in
having a continuous supply of ULAB /
SCRAP Materials for production , so
that their will be no stoppage in
operation.

August, 2007 PRI 1st Sem QEMS Management Review 154


Strengths Weaknesses
o100% availability of PPEs oSpace constraint
oComprehensive RPE program oLimited personnel capability
oEffective disposal of used PPEs oBudget constraint in RPE upgrade for high
oComplete manning risk activity
oDaily maintenance, inspection and
sanitation of RPE
oProactive personnel
oUpgrade 100% PPE used by PRI employees

Opportunities Threats
oWorld class RPE custodian center oHigh level of lead exposure of personnel
oAssociated to decontamination operation oManpower shortage
oDeputize safety function
oMultiskilled personnel
oVacuum facilities for all employees

August, 2007 PRI 1st Sem QEMS Management Review 155


CONCLUSION
o The section is doing well but we need to
improved the following:

o 1. GHK procedure
o 2. PPE warehouse expansion
o 3. Training of personnel

August, 2007 PRI 1st Sem QEMS Management Review 156

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