MONITORING METHODOLOGY
CHAPTER 7 RESULTS
7.1 Results from Existing Data
Company documentation which was consulted for information gathering was of two basic types, namely that containing data on material inputs and on material outputs in the powder coating process. Tables 7.1 to 7.3 show the total surface area of the workpieces treated on the Paint Line during the three operating cycles. The surface areas for these workpieces were calculated by multiplying the number of each type of workpiece by the estimated surface area of each workpiece. These surface areas were calculated from the formulae derived from breaking down the structure of the workpiece into simple shapes.
The workpieces' dimensions needed for the calculation were obtained by direct measurement of the workpieces and from specifications given by the factory supervisor.
The name and the product code for the workpieces undergoing phosphating were entered in the Daily Production Sheets kept by the line supervisor. The code gives the variable dimensions of the workpiece. The structure and shape of the workpiece were ascertained by observation.
Table 7.1 Workpieces treated on the Paint Line in OC1 Monitoring Period
1 2 3 4 5 6 7 Total
Number of Days 2
4 5 6 3 5 4 29
Number of Workpieces
Treated 11304
8238 6588 9802 3214 3384 3419 45949
Total Surface Area of the Workpiece
Treated (m2) 1667 1060 1204 1204 435 690 2020 8280 Table 7.2 Workpieces treated on the Paint Line in OC2
Monitoring Period 8
9 10 11 12 13 14 15 Total
Number of Days 6
6 3 5 6 6 6 5 43
Number of Workpieces Treated
5459 13288 94 3325 5087 3355 4583 4655 39846
Total Surface Area of the Workpiece
Treated (m2) 2390 2987 201 3990 3117 816 3281 1613 18395 Table 7.3 Workpieces treated on the Paint Line in OC3
Monitoring Period 16
17 18 19 Total
Number of Days 4
7 6 6 23
Number of Workpieces
Treated 5565 10801 3622 796 20784
Total Surface Area of the Workpiece
Treated (m2) 2582 4493 4044 1925 13044 Another piece of new data collected from existing documentation was the chemical additions made to the process solutions contained in Tanks 1 and 2. Table 7.4 shows the date and the volume of Chemrox's Chemcoater 755 (Chemcoater) addtions made to each process tank. Most of the data were recorded in litres. However, three entries were recorded in fractions of a drum and these data were then converted into litres.
Table 7.4 Chemical additions (litres) made to the process solutions after make-up Date
1/0304 2/03/04 3/04/04 8/03/04 9/03/04 10/03/04 24/03/04 25/03/04 26/03/04 1/04/04 19/04/04 20/04/04 4/05/04 12/05/04 21/05/04 24/05/04 25/05/04 1/06/04 3/06/04 7/06/04 10/06/04 17/06/04 24/06/04 30/06/04 8/07/04 13/07/04 15/07/04 19/07/04 22/07/04 23/07/04 26/07/04 27/07/04 29/07/04 Total
Tankl 13 50 13 13 13 0 0 13 0 0 0 25 25 10 0 0 8 0 13 0 0 0 0 0 13 13 0 0 13 0 13 13 0 261
Tank 2 6 0 19 6 6 20 13 0 20 20 12 12 13 10 5 13 25 13 13 13 13 13 13 19 13 13 13 13 13 13 13 13 13 414
Table 7.5 presents the data on the chemicals purchased by the company and used on the Paint Line for the full monitoring period. These include both the quantity and average unit cost for the water, powder, paraffin and Chemcoater. The volume of water coming into the factory was obtained from the Msunduzi Municipality bills. Factory requisition sheets held by dispatch were consulted for powder purchases and data were compiled by Administration on paraffin, steel, Chemcoater and powder. These data are broken down to show the consumption of these raw materials on the paint line for each of the
Monitoring Periods within an Operating Cycle in Tables 7.6 to 7.8. The steel is supplied in many different forms eg. sheets, coils and strips of varying dimensions. These have been allocated by the company Administration in these terms. However it is impossible to present all these data concisely. Therefore the term 'unit' has been used to describe all forms in which the raw material is supplied.
Table 7.5 Raw material data for the factory for the full monitoring period (01/03/04 to 29/07/04)
Raw material Water (kL) Chemcoater
(L) Powder
(kg) Paraffin (L)
Packaging Steel (unit)
Average unit cost/R
6.45+ 7.10*
8.42 31.02 2.59
Into factory from supplier Quantity
685 99 1836 L 10420 52350
Cost (R) 5037
801 15459 323205 135399
Out of store to the Paint Line Quantity Cost (R)
Unavailable Data Data Not Recorded 10717 kg
#*31500
332441 81472 Unavailable Data
5.62 698814 4051301 Not applicable"
Table 7.6 Raw materials used on the Paint Line for OC1 Raw
materials used Water (kL) Chemcoater
755 (L) Powder (kg) Paraffin (L) Packaging Steel (unit)
OC1 MP1
20.7 68.5 340
MP2 10.6 62.25 440
MP3 11.3 88.25 500
MP4 13.1 88.25 560
MP5 5.70 12.5 540
MP6 9.25 12.5 540
MP7 2.90 49 560
Total quantity
73.6 381.25 3480
Cost
499 3210 107950 Data Not Recorded
Unavailable Data
13302 8586 9802 9802 3344 3521 5051 53408 300153
This tariff was charged from the 2nd of February to the 25th of June
*This was the new tariff charged in July
This data was not available as the steel was delivered directly to the Press Department
This quantity was calculated from an average consumption (300 L) per day by dividing the total quantity recorded for 16 days (4800 L)
Table 7.7 Raw materials used on the paint line from 04/05/04 to 02/07/04 for OC2
Raw materials
used
Water (kL) Chem- coater 755
(L) Powder
(kg) Paraffin
(L) Packaging
OC2 MP
8 4.52 37.5 857
MP 9 2.05
0 360
MP 10 2.03 25.5 280
MP 11 5.46
33 640
MP 12 4.65
50 1137
MP 13 5.50 12.5 963
MP 14 4.32 37.5 660 Data Not Recorded
MP 15 2.95
19 600 1200
Total quantity
31.5 215 5497 1200
Cost
214 1810 170517 3108 Unavailable Data
Table 7.8 Raw materials used on the paint line for OC3
Raw materials
used Water (L) Chemcoater
755 (L) Powder
(kg) Paraffin (L)
Packaging Steel (unit)
OC3 MP16
4.89 25 340 1400
MP17 7.39
50 680 2600
MP18 4.71
50 500 2200
MP19 10.7
100 220 Data Not Recorded
Total quantity
27.7 225 1740 6200
Cost 188 1895 53975 16058 Unavailable Data
5861 11368 3722 769 21747 122218
Table 7.9 shows the quantity and cost of the solid waste (domestic) removal. These data are obtained from the Msunduzi Municipality bills. Filled skips, containing solid waste from the process, are rented from and uplifted by a private contractor, Wasteman.
Invoices reflecting these respective costs were unattainable but the estimated cost, obtained verbally, was R300 per month. The maximum error for this value is likely to be
17 % as this verbal estimate was based on recall. However, after checking with commercial removal companies, this does seem to be a good estimate in this case. The information presented in Table 7.10 was compiled from data given in invoices and receipts from Waynes Scrap Metal.
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Table 7.9 Solid waste removed by the municipality Date
02/03/04 - 29/03/04 29/03/04 - 26/04/04 26/04/04 -26/05/04 26/05/04 - 25/06/04 25/06/04 - 30/07/04
Solid waste uplifted by municipality Volume (kL)
1.75 1.75 1.75 1.75 1.75
Cost (R) 712.84 712.84 712.84 712.84 819.74 Table 7.10 Metal waste sold to private contractor Product
Subs Steel Subs Punchings Steel 80 Sub 20
Mixed Steel Steel Punchings
Mixed Steel Steel / Drum L/
Steel 50 / Sub 50
Date 24/02/04
11/03/04 23/03/04 16/04/04 19/05/04 14/06/04 30/06/04 01/07/04 15/07/04 30/07/04 20/08/04 30/08/04 30/08/04
Weight (kg) 2250 3220 1490 1520 1260 1410 1480 3870 1430 1300 310 900 1450 Total
Revenue 1539 2203 2059 0 756 846 888 2322 858 780 201 540 870 13862