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Tundish Centering - CCR - Pratibha

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         From – PRATIBHA- Birla Copper
Hindalco Industries Limited
(Unit : Birla Copper )
Village : Lakhigam
P. O. : Dahej - 392130
Taluka :Vagra
District : Bharuch
Gujarat
Birla Copper Complex
                       Vision, Mission & Goals
Our Vision
Our goal is to be one of the largest manufacturers and suppliers of World Class Quality
Copper and also achieve and maintain World Class Standards in relation to Safe
Workplace, Environment and friend of the Community.
Our Mission
We continue to be System Driven Organization and achieve standards of Excellence in
all areas of Business Operation.

We continue to provide all requisite resources, support, guidance and environment to
our employees and business associates to excel in their standard of performance
focusing on Internal and External Customer Delightfulness.

We continue to lead and support rural development initiatives in relation to education,
health and community development.
Our Goals
To reach productivity and efficiency norms that are international benchmarks for a cost
conscious management of business operations which will not only maximise
shareholder value but also create cost effective option for our customers. These will be
achieved by adopting highest busuness values at all levels.
                     Achievements
Birla Copper's quality standards are recognized internationally. It has been
accorded the LME (London Metal Exchange) registration: its copper cathodes
marketed as "Birla Copper", have been approved as a 'Grade A' Copper brand by
the LME.


Birla Copper has been accredited ISO-9001:2000 (Quality Management
System) and ISO-14001:1996 (Environmental Management System)
certification. Recommended for OHSAS – 18001 Certification.


Dahej Harbour and Infrastructure Ltd. has been awarded the ISO 9001:2000 (Port
Management for Handling Dry and Liquid Cargo) certificate by KPMG.



Birla Copper is awarded commendation certificate - Ramakrishna Bajaj National
Quality Award 2002 of Indian Merchant Chambers for Business Excellence and
Quality Achievements in manufacturing companies category for the year 2002
                     Technologies in Place
Sl No   Plant Area            Process               Technology

  1     Smelter               Flash Smelting        OEC, Finland

  2     Converter             P.S. Converting       OEC, Finland

  3     Copper Refinery       ISA Process           MIM, Australia

  4     Sulphuric Acid        5-stage DCDA          Monsanto, USA

  5     CC Rod                Casting & Rolling     Southwire, USA
  6     Phosphoric Acid       Di-hydrate            SNC-Lavlin, Belgium
  7     DAP Plant             Pipe Reactor          Incro, Spain

  8     PMR Plant             Pyro- Metallurgical   OEC, Finland
                                                    Prax   Air,    USA    and
  9     Oxygen Plant          Cryogenic             Air Liquide ,France

  10    Captive Power Plant   Coal Based            Krupp, Germany

  11    Jetty                 Material Handling     Howe, India
Process Flow
Continuous Cast copper Rods
          Plant – CC Rod
          Technology – Southwire ,USA
          Installed Capacity : 80,000 TPA

          •   Refined Copper Cathode is
              transformed into Continuous Cast
              Copper Rod in the CC Rod plant
              for higher value addition.
          •   Continuous cast copper rods of 8,
              11, 12.5, 16 and 19 mm
              diameters are produced to cater
              to the needs of a wide customer
              range.
          •   The rods hence produced undergo
              on-line defectomat scanning to
              International Quality Standard
              (ASTM B/49/92
                        TEAM

    TEAM MEMBER              RESPONSIBILITY
Mr. SHAKIR VAHORA        • Improvement Implementation.
(Technician)             • Control at Shop-floor level.
Mr. URMESH RANA          • Improvement Implementation.
(Casting Operator)       • Control at Shop-floor level.
Mr. MAHESH AHIR          • Improvement Implementation.
(Casting Operator)       • Control at Shop-floor level.
NILESH CHAMPANERYA       •Data collection
(Mechanical Operator)    •Maintenance Support

Mr. MANOJ SADANANDAN     • Problem Analysis.
(Shift In-charge)        • Action Plan Preparation.
                         • Overall Project Co-ordination.
                        CCR - PROCESS FLOW DIAGRAM



                 HOLDING FURNACE
        Temp
        1200°C    Temp
                  1150°C

   MELTING FURNACE
                                       Tundish
SKIP
HOIST
                                                               ROLLING MILL             NON ACID PICKLING SYSTEM
                                   BAR PREPARATION UNIT
                                                          2 no’s 12” Roughing Stand           IPA treatment
                                                          8no’s of 8” Finishing Stand
                                         Spout
                  CASTING MACHINE                                                                              COILER
                     18 Mt / Hr                                                                               Compacting,
                                                                                                                Strapping,
                                                                                                                & Stretch
                                                                                                                wrapping.
                 FOCUS AREA




Lump Formation
                    PROJECT DETAILS


 START DATE :- 30.07.2004       FINISH DATE :- 30.11.2004

NO. OF MEETINGS             :       16
MEETING DURATION                    :      30 MIN
                                    (EVERY MONDAY)
         IMPACT OF THE IMPROVEMENT

  IMPROVED CAST BAR STRUCTURE.
  REDUCTION IN LUMP FORMATION.
  REDUCED REJECTION AND RECYCLE.
REASONS FOR PROJECT SELECTION

  SELECTION OF THE PROJECT


 REJECTION ON THE GROUND OF
        SPOUT CLEANING


    SOLIDIFIED LUMPS NEAR
            SPOUT


      HEAVY SPLASHING
    WHY SELECTION

 PRODUCTIVITY LOSS.

DETERIORATION OF QUALITY

VALUE LOSS.

CUSTOMER COMPLAINT
                         SPLASHING



EFFECTS ON THE PROCESS :-
Lump formation near spout because of metal splashing.

Lump cleaning leads to rejection of coil.

Metal splashing leads to oxide inclusions in cast bar.
              METHODOLOGY FOLLOWED


            ROOT CAUSE IDENTIFICATION
                        &
            TOOLS AND TECHNIQUES USED

(01) WHY-WHY ANALYSIS was carried out simultaneously to
   arrive at specific conclusion for high risk factors.

(02) ACTION PLAN was drawn on the basis of Analysis and
     Improvement Plan & IMPLEMENTED subsequently.

(03) Sustenance of IMPROVED PRACTICES
                        DATA SOURCE

(1) Shift Engineers’ Log Book.

(2) Coil wise / Parameter wise Inspection Report.

(3) Casting operators logbook.

 Meetings were held once on weekly basis among the team
  members to find a solution.

 Brainstorming + creative thinking were undertaken along
  with Gemba investigation in order to solve the problem.
                       WHY-WHY ANALYSIS
                           Metal Splashing
                                      Why ?
                   Off centered metal flow from
                          pouring spout
                                      Why ?
                          Improper centering of
                        Tundish on casting Machine

                                     Why ?
                       Visual judgment error

                                     Why ?
                   No tool for precision centering
                            CONCLUSION
(01) Some tool has to be designed to eliminate human error in centering
                           ACTIONS TAKEN


No.             ACTIONS TAKEN – AT A GLANCE
1     Study of location of pool position
2     An in-house template designed
3     Trial taken.
4     Operators trained to do centering with help of template
               BEFORE USE OF TEMPLATE




LUMP
FORMATION
AFTER 12 Hrs
of Operation
                ACTIONS TAKEN




TEMPLATE PHOTOGRAPH
EFFECT OF SPOUT POSITION IN X AXIS


       POURING SPOUT




                       LIQUID POOL

  METAL STREAM
         EFFECT OF SPOUT POSITION IN Y AXIS



     POURING SPOUT


    METAL STREAM


                               MOVABLE PRESSURE WHEEL




CASTING WHEEL




                       LIQUID POOL
       RESULTS AFTER USE OF TEMPLATE




NO LUMP
EVEN AFTER
48 Hrs of
Operation
             COST OF PROJECT




TOTAL PROJECT COST                Rs.200
(MATERIAL COST + MANPOWER COST)
             COST DUE TO SPOUT CLEANING


     Estimated Cost Element     Cost / MT
1.   PROPANE                     Rs. 870 / MT
2.   POWER                       Rs. 225 / MT
3.   IPA                         Rs. 60 / MT
4.   CONSUMBLES                  Rs. 320 / MT
5.   OTHERS                      Rs. 175 / MT

Recycle Cost for rejected     Rs. 1650 / MT
material
          ADVANTAGES

LOW SPLASHING IN METAL POOL

 NO LUMP FORMATION NEAR SPOUT


      NO REJECTION DUE TO
        SPOUTCLEANING


     REDUCED RECYCLE LOAD


      HIGHER PRODUCTIVITY
                    RESULTS


       REJECTION DUE TO SPOUT CLEANING

100

 80

 60

 40

 20

  0
       July   Aug     Sep   Oct    Nov   Dec

TONS   81     28      37    33     18    13
                           BENEFITS

TANGIBLE BENEFITS :
SAVING :      Average Reduction in recycle load from 9 Kg./MT to
3 Kg/MT i.e. 6.0 Kg/MT.
Actual SAVINGS :
Considering Annual CCR production during 2003-04 : 91,848 MT
It turns out to be 551 MT per Annum
551 * 1650 Rs./MT = Rs. 9,09,150/-

Potential SAVINGS :-
Considering Annual CCR production capacity of 1,20,000 MT
It turns out to be 720 MT per Annum
551 * 1650 Rs./MT = Rs. 11,88,000/-
                       BENEFITS


INTANGIBLE BENEFITS:

 Improved casting control.

 Better product quality and consistency.

 Eliminating unsafe working condition.

 Increased team bonding and motivation levels.
                        SUSTENANCE PLAN

Sr.   Control Mechanism         Responsibility Frequency   Review
                                                           Mechanism


1     To Prepare document       SHAKIR        Immediately SHAKIR
      on standard procedure
      for tundish centering
2     Regularly implement       Casting       Regularly    Shift
      centering procedure in    Operator                   Engineer
      every changeover
3     Regular linkage of        Manoj         Regularly    Shift
      Procedure with the                                   Engineer
      results and suggest
      further up gradation if
      required.
                ACKNOWLEDGEMENT


We acknowledge our sincere thanks to team of CCR
especially CASTING AND FURNACE AREA for their
valuable suggestion during Brain Storming session
and their support during execution of our project.

We are thankful to HOD-Mr. A. Chakraborty for
pondering the responsibility and support for taking
up the project.

We are thankful to Mr. R. Shankar, Mr. Anil Patro
(Dy,Mgrs-CCR) and Mr. Kunal Joshipura (Sr. Engr.)
for their valuable suggestions and support during
execution of our project.

				
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