QC Presentation Theme
From – PRATIBHA- Birla Copper
Hindalco Industries Limited
(Unit : Birla Copper )
Village : Lakhigam
P. O. : Dahej - 392130
District : Bharuch
Birla Copper Complex
Vision, Mission & Goals
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.
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.
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.
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
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
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
• The rods hence produced undergo
on-line defectomat scanning to
International Quality Standard
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
ROLLING MILL NON ACID PICKLING SYSTEM
BAR PREPARATION UNIT
2 no’s 12” Roughing Stand IPA treatment
8no’s of 8” Finishing Stand
CASTING MACHINE COILER
18 Mt / Hr Compacting,
START DATE :- 30.07.2004 FINISH DATE :- 30.11.2004
NO. OF MEETINGS : 16
MEETING DURATION : 30 MIN
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
SOLIDIFIED LUMPS NEAR
DETERIORATION OF QUALITY
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.
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
(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.
Off centered metal flow from
Improper centering of
Tundish on casting Machine
Visual judgment error
No tool for precision centering
(01) Some tool has to be designed to eliminate human error in centering
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
AFTER 12 Hrs
EFFECT OF SPOUT POSITION IN X AXIS
EFFECT OF SPOUT POSITION IN Y AXIS
MOVABLE PRESSURE WHEEL
RESULTS AFTER USE OF TEMPLATE
48 Hrs of
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
LOW SPLASHING IN METAL POOL
NO LUMP FORMATION NEAR SPOUT
NO REJECTION DUE TO
REDUCED RECYCLE LOAD
REJECTION DUE TO SPOUT CLEANING
July Aug Sep Oct Nov Dec
TONS 81 28 37 33 18 13
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/-
Improved casting control.
Better product quality and consistency.
Eliminating unsafe working condition.
Increased team bonding and motivation levels.
Sr. Control Mechanism Responsibility Frequency Review
1 To Prepare document SHAKIR Immediately SHAKIR
on standard procedure
for tundish centering
2 Regularly implement Casting Regularly Shift
centering procedure in Operator Engineer
3 Regular linkage of Manoj Regularly Shift
Procedure with the Engineer
results and suggest
further up gradation if
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.