ROURKELA STEEL PLANT

ERW PIPE PLANT

(ISO 9001 & API Q1) QUALITY MANAGEMENT SYSYTEMS

ACTION PLAN FOR CONTINUAL IMPROVEMENT PARAMETERS FOR THE YEAR (2015-2016)
KEY
SL. TIME
PERFORMANCE PLANNED ACTION PLAN RESPONSIBILITY
NO. FRAME
INDICATORS
91.75 % i) COORDINATION WITH HSM & PPC TO ENSURE THAT COILS
(for 12 3/4" ARE ROLLED IN CLOSE TOLERANCE OF + 0.1 / - 0 MM IN
SECTIONAL I/C (OPN.)
THICKNESS & + 10 / - 0 MM WIDTH. FEEDBACK TO BE GIVEN CONT.
to 18" O.D) AND MILL INCHARGE
TO HSM FOR ANY DEVIATION IN THICKNESS & WIDTH THAN
DESIRED.

ii) COORDINATION WITH HSM TO ENSURE THAT THE THERE IS

NO CAMBER IN THE LEADING & TAIL ENDS OF EACH COIL. SECTIONAL I/C (OPN.)
CONT.
CUTTING OF HEAD & TAIL END IN EACH COILS IS TO BE KEPT AND MILL INCHARGE
TO THE MINIMUM LIMIT AS REQUIRED.
 
91.30% iii) SCRAP PIPE LENGTH GENERATED AS A RESULT OF CROSS
(for 10 3/4" END WELDING IS TO BE KEPT TO THE MINIMUM POSSIBLE. SHIFT I/C
MATERIAL ALSO OD TRIMMING TO BE RESTORED AT THE EARLIEST AFTER (OPERATIONS)
CONT.
1 O.D)
YIELD (%) START OF WELDING.
  iv) EXTERNAL TRIMMING OF UNTRIMMED PIPES AFTER SHIFT I/C
CONT.
REHEATING WITH NEW OD BEAD TRIMMER. (OPERATIONS)
89.64 %
v) UNWELDED PORTION TO BE ADJUSTED & CUT IN FLYING
(for 8 5/8" SHIFT I/C
CUT- OFF M/C SO THAT REJECTED PIPE LENGTH IS AT THE CONT.
O.D) (OPERATIONS)
MINIMUM.

 
vi) CUT-OFF PIPES TO BE SENT TO RFC AFTER PROPER PAINT
SHIFT I/C
MARKING IN WORKS INSPECTION SKID TO ENSURE CUTTING AT CONT.
(OPERATIONS)
THE RIGHT LOCATION.

ACTION PLAN FOR EFFECTIVENESS PARAMETERS FOR THE YEAR (2015-2016)

 KEY
SL. TIME
PERFORMANCE PLANNED ACTION PLAN RESPONSIBILITY
NO. FRAME
INDICATORS
I. CORDINATION WITH PPC / SRM / CMO FOR ENSURING THE
AVAILABILITY OF ORDER FOR THE FULL MONTH.
ROLLING RATE HOD / SECTIONAL
9.10 MT / HR. II. TO ENSURE GOOD EQUIPMENT AVAILABILITY BY PROPER REG.
(FOR 8 5/8" O.D) HEADS (O / M / E )
SHUT DOWN PLANNING & COORDINATION WITH MAINTENANCE
AGENCIES.
I. CORDINATION WITH PPC / SRM / CMO FOR ENSURING THE
ROLLING RATE AVAILABILITY OF ORDER FOR THE FULL MONTH.
2 HOD / SECTIONAL
(FOR 10 3/4" 12.20 MT/HR. II. TO ENSURE GOOD EQUIPMENT AVAILABILITY BY PROPER REG.
HEADS (O / M / E )
O.D) SHUT DOWN PLANNING & COORDINATION WITH MAINTENANCE
AGENCIES.
I. CORDINATION WITH PPC / SRM / CMO FOR ENSURING THE
ROLLING RATE AVAILABILITY OF ORDER FOR THE FULL MONTH.
HOD / SECTIONAL
(FOR 12 3/4" to 16.50 MT/HR. II. TO ENSURE GOOD EQUIPMENT AVAILABILITY BY PROPER REG.
HEADS (O / M / E )
18"O.D) SHUT DOWN PLANNING & COORDINATION WITH MAINTENANCE
AGENCIES.

I. TO ENSURE MINIMUM MILL STOPPAGES

SECTIONAL HEADS
3 REJECTION 0.92 % (MAX.) II. TO ENSURE PROPER IDENTIFICATION OF CROSS-WELD REG.
(O/M/E)
DURING CUTTING IN FLY CUT-OFF & RFC M/C.

I. COORDINATION WITH DIFFERENT AGENCIES LIKE RCL /

OPERATION
MAINT. / TRAFFIC ETC. TO RDEUCE DELAY TIME. SECTIONAL HEAD
18:30 HOURS REG.
II. ENSURE TIMLELY AVAILABILITY OF CRITICAL / REGULAR (OPERATION)
(MAX)
SPARES.
I. TIMELY LIQUIDATION OF DEFECTS.
MECHANICAL
II. ENSURE TIMELY AVAILABILITY OF CRITICAL / REGULAR SECTIONAL HEAD
4 DELAYS 11:00 HOURS REG.
SPARES. III. ENSURE INSPECTION OF EQUIPMENTS AS PER (MECHANICAL)
(MAX)
SCHEDULE
I. TIMELY LIQUIDATION OF DEFECTS.
ELECTRICAL
II. ENSURE TIMELY AVAILABILITY OF CRITICAL / REGULAR SECTIONAL HEAD
7:00 HOURS REG.
SPARES. III. ENSURE INSPECTION OF EQUIPMENTS AS PER (ELECTRICAL)
(MAX)
SCHEDULE
 ACTION PLAN FOR EFFECTIVENESS PARAMETERS FOR THE YEAR (2015-2016)
KEY
SL. PERFORMANC TIME
PLANNED ACTION PLAN RESPONSIBILITY
NO. E FRAME
INDICATORS
RCL, SECTIONAL I/C
I. To plan as per the process chart/Quality plan of RCL prepared for
(OPN.) AND MILL REG.
meeting the requirement of the said Sale order.
INCHARGE
SECTIONAL I/C (OPN)
II. To ensure the competency of the operators through trainings and skill
& REG.
transfers, so that the quality of the product is maintained at all times.
TRAINING ENGINEER

III. Co-ordination with HSM & PPC for rolling of input H.R coils strictly SECTIONAL I/C (OPN.)
REG.
adhering to the requirements of the API specifications. AND MILL INCHARGE

API YIELD FOR

80% IV. To ensure proper calibration of mill stands and mill settings to meet
5 GRADES ABOVE SECTIONAL HEADS
minimum the quality as per Process Chart/quality Plan from the first day of REG.
(O/M/E)
X42(Min %) production.

V. To Ensure the validation of the mill & NDT process for the first day
production is being done and adherence to the frozen parameters is SECTIONAL I/C (OPN.)
REG.
being followed for meeting the quality requirements and also minimizing AND MILL INCHARGE
generation of non conformance products.
SECTIONAL I/C (OPN.),
MILL & NDT NCHARGE
VI. Maintaining the health of the equipments for avoiding reduction of
And SECTIONAL REG.
quality due to equipment malfunctioning.
INCHARGE (MECH. &
ELEC.)

VII. Regular review of the performance and to carry out necessary HOD,SECTIONAL
REG.
CAPA. INCHARGES &RCL

APPROVED BY-