Steel Ltd, Vijayanagar

Innovation Project Summary Document No: 2017/INNO/BRM2 - 02

Title Team members (name & section) Project objective Department
ARRANGEMNET OF BENCH GRINDING MACHINE FOR 1 Mr. Rakesh
Uniform profile maintained for
REDRESSING OF BRANDING ELECTRODES. 2 Mr. Arun BRANDING ELECTRODES by Start Date End Date
Team Leader 3 Mr. Abhishek making an arrangement of Bench BRM#2- Operation
grinding machine for Redressing 12.3.2017 21.4.17
4 Mr. Vishwanth Letters.
Name: Mr. Harish M.P

A. Ideation a3. Idea Generation - Possible Solutions for the Problem C. Project Standardization & Commercialization

a1. Problem Definition 1 Changing the Letter Font

 In the Finishing stand LOGO TC ring of sizes 12rb, 16RB & 20rb the profile of branding electrodes was not uniform,Due to which whIle doing 2 Change the Electrode material
spark erosion the depth of the letters marked was not uniform. 3 Making the uniform profile on Letter

a4. Selection of Idea

Idea 1 ie. Changing the Letter Font & Change the logo design are 40
not feasible since it is part of standardized brand

Idea 2 ie Change the Electrode material - is not selected because it

did not match for Machine standards.

Idea 3 ie Making the uniform profile on letter - was selected for

implementation

MATCHING THE PROFILE WITH

TEMPLATE
B. Idea Development (Research & Technology)

1). Observed and studied the process of marking the logo on TC
Rings & brainstorming done to identify the solution for the
mentioned problem.
2). Grinding wheel with same radius profile is procured and
mounted to the bench grinder
3). Three axes movable electrode holder designed, Fabricated and
mounted at convenient distance from the grinding machine.
4). Burrs generated during grinding are removed with needle files.
Results (Calculation)
Pass change time before modification = 517 mins
Pass cahnge time after modification = 435 mins
Decresaed in pass change time after modification = 85 mins
No of Rings required before modification = 100 nos
No of Rings required After modification = 82 nos
No of rings saved after modification= 18 nos

a2. Problem Analysis

1).Profile of electrodes early

Why
2). The depth along the letter is not same as bottom and at
the lugs.
Why
3).Due to problem in the wear out pattern of the logo
electorde
Why
4). Due to design of the logo letter
Why
5.) The area of the lugs and the bottom shank is different
which resulted in more wear out in projected lugs area than
bottom shank

SUMMARY
Saving due to pass change time reduction (A) 9801000 INR
Saving due to pass life improvement (B) 1530000 INR

Total Savings= 1.13 Crore/Year

 Control Chart to monitor process variation
AV EG. E L ET TE R DEP TH AT PO INT A
0.7 B

0.65

0.6
N
0.55

0.5

0.45

AV EG. E LET TE R DEP T H AT P OIN T B

0 7
. B

0.65

0 6
.
N
0.55

0 5
.

0.45

A
Savings Calculation
 Before
Month Rs/T
Sep'16 40.1
Before Rs/T
Oct'16 34.91 50
Nov'16 32.7 40
Dec'16 32.11 30
Jan'16 38.86 20
Feb'16 31.36 10
Mar'16 32.05 0
Sep'16 Oct'16 Nov'16 Dec'16 Jan'16 Feb'16 Mar'16 Apr'1
Apr'16 28.56

After
Month Rs/T
After Rs/T
June'17 25.83 40.00
July'17 18.95
30.00
Aug'17 12.21
Sept'17 21.48 20.00
Oct'17 17.21 10.00
Nov'17 11.00 0.00
Dec'17 30.66 June'17 July'17 Aug'17 Sept'17 Oct'17 Nov'17 Dec'17 Jan
Jan'18 21.20
e Rs/T

Rs/T

16 Feb'16 Mar'16 Apr'16

Rs/T

Rs/T

ct'17 Nov'17 Dec'17 Jan'18

 Pass tonnage and letters depth d
Average depth of other letters (LA & LB )

Sr No. Date of pass change

J S W N E O S T E E L

1 ### 0.42 0.41 0.42 0.41 0.41 0.42 0.41 0.42 0.42 0.42 0.41
2 ### 0.42 0.42 0.41 0.42 0.42 0.42 0.42 0.41 0.41 0.41 0.41
3 ### 0.42 0.41 0.42 0.41 0.41 0.42 0.41 0.42 0.42 0.42 0.41
4 ### 0.41 0.41 0.41 0.41 0.41 0.41 0.41 0.41 0.41 0.41 0.41
5 ### 0.42 0.41 0.42 0.41 0.41 0.42 0.41 0.42 0.42 0.42 0.41
6 ### 0.42 0.41 0.42 0.41 0.41 0.42 0.41 0.42 0.42 0.42 0.4
7 ### 0.42 0.43 0.41 0.41 0.41 0.41 0.42 0.43 0.43 0.43 0.41
8 ### 0.42 0.41 0.42 0.43 0.43 0.41 0.42 0.41 0.41 0.41 0.41
9 ### 0.42 0.41 0.42 0.41 0.41 0.41 0.42 0.41 0.41 0.41 0.42
10 ### 0.42 0.41 0.42 0.41 0.41 0.42 0.41 0.42 0.42 0.42 0.42
11 ### 0.42 0.42 0.41 0.42 0.42 0.42 0.42 0.41 0.41 0.41 0.41
12 ### 0.42 0.41 0.42 0.41 0.41 0.42 0.41 0.42 0.42 0.42 0.42
13 ### 0.41 0.41 0.41 0.41 0.41 0.41 0.41 0.41 0.41 0.41 0.42
14 ### 0.42 0.41 0.42 0.41 0.41 0.42 0.41 0.42 0.42 0.42 0.42
15 ### 0.42 0.4 0.41 0.4 0.4 0.42 0.4 0.41 0.41 0.41 0.42
16 ### 0.42 0.4 0.41 0.4 0.4 0.41 0.41 0.41 0.41 0.41 0.42
17 ### 0.41 0.41 0.41 0.41 0.41 0.42 0.4 0.4 0.4 0.4 0.42
18 ### 0.41 0.41 0.41 0.42 0.42 0.42 0.42 0.41 0.41 0.41 0.42
19 ### 0.41 0.41 0.42 0.43 0.43 0.42 0.42 0.41 0.41 0.41 0.42
20 ### 0.41 0.41 0.42 0.42 0.42 0.41 0.42 0.42 0.42 0.42 0.41
21 ### 0.42 0.41 0.42 0.41 0.41 0.42 0.41 0.42 0.42 0.42 0.4
22 ### 0.42 0.43 0.41 0.41 0.41 0.42 0.43 0.41 0.41 0.41 0.41
23 ### 0.42 0.41 0.42 0.41 0.41 0.41 0.41 0.41 0.41 0.41 0.42
24 ### 0.42 0.4 0.41 0.4 0.4 0.41 0.41 0.41 0.41 0.41 0.42
25 ### 0.41 0.42 0.41 0.42 0.42 0.42 0.41 0.42 0.42 0.42 0.4
26 ### 0.41 0.42 0.41 0.42 0.42 0.42 0.41 0.42 0.42 0.42 0.4
27 ### 0.41 0.42 0.41 0.42 0.42 0.42 0.41 0.42 0.42 0.42 0.4
28 ### 0.41 0.42 0.41 0.42 0.42 0.42 0.41 0.42 0.42 0.42 0.4
29 ### 0.41 0.42 0.41 0.42 0.42 0.42 0.41 0.42 0.42 0.42 0.4
30 ### 0.41 0.42 0.41 0.42 0.42 0.42 0.41 0.42 0.42 0.42 0.4
31 ### 0.41 0.42 0.41 0.42 0.42 0.42 0.41 0.42 0.42 0.42 0.4
e and letters depth details for 12Rb from Apr'17 to Jan'18
A & LB )
Avg. letter Avg. letter
depth on Mid point depth on Tonnage
botton of Letters lugs end at Rolled
5 0 0 D 12 shank 'B' new pass
'A' 'C'

0.41 0.41 0.41 0.42 0.42 0.48 0.55 0.25 215

0.41 0.41 0.41 0.42 0.42 0.48 0.54 0.4 450
0.41 0.41 0.41 0.42 0.44 0.47 0.53 0.44 388
0.41 0.41 0.41 0.42 0.43 0.47 0.52 0.43 515
0.41 0.41 0.41 0.42 0.43 0.465 0.51 0.525 620
0.42 0.42 0.41 0.42 0.43 0.48 0.52 0.25 1590
0.41 0.41 0.41 0.41 0.42 0.48 0.53 0.4 1482.5
0.41 0.41 0.41 0.42 0.42 0.47 0.54 0.44 551.25
0.41 0.42 0.41 0.42 0.44 0.47 0.55 0.43 551.25
0.41 0.42 0.41 0.42 0.43 0.55 0.56 0.58 1056.25
0.41 0.41 0.42 0.42 0.41 0.55 0.57 0.58 1498.75
0.42 0.41 0.41 0.4 0.42 0.55 0.58 0.58 898.75
0.43 0.42 0.42 0.41 0.42 0.55 0.59 0.58 751.25
0.41 0.42 0.43 0.41 0.42 0.55 0.6 0.58 1853.75
0.42 0.41 0.42 0.42 0.41 0.55 0.61 0.58 2008.75
0.43 0.42 0.42 0.42 0.42 0.55 0.62 0.58 1001.25
0.43 0.42 0.42 0.42 0.42 0.55 0.63 0.58 1441.25
0.42 0.42 0.41 0.42 0.43 0.55 0.64 0.58 1128.75
0.41 0.42 0.41 0.42 0.41 0.55 0.65 0.58 1687.5
0.42 0.41 0.41 0.41 0.4 0.55 0.66 0.58 2275
0.43 0.42 0.42 0.42 0.42 0.55 0.66 0.58 1560
0.42 0.42 0.41 0.42 0.43 0.62 0.66 0.64 1866.25
0.41 0.42 0.41 0.42 0.42 0.62 0.66 0.64 1866.25
0.42 0.4 0.41 0.42 0.42 0.62 0.66 0.64 1432.75
0.42 0.41 0.42 0.41 0.43 0.62 0.66 0.64 1432.75
0.42 0.41 0.42 0.41 0.43 0.62 0.66 0.64 1668.75
0.42 0.41 0.42 0.41 0.43 0.62 0.66 0.64 1668.75
0.42 0.41 0.42 0.41 0.43 0.62 0.66 0.64 1687.5
0.42 0.41 0.42 0.41 0.43 0.62 0.66 0.64 1687.5
0.42 0.41 0.42 0.41 0.43 0.62 0.66 0.64 1106.25
0.42 0.41 0.42 0.41 0.43 0.62 0.66 0.64 1106.25
n'18
Reason for pass change
DUE TO LINE MARK IN LINE'A'&LINE'B'
LINE MARK IN LOGO RING (LINE A)
LINE MARK IN LOGO RING (LINE B)
MATERIAL CHIP OUT BETWEEN N AND E
DUE TO CORE SURFACE ROUGHNESS
MATERIAL CHIP OUT BETWEEN N AND E
DUE TO LINE MARK IN LINE'A'&LINE'B'
DUE TO CORE SURFACE ROUGHNESS
DUE TO 'E''W''N' LETTRS WEAR OUT
DUE TO GRADE CHANGE
(500 TO 500D )
DUE TO 'E''W''N' LETTRS WEAR OUT
DUE TO SECTION CHANGE
CRS pass
MATERIAL CHIP OUT BETWEEN N AND E
DUE TO 'N' LETTER CHIP OUT
DUE TO CORE SURFACE ROUGHNESS
DUE TO CORE SURFACE ROUGHNESS
CRS pass
DUE TO CORE SURFACE ROUGHNESS
DUE TO CORE SURFACE ROUGHNESS
DUE TO CORE SURFACE ROUGHNESS
GRADE CHANGED FROM 500D TO CARES
GRADE CHANGED FROM 500D TO CARES
DUE TO CORE SURFACE ROUGHNESS
DUE TO CORE SURFACE ROUGHNESS
DUE TO CORE SURFACE ROUGHNESS
DUE TO CORE SURFACE ROUGHNESS
GRADE CHANGED FROM 500D TO CARES
GRADE CHANGED FROM 500D TO CARES
DUE TO CORE SURFACE ROUGHNESS
DUE TO CORE SURFACE ROUGHNESS
Remarks
Before Grinding
Before Grinding
Before Grinding
Before Grinding
Before Grinding
Before Grinding
After grinding on electrodes
After grinding on electrodes
After grinding on electrodes
After grinding on electrodes
After grinding on electrodes
After grinding on electrodes
After grinding on electrodes
After grinding on electrodes
After grinding on electrodes
After grinding on electrodes
After grinding on electrodes
After grinding on electrodes
After grinding on electrodes
After grinding on electrodes
After grinding on electrodes
After grinding on electrodes
After grinding on electrodes
After grinding on electrodes
After grinding on electrodes
After grinding on electrodes
After grinding on electrodes
After grinding on electrodes
After grinding on electrodes
After grinding on electrodes
After grinding on electrodes