VISA STEEL Page |0

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National Convention on Quality Concepts
NCQC- 2022
E a) Name : VISA Steel Limited

Sl. No : Kalinganagar Industrial ComplexPage No.

Contents
PoVISA STEEL LIMITED
: Jakhapura
b) Address
Dist. : Jajpur,
1 Company IntroductionKalinganagar Industrial3 Complex
Odisha Pin :
2 CASE STUDY to DRI
Introduction Jakhapura Road, Odisha- 75502
755026
4
: Phone : (+91 – 6726) 242444
3 Quality Circle CoverMobile
Page : +91-7606845177 5-6
c) Phone / Fax/ Email
Fax : (+91 – 6726) 242444
4 ELIMINATION OF FREQUENT
Identification of Problems
Email : qms@visasteel.com 7 - 8
5 FAILURE OF Selection
BAGGING MACHINES
of Problem 8 - 10
d) Contact person/ Coordinator : Mr. Ajeet Singh
6 AND SPILLAGE OF SPONGE
Define IRON
the Problem 11 – 14
7 e) When QC movement
Setting of objectives
started : Jan – 2017 14 - 16
8 Identification of Causes 16 - 18
f) No. of QC in the Organization : 27
9 Validation of Causes 19
10g) No. of Employees
Root– Couse
ExecutiveAnalysis
/ Staff : 546 (Ex - 214 + Non - Ex - 332) 19-21

11 Data Analysis 21-23

: Pig Iron, Sponge Iron, Billet, Angle,
Wire Rod, Round Bar, TMT, Flat ,
12h) Product / Service
Developing Solution 24
Ferrochrome
13 Foreseeing Probable Resistance 25
i) Other quality concept implemented : ISO-9001:2015, KAIZEN, 5S and TPM
14 Trail Implementation 26-32
15j) QCFI Institutional
Check List
Membership no : 071539117761
33-35

CASE STUDY – ELIMINATION OF FREQUENT FAILURE OF BAGGING MACHINES AND SPILLAGE OF SPONGE IRON

CONTENTS

T E A M INNOVATOR
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COMPANY INTRIDUCTION
VISA Steel Limited is a part of the VISA Group founded in 1994 by Mr.Vishambhar Saran. The
VISA Group is a Minerals, Metals and Energy Conglomerate that believes in
leveraging its core strengths to create high quality assets and rewarding long term
businesses in Steel, Power and International Trading. VISA Steel has created facilities
for production of Special Steel, Ferro Chrome and Coke at Kalinganagar Industrial
Complex, in the mineral rich State of Odisha based on MoU signed with the State
Government. The Company is having its Registered Office in Bhubaneswar; Corporate
office in Kolkata and Branch Offices across India. The Company is having a reputed
Board of Directors, experienced and professional Promoters and Management Team, who have a strong
track record in business and industry. VISA Steel’s shares are traded on the BSE and NSE.

 Commodity Trading
 Shipping & Chartering
 Structured Trading
 Investment in Mining

VISA
MINMETAL

 1,50,000 TPA Ferro Chrome Plant

 25x3 MW Captive Power Plant
 2,25,000 TPA Blast Furnace Plant
 3,00,000 TPA DRI Plant
 5,00,000 TPA Steel Melting Shop
and Wire Rod & Bar Mill
VISA STEEL

 4,00,000 TPA Coke Plant

 Equipped with environmental friendly
Chinese technology.
 Major supplier for Blast
Furnaces & Foundries
VISA COKE

INNTRODUTION TO DRI

T E A M INNOVATOR
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Sponge Iron

It is the resulting product of solid state reduction of iron ores or pallets (generally of high
grade), the principal constitutes of which are Metallic iron, residual iron oxides, Carbon, and
impurities such as Sulphur, Phosphorus and Gangue.
The mass obtained after reduction is quite softer and in spongy form. The structure of it
looks like honeycomb so it is called Sponge Iron.
Iron ore (hematite Fe2O3) being fed to the rotary kiln in the presence of temperature

(8000C to 11000C) and reductant CO, getting from coal which is fed from feed side of kiln with
iron ore and injected from kiln outlet. Coal is being burnt by the air input provided from shell
air fan mounted on kiln shell and central burner fan provided at kiln outlet. After reduction
material taken to cooler through transfer trolley where indirect cooling occurs by water sprinkled
on cooler shell. The cooled DRI with dolochar discharged from cooler below 80 0c conveyed to
product separation building where the non-magnetic (dolochar) and magnetic (DRI) are
separated and stored in different bins for dispatch.

T E A M INNOVATOR
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QUALITY CIRCLE COVER PAGE INFORMATION

 Project started : 1/02/2022

 Project implemented: 31/03/2022

Organization VISA STEEL LIMITED

QCFI Membership No.  071539117761
Title of Case Study ELIMINATION OF FREQUENT FAILURE OF
BAGGING MACHINES AND SPILLAGE OF
SPONGE IRON
Our QC consists of members(Female/Male) Male – Four Members
Average age of our QC member 25 - 35
is(youngest/oldest)
QC meeting takes place During working hours
Meeting Day/Frequency Wednesday(Weekly)
Name of chapter convention attended in 2021

Project:- Elimination of frequent failure REASON FOR SELECTION

of bagging machine and spillage of o Unable to track fault in Bagging M/C.
sponge iron o Elimination of spillage of sponge iron.
o Reducing failure of Bagging.

PROJECT NUMBER DATE OF BEGINNING DATE OF COMPLETION

01 1st Feb 2022 30th April 2022

MEETING DAY TIME NO OF PROJECT
COMPLETED
WEDESNEDAY 3:00 PM TO 4:00 PM 01

T E A M INNOVATOR
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T E A M INNOVATOR
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T E A M INNOVATOR