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WELCOME TO QC PRESENTATION BY QC ACHIEVERS

Durgapur is situated in the district of Barddhaman in West Bengal state in India. It is located at a distance of 158 kilometer from Kolkata (Calcutta).Its geographical location is defined as 23027’ north and 88029’ east. It is on the bank of the Damodar River. National Highway 2 (Grand Trunk Road) and the Calcutta Delhi railway line passes through Durgapur

QC RESUME
Name of QC
QCFI Membership No. Organisation Address

ACHIEVERS
081516027 Durgapur Steel Plant Durgapur - 713203

Contact Person
Phone No. No. of employees QC team formed on Registration Number Meets on Problem solved till now 3

Mr. Goutam Majumdar
0343-2583436 11884 7th May, 2012 1684 Every Monday 3
STEEL MELTING SHOP (SMS)

Subhasish Singha Roy Mr. Kallol Kumar Ghosh Leader Mr. Facilitator Mr. Devdutta Bhattacharya.MEMBERS – QC ACHIEVERS 4 Mr. Rajesh Prasad Mr. Rama Shankar Kumar Mr. Sudip Kumar Khan .

PROCESS FLOW .DSP CCP W& AP 5 .

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WORK AREA Mechanical Maintenance of the following equipments and systems CONVERTERS LANCE SYSTEM FERRO ALLOY SYSTEM BULK MATERIAL SYSTEM BOTTOM REPLACEMENT DEVICE FURNACE RELINING DEVICE SLAG RETAINING DEVICE GAS VALVE STATIONS 7 .

Mechanical Maintenance of the following equipments and systems WORK AREA STEEL TRANSFER CARS SLAG POT TRANSFER CARS ONLINE PURGING SYSTEM PNEUMATIC TRANSPORT SYSTEM LINING BREAKING MACHINES 8 .

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1 2 3 4 5 6 7 IDENTIFIED PROBLEMS Metal spillage on umbrella skirt and Heat shield during oxygen blowing Delay during tap hole clearing affecting productivity Deflecting shield of Converter getting damaged Huge delay during Converter campaigning Huge delay during old and new hood shifting Dog House door getting frequently deformed and getting jammed blowing Huge quantity of dust and gas emission during oxygen in Converter CATEGORY A A B A C A C . No.LIST OF IDENTIFIED PROBLEMS SL.

CATEGORY A A 10 11 12 13 14 B B A A C . 8 9 IDENTIFIED PROBLEMS Frequent failure of Resilience coupling of Converter Tilting drive Difficulty in checking oil level through glass indicator in Planetary and Bull Gear Box Oil leakage through oil seal from Bull Gear Box of Tilting Drive of Converter Damage of Converter shell at Tap Hole area Bottom screw of Converter getting frequently damaged Frequent damage of converter sample taking pipe Bottom levers of converter getting dislodged very often.LIST OF IDENTIFIED PROBLEMS SL. No.

CATEGORY C C 17 18 19 20 21 Lance emergency lifting clutch failure. Lack of approach of while lubricating out side wheels of lance trolley. 15 16 IDENTIFIED PROBLEMS Frequent failure of coupling pad in convertor tilting drive. No.LIST OF IDENTIFIED PROBLEMS SL. Lance carriage roller getting damaged frequently. Lance cooling hose getting damaged very often Lance oxygen hose frequently getting damaged Lance carriage rope getting jumbled B B C C B .

pneumatic line door getting .LIST OF IDENTIFIED PROBLEMS SL. Huge accumulation of dust in lance manual valve station. No. IDENTIFIED PROBLEMS Failure of pneumatic emergency lifting limit switch of lance CATEGORY 22 23 24 25 26 27 28 A B B B A A A Lack of approach during lance carriage changing Lance trolley locking system failure. Sample carrier getting stuck up frequently inside pneumatic line Sample carrier outer surface getting deformed Sample carrier deformed.

Difficulty In positioning BRD at zero meter level during campaign repair. SRD Need frequent calibration SRD swiveling cylinder pin damage at regular interval Frequent damage of online purging hose in all 3 convertors. BRD getting derailed from track.LIST OF IDENTIFIED PROBLEMS SL. IDENTIFIED PROBLEMS SRD Pneumatic system functioning inconsistently. CATEGORY 29 30 31 32 33 34 35 B B A B A B B . OLP hose getting stuck up in OLP drum during changing. No.

No.LIST OF IDENTIFIED PROBLEMS SL. Furnace relining device cage out very often FRD roller getting damaged very often. Input coupling bolts of telfer getting frequently loose Gear box failure of telfer Input coupling bolts of telfer getting frequently loose Frequent shearing of tool holder bracket in LBM CATEGORY B A A A A/K A/K B . 36 37 38 39 40 41 42 IDENTIFIED PROBLEMS Leveling and centering of FRD difficult under converter.

LIST OF IDENTIFIED PROBLEMS SL. IDENTIFIED PROBLEMS Frequent wear out of drill bit of LBM Huge accumulation of slag and debris in front of passenger lift creating hazards Frequent jamming of HSBD (hood bottom closer device) movement Large number of refractory bricks of main girders damaged Air getting trapped during pneumatic grease pump lubrication with CATEGORY 43 44 45 46 47 48 49 B B C B A A B Co gas line jamming of burner of ladle filling compound Lack of welding provision at pit side area . No.

IDENTIFIED PROBLEMS Frequent wear out of drill bit of LBM Huge accumulation of slag and debris in front of passenger lift creating hazards Frequent jamming of HSBD (hood bottom closer device) movement Large number of refractory bricks of main girders damaged Air getting trapped during pneumatic grease pump lubrication with CATEGORY 43 44 45 46 47 48 49 B B C B A A B Co gas line jamming of burner of ladle filling compound Lack of welding provision at pit side area . No.LIST OF IDENTIFIED PROBLEMS SL.

No.LIST OF IDENTIFIED PROBLEMS SL. IDENTIFIED PROBLEMS Scrap car positioning problem at 0 meter Failure of Nitrogen splashing control valve Huge skull and slag accumulation on lance body Lance centering problem Damage of hand railing of online jam cutting platform Huge slag accumulation at dome area of Lance Insufficient stand for keeping ready lance CATEGORY 50 51 52 53 54 55 56 B A A B A B C .

Lack of approach while tightening coupling bolts in transfer cars Uncontrollable rolling of SLTC and SPTC at sample testing zone and tapping zone Difficulty to position at valve station during hose changing CATEGORY 57 58 59 60 61 62 63 C B B A A B C . IDENTIFIED PROBLEMS Frequent bearing failure of wheel pedestal in steel ladle transfer car and slag pot transfer car Huge slag accumulation on SPTC and SLTC body Unavailability of gear box component causes difficulty Transfer car body crack.LIST OF IDENTIFIED PROBLEMS SL. No.

64 65 IDENTIFIED PROBLEMS Difficulty in lance skull disposal at 26 meter level Torquing technique of wheel pedestal is very difficult and laborious CATEGORY C B 66 67 68 69 70 Transfer car track misalignment Failure of heat shield in transfer car gear box Lance tip failure frequently Cover of SPTC frequently and SLTC getting damaged A A B A B Lance carriage hose resting bracket shear frequently . No.LIST OF IDENTIFIED PROBLEMS SL.

71 72 73 74 75 76 77 IDENTIFIED PROBLEMS Coupling bolts of SPTC and SLTC getting frequently loose Slag Pot top stand getting deformed very often Lance calibration platform getting damaged in regular interval Frequent damage of ultra bush in SPTC and SLTC Bearing end cover of transfer cars coming out frequently Collar deformation of wheel of SPTC and SLTC Cable arm frequently damaged in transfer cars.LIST OF IDENTIFIED PROBLEMS SL. No. CATEGORY A/K B A A A B A .

78 79 80 81 82 83 84 IDENTIFIED PROBLEMS Cabin window too high for operators in pulpit of transfer cars Transfer car coupler damaged Difficulty in fixing EUBA in BMS top end at 34 meter level Vibro feeder canvas damaged in regular intervals Transfer car ladle online purging hose damaged frequently Frequent leakage from intermediate bunkers Slow discharge from vibro feeders CATEGORY C A B A B B A .LIST OF IDENTIFIED PROBLEMS SL. No.

LIST OF IDENTIFIED PROBLEMS
SL. No. 85 86 87 88 89 90 91

IDENTIFIED PROBLEMS
Inspection door of transfer car getting frequently deformed
Conveyor belt getting damaged frequently Ferro Alloy weigh hopper load cell damaged Damage of gunning mass container gate causes delay Frequent leakage through gunning machine pad. Bearing damage of BMS EUBA drive Frequent failure of BMS pneumatic cylinder

CATEGORY A/K B B A A A A

LIST OF IDENTIFIED PROBLEMS
SL. No. 92 93 94 95 96 97 98

IDENTIFIED PROBLEMS
Ferro Alloy conveyor belt frequently getting off centered
Damage of gunning discharge hose Spillage and leakages through Fe-Alloy vibro feeder Difficulty in pouring oil in Gear Box of Transfer cars Gunning mass hose crushed under heavy vehicles Ferro Alloy vibro feeder core misalignment. Gunning mass getting solidified in short delivery pipe.

CATEGORY A A B A A A A

LIST OF IDENTIFIED PROBLEMS
SL. No.

IDENTIFIED PROBLEMS
Frequent damage of rollers in ferro alloy conveyor belts. Filter Regulator malfunctioning. Lubricator system of BMS

CATEGORY

99
100 101 102 103 104 105

B
A A B B B A

Frequent leakage through Ferro Alloy additive chute. Failure of Centralized Grease Lubrication system in BMS. Slag deposition at the mouth of ferro alloy additive chute. BMS tray insider liner damage. 10 ton weigh hopper bracket fixing bolts damaged regularly.

. No.LIST OF IDENTIFIED PROBLEMS SL. 106 107 108 IDENTIFIED PROBLEMS Water valve of gunning machine getting frequently damaged. Gunning mass discharge short pipe damaged frequently. CATEGORY A A/K A Huge accumulation of gunning mass in gunning machine parking area.

CATEGORISATION OF PROBLEMS 60 50 40 30 20 10 0 A B C A/K Number of problems in each category 49 41 13 5 .

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CRITERIA FOR PRIORITIZATION SAFETY (A) PHYSICAL STRAIN (B) ENVIRONMENT (C) COST CONTROL (D) PRODUCTION DELAY (E) 29 .

“A” CATEGORY PROBLEMS AFFECTING CRITERIAS SL. No IDENTIFIED PROBLEMS Metal spillage on umbrella skirt and Heat shield during  oxygen blowing Delay during tap hole clearing affecting productivity Huge delay during Converter campaigning    1 2 3 4 5 6 7               Dog House door getting frequently deformed and getting   jammed Frequent failure of Resilience coupling Tilting drive of Converter  Difficulty in checking oil level through glass indicator in Planetary and Bull Gear Box Bottom screw of Converter getting frequently damaged .

pneumatic line door getting SRD swiveling cylinder pin damage at regular      interval OLP hose getting stuck up in OLP drum during   changing.  . IDENTIFIED PROBLEMS Frequent damage of converter sample taking pipe Failure of pneumatic emergency lifting limit switch of lance  8 9 10 11 12 13 14           Sample carrier getting stuck up frequently inside  pneumatic line Sample carrier outer surface getting deformed Sample carrier deformed.“A” CATEGORY PROBLEMS AFFECTING CRITERIAS SL. No.

No.“A” CATEGORY PROBLEMS AFFECTING CRITERIAS SL. Lack of approach while tightening coupling bolts in transfer cars 15 17 17 18 19 20 21                  Lance calibration platform getting damaged in      regular interval Frequent damage of ultra bush in SPTC and SLTC     . IDENTIFIED PROBLEMS Failure of Nitrogen splashing control valve Huge skull and slag accumulation on lance body Damage of hand railing of online jam cutting platform Transfer car body crack.

“A” CATEGORY PROBLEMS AFFECTING CRITERIAS SL. No. 22 23 24 25 26 27 28 IDENTIFIED PROBLEMS Bearing end cover of transfer cars coming out frequently Cable arm frequently damaged in transfer cars. Transfer car coupler damaged Vibro feeder canvas damaged in regular intervals Slow discharge from vibro feeders                      Damage of gunning mass container gate causes  delay Frequent leakage through gunning machine pad.      .

No.“A” CATEGORY PROBLEMS AFFECTING CRITERIAS SL. 29 30 31 32 33 34 35 IDENTIFIED PROBLEMS Bearing damage of BMS EUBA drive Frequent failure of BMS pneumatic cylinder                       Ferro Alloy conveyor belt frequently getting off  centered Damage of gunning discharge hose Difficulty in pouring oil in Gear Box of Transfer cars Gunning mass hose crushed under heavy vehicles Ferro Alloy vibro feeder core misalignment. .

10 ton weigh hopper bracket fixing bolts damaged    regularly. Huge accumulation of gunning mass in gunning  machine parking area. Water valve of gunning machine getting frequently   damaged. 36 37 38 39 40 IDENTIFIED PROBLEMS Gunning mass getting solidified in short delivery  pipe.  41 42    10 ton weigh hopper bracket fixing bolts damaged      regularly.“A” CATEGORY PROBLEMS AFFECTING CRITERIAS SL. Filter Regulator malfunctioning. . Lubricator system of BMS         Frequent leakage through Ferro Alloy additive chute. No.

Huge accumulation of gunning mass in gunning machine parking area. 43 44 45 46 47 IDENTIFIED PROBLEMS FRD roller getting damaged very often. Input coupling bolts of telfer getting frequently loose         Difficulty in pouring oil in Gear Box of Transfer   cars Gunning mass hose crushed under heavy vehicles Ferro Alloy vibro feeder core misalignment. No.      48 49 Gunning mass getting solidified in short delivery  pipe.      .“A” CATEGORY PROBLEMS AFFECTING CRITERIAS SL.

TOTAL 595 . A B C D E F G H PROBLEM DELAY (HR) 2009 391 46 8 94 32 87 10 30 2010 284 31 7 79 36 68 14 37 524 2011 179 28 9 75 32 80 11 41 580 854 95 24 248 100 235 35 108 1699 TOTAL Huge delay during Converter campaigning SRD swiveling cylinder pin damage at regular interval Failure of Nitrogen splashing control valve Lance calibration platform getting damaged in regular interval Vibro feeder canvas damaged in regular intervals Frequent leakage through gunning machine pad.No.DELAY DETAILS OF SHORT LISTED PROBLEMS SL . Bearing damage of BMS EUBA drive 10 ton weigh hopper bracket fixing bolts damaged regularly.

59 96.86 F Frequent leakage through gunning machine pad.6 CUM.89 90. 235 13.83 78.94 B 95 5.59 G 35 2. 108 6. % 50.26 14.26 64.59 C 24 1.36 85.05 E Vibro feeder canvas damaged in regular intervals SRD swiveling cylinder pin damage at regular interval Bearing damage of BMS EUBA drive Failure of Nitrogen splashing control valve 100 5.69 H 10 ton weigh hopper bracket fixing bolts damaged regularly.PARETO TABLE Problem Code A D PROBLEM Huge delay during Converter campaign Lance calibration platform getting damaged in regular interval DELAY 854 248 % OF TOTAL 50.06 98.41 100 TOTAL 1699 100 100 .

PARETO CHART 1700 1275 Delay Hours 50 850 Cumulative % 100 75 425 0 PROBLEM CODE A D F H E B G C 25 .

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No. 1 2 3 4 5 6 7 8 9 10 ACTIVITIES Definition of Problem Analysis of the Problem Finding out Causes Root Cause Analysis Data Analysis Development of Solution Foreseeing probable resistances Trial Implementation & check performances Regular Implementation Follow up & Review Week Week Week Week Week Week Week Week Week 1 2 3 4 1 2 3 4 1 2 3 4 1 2 3 4 1 2 3 4 1 2 3 4 1 2 3 4 1 2 3 4 1 2 3 4 2 2 1 1 2 2 1 7 3 Continuous 41 .MILESTONE CHART (PLANNED ) Quality Circle: ACHIEVERS Regn. 2012 May ‘12 Jun ‘12 Jul ‘12 Aug ‘12 Sep ‘12 Members Name: Kallol Kumar Ghosh (Leader) Subhasish Singha Roy Sudip Kumar Khan Rajesh Prasad Rama Shankar Kumar Oct ‘12 Nov ‘12 Dec ‘12 Jan ‘13 Number of Meetings Sl. No.Bhattacharya Date of starting the project: 12 May.: 1684 Project : Huge Delay Converter Campaign during Department: SMS Facilitator: D. 2012 Planned Date of completion: 19 Sep .

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BOF CONVERTERS 43 .

BOF CONVERTER 44 .

In the centre section of the vessel the tap hole nozzle is arranged on the tapping side for the liquid steel tapping.scrap. the second step is blowing oxygen into the converter and lastly taking out the liquid steel from the converter into steel ladle. ferro alloy and lime.  The converter vessel is symmetrical types with detachable bottom.PROBLEM DEFINITION Now the process of steel making basically involves three steps-first Is charging of hot metal . .

Inside the converter i. . m. With the help of spur gear .PROBLEM DEFINITION • The working volume of converter vessel with refractory's is 114 cu. Converter can rotate 360 deg. The converter vessel is fastened in the trunion by means of tendon. furnace vessel refractory lining is basic in nature so it is called basic oxygen furnace as oxygen blow is conducted inside the furnace to make the steel ready with required quality.e.

REFRACTORY LINING . tendon tensioning etc.  Converter vessel relining activities and other major activities such as vessel shell repair. tap hole changing.PROBLEM DEFINITION  Inside the converter vessel refractory linings with bricks are basic in nature. commonly known as campaign repair. lip ring changing. This lining needs change after average 4000 heats or according to the condition of converter lining.

THE BOTTOM REPLACEMENT DEVICE(BRD).PROBLEM DEFINITION FOR THE CAMPAIGN REPAIR ACTIVITY THE PRIME IMPORTANT EQUIPMENT IS THE FURNACE RELINING DEVICE(FRD). THE LINING BREAKING MACHINE(LBM) LBM .

.PROBLEM DEFINITION  To perform relining activities the major equipments are bottom replacements device (BRD) and furnace relining device (FRD). With the help of BRD detachable bottom can be removed and with the help of FRD all the relining activities in the converter vessel are done.

FRD machine is taken from parking area to the bottom of converter for remaining task of campaign repair.FRD is prime important machine of campaign repair as almost more than half of the repair job is performed by the FRD itself. After tap hole fixing . After rectification of shell plate new tap hole fixing job is done by the help of BRD machine.After de bricking the converter shell is inspected by operation personnel and required rectification is done by mechanical. .PROBLEM DEFINITION  After LBM completion of bottom removal de bricking inside the converter is done by LBM machine .

START Take Shutdown of Converter Cooling of Converter shell Converter Bottom removal De-bricking of Converter lining Shell inspection by Operation Shell inside cleaned? YES NO Clean and rectified .

K. NO Proper adjustment & repairing • Handed over to refractory for relining job Relining work by using FRD Removal of F.Handed Over to mechanical positioning BRD & tap hole fixing Positioning & centering of FRD For relining YES POSITION O.R. Handed over to Operation END .D.D Bottom fixing with B.R.

we have found that cumulative delay in the 3 years from 2009. .2011 has been 854 hours.IMPACT OF THE PROBLEM  From the data obtained from operation and refractory log book.  Not only the production delay there has been 9 accidents including 11 11  fatal case .

SETTING OBJECTIVES 54 Objective Policy What? How? Methodology Policy .

. rollers . rollers and hoist rope at least 70% and zero accident within 15 November 2012. reduction of consumption of cage telescopic pipe. Our goal is to reduce the delay time by at least 70% and reduction of consumption of cage telescopic pipe. hoist rope and accident at the lowest limit .Our objective is to reduce the delay time at the most.

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ANALYSIS OF PROBLEM(4W-1H) RELINING OF CONVERTER HOW ? Deformation of track & roller WHO ? Maintenance & Refractory crew WHEN ? During Relining WHERE ? Under BOF Converter 461 Hours delay in 3 years WHAT ? FRD Cage out. FRD Centering problem .

ANALYSIS OF PROBLEM(4W-1H) SHELL PLATE REPAIR HOW ? Mismatching of shell plate WHO ? Mechanical maintenance crew WHEN ? During campaign repair WHERE ? Converter body 64 Hours delay in 3 years WHAT ? Delay in changing the damage shell. .

ANALYSIS OF PROBLEM(4W-1H) TAP HOLE FIXING HOW ? Due to centering & tap hole loose WHO ? Maintenance & Refractory crew WHEN ? During campaign repair WHERE ? Converter steel tapping point 15 Hours delay in 3 years WHAT ? Centering & alignment .

ANALYSIS OF PROBLEM(4W-1H) REMOVAL OF OLD BOTTOM HOW ? Due to non splashing of slag WHO ? Mechanical maintenance crew WHEN ? While removing the old bottom WHERE ? Converter bottom area 16 Hours delay in 3 years WHAT ? Old bottom getting heavily jam .

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CAUSE & EFFECT DIAGRAM DELAY IN RELINING Due to roller damage DELAY IN BOTTOM REMOVAL Deformation of track Due to leakage of metal through bricks FRD Cage out Packing material stuck up between ropes Imbalance of rope Due to roller deformation Spillage of metal Bottom stuck up Due to non nitrogen splashing before starting the furnace Due to centering problem of locking eye bolt FRD derail problem Not proper cleaning Presence of skull on the track Interrupted pallet movement Uneven tension of ropes Mismatching of tracks of cage and working platform Damage Shell plate removal& new plate fixing problem Approach problem Telescopic pipe damage Uneven load on pipe Seize of locking screw of bottom lever Overheating of machine Delay during jacking of bottom DELAY DURING CAMPAIGN REPAIR BRD movement problem due to hydraulic failure Shell plate matching problem Converter shell badly deformed Welding machine problem Welding problem Insufficient machine Non availability of overhead crane BRD centering problem During jam cleaning with ACE machine Uneven surface of track New tap hole assembly improper fitted Welding failure Lack of skill of welder Delay in material handling Non availability of overhead crane Tap hole plate improper matching Deformation of tap hole pipe in converter shell DELAY IN SHELL PLATE REPAIR DELAY IN TAP HOLE FIXING 62 .

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CAUSES DELAY IN CONVERTER RELINING DELAY IN BOTTOM REMOVAL/ FIXING DELAY IN SHELL PLATE REPAIR DELAY IN TAP HOLE PLATE FIXING DELAY IN FINAL SYSTEM CHECKING 2009 165 hrs 20 hrs 16 hrs 4 hrs 6hrs 2010 126 hrs 09 hrs 12hrs 6 hrs 7hrs 2011 170 hrs 12 hrs 36 hrs 5 hrs 6 hrs .

New bottom fixing to converter J. New tap hole in converter G. Converter shell repair 2009 3 hrs 20 hrs 6 hrs 7 hrs 16 hrs 2010 2 hrs 9 hrs 3 hrs 4 hrs 12 hrs 2011 5 hrs 12 hrs 4 hrs 4 hrs 36 hrs F. Bottom ramming 4 hrs 165 hrs 6 hrs 8 hrs 4 hrs 6 hrs 126 hrs 7 hrs 4 hrs 3 hrs 5 hrs 170 hrs 6 hrs 4 hrs 4 hrs . Converter bottom removal C. Converter shell de bricking D. Relining delay due to FRD H. Converter shell cooling B. Final system checking I.DELAY ANALYSIS OF CAMPAIGN REPAIR DELAY ANALYSIS A. Converter shell cleaning E.

WHY – WHY ANALYSIS .

RELINING DELAY DUE TO FRD CAGE OUT • Uneven tension in FRD cage rope • Jumbling of FRD rope drum ropes • Overlapping of ropes Why Why Why • Brick packing material getting inserted into the rope drum Why .

INTERRUPTED PALLET MOVEMENT OF TROLLEY AT WORKING PLATFORM • Mismatch of track of trolley and working platform Why • Uneven tension in ropes of FRD cage Why • Packing material getting inserted between ropes of FRD rope drum Why .

INTERRUPTED PALLET MOVEMENT TROLLEY AT WORKING PLATFORM OF • Mismatch of track of trolley and working platform Why • Uneven tension in ropes of FRD cage Why • Shearing of cage holding guide roller Why .

FRD CAGE HOLDING TELESCOPIC PIPE DAMAGE Why Why • Uneven load on telescopic pipe • Sudden derailment of cage • Jumbling of ropes in rope drum with packing materials Why .

FRD DERAILMENT • Deformation of track line and having single collar in FRD wheel Why • Presence of skull and slug on FRD track Why Why • No proper cleaning of track line .

ROOT CAUSES FRD ROPE JUMBLE AND DEFOMATION OF FRD GUIDE ROLLER DERAILMENT OF FRD 72 .

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PARETO . STRATIFICATION.DATA ANALYSIS 74 TOOLS AND TECHNIQUE USED DATA COLLECTION.

5 hrs 2.3 156.3 hrs 2.DATA ANALYSIS OF FRD PROBLEMS DELAY ANALYSIS A.7 hrs 16.8 hrs 4. Delay due to power failure G. Delay due to hydraulic problem B Delay due to rope locking C. Final system checking I .7 hrs 2011 2.8 hrs 2.Delay during lowering the FRD platform J.8 hrs 3. Delay due to centering problem E Delay due to FRD derailment 2009 3.8 hrs 2.6 hrs 19.1 hrs 4.6 64.6 hrs 1. Delay due to FRD fork lift platform dis balancing H.9 hrs 3.2 hrs 77.2 TOTAL 178.1 hrs 29.2 hrs TOTAL (HOURS) 9.7 hrs 1.8 175.1 hrs 43.5 138.8 hrs 2010 2.5 hrs 52.8 hrs 3.7 11.6 21.8 hrs 42.5 hrs 11.9 .2 9 23.6 526.8 9.6 hrs 3. Delay due to FRD balancing problem 4.4 227.9 83.9 hrs 9.9 hrs 3.8 hrs 2.6 hrs F.9 hrs 8.8 hrs 2.9 hrs 66. Delay due to guide wheel failure D.

5 11.DELAY PERCENTAGE TABLE CODE DELAY (Hrs) % G E B F J D A 21.2 64.6 9.8 9 23.7 4.9 227.9 26.34 1.6 11.31 43.2 9.8 1.7 C H I TOTAL 138.7 526.2 2.4 4 12.17 2.49 .1 1.

34 12.8 1.4 9 4 2.51 81.CODE B C E I DELAY(HRS ) 227.2 2.49 CUM% 43.31 92.9 23.6 11.41 98.17 69.13 100 .82 86.5 138.17 26.2 9.1 1.31 4.51 94.7 1.6 9.31 G F J D A H 21.61 96.7 % 43.7 90.2 11.8 64.

PARETO DIAGRAM
500
100 75 50 25 0

400
300 200 100 0 CAUSES B C E I G F J D A H

ROOT CAUSE
FRD ROPE JUMBLE & GUIDE ROLLER DEFORMATION OF FRD CAGE

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DEVELOPING SOLUTIONS
80

TOOLS AND TECHNIQUE USED

BRAINSTORMING

DEVELOPING SOLUTION • While developing solution first proposal to check the cage alignment every hour Evaluation • It will result in delay during campaign repair. 1st Proposal Remarks 81 .

DEVELOPING SOLUTION • The second proposal was that proper track level should be maintained & cage guide channel & telescopic pipe to be chamfered . 2nd Proposal 82 Evaluation • It will eliminate the chances of FRD cage out. Remarks .

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3rd Proposal Remarks 85 .DEVELOPING SOLUTION • Providing a air blower in front of the cage drum to drive out the packing material Evaluation • There is no scope of providing a blower due to scarcity of space on FRD platform.

DEVELOPING SOLUTION Evaluation • Providing cover fabrication on rope drum. 4th Proposal • This will prevent the packing material from getting entangle with the rope drum. Remarks 86 .

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• This will minimize the chances of roller failure due to having more shock absorbing capacity of soft roller.DEVELOPING SOLUTION Evaluation • Replacement of hard roller with soft roller. 5th Proposal Remarks 89 .

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6thProposal Evaluation Remarks 92 .DEVELOPING SOLUTION • Providing guide collar at all the four corners beside FRD wheel .

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9.12 13.0912 17.9.12 14. 1 2 3 4 5 6 7 8 9 10 11 12 TASK Approval to obtain for implementing solution Measurement & Drawing Discussion & check for material availability Approval for procurement Procurement of required materials Fabrication of guide rollers Arrangements to be made before erection Machining of Telescopic pipe Erection of Guard net on rope drum Fitting of new guide rollers Checking Corrective Action to be taken Responsibility SSR KKG SK RP RSK Time Frame Actual time taken Same Same Same Same Same Same Same Same Same Same Same Same 03.10.9.09.09.12 13 14 Checking Data Collection to sustain the process 27.5.9.09.9. Same Same SSR: Subhasish Singha Roy KKG: Kallol Kumar ghosh SK: Sudip Kumar Khan RP: Rajesh Prasad RSK: Rama Shankar Kumar Primary Responsibility Secondary Responsibility In case of Emergency 95 QC Achievers Step 8 DURGAPUR STEEL PLANT .9.12 16.12 15.9.12 24.12– 30.12 – 23.09.9.12 – 26.9.05.12 8.12– 11.12 04.05.12 – cont.RESPONSIBILITY SHARED ACTION PLAN Sl.12 05.12 06.12 07.12 01.

FORESEEING PROBABLE RESISTANCES AND OVERCOMING THEM 96 Tools and Technique used Brainstorming .

FORESEEING PROBABLE RESISTANCES AND OVERCOMING THEM Resistance # 1 • Fixing of cover net over the rope drum of cage by welding was problematic during changing the rope We made removable clamping system of net for easy removing at need Resistance # 2 • To reduce the vibration while moving the cage up& down only chamfering of cylinder was not sufficient • Management had concern about longevity of the hard rollers Chamfering of cage guide channel also done and stud length increased to make it full proof Resistance # 3 Periodic changing of rollers one by one proved that our decision was correct It was a counseling factor to explain them that it will not harm any established design Resistance # 4 • Operation had objection of welding any jack pad to eradicate the leveling problem Resistance # 5 • Management was reluctant of changing any parent design Proper explanation with drawing made it possible to make them agree Resistance # 6 97 QC Achievers • Mental Blockage and reluctant to change This can be overcome with proper counseling Step 9 DURGAPUR STEEL PLANT .

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TRIAL IMPLEMENTATION AND CHECKING PERFORMANCES 99 .

TRIAL IMPLEMENTATION Incorporating the chamfering job on the telescopic tubes and cage guide channel within 19 Sep 12 Replace all the hard rollers with the soft rollers within19 Sep 12 Installing a covering net over the rope drum within 19 Sep12 100 .

CHECKING PERFORMANCES No of cage out before & after modification 6 5 4 3 2 1 0 101 .

CHECKING PERFORMANCES T i m e i n m i n s 400 350 300 250 200 330 360 270 180 210 360 150 210 140 50 100 210 240 0 Campaign time Top Cone Changing Bottom Cone Changing Barrel changing Hood Changing Average time taken for maintenance activities .before and after modification Time taken after modification (in minutes) Time taken before modification (in minutes) 102 .

PDCA. Graph .REGULAR IMPLEMENTATION 103 Tools and Technique used Milestone Chart. Data Collection.

COMPARATIVE GRAPHS 6 Before QC 5 After QC 5 Period of implementation 4 4 4 4 3 3 3 3 3 3 3 2 2 1 1 0 0 0 0 0 0 0 0 SEP 2011 OCT NOV 2011 DEC 2011JAN 2011 2012 FEB MAR 2012APR 2012 MAY 2012JUN 2012JUL 2012AUG 2012 SEP 20122012 OCT NOV 2012DEC 2012JAN 20122013 FEB MAR 2013 2013 104 .

(’000 T) 2034 1914 1966 1888 1961 2008-09 2009-10 2010-11 2011-12 2012-13 105 Remarkable increase in Production of Crude Steel after QC .

95. 000 /. 38.TANGIBLE BENEFIT Increase in number of Heats because of this modification: 30 Heats Average Heat Size: 118 ton liquid steel 30 Heats equivalent to (30 X 118) = 3540 ton of liquid steel Quantity of saleable steel produced @ 90% yield = 3186 ton Thus annual increase in production= 3186 ton / year Value of saleable steel = Rupees 12000 / ton By deducting the value of pig iron from the value of saleable steel. Tangible Benefit = Rupees {3186 X (12000 – 4500)} = Rupees (3186 X 7500) = Rupees 2.per year 106 .

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 Safe working atmosphere Maintenance work simplified Fatigue reduced Better housekeeping Self Satisfaction      Team Spirit increased .

Graph .FOLLOW UP AND REVIEW 109 Tools and Technique used Data Collection.

STANDARDIZATION Necessary changes are made in SMP to prevent future breakdown 110 .

#1 #2 #3 .converter Furnace availability % in BOF BEFORE QC 76 79 81 AFTER QC 95 98 98 NO.

Milestone Chart (Planned vs Actual) Quality Circle: ACHIEVERS Regn.: 1684 Department: SMS Facilitator: D. 2012 Members Name: Kallol Kumar Ghosh (Leader) Subhasish Singha Roy Sudip Kumar Khan Rajesh Prasad Rama Shankar Kumar May ‘12 Sl. 1 2 3 4 5 6 7 8 9 10 ACTIVITIES Definition of Problem Analysis of the Problem Finding out Causes Root Cause Analysis Data Analysis Development of Solution Foreseeing probable resistances Trial Implementation & check performances Regular Implementation Follow up & Review Jun ‘12 Jul ‘12 Aug ‘12 Sep ‘12 Oct ‘12 Nov ‘12 Dec ‘12 Jan ‘13 Number of Meetings Week Week Week Week Week Week Week Week Week 1 2 3 4 1 2 3 4 1 2 3 4 1 2 3 4 1 2 3 4 1 2 3 4 1 2 3 4 1 2 3 4 1 2 3 4 2 2 1 1 2 2 1 7 3 Continuous Planned Actual 112 .Bhattacharya Date of starting the project: 12th May. 2012 Repair of Converter Actual Date of completion: 18th September. No. 2012 Project : Delay in Campaign Planned Date of completion: 19th September. No.

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