NCQC 2018

5S TEAM “SACHET”-PLATE MILL

BHILAI STEEL PLANT
 5S PRESENTATION
TEAM “SACHET” PLATE MILL
 TEAM “SACHET”

AK Agrawal TR Sulakhe
(Facilitator) (Leader)

VK Sengar (Dy Leader) Yugal Chandrakar

(Member)
PLATE MILL
 PLATE MILL PROCESS FLOW CHART

Depilers Weighing Machine Reheating Furnace Descaler Vertical Edger Roughing Mill

Accelerated Cooling System

Hot Crop Shear Hot Stamping Machine Finishing Mill

Flame Cutting

Leveller Inspection bed Paint marking Machine Shearing Lines

Thinner Plates Thicker Plates

Normalizing Furnace

Despatch
 5S PROJECT

“RECHARGING OF MORE THAN 200

UNIDENTIFIED ASSORTED/RETURNED
SLABS IN PLATE MILL AND
DEVELOPING SOP FOR TIMELY
RECHARGING OF RETURNED SLABS ”
 WHY 5S NEEDED
5S is a structured approach to getting a
workplace cleaned up, organized, standardized,
creating efficiency rather than waste, and
sustaining improvements made.
 GENERATION OF
ASSORTED/RETURNED SLABS
Assorted/Returned slabs are the slabs generated
due to following reason:
1. Slab length not matching as per order
2. Unavailability of orders
3. Slabs not suitable for rolling as per mill
schedule
4. Poor temperature/Problem in mill area
5. Crack, Bend slabs
 WHY ASSORTED/RETURNED SLABS
ACCUMULATED
1. Huge availability of regular heats
2. Loss of identity of slabs
3. Logistics problems for recharging
4. Unavailability of orders
5. Fear of defect on slabs like crack
6. Rolling rate hampered during returned slab
rolling
 ANALYSIS OF PROBLEM USING 5S
TOOLS
1. SEIRI (SORTING)- Sorting of defective and
usable slabs
2. SEITON( SET IN ORDER)- Numbering of slabs
3. SEISO (SHINE)- Chemical analysis,
measurement and allocation
4. SEIKETSU( STANDARDISE)- Process
standardisation
5. SHITSUKE (SUSTAIN)- Continual monitoring
 RESPONSIBILITY MATRIX
Sr ACTIVITY TIME FRAME RESPONSIBILITY
No.

1 Sorting of slabs 4 weeks TRS/ YKC

2 Numbering of slabs 3 week TRS

3 Chemical analysis 2 weeks TRS/VKS

4 Measurement of slabs 2 weeks TRS/VKS

5 Identification and allocation 3 weeks TRS/VKS

6 Shifting of slabs for charging Continuous TRS/YKC

7 Monitoring Continuous All

GANTT CHART
 SORTING OF SLABS ( 1S )

Defective slabs (Bend, Crack) Unidentified Slabs for recharging

Red Tag
NUMBERING OF SLABS (2S)
XRF MACHINE FOR C.A. (3S)
 CHEMICAL ANALYSIS,MEASUREMENT &
ALLOCATION OF SLABS (3S)
SERIAL NO. SLAB SIZE CHEMICAL GRADES THICKNESS SLAB NO.
ANALYSIS ALLOCATED ROLLED ALLOCATED
(MM)
226 G2-3140 Mn=1.25,Nb=0.078 E410 20 2130095
, V=0.09 NORM.

235 G2-2450 Mn=1.08,Cu=1.05, R355 12 2253253

Cr=0.84,
V=0.09
195 G2-2080 Mn=1.69 E410C 10 2186069
64 C-3150 Mn=1.29,Cu=0.28, S355 J2WN 16 2342675
Nb=0.1
92 H3-1860 Mn=1.1, Cr=0.5, E410BR 10 2121241
Cu=0.4
203 C-2200 Mn=0.75 E250BR 12 2339257

202 C-1900 Mn=0.69 E250BR 25 2334030

IDENTIFICATION OF SLABS ( 3S )
 SHIFTING OF SLABS FOR
CHARGING

ASSORTED/
HEAVY PLATE RETURN SLAB
RETURN SLAB TRANSFER CAR TRANSFER CAR
YARD

CHARGING OF
ROLLING OF CHARGING OF
SLABS ON
SLABS SLABS IN RHF
ROLL TABLE
STANDARDAIZATION (4S)

Standardization of process

1. SEIRI (SORTING)- Sorting of defective and

usable slabs
2. SEITON( SET IN ORDER)- Numbering of
slabs
3. SEISO (SHINE)- Chemical analysis,
measurement and allocation
 SUSTAIN (5S)
• Self discipline
• Continual Monitoring
 After
15/03/2018

Before
01/11/2017
 TANGIBLE BENEFITS…
• More than 200 slabs have been salvaged and
rolled in suitable orders thus saving around 4.2
crores of heat making.
Av. cost of slab = Rs 30,000/T
Av. slab weight = 7 T
Saving = Rs. 30,000 X 7 X 200 = Rs 4.2 Crores.

• During heat shortage these slabs helped in

production of plate mill
 INTANGIBLE BENEFITS
• Better house keeping

• Safe work place

• Motivation for continuous improvement

• Standardization of process
 FUTURE PLAN

Recharging of returned slabs within

3 days of returned by continual
monitoring
 KAIZEN 1
• Online CO level monitoring
Total 14 nos of online CO monitor are fixed at
different location of reheating furnaces which
current co level in that area. If level is high,
immediate action can be taken. Safety of the
persons working has got increased.
 KAIZEN 2
• Roller table Jamming
Slabs are transported through roller table from
reheating furnace to rolling stands for rolling of
plates. This roller tables are getting jammed. No
indication was coming before failure. Online
current consumed by motor of this roller table
was shown in each HMI. If current is increasing,
then immediate action taken to avoid
breakdown.
 HMI SCREEN

BEFORE AFTER
 KAIZEN 3
Ensuring working of air cooling system of bull
nose lintel beam structure
Blower is used in reheating furnace to cool bull
nose lintel beam structure of furnace. Earlier
there was no indication of blower functioning
Now pressure inside beam ensures working of
nose cooling blower.
Reheating furnace
 BULL NOSE STRUCTURE

NOSE COOLING FAN

3 Phase 440VAC supply
7.5KW, 2850 RPM

BRICK HANGER
For lining

HOLES
HOLES

9300MM X 500MM SIZE

HOLLOW RECTANGLE SHAPE
BEAM.
 KAIZEN 4
• Better housekeeping using newly designed
buckets
 CREATING AWARENESS
• Regular safety and 5S talk in shift
• Prize distribution to motivate the best 5S team
• To encourage 5S team for KAIZEN
• Continual monitoring of the project
• 5S march past in shop to create awareness
about safety and good house keeping
5S AWARENESS
5S MARCH PAST
5S MARCH PAST
SAFETY MARCH PAST
YOUR QUERY AND SUGGESTION
WILL MOTIVATE US