Lean Six Sigma Project

Reduction of Mix Grade (NCO) generation for HRC

PPC (STEEL ZONE)
Business Excellence 1
PROJECT BACKGROUND
Caster1 Grade Width Thk Caster2 Grade Width Thk
• JSW Dolvi works produce hot rolled coils (Normal grades-high L WT41AM 1250 3.15 - 5.0 L ST29DC 1260 4.5
L+1 MC2052 1250 2.9 - 5.0 L+1 ST29DC 1260 4.5
volume, low strength & Value added grades-low volume, high L+2 MC2052 1250 2.9 - 5.0 L+2 ST29DC 1260 4.5
strength). L+3 MC2052 1250 2.9 - 5.0 L+3 ST29DC 1230 4.5
L+4 SAP44M 1250 4.2 - 5.0 L+4 ST29DC 1230 4.5
• JSW Dolvi plant caters to several industries including automotive, L+5 SAP44M 1230 4.2 - 5.0 L+5 ST29DC 1230 4.5
L+6 SAP44L 1230 2.5 - 2.6 L+6 CG04B1 1230 2.55
projects and construction, machinery, LPG cylinder-makers, cold L+7 SAP44L 1250 2.3 - 3.2 L+7 CG04B1 1230 2.55
rollers, oil and gas sector and consumer durables. L+8 SAP44L 1250 2.3 - 3.2 L+8 CG04B1 1230 2.55
L+9 TR34AL 1250 1.9 - 3.0 L+9 CG04B1 1230 2.55
L+10 TR34AL 1250 1.9 - 3.0 L+10 CG04B1 1230 2.55
• HRC coils width varies from (900mm to 1550mm) & thickness L+11 TR34AL 1250 1.6 - 3.0 L+11 CG04B1 1260 2.6 - 3.25
range from (1.00 mm to 20mm). L+12 TR34AL 1250 1.6 - 3.0 L+12 CG04B1 1260 2.6 - 3.25
L+13 TR34AL 1250 1.6 - 3.0 L+13 CG04B1 1260 2.6 - 3.25
• JSW Dolvi works uses the compact strip production (CSP, Nos-2) L+14 TR34AL 1250 1.6 - 3.0 L+14 CG04B1 1260 2.6 - 3.25
L+15 TR34AL 1250 1.6 - 3.0 L+15 CG/CR 1250 2.5
for producing hot rolled coils. L+16 TR34AL 1250 1.6 - 3.0 L+16 CG/CR 1250 2.5
L+17 TR34AL 1250 1.6 - 3.0 L+17 ST29AC 1250 2.5
• Mix Grade Coils: Hot Rolled Coils which have 2 different L+18 TR34AL 1250 1.6 - 3.0 L+18 ST29AC 1250 2.5
L+19 TR34AL 1250 1.6 - 3.0 L+19 CG/CR 1235 2.5/3.2
Chemical Composition in same coils declared as a mix grade L+20 SH29AL 1250 1.5 - 4.0 L+20 CG/CR 1235 2.5/3.2
coils. L+21 SH29AL 1250 1.5 - 4.0 L+21 CG/CR 1235 2.5/3.2
L+22 SH29AL 1250 1.5 - 4.0 L+22 CG/CR 1235 2.5/3.2
L+23 ST43SL 1250 3.2 L+23 CG/CR 1235 2.5/3.2
L+24 ST43SL 1250 3.2 L+24 CG04BC 1230 2.2
L+25 CG04BC 1230 2.2
L+26 CG04BC 1230 2.2

Business Excellence 2
CHEMICAL COMPOSITION IN DIFFERENT GRADES
All Grades are based on Chemical composition of following Elements ( Minimum & Maximum %) ,as mentioned in TDC.
Carbon (C) : Increased amounts of carbon increase hardness and tensile strength, as well as response to heat treatment (hardenability)
Increased amounts of carbon will reduce weldability
Silicon (Si): increases strength and hardness but to a lesser extent than manganese.

Sulphar (S): improves machinability but lowers transverse ductility and notched impact toughness.

Phosphorus: Increases the tensile strength of steel and improves machinability

Manganese (Mn) : increases hardenability and tensile strength of steel, but to a lesser extent than carbon.

Nickel (Ni) : is added to steels to increase hardenability. It often improves the toughness and ductility of the steel

Chromium (Cr) : increase hardenability of steel and increase the corrosion resistance as well as the yield strength

Copper (Cu) : primary corrosion resistance elements

Molybdenum (Mo):
Niobium (Nb) :
Boron (B) : (ppm)
Vanadium (V) : The addition of vanadium will result in an increase in the hardenability of a steel
Titanium (Ti) : control grain size growth, which improves toughness. Also transforms sulfide inclusions form
elongated to globular, improving strength and corrosion resistance as well as toughness and ductility

Aluminum (Al): added to steel in very small amounts as a deoxidizer. It also is a grain refiner for improved toughness
Nitrogen (N) : (ppm)z

Business Excellence 3
PROJECT SELECTION

FY 2017-18

HRC Production – 3183890 (Tonnes) Mix Grade – 0.78%

MIX Grade Generation – 24703 (Tonnes)
This project selected for both
grades

Normal Grades Value Added Grades

Production - 2511303 (Tonnes) Production – 672587 (Tonnes)

Mix Grade Generation – 10345 Mix Grade Generation – 14358

(Tonnes) (Tonnes)

Mix Grade – 0.41 % Mix Grade – 2.13 %

Non-Confirming Orders (NCO): Orders which are not directly allocated to customers. The non confirming orders include Step
down coils, mix grade coils, taper coils, short coils, defects, etc.

*NCO: Non-conforming orders Source: Production data from PPC

Business Excellence 4
HISTORICAL TREND OF MIX GRADE (NCO) GENERATION FOR HRC (FY 2017-18)

Historical trend of mix grade (NCO) generation (FY 2017-18)

1.20
Mix grade (NCO) generation (%)

1.00 0.95
0.87
0.84
0.81 0.79 0.77 0.77 0.77
0.80 0.75
0.69 0.70
0.56
0.60

0.40

0.20

0.00
Apr'17 May'17 Jun'17 Jul'17 Aug'17 Sep'17 Oct'17 Nov'17 Dec'17 Jan'18 Feb'18 Mar'18

Business Excellence 5
HRC GRADES MADE IN FY 2017-18

HRC GRADES -109 No's

Normal Grades – 19 No's Value Added Grades – 90 No's

JDHCG04ACN JDHSH29ALE JDHCP41ALN JDHST37ALE JDHST44NLJ JDHST54AT1 JDHWT41AH0
JDHCG04ASN JDHSH29ALN JDHCP41AMN JDHST37ATE JDHST44NMJ JDHST57AT1 JDHWT41AH1
JDHCG04CSN JDHST29ACN JDHCP41ATN JDHST37CCZ JDHST46GLA JDHTR34ALA JDHWT41AHE
JDHCG04AIZ JDHST29DCN JDHMC2052A JDHST420CZ JDHST46IHA JDHTR34ALN JDHWT41AHN
JDHCG04BCN JDHST29EXZ JDHGC24ACN JDHST43SLN JDHST46IHN JDHTR34ALZ JDHWT41AHZ
JDHCG04BCA JDHWG29ACN JDHMC20BCN JDHSAP44LJ JDHST46ILA JDHTR34ATA JDHWT41ALN
JDHCG04B1N JDHWG29CCZ JDHMC20BCS JDHSAP44MJ JDHST46ILN JDHTR34ATN JDHWT41AMA
JDHCG04BCS JDHWG29TCZ JDHMC26TPS JDHSG41GLZ JDHST46ILZ JDHTR34ATZ JDHWT41AME
JDHCG04BIZ JDHMC410M1 JDHSG41GMZ JDHST46IMA JDHTR35ALN JDHWT41AMN
JDHCR04ACN JDHPP43MMZ JDHSG41GTZ JDHST46IMN JDHTR35ALZ JDHWT41AMZ
JDHCR04SPN JDHPP46MSZ JDHSG49TCZ JDHST46ITA JDHTR38ACE JDHWT41AT0
JDHPP46RCP JDHSG52TCZ JDHST46ITN JDHTR46TCA JDHWT41ATE
JDHPP46RMZ JDHSH41AKN JDHST52AH0 JDHTR46TCZ JDHWT41ATN
JDHPP46RTZ JDHSH41ALN JDHST52ALE JDHWG34ALN JDHWT41ATZ
JDHPP52MMZ JDHSH41AMN JDHST52ALN JDHWG34ALZ JDHWT41GTZ
JDHPP52MSZ JDHSH41CLN JDHST52AT0 JDHWG34AMN JDHWT41KLZ
JDHPP60MEZ JDHSPF540J JDHST52ATE JDHWT34AMN JDHWT41LHZ
JDHPP60MSZ JDHSPF590J JDHST52GLN
JDHPP65MSZ JDHST52TCZ

Note: As per TDC Agreements, there are 133 TDC’s for VA Grades & 48 for NVA Grades.( Total 133+48 = 181)

Business Excellence 6
 Define Phase

Define Measure Analyze Improve Control

Business Excellence 7
 PROJECT CHARTER

Team Charter
Project Title Reduction of Mix Grade (NCO) generation at for HRC
Business Case Opportunity Statement

This project is taken up to support department objective (D 2.1) to For FY 2017-18 Mix Grade (NCO) generation at Dolvi for HRC was 0.78% , Project target is
reduction of Mix Grade (NCO) generation at Dolvi for HRC in line with reduction from 0.78 to 0.60 %. For FY 2018-19. Project Annual saving will be Lakhs.
focus area "Customer & Quality" from President Policy.

Goal Statement Project Scope

Current Target
S. No. CTQ Goal
Level Time Process : Production Planning & Control
1 Mix Grade generation 0.78 % 0.60 % 31.08.2018
Start Point : HRC Order login in SAP
End Point : NCO Allocation in SAP
Scope In : Monitoring HRC Rolling
Scope Out : Market Constraint
Project Plan Team Members
Phase Start Date End Date Actual End Role in the Team Name Function
Define 01.04.18 30.04.18 30.04.18 Sponsor : Anil Kumar Singh HOD (PPC & Logistic)
Measure 01.05.18 31.05.18 Champion : Ashish Srivastava PPC (Sr Manager)
Analyze 01.06.18 31.06.18 Leader : Sanjeev Pratap Singh PPC (Plant Control)
Improve 01.07.18 15.01.18 Member : Sachin rajore PPC (Plant Control)
Control 01.08.18 3108.18 Member : Yogendra Gupta PPC (Scheduler)
Member : Rajesh Kumar PPC (Plant Control)

Business Excellence 8
 PROJECTED SAVING CALCULATION SHEET

PROJECTED SAVING CALCULATION

Net Sales Revenue of prime coil / Ton RS- /-

Net Sales Revenue of Mix grade generation coils / Ton RS- /-
Difference NSR (Prime – Mix grade generation) RS- /-

2017-18 DATA VAG

Total tonnes produced
Total Mix grade generation produced
NCO % 0.78 %

Target 0.60% LAKHS

Target mix grade generation (NCO) produced SAVING
Difference
Total tonnes saved in mix grade generation (NCO) produced
POJECT SAVING (Lakhs)

Business Excellence 9
NCO FAMILY TREE

NCO
(Non confirming Orders)

Level-1 Grade

Normal Grades Value Added Grades

(Low end application) (High End application)

Level-2 Agency

Marketing Plant Commercial(Quality Arising

(Due to absence of required (Due to Plant diverted due to defects) (Qualitydiverted due to
rolling orders or process Breakdowns & defects)
requirements) Problems)

Level-3 Reason

Quality defects
Mix grade Coils Step down Coils Taper Coils Short Coils
Coils

*NCO: Non-conforming orders

Business Excellence 10
CRITICAL TO PROCESS CHART

Critical Business Critical to

Business Gap Voice of Customer
Requirement Processes

Mix grade (NCO) Minimize the Mix grade Mix grade (NCO) To reduce mix grade
generation. (NCO) generation for generation should be < (NCO) for HCR from
HRC. 0.50 %. 0.78% to 0.60%.

*Note: At this stage it is clear that reduction of mix grade (NCO) generation will be achieved by actions pertaining to marketing (NCO).

Business Excellence 11
SIPOC DIAGRAM – PRODUCTION PLANNING CONTROL

Suppliers Inputs Process Outputs Customers Requirements

•Marketing •Quantity •Hot rolled Coils •WIP •As per customer
•Grade •Final customer specification
•Thickness
•Width
•Edge condition

Start Process Flow End

Order Inventory Sequence Create Rolling Program Release Rolling Control process Mix grade
Login in Check planning Program declared in SAP
SAP

Business Excellence 12
QUICK WINS IDENTIFICATION
To be
S. No. Observation Problem Description Proposed Solution 1 2 3 4 5
implemented
It is observed that Sequence first, Last,
Out of standard First, Last, Step step-down or short coils rolled by mill is Co-ordination with Mill for rolling
1 Y Y Y Y Y Yes
thickness down, Short Coils other than standard customer thickness in standard thickness.
earlier.

S. No. Quick Wins Evaluation Criteria

1 Have a minimal or no capital expenditure
2 Narrow and focused scope (They are not trying to fix the whole process, just a small piece).

3 Improvements may be implemented quickly ( Within 1-2 weeks, usually 1-3 day)

4 Project team has the authority to implement the desired changes

5 Root cause is known and solution obvious to all

QUICK WINS IMPLEMENTATION PLAN

Responsibilities Standardization of
S.No Quick wins Activities Target date Actual date
Person Completion

Out of standard Monitoring of rolling and provided standard

1 thickness rolling thickness to mill in sequence start and Plant Control 20.10.2018 31.10.2018 31.10.2018
end in case unavailable rolling orders.

Business Excellence 13
QUICK WINS IMPLEMENTATION RESULT

Business Excellence 14
 Measure Phase

Define Measure Analyze Improve Control

Business Excellence 15
BRAINSTORMING FOR Y
Following are the possible Causes arrived through brainstorming with team members.

Note: Further drill down these axes have been done in the CE Team Members (Name) Role
diagram given on next slide 1. Sanjeev Pratap Singh Plant Control
2. Sachin Rajore Plant Control
3. Rajesh Kumar Plant Control
Business Excellence 16 4. Yogendra Kumar Gupta Scheduler
DATA COLLECTION PLAN

Data collection plan is shown below in tables for Performance measure (Y) & potential (X) factors.

Performance measure Operational definition Data source and Sample Who will When will data How will data be Other data that
(Y) location size collect the be collected collected should be
data collected at the
same time

Process / Input (X) Operational definition Data source and Sample Who will When will data How will data be Other data that
location size collect the be collected collected should be collected
data at the same time

Business Excellence 17
DATA COLLECTION CHECK SHEET
Coil Material Prod SO Cust Allocation SO_Cust Caster Heat_Posi Slab Rolling
Prod Dt Shift Coil No Batch JSW Grade Width Thick Current SO Cust Name SLoc UD Code Prod Qty Base Price NCO Reason Defect
Status Code Name Reason Seg Number tion Thickness Time

BAVTAWALA IRON & Dummy M_SEQ OPTIMIZATION_MIX MIX Mix grade

4/1/2017 B 1730135810 17D0000057 D S_HRCW JDHCR04SPN 1265 6.00 HSM1 PRIME 24.040 33,685.00 GE 1 L+19 65.000 22:57:35
STEEL PVT LTD. Marketing OEM GRADE GRADE cleared
Dummy M_SEQ OPTIMIZATION_MIX MIX Suitable for
4/1/2017 A 1720140708 17D0000083 D S_HRCW JDHST37ALE 1265 4.50 GIRIRAJ IRON LIMITED HSM1 PRIME 19.630 33,685.00 GE 2 L+18 65.000 22:31:37
Marketing OEM GRADE GRADE Trade only
Dummy MV_SEQ MIX Suitable for
4/1/2017 B 1710137501 17D0000094 I S_HRCW JDHWT41ATN 1260 6.00 JSW CEMENT LTD. HSM1 PRIME 19.500 73,920.00 OTHERS 2 L+19 65.000 22:37:09
Marketing OEM OPTIMIZATION_MIX GRADE GRADE Trade only
MIX
BHARAT IRON Dummy MV_SEQ Cleared by Sr.
4/1/2017 B 1710137508 17D0000101 D S_HRCW JDHST46ITA 1250 8.00 HSM1 PRIME 19.340 33,830.00 GRADE GE 2 L+19 65.000 23:27:39
SYNDICATE Marketing OEM OPTIMIZATION_MIX GRADE Level
CLEARED
MIX
Dummy MV_SEQ Cleared by Sr.
4/1/2017 B 1710137509 17D0000102 D S_HRCW JDHST52AT0 1250 10.00 GIRIRAJ IRON LIMITED HSM1 PRIME 19.350 33,985.00 GRADE GE 2 L+19 65.000 23:33:33
Marketing OEM OPTIMIZATION_MIX GRADE Level
CLEARED
MIX
BHARAT IRON Dummy MV_SEQ Cleared by Sr.
4/1/2017 A 1720140907 17D0000161 D S_HRCW JDHST54AT1 1250 8.00 HSM1 PRIME 23.920 33,830.00 GRADE GE 2 L+22 65.000 02:22:26
SYNDICATE Marketing OEM OPTIMIZATION_MIX GRADE Level
CLEARED
MIX
Dummy MV_SEQ Mix grade
4/1/2017 C 1720141001 17D0000194 D S_HRCW JDHWT41AT0 1250 8.00 MITTAL AGENCIES HSM1 PRIME 19.350 37,925.00 GRADE GE 2 L+23 65.000 02:27:23
Marketing OEM OPTIMIZATION_MIX GRADE cleared
CLEARED
MIX
BAVTAWALA IRON & Dummy MV_SEQ Suitable for
4/1/2017 A 1730136008 17D0000320 D S_HRCW JDHST46ITN 1250 8.00 HSM1 PRIME 18.780 33,685.00 GRADE GE 1 L+1 65.000 04:46:23
STEEL PVT LTD. Marketing OEM OPTIMIZATION_MIX GRADE Trade only
CLEARED
MIX
Dummy MV_SEQ Cleared by Sr.
4/1/2017 C 1720141101 17D0000339 I S_HRCW JDHST46IMN 1250 6.00 JSW CEMENT LTD. HSM1 PRIME 18.770 73,920.00 GRADE OTHERS 1 L+2 65.000 04:51:14
Marketing OEM OPTIMIZATION_MIX GRADE Level
CLEARED
MIX
ASIAN COLOUR COATED Dummy M_SEQ OPTIMIZATION_MIX No Complaint
4/1/2017 A 1730136310 17D0000609 D S_HRCW JDHST29DCN 1250 2.50 HSM1 PRIME 18.740 37,235.00 GRADE CR&GL 1 L+3 65.000 06:34:10
ISPAT LIMITED Marketing OEM GRADE basis
CLEARED
MIX
JSW STEEL COATED Dummy Plant M_SEQ OPTIMIZATION_MIX
4/1/2017 B 1730136401 17D0000853 D S_HRCW JDHCG04BCN 1250 2.50 HSM1 PRIME 18.690 37,450.00 GRADE CR&GL 1 L+4 65.000 06:40:25
PRODUCTS LTD-KLM OEM GRADE
CLEARED
ABHAY ISPAT (INDIA) Dummy M_SEQ OPTIMIZATION_MIX No Complaint
4/2/2017 B 1720141810 17D0001950 D S_HRCW JDHST37ALE 915 2.55 HSM1 PRIME 13.640 33,985.00 . GE 1 L+1 65.000 14:45:03
PVT LTD Marketing OEM GRADE basis
MIX
JSW STEEL COATED Dummy MV_SEQ
4/2/2017 A 1740138401 17D0001965 D S_HRCW JDHST46ILN 915 2.55 HSM1 PRIME 13.620 39,950.00 GRADE CR&GL 1 L+2 65.000 14:52:35
PRODUCTS LTD-KLM Marketing OEM OPTIMIZATION_MIX GRADE
CLEARED
ABHAY ISPAT (INDIA) Dummy MV_SEQ Cleared as
4/2/2017 A 1740138411 17D0001975 D S_HRCW JDHST46ILN 915 3.50 HSM1 PRIME 14.530 34,485.00 . GE 1 L+2 65.000 16:04:37
PVT LTD Marketing OEM OPTIMIZATION_MIX GRADE NCO
BAVTAWALA IRON & Dummy M_SEQ OPTIMIZATION_MIX Cleared as
4/2/2017 C 1710138301 17D0001999 D S_HRCW JDHST37ALE 915 3.20 HSM1 PRIME 14.520 33,685.02 . EN 1 L+3 65.000 16:08:52
STEEL PVT LTD. Marketing OEM GRADE NCO
BAVTAWALA IRON & Dummy M_SEQ OPTIMIZATION_MIX Cleared as
4/3/2017 C 1720142409 17D0002493 D S_HRCW JDHST29DCN 1035 3.20 HSM1 PRIME 15.550 34,485.00 . GE 1 L+8 65.000 23:18:33
STEEL PVT LTD. Marketing OEM GRADE NCO
MIX
JSW STEEL COATED Dummy MV_SEQ
4/3/2017 A 1710138801 17D0002696 D S_HRCW JDHWT41KLZ 1040 4.50 HSM1 PRIME 15.500 36,200.00 GRADE CR&GL 1 L+9 65.000 23:23:06
PRODUCTS LTD-KLM Marketing OEM OPTIMIZATION_MIX GRADE
CLEARED
MIX
JSW STEEL COATED Dummy M_SEQ OPTIMIZATION_MIX
4/3/2017 B 1740139101 17D0003719 D S_HRCW JDHCG04ACN 1015 2.15 HSM1 PRIME 20.160 37,250.00 GRADE CR&GL 2 L+6 65.000 08:04:28
PRODUCTS LTD-VASIN Marketing OEM GRADE
CLEARED

Business Excellence 18
 BASE LINE PERFORMANCE - SIGMA CALCULATION FOR MIX GRADE GENERATION (NCO) FOR HRC

 The calculation of a Sigma level, is based on the number of defects per million opportunities (DPMO).
In order to calculate the DPMO, three distinct pieces of information are required:
a) the number of units produced
b) the number of defect opportunities per unit
c) the number of defects
The actual formula is:
(Number of Defects X 1,000,000)
DPMO =
((Number of Defect Opportunities/Unit) x Number of Units)
For Mix grade generation (NCO) Case:
 Defects: 24703 Six Sigma Table
 Opportunities: 3184132 1 690,000
 Defect Opportunities per unit:1 2 308,000
 DPMO: 7758 3 66,800
 Process Sigma Level : 3.92 4 6,210
5 320
6 3.4

Business Excellence 19
 Analyze Phase

Define Measure Analyze Improve Control

Business Excellence 20
PRODUCTION VS. MIX GRADE GENERATION MAPPING (FY 2017-18) 109 Grades as per TDC
Grades Prod Mix Grade Mix Grade (%) Grades Prod Mix Grade Mix Grade (%) Grades Prod Mix Grade Mix Grade (%)
JDHCG04ACN 231455 5199 2.25 JDHSH29ALE 1071 0 0 JDHTR34ALA 5152 19 0.37
JDHCG04AIZ 1523 0 0.00 JDHSH29ALN 73718 251 0.34 JDHTR34ALN 2925 0 0.00
JDHCG04ASN 433066 640 0.15 JDHSH41AKN 2416 36 1.47 JDHTR34ALZ 9424 0 0.00
JDHCG04B1N 271688 20 0.01 JDHSH41ALN 43343 288 0.67 JDHTR34ATA 3569 63 1.75
JDHCG04BCA 142 0 0.00 JDHSH41AMN 9253 204 2.21 JDHTR34ATN 38 0 0.00
JDHCG04BCN 1127196 1259 0.11 JDHSH41CLN 13941 226 1.62 JDHTR34ATZ 3128 0 0.00
JDHCG04BCS 118 0 0.00 JDHSPF540J 146 0 0 JDHTR35ALN 5551 54 0.98
JDHCG04BIZ 36935 0 0.00 JDHSPF590J 4505 0 0 JDHTR35ALZ 1759 0 0.00
JDHCG04CSN 1569 0 0.00 JDHST29ACN 81091 452 0.56 JDHTR38ACE 2701 61 2.27
JDHCP41ALN 5514 0 0.00 JDHST29DCN 55073 1379 2.50 JDHTR46TCA 15302 77 0.51
JDHCP41AMN 1143 20 1.79 JDHST29EXZ 70665 0 0.00 JDHTR46TCZ 5770 0 0.00
JDHCP41ATN 5880 64 1.09 JDHST37ALE 4742 3990 84.14 JDHWG29ACN 10017 86 0.86
JDHCR04ACN 45919 28 0.06 JDHST37ATE 394 159 40.35 JDHWG29CCZ 11117 0 0.00
JDHCR04SPN 57516 1032 1.79 JDHST37CCZ 632 0 0 JDHWG29TCZ 1423 0 0.00
JDHGC24ACN 3075 53 1.73 JDHST420CZ 695 0 0 JDHWG34ALN 16563 45 0.27
JDHMC2052A 3890 95 2.45 JDHST43SLN 1328 0 0 JDHWG34ALZ 3015 0 0.00
JDHMC20BCN 268 19 6.93 JDHST44NLJ 331 0 0 JDHWG34AMN 215 43 20.14
JDHMC20BCS 546 0 0.00 JDHST44NMJ 326 0 0 JDHWT34AMN 5178 62 1.20
JDHMC26TPS 354 19 5.25 JDHST46GLA 4278 72 1.69 JDHWT41AH0 32901 124 0.38
JDHMC410M1 763 286 37.44 JDHST46IHA 336 0 0 JDHWT41AH1 8564 0 0.00
JDHPP43MMZ 2431 0 0.00 JDHST46IHN 77 0 0 JDHWT41AHE 295 0 0.00
JDHPP46MSZ 2012 0 0.00 JDHST46ILA 1633 54 3.31 JDHWT41AHN 7699 73 0.95
JDHPP46RCP 2573 21 0.81 JDHST46ILN 4473 236 5.28 JDHWT41AHZ 18141 25 0.14
JDHPP46RMZ 2289 0 0.00 JDHST46ILZ 45874 317 0.69 JDHWT41ALN 29935 230 0.77
JDHPP46RTZ 15980 0 0.00 JDHST46IMA 2214 437 19.74 JDHWT41AMA 117 0 0.00
JDHPP52MMZ 28 0 0.00 JDHST46IMN 3717 490 13.18 JDHWT41AME 8288 0 0.00
JDHPP52MSZ 2334 0 0.00 JDHST46ITA 1050 94 8.92 JDHWT41AMN 80023 2935 3.67
JDHPP60MEZ 3313 21 0.63 JDHST46ITN 219 70 32.16 JDHWT41AMZ 1899 0 0.00
JDHPP60MSZ 1182 0 0.00 JDHST52AH0 760 25 3.28 JDHWT41AT0 42243 593 1.40
JDHPP65MSZ 4199 0 0.00 JDHST52ALE 381 22 5.82 JDHWT41ATE 2567 24 0.93
JDHSAP44LJ 3694 0 0.00 JDHST52ALN 18053 434 2.40 JDHWT41ATN 13023 1149 8.82
JDHSAP44MJ 969 40 4.12 JDHST52AT0 15221 491 3.23 JDHWT41ATZ 8814 0 0.00
JDHSG41GLZ 4407 0 0.00 JDHST52ATE 43 0 0 JDHWT41GTZ 716 0 0.00
JDHSG41GMZ 6318 20 0.31 JDHST52GLN 105 0 0 JDHWT41KLZ 36571 388 1.06
JDHSG41GTZ 2132 24 1.15 JDHST52TCZ 367 0 0.00 JDHWT41LHZ 33054 0 0.00
JDHSG49TCZ 161 0 0 JDHST54AT1 1173 24 2.04 Total 3183890 24703 0.78
JDHSG52TCZ 9562 40 0.42 JDHST57AT1 403 0 0.00 Note: Prod & Mix Grade Qty in Tonnes

Business Excellence 21 *Source: Data collected from check sheet

MIX GRADE GENERATION FOR HRC PORTFOLIO MATRIX
3 categories – A,B,C
(Based on prod volume) Mix Grade Generation for HRC (FY 2017-18)
3 Priorities – P1,P2,P3 Category A Category B Category C
(Based on mix grade %)
(Volume >10k ) (Volume 1k to 10k) (Volume <1k)
JDHST37ALE JDHMC410M1
High (=>10) JDHST46IMA JDHST37ATE
JDHST46IMN JDHST46ITN
(Priority-1) JDHWG34AMN

JDHCG04ACN JDHWT41AMN JDHCP41AMN JDHSH41AMN JDHTR34ATA JDHMC20BCN

Medium JDHCR04SPN JDHWT41AT0 JDHCP41ATN JDHST46GLA JDHTR38ACE JDHMC26TPS
(=>1 to <10) JDHSH41CLN JDHWT41ATN JDHGC24ACN JDHST46ILA JDHWT34AMN JDHSAP44MJ
JDHST29DCN JDHWT41KLZ JDHMC2052A JDHST46ILN JDHST52AH0
(Priority-2) JDHST52ALN JDHSG41GTZ JDHST46ITA JDHST52ALE
Mix Grade JDHST52AT0 JDHSH41AKN JDHST54AT1
Genertion
(%) JDHCG04ASN JDHPP46RTZ JDHCG04AIZ JDHSAP44LJ JDHPP46RMZ JDHCG04BCA JDHST420CZ
JDHCG04B1N JDHSH41ALN JDHCG04CSN JDHSG41GLZ JDHPP52MSZ JDHCG04BCS JDHSG49TCZ
JDHCG04BCN JDHST46ILZ JDHSH29ALE JDHSG41GMZ JDHPP60MEZ JDHST37CCZ JDHPP52MMZ
JDHCG04BIZ JDHTR46TCA JDHTR34ALA JDHSG52TCZ JDHPP60MSZ JDHTR34ATN JDHSPF540J
Low (<1)
JDHCR04ACN JDHWT41AH0 JDHTR34ALN JDHSPF590J JDHPP65MSZ JDHST44NLJ JDHST57AT1
(Priority-3) JDHST29ACN JDHWT41AHZ JDHTR34ALZ JDHST43SLN JDHWT41AH1 JDHST44NMJ JDHMC20BCS
JDHST29EXZ JDHWT41ALN JDHTR34ATZ JDHTR46TCZ JDHWT41AHN JDHST46IHA JDHWT41AHE
JDHSH29ALN JDHWT41LHZ JDHTR35ALN JDHCP41ALN JDHWT41AME JDHST46IHN JDHWT41AMA
JDHWG29ACN JDHTR35ALZ JDHPP43MMZ JDHWT41AMZ JDHST52ATE JDHWT41GTZ
JDHWG29CCZ JDHWG29TCZ JDHPP46MSZ JDHWT41ATE JDHST52GLN
JDHWG34ALN JDHWG34ALZ JDHPP46RCP JDHWT41ATZ JDHST52TCZ

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MIX GRADE GENERATION CATEGORIES (A,B,C)– PRIORITIES (P1,P2,P3)
Category A – Priorities - 1 (3 Grades)
Contribution Grades Prod Qty NCO Qty Prod (%) NCO (%)
Category-A, P-1

Category A – Priorities - 2 (10 Grades)

Contribution Grades Prod Qty NCO Qty Prod (%) NCO (%)
Category-A, P-2

Category A – Priorities - 3 (19 Grades)

Contribution Grades Prod Qty NCO Qty Prod (%) NCO (%)
Category-B, P-3

Category B – Priorities - 2 (15 Grades)

Contribution Grades Prod Qty NCO Qty Prod (%) NCO (%)
Category-B, P-2

Category B – Priorities - 2 (33 Grades)

Contribution Grades Prod Qty NCO Qty Prod (%) NCO (%)
Category-B, P-3

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MIX GRADE GENERATION CATEGORIES (A,B,C)– PRIORITIES (P1,P2,P3)
Category C – Priorities - 1 (4 Grades)
Contribution Grades Prod Qty NCO Qty Prod (%) NCO (%)

Category-C, P-1

Category C – Priorities - 2 (5 Grades)

Contribution Grades Prod Qty NCO Qty Prod (%) NCO (%)

Category-C, P-2

Category C – Priorities - 3 (20 Grades)

Contribution Grades Prod Qty NCO Qty Prod (%) NCO (%)

Category-C, P-3

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Business Excellence 25
Business Excellence 26
 Improve Phase

Define Measure Analyze Improve Control

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LEARNINGS + SUGGESTED ACTIONS
Non
Category Grades Finding Potential reason Tool Used Suggested action VAG
VAG

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IMPROVE - ACTION PLAN
Suggested action Responsible Target Date Status

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TREND CHART - MIX GRADE (NCO) GENERATION FOR HRC (FY 2017-18)

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 SIGMA CALCULATION FOR MIX GRADE GENERATION (NCO) FOR HRC – AFTER IMPROVEMET

 The calculation of a Sigma level, is based on the number of defects per million opportunities (DPMO).
In order to calculate the DPMO, three distinct pieces of information are required:
a) the number of units produced
b) the number of defect opportunities per unit
c) the number of defects
The actual formula is:
(Number of Defects X 1,000,000)
DPMO =
((Number of Defect Opportunities/Unit) x Number of Units)
For Mix grade generation (NCO) Case:
 Defects: Six Sigma Table
 Opportunities: 1 690,000
 Defect Opportunities per unit: 2 308,000
 DPMO: 3 66,800
 Process Sigma Level : 4 6,210
5 320
6 3.4

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ACTION NO - (MIX GRADE MATRIX)
Mix Grade matrix (SS = Short Slab, FS = Full length slab)
S.No. Grades 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25
1 JDHSH41CLN FS SS SS FS FS SS SS SS SS SS FS SS SS SS SS SS SS SS SS SS FS FS SS SS
2 JDHSH41ALN FS FS SS FS FS SS SS SS SS SS FS SS SS SS SS SS SS SS SS SS SS SS SS SS
3 JDHWT41AMN FS SS SS SS SS SS SS SS SS SS SS SS SS SS SS SS SS SS SS SS SS SS SS SS
4 JDHST52ALN SS SS FS SS SS SS SS SS SS SS SS FS SS SS FS SS SS SS SS SS SS SS SS SS
5 JDHST37ALE SS FS SS SS SS SS SS FS SS SS SS SS SS SS SS SS FS FS SS SS SS FS SS SS
6 JDHSH41AMN FS FS FS FS SS SS SS SS SS SS SS SS SS SS FS SS SS SS SS FS SS SS SS SS
7 JDHWT41ATN SS FS FS FS SS SS SS SS SS SS SS SS SS SS SS SS SS SS SS SS SS SS SS SS
8 JDHST46ILN SS SS SS SS FS SS FS FS SS FS FS SS SS SS SS SS SS SS SS SS SS SS SS SS
9 JDHST46IMN SS SS FS FS SS FS SS FS SS SS SS SS SS SS FS SS FS SS SS FS SS SS SS SS
10 JDHCP41ATN SS FS FS SS FS FS FS SS SS SS SS SS SS SS SS SS SS SS SS SS SS FS SS SS
11 JDHST46IMA SS FS FS SS FS FS FS SS SS FS SS SS SS SS SS SS SS SS SS SS SS SS SS SS
12 JDHSG41GMZ FS FS SS SS SS SS SS SS SS SS SS SS SS SS FS SS SS SS SS FS SS SS SS SS
13 JDHMC2052A SS SS SS SS SS SS SS SS SS SS SS SS SS SS SS SS SS SS SS SS SS SS SS SS
14 JDHST46GLA SS SS SS SS SS SS SS SS SS SS SS SS SS SS SS FS SS SS SS SS SS SS SS
15 JDHGC24ACN SS SS SS SS SS SS SS SS SS SS SS SS SS SS SS SS SS SS SS SS SS SS SS SS
16 JDHTR38ACE SS SS FS SS SS SS SS SS SS FS SS SS SS SS SS SS SS SS SS SS SS SS SS SS
17 JDHPP46RMZ FS SS FS SS SS SS SS SS SS SS SS SS SS SS SS SS SS SS SS SS SS SS SS SS
18 JDHST46ITA SS SS SS SS SS SS FS SS SS FS SS SS SS SS SS SS SS SS SS FS SS FS SS SS
19 JDHMC20BCS SS SS SS SS SS SS SS SS SS SS SS SS SS SS SS SS SS SS SS SS SS SS SS SS
20 JDHSAP44MJ SS SS SS SS SS SS SS SS SS FS SS FS SS SS SS SS SS SS SS SS SS SS SS SS
21 JDHMC410M1 SS SS SS SS SS SS SS SS SS SS SS SS SS SS SS SS SS SS SS SS SS SS SS SS
22 JDHST37ATE SS SS SS SS SS SS SS SS SS SS SS SS SS SS SS SS SS SS SS SS SS SS SS SS
23 JDHST32ALN FS SS FS SS FS SS SS FS SS SS FS FS FS SS SS FS SS SS SS SS SS SS SS SS
24 JDHPP52MMZ SS SS SS SS SS SS SS SS SS SS SS SS SS SS SS SS SS SS SS SS SS SS SS SS
25 JDHST52ALE FS SS SS FS FS SS SS FS SS FS SS SS SS SS SS SS SS SS SS SS SS SS SS SS
Note: Mix grades matrix will be updated by scheduler for rolling sequence after discussion with quality. This is for Plant control team (internal purpose) for optimize mix grades coils.

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 Control Phase

Define Measure Analyze Improve Control

Business Excellence 33
FULL SCALE IMPLEMENTATION PLAN
Responsible
Tasks Activities Status Actions
person
1. Planning

2. Execution

3. Control

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VISUAL CONTROL SYSTEM - PPMS
Visual Control:
Heat Tapping:
Heat tapping from Shell-1/2/3/4 monitor
by PPMS – Time plan it gives real time
tapping status of heat.

Heat Chemistry: Heat chemistry

(monitor by PPMS) time plan mentoring
screen before connecting to casters &
confirmed by Express lab through
telephonic communication if case of
variation.

Heat Casting: Casting of heat (Heat

position, Casting speed, Ladle
remaining, slab no) monitor through
PPMS – Operation screen.

Heat rolling: Rolling of coils

(Parameter- Grade, width, thickness,
weight) is monitor through PPMS –
Operation screen.

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Business Excellence 36
 Thank You

Business Excellence 37