Reducing of Line Stopagges

CONTINUOUS GALVANIZING LINE-2 QC PROJECT
Reducing of Line
Stoppages in CGL-2
CGL 1 1
TEAM MEMBERS
• Mr. Amit Mittal (LEADER)

• Mr. Samit Killedar (Member)
• Mr. Bhavik Patel (Member)
• Mr. Vijay Ambaliya (Member)
CGL 1 2
DEFINE
CGL 1 3
LINE TECHNICAL SPECIFICATIONS

• Line Speed : 150 MPM (max)
Thickness range : 0.12 mm to .60 mm

Width : 700-1250 mm
Furnace Output : 25 MT/Hrs
•Input Material Grades: Cold rolled low/Med/high carbon steel

•Output Material Grades: CQ,LFQ & Full Hard Galvanisied
material
CGL 1 4
CGL 1 5
EFFECTS OF DELAY
 Line stoppages.
 Diversion of Material.
 Sheet breakage.
 Time loss in setting line again.
 Production loss .
CGL 1 6
Methodology
1) Data Collection. (July-06)
2) Analyzed the Process & Data. (Aug-06)
3) Verification. (15th Sep-06)
4) Implements of Action. (March-07)
5) Hand over of project.
CGL 1 7
MEASURE
CGL 1 8
CGL2 DELAY FOR 2006-2007
DELAY FOR CGL_2 2006-07

Month % DELAY Stoppages 1 0.95 100
Apr-06 0.17 10
May-06 0.95 22 0.9 90
Jun-06 0.59 13
0.8 80
0.7 70
No. of Stoppages
Power Failure is not Included 0.59
0.6 60
in this Graph % DELAY
0.5 50
0.4 40
0.3 30
0.2 0.17 22 20
13
0.1 10 10
0 0
Apr-06 May-06 Jun-06
MONTH
CGL 1 9
R EA S ON F OR Ap ril M ay J une J uly Aug Sep

D EP T
D ELA Y S
R ES P ON S IB LE Time (min) Delay Time (min) Delay Time (min) Delay Time (min) Delay Time (min) Delay Time (min) Delay
M o t o r/ D riv e 28 3 42 12 102 5 4 1 95 2 7 2
P LC 28 5 0 0 0 0 0 0 0 0 0 0
F urna c e 0 0 0 0 0 0 15 1 422 3 0 0
Ele c t
F ie ld D e v ic e 0 0 356 7 100 7 23 3 0 0 4 1
W e ld e r 15 1 0 0 0 0 20 1 3 1 0 0
Ot he rs 3 1 26 3 52 1 140 1 0 0 131 1
R EA S ON F OR Oct No v Dec J an Feb M ar
D EP T
D ELA Y S
R ES P ON S IB LE Time (min) Delay Time (min) Delay Time (min) Delay Time (min) Delay Time (min) Delay Time (min) Delay
M o t o r/ D riv e 0 0 11 2 36 6 9 2 40 3 19 3
P LC 0 0 0 0 536 3 0 0 0 0 0 0
F urna c e 0 0 65 2 30 1 110 1 0 0 0 0
Ele c t
F ie ld D e v ic e 0 0 0 0 0 0 0 0 0 0 0 0
W e ld e r 0 0 4 1 64 1 109 1 22 1 0 0
Ot he rs 0 0 15 1 195 3 0 0 66 1 0 0
CGL 1 1
0
CGL-2 DELAY FOR 2006-2007
EQUIPMENT DELAY FREQ. % DELAY DELAYS FOR CGL-2 2006-07

700 100
Furnace 642 8 21.78 642 628
Others 628 12 21.31 90
600 564
PLC 564 8 19.14 80
483
Field Device 483 18 16.39 500 70
Motor/Drive 393 41 13.34 393 60
DELAY (Min)
FREQUENCY
400
Welder 237 7 8.04
50
TOTAL 2947 94 100
300 41
237 40
200 30
18
20
100
12
8 8
10
7
0 0
Furnace Others PLC Field Device Motor/Drive Welder
EQUIPMENT
CGL 1 1
1
ANALYSIS
CGL 1 1
2
Total Fishbone Analysis

Electrical
Breakdown Operation Breakdown
USSD
Line Stoppages
Mechanical
Breakdown
Utility
Raw Material
Breakdown
Schedule Problem
Shutdown
CGL 1 1
3
Fishbone Analysis
Electrical Breakdown
PLC
Furnace
Field Devices
Electrical
Stoppages
Motor /Drives
Welder
CGL 1 1
4
Tension Leveller Rolls Fishbone Analysis

Mechanical Breakdown
Steering Units Exit Section
Uncoiler Recoiler
Chromic Section
Coil Car
Exit Looper
Br-7
Mechanical
Stoppages
Water Cool Damper

Wringer Roll
Control Valves Water Pump Pot Rolls
Air Knife
Blowers Dunk Roll
Welding Snout
Boot Roll Pneumatic problem
machine Hearth Roll
Water QT Zn Pot Area
Jet Cooler
TDR
Furnace
Section
CGL 1 1
5
Fishbone Analysis
Operation Breakdown
Steering Units New Product development
Welding machine
Coil Cutting &

Feeding
Operation
Stoppages
Pot Roll Scraping

Coil Not Ready
Side Tracking Zn Pot Area Operator Mistakes

Strip
Breakages
CGL 1 1
6
ROOT CAUSE & COUNTER MEASURES (ACTION PLANS): For Maintenance

1) FURNACE SECTION.
A) Root causes:-
 Hearth Roll was not going in oscillation mode during Line Stop.
 N2 Quenching was not sufficient during line stop in Zone-3
 Seal Roll was not getting DN after line starting & no F/B was in HMI.
 Furnace tripped because there was no delay for valve Micro switch f/b.
B) Root causes Action Plan:-
 Made logic in PLC for Hearth Roll oscillation mode selection during Line Stop. so that if
operator forget to put in oscillation mode it will go Automatically. This will avoid roll bending
Problem.
 Additional Valve provided for N2 Quenching during line stop in Zone-3.This additional
quenching avoid the strip breakage in line stop.
 Made logic in PLC for automatic Seal Roll DN after line starting & its F/B given in HMI. This
will avoid the Adherence or Furnace pressure problem.
 Provided delay time for valve Activation F/B in PLC. This will avoided spurious tripping of
furnace.
CGL 1 1
7

1) FURNACE SECTION.
A) Counter Measures:-
 Modification of Burners & new UV Sensor to be installed because of the prevalent problem
of burner sensing.
 Damper Flow S/W to be provided with furnace tripping interlock..
 Furnace Automation in STC Mode to be tuned.
 Furnace Entry Seal Blower Temp F/B was not available in HMI.
 Damper should Open with N2 Quenching as well as with line stop.
 Water Level of emergency tank F/B to be given in HMI.
B) Counter Measures Implemented Action Plan:-

 Modification of Burners & new UV Sensor to be installed because of the prevalent
problem of
burner sensing (Still pending).
 Damper Flow S/W FB taken in PLC & HMI & Also taken in furnace tripping interlock . It
will
avoid the damper failure in case of water flow fail in damper.
CGL 1 1
8
Implemented Action Plans & Action against the root causes & its Advantages:
1) FURNACE SECTION.
 Done furnace PID tuning & changeover it to STC mode & Auto Control.
 Furnace Entry seal blower temp. FB given in HMI to monitor seal temp.
 Made logic for damper Open with N2 Quenching as well as with line stop. to avoid the damper failure
due to high temp. & pressurized flue gases.
 Water Level of emergency tank F/B given in HMI. With minimum limit Alarm this will alert to
operator & avoid the water cool damper & JCF heat exchanger.
CGL 1 1
9

2 ) PLC.
A) Root causes:-
 CGL-2 Main NG Valve I/C NG Supply from Gal-1 because of Common
NG Line from Gal-1.
 Provide Separate Power Supply to NG Valve in case of CGl-1 Power Failure.
 Line HMI Communication Failure because of TCP/IP Cable loosed at PLC.
 L-2 Automation to be Implemented with L-1 for line set points.
 SBS Supply to be provided for UPS system.
CGL 1 2
0

2 ) PLC.
 Line HMI Communication Failure because of TCP/IP Cable loosed at PLC.
 L-2 Automation to be Implemented with L-1 for line set points.
 SBS Supply to be provided for UPS system.

 Done Cable dressing properly to avoid the loose connection at TCP/IP Port.
 Made Logic For data transfer from Level-2 To level-1 & Implemented with transferring
the various set points from L-2.

 SBS Supply is a external Supply will switching whenever any problem occurred in
UPS internally. This will avoid the CPU Memory wash out.
CGL 1 2
1

3) WELDER SECTION.
A) Root causes:-
 Welder Cooling Pump was off after power failure which was the cause of line stoppage.
 Welder Shear Limit Switch lever got broken which was the cause of line stoppage.
 Welder Weld head Proxy got stuck with strip due this line stopped.

 Made logic for welder pump automatically ON after Power Failure, to avoid the such type of
delays.
 Made Arrangement for Proximity instead of Limit Switch.
 Made Arrangement of Safety cover for Proximity Protection.
CGL 1 2
2

3) WELDER SECTION.
 Line Emergency S/w to be provided at Welder Desk.
 Entry Jog switch to be provided at Welder Desk.
 Welder Unitroll Current Controller was getting Hanged due insufficient cooling in panel .

 Line Emergency switch provide at welder desk as concern safety & slippages of sheet from bridle.
 Entry jog Switch Provide at welder desk to avoid the welding delay.
 Made arrangement of cooling Fan inside the panel to avoid the heating which was the cause of
Unitroll Current Controller Hanging.
CGL 1 2
3
4) DRIVES SECTION.
A) Root causes:-
 All Furnace hearth roll & Seal Roll Drive Communication failure during Multidrives ACB off for
Maintenance.
 Exit Pinch roll-5 & 6 Motor jog with starter was the cause of loop formation in exit section.
 Aux. Drives MCCB Tripping Problem was due to load current setting was not proper.
 Drives tripping At Cho fault still pending. Solution Awaited from M/S ABB.

 ALL Drives NDBU supply was from Multidrives ACB. Provide separate UPS Supply for NDBU
instead of Multidrives ACB.
 Spare AC Drives used for Pinch Roll-5 & 6 instead of Starter to avoid the Loop formation
problem in exit.
 Done all Aux. Drives Incomer Current setting as per max. load.
CGL 1 2
4
4) DRIVES SECTION.
 APC Blower & Air Knife drive emergency s/w to be provided at the equipment.
 Entry Looper counter weight to be increase for proper tension compensation.
 Exit looper position Absolute value Encoder to Be fixed & calibrated.
 Fan Cooled AC Drives SFU to taken with Fan Switch on interlock.

 Provide Emergency switch at APC Blower & Air Knife Blower to avoid the safety hazard.
 Entry looper Counter weight increase & done its tuning for proper tension compensation.
 Exit Looper Absolute Position Encoder installed & calibrated it. Also made option in PLC to
use either Motor tacho or Absolute Encoder.
 Fan Cooled AC drives SFU to be on Only when its Cooling Fan MCB is on. This is to avoid the
drive over temperature tripping in case of if maintenance people forget the Switch on Fan MCB.
CGL 1 2
5

5) Field Devices.
A) Root causes:-
 Line Steering 3 & 4 was not controlling in auto mode due to LVR was not there.
 Control Desk 24V Looping loose in CD was the cause of line stoppages.
 Line All Pressure Switch Setting to be done.
 Steering Panel Found OFF was the cause of Line stoppages.

 Steering 3 & 4 new LVR Installed & done its calibration for Auto Control as per LVR FB.
 To avoid +24 Volt Looping loosing problem provide separate looping at another end in
all Control Desk.

 All Line Pressure switch setting done as per required Pressure.
 To avoid the such type of Problem given its FB in HMI Alarm as well as Provide hooter.
CGL 1 2
6
5) Field Devices.
 Air Knife Exit side Pressure was getting drooped at Air Knife.
 Pneumatic Clamp to be installed in the line Entry Process & Exit Area.
 Steering -3 mounting Design was not proper As per EMG. It to be mounted vertically as
per new design.

 Air Knife Control Valve removed from the Air Knife end to avoid the such type of problem.
 To Avoid the Strip Slippages during strip breakages or threading Pneumatic clamp installed
at Furnace & Bridle-7. Also given its FB in HMI. Bridle -1 Pneumatic Clamp to be installed
 Steering -3 vertically Mounting to be done in July Shutdown.
CGL 1 2
7
CONTINUOUS
ROOT GALVANIZING
CAUSE & COUNTER LINE-2
MEASURES QC PROJECT
(ACTION PLANS): For Maintenance
6) OTHERS.
A) Root causes:-
 UPS Supply tripped due to spike buster got faulty. Which was the cause of line stop.
 Air Knife Tilting problem due to its power cable was underrating.
 Chromic Dryer Controller was getting hanged which was the cause of line stop.
 Air Knife overlap was cause of screw failure because there was no Safety limit .
 Steering unit tripping was cause of line stoppages.

 All Spike Buster Lighting LED Remove which was the cause of UPS Tripping.
 Air Knife Tilting Motor power cable was under rating. Replaced the same with proper Rating.
 Chromic Dryer controller was getting Hanged due to its Burner Sequence controller design
problem. As per new Sujhav we made logic in line PLC & its all FB & control given in HMI.
 To Avoid the Air knife Screw Failure problem Provided Proximity for its Safety Limit.
 All Steering off or tripping interlock removed from Line stoppages & given its Tripping Alarm with
Hooter in HMI.
CGL 1 2
8

6) OTHERS.
B) Counter Measures:-
 After Pot Cooling Load Cell Installation to be done & to be taken in close loop.
 Leveller Curvature & nest Postion Postion Transducer to be installed.
 Belt wrapper Automation to be done to minimize the coil feeding in coiler.
 Inductor Abnormality & its current Status to be taken in HMI history as well its Alarm with hooter to
be given.
 Weld Hole Sensor to be installed for weld tracking for L2 Automation.
 Stagger winding was not proper because of its camera mounting frame vibrating.
 CCTV camera to be installed at Welder, APC, Steering -3 Area.
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9
6) OTHERS.
 New Load cell installed at APC & done its calibration. Taken this load cell FB for Pot tension control
in close loop.
 Leveller Curvature & nest Position transducer installed & given its FB in HMI. This for ref. for the
operator for proper elongation.
 Made logic for belt wrapper for Automation to minimize its time for coil feeding.
 Zn Pot Inductor current , Voltage & power FB taken in HMI History, Also taken all its fault taken in
PLC & generate is Alarm & Hooter for any abnormality to operator.
 New weld hole sensor installed at Bridle-4 for weld tracking for L2 Automation.
 EMG Staggering Winding Camera Installed at separate column to avoid the line structure vibration
& Provide the hood above its camera to avoid external light source interference.
 New CCTV camera installed at welder ,Steering -3, APC unit for the operator. This also a helpful to
avoid the line delay in case of problem in welder, steering units.
CGL 1 3
0
Must Implement Plans: (Pending)

 Modification of Burners & new UV Sensor to be installed because of the prevalent problem of
burner sensing.
 Bridle-1 Pneumatic Clamp to be made ready.
 Weld hole sensor in entry & exit section to be installed for complete weld tracking.
 Drives tripping At Cho fault still pending. Solution Awaited from M/S ABB.
CGL 1 3
1
IMPROVE
CGL 1 3
2
CGL2 DELAY FOR 2006-2007
DELAY FOR CGL_2 2006-07

Month % DELAY Stoppages 2.5 100
Apr-06 0.17 10
May-06 0.95 22 90
Jun-06 0.59 13 2
1.93
80
Jul-06 0.62 8 BEFORE AFTER
Aug-06 1.16 5 70
No. of Stoppages
Sep-06 0.33 4 1.5 60
Oct-06 0.00 0 % DELAY Due to Drive
1.16 50
Nov-06 0.22 6 CH0 Fault
0.95
Dec-06 1.93 14 1 40
Jan-07 0.51 4
0.59 0.62 30
Feb-07 0.32 5 0.51
Mar-07 0.04 3 0.5 22 20
0.33 0.32
0.1710 13 0.22 14
8 10
4 0.00
5 6 4 5 0.043
Power Failure is not Included 0 0 0
in this Graph Apr-06 May- Jun-06 Jul-06 Aug- Sep-06 Oct-06 Nov-06 Dec-06 Jan-07 Feb-07 Mar-07
06 06
MONTH
CGL 1 3
3
Total Line Stoppages Graph Analysis
CGL 1 3
4
CONTROL
CGL 1 3
5
PLAN OF FOLLOW-UP FOR COUNTERMEASURES/ACTION PLANS DEFINED

INCLUDING FREQUENCY
Sr No Action To Be Taken Action By Responsiblity
Made Preventive Maintenance

1 Line Manager Electrical
Schedule.
2
CGL 1 3
6
DELAY ANALYSIS
CGL 1 3
7
COST BENEFIT AT THE END OF THE PROJECT

DIRECT BENEFIT:-
1) Loss because of quality Diversion Afetr Reduce no of delayxRs 7000 / MT
2) Loss because of quantity Rs
3) Fixed Cost
CGL 1 3
8
THANKS
CGL 1 3
9

Reducing of Line Stopagges

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Reducing of Line Stopagges

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CONTINUOUS GALVANIZING LINE-2 QC PROJECT

• Mr. Amit Mittal (LEADER)

LINE TECHNICAL SPECIFICATIONS

Thickness range : 0.12 mm to .60 mm

•Input Material Grades: Cold rolled low/Med/high carbon steel

DELAY FOR CGL_2 2006-07

R EA S ON F OR Ap ril M ay J une J uly Aug Sep

CGL-2 DELAY FOR 2006-2007

EQUIPMENT DELAY FREQ. % DELAY DELAYS FOR CGL-2 2006-07

Total Fishbone Analysis

Tension Leveller Rolls Fishbone Analysis

Water Cool Damper

Coil Cutting &

Pot Roll Scraping

Side Tracking Zn Pot Area Operator Mistakes

ROOT CAUSE & COUNTER MEASURES (ACTION PLANS): For Maintenance

ROOT CAUSE & COUNTER MEASURES (ACTION PLANS): For Maintenance

B) Counter Measures Implemented Action Plan:-

ROOT CAUSE & COUNTER MEASURES (ACTION PLANS): For Maintenance

B) Root causes Action Plan:-

 Provide Separate Power Supply to NG Valve in case of CGl-1 Power Failure.

B) Counter Measures Implemented Action Plan:-

ROOT CAUSE & COUNTER MEASURES (ACTION PLANS): For Maintenance

B) Counter Measures Implemented Action Plan:-

the various set points from L-2.

ROOT CAUSE & COUNTER MEASURES (ACTION PLANS): For Maintenance

B) Root causes Action Plan:-

ROOT CAUSE & COUNTER MEASURES (ACTION PLANS): For Maintenance

B) Counter Measures Implemented Action Plan:-

B) Root causes Action Plan:-

B) Counter Measures Implemented Action Plan:-

ROOT CAUSE & COUNTER MEASURES (ACTION PLANS): For Maintenance

B) Root causes Action Plan:-

all Control Desk.

B) Counter Measures Implemented Action Plan:-

B) Root causes Action Plan:-

ROOT CAUSE & COUNTER MEASURES (ACTION PLANS): For Maintenance

 CCTV camera to be installed at Welder, APC, Steering -3 Area.

Must Implement Plans: (Pending)

 Bridle-1 Pneumatic Clamp to be made ready.

DELAY FOR CGL_2 2006-07

Total Line Stoppages Graph Analysis

PLAN OF FOLLOW-UP FOR COUNTERMEASURES/ACTION PLANS DEFINED

Made Preventive Maintenance

COST BENEFIT AT THE END OF THE PROJECT

1) Loss because of quality Diversion Afetr Reduce no of delayxRs 7000 / MT

2) Loss because of quantity Rs

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