Project Charter to Reduce Ferro-alloy reduction

Rev No. 00,

TQM Unit
Idea No

FP Division

Team Details

Name

Unit Champion

Shainu Suresh

Idea Owner

Shainu Suresh

Effective date: Apr'15

Project Title

Roll No

Phone No

Titanium Reduction in Grade A of Steel Melt Shop

Present specification of Grade A is: Ti:0.06-0.07%
Ti addition causes clogging of nozzle but as the steel property requires Ti so a study has been taken up to
assess the optimum level of Ti which will suffice property requirement and also will also prevent clogging
tendency during continuos casting of Grade-A.

Dept.
Brief Description

Ti reduction will lead to reduction in Ferro-alloy consumption.

Reduction in downgrading on a/c of clogging.

Rateesh Mayank
Project Objective and
Scope

Members

Gyanesh Dubey

Anurag Tripathy
Applicable to
KPI IMPACT
% Ti in Grade-A

As is

To be

Target Month

0.06min

0.05min

Jan-16

Assumptions and
Constraints

With reduction in Ti there will be no impact on Customer's requirement and processes.

Constraint is that the feedback has higher cycle time.

A. Revenue (Rs Cr)

Risk

C. Capex

0.0

(RsCr)

Net EBITDA (Rs Cr)

Financial Evaluation
Value

UOM

Remarks

OTHER ADVANTAGES
Will result in reduced clogging tendency during
Detailed Characterisation of low Ti to simulate the impact of change.
casting
Timeline and Schedule
Major Activities

Responsibility

Start Date Finish Date

Start Date (A)
(P)
(P)
Oct-15
Oct-15

Finish
Date (A)

Present Ti% in Grade-A

0.06

Feasibility assessment of lowering Ti in Grade-A

Shainu

Proposed Ti%

0.050

Detailed Characterisation of low Ti

Anurag

Nov-15

Nov-15

Done

Reduction in Ti%

0.010

Trial Plan Raise and approval

Gyanesh

Dec-15

Dec-15

Done

Reduction in Ti /heat

12.5

Kg

First phase controlled trial

Gyanesh

Dec-15

Dec-15

Done

Avg. No. of heats made/month

130

No.

Based on phase1 trials ,do extended trials

Shainu

Dec-15

Dec-15

Done

Savings in Ti /month

1625

Kg

Implementation based on extended trial success

Rateesh

Jan-16

Jan-16

Done

Savings in Ti/year
Cost of FeTi (low Al)

19.50
340,266

ton

Annual savings

TOTAL SAVINGS
Assumptions

0.5

Mitigation plan

Change in chemistry can impact Customer process or changes in requirement.

Item

B. Opex (Rs
Cr)

0.5

0.531

0.5

Rs/ton
Rs Cr

Rs. Cr.

Sign off

Done

SYNDICATION SIGN OFFs

80%
conservative
factor

Name

Designation

Role

Shainu Suresh

Shainu Suresh

Rateesh Mayank

Rateesh Mayank

Idea owner

Gyanesh Dubey

Gyanesh Dubey

Team member

Anurag Tripathy

Anurag Tripathy

Team member

Customer

Customer

Idea Champion

Signature

Remarks

KPI Tracker (FY-15 & FY-16)

Avg Ti% in Grade-A(Plan)
Avg Ti% in Grade-A (Actual)

Jan-16

Feb-16

Mar-16

Apr-16

May-16

Jun-16

Jul-16

Aug-16

Sep-16

Oct-16

Nov-16

Dec-16

Jan-17

0.050

0.050

0.050

0.050

0.050

0.050

0.050

0.050

0.050

0.050

0.050

0.050

0.050