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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)

MEMBERS QC ACHIEVERS
4

Mr. Rama Shankar Kumar Mr. Devdutta Bhattacharya, Facilitator Mr. Rajesh Prasad

Mr. Subhasish Singha Roy

Mr. Kallol Kumar Ghosh

Leader
Mr. Sudip Kumar Khan

PROCESS FLOW - DSP

CCP

W& AP

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

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

LIST OF IDENTIFIED PROBLEMS


SL. No. 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

LIST OF IDENTIFIED PROBLEMS


SL. No. 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.

CATEGORY A A

10
11 12 13 14

B
B A A C

LIST OF IDENTIFIED PROBLEMS


SL. No. 15 16

IDENTIFIED PROBLEMS
Frequent failure of coupling pad in convertor tilting drive.
Lack of approach of while lubricating out side wheels of lance trolley.

CATEGORY C C

17
18 19 20 21

Lance emergency lifting clutch failure.


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

LIST OF IDENTIFIED PROBLEMS


SL. 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. Huge accumulation of dust in lance manual valve station. Sample carrier getting stuck up frequently inside pneumatic line Sample carrier outer surface getting deformed Sample carrier deformed. pneumatic line door getting

LIST OF IDENTIFIED PROBLEMS


SL. No.

IDENTIFIED PROBLEMS
SRD Pneumatic system functioning inconsistently.
SRD Need frequent calibration SRD swiveling cylinder pin damage at regular interval Frequent damage of online purging hose in all 3 convertors. OLP hose getting stuck up in OLP drum during changing. BRD getting derailed from track. Difficulty In positioning BRD at zero meter level during campaign repair.

CATEGORY

29
30 31 32 33 34 35

B
B A B A B B

LIST OF IDENTIFIED PROBLEMS


SL. No. 36 37 38 39 40 41 42

IDENTIFIED PROBLEMS
Leveling and centering of FRD difficult under converter.
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

LIST OF IDENTIFIED PROBLEMS


SL. 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

LIST OF IDENTIFIED PROBLEMS


SL. 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

LIST OF IDENTIFIED PROBLEMS


SL. No.

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

LIST OF IDENTIFIED PROBLEMS


SL. No.

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. 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

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

LIST OF IDENTIFIED PROBLEMS


SL. No. 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.

CATEGORY A/K B A A A B A

LIST OF IDENTIFIED PROBLEMS


SL. No. 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. 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.

LIST OF IDENTIFIED PROBLEMS


SL. No. 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

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

A CATEGORY PROBLEMS AFFECTING CRITERIAS

SL. No.

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. pneumatic line door getting

SRD swiveling cylinder pin damage at regular interval OLP hose getting stuck up in OLP drum during changing.

A CATEGORY PROBLEMS AFFECTING CRITERIAS

SL. No.

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. 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

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.

A CATEGORY PROBLEMS AFFECTING CRITERIAS


SL. No. 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.

A CATEGORY PROBLEMS AFFECTING CRITERIAS


SL. No. 36 37 38 39 40

IDENTIFIED PROBLEMS
Gunning mass getting solidified in short delivery pipe. Filter Regulator malfunctioning. Lubricator system of BMS

Frequent leakage through Ferro Alloy additive chute.

10 ton weigh hopper bracket fixing bolts damaged regularly.


Water valve of gunning machine getting frequently damaged. Huge accumulation of gunning mass in gunning machine parking area.

41
42

10 ton weigh hopper bracket fixing bolts damaged regularly.

A CATEGORY PROBLEMS AFFECTING CRITERIAS


SL. No. 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.

48
49

Gunning mass getting solidified in short delivery pipe. Huge accumulation of gunning mass in gunning machine parking area.

DELAY DETAILS OF SHORT LISTED PROBLEMS


SL .No. 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. Bearing damage of BMS EUBA drive 10 ton weigh hopper bracket fixing bolts damaged regularly.

TOTAL

595

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
50.26 14.6

CUM. %
50.26 64.86

Frequent leakage through gunning machine pad.

235

13.83

78.69

10 ton weigh hopper bracket fixing bolts damaged regularly.

108

6.36

85.05

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

5.89

90.94

95

5.59

96.59

35

2.06

98.59

24

1.41

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

MILESTONE CHART (PLANNED )


Quality Circle: ACHIEVERS Regn. No.: 1684 Project : Huge Delay Converter Campaign during Department: SMS Facilitator: D.Bhattacharya Date of starting the project: 12 May, 2012 Planned Date of completion: 19 Sep , 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.
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

BOF CONVERTERS

43

BOF CONVERTER

44

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

PROBLEM DEFINITION
The

working volume of converter vessel with refractory's is 114 cu. m. The converter vessel is fastened in the trunion by means of tendon. Converter can rotate 360 deg. With the help of spur gear . Inside the converter i.e. 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.

PROBLEM DEFINITION
Inside

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

REFRACTORY LINING

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

PROBLEM DEFINITION
After

LBM

completion of bottom removal de bricking inside the converter is done by LBM machine .After de bricking the converter shell is inspected by operation personnel and required rectification is done by mechanical. After rectification of shell plate new tap hole fixing job is done by the help of BRD machine. After tap hole fixing , 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.

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

Handed Over to mechanical positioning BRD & tap hole fixing


Positioning & centering of FRD For relining

YES

POSITION O.K.

NO

Proper adjustment & repairing

Handed over to refractory for relining job

Relining work by using FRD Removal of F.R.D Bottom fixing with B.R.D. Handed over to Operation

END

IMPACT OF THE PROBLEM


From the data obtained from

operation and refractory log book, we have found that cumulative delay in the 3 years from 2009- 2011 has been 854 hours.
Not

only the production delay there has been 9 accidents including 11 11 fatal case .

SETTING OBJECTIVES
54

Objective Policy

What?

How?

Methodology Policy

Our objective is to reduce the delay time at the most, reduction of consumption of cage telescopic pipe, rollers , hoist rope and accident at the lowest limit .

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

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

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

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

DELAY ANALYSIS OF CAMPAIGN REPAIR


DELAY ANALYSIS A. Converter shell cooling B. Converter bottom removal C. Converter shell de bricking D. Converter shell cleaning E. 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. New tap hole in converter G. Relining delay due to FRD


H. Final system checking I. New bottom fixing to converter J. 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

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

DATA ANALYSIS
74

TOOLS AND TECHNIQUE USED DATA COLLECTION, STRATIFICATION, PARETO

DATA ANALYSIS OF FRD PROBLEMS


DELAY ANALYSIS
A. Delay due to hydraulic problem B Delay due to rope locking C. Delay due to guide wheel failure D. Delay due to centering problem E Delay due to FRD derailment

2009
3.8 hrs

2010
2.7 hrs

2011
2.9 hrs 66.8 hrs 42.8 hrs 3.6 hrs 19.2 hrs

TOTAL
(HOURS)

9.4 227.5 138.8 9.6 64.9

83.2 hrs 77.5 hrs 52.1 hrs 43.9 hrs 3.3 hrs 2.7 hrs 16.1 hrs 29.6 hrs

F. Delay due to power failure G. Delay due to FRD fork lift platform dis balancing
H. Final system checking I .Delay during lowering the FRD platform J. Delay due to FRD balancing problem

4.8 hrs 2.8 hrs


4.8 hrs 3.1 hrs 4.8 hrs

2.9 hrs 9.6 hrs


1.7 hrs 1.8 hrs 2.9 hrs

3.9 hrs 8.8 hrs


2.5 hrs 2.6 hrs 3.5 hrs

11.6 21.2
9 23.7 11.2

TOTAL

178.8 175.3

156.6 526.9

DELAY PERCENTAGE TABLE


CODE DELAY (Hrs) %

G E B F J D A

21.2 64.9 227.5 11.6 11.2 9.6 9.4

4 12.31 43.17 2.2 2.1 1.8 1.7

C H
I TOTAL

138.8 9
23.7 526.9

26.34 1.7
4.49

CODE B C E I

DELAY(HRS ) 227.5 138.8 64.9 23.7

% 43.17 26.34 12.31 4.49

CUM% 43.17 69.51 81.82 86.31

G F
J D A H

21.2 11.6
11.2 9.6 9.4 9

4 2.2
2.1 1.8 1.7 1.7

90.31 92.51
94.61 96.41 98.13 100

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

79

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

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.

3rd Proposal Remarks

85

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

DEVELOPING SOLUTION

Evaluation
Replacement of hard roller with soft roller.

This will minimize the chances of


roller failure due to having more shock absorbing capacity of soft roller.

5th Proposal

Remarks

89

DEVELOPING SOLUTION

Providing guide collar at all the four corners beside FRD wheel .
6thProposal

Evaluation

Remarks

92

RESPONSIBILITY SHARED ACTION PLAN


Sl. 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

03.09.12 04.9.12 05.05.12 06.05.12 07.5.12 8.9.12 11.9.12 13.09.12 14.09.12 15.09.12 16.0912 17.9.12 23.9.12 24.9.12 26.9.12

13
14

Checking
Data Collection to sustain the process

27.9.12 30.9.12
01.10.12 cont.

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

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

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

REGULAR IMPLEMENTATION
103

Tools and Technique used

Milestone Chart, PDCA, Data Collection, Graph

COMPARATIVE GRAPHS
6

Before QC
5

After QC

Period of implementation
4

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

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, 38, 95, 000 /- per

year
106

Safe working atmosphere Maintenance work simplified Fatigue reduced Better housekeeping Self Satisfaction

Team Spirit increased

FOLLOW UP AND REVIEW


109

Tools and Technique used

Data Collection, Graph

STANDARDIZATION

Necessary changes are made in SMP to prevent future breakdown

110

converter

Furnace availability % in BOF


BEFORE QC 76 79 81 AFTER QC 95 98 98

NO. #1 #2 #3

Milestone Chart (Planned vs Actual)


Quality Circle: ACHIEVERS Regn. No.: 1684 Department: SMS Facilitator: D.Bhattacharya Date of starting the project: 12th May, 2012 Project : Delay in Campaign Planned Date of completion: 19th September, 2012 Repair of Converter Actual Date of completion: 18th September, 2012 Members Name: Kallol Kumar Ghosh (Leader) Subhasish Singha Roy Sudip Kumar Khan Rajesh Prasad Rama Shankar Kumar

May 12
Sl. 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

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

114

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