Pillar KAIZEN IDEA - SHEET Adhunik Metaliks Ltd, Rourkela Plant : Kaizen Theme : Prevention of Overflow of Hot Metal

from runner Problem/Present Status : Earlier for diverting the hotmetal from one laddle to other sand stopper was provided.This was failed on few occassions and resulted in overflow of hotmetal from the runner and estimated around 1ton of hot metal loss in month.SAFETY issues were also arised due to this failure.As the hot metal overflow falls into the passage which is very dangerous to the Movement in laddle area. Countermeasure : 1. One metalic plate with pulley arrangement done 2.Mock trial for height and closing done 3.After succesful trials implimented the same MBF Machine :Cast House Idea : Loss Type

KK JH QM PM BD SA CR SU P Q C

SHE MI D

OT DM SP S QR E

MT MN LO LS MA

YD EY

Result Area Kaizen No

MBF/Kaizen/Oct-12

Metalic stopper with sand Dam provision to divert the runners Bench Mark Target Kaizen Start Kaizen Finish Team Members

Mr. Basudev Behera / Mr. Surya N Analysis : why Metallic stopper with Sand dam provision Due to occasional failure of Sand dam and hot metal overflows from runner Why There is a failure of SAND Dam Due to Weakness
Why there is weakness in Sand dam

Benefits:
Results :After this kaizen there was no overflow of Hot Metal

1.No overflow of hotmetal from run

2.Perfect diversion with out more la 3.Estimated saving per month is R

Due to impact of Hotmetal flow occassiuonally

Scope & plan for Horizontal Deploy Sl M/c No. No.

BD: Break Down, SA: Setup & Adjustment, CR: Cutting-Tool replacement, SU: Startup, MI: Minor Stops & Idling, SP: Speed, QR: Quality Defect & Rework, SD: Shutdown MT: Management, MN: Motion, LO: Line Organization, LS: Logistics, MA: Measurement & Adjustment, YD: Yield, EY: Energy, CS: Consumables

ET SD CS M MBF/Kaizen/Oct-12

ners Bench Mark Kaizen Start Kaizen Finish Team Members Mr. Basudev Behera / Mr. Surya Narayana Rao / Mr. Babu Rao Overflow of Laddles Nil Overflow 01.09.2012 18.09.2011

Benefits:
1.No overflow of hotmetal from runner 2.Perfect diversion with out more labour involvement 3.Estimated saving per month is Rs24000/-(1MT Hot metal) approx

Scope & plan for Horizontal Deployment : Target Date Responsibility Status