Process Optimization of Colour Coating Line

and Analysis of the losses due to cold run

(LPG, Power), scrap and to study the reasons
for the Cold Run and Scrap

Under the guidance of

Mr. Rahul Mahakal
AGM Production-CCL
OBJECTIVE

The main objective was to understand and analyze the
prevailing losses in the Colour Coating Line -1 and Line
-2, for the First quarter of FY2010-11.



METHODOLOGY
PROCESSES AT JSW-
TARAPUR PLANT
FLOW CHART OF CCL
BONE DIAGRAM FOR CAUSE AND EFFECT OF COLD

ELECTRICA L M ECHA N ICA L

PO W ER
FROM BO LTSHEA R
M .S.E.B SIDETRA CK
LIN ESTO P
W ATER
Q U EN CHIN G
CO M PRESSO
TRIP
R
SHEETB REA KA G E RO LLER
OR
O VEN TRIP
CO U PLIN G CHA N GE
REA SO N S FOR
CO LD RU N
DEN T DRO SS CO LOU R CHA N G E SIZECHA N G E

RO LL CHA N G E
EDG E DA M A G E DELTA V RIATIO N P RIM ER CHA N G E
PLA N CHA N G E
SHA DE VA RIATIO N
EDGE W AV IN ESS SA M P LE
COA TIN G
BU CKLIN G O PERA TION
RA WM A TERIA L

Fold formation
PEROT ANALYSIS OF COLD
RUN REASONS
PEROT ANALYSIS OF COLD
RUN REASONS
PEROT ANALYSIS OF COLD
RUN REASONS
PEROT ANALYSIS OF COLD
RUN REASONS
PEROT ANALYSIS OF COLD
RUN REASONS
PEROT ANALYSIS OF COLD
RUN REASONS
 FINDINGS IN SCRAP
GENERATION

to sheets and they are stacked vertically one upon another, this helps reduce the

 The scrap generated at CCL 1 is significantly

more then in comparison with CCL 2. The major
reasons in generation of scrap were dents and
edge damages

Key Observations in LPG &
Electrical Consumption
Suggestions

inventory level should be maintained and monitored closely

Taking into consideration small details like tool box etc

 CONCLUSION
 By means of this project we were able to figure out


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

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