Coated Products Ltd, Kalmeshwar

TEAM – ROCKERS
Reg No - 802

Welcome
34th CHAPTER CONVENTION ON QUALITY CONCEPTS,
CCQC-2023
ROCKERS TEAM
Facilitator Leader Member Member

Mr. Rahul Borade Mr. Piyush Songhare Mr. Subham Singh Ms. Sayali Thawkar
To Reduce Gl Scrap & Rework Of
Project Theme
Member Galvalume Line Member
Theme selected on 01-01-2023
Project completed on 31-08-2021
No. of meetings 20
Attendance 96%
Day of meeting Saturday
No. of Projects solved 8
Timing of QC Meeting 4 – 5 pm
Mr. Ramdayal Quality Circle start on Mar- 2019 Mr. Ramkishan Rana
2
Where there’s steel, there’s JSW.

SHRI. OM PRAKASH JINDAL

FOUNDER CHAIRMAN
 JSW GROUP: KEY VERTICALS
• India’s largest steel producer
• Capacity of 28.5 mtpa, growing
to 38.5 mtpa
• Listed on NSE, BSE. Market cap
of US$20.6bn
• Capacity of 17 mtpa,
growing to 25 mtpa
• India’s leading green
cement company
• Capacity of 4.6 GW (Hydro,
Renewable and Thermal)
• Growing to 20 GW by 2030
with 85% renewable portfolio
• Listed on NSE, BSE. Market cap
of US$6.6bn
Foundation
• Social development arm
of the Group, with
footprint across 11 states
and 15 districts
• Reaching out to +1 mn
individuals around the
operating locations
• Capacity of 130,000 klpa
• Only fully-automated, water-
based plant in India
• Aims at nurturing the
sporting dream of India
• Trained Olympic medal
winners
• Associated with champion
teams like Delhi Capitals,
Bengaluru FC and
Haryana Steelers
• Ports capacity of 153 mtpa
• Operations across East,
West & Southern coasts of
India
• Early stage, tech focused
Venture Capital fund
• Invests in companies building
innovative solutions that
leverage India’s demographic
dividend, consumption drivers
and technological
advancements
3
THE HIGHEST QUALITY CERTIFICATION – DEMING PRIZE

JSW Steel Vijayanagar Plant - 2018 JSW Steel Salem Plant - 2019

4
 THE JOURNEY OF JSW STEEL COATED KALMESHWAR

CAPACITY RAMP –UP (Mtpa)

 Plant established in 1985 named as Nippon Dendro.
 JSW Acquired from ISPAT in 2011.
 The first plant in India featuring the Hitachi 6 Hi cold reversing facility from Japan.
 A first-of-its-kind continuous pickling Line.
 India’s first Fastest Color Coating Line with the Speed of 200mpm.

Color Coating -1988

PLANT HISTORY

Galvanizing 2 - 2003 12
Galvalume 1 - 2007
Acquisition by JSW
Color Coating 2 – 2013
1.00
Color Coating 3 – 2021
0.72
0.72
Galvalume 2- 2021 0.68
0.68
0.65
0.65
0.41
0.41
0.33 0.35
0.35
0.3
1999 2004 2011
2011 2014
2014 2017
2017 2019
2019 2021
2021 2024
Financial Year
7
0757: SHOP FLOOR MANTRA FOR CONTINUOUS IMPROVEMENT

0757 is our shop floor mantra to solve shop floor related problems
9
 OUR CSR EFFORTS

Key intervention areas

Health &
Agriculture
Nutrition

Water,
Environment & Education Mega health and cancer detection Eye camps to extend Vision Screening
Sanitation camp in Odisha and Correction at Vasind & Dolvi

Waste Skill
management development

Art, culture & Sports

heritage

51 Classrooms in 9 schools renovated JSW Shakti: Entrepreneurship

in Kalmeshwar, Maharashtra Development and Women Empowerment
program
MILESTONES OF KALMESHWAR

Winner of PRIME GOLD AWARD at ICQCC – Indonesia, Jakarta

9
OVER VIEW OF JSW STEEL COATED PRODUCTS LTD., KALMESHWAR PLANT
PICKLING PROCESS

Shear Welder Wet Loop Pit Pickling Tanks Exit Looper Side Trimmer Shear
Uncoiler

GALVANIZING/GALVALUME PROCESS
COLD ROLLING PROCESS Jet Chromate
Cooling Tank

Quench
Furnace Tank
Skin Pass Mill cum
Cold Rolling Mill Uncoiler Shear Welder Zinc Pot Tension leveler Exit Looper
Entry Looper

COLOR COATING PROCESS

Guard Oven Oven Prime
Film Top Coater
Coater
Unit
Exit Loop Entry Loop

Pretreatment Back Oven Water Dryer

Shear Joint Tanks Coater Cooling
Shear
Press

10
INDEX
SR. NO. CONTENT SLIDE NO.
1 PROBLEM IDENTIFICATION 14-17
2 SELECTION OF PROBLEM 18-29
3 DEFINITION OF PROBLEM 30-38
4 ANALYZING THE PROBLEM 39-41
5 IDENTIFYING THE CAUSES 42-44
6 FINDING OUT ROOT CAUSE 45-52
7 DATA ANALYSIS 53-59
8 DEVELOPMENT OF SOLUTIONS 60-64
9 FORESEEING PROBABLE RESISTANCE 65-66
TRIAL IMPLMENTATION & CHECK
10 67-71
PERFORMANCE
11 REGULAR IMPLEMENTATION 72-77
12 FOLLOW-UP / REVIEW 78-90
11
 STEP 1 - IDENTIFICATION OF PROBLEM
“All improvement happens project by project and in no other way”
- Joseph M Juran

TOOL USED
BRAIN STORMING

12
 STEP1:IDENTIFICATION OF PROBLEM
● During QC meeting, Brainstorming sessions
were conducted and 80 problems were SR. NO. IDENTIFIED PROBLEMS
identified.

1 Acrylic Coater head engage/dis-engage problem

2 Top Coater Head leaving the band from D/S
3 Hydraulic Pressure fluctuation at Exit power pack
4 Recoiler Wrapping improper
5 Heavy dross accumulation in Sink roll and support roll arms
6 Sink roll dent generation
7 Support roll bend mark
8 High Propane Consumption
9 Heavy black patches in CR
10 Vibration in Sink Roll
11 Support roll scraper lead screw bearing failure
12 Sink roll scraper arm broken
13 Improper cleaning of coils in ECL lines
14 Sink roll Scraper cylinder Hose puncture
15 Furnace Hearth roll bend and not rotating
13
 STEP1:IDENTIFICATION OF PROBLEM
S.N DESCRIPTION S. N. DESCRIPTION
16 ECL sink roll drive failure 31 Small Galvalume Coating Pot
17 Dross stuck at the bottom of the main pot to be removed 32 Less Furnace capacity
18 Inductors are damaged 33 ECL tank poor rubberizing
19 Furnace refractory in damaged condition 34 Inferior quality of Brush rolls
20 Re-weld the equipment's with poor welds 35 Alkali solution of low quality
21 Bridle 8.2 Motor failure 36 Higher consumption of Power in line
22 Support roll Misaligned 37 Black patches diversion GL coils
23 Sink Roll damaged 38 Lopper rope of poor quality
24 Emergency Limit actuating automatically 39 Al and zinc ingots poor quality
25 Damaged radiant tube heaters 40 Input coils poor shape
26 Inefficient combustion blower 41 Poor quality of Acrylic coating
27 Wiping nozzles choked 42 High plate outs on input strip
28 Wiping nozzle header misaligned 43 High iron on input strip
29 Poor quality of bridle rolls coating 44 Undercooling of CAG blowers
30 Choking of zinc unloading pump 45 Under design of JET Coolers
14
 STEP1:IDENTIFICATION OF PROBLEM

S.N. DESCRPITION S. N. DESCRIPTION S. N. DESCRIPTION

46 Improper functioning of Oiler 59 No H2 leak detector available 71 Hearth roll rotation problem
Improper functioning of Fume exhaust
47 Al-Zn Peel off 60
blower 72 Furnace pressure fluctuation
48 Improper wiping of strip 61 Excess coating in Galvalume line
Inefficient melting of metal ingots in Improper soaking in Vertical soaking 73 Huge coil end generation in line
49 62 section
pre-melting pot
74 Lamination in CR coil
50 Under capacity of Tension Leveler
63 Less melting capacity of pre-melting pot
51 Un-coiler speed mismatch 75 Crack edge in input coil
64 Furnace Back fire while firing after SSD
Improper water balancing in hot well
52
and cold well tank. 65 Zone-3 Temperature not getting down 76 Water carryover from quench tank
Frequent breakdowns in submersible
53
Pumps 66 Quench Tank water carry over problem 77 Zone air gas fluctuation
54 Hardness Variation issue
67 Induction furnace getting trip frequently 78 Induction f/c tripping problem
55 Only one Recoiler available
68 Improper Logo printing
56 Improper burning of fuel 79 ECL roll shaft broken
57 Improper dew point 69 Low CR ratio of the Inductors main pot
58 Lower line speed 70 ECL holding tank pump gland failure 80 Steam pressure reduced

These problems are classified into A, B & C category 15

 STEP 2 - SELECTION OF PROBLEMS
“It is not enough to do your best; you must know what to do, and then do your
best”
- W. Edwards Deming

TECHNIQUES USED
STARTIFICATION
RANKING METHOD

TOOLS USED
BELT GRAPH

16
 STEP:2 SELECTION OF PROBLEMS A, B, C STRATIFICATION
● During QC meeting, Brainstorming
sessions were conducted and 80 DESCRIPTION CATEGORY
problems were identified and
categorized into A,B,C depending on
A B C
the involvement of other department 1) Acrylic Coater head engage/dis-engage problem *
and management. 2) Top Coater Head leaving the band from D/S *
3) Hydraulic Pressure fluctuation at Exit power pack *
4) GL scrap and Rework increases *

B
With help 5) Heavy dross accumulation in Sink roll and support roll arms *
of other
departme 6) Sink roll dent generation *
nt 7) Support roll bend mark *
8) High Propane Consumption *
9) Heavy black patches in CR *
Solved by
10) Vibration in Sink Roll *
Our self It requires huge 11) Support roll scraper lead screw bearing failure *
investment &
solved by top 12) Sink roll scraper arm broken *
management
13) Improper cleaning of coils in ECL lines *
14) Sink roll Scraper cylinder Hose puncture *
15) Furnace Hearth roll bend and not rotating *
17
STEP:2 SELECTION OF PROBLEMS
PROBLEMS CATEGORY

A B C
16) ECL sink roll drive failure *
17) Dross stuck at the bottom of the main pot to be removed *
18) Inductors are damaged *
19) Furnace refractory in damaged condition *
20) Re-weld the equipment's with poor welds *
21) Bridle 8.2 Motor failure *
22) Support roll Misaligned *
23) Sink Roll damaged *
24) Emergency Limit actuating automatically *
25) Damaged radiant tube heaters *
26) Inefficient combustion blower *
27) Wiping nozzles choked *
28) Wiping nozzle header misaligned *
29) Poor quality of bridle rolls coating *
30) Choking of zinc unloading pump *
18
STEP:2 SELECTION OF PROBLEMS
DESCRIPTION CATEGORY

A B C
31) Small Galvalume Coating Pot *
32) Less Furnace capacity *
33) ECL tank poor rubberizing *
34) Inferior quality of Brush rolls *
35) Alkali solution of low quality *
36) Higher consumption of Power in line *
37) Black patches diversion GL coils *
38) Lopper rope of poor quality *
39) Al and zinc ingots poor quality *
40) Input coils poor shape *
41) Poor quality of Acrylic coating *
42) High plate outs on input strip *
43) High iron on input strip *
44) Undercooling of CAG blowers *
45) Under design of JET Coolers * 19
STEP:2 SELECTION OF PROBLEMS
DESCRPITION CATEGORY
A B C
46) Improper functioning of Oiler *
47) Al-Zn Peel off *
48) Improper wiping of strip *
49) Inefficient melting of metal ingots in pre-melting pot *
50) Under capacity of Tension Leveler *
51) Un-coiler speed mismatch *
52) Improper water balancing in hot well and cold well tank. *
53) Frequent breakdowns in submersible Pumps *
54) Hardness Variation issue *
55) Only one Recoiler available *
56) Improper burning of fuel *
57) Improper dew point *
58) Lower line speed *
59) H2 leak detector not available *
60) Improper functioning of Fume exhaust blower *
20
 STEP:2 SELECTION OF PROBLEMS

DESCRIPTION CATEGORY DESCRIPTION CATEGORY

A B C
A B C
61) Excess coating in Galvalume line *
71) Hearth roll rotation problem *
*
62) Improper soaking in Vertical soaking section 72) Furnace pressure fluctuation *
63) Less melting capacity of pre-melting pot * 73) Huge coil end generation in
*
line
64) Furnace Back fire while firing after SSD *
74) Lamination in CR coil *
65) Zone-3 Temperature not getting down quickly
* 75) Crack edge in input coil *
after line stop
66) Quench Tank water carry over problem * 76) Water carryover from quench
*
tank
67)Induction furnace getting trip frequently *
77) Zone air gas fluctuation *
68) Improper Logo printing *
78) Induction f/c tripping problem *
69) Low CR ratio of the Inductors main pot * 79) ECL roll shaft broken *
70) ECL holding tank pump gland failure * 80) Steam pressure reduced *

Number of problems belonging to each category are listed separately by using STRATIFICATION METHOD
21
 STEP:2 SELECTION OF PROBLEMS
 80 Problems were identified and they were categorized in A, B, C, depending on the involvement of other
department and management.

STRATIFICATION OF PROBLEMS - ABC ANALYSIS

CATEGORY SERIAL NO. TOTAL PERCENTAGE

B 25 %
A 1, 2, 4, 8, 11, 13, 14, 16, 19 to 22, 34 42.5 %
24, 25, 27, 28, 30, 34,
35,36,37,38,41, 46 to 49, 52,53,
56,57, 61, 67,70
B 3, 6,7, 9, 10, 12, 23, 33,39,40, 42, 20 25 % A
43, 54, 59, 64,68, 74,77,78,80
42.5 %
C
C 5, 15, 17,18, 26, 29,31,32, 26 32.5 %
44,45,50,51, 55,58,60, 62, 63, 65, 32.5 %
66, 69,71,72,73,75,76,79

Total 80 100 %

As the percentage of A type problems is highest, they are further categorised into solved & to be
solved problems. 22
STEP:2 SELECTION OF PROBLEMS
DESCRIPTION CATEGORY

A STATUS
1) Acrylic Coater head engage/dis-engage problem * To be Solved
2) Top Coater Head leaving the band from D/S * Solved by STAR QC
3) GL scrap and Rework increases * Solved by STAR QC
3) High Propane Consumption * To be Solved
4) Support roll scraper lead screw bearing failure * To be Solved
5) Improper cleaning of coils in ECL lines * Solved by ROCK QC
6) Sink roll Scraper cylinder Hose puncture * Solved by STAR QC
7) ECL sink roll drive failure * To be Solved
8) Furnace refractory in damaged condition * To be Solved
9) Re-weld the equipment's with poor welds * Solved by ROCK QC
11) Inadequate pressure of liquid nitrogen * To be Solved
12) Support roll Misaligned * Solved by STAR QC

13) Emergency Limit actuating automatically * To be Solved

23
 STEP:2 SELECTION OF PROBLEMS
DESCRIPTION CATEGORY DESCRIPTION CATEGORY
A STATUS A STATUS
14) Damaged radiant tube heaters * To be Solved 24) Al-Zn Peel off * Solved by ROCK QC

15) Wiping nozzles choked * Solved by ROCK QC 25) Improper wiping of strip * To be Solved

* To be Solved 26) Inefficient melting of metal ingots in pre-

16) Wiping nozzle header misaligned * To be Solved
melting pot
* To be Solved 27) Improper water balancing in hot well and
17) Choking of zinc unloading pump * To be Solved
cold well tank.
18) Inferior quality of Brush rolls * To be Solved 28) Frequent breakdowns in submersible Pumps * Solved by SHINE QC

19) Alkali solution of low quality * To be Solved 29) Improper burning of fuel * To be Solved

20) Higher consumption of Power in line * To be Solved 30) Improper dew point * Solved by SHINE QC

21) Looper rope of poor quality * Solved by ROCK QC 31) Excess coating in Galvalume line * Solved by ROCK QC

22) Poor quality of Acrylic coating * To be Solved 32) Induction furnace getting trip frequently * Solved by STAR QC

23) Improper functioning of Oiler * To be Solved 33) ECL holding tank pump gland failure * To be Solved

To find which problem is to be solved from above category of “TO BE SOLVED” status, RANKING
METHOD is done 24
 STEP:2 SELECTION OF PROBLEM
 From the list of ‘A’ category problems, some were solved by other QC teams. From remaining 19 problems, to find
out the problem which is to be solved is identified using rating Table Analysis
RATING TABLE ANALYSIS
Sr.No. "A" CATEGOERY PROBLEMS C Q L S E TOTAL PRIORITY
1 Acrylic Coater head engage/dis-engage problem 6 5 5 6 6 28 12
2 Inadequate pressure of liquid nitrogen 6 5 7 8 9 35 3
3 Support roll scraper lead screw bearing failure 7 6 6 7 6 32 7
4 Improper cleaning of coils in ECL lines 5 6 7 6 5 29 10
5 Furnace refractory in damaged condition 7 7 5 6 4 29 11
6 Re-weld the equipment's with poor welds 4 5 6 8 5 28 13
7 Support roll Misaligned 6 8 2 6 5 27 15
8 Damaged radiant tube heaters 6 6 5 6 4 27 16
9 Wiping nozzles choked 6 6 4 5 4 25 18
10 Choking of zinc unloading pump 6 8 2 7 2 25 19
Maximum mark has been rated as 10 & Minimum mark has been rated as 1
Problems are rated depending upon C:Cost, Q:Quality, L:Loss, S:Safety, E:Enivroment using Brainstorming by
QC members
25
 STEP:2 SELECTION OF PROBLEM
 From the list of ‘A’ category problems, some were solved by other QC teams. From remaining 20 problems, to find
out the problem which is to be solved is identified using rating Table Analysis
RATING TABLE ANALYSIS

Sr. No. "A" CATEGOERY PROBLEMS C Q L S E TOTAL PRIORITY

11 Alkali solution of low quality 9 8 6 6 7 36 2
12 Poor quality of Acrylic coating 3 5 7 3 4 22 20
13 Improper functioning of Oiler 8 7 6 7 5 33 5
14 Al-Zn Peel off 8 8 8 5 5 34 4
15 Improper water balancing in hot well and cold well tank. 4 5 6 8 7 30 9
16 High Propane Consumption 10 6 8 9 7 40 1
17 Frequent breakdowns in submersible Pumps 6 8 7 6 5 32 6
18 Improper burning of fuel 7 6 5 6 7 31 8
19 Excess coating in Galvalume line 8 6 7 3 2 26 17
20 ECL holding tank pump gland failure 6 8 5 4 5 28 14
These survey data sheets put in ranking matrix helped to identify and select the problem with Highest Priority.
Since “High Propane Consumption” gets the first priority according to ranking matrix, it is selected as the project
theme for quality circle. 26
 STEP:2 SELECTION OF PROBLEM

BELT GRAPH ECL holding tank pump gland failure

Excess coating in Galvalume line
FOR PROBLEM Improper burning of fuel
SELECTION Frequent breakdowns in submersible Pumps
High Propane Consumption
Improper water balancing in hot well and cold well…

A Type Problem Statement

Al-Zn Peel off
Improper functioning of Oiler
Poor quality of Acrylic coating
Alkali solution of low quality
Choking of zinc unloading pump
Wiping nozzles choked
Damaged radiant tube heaters
Support roll Misaligned
Re-weld the equipment's with poor welds
Furnace refractory in damaged condition
Improper cleaning of coils in ECL lines
Support roll scraper lead screw bearing failure
Inadequate pressure of liquid nitrogen
Acrylic Coater head engage/dis-engage problem
0 5 10 15 20 25 30 35 40 45
Cost Quality Loss Safety Environment TOTAL SCORE

What is GL scrap and Rework increases? It is defined in Step 3 i.e. Definition of Problem 27
 MILESTONE CHART
 We make the Mile Stone Chart and then submit the coordinator for the registration of the project.
MILE STONE CHART+B3:Q22B5B3:Q21B3:Q23B3:Q22
QUALITY CIRCLE NAME : ROCKERS DEPARTMENT : GALVALUME 1 MEMBERS NAME
P. Songhare
PROJECT: To Reduced High Propane Consumption MANAGER: RAHUL BORADE
R. Rana
PROJECT NO - 9 FACILITATOR: RAHUL BORADE Ramdayal
MEETING DAY : SATURDAY DY. FACILITATOR: SAYALI THAWKAR Subham
MEETING TIME : 16:00 TO 17:00 START- 01-01-2023 END:-31-08-2023 S. Thawkar
REGISTRATION NO:
ACTIVITY WEEK 1 2 3 4 5 6 7 8 9 10 11 12 TARGET ACTUAL
1 Define the problem 1 Week
2 Analyze the problem 1 Week
3 Identification of causes 1 Week
4 Finding out the root causes 2 Week
5 Data analysis 1 Week
6 Developing solution 2 Week
Foreseeing probable
7 1 Week
resistance
Trial implementation &check
8 1 Week
performance
9 Regular implementation 1 Week
10 Follow up / review 1 Week
TARGET ACTUAL

Milestone Chart is the planning schedule made to ensure the completion of the project on time 28
 STEP 3 - DEFINITION OF PROBLEMS
“ Quality control starts and ends with training”
- Kaoru Ishikawa

TOOLS USED
FLOW DIAGRAM

29
 STEP:3 DEFINITION OF PROBLEM
OUR PROCESS – IN BRIEF
GALVALUME is a coating consisting of zinc, aluminum and silicon that is used to protect a metal (primarily
steel) from oxidation. It is similar to galvanizing in that it is a sacrificial metal coating which protects the
base metal.

GALVALUME metals are made with steel panels having a coating of corrosion resistant aluminum-zinc
alloy applied by a continuous hot dip process. The nominal composition of the coating is 55% aluminum,
43.5% zinc and 1.5% silicon. GALVALUME is the trade name for this patented sheet steel product.

GALVALUME sheet has been successfully used in roofing applications for more than 40 years; it has been
evaluated in outdoor R&D tests for well over 50 years.
PURPOSE OF ELEMENTS IN AL-ZN ALLOY
Elements Percentage Purpose
Aluminium 55% For Preventing the Coil from Rust
Zinc 43.5% Acts as Sacrificing agent & increase the durability
Silicon 1.5% For proper bonding of molten metal coating with sheet

Process Flow Chart indicates the process within the 30

STEP:3 DEFINITION OF PROBLEM
GALVALUME LINE

31
 STEP:3 DEFINITION OF PROBLEM PROCESS FLOW OF GALVALUME LINE

DRYER 80 TO
100 Degree C
TEMP

ENTRY SECTION FOR COIL & ECL UNIT-- ALKALI AND ECL TANK
WELDING OF CRFH
FEEDING OF CRFH COIL ON WITH 2 TO 4 % CONC AND 65 TO
COIL
UNCOILER 100 Degree C

QUENCHING TANK FOR

COOLING SPOONER BLOWER – FOR
COOLING OF SHEET GALVALUME POT MAIN ANNEALING FURNACE
POT TEMP 600 Degree C

SKINPASS & TLL FOR CRUSHING OF

SPANGLE (if Required) and SHAPE LINER MARKING MACHINE EXIT SECTION FOR
ACRYLIC COATER LOGO MACHINE
IMPROVEMENT RECOILING 32
STEP:3 DEFINITION OF PROBLEM

 Propane is commonly used in a galvalume line for producing heat energy and temperature control for
annealing. The Galvalume coating process involves high-temperature annealing, which requires controlled heat
and precise temperature management. Propane serves as a versatile and efficient fuel source for meeting these
requirements.

 Propane is used in furnace for degreasing, reduction and annealing process in the furnace coils before coating
process. This heating helps in preparing the steel for coating and ensures better adhesion of the Galvalume
layer
 STEP:3 DEFINITION OF PROBLEM

Basically for every consumable there is fixed norms like that in Gal Propane consumption
fixed norms but consumption is very high above norms and so faced losses.

Some major impacts of our problems are……..

a) Increase in CR to GL conversion Cost
b) Increase in Quality related issues
c) Increase in Green House Gas Emission
d) Inefficiency of Furnace
e) Reduction in Furnace lifespan

33
STEP:3 DEFINITION OF PROBLEM

OBJECTIVES

To reduce leakages in the furnace from 12 to 0.

To avoid unburnt propane in furnace

GOAL

To Reduced the propane consumption from 12.65 to 11.65 kg/t

After Problem Definition, Analysis of the problem is done in the 4th Step 34
 STEP 4 - ANALYSIS OF THE PROBLEM
“It is only the last turn of a bolt that tightens it; the rest is just movement”
-Shigeo Shingo

TECHN IQUES USED

4W & 1H

TOOLS USED
DATA COLLECTION

35
 STEP:4 ANALYSIS OF THE PROBLEM

IMPACT OF HIGH PROPANE CONSUPTION

EXTRA ACTUAL
NORMS ACTUAL TOTAL RATE OF
MONTH TOTAL VARIENCE CONSUMPTION GAIN/LOSS IN
KG/t CONSUMPTION PRODUCTION PROPANE IN RS
IN KG LACS
Jan-22 11.65 12.55 24068 -0.90 47.96 -21661 -10.39
Feb-22 11.65 12.60 23228 -0.95 50.15 -22067 -11.07
Mar-22 11.65 12.42 25910 -0.77 56.00 -19951 -11.17
Apr-22 11.65 12.20 20260 -0.55 59.88 -11143 -6.67
May-22 11.65 12.45 24422 -0.80 61.62 -19538 -12.04
Jun-22 11.65 12.53 24526 -0.88 69.75 -21583 -15.05
Jul-22 11.65 12.51 23080 -0.86 75.55 -19849 -15.00
Aug-22 11.65 12.52 19040 -0.87 73.06 -16565 -12.10
Sep-22 11.65 12.64 20567 -0.99 67.62 -20361 -13.77
TOTAL -107.26
Because of Higher Loss in propane consumption it is incurred in all the months since Apr 22. Hence it became
important to find measures to reduce high propane consumption at GALVALUME

4 W & 1 H of the problem is done on the next slide 36

 STEP:4 ANALYSIS OF THE PROBLEM

What is the problem? ANALYSIS DONE USING

Higher Propane 4W & 1H TECHNIQUE
Consumption Where

Where is the How to reduce Problem?

Problem?
When
By resolving the root
Furnace & How 4W & 1H causes
operational practices Analysis

When it Occurred? Who is affected ?

What Why
During running line Conversion Cost

Next Step is Identification of Problem i.e. Step 5 37

 STEP 5 - IDENTIFICATION OF CAUSES
“Having no problem is the biggest problem of all”
-Taichi Onho

TECHNIQUES USED
BRAINSTORMING

TOOLS USED
AFFINITY DIAGRAM
CAUSE & EFFECT DIAGRAM

38
 STEP:5 IDENTIFICATION OF CAUSES
 By brain storming method , we listed out the various probable causes for this problem. By using this
probable causes we mapped Affinity diagram.
AFFINITY DIAGRAM
Higher Propane Consumption
MAN MATERIAL
1) Lack of Skilled Man 1) Defective raw material
Power supplied by supplier
2) Poor Maintenance
2) Line delay increases due
Schedule
to raw material.
3) Low consistency of work
4) Poor work environment

MACHINE
MEASUREMENT
METHOD
1) Repetitive breakdown 1) Feedback system for 1) Generation of excessive
2) Poor preventive maintenance continuous monitoring of scrap or rework
3) Exact reason not identify equipment not available 2) Improper alignment in
4) Equipments working on trial 2) Display system not entry & exit loopers
and error. available for monitoring 3) Lack of awareness about
of losses losses.
39
 STEP:5 IDENTIFICATION OF CAUSES

MACHINE METHOD MAN

Generation of
Repetitive breakdown Poor work Lack of Skilled Man Power
excessive scrap or
environment
rework Improper working knowledge
Poor preventive
maintenance Improper alignment in No proper training
entry & exit loopers Unsafe Conditions
Exact reason not identify Poor Maintenance Schedule
Low
Equipment's working on trial Lack of awareness consistency of Lack of Equipment Knowledge
and error about losses. work
Lack of feedback system
Higher Propane
Defective raw material Consumption
supplied by supplier
Defective finish material produced Feedback system for
due to defective raw material continuous monitoring of Display system not available
Line delay increases equipment not available for monitoring of losses
due to raw material

Due to hard cycle defect not

eliminate in existing equipment MATERIALS MEASUREMENT

6th Step i.e. Finding out the Root Causes, tools used in this step will help to find out the Root Cause causing
diversion in rework & GL scrap 40
 STEP 6 - FINDING OUT THE ROOT CAUSES
“It is not enough to do your best; you must know what to do, and then do your
best”
-W. Edwards Deming

TECHNIQUES USED
BRAINSTORMING

TOOLS USED
WHY-WHY ANALYSIS
CAUSE & EFFECT DIAGRAM

41
STEP:6 ROOT CAUSE ANALYSIS : MAN

Identification by validation of “MAN” related Root Cause by Why-Why Analysis

PROPER
WHY WHY
CAUSES JUSTIFICATION JUDGMENT
Sub-Cause Sub-Cause Validation Results

Lack of Skilled Improper working

No proper training Training given to workers INVALID CAUSE
Man Power knowledge

All schedule done for

Poor operation Lack of line Lack of awareness of
regular jobs with training VALID CAUSE
practices discipline losses
given
No standard
Poor Maintenance Lack of Equipment Standard maintenance
maintenance INVALID CAUSE
Schedule Knowledge procedure available
procedure

Low consistency of
Due to work fatigue More work load Work schedule following INVALID CAUSE
work

Data Shows that Man is not a Problem next validation done for Machine 42
STEP:6 ROOT CAUSE ANALYSIS : MACHINE

Identification by validation of “MACHINE” related Root Cause by Why-Why Analysis

PROPER
WHY WHY
CAUSES JUSTIFICATION JUDGMENT
Sub-Cause Sub-Cause Validation Results

Repetitive Due to root cause Feedback system Provide feedback system

INVALID CAUSE
breakdown identification problem required to analysis with data analysis

Poor preventive Lack of proper Schedule proper

Improper maintenance INVALID CAUSE
maintenance schedule for PM maintenance procedure

Exact reason not Not sufficient focus on Brain storming required on

Analysis problem INVALID CAUSE
identify problem each problem

Equipment's working Because of root cause Step by step Multiple modification may INVALID CAUSE
on trial and error. not identify modification & observe increase problem

Data Shows that Machine may be a Problem next validation done for Method 43
STEP:6 ROOT CAUSE ANALYSIS : METHOD

Identification by validation of “METHOD” related Root Cause by Why-Why Analysis

Why Why Proper Justification

Causes Judgment
Sub-cause Sub-cause Validation Results

Problem action plan &

Inappropriate Air Due to incomplete Due to air fuel ratio
implementation to be VALID CAUSE
Fuel Ratio combustion not balance
done
Plan to arrest all leakages
High H2% in in furnace and
Leakages in furnace Due to old furnace VALID CAUSE
furnace consistency to be
maintain

Schedule on job training

Lack of awareness Due to less on job Lack of self interest
to be done for all INVALID CAUSE
about losses training by operator
mandatory

Data Shows that Method is not a Problem next validation done for Measurement 44
 STEP:6 ROOT CAUSE ANALYSIS : MEASUREMENT

Identification by validation of “MEASUREMENT” related Root Cause by Why-Why Analysis

Why Why Proper Justification

Causes Judgment
Sub-Cause Sub-Cause Validation Results

Feedback system for

Not available in old It is an obsolete New feedback system to be
continuous monitoring of INVALID CAUSE
technology technology installed
equipment not available

Display system not available Lack of display Lack of experience In-house modifications can
INVALID CAUSE
for monitoring of losses board in the field be done

Data Shows that Measurement may not be a Problem. Next validation done for Material 45
STEP:6 ROOT CAUSE ANALYSIS : MATERIAL

Identification by validation of “MATERIAL” related Root Cause by Why-Why

Analysis

Why Why Proper Justification

Causes Judgment
Sub-cause Sub-cause Validation Results

Raw material By regular feedback

Less feedback INVALID
Old furnace supplier used old possible to take
about raw material CAUSE
equipment corrective action

Poor material Working on both and INVALID

Lack of awareness Due to negligence
safety save material CAUSE

Data Shows that Material not a Problem. All valid Root Causes Listed down in next slide 46
STEP:6 ROOT CAUSE ANALYSIS

LIST OF VALID CAUSES

PROPER JUSTIFICATION
SR. NO. CAUSES JUDGEMENT
VALIDATION RESULTS
Due to old furnace minor cracks &
1 Old Furnace vibration in furnace need to plan to VALID
change it identify portion CAUSE
Identify points to be rectify perfectly and
2 Leakages in furnace
cross checking required

Air fuel ratio need to be cross check

3 In appropriate Air Fuel Ratio
regularly and maintain it

Need to improve line discipline by regular

4 Poor operation practices
checkpoint and data monitoring.

Valid Causes are shown in next slide in the form of Fish-Bone Diagram 47
 STEP:5 IDENTIFICATION OF CAUSES

MACHINE METHOD MAN

Repetitive breakdown Propane loss Poor operation Lack of Skilled Man Power
increases practices
Poor preventive Improper working knowledge
maintenance Huge leakages No proper training
Unsafe Conditions
in furnace Poor Maintenance Schedule
Exact reason not identify Low
Equipment's working on trial Lack of awareness consistency of Lack of Equipment Knowledge
and error about losses. work
Lack of feedback system RESULTANT Higher
Propane
Due to old furnace
Consumption

Propane loss increases Feedback system for

continuous monitoring of Display system not available
Poor material safety equipment not available for monitoring of losses

Due to not taking care finish

material MATERIALS MEASUREMENT

Next Step is Step 7 i.e. Data Analysis

48
 STEP 7 - DATA ANALYSIS
“Without a standard there is no logical basis for making decisions or taking decisions”
- Joesph M Juran

TOOLS USED
GRAPH
PARETO

49
STEP:7 DATA ANALYSIS

This are the list of factors which were contributing to HIGHER PROPANE CONSUMPTION
Some major reasons are……..

a) Improper burner balancing in furnace air fuel ratio.

b) Heavy leakages in furnace.
c) Line run on low air fuel ratio.
d) Less quantity of combustion air due to that unburnt combustion in furnace
e) Improper operational practices during line run.

Defect diversion Data was collected for black patch above problems

50
 STEP:7 DATA ANALYSIS

AVERAGE LOSS PER

SR. MAIN REASONS FOR HIGHER AVERAGE PER MONTH COST AVERAGE COST PER YEAR
MONTH
NO. PROPANE CONSUMPTION RS LACS
KG/T

Improper burner balancing in furnace

1 0.34 474300 56.916
air fuel ratio.

2 Heavy leakages in furnace. 0.31 432450 51.894

3 Line run on low air fuel ratio. 0.28 390600 46.872

Less quantity of combustion air due
4 to that unburnt combustion in 0.26 362700 43.524
furnace

Improper operational practices

5 0.11 153450 18.414
during line run.

7 Input sheet not clean 0.05 69750 8.37

8 Material defect 0.02 27900 3.348

Pareto for all the above propane losses kg/t & cost is plotted in next slide 51
STEP:7 DATA ANALYSIS
AVERAGE LOSS PER MONTH KG/T

Pareto of propane loss per month cost is shown in next slide 52

STEP:7 DATA ANALYSIS

AVERAGE PER MONTH COST IN LACS

Propane loss major reasons from Pareto chart in next slide 53

STEP:7 DATA ANALYSIS

From the Pareto diagram it is observed that …………

1) Improper burner balancing in furnace air fuel ratio.

2) Heavy leakages in furnace.

3) Line run on low air fuel ratio.

4) Less quantity of combustion air due to that unburnt combustion in

furnace

Contribute to Higher loss and Higher Cost.

Next Step is Development of Solution i.e. Step no. 8

54
 STEP 8 - DEVELOPMENT OF SOLUTION
“The starting point for improvement is to recognize the need”
- Masaaki Imai

TECHNIQUES USED
BRAINSTORMING

54
 STEP:8 DEVELOPMENT OF SOLUTION
● For developing the solution, we used round robin method of brain storming. In the brainstorming session we
got many ideas and suggestions
SR. ACCEPTED BY QC
SUGGESTED SOLUTIONS REMARKS
NO. TEAM

1 Change total non oxidising zone NOT ACCEPTED Its not possible not accepted by management

Frequency of burner balancing to be

We can improve furnace efficiency by best
2 changed & in 3 days SSD changed damage ACCEPTED
practices
burner.
Replace old furnace with new to avoid
3 NOT ACCEPTED Not feasible
heavy leakages in furnace
Identify heavy leakages furnace parts to be This we can do after taking permission from
4 ACCEPTED
modify or changed. management
By suggestion of furnace manufacture We can do and observation to be noted as per
5 ACCEPTED
increase air fuel ratio to avoid unburnt gas result
Combustion blower to be change with Change equipment its not solution and high
6 NOT ACCEPTED
higher capacity budget is required for change blower

56
STEP:8 DEVELOPMENT OF SOLUTION

ACCEPTED BY QC
S.N. SUGGESTED SOLUTIONS REMARKS
TEAM

Combustion air to be increase for ACCEPTED

7 We can do this in-house by Mech team support
complete combustion

8 All damage manhole to be modified ACCEPTED We can do in house

ECL section to be changed for better Change equipment its not solution and high
9 NOT ACCEPTED
cleaning budget is required for change.

Accepted Solutions are discussed in the next slides 57

 STEP:8 DEVELOPMENT OF SOLUTION
● The ACCEPTED SUGGESTIONS
MAIN ROOT CAUSE
Improper burner balancing in
furnace air fuel ratio.
Heavy leakages in furnace.
Line run on low air fuel ratio.
Less quantity of combustion air due
We time to time try to arrest leakages in To avoid regular failure its better to modify
to that unburnt combustion in
some manhole but not get consistent result such a manhole for better result
furnace
were the plausible solutions for which solution is developed.
DEVELOPED SOLUTION FOR
WHAT CAUSED IT TO HAPPEN?
PROBLEM
In present condition burner balancing
frequency once in a month and air fuel If we increase burner balancing efficiency
ratio we run as per previous operation it help to increase furnace efficiency & by
practices. So unburnt combustion increases increasing ratio we sane propane by avoid
& burner also damage due to thermal unburnt combustion
shock
Identify and replaced all such a parts
Due to heavy leakages in some potion
rather than continue repaired. Cost of
defect generated and to avoid defects high
diversion & losses is more than replaced
propane consumption for increase temp.
damage parts
We continue old operation practices but After discuss with party and Mech team we
due to less combustion air unburnt increase combustion air to avoid unburnt
combustion in furnace combustion in furnace.

Time Bound & Responsibility Chart is discussed in next slide 58

 STEP:8 DEVELOPMENT OF SOLUTION

TIME BOUND AND RESPONSIBILITY SHARED ACTION PLAN

SOLUTION ACTION PLAN RESPONSIBILITY

Frequency of burner balancing to be changed &

in 3 days SSD changed damage burner. Operation practices to be improve and data to be
Piyush & Rana
By suggestion of furnace manufacture maintain to monitor results
increase air fuel ratio to avoid unburnt gas

Identify heavy leakages furnace parts to be J/c section, HBR section to be replaced after
Ramdayal & Subham
modify or changed modification done

Combustion air to be increase for complete Discuss with Mech team combustion blower air
Piyush & Ramdayal
combustion to be increase and monitor all line observation.

Modification to be done in all identify heavy

All damage manhole to be modified Ramdayal & Rana
leakage manhole

Next Step is Step 9 i.e. Foreseeing Probable Resistance 59

STEP 9 - FORESEEING PROBABLE RESISTANCE
“If you can't describe what you are doing as a process, you don't know what you're
doing”
- W. Edwards Deming

TECHNIQUES USED
BRAINSTORMING

58
 STEP 9: FORESEEING PROBABLE RESISTANCE

SOLUTION RESISTANCE REMARK

High Temperature, Pressure of Hot We have provided heat resistant PPE

To Change The HBR Man Hole Design
Bridle Roll section and fan for cooling.

We plan our jobs with capex capital

Management approval need for long
To Change The Damaged Burner Block SSD with prior permission from
SSD with budget
management.
To Change The Design Of Convergent-
divergent Nozzle Which Was The Reason Chances of failure is more or By continue monitoring data and
For Disturb Readings Of Furnace Burner increase diversion quality gradually increase air flow
Balancing

To Change The Expansion Joints & Long SSD required for manhole We prepare all modification activity
Expansion Bellows changing activity offline to reduced SSD hours.

Next step is Step 10 – Trial Implementation & Check Performance 61

 STEP 10 - TRIAL IMPLEMENTATION AND
CHECK PERFORMANCE
“Quality has to be caused, not controlled”
- Philip B. Crosby

TECHNIQUES USED
BRAINSTORMING

TOOLS USED
PDCA CYCLE

60
STEP 10:TRIAL IMPLEMENTATION AND CHECK PERFORMANCE

Action plan using PDCA & 5W-1H is developed for trial implementation & check performance of all
the Root Causes 63
 STEP 10:TRIAL IMPLEMENTATION AND CHECK PERFORMANCE
PLAN - TO CHANGE THE HBR MAN HOLE DESIGN DO -
STEPS - 1) Discussion with team about the Alternative way to change
the Hinged type nut-bolt design of HBR Manhole
Conclusion from discussion – Change Hinged type Design with Flange
type design due to which number of nut-bolts will increase

2) This Solution is Discussed with Supplier & accordingly material is

procured

CHECK
After HBR manhole design is changed, HINGED type HBR manhole (BEFORE)
readings were noted of Hydrogen (ppm)
ACT leakage. Readings were observed for 2 days
The FLANGED type & readings were taken thrice a day.
HBR Manhole Hydrogen leakages from Hydrogen leakages
Design is HINGED type HBR from FLANGED type
Manhole HBR Manhole
implemented & is 1) 1235 1) 0
put in actual 2) 1244 2) 2
Implementation 3) 1229 3) 0
4) 1234 4) 0
5) 1243 5) 0
FLANGED type HBR manhole (AFTER)
6) 1254 6) 0
64
 STEP 10:TRIAL IMPLEMENTATION AND CHECK PERFORMANCE
DO
PLAN - TO CHANGE THE DAMAGED BURNER BLOCK
STEPS - During Shutdown, our team realized that Furnace
Burner Blocks are also damage & it might be affecting the Flame
length of Burner. So decision was taken to change the Furnace
Burner Blocks

Damaged Furnace Burner Block(BEFORE)

ACT
As satisfied results are
obtained as per requirement
of the Furnace, the decision
was taken to change all the
damaged Furnace blocks
CHECK
If proper Flame length is
achieved or not as per
requirement is Checked.

New Furnace Burner Block (AFTER)

65
 STEP 10:TRIAL IMPLEMENTATION AND CHECK PERFORMANCE
DO
PLAN - TO CHANGE THE DESIGN OF
CONVERGENT-DIVERGENT NOZZLE WHICH
WAS THE REASON FOR DISTURB READINGS OF
FURNACE BURNER BALANCING
STEPS - To change the design of Nozzle, the idea was
discussed with the OEM supplier. Then, the nozzle was
changed with a pipe of Uniform cross-section area

ACT
By the change in design,
Satisfied results were
obtained. So the Change
was implemented
CHECK
Readings of Furnace Burner
balancing of old & new pipe
design were compared

Convergent-Divergent Uniform Cross- Section

Nozzle (BELOW) pipe (AFTER)

66
 STEP 10:TRIAL IMPLEMENTATION AND CHECK PERFORMANCE
DO
PLAN - TO CHANGE THE EXPANSION JOINTS &
EXPANSION BELLOWS
STEPS - Plan was made to perform leakage testing of
Expansion Joints & Bellows & during testing it was
observed by the team that Joints & bellows are damaged
badly from inside also

ACT
Fitting of New Expansion
Joints & Bellows in the
GALVALUME line
CHECK
Readings were noted of Leakage in Expansion New Expansion Joint
Hydrogen (ppm) leakage Joint (BEFORE) (AFTER)
from Expansion Joints &
Bellows. Readings were
observed for 2 days &
readings were taken thrice a
day

Damaged & New Expansion Bellow

Success achieved by QC Team before & after QC project 67
 STEP 11 - REGULAR IMPLEMENTATION
“Cost is more important than quality but quality is the best way to reduce the cost”
-Genichi Taguchi

TECHNIQUES USED
BRAINSTORMING

TOOLS USED
CHARTS

65
 STEP 11: REGULAR IMPLEMENTATION MILESTONE CHART

MILE STONE CHART

QUALITY CIRCLE NAME : ROCKERS DEPARTMENT : GALVALUME 1 MEMBERS NAME
P. Songhare
PROJECT: To Reduced High Propane Consumption MANAGER: RAHUL BORADE
R. Rana
PROJECT NO - 9 FACILITATOR: RAHUL BORADE Ramdayal
MEETING DAY : SATURDAY DY. FACILITATOR: SAYALI THAWKAR Subham
MEETING TIME : 16:00 TO 17:00 START- 01-01-2023 END:-31-08-2023 S. Thawkar
REGISTRATION NO:
ACTIVITY WEEK 1 2 3 4 5 6 7 8 9 10 11 12 TARGET ACTUAL
1 Define the problem 1 Week 1 Week
2 Analyze the problem 1 Week 1 Week
3 Identification of causes 1 Week 1 Week
4 Finding out the root causes 2 Week 2 Week
5 Data analysis 1 Week 1 Week
6 Developing solution 2 Week 2 Week
Foreseeing probable
7 1 Week 1 Week
resistance
Trial implementation &check
8 1 Week 1 Week
performance
9 Regular implementation 1 Week 1 Week
10 Follow up / review 1 Week 1 Week
TARGET ACTUAL
 STEP 11: REGULAR IMPLEMENTATION
BEFORE QC CIRCLE
MAIN REASONS FOR HIGHER AVERAGE LOSS PER MONTH AVERAGE PER MONTH COST AVERAGE COST PER YEAR
SR. NO.
PROPANE CONSUMPTION KG/T RS LACS
Improper burner balancing in
1 0.34 4.743 33.201
furnace air fuel ratio.
2 Heavy leakages in furnace. 0.31 4.3245 30.2715
3 Line run on low air fuel ratio. 0.28 3.906 27.342
12.9735 90.8145

AFTER QC CIRCLE

MAIN REASONS FOR HIGHER AVERAGE LOSS PER MONTH AVERAGE PER MONTH COST AVERAGE COST PER YEAR
SR. NO.
PROPANE CONSUMPTION KG/T RS LACS
Improper burner balancing in
1 0.10 1.40 9.765
furnace air fuel ratio.
2 Heavy leakages in furnace. 0.06 0.84 5.859
3 Line run on low air fuel ratio. 0.02 0.28 1.953
2.511 17.577
70
 STEP 11: REGULAR IMPLEMENTATION
AFTER QC RESULTS
EXTRA
NORMS ACTUAL TOTAL RATE OF PROPANE IN ACTUAL GAIN/LOSS
MONTH TOTAL VARIENCE CONSUMPTION IN
KG/t CONSUMPTION PRODUCTION RS IN LACS
KG

Jan-23 11.65 11.68 16843 -0.03 63.61 -505.29 -0.32

Feb-23 11.65 11.62 22458 0.03 62.68 673.74 0.42
Mar-23 11.65 11.63 19568 0.02 71.91 391.36 0.28
Apr-23 11.65 11.60 21941 0.05 71.87 1097.05 0.79
May-23 11.65 11.58 26256 0.07 72.00 1837.92 1.32
Jun-23 11.65 11.55 21334 0.10 72.00 2133.40 1.54
Jul-23 11.65 11.51 24000 0.14 72.00 3360.00 2.42
Aug-23 11.65 11.49 23000 0.16 72.00 3680.00 2.65
TOTAL 9.10

After QC last Eight month average we got

“Last Seven month average till Aug’23 we don’t have any

propane consumption loss“
Due to control propane loss after QC last few month average we achieved next slide
71
 STEP 11: REGULAR IMPLEMENTATION

COST OF OUR PROJECT

S.N. Equipment Cost
1 Manhole modification Rs. 7000/- Cost of Project –
2 Furnace expansion Bellow Rs. 70000/- 85000/-
3 Furnace pipe modification Rs. 8000/-

COST SAVING

MAIN REASONS FOR HIGHER AVERAGE LOSS PER MONTH AVERAGE PER MONTH COST AVERAGE COST PER YEAR
SR. NO.
PROPANE CONSUMPTION KG/T RS LACS
Improper burner balancing in
1 0.10 1.40 9.765
furnace air fuel ratio.
2 Heavy leakages in furnace. 0.06 0.84 5.859
3 Line run on low air fuel ratio. 0.02 0.28 1.953

Total COST SAVING = Rs. 10.46 Lacs Per Month

Total COST SAVING = Rs. 73.22 Lacs (In 7 months)
72
 STEP 11: REGULAR IMPLEMENTATION
INTANGIBLE BENEFITS

Enhanced problem Enhanced Presentation Mutual understanding

solving capability Skills

Enhanced Presentation
Skills

Enriched knowledge Self confidence

The intangible benefits are formulated into a Radar chart & ratings of various benefits were shown “BEFORE QC”
& “AFTER QC” 73
 STEP 11: REGULAR IMPLEMENTATION
PARAMETERS ALLOWABLE NORMS
-10 (°C) min to -45 (°C) max
DEW POINT
(Min. -10 and below)
H2 % LEAKAGE IN THE FURNACE Target 0 ppm

BURNER BALANCE READINGS +- 5 mmWc

REGULAR ACTIVITIES -
a) Dew point checking
b) H2 % leakage testing
c) Differential Pressure Readings

All these activities are monitored Regularly

In Regular Implementation, all the parameters are within norms. They are shown graphically in the next slides 74
 STEP 11: REGULAR IMPLEMENTATION
DEW POINT & HYDROGEN LEAKAGE READINGS
DEW POINT READINGS FOR JUN-23 HYDROGEN LEAKAGE (PPM) IN
Dew Point (target) Dew Point (Actual) FURNACE
10

0 9
1 3 5 7 9 11 13 15 17 19 21 23 25 27 29 31
8
DEW POINT READINGS (°C)

HYDROGEN (ppm)
6
-20 5

2
-40
1

0
1 3 5 7 9 11 13 15 17 19 21 23 25 27 29 31
DAYS
-60
DAYS Target Amount of H2 leaked (ppm)

Dew point is found in the range of -30 °C to -40 °C. Hydrogen Leakage almost found to be NIL. 2 or 3
Thus, furnace is healthy ppm leakage is found but it is OKAY
75
STEP 11: REGULAR IMPLEMENTATION
SAMPLE FURNACE BURNER BALANCING READINGS AFTER
REGULAR IMPLEMENTATION

Differential Pressure Readings of Furnace Burner Balancing are found within the norms i.e. +- 5 mmWc
76
 STEP 12 – FOLLOW UP
“Quality is fitness for intended use”
-Joseph M Juran

TECHNIQUES USED
BRAINSTORMING

74
 QUALITY CIRCLE TOOLS AND TECHNIQUES USED

Pareto 4W1H
Analysis Fish Bone Technique
Brainstorming
Diagram

Flow Milestone
Diagram PDCA
chart

Data
collection
Stratification

Tools and
Techniques
78
STEP 12: FOLLOW UP & REVIEW
Functional procedure BEFORE QC PROJECT Functional procedure AFTER QC PROJECT

79
STEP 12: FOLLOW UP & REVIEW
Functional procedure BEFORE QC PROJECT Functional procedure AFTER QC PROJECT

80
 12. FOLLOW UP & REVIEW
KAIZEN
Date:
Kaizen Project Format Department : GALVALUME Quality Circle Name : Galvalume rockers Project No:
11.03.2023
Title of Project : CPC 1 Rubber roll replacement with metallic roll.
Idea: Safety Observation System
Category: ( * ) Productivity, ( *) Quality, (* ) Cost, ( ) Delivery, ( ) Safety, ( ) Morale, ( ) Environment
Before (Situation) Root Cause Analysis Improvement Measures After (Situation)
Previously we are using rubber roll which after Due to rubber roll our mainteinance activity 1.New Modification done by replacing the rubber roll After modification roll
some time wear and tear. increased as it was get damaged after one or with metallic roll . replacement frequency reduced
two week. 2.Due to this the chances of roll damage reduced and cost saving insured.
3.One time rubber replacement cost is around 8000
rs and we replaced the rubber roll in once a month so
at one roll we saved 16000 rs and also manhours
saved.

Benefits : 1)increase life of roll 2)Reduced Member Details:Biswas, Nazeef,Avadh,Ashish

Standardization :- 1.This design will be applied for rubber roll frequent replacement Horizontal Deployment Opportunities (Replication) : In similar areas where roll replacement is
KPI Name: Improve the working environment
Single Point Lesson : Reliable output with smart working Improvement: Ease of job execution.
Remarks of evaluator:
Date of Starting : 03.03.2023 Date of Completion : 11.03.2023 Name: Signature:
Along with QC project some, Kaizens were done to take care of Safety
 STEP 12: FOLLOW UP & REVIEW
KAIZEN
Quality Circle Name : Galvalume
Kaizen Project Format Department : GALVALUME Project No: Date: 04.05.2023
rockers
Title of Project : Top dross location not defined.
Idea: top dross location fixed.
Category: ( ) Productivity, ( ) Quality, ( ) Cost, ( ) Delivery, ( * ) Safety, ( * ) Morale, (* ) Environment
Before (Situation) Root Cause Analysis Improvement Measures After (Situation)
No defined location for top dross,kept simply in platform. top dross location was not 5s activity Top dross location defined in pot area which
defined. improves line 5s activity.

Benefits : Safe working,line housekeeping activity Member Details: Rupesh,bandhe,tekade

Standardization :- 1.This methodology will be applied for all other lines pot Horizontal Deployment Opportunities (Replication) : In similar areas where same process

KPI Name: Improve the working practice

Single Point Lesson : Safe output with smart working Improvement: dross to be collected and arranged.
Remarks of evaluator:
Date of Completion : Name: Signature:
Date of Starting : 05.05.2023
05.05.2023

82
 STEP 12: FOLLOW UP & REVIEW
KAIZEN
Ref : TQM/VJNR/2016-17/EE/FMT17/REV02
Quality Circle Name :
Kaizen Project Format Department : GALVALUME Project No: Date: 10.02.2023
Galvalume Rockers
Title of Project : To fabricate the leak proof and quick fixing arrangment for Soaking zone drive side Manhole.
Idea: Leak proof and easy to lock arrangment for the Furnace Manhole
Category: ( * ) Productivity, (* ) Quality, ( * ) Cost, ( ) Delivery, ( ) Safety, ( ) Morale, ( * ) Environment
Before (Situation) Root Cause Analysis Improvement Measures After (Situation)
1)Existing Furnace Soaking zone section Drive side Manhole 1) InefficientTension on the 1) New Modified Square
design was not effective and it was very difficult to mount. manhole flange due to Hing bolted flange type manhole
2) 25 mm O-Ring cord used to fit inside the Manhole with type design. to be fabricated inhouse.
flange to furnace body contact area. This was not effective as2) No of bolts were 8 only 2) Total 20 nos tightening
O-Ring frequently comes out and on Bend portion leakages hence effective pressure
bolts arrangment to be
chances were more. was not upto the mark.
made for proper pressure
3)However Hing type bolting was also very less total 8 nos 3) O-Ring cord of 25 mm
on total contact surface.
boltings were there which producess less tension and was used instead of
leakages are always there rectangular gasket. 3) Pre-Cut Silicon material
Earlier H2 Leakages readings are as follows 4) Leakages of H2 from this square gasket to be
Soaking Drive Side manhole entry side = 402 ppm manhole was most procured as per PCD.
After Modification
Soaking Drive Side manhole Top side = 555 ppm common. 4) Ease in lifting and After Modification leakages checked found
Soaking Drive Side manhole Bot side = 327 ppm 5) Due to frequent leakages handeling design Soaking Drive Side manhole entry side = 0 ppm
Before Modification Old O-Ring Arrangment Soaking Drive Side manhole Top side = 0 ppm
Soaking Drive Side manhole Exit side = 292 ppm Due point temperature was
Soaking Drive Side manhole Bot side = 0 ppm
getting dropped. resulting in Soaking Drive Side manhole Exit side = 0 ppm
Peel off
Benefits : 1) No H2 Leakages after modification 2) Proper tension on the contact surface Member Details:1) Dinesh Satpute 2) Ganesh Dewase 3) Siraj Khan 4) Praduman Upadhya 5) Sunil
of body with the Manhole flange 3) Hex Bolts M16 to be used for mounting which is under
min max item, earlier special design bolts needs to be procured.
Standardization :- Horizontal Deployment Opportunities (Replication) : This type of opportunities to be hunt in other such process across plant.
Quick and leak proof mounting arrangment, easy to remove and re-install design. Spare
gaskets needs to be replaced only. No chances of damages to the gaskets.
KPI Name Leak proofing of the furnace to maintain bellow -10 Deg C due point Temp
Single Point Lesson : No Leakages No peel off To maintain the Due point temp bellow -10 Deg C and resulting in no peel off in 150 GSM and above coating
Improvement materials. Diversion reduced, Quality yeild increased, operating efficiency increased line running at 160 MPM
process speed.
Remarks of evaluator:
Date of Starting : 01.02.2023 Date of Completion : 10.02.2023 Name: Signature:

83
 STEP 12: FOLLOW UP & REVIEW
KAIZEN
Quality Circle Name : Galvalume
Kaizen Project Format Department : GALVALUME Project No: Date: 11.03.2023
rockers
Title of Project : Safe operation of moving trolley
Idea: Working Safety System
Category: ( ) Productivity, ( ) Quality, ( ) Cost, ( ) Delivery, ( * ) Safety, ( ) Morale, ( ) Environment
Before (Situation) Root Cause Analysis Improvement Measures After (Situation)
Previously moving trolley without Unsafe and manpower Trolley make motorized after trolley made motorized its operation is safe.
motor so operation done by manually consuming
which is very risky and manpower consuming. operation

Benefits : trolley area is complete safe now for operation. Member Details: Nilesh,ashish

Standardization :- 1.This methodology will be applied for all other lines where manual trolley Horizontal Deployment Opportunities (Replication) : In similar areas where unsafe area.
movements are there.

KPI Name: Improve the working environment (Safety)

Single Point Lesson : Safe output with smart working Improvement: Ease of job execution.
Remarks of evaluator:
Date of Completion : Name: Signature:
Date of Starting : 02.03.2023
02.03.2023

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STEP 12: FOLLOW UP

Management of Change TRAINING ATTENDANCE SHEETS

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STEP 12: FOLLOW UP

APPRECIATION LETTER

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 HORIZONTAL DEPLOYMENT

The same Quality Circle Project registered in the JSW’s TMS Portal for Horizontal Deployment
STANDARD OPERATING PROCEDURE

BEFORE

AFTER
 FUTURE PLANS

1. Line speed enhancement 250 MPM.

2. New Induction Oven to be installed

Future
Plans 3. Automation to be done in entry section.

4. Automation to be done in ECL section

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हर रोज, Everyday
Better कुछ बेहतर