Focused Improvement Project

Reduction of Furnace Tap to Tap Time

 Model Line: Reduction of induction furnace tap to tap time

Team Leader Three Key Team members

Md. Afsar Hossain

Akram Uddin Ahmed

Sadhan Kumar Roy
Nurul Karim

FI Zone: IF Shop Floor Activity

Sub Zone: RM Yard Activity
Sl. No. Other Team Members
1 Debashis Kumar Dey/S. M. Sajjad Hossen
2 Kazi Mohoshi Uddin Ahmed/Abdul Halim Khan
1 Rajib Debnath
2 Argha Sikder Saurav
3 Md. Naimur Rahman Antu
 Background
• The objective of this focus improvement is to decrease tap to tap time
which will increase Production & reduce Power & Lining cost significantly.

• Primary thinking is minimum tap to tap time with maintaining higher heat
size.

• It can be achieved by maintaining proper scrap recipe, smooth charging &

chemistry set in schedule time.

• Low Tap to Tap time also depends on low slag generation & bridging free
melting.

• Need to procure good quality scarp to achieve minimum Tap to Time time.
Focused Improvement Action Plan on Tap to Tap time

Area/Topic Point Responsible Concern Pillar Leader Action Plan Target Date Current Status

Have to show a bar chart or

Tap to Tap Time network of the Man-Machine Sadhan Kumar Roy Md. Hafazutur Rahman ECRS to be developed
interference.

Have to find out all the things

Tap to Tap Time what is happening during the Sadhan Kumar Roy Md. Hafazutur Rahman ECRS to be developed
whole tap to tap time.

Have to identify all the people

who is involved in different
Tap to Tap Time Sadhan Kumar Roy Md. Hafazutur Rahman ECRS to be developed
works during the whole tap to
tap time.

Have to find out all the critical

Tap to Tap Time path and critical time to cut Sadhan Kumar Roy Md. Hafazutur Rahman ECRS to be developed
down the tap to tap time.

Have to engage man power with

camera to take videos in
different places with respect to
Video recording & ECRS to be
Tap to Tap Time the whole process time. Then Sadhan Kumar Roy Md. Hafazutur Rahman
developed
those videos should be merged
to understand who is working
when.
 SOP

SOP Work
Instruction

WI - Melting in
SOP - Safe
furnace
Melting
Recipe
Process Flowchart
 Master Plan

Activities TIMELINE 2023

April May June

Best scrap recipe selection 25th April to 30th June

Bridging free melting 25th April to 30th June

25th April to 30th June

%P Adjustment Delay
25th April to 30th June
%C Adjustment Delay
25th April to 30th June
Furnace trip reduction
ACTIVITIES
ECRS WORKSHEET
Furnace mechanism
 Result

FY 2021-2022 FY 2022-
In FY 2021-2022 TTT (Min) 104.96 Particulars
(March) 2023(March)
Our target TTT (Min) 96 Power consumed in IF
(KWh/MT) 570 566
Total Production per year
TTT decreased (Min) 8.96
(MT) 758,303 741,442
We can gain extra production
5.32 Total power (KWh)
(MT) 432,232,710 419,656,172
Yearly extra production (MT) 103,367.60 BDT.
4,322,327,100 4,196,561,720
Cost savings in 2023
BDT of extra production 485,827,720.00
compared to 2022 (BDT.) 125,765,380

Impact on product Impact on power

THANK YOU