QC Presentation Theme
From – PRATIBHA- Birla Copper
Hindalco Industries Limited
(Unit : Birla Copper )
Village : Lakhigam
P. O. : Dahej - 392130
Taluka :Vagra
District : Bharuch
Gujarat
Birla Copper Complex
Vision, Mission & Goals
Our Vision
Our goal is to be one of the largest manufacturers and suppliers of World Class Quality
Copper and also achieve and maintain World Class Standards in relation to Safe
Workplace, Environment and friend of the Community.
Our Mission
We continue to be System Driven Organization and achieve standards of Excellence in
all areas of Business Operation.
We continue to provide all requisite resources, support, guidance and environment to
our employees and business associates to excel in their standard of performance
focusing on Internal and External Customer Delightfulness.
We continue to lead and support rural development initiatives in relation to education,
health and community development.
Our Goals
To reach productivity and efficiency norms that are international benchmarks for a cost
conscious management of business operations which will not only maximise
shareholder value but also create cost effective option for our customers. These will be
achieved by adopting highest busuness values at all levels.
Achievements
Birla Copper's quality standards are recognized internationally. It has been
accorded the LME (London Metal Exchange) registration: its copper cathodes
marketed as "Birla Copper", have been approved as a 'Grade A' Copper brand by
the LME.
Birla Copper has been accredited ISO-9001:2000 (Quality Management
System) and ISO-14001:1996 (Environmental Management System)
certification. Recommended for OHSAS – 18001 Certification.
Dahej Harbour and Infrastructure Ltd. has been awarded the ISO 9001:2000 (Port
Management for Handling Dry and Liquid Cargo) certificate by KPMG.
Birla Copper is awarded commendation certificate - Ramakrishna Bajaj National
Quality Award 2002 of Indian Merchant Chambers for Business Excellence and
Quality Achievements in manufacturing companies category for the year 2002
Technologies in Place
Sl No
Plant Area
Process
Technology
1
Smelter
Flash Smelting
OEC, Finland
2
Converter
P.S. Converting
OEC, Finland
3
Copper Refinery
ISA Process
MIM, Australia
4
Sulphuric Acid
5-stage DCDA
Monsanto, USA
5
CC Rod
Casting & Rolling
Southwire, USA
6
Phosphoric Acid
Di-hydrate
SNC-Lavlin, Belgium
7
DAP Plant
Pipe Reactor
Incro, Spain
8
PMR Plant
Pyro- Metallurgical
OEC, Finland
Prax
Air,
USA
9
Oxygen Plant
Cryogenic
Air Liquide ,France
10
Captive Power Plant
Coal Based
Krupp, Germany
11
Jetty
Material Handling
Howe, India
and
Process Flow
Continuous Cast copper Rods
Plant – CC Rod
Technology – Southwire ,USA
Installed Capacity : 80,000 TPA
•
•
•
Refined Copper Cathode is
transformed into Continuous Cast
Copper Rod in the CC Rod plant
for higher value addition.
Continuous cast copper rods of 8,
11, 12.5, 16 and 19 mm
diameters are produced to cater
to the needs of a wide customer
range.
The rods hence produced undergo
on-line defectomat scanning to
International Quality Standard
(ASTM B/49/92
TEAM
TEAM MEMBER
RESPONSIBILITY
Mr. SHAKIR VAHORA
(Technician)
• Improvement Implementation.
Mr. URMESH RANA
(Casting Operator)
• Improvement Implementation.
Mr. MAHESH AHIR
(Casting Operator)
• Improvement Implementation.
NILESH CHAMPANERYA
(Mechanical Operator)
•Data collection
•Maintenance Support
Mr. MANOJ SADANANDAN
(Shift In-charge)
• Problem Analysis.
• Control at Shop-floor level.
• Control at Shop-floor level.
• Control at Shop-floor level.
• Action Plan Preparation.
• Overall Project Co-ordination.
CCR - PROCESS FLOW DIAGRAM
Temp
1200°C
HOLDING FURNACE
Temp
1150°C
Tundish
MELTING FURNACE
SKIP
HOIST
BAR PREPARATION UNIT
ROLLING MILL
2 no’s 12” Roughing Stand
8no’s of 8” Finishing Stand
NON ACID PICKLING SYSTEM
IPA treatment
Spout
CASTING MACHINE
18 Mt / Hr
COILER
Compacting,
Strapping,
& Stretch
wrapping.
FOCUS AREA
Lump Formation
PROJECT DETAILS
START DATE :- 30.07.2004
NO. OF MEETINGS
MEETING DURATION
FINISH DATE :- 30.11.2004
:
16
:
30 MIN
(EVERY MONDAY)
IMPACT OF THE IMPROVEMENT
IMPROVED CAST BAR STRUCTURE.
REDUCTION IN LUMP FORMATION.
REDUCED REJECTION AND RECYCLE.
REASONS FOR PROJECT SELECTION
SELECTION OF THE PROJECT
REJECTION ON THE GROUND OF
SPOUT CLEANING
SOLIDIFIED LUMPS NEAR
SPOUT
HEAVY SPLASHING
WHY SELECTION
 PRODUCTIVITY LOSS.
DETERIORATION OF QUALITY
VALUE LOSS.
CUSTOMER COMPLAINT
SPLASHING
EFFECTS ON THE PROCESS :Lump formation near spout because of metal splashing.
Lump cleaning leads to rejection of coil.
Metal splashing leads to oxide inclusions in cast bar.
METHODOLOGY FOLLOWED
ROOT CAUSE IDENTIFICATION
&
TOOLS AND TECHNIQUES USED
(01) WHY-WHY ANALYSIS was carried out simultaneously to
arrive at specific conclusion for high risk factors.
(02) ACTION PLAN was drawn on the basis of Analysis and
Improvement Plan & IMPLEMENTED subsequently.
(03) Sustenance of IMPROVED PRACTICES
DATA SOURCE
(1) Shift Engineers’ Log Book.
(2) Coil wise / Parameter wise Inspection Report.
(3) Casting operators logbook.
 Meetings were held once on weekly basis among the team
members to find a solution.
 Brainstorming + creative thinking were undertaken along
with Gemba investigation in order to solve the problem.
WHY-WHY ANALYSIS
Metal Splashing
Why ?
Off centered metal flow from
pouring spout
Why ?
Improper centering of
Tundish on casting Machine
Why ?
Visual judgment error
Why ?
No tool for precision centering
CONCLUSION
(01) Some tool has to be designed to eliminate human error in centering
ACTIONS TAKEN
No.
ACTIONS TAKEN – AT A GLANCE
1
Study of location of pool position
2
An in-house template designed
3
Trial taken.
4
Operators trained to do centering with help of template
BEFORE USE OF TEMPLATE
LUMP
FORMATION
AFTER 12 Hrs
of Operation
ACTIONS TAKEN
TEMPLATE PHOTOGRAPH
EFFECT OF SPOUT POSITION IN X AXIS
POURING SPOUT
LIQUID POOL
METAL STREAM
EFFECT OF SPOUT POSITION IN Y AXIS
POURING SPOUT
METAL STREAM
MOVABLE PRESSURE WHEEL
CASTING WHEEL
LIQUID POOL
RESULTS AFTER USE OF TEMPLATE
NO LUMP
EVEN AFTER
48 Hrs of
Operation
COST OF PROJECT
TOTAL PROJECT COST
(MATERIAL COST + MANPOWER COST)
Rs.200
COST DUE TO SPOUT CLEANING
Estimated Cost Element
Cost / MT
1.
PROPANE
Rs. 870 / MT
2.
POWER
Rs. 225 / MT
3.
IPA
Rs. 60 / MT
4.
CONSUMBLES
Rs. 320 / MT
5.
OTHERS
Rs. 175 / MT
Recycle Cost for rejected
material
Rs. 1650 / MT
ADVANTAGES
LOW SPLASHING IN METAL POOL
NO LUMP FORMATION NEAR SPOUT
NO REJECTION DUE TO
SPOUTCLEANING
REDUCED RECYCLE LOAD
HIGHER PRODUCTIVITY
RESULTS
REJECTION DUE TO SPOUT CLEANING
100
80
60
40
20
0
TONS
July
Aug
Sep
Oct
Nov
Dec
81
28
37
33
18
13
BENEFITS
TANGIBLE BENEFITS :
SAVING :
Average Reduction in recycle load from 9 Kg./MT to
3 Kg/MT i.e. 6.0 Kg/MT.
Actual SAVINGS :
Considering Annual CCR production during 2003-04 : 91,848 MT
It turns out to be 551 MT per Annum
551 * 1650 Rs./MT = Rs. 9,09,150/-
Potential SAVINGS :Considering Annual CCR production capacity of 1,20,000 MT
It turns out to be 720 MT per Annum
551 * 1650 Rs./MT = Rs. 11,88,000/-
BENEFITS
INTANGIBLE BENEFITS:
 Improved casting control.
 Better product quality and consistency.
 Eliminating unsafe working condition.
 Increased team bonding and motivation levels.
SUSTENANCE PLAN
Sr.
Control Mechanism
Responsibility Frequency
Review
Mechanism
1
To Prepare document
on standard procedure
for tundish centering
SHAKIR
Immediately SHAKIR
2
Regularly implement
centering procedure in
every changeover
Casting
Operator
Regularly
Shift
Engineer
3
Regular linkage of
Procedure with the
results and suggest
further up gradation if
required.
Manoj
Regularly
Shift
Engineer
ACKNOWLEDGEMENT
We acknowledge our sincere thanks to team of CCR
especially CASTING AND FURNACE AREA for their
valuable suggestion during Brain Storming session
and their support during execution of our project.
We are thankful to HOD-Mr. A. Chakraborty for
pondering the responsibility and support for taking
up the project.
We are thankful to Mr. R. Shankar, Mr. Anil Patro
(Dy,Mgrs-CCR) and Mr. Kunal Joshipura (Sr. Engr.)
for their valuable suggestions and support during
execution of our project.