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INTRODUCTION
TITLE OF THE PROJECT
Reduction in consumable nozzle cost
With improved efficiency
THEME OF THE PROJECT
Waste Elimination
TEAM DETAIL
Meeting Day : Tuesday , Meeting Time : 3:30 PM
Ownership Area : Welding Machine Area
Team formation date : 01.07.04
TEAM MEMBER
RESPONSIBILITY
K.V. Joshi( Leader)
To Provide Resources and Guidance, Data analysis
& Use of PS Tools
P.J. Prajapati
Execution of jobs mentioned in action plan such as
welding, brazing etc.
Mahendra Panchal
Development of fixtures related to spot facing and
internal drilling
Mehul Kachhia
Machining of fixtures related to spot facing and
internal drilling ( Operation of Lathe and milling
machine)
Pravin Chitte
Equipment Study and Co-ordination during
machining jobs
4
5
Hindalco Industries Limited
(Unit : Birla Copper )
Village : Lakhigam
P. O. : Dahej - 392130
Taluka :Vagra
District : Bharuch
Gujarat
Birla Copper Complex
6
Product Profile
BIRLA COPPER
– Cathode (99.99%)
– Continuous Cast Rod
• in 8, 11, 12.5, 16 and 19mm dia .
Precious Metals (99.9 %)
– BIRLA Gold
– BIRLA Silver
DAP & Complexes
– Birla Balwan
• Di-Ammonium Phosphate (DAP)
• 20:20:0 Ammonium phosphate sulphate
• NPK 10:26:26 & NPK 12:32:16.
By Products
Copper Slag
Sulphuric Acid
Selenium
PGM Mix
Phospho Gypsum
HFA
7
Achievements
8
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
9
Our Focus Areas
Receiving third prize
in CII QC Circle
Competition at
Ahmedabad.
Receiving third prize in
Inter Hindalco Kaizen
Competition at
Renukoot. (January
2005)
Process Flow
10
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QUALITY POLICY – BIRLA COPPER
 We at Birla Copper are committed to evolving and sustaining
excellence in every area of activity .
 Birla Copper will be driven by a sharp focus on maximizing
customer satisfaction . Towards that end, an accent on quality
will mark every aspect of our operation
 We will also work continuously to improve on existing
processes and introduce innovative technology.
P Balakrishnan
Executive President-Birla Copper
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PROBLEM
 Unavailability of Plasma Cutting Machine
on account of non availability of Nozzles
 Lower cutting length per Nozzle
 High cost of nozzles
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FISH BONE DIAGRAM
Method
Improper
Method of
cutting
Material
Cutting Head
Holding Time
Cutting Profile
Tightness of
Nozzle
Improper Cutting
Head Height
Plate Thickness
Hole
Worn
Out
Gap at Plate
Bottom
Moisture in
Air
Nozzle Head
Operating
Personnel skill
Spacer Ring
Air Pressure
Material’s Personnel
Availability
Improper
Earthing
Machine
Type of SS
Material
Man
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WHY-WHY ANALYSIS
Unavailability of Plasma Cutting Machine
WHY
Earthing Problem
WHY
It was difficult to maintain the Gap between plate and Nozzle
WHY
Burr Generation
WHY
Nozzle Hole became Oval Shaped instead of Circular
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Plasma Cutting Nozzle
New Nozzle
Damaged Nozzle
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PDCA CYCLE
P
STEP 1
STEP 2
STEP 3
STEP 4
D
STEP 5
C
STEP 6
A
STEP 7
Act
Plan
Check
Do
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ROOT CAUSE
After
brainstorming,
It
was
found
that
High
consumption of nozzle is attributable to oval shape in
cutting nozzle hole and due to this Nozzle is getting
discarded.
Can we do with this Oval Shaped Nozzle and make it
further usable ?????????
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ACTIONS TAKEN
 Brazing of Oval Shaped Nozzle with 1805 Copper
Filler Wire.
 Inside Spot facing to maintain 1.5 mm gap between
plasma electrode and cutting nozzle.
 Ø 1.4 mm center hole drilling on lathe
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PROBLEM FACED IN IMPLEMENTATION
 During brazing, metal of nozzle melt and distort the
shape and size of nozzle.
 Inside holes provided for cooling, get chocked.
 Holding of Nozzle for Spot Facing
 Holding of Nozzle for Internal Hole drilling
ACTION TAKEN TO OVERCOME THE
FACED PROBLEM
 Instead of conventional top heating (90º job
heating) , we have used inclined heating (45º
job heating)
 Fixture has been developed for spot facing as
per drawing.
 Fixture has been developed for internal hole
drilling as per drawing.
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Fixture for Spot Facing and Internal Drilling
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RESULT ACHIEVED
 Reduction in Consumption of Cutting Nozzles.
 Uninterrupted Availability of Plasma Cutting
Machine.
 Cutting length per nozzle (in meter) increased.
 Reduction in Inventory of Cutting Nozzle.
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BASIC COST FOR PROJECT:
Cost Of Implementation
per Nozzle (In Rs.)
Brazing –
Spot Facing –
Hole Drilling Total -
Rs. 07.00
Rs. 13.00
Rs. 05.00
Rs. 25.00
Thus total repair cost per nozzle is Rs.25/
as against Rs. 400/ for a new one
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TANGIBLE BENEFITS:
(A)
Consumption of Cutting Nozzle
(Before Improvement)
= 725 Nos./Year
Consumption of Cutting Nozzle
(After Improvement)
= 290 Nos./Year
Cost of One Nozzle procured from O.E.M. = Rs. 400/
Cost of Repairing one Nozzle
= Rs. 25/
(725-290)x(400-25) = Rs. 1,40,625 /- per annum
Total saving per annum is Rs.1,40,625 /-
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TANGIBLE BENEFITS:
Down time
(Before Improvement)
Down time
(After Improvement)
(B)
= 20 hrs./month.
=
0 hrs./month.
Thus reduction in down time per annum
=240 Man hrs/ annum
Total saving per annum is Rs.1,40,625 /-
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KEY LEARNING
1. Better understanding of the use of problem solving tools.
2. Improved communication skill.
3. Opportunity for
management.
team
members
to
give
suggestion
to
4. Enhancing team capability for presentation in front of public
audience.
5. Better understanding of methodology.
6. Better service to internal customer.
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THANK YOU.