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VIRENDER DHAWAN, DGM I/C (O) CCS, BSP RAJEEV SEHGAL, DGM I/C (O) CS, BSP.

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Presentation on theme: "VIRENDER DHAWAN, DGM I/C (O) CCS, BSP RAJEEV SEHGAL, DGM I/C (O) CS, BSP."— Presentation transcript:

1 VIRENDER DHAWAN, DGM I/C (O) CCS, BSP RAJEEV SEHGAL, DGM I/C (O) CS, BSP

2  Non Metallic inclusions (NMI)  Longitudinal Crack  Spider Crack  UT Failure (NDT)

3  DEFECTIVE DUE TO STEEL DEFECTS : 1.40 % max  DEFECTIVE DUE TO MILL DEFECTS : 0.43 % max

4 YEAR WISE ANALYSIS OF STEEL DEFECT YEAR STEEL DEFECTS

5 ANALYSIS OF STEEL DEFECT APRIL-NOV 2012 NCO

6 DEFECT WISE STEEL DEFECT DEFECTIVE

7  Delay in order servicing  Chocking of Plate Mill finishing area  Loss of market

8 CHALLENGE Evolve a system which aligns process capability with customer needs

9 ROOT CAUSE ANALYSIS OF UT FAILURE Major Reasons identified for UT Failure  Hydrogen cracking  Caster Condition  Process route - Not aligned with customer need

10 1. DEFINING OF PROCESS ROUTE FOR DIFFERENT GRADES/THICKNESS  Technological Process Route Converter LF RH Caster Plate Mill NDT This process route is to be followed for  For all high tensile (with or without Cu) below 410 MPa YS, steel plates of 32 mm and above thickness.  For 2062 E410 and above grades this route shall be followed for plate thickness 28 mm and above.  Calcium treatment in LF for all high tensile, micro alloyed heats and EME grades.  All mild heats for plates of 32 mm and above thickness.  All BQ heats irrespective of plate thickness

11 2. APPROVAL OF INITIATIVES FROM GM (QUALITY) ON INCORPORATING PROCESS ROUTE IN MES

12 4. IMPROVING EFFICIENCY OF DIFFERENT STATIONS IN PROCESS ROUTE  Ensuring vacuum level of <3 mbar in 2 to 2.5 minutes and achieving vacuum level of <1 mbar in 3.5 to 4 minutes  Measurement of RH out hydrogen at least once in a day. Aimed hydrogen less than 1.5 ppm in tundish  RH Off take change/maintenance planned after 1500 heats.

13 5. CASTER MAINTENANCE  Timely segment changes at caster 6 based on logger readings and feed back on UT results.  Increased frequency of manual inspection of Caster 3  Tightening of foundation bolts of caster by hydraulic torque wrench up to 400 Kg/cm 2

14 6. PROCESS CONTROL Initiatives taken under this are  Minimum 15’ degassing for 1 st heat of sequence / tundish and ensuring a hydrogen level of less than 1.6 ppm.  First heat of tundish / sequence planned only for thinner plates and not for heavy plates.  Use of MES for effective monitoring of quality feedback and based on this feed back caster maintenance plan made.  Diverting heats with less degassing to lower thickness ACTION PLAN

15  Leaner chemistry for lower segregation  Inclusion rating on regular basis Aim below 1.0 for EME grades  Periodical Sulphur print of slabs for monitoring caster condition ACTION PLAN

16 RESULTS OF IMPROVEMENT INITIATIVES M/C # 6 Performance InspNDTPeriod% Heat Number FromTo Before After Till 24th

17 RESULTS OF IMPROVEMENT INITIATIVES M/C # 3 Performance InspNDTPeriod% Heat Number FromTo Before After Till 24th

18 COST OF POOR QUALITY - FOR PLATES MonthOct-12Nov-12Dec-12Jan-13Feb-13Mar-13 Defective (Ton) Opprotunity Loss (Cr) Total Sales(Cr) Opp Loss/Sales (%)

19 YEAR WISE ANALYSIS OF STEEL DEFECT

20 Timely servicing of ordersIncrease in customer confidence Capability to service S2E3 (NDT) plate orders developed

21 REDUCED COST

22 TATA HITACHI Subject: FW: feedback from Tata Hitachi (TELCON) Feed back from customer is sent please Balu From:Ajay Kumar [mailto: Sent: 03 April :02 To: KL Balasubramanian Cc: Prabhat; Manoj Barik; Malay Palit Subject: feedback Dear sir. The quality of plates have been improved in all parameters. We continue to look forward to similar support in the future also. Regards Ajay Kumar Divisional Manager (Supply Chain Management) TATA Hitachi Construction Machinery Co. Ltd. Tata Motors premises, Telco Jamshedpur INDIA

23 RSB TRANSMISSION JAMSHEDPUR Sent: Tuesday, 26 February 2013, 17:34 Subject: Feed back on quality from M/s RSB Dear Sir(s), Submitted herewith the feedback on quality from M/s RSB Transmission please Balu KL Balasubramanian DGM (Quality) Bhilai Steel Plant Mob: Dear Sir, Please find the Details of Heat no.which we receive after heat no We find no complain on these Heat nos. Regards, Manzar Alam Sr.Manager (Materials) RSB Transmission (I) LTD.Unit-II Jamshedpur( INDIA) - M

24 Lowest ever steel defects of 0.48 % in May ‘2014 Overall steel defect till Jan 0.88 %

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26 From: Manzar Alam Sent: 26 February :17 To: 'KL Balasubramanian' Cc: bmbok Subject: Improvement in Plates Quality & Implementation of EME Grade. Dear Sir, As discussed during our Visit to SAIL CMO BOKARO, with Branch manager(Mr.Anil Arora and Mr.Prbhat Kumar and Subsequent telephonic discussion with you regarding the implementation of EME Grade. As we are finding Improvement in the Quality of plates, we still needs the EME to be mentioned in the T.C. as well as on the Plates, to avoid any gap during lifting from Stockyard. Regards, Manzar Alam Sr.Manager (Materials) RSB Transmission (I) LTD.Unit-II Jamshedpur ( INDIA ) - M

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28 New initiatives adopted Minimum 15 minutes degassing for first heat of sequence / Tundish Minimum 12 minutes for subsequent heats. First heat of Tundish/sequence will be planned only for thinner sections and not for heavy plates even if the heat is degassed for 15 minutes. Quality improvement initiatives

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33 From: Manzar Alam Sent: 26 February :02 To: 'KL Balasubramanian' Cc: bmbok; Subject: Tracking of Heat No. After Attachments: Sail Heat no-bhilai.xls Dear Sir, Please find the Details of Heat no.which we receive after heat no We find no complain on these Heat nos. Regards, Manzar Alam Sr.Manager (Materials) RSB Transmission (I) LTD.Unit-II Jamshedpur ( INDIA ) - M

34 From: Ajay Kumar Sent: 03 April :02 To: KL Balasubramanian Cc: Prabhat; Manoj Barik; Malay Palit Subject: feedback Dear sir. We take this opportunity to thank you sincerely for the quality improvement done as per our new TDC. The quality of plates have been improved in all parameters. And we expect further improvement in surface ( MINIMIZING THE SCALE FOR FURNACE NORMALISED PLATES ). We continue to look forward to similar support in the future also. Regards Ajay Kumar Divisional Manager (Supply Chain Management) TATA Hitachi Construction Machinery Co. Ltd. Tata Motors premises, Telco Jamshedpur INDIA

35 From: Shankar V - Axles India Sent: 28 January :34 To: Cc: Madhusudhan.Surathi; steel.com; Subject: FW: sail plate feedback Attachments: SAIL PLATES FEED BACK.xls Dear Mr K M Balasubramanian, We thank you for your efforts in controlling the issue of inclusions and spot laminations. We have checked the heats supplied in Nov and Dec 2012 and confirm that there are no inclusions and laminations. There are no rejections on this account and Quality has improved. We thank your effort and support extended SMS, Quality and plate mill for achieving the mail stone. Regards Shankar

36 -----Original Message----- From: K S Ravi Shankar To: KL Balasubramanian; 'ASHISH KUMAR SINGH'; Cc: Vijaya Vittala M Subject: Fwd: Ultrasonic test Audit on Steel plates Dear Mr. Ashish / Balasubramananian, For your information and records. Self and Mr.Ravishankar conducted ultrasonic test audit on steel plates at M/S Model Infra Corporation today as a pro active measure to give periodic feed back to SAIL on internal soundness. We have checked four plates along with three UT certified personnel of MIC after explaining the Quality requirements of UT as per the standard ASTM A 578 Level B. The plates audited by UT are also verified with mill test certificate of SAIL and confirmed plate procurement with relevant mill test certificates are in place at MIC. Based on UT, We observed that all the plates are free from defects. This confirms that the countermeasure taken by SAIL are effective.


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