7 IMPACT OF HIGH STEEL DEFECT Delay in order servicingChocking of Plate Mill finishingareaLoss of market
8 Evolve a system which aligns process capability with customer needs CHALLENGEEvolve a system which aligns process capability with customer needs
9 ROOT CAUSE ANALYSIS OF UT FAILURE Major Reasons identified for UT FailureHydrogen crackingCaster ConditionProcess route - Not aligned with customer need
10 ACTION PLAN FOR REDUCING NDT FAILURES 1. DEFINING OF PROCESS ROUTE FOR DIFFERENT GRADES/THICKNESSTechnological Process RouteConverter LF RH Caster Plate Mill NDTThis 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 ACTION PLAN2. APPROVAL OF INITIATIVES FROM GM (QUALITY) ON INCORPORATING PROCESS ROUTE IN MES
12 ACTION PLAN4. IMPROVING EFFICIENCY OF DIFFERENT STATIONS IN PROCESS ROUTEEnsuring vacuum level of <3 mbar in 2 to 2.5 minutes and achieving vacuum level of <1 mbar in 3.5 to 4 minutesMeasurement of RH out hydrogen at least once in a day. Aimed hydrogen less than 1.5 ppm in tundishRH Off take change/maintenance planned after 1500 heats.
13 IMPROVING EFFECIENCY OF DIFFERENT STATIONS IN PROCESS ROUTE 5. CASTER MAINTENANCETimely segment changes at caster 6 based on logger readings and feed back on UT results.Increased frequency of manual inspection of Caster 3Tightening of foundation bolts of caster by hydraulic torque wrench up to 400 Kg/cm2
14 ACTION PLAN 6. PROCESS CONTROL Initiatives taken under this are Minimum 15’ degassing for 1st heat of sequence / tundishand ensuring a hydrogen level of less than 1.6 ppm.First heat of tundish / sequence planned only for thinnerplates and not for heavy plates.Use of MES for effective monitoring of quality feedbackand based on this feed back caster maintenance plan made.Diverting heats with less degassing to lower thickness
15 ACTION PLAN Leaner chemistry for lower segregation Inclusion rating on regular basis Aim below 1.0 for EME gradesPeriodical Sulphur print of slabs for monitoring caster condition
18 COST OF POOR QUALITY - FOR PLATES MonthOct-12Nov-12Dec-12Jan-13Feb-13Mar-13Defective (Ton)31842068112510339331419Opprotunity Loss (Cr)4.672.722.214.171.1241.27Total Sales(Cr)352.52304.46327.39333.67313.99333.06Opp Loss/Sales (%)1.330.910.370.340.270.38
22 CUSTOMER FEED BACK 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 CUSTOMER FEED BACK 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 HIGHLIGHTS OF 2014-15 Lowest ever steel defects of 0.48 % in May ‘2014 Overall steel defect till Jan 0.88 %
26 Sr.Manager (Materials) RSB Transmission (I) LTD.Unit-II From: Manzar AlamSent: 26 February :17To: 'KL Balasubramanian'Cc: bmbokSubject: 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 andSubsequent 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 AlamSr.Manager (Materials)RSB Transmission (I) LTD.Unit-IIJamshedpur (INDIA)-M
28 Quality improvement initiatives New initiatives adoptedMinimum 15 minutes degassing for first heat of sequence / TundishMinimum 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.
33 We find no complain on these Heat nos. From: Manzar AlamSent: 26 February :02To: 'KL Balasubramanian'Cc: bmbok;Subject: Tracking of Heat No. AfterAttachments: Sail Heat no-bhilai.xlsDear Sir,Please find the Details of Heat no.which we receive after heat noWe find no complain on these Heat nos.Regards,Manzar AlamSr.Manager (Materials)RSB Transmission (I) LTD.Unit-IIJamshedpur (INDIA)-M
34 From: Ajay Kumar [Ajay.Kumar@tatahitachi.co.in] Sent: 03 April :02To: KL BalasubramanianCc: Prabhat; Manoj Barik; Malay PalitSubject: feedbackDear 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.RegardsAjay KumarDivisional Manager (Supply Chain Management)TATA Hitachi Construction Machinery Co. Ltd.Tata Motors premises, TelcoJamshedpurINDIA
35 From: Shankar V - Axles India [email@example.com] Sent: 28 January :34To: Cc: Madhusudhan.Surathi;Subject: FW: sail plate feedbackAttachments: SAIL PLATES FEED BACK.xlsDear 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.RegardsShankar
36 -----Original Message----- From: K S Ravi ShankarTo: KL Balasubramanian; 'ASHISH KUMAR SINGH';Cc: Vijaya Vittala MSubject: Fwd: Ultrasonic test Audit on Steel platesDear Mr. Ashish / Balasubramananian,For your information and records.Self and Mr.Ravishankar conducted ultrasonic test audit on steel plates at M/SModel 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 inplace at MIC. Based on UT, We observed that all the plates are free from defects. Thisconfirms that the countermeasure taken by SAIL are effective.