QC Presentation Theme From PRATIBHA Birla Copper Hindalco

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

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 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. • 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 8 no’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 FINISH DATE : - 30. 11. 2004 NO. OF MEETINGS : 16 MEETING DURATION : 30 MIN (EVERY MONDAY) IMPACT OF THE IMPROVEMENT ØIMPROVED CAST BAR STRUCTURE. ØREDUCTION IN LUMP FORMATION. ØREDUCED REJECTION AND RECYCLE.

REASONS FOR PROJECT SELECTION OF THE PROJECT REJECTION ON THE GROUND OF SPOUT CLEANING SOLIDIFIED LUMPS NEAR SPOUT HEAVY SPLASHING

WHY SELECTION ü PRODUCTIVITY LOSS. üDETERIORATION OF QUALITY üVALUE LOSS. üCUSTOMER 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. v Meetings were held once on weekly basis among the team members to find a solution. v 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

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.