The document summarizes a quality circle project at Bokaro Steel Plant to dismantle roller table foundations of four hot strip mill re-heating furnaces within five days during a capital repair. They faced the problem of only having two functioning pneumatic breakers, which would not be enough to finish the job on time. Through brainstorming, the quality circle revived 18 pneumatic breakers by collecting unused parts, studying drawings, substituting parts from other equipment, grinding chisels, and welding components. This allowed them to break 29 foundations within the five-day timeframe and save Rs. 6,30,000 that would have been spent on a new breaker. Benefits also included improved self-confidence and work appreciation.

1. SAIL, BOKARO STEEL PLANT
QC No: 186 (CED/W)
Introduction
D Soren-Leader, N K Mahto-Dy.Leader, A Tiwary-Member, D Murmu- Member,
Md S Haque- Member, P Minz-Promoter .
PROJECT TITLE
A CHALLENGING JOB OF PNEUMATIC BREAKER DURING THE
CAPITAL REPAIR OF HOT STRIP MILL, FY 2011-12 BY CED(W).
The Re-Heating furnaces of Hot Strip Mill are in 04 no’s whose discharging side roller
table foundation were damaged and the job of dismantling vis-a-vis re-casting was a
herculean task given to Civil Engineering Department. We had to dismantle the roller
table foundation within 5 days from the start of capital repair keeping in mind of other
central agencies role which comes after the dismantling.
Problem faced:
We had only two pneumatic breakers machine in running conditions available in
department of CED(W), never had technician to assist us for its maintenance and change
of spares. With 02 pneumatic breakers we could never finish the job of dismantling
foundation due to time constraints.
Solution:
Through the technique of brain storming, innovative solutions QC:186 developed a
strategy. Without the guidance of technical experts, we collected all the unused parts of
breakers, we studied detail drawings of parts collected through internet, serviced it,
substituted parts of other machinery equipments, grinded chisels, welded throttle,

2. replacing one’s part on another, revived 18 no’s pneumatic breaker. We implemented it for
breaking 29 no’s foundations in capital repair & within 05 days we completed.
Benefits Achieved:
i) Cost of 01 new pneumatic breaker = Rs 35,000.00
ii) Total assembled breakers manually = 18 Nos
iii) Direct saving = Rs 6,30,000.00
% of average breakdown of breakers = 33 %
After completion of project B/D Hrs = Nil
Intangible benefits: Improvement in self confidence, appreciation in work, better
industrial relationships, and accepting challenging works through Quality Circle.