Improvement in HR to CR yield at JSW STEEL kalmeshwar

Shourya
JSW STEEL COATED PRODUCTS LIMITED
KALMESHWAR
ISO 9001: 2015,ISO 14001:2015, ISO45001:2007,ISO 50001:2018 CERTIFIED UNIT
Quality Circle : SHOURYA
34th National Convention on Quality Concept
Welcomes You
Theme -: Self-Reliant India through Quality Concept 1

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SR. No DESCRIPTION Slide No
1 Introduction 6 - 16
2 Awards and CSR & Management initiatives 17 - 18
3 Introduction of Department and Quality Circle 19 - 21
4 Identification of problems 22 - 27
5
Selection of problem
• Categorization in A,B,C - A,B,C Analysis
• 3 – P Analysis (Ranking, weightage, Pareto Diagram)
28 – 41
6
Definition of problem
• Gantt Chart
• Introduction
• Process Description through flow diagram
• Problem Description in brief
• Explanation of problem – its impact.
• Setting of Objectives and Goals
42 - 59
7
Analysis of problem
• Data collection
60 - 66
Index
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8
Cause and Effect analysis
• Affinity Diagram
• Cause and effect diagram (Fish bone diagram)
67 - 70
9
Root cause analysis
• Why-Why Analysis
• Identification by Validation
• Summary of Problem using 5 W and 1 H Analysis
71 - 84
10
Data analysis
• Data Collection
• Bar Graph •
• Comparative study
• Pie-Chart
85- 98
11
Development of solution
• Development of solutions through brain storming
• ICITE matrix
• Time Bound and responsibility shared action Plan.
99 - 108
12 Foreseeing probable Resistance and points to overcome them 109 - 112
Index
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13
Trial implementation & Check Performance
• Smart Analysis
• PDCA Cycle
• Comparative study before QC and during trial.
• Trial and Actual plan
113 - 122
14
Regular implementation
• Data collection after regular implementation.
• Comparative study before and after QC graphs.
• Tangible and Intangible benefits
123 - 132
15
Follow up and Review and Recurrence Prevention
• Check lists
• Gantt chart with reason for Variation
• Kaizen
133 - 146
Index
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SHRI O.P.JINDAL
(August 7, 1930 – March 31, 2005)
“ Where others saw walls, he saw doors ”
Our Founder Chairman
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• JSW Group is a major player in steel industry
amongst the leading conglomerates in India, it is a
$14 billion company. It has become a single largest
steel plant in India through speed and innovation in
short span of time
• JSW STEEL LTD. is India's leading integrated steel
manufacturer with capacity of 18 MTPA
• Its Key Infrastructure Sectors are :
Integrated Steel Plant
Downstream Plant
Steel Energy Infrastructure Cement Ventures
Paints Realty
Introduction of JSW Steel
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With our strong VPV, JSW is a mark of trust and quality that millions of
customers around the world depend on
VISION
TO BRING POSITIVE TRANSFORMATION TO EVERY LIFE
WE TOUCH
PURPOSE
ACCELERATE THE GROWTH AND PROSPERITY OF THE
COMMUNITIES WE LIVE IN BY
VALUES
Confidence Courage Commitment Compassion Collaboration
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ACHIEVEMENTS OF JSW STEEL
JSW Salem Won Deming Prize in
2019
Steel Minister’s Trophy Recognized by
World Steel
Associations
President
Donald
Trump
Acknowledges
JSW Steel’s
efforts in the
US
CSR Award
2020 Energy
Management
Award
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Some CSR Activities
 Our JSW Foundation is committed to creating more smiles at every step of the journey. The
organization is in constant pursuit of making life better for communities with its various initiatives in
the fields of health, education, livelihood and sports along with art and culture.
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0757: Shop floor mantra for continuous improvement
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JSW STEEL COATED PRODUCTS, KALMESHWAR
State : Maharashtra
District : Nagpur
Location : MIDC Area of Kalmeshwar
Estb : 1st August, 1985
Area : 147 Acres
No. of Employees : 680
Capacity : 0.66 Million Ton / Year
Kalmeshwar
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HR Slitter CPL
MILL-1 CGL-1
MILL-2
MILL-3
CGL-2
GALVALUME
Finishing lines
CCL-1/CCL-2
Dispatches
HR COIL
Cold Rolling Galvanizing
Pickling
HR Slitting
CR/GP Slitting
Colour Coating
Overview of JSW Kalmeshwar
•The first plant in India featuring the Hitachi 6 Hi cold
reversing facility from Japan
•A special combination to process thinner gauge and thicker
gauge (Up to 3.15 mm – G/HRGI Production)
•A first-of-its-kind continuous pickling Line
•It manufactures licensed BIEC – a specialized Galvalume
product
•Its central location makes its products accessible to domestic
partners across India
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Joint
Press
Pretreat
ment
Tanks
Cold Rolling Process
Color Coating Process
Shear
Pickling Process
Galvanizing Process
Uncoiler
Shear Welder Wet Loop Pit Pickling Tanks Exit Looper Side Trimmer Shear
Cold Rolling Mill Un coiler
Shear Welder
Entry Looper
Furnace
Zinc Pot
Jet Cooling
Quench
Tank
Skin Pass Mill cum
Tension leveler
Chromate
Tank
Exit
Looper
Shear
Guard
Film
Unit
Exit Loop
Entry Loop
Back
Coater
Oven Water
Cooling
Dryer
Prime
Coater
Top Coater
Oven
Oven
Process Flow
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Major Equipment's in Lines with there uses
Acid Pickling Tank in Continuous Pickling
Line (CPL) - To Remove Oxide layers.
Cold Rolling Mill (CRM) - It is used to reduce
thickness of Coil
Cold Rolling Skin Pass Mill (SKP) – It is used
to clear defects and make elongation.
Zinc pot and Furnace is used in Galvanizing line (CGL-1 & 2) – Galvanizing is done to prevent
the rust of coil.
Color Coating Line (CCL) – It is used to coat
the coil with color.
Zinc pot Furnace
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Our Products and Esteem Customers
Products
Cold Rolled (CR)
Color Coated Products Galvanized
Galvalume
Customers
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Applications
Roofing Sheets Steel Pipes TMT Bars
Stainless Steel Automobile Chequered Plates
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Our Credentials
Sr No NATIONALAWARDS YEAR
1 The Honorable Ramkrishna Bajaj National Quality Award 2019
2
JSW Kalmeshwar is awarded with National Energy Conservation award in appreciation of
efforts in energy conservation in the mini Blast Furnace Sector
2018
3 Silver certificate of merit, India Manufacturing Excellence Award 2017
Sr No STATE AWARDS YEAR
1 GHR (G H Raisoni) Award for innovative Practices in manufacturing 2019
2
Certificate of Merit at State Level Award for Energy Conservation & Management in metal
& steel Sector
2017-18
3 1ST Position, Best Domestic Customer, Concor Award 2017
4 3RD Position by MEDA for Energy Conservation 2016
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Our Achievements
Our quality circle ‘YUKTI’ have also
won some CCQC and NCQC awards in
2019
We have also won CCQC
Platinum Award in Nagpur
Chapter 2020
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Our Inspiration
Mr. Paresh Shah
Plant Head
Mr. Devendra Vaidya
HOD, Operation
Department
Mr. Abhay Girare
HOD, Business
Excellence
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Our Team Members and Details of QC
QUALITY CIRCLE NAME SHOURYA
TITLE IMPROVEMENT IN HR TO CR YIELD
PROJECT STARTED ON May 01, 2020
PROJECT COMPLETED ON July 20, 2020
NO. OF MEETINGS 22
ATTENDANCE 94%
PERIODICITY OF MEETINGS On Every Wednesday
VENUE Mill Conference Hall
Sagar Patil Shraddha Chikhale Mahesh Werulkar
Dhanesh Vijayan
Rohit Gupta
Leader
Facilitator Team Member
Team Member
Team Member
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Flow of Our Presentation
12
11
10
9
8
7
6
5
4
3
2
1 Problem Identification
Follow-Up / Review
Categorization Problem
Selection of problem
Analyzing the problem
Identifying the causes
Finding out root cause
Data analysis
Developing solutions
Foreseeing resistance
Trial check performance
Regular implementation
We Followed DEMING
WHEEL, PDCA 12-Step
Methodology To Solve
Our Problem
 DEMING Wheel (PDCA 12-Step Methodology) :
 Sample PDCA Model
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Step – 1 :
Identification of Problems
Tools Used : Brain Storming
“All improvement happens project by project and
in no other way”
- Joseph M Juran
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DESCRIPITION CATEGORY
1. Gamma ray problem B
2. High Leaderend generation A
3. High Oil Consumption A
4. Roll coolant leakage in hose pipe B
5. Frequent nozzle choking C
6. Roll lock get open during running B
7. High ph of DM water B
8. Non-availability of crane due to
breakdown
A
9. Roll coolant carryover B
10. High roll consumption A
11. Hydraulic leakage from bending
cylinder
C
12. Morg oil leakage C
13. Delay in SAP C
14. Thickness variation A
15. CR Sheet A
16. Delivery Tension Reel Drive
Problem
B
17. (Air oil) Mist Leakage B
18. Morg Oil Pressure C
19. Black surface A
20. PLC Communication error B
21.Heat exchanger problem B
22. Proximity switches malfunction B
23. WR + IMR bending Cylinder
leakage
A
24. Improper calibration C
25. CR baby A
26. Error in Magna Scale C
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41. CR trimming A
42. Drives tripped B
43. HR Trimming A
44. High noise generation A
45. Gamma Ray shutter closed in
running
C
46. Fumes generation A
47. Slippery Area A
48. Wrinkle A
49. Alignment problem B
50. Poor shape due to buckling C
51. Coolant Contamination C
52. Width Variation A
53. Poor trimming in HR A
27. Chattering Mark A
28. DC breaker tripping C
29. ETR Motor high temperature B
30. Gauge Reading error B
31. HMI error C
32. Level 2 PC Malfunctioning C
33. CR Arising A
34. Band Generation A
35. Ridge Formation in CR coil A
36. Rusty Patches A
37. ASD Failure B
38. EBA Failure C
39. Coolant leakages A
40. Air leakages A
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67. Spalling of rolls A
68. Frequent tripping of crane A
69. HR end cut A
70. Sliver in HR coil A
71. Shortage of DM water A
72. HDPE liner came out from clamp B
73. Flapper guide finger issue B
74. Auxiliary tripped B
75. High DM water consumption A
76. Hydraulic leakage from main jack
cylinder
A
77. Oil spillage after taking out roll
from mill
B
78. Frequent tightening of side guide
Cassette
B
54. HR side slit A
55. Miss roll generation A
56. Feeding delay in Hard Grade coil A
57. Bearing pitting mark C
58. Bearing seize problem C
59. Side guide roller change for damage B
60. HR baby A
61. High waste Oil generation A
62. CPC not available at POR B
63. Gamma ray error A
64. Skidding problem A
65. Shear non-availability at POR B
66. Tension reel fault A
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93. Shortage of rolling oil A
94. Shortage of coil storage area A
95. Roll bite Problem C
96. Shortage of rolls A
97. Shortage of manpower A
98. Deflector roll temperature problem C
99. Side roll bearing failure B
100. Mandrel gripper failure C
101. Mandrel Bearing failure C
102. OBBS failure B
103. Wedge Display measurement
problem
B
104. Auto Zeroing problem A
105. Levelling problem A
79. Scratch mark A
80. V-Notch in coils A
81. Holes in Coil A
82. BUR roll damage mark A
83. Improper coil winding A
84. OD wrap get shifted during taking
out coil
C
85. High power consumption C
86. Side tracking in all the lines B
87. Shearing problem C
88. Passline failure problem B
89. Failure of WR and IMR locker B
90. Pipe hose leakage C
91. Cobble guard problem C
92. Tilting problem A
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 So, we Identified 105 number of problems and categorized them into A, B
and C category which we have explained in next step
There are mainly 5
Types of
Brainstorming
1. Conventional
Method
2. Affinity Method
3. Idea based Method
4. KPI based method
5. Direct method
For Identification of
Problems, we mainly
used the Conventional
Method.
 Brainstorming :
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Step – 2 :
Selection of Problems
Tools used : ABC Analysis
Pie Chart
3P Analysis
Bar Graph
Stacked Bar Graph
Pareto Chart
“It is not enough to do your best; you must know what to do, and then do
your best”
W. Edwards Deming
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Step 2 : Selection of Problem
Categorization of Problem : Using ABC analysis
A : Problems which can be
solved within the
Department
B : Problems which can be
solved with the help of
other Department
C : Problems which needs
help from the Management
TYPE PROBLEMS NO TOTAL PERCENTAGE
A 2,3,8,10,14,15,19,23,25,27,33,34,35,3
6,39,40,41,43,44,46,47,48,52,53,54,5
5,56,60,61,63,64,66,67,68,69,70,71,7
5,76,79,80,81,82,83,92,93,94,96,97,1
04,105
51 56.67%
B 1,4,6,7,9,16,17,20,21,22,29,30,37,42,
49,59,72,73,77,62,65,74,78
23 25.56%
C 5,11,12,13,18,24,26,28,31,32,38,45,50
,51,57,58
16 17.78%
 After Categorization of problems into A, B and C Category, we made a pie chart
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57%
25%
18%
PERCENTAGE
A B C
B
C
A
• After plotting Pie Chart, we found that A
Category has more number of
problems with the highest percentage
than other categories.
• So we decided to solve this category
problems first, as other categories can
be controlled easily by controlling A
category which posses no other serious
issues.
 Thus, we analyze the percentage of each category by using pie chart. Further, we
use 3PAnalysis to solve A category problem.
Pie Chart :
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3PAnalysis to solve identified A category problems
1st P –
PROPRIETERY :
(Nominal groupings) based
on company’s policy and
strategic planning.
2nd P –
PRIORITY : Selection of
one from above with
specific concern of dept.
On weightage system.
3rd P –
PREFERENCE : Final
selection of one problem
from sensitive group, based
on data collection.
3PAnalysis
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1st P – PROPRIETERY
 From brainstorming, we have identified five sensitive aspects of our work area as the proprieties of our company.
 We have classified all categories of problems based on nature of work in following aspects.
Proprietary Problem Nos. Total %
Utilization 8,23,39,56,63,64,66,68,76,92,93,96,97,104,105 15 28.85
Material Yield 2,15,25,33,41,43,54,55,60,69,70,71,79,80,81,82,83 18 34.62
Quality 14,19,27, 34,35,36,48,52,53 9 17.31
Cost 10,3,40,61,67,75 6 11.54
Safety 44,46,47,94 4 7.69
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1st P – PROPRIETERY
Thus, after analyzing the Proprietary, we found that ‘Material Yield’ has the higher
number of percentage. So, we decided to give ranking using Priority method i.e. 2 P
0
2
4
6
8
10
12
14
16
18
20
Total
Total
Proprietery
Proprietary
Utilization Material Yield Quality Cost Safety
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2nd P – PRIORITY
 1 P- Proprietary grouping, further prioritized by Ranking Method using ECT technique
( ECT = Effect, Cost and Time, respectively )
Sr.
No
Priority
Team Members Name
Total Percentage
Shraddha Rohit Mahesh Dhanesh Sagar
1 Utilization 3 4 3 2 4 16 21.92%
2
Material
Yield
5 4 5 5 4 23 31.51%
3 Quality 4 2 1 3 3 13 17.81%
4 Cost 1 2 3 4 1 11 15.07%
5 Safety 2 1 2 2 3 10 13.70%
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2nd P – PRIORITY
 In this 2 P, each member of our group gave there rankings according to the ECT. Thus, we found
that Material Yield has highest percentage. So we selected Material Yield related problems to solve.
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3rd P – PREFERENCE
,
Sr. No
Material Yield Related
Problems
Effect Cost Time Total
1 High Leader end generation 5 5 4 14
2 CR Sheet 3 1 2 6
3 CR baby 2 2 1 5
4 CR Arising 1 3 3 7
5 CR trimming 5 1 2 8
6 HR Trimming 5 1 1 7
7 HR side slit 3 4 2 9
8 Miss roll generation 1 3 2 6
9 HR baby 1 1 1 3
 After 2 P, we further elaborated each ‘Material Yield’ related problems which has major contribution.
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Sr. No
Material Yield Related
Problems
10 HR end cut 4 2 1 7
11 Sliver in HR coil 2 4 3 9
12 Shortage of DM water 1 3 4 8
13 Scratch mark 3 2 2 7
14 V-Notch in coils 5 1 1 7
15 Holes in Coil 1 3 2 6
16 BUR roll damage mark 3 5 1 9
17 Improper coil winding 2 4 2 8
 Cont..
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0 5 10 15 20 25 30
High Leader end generation
CR Sheet
CR baby
CR Arising
CR trimming
HR Trimming
HR side slit
Miss roll generation
HR baby
HR end cut
Sliver in HR coil
Shortage of DM water
Scratch mark
V-Notch in coils
Holes in Coil
BUR roll damage mark
Improper coil winding
Stacked Bar Graph
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Sr. No Material Yield Problems
Diverted Qty
(MT)
Cumulative %Cum
1 P-2 : High Leaderend Generation 1299.3 1299.3 45.84%
2 P-15 : CR Sheet 36.6 2255.8 79.59%
3 P-25 : CR Baby coils 79.4 2378.241 83.91%
4 P-33 : CR Arising 20.8 2481.041 87.54%
5 P-41 : CR Trimming 41.7 2560.441 90.34%
6 P-43 : HR Trimming 956.5 2613.241 92.21%
7 P-54 : HR side slit 31.8 2654.941 93.68%
8 P-55 : Miss Roll generation 8.9 2691.541 94.97%
9 P-60 : HR Baby coils 11.8 2723.341 96.09%
Note : In this table, P indicates problem
• After that, we also made a ‘Pareto Chart’
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Sr. No Quality Related Problems
Diverted
Qty (MT)
Cumulative %Cum
10 P-69 : HR end cut 52.8 2745.336 96.87%
11 P-70 : Sliver in HR coil 18.2 2766.136 97.60%
12 P-71 : Shortage of DM water 1.82 2784.336 98.24%
13 P-79 : Scratch Mark 122.441 2801.171 98.84%
14 P-80 : V Notch in Coils 102.8 2812.971 99.25%
15 P-81 : Holes in coil 10.43 2823.401 99.62%
16 P-82 : BUR rolls damage mark 21.995 2832.301 99.94%
17 P-83 : Improper coil winding 16.835 2834.121 100.00%
 Based on the above data, we plotted a Pareto chart
 Cont..
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 After Plotting and
analyzing the Pareto
chart we found that, P-2
has highest number of
diversion.
So, we selected our Problem
as
“Improvement
In HR To CR
Yield”
Vital Few Useful Many
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Step – 3 :
Definition of Problem
Tools used : Gantt Chart
Flow Diagram
Data Collection
Clustered Graph
Pie-Chart
“ Quality control starts and ends with training”
- Kaoru Ishikawa
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Step 3 : Definition of Problem
 Scheduled Gantt Chart :
SR No ACTIVITIES 1 2 3 4 5 6 7 8 9 10 11
12-
18
18-
22
REMARKS
1 Identification of Work related problems Planned for 1 Week
2 Selection of Problems Planned for 1 Week
3 Define the Problems Planned for 1 Week
4 Analyze the problem Planned for 1 Week
5 Identification of causes Planned for 1 Week
6 Finding out the root causes Planned for 1 Week
7 Data analysis Planned for 2 Weeks
8 Developing solutions Planned for 1 Week
9 Foreseeing Probable resistance Planned for 1 Week
10 Trial Implementation and check performance Planned for 2 Weeks
11 Regular Implementation Planned for 1 Week
12 Follow Up/Review Planned for 1 Week
Team Name : SHOURYA
Title : IMPROVEMENT IN HR TO CR YIELD
Start Date : 1st May 2020
End Date : 20th July 2020
Leader : Shraddha Chikhale
Facilitator : Rohit Gupta
Members : Sagar Patil
Dhanesh Vijayan
Mahesh Werulkar
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- It is a Metal forming process in which an Ingot is passed
between hard rollers to get a desired shape, thickness and
surface finish.
Ingot : A piece of relatively pure metal, usually metal, that is
cast into a shape for further processing.
 Definition of Rolling :
 Cold Rolling :
- If the temperature of the metal is below its recrystallization
(between 400-700 °C) temperature, the process is known as cold rolling.
(Advantages : Good dimensional accuracy and Surface
Finish)
 Reversible Rolling Mill :
- A reversing mill is a rolling mill in which the work piece is
passed forward and backward through a pair of rolls.
The reversing mill is so named because the steel runs back and
forth between the rollers, reducing the thickness incrementally
with each pass.
- A reversing mill can be used to reduce material to gauge.
Rolling
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TECHNICAL SPECIFICATIONS
1 Speed 1200 mpm
2 Input Rolling Thickness 1.2 to 6 mm
3 Output Rolling Thickness 0.13 to 3.5 mm
4 Width 500 to 1290 mm
5 Thickness control Auto gauge control
6 Flatness control Intermediate roll shifting/ roll bending
6 Hi Reversible Rolling Mill
 HITACHI Cold Rolling Mill :
 Grades :
JDHCG04ACN JDHST29ACN JDHCG04BCN JDHST46ILZ
JDHCG04B1N JDHST29DCN JDHCG06BCN JVHGLE4AS0
JDHCG04BCN JDHST46ILZ JDHSH41ALN JVHGLH4AS0
JDHCG06BCN JDHCG04ACN JDHST29ACN JVHWT02A00
JDHSH41ALN JDHCG04B1N JDHST29DCN TBLCO8
 Context :
- Our Plant is the first in India featuring Hitachi 6 Hi cold
reversing Mill from Japan.
- A Hitachi 6 Hi Cold Rolling Reversible Mill is installed
for cold rolling of the pickled coils to the desired thickness
as per the customers requirements.
- Mill has the capacity and capability to produce cold
rolled sheet of table top flatness.
- Finished product of mill ( CR Coils ) are processed further
in coating lines.
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DTR ETR POR
Mill Stand
Coil selection
from plan
Coil charging in
POR mandrel
Pass schedule
preparation for
selected coils
Feeding of coil
from POR to DTR
After giving load
and tension rolling
start
Taking out feeding coil from
one side and scrap from
other side
Diverting / Parting
of Coil
Send to Next Process
Salvage
Quality
Check
 Basic Layout of 6 HI Mill :
 Process Description of Mill through Flow Chart :
Delivery
Tension Reel
Entry
Tension Reel
Pay Off Reel
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Loading of coil on entry
skid
Putting of coil on pay off
reel
Removing of coil
Output product of mill
Rolling of coil to get
specified thickness
Scheduling (as per plan)
Rolling process of 6HI
mill
Feeding of 1st pass
Note : Here we have shown pictorial representation of our Mill 47

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Supplier Input
CPL
HR Coil
Width Range : 700-1270 mm
Thickness : 1.6 – 4.5 mm
Coil – Inner/Outer Dia :
Coil Weight : 25 Ton (Max)
Utility DM Water
Ph : 5.5 - 6.5
Conductivity : 10
(Max)
MSEB Power
Bao Steel,
Bajrang Steel,
GPI, Sino steel,
Superior Forge,
Union Electric.
Rolls
Houghton,
Witmans
Advanced Fluid
Rolling Oil
Process Output Customer
6HI CRM - 1
(HITACHI)
Max. Mill Speed
1200 MPM
CR Coil
Thickness: 0.12 mm – 3.0 mm
Width range: 700 –1270 mm
Coil – Inner/Outer dia: 508/1850
Coil wt: 25 Ton (Max)
CR Leader end: upto 400 Kg
CR Baby: 500 Kg < Wt< 2000 Kg
HR Baby: 500 Kg < Wt< 2000 Kg
Galvalume
CCL
CGL
 Mill Processing Details :
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 Generation of Leader End at Mill :
- In Reversible Mill, CR coils are finalized either at DTR side or ETR Side
and Leader End generate at the opposite end of the final product.
- Also, in ID there is leader end which goes with CR coil to further
processing lines i.e., CGL1, CGL2 and Galva.
- At these lines, leader end at the ID gets cut for reducing the stoppage of
lines.
- These cut portion i.e., leader end at Mill and coating lines directly
impacts to yield which is a direct loss to our company.
Leader End Finished CR Coil
Unrolled Part ( Roll bite to Mandrel)
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 What is Leader End ?
- It is an unrolled portion of coil which is generated in Reversible Cold Rolling Mill.
 How Leader End is generated in Mill ?
- While processing the HR coil from POR to DTR, some unrolled HR is left in
ID due to process limitation, as end to end rolling is not possible in cold
reversible mill
 Why unrolled portion in ID ?
- End of HR coil is gripped in gripper and 1.5 wraps (min) is taken in mandrel also Length of material from
mandrel to roll bite is not processed in gauge required.
- This unrolled portion of HR in ID,
 provides base for coil build up
 prevents coil from collapse
 How Leader End is generated in processing lines ?
- Galvanizing lines are continuous processing lines, and they process only prime material
which is as per gauge and shape requirement. As there is HR and off gauge in ID of CR
coils, which is sent from cold rolling mills, so this material in ID is parted and removed.
Leader End
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Here we shown
how leader end
is generated at
galvalume line
due to black
patches
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 Why Leader End generation is high?
- The norms which are set to cut the Leader End is 400 kg.
- But if some problems are identified prior to HR wraps, then
operator cut this portion so as to avoid the line stoppage.
- This portion of coil which they cut sometimes come more than 400 kg
- So this higher weight of Leader End becomes direct loss to our
company and ultimately affects the yield.
 List of problems which are identified prior to HR wraps, resulted in high Leader End generation :
HR in ID Off- Gauge Buckling
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Black Patches Edge Waviness
Description
Norms
%
Percentage of Leader
Ends
Leader End Mill 1.1% 1.15 %
Leader End (CGL1) 2.0% 2.02 %
Leader End (CGL 2) 2.0% 2.08 %
Leader End (Galva) 2.0% 2.42 %
 Percentage of Leader Ends at various Lines due to above problems which are below 400 kg are :
 From the table drawn, it is found that Percentage of Leader
End at Galva is more than its norms i.e., 2.42 % which is
much more higher than other lines.
 Due to this higher Leader End, delay and division takes place
in lines.
 So to avoid this, we first calculated the number of coils which
are diverted due to the above problems in each month since the
problem started.
Edge Damage
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 Diversion Quantities in galvalume month wise :
Problems
Dec 19
(MT)
Jan 20
(MT)
Feb 20
(MT)
Mar 20
(MT)
Apr 20
(MT)
Grand
Total MT
Percentage
HR in ID 1.2 0.84 2.13 1.86 0 6.03 3.79%
Off -Gauge 3.2 0.98 1.415 0.84 0 6.435 4.05%
Buckling 8.72 5.48 3.68 4.89 0 22.77 14.33%
Black Patches 36.41 11.73 20.32 10.625 0 79.085 49.77%
Edge Crack 4.115 10.739 5.82 0.88 0 21.554 13.56%
Edge Waviness 12.19 5.99 3.26 1.59 0 23.03 14.49%
 Further we have also shown quality assurance report where we have identified more number of
problems from other coating lines.
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We are getting this
Quality Assurance report
from quality dept. where
the problems of all the
processing lines are
shown
Quality Assurance Report :
 To further elaborate this, we made a Clustered Chart and Pie Chart for proper detail clarification so as
to get which problem has higher impact and affecting to it; which results in high Leader End.
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5%
6%
11%
52%
13%
13%
Percentage
HR in ID Off-Guage Buckling
Black Patches Edge Crack Edge Waviness
- From Pie Chart we found that, Black Patches have
highest number of diversion percentage i.e. 52 %
- It is much more higher than other problems.
- It is accountable for the major problematic part of
yield loss.
- Further, we also made graph related to diversion as
shown in next slide.
0 50 100 150 200
HR in ID
Off-Guage
Buckling
Black Patches
Edge Crack
Edge Waviness
Percentage - With the help of this Clustered Chart we found that,
Black Patches contribute major in all problems.
- It has total of 161.41 Qty (MT) of Diverted coils
23.03
21.554
79.085
22.77
6.435
6.03
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 Emails from the coating lines expressing their concerns and disappointment regarding their issues
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System generated yield report is shown above
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Impact of Problem :
Improvement in
HR to CR yield
due to Black
Patches
Quality Related
Production Related
Internal Customer Complaint Increases by 0.42%
Production Yield Reduced by 2.42 %
Delay time Increases by 4 hr /month
Utilization Decreases by 0.5% per month
Diversion Increases by 0.6% per month
Goals and Objectives of our QC are :
Goal: To Improve HR to CR yield from 2.42% To 2%.
Objective:
1. To reduce leader end generation at coating lines
2. To reduce diversion
3. To increase mill utilization by avoiding delays for coolant leakage arresting
4. To provide good CR coils to further processing line by reducing Black Patches
5. To maintain roll coolant parameters within norms
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Step – 4 :
Analysis of Problem
Tools used : Data Collection
“It is only the last turn of a bolt that tightens it; the rest is just movement”
-Shigeo Shingo
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 First we gathered the data of particular coils from Galvalume Line :
NNote : Leader Ends are also known as Coil Ends
Step 4 : Analysis of Problem
Coil End Report (Galva) :
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 After that we segregated the Black patches coils having Leader Ends above and below 400 kg using
Pivot Table; of Mill and Galvalume Line of each month as shown below :
Cum till June Galva
Incharge Below 250
Kg
251-300
Kg
301-350
Kg
351-400
Kg
401-450
Kg
451-500
Kg
501-1000
Kg
Above 1000
Kg
Grand Total
Kg
ANKIT 1 31 63 82 48 19 47 1 292
DHIRENDER 33 68 36 34 12 18 1 202
GANESH 1 8 22 22 23 12 11 13 112
JITENDRA 3 13 24 36 18 4 13 111
KUMRAWAT 1 1 3 1 4 10
TASLIM 1 24 65 53 48 19 18 1 229
Grand Total 7 109 242 230 174 67 111 16 956
Percentage 0.73% 11.40% 25.31% 24.06% 18.20% 7.01% 11.61% 1.67% 100.00%
61.51% 38.49%
Note :
Here we have
shown only a
sample of June,
2020
Pain area,
38% to be
reduced to
20%
No of Coils
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Cum till June Galva
Incharge Below 250
Kg
251-300
Kg
301-350
Kg
351-400
Kg
401-450
Kg
451-500
Kg
501-1000
Kg
Above 1000
Kg
Grand Total
Kg
ANKIT 1 31 63 82 48 19 47 1 292
DHIRENDER 33 68 36 34 12 18 1 202
GANESH 1 8 22 22 23 12 11 13 112
JITENDRA 3 13 24 36 18 4 13 111
KUMRAWAT 1 1 3 1 4 10
TASLIM 1 24 65 53 48 19 18 1 229
Grand Total 7 109 242 230 174 67 111 16 956
Percentage 0.73% 11.40% 25.31% 24.06% 18.20% 7.01% 11.61% 1.67% 100.00%
61.51% 38.49%
 Our main concern area is coil ends above
400kg
 So we have collected the data of coil end
above 400 kg (<400 kg) affected due to
black patches as shown in our next slide.
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 Data of Coil Ends above 400 Kg
DATE SHIFT CR BATCH
CR THK
(MM)
CR WIDTH
(MM)
CR WT
(MT)
COIL END
WT (MT)
REASON FOR COIL END
GENERATION
10.07.2020 C KM2A0G0322 0.306 1220 20.06 0.46 HR AND BLACK PATCH
10.07.2020 C KM1A0G0299 0.406 1220 20.02 0.67 Loose shape/CB/Shifting
10.07.2020 C KM1A0G0297 0.406 1220 20.15 0.8 Loose shape/CB/Shifting
11.07.2020 A KM2A0G0327 0.406 1220 19.82 0.41 HR AND BLACK PATCH
11.07.2020 B KM1A0G0270 0.444 1220 12.61 0.58 Loose shape/CB/Shifting
11.07.2020 B KM1A0G0314 0.406 1220 20.1 0.44 HR
11.07.2020 B KM2A0G0346 0.312 1220 20.2 0.45 HR
11.07.2020 B KM2A0G0344 0.306 1220 20.31 0.47 HR
12.07.2020 A KM2A0G0365 0.462 1220 20 0.53 LOOSE SHAPE,SHIFTING D/S
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 Also checked all Roll Coolant parameters of Oil
Shift Wise Norms A B C
6 Hi (M1)
(WITMA
NS
LUBRO
DL 603)
Total Oil (%) 2.00 - 3.50 2.89 2.20 2.09
Scum (%) 1.00 (Max) 0.30 0.20 0.16
Iron (ppm) 400 (Max) 346 389 249
pH 5.50 - 6.50 5.96 6.42 5.39
Conductivity
(μs/cm)
300 (Max) 196 223 223
 Checked Emulsion of oil :
Whitman OIL
Line Parameters checked Requirements Results
6 HI (M1)
Chloride (PPM) 60 Max. 54.00
Sap value (mg KOH/gm) 180 Min. 179.26
Acid value(mg KOH/gm) 30 Max. 29.41
Active oil % 85 Min. 81.565
Tramp oil % 15 Max. 9.85
 We collected Shift wise data and found from the above Roll Coolant Parameters of Oil and Emulsion of Oil that it
has no such significant effect to our problem. As all are in the required range of targeted norms.
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Checked some Components of our Mill :
1. We have also taken some planned shutdown to analyze whether there is Maintenance
related problems or not.
2. Thus, we checked each and every component of our mill which may directly effects
to Black Patches and increases our Leader Ends.
3. Following are the job list which we checked while shutdown :
• Roll Coolant Nozzle
• Roll Coolant Pipe / Hose Leakage
• Effectiveness of Air Wiper system for Coolant removal from strip
• Dripping of accumulated coolant over strip in running
• Effectiveness of fume exhaust system to check dripping of condensate fumes
• Roll coolant header (cobble guard) condition for any leakage and puncture
• Scope of extra air wiping system
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Step – 5 :
Identification Of Causes
Tools used : Affinity Diagram
Fish-Bone Diagram
“Having no problem is the biggest problem of all”
-Taichi Onho
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By Brainstorming Method, we listed out all various probable causes. And by using
this probable causes, we mapped Affinity Diagram.
MAN METHOD MATERIAL MACHINE
• Unskilled
Operator
• Improper
Knowledge
• Low Observation
Skills
• SOP not followed
• Coolant
Parameters not
maintained
• SOP Not followed
• Wiping Nozzle not
operated at the
right time
• Coolant
Parameters not
maintained
• Roll coolant level
not maintained
• Improper Pickling
• Line Speed
variation
• Rolling oil
quality not
adequate
• Improper pH of
DM water
• Acid carryover
in HR coil
• Improper pH of
roll coolant
• Poor anti
staining quality
of emulsion
• Inadequate
Pneumatic system
Pressure
• Coolant leakage in
system
• Gap between air
wiping knife not
properly set
• Insufficient time lag
for auto coolant
blow off
Step 5 : Identification of Causes
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Fishbone
 After listing out probable causes, we made FISHBONE
Diagram for further analysis (Cost and Effect Diagram)
Brainstorming
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Improvement
in HR to Cr
Yield
MAN
MACHINE
METHOD
MATERIAL
Unskilled Operator
Coolant Parameters not maintained
Low Observation Skills
SOP not followed
Improper Knowledge
Roll coolant level not maintained
SOP Not followed
Wiping Nozzle not operated at the right time
Improper Pickling
Line Speed variation
Rolling oil quality not adequate
Poor anti staining quality of emulsion
Acid carryover in HR coil
Improper pH of roll coolant
Improper pH of DM
water
Inadequate Pneumatic system Pressure
Insufficient time lag for auto
coolant blow off
Coolant leakage in system
Gap between air wiping knife
not properly set
FISHBONE Diagram (Cost and Effect Diagram) :
Note : Black = Causes ; Yellow = Sub Causes 70

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Step – 6 :
Root Cause Analysis
Tools used : WHY-WHY Analysis
FISH-BONE Analysis
5W-1H Technique
“It is not enough to do your best; you must know what to do, and then do your best”
-W. Edwards Deming
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 WHY-WHYAnalysis of valid root causes
Identification of man related causes
Man related
Cause Remarks Significant
Unskilled Operator
Training to be given to
operators
Significant
Improper
Knowledge
Some workers don’t have
deep knowledge
Non Significant
Low Observation
Skills
operators
Non Significant
SOP not followed
Not aware of importance of
SOP compliance
Non Significant
Coolant Parameters
not maintained
Not following SOP for
maintaining and monitoring
of roll coolant parameters
Significant
Step 6 : Root Cause Analysis
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Man Related causes :
Identification of man related causes
Man related
Unskilled Operator Training to be given to operators Significant
Coolant Parameters not
maintained
Not following SOP for maintaining and
monitoring of roll coolant parameters
Significant
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Identification of material related causes
Material
related
Rolling oil quality
not adequate
Complaint to be raised of
supplier
Non Significant
Poor anti staining
quality of emulsion
Complaint to be raised of
supplier to provide better
anti staining property of
emulsion
Non Significant
Improper pH of
roll coolant
Pickling quality to be
improved
Significant
Acid carryover in
HR coil
SOP to be updated to
improve pickling quality
Non Significant
Improper pH of
DM water
DM water pH to be
monitored and immediate
action to be taken in case of
any deviation
Non Significant
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Material Related causes :
Identification of material related causes
Material related
Improper pH of roll
coolant
Pickling quality to be improved Significant
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Identification of machine related causes
Machine
related
Inadequate
Pneumatic system
Pressure
Air pressure to be monitored
and maintained regularly
Significant
Insufficient time
lag for auto coolant
blow off
Coolant blow off time to be
increased from 20 sec to 30
sec
Significant
Gap between air
wiping knife not
properly set
Gap between air knife slit to
be checked and maintained
on regular basis
Significant
Coolant leakage in
system
Coolant leakage to be
arrested immediately
Significant
Aging of equipment
New wiping system to be
procured
New pipe line to be installed
Non significant
Machine
Mill Photo
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Machine Related causes :
Identification of machine related causes
Machine related
Inadequate Pneumatic
system Pressure
Air pressure to be monitored and
maintained regularly
Significant
coolant blow off
Coolant blow off time to be increased
from 20 sec to 30 sec
Significant
Gap between air wiping
knife not properly set
Gap between air knife slit to be checked
and maintained on regular basis
Significant
Coolant leakage to be arrested
immediately
Significant
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Identification of Method related causes
Method
SOP Not followed
Not aware of importance of
SOP compliance
Non significant
Line stoppage
Line stoppage will cause
more black patch generation
Non significant
Improper Pickling
Pickling quality to be
improved
Non significant
Roll coolant level
not maintained
Not effective
Non significant
Wiping Nozzle not
operated at the right
time
operators for timely operation
of air wiping nozzle
Significant
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Method Related causes :
Identification of Method related causes
Method
Wiping Nozzle not operated
at the right time
Training to be given to operators for
timely operation of air wiping nozzle
Significant
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 List of Significant Causes :
Sr. No Category Significant Causes
1 Man Unskilled Operator
2 Method Wiping Nozzle not operated at the right time
3 Machine Inadequate Pneumatic system Pressure
Insufficient time lag for auto coolant blow off
Gap between air wiping knife not properly set
4 Material Rolling oil quality not adequate
 Man Related causes :
WHY ? WHY ? VALID
Unskilled
Operator
Lack of basic
Knowledge
Lack of Training
Proper Training
given related to
the production
Need for training
not identified
N
WHY ?
Man
Method
Machine
Material
Man
Method
Machine
Material
Note : Green = Valid ; Black = Invalid 80

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Coolant
Parameters not
maintained
Lack of knowledge
about parameters
Lack of Training
Proper Training
given related to
maintaining of
coolant parameters
 Man Related causes :
Wiping Nozzle
not operated at
the right time
- Valve malfunctioning
- Wiping nozzles not
operated on time
Malfunctioning of
FRL Unit
Debris in Air
Training to be
given to operators
for timely
operation of air
wiping nozzle
 Method Related causes :
WHY ?
WHY ?
WHY ? WHY ?
WHY ?
VALID
N
VALID
N
Air leakages in pipe
Air pressure to be
monitored and
maintained regularly
Pipeline Erosion
Inadequate
Pneumatic system
Pressure
Erosive
Environment
Ageing of pipeline
WHY ? WHY ?
WHY ? VALID
N
 Machine Related causes :

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Gap between air
wiping knife not
properly set
- Due to shearing of
bolts
- Scum stuck between
it Impact from
strip breakage
Gap between air
knife slit to be
checked and
maintained on
regular basis
As per planned
maintenance gap
not checked
Ageing factor
Coolant leakage
in system
Hose and pipe
Ageing factor Pipeline erode
Vibration in
pipeline
Not done proper
clamping
Coolant leakage to
be arrested
immediately
WHY
WHY ? WHY ?
VALID
N
VALID
N
WHY ?
WHY ?
WHY ?
WHY ?
 Machine Related causes :
 Material related causes :
Inappropriate
rolling oil
properties
Required norms
not maintained by
supplier
Complaint to be
raised to supplier
Inadequate quality
of rolling oil
WHY ? WHY ? VALID
N
Acid carryover in
HR coil
Squeeze rolls
damaged
Lack of inspection
procedure
SOP to be updated to improve
pickling quality
WHY ? WHY ? VALID
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Improvement
in HR to Cr
Yield
MAN
MACHINE
METHOD
MATERIAL
Unskilled Operator
Low Observation Skills
SOP not followed
Improper Knowledge
Roll coolant level not maintained
SOP Not followed
Wiping Nozzle not operated at the right time
Improper Pickling
Line Speed variation
Rolling oil quality not adequate
Poor anti staining quality of emulsion
Improper pH of roll coolant
Improper pH of DM
water
Inadequate Pneumatic system Pressure
coolant blow off
Gap between air wiping knife
not properly set
Note : Black = Causes ; Yellow = Sub Causes
 After listing out probable causes, we made FISHBONE Diagram for further analysis (Cost
and Effect Diagram)
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Questions Analysis
What is the
situation?
High weight leader end due to black
patches
Where is the
problem?
At coating lines which is next process after
rolling
When does it
occur?
Due to heavy coolant carryover
Which factors
get affected?
Production and power consumption
Why does it
happen?
Coolant leakage at mill from coolant hoses
How does it
happen?
Blackish patches are generated in coil
when coolant get dried over sheet
 5W-1H Analysis : ( What, Where, When, Which, Why-How )
5W &
1H
Analysis
What
When
Why
How
Where
Which
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Step – 7 :
Data Analysis On Causes
Tools used : Data collection
Bar-Graph
Comparative Study
Stratification Graph
Pie - Chart
“Without a standard there is no logical basis for making decisions or taking decisions”
-Joesph M Juran
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0
100
200
300
400
500
600
700
2020.02.01
2020.02.03
2020.02.05
2020.02.07
2020.02.09
2020.02.11
2020.02.13
2020.02.15
2020.02.17
2020.02.19
2020.02.21
2020.02.23
2020.02.25
2020.02.27
2020.02.29
Feb-20 (Liters/Day)
 Oil Consumption Trend :
1. From the above graphs , It is inferred that our consumption was initially at higher side (Nov-19 to Feb-20)
than its expected norms (7500 Ltr per Month) as shown.
2. In the month of Feb-20, the range is much more higher. So we collected the Feb-20 day wise data and
observed that ‘The Coolant Parameters’ were not within our Range. So further we studied Coolant
Parameters.
TGT -250 Ltr/Day
 Observations and Findings :
Step 7 : Data Analysis on causes
7206
8536
7956
9115
8413
0
8589
0
1000
2000
3000
4000
5000
6000
7000
8000
9000
10000
Nov, 19 Dec, 19 Jan, 20 Feb, 20 Mar, 20 Apr, 20 May, 20
Litres
Month
Oil Consumption (Litres/Month)
Lockdown
Target (7500Ltr/Day)
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Oil Consumption Trend in the month of February
DM Board of Oil Consumption
Here as we
see, trend
in the
month of
Feb is
much more
higher than
its norms
i.e., above
0.5 L/T
Higher
Range
 We have also Collected data of oil concentration in Lit/Ton
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0
0.5
1
1.5
2
2.5
3
3.5
4
Concentration % (Feb-20)
 Coolant parameters : Oil Concentration
- From the above graph as shown, after studying The Coolant parameters it is found that we are not getting required
Oil Concentration.
Expected range - 2.00% to 3.50%
Actual range – Below 2.00%
Note : Here we have shown the data of feb-20, as the oil concentration was too less as compared to other month
TGT – 2 to 3.5%
1.75%
1.80% 2.00%
1.40%
1.68%
0.00%
1.88%
0.00%
0.50%
1.00%
1.50%
2.00%
2.50%
3.00%
3.50%
4.00%
4.50%
Conc.
%
Month
Oil Concentration % ( Month Wise)
Target (2.0 to 3.5%)
Lockdown
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 Coolant parameters : pH Concentration
- From the above graph as shown, after studying The Coolant parameters it is found that we are not getting
required Oil Concentration.
Expected range - 5.50 to 6.50
Actual range – Below 5.50
Note : Here we have shown the data of feb-20, as the pH level was too less as compared to other month
0
0.5
1
1.5
2
2.5
3
3.5
4
4.5
5
5.5
6
6.5
7
7.5
pH Level
TGT – 5.5 to 6.5
4.67
4.9
5
2.89
4.89
0
5.1
0
0.5
1
1.5
2
2.5
3
3.5
4
4.5
5
5.5
6
6.5
7
7.5
pH
Level
Month
pH range (5.5-6.5)
Target (5.50 to 6.50)
Lockdown
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0
100
200
300
400
500
600
700
800
900
1000
Fe concentration (PPM)
- From the above graph as shown, after studying The Coolant parameters it is found that we are not getting required
Iron Content.
Expected range – Below 400 (PPM)
Actual range – Above 400 (PPM)
Note : Here we have shown the data of feb-20, as the Iron content was too high as compared to other month
 Coolant parameters : Iron Content
TGT – Below 400 PPM
600
589 542
789
550
0
643
0
100
200
300
400
500
600
700
800
900
Iron
Content
Month
Iron Content (PPM)
Target (Below 400 PPM)
Lockdown
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Here as we
see,
Process
Parameters
in the
month of
Feb of our
DM Board
Higher
Range
DM Board of Process parameters
Oil
Iron Content
PH
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- To check whether wiping nozzle (Air Knife) is impacting or not to Black Patches, we have performed
following activities during our Planned Shutdown.
Sr. No Activities Observation Remarks
1 Pneumatic valve checked All valves are ok and in working Condition No Impact
2
Pressure of Pneumatic
system Checked
Pressure is ok (5 to 6 kg / cm² ) No Impact
3
Checked Condition of FRL
unit
All three filters, regulator and lubricator are
functioning good and OK
No Impact
4 Dry air at Line calculated
No moisture contained in line and air is suitable
for working condition
No Impact
5 Air Knife gap checked
Gap Checked with filler gauge and Found equal
throughout its length
No Impact
6 Blow OFF time Checked Blow OFF time : 20 sec i.e., OK No Impact
 Malfunctioning of Wiping Nozzle :
Note : From the above data, we found that there were no problems contributing to Black Patches 92

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Air Knife gap checked Pneumatic valve checked
Checked FRL unit
Pressure of Pneumatic
system Checked
 Above are the images that we have checked related to the Malfunctioning of
Wiping Nozzle in system but NO IMPACT was found due to it
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SR.
NO
ACTIVITIES OBSERVATION REMARKS
1
Coolant nozzle header in
cobble guard checked
No leakage found in cobble guard nozzle No impact
2
Coolant leakage from pipe line
checked
No leakage found in coolant pipe line No impact
3
Coolant leakage from strip
coolant header checked
No leakage found in strip coolant header No impact
4
Inspection done for coolant
accumulated in gamma ray
runner
Gamma ray runner found free from accumulated
coolant
No impact
 Coolant leakages in system :
Note : From the above data, no impact was found in ‘Black Patches’
- To check whether Coolant leakages is impacting or not to Black Patches, we have performed following
activities during our Planned Shutdown.
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 Above are the images that we have checked related to the coolant leakages in system but NO
IMPACT was found due to it
 So we have not found any impact of above activities (Wiping Nozzle and Coolant Leakages) on
our issue (i.e., Black Patches), so the issue has not been taken into the account.
Coolant leakage from Pipe
Line checked
Coolant nozzle header in
Cobble Guard checked
Checked coolant accumulation
in Gamma Ray Unit
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Data Analysis on Root Causes for Validation
Month Coolant parameters
Wiping Nozzle mal-
functioning
Coolant leakages
in system
Total
Nov-20 2 0.5 1.8 4.3
Dec-20 1.8 1.23 0.1 3.13
Jan-20 4 0.68 0.32 5
Feb-20 3.7 1.67 0.2 5.57
Mar-20 6.1 1.1 1.84 9.04
Apr-20 0 0 0 0
Total 17.6 5.18 4.26
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Data Analysis on Root Causes for Validation
0
2
4
6
8
10
12
14
16
18
Coolant parameters Wiping Nozzle mal-functioning Coolant leakages in system
No
of
times
it
affected
Root Causes
Nov-20 Dec-20 Jan-20 Feb-20 Mar-20 Apr-20
Note : Stratification graph shows that, Coolant Parameters are major reason behind the Black patches 97

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95.36%
2.12% 2.52%
Impact in %
Coolant parameters Wiping Nozzle malfunctioning
Coolant Leakages in system
Also, From the pie-chart as
shown, contribution of each
affecting factors, i.e.,
1. Coolant parameters :
95.36%
2. Wiping nozzle
malfunctioning : 2.52%
3. Coolant leakages in
system : 2.12%
As the coolant parameters
are playing major role in
generation of black patches.
So we have focused mainly
on Coolant Parameters
98

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Step – 8 :
Development of solutions
Tools used : Brain-Storming
ICTIE Matrix
Responsibility Chart
“The starting point for improvement is to recognize the need”
- Masaaki Imai
99

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 For Developing solutions, we used Brainstorming Method and we got simple ideas to overcome this Problem.
SR.
NO.
POSSIBLE SOLUTIONS
1. Addition of emulsifier (WA10382) to improve oil concentration
2. Mixing of pH booster (WA10128)
3. Change of magnetic separator cycle time (ON/OFF) .
4. pH of DM water should be maintained
5. Additives of oil to be maintained
6. Controlled rate of oil addition for reducing oil consumption
7. Scum generation to be minimised with regular skimming
8. Synthetic oil to be used
Step 08 : Development of Solutions
We used ‘Brainstorming’
technique with our Associates
to find out possible solutions
100

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SR.
NO.
POSSIBLE SOLUTIONS REMARKS
1.
Addition of
emulsifier to
improve oil
concentration
• Standard quality of emulsifier to be used.
• It helps to mix oil and water easily to boost oil
concentration
• At our Mill, we used WA10382 emulsifier to get
required coolant concentration
2.
Scum generation
to be minimised
with regular
skimming
• Regular skimming is not possible due to limited
capacity of sump pit
• During production, continuous waste generation
takes place due to which sump pit already gets
occupied
• As it takes more time to separate oil and water at
ZLD ( Zero Liquid Discharge ), so draining is not
possible at fixed interval
Sump Pit
101

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SR.
NO.
3.
Change of
magnetic
separator cycle
time (ON/OFF) .
• Proper (ON/OFF) cycle to be maintained to
remove Fe at control rate.
• Earlier the cycle timing was 10/40 min, but it
causes loss of oil along with iron.
• So we reduced cycle time to 5/30 min which helps
us to remove iron at controlled rate
4.
pH of DM water
should be
maintained
• By Maintaining DM water in range, we get proper
pH of emulsion
• Previous we were getting low pH of DM water
due to which coolant pH maintaining was not
possible.
• pH Buffer is also added to maintain the pH of DM
water in required range
102

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SR.
NO.
5.
Synthetic oil to
be used
• Using this oil, we get proper oil concentration with
low oil consumption.
• Not possible as it is costlier
• Mill condition is not suitable for using this oil
6
Controlled rate
of oil addition for
reducing oil
consumption
• We have made pan for 30 L capacity with stopper
at oil top up area, consumption of oil can be easily
controlled
• Earlier we were adding approximate oil without
any measured instrument, resulting in more
addition of oil than its required limit.
• Now by using stopper, we have managed addition
of excess oil into the Coolant tank.
103

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SR.
NO.
7
Additives of oil to be
maintained
• Oil must have proper additives such as anti Staining, Anti oxidant and Anti
Corrosive agents for getting required quality of finished product.
• Anti-Staining agents to be used for preventing excess adhesiveness on strip
surface
• Anti oxidants agents to be used to prevent oxide formation in Coolant.
• Anti Corrosive agents to be used to prevent the equipment ( Agitator, Coolant
Tank Inner surface, Magnetic Separator and Self Cleaning Filter, Backwash
Filter, Coolant pipeline, etc. ) which are in continuous contact with coolant.
8
Mixing
of pH
booster
• Standard quality of pH Booster to be used. For e.g. (WA10128)
• Due to low pH, separation of oil from water is not possible.
• Layer of oil gets formed over emulsion
• Creating problems in ETP ( Effluent Treatment Plant) like variation in colour
such as brown, reddish and black colour)
• Due to which more time required for waste treatment process at ZLD
• Frequent skidding problems taking place in Mill while operating any coil.
104

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SR.
NO.
FACTORS AFFECTING RESULTS
1.
Addition of emulsifier (WA10382) to improve oil
concentration
Build up proper concentration
2. Mixing of pH booster (WA10128) Required pH range obtained
3. Change of magnetic separator cycle time (ON/OFF) . Fe content and oil losses decreases
4. pH of DM water should be maintained Required Roll Coolant pH range obtained
5. Additives of oil to be maintained
Generation of Black patches has been reduced due to effective
anti staining properties
6 Controlled rate of oil addition for reducing oil consumption Oil consumption decreases
• After finding out the possible solutions for maintaining coolant parameters, we observed that the
intensity of black patches has been reduced significantly.
• In further processing lines, leader end generation has been reduced.
• Weight of leader end, earlier which was above 400 kg has now been reduced to below 400 kg
(within norms).
• It helps us in improving Hr to Cr yield which ultimately increases rate of production of Mill
and further coating lines ( Galva)
 Impact on Generation of Leader End
Leader End Photo
105

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Sr.
No.
Possible Solutions
Impact Of
Idea
Cost
Innovation
quotient
Time
Ease of
Implementation
Total
30+ Accepted
>30 NA
1.
Addition of emulsifier (WA10382)
to improve oil concentration
9 6 4 9 8 36
2. Mixing of pH booster (WA10128) 7 8 5 8 6 34
3.
Scum generation to be minimised
with regular skimming 4 6 3 5 7 25
4.
pH of DM water should be
maintained
6 5 6 7 4 28
5. Additives of oil to be maintained 7 6 5 8 6 32
6
Controlled rate of oil addition for
reducing oil consumption
5 7 5 6 6 29
7
Change of magnetic separator
cycle time (ON/OFF) . 8 6 6 7 7 34
8 Synthetic oil to be used 5 8 3 2 5 21
 We used ICTIE (Matrix for the best solution), also we have given numbers out of 10. 106

Shourya
Sr. No Probable Solution Suggested By Accepted / Rejected Remarks
1 Addition of emulsifier (WA10382) Shraddha Accepted Effective way for
building concentration
and maintaining pH
2 Mixing of pH booster (WA10128) Rohit Accepted
3 Scum generation to be minimised Mahesh Werulkar Rejected Not Feasible
4 Maintaining pH of DM water Shraddha Rejected Already in range
5 Additives of oil to be maintained Dhanesh Vijayan Accepted
Plays major role in
improving quality of
strip surface
6 Controlled rate of oil addition Rohit Rejected
Proper training should
be given for oil
addition
7
Change of magnetic separator cycle
time (ON/OFF) .
Sagar Accepted
Effective and easy way
to prevent oil losses
8 Synthetic oil to be used Mahesh Werulkar Rejected
Costlier and not
suitable for Mill
 Responsibilities were given to respective team members to monitor the solutions 107

Shourya
Sr.
No
Activity Responsibility
Target Days to
complete
Why to be done
1
Addition of emulsifier
(WA10382)
Shraddha 2 days
To ensure proper
concentration of
emulsion
2
Mixing of pH booster
(WA10128)
Rohit 2 days
To obtain required pH
level
3
maintained Dhanesh Vijayan 3 days
To maintain proper
anti staining
properties of coolant
4
Change IN magnetic
separator cycle time
(ON/OFF) .
Sagar 4 days
To maintain required
Fe content along with
less oil losses
 Responsibility Chart :
 The Members monitored each activity and their remarks were used to find the best solution. 108

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Step – 9 :
Foreseeing Probable Resistance
Tools used : Brainstorming
“If you can't describe what you are doing as a process, you don't know what you're doing”
- W. Edwards Deming
109

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Addition of
emulsifier to
improve oil
concentration
Faced Difficulties while
Selection of proper
emulsifier
By studying properties of
emulsifier which gives
better concentration
Lack of information about
’ How much quantity of
emulsifier to be added ?
Decided Standard quantity
to be added by taking
various trials
Mixing of pH
booster
Selected pH booster
already available to us
was not satisfying mill
condition
Standard range decided to
add pH booster in coolant
With the help of quality
person and oil supplier we
have selected suitable pH
booster
Use of excessive pH
booster leads to mill
problem (skidding)
 Using Brainstorming, we noted down what resistances might be incurred with the selected Solution and worked
on overcoming these Resistances
Step 9 : Foreseeing Probable Resistance
Resistance - 1
Resistance - 2
110

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Change of
magnetic
separator
cycle time
(ON/OFF) .
Not getting required quality
of strip surface (Formation
of black patches increased)
Studied Standard quantity
of Anti Agents for getting
good quality of oil
Excessive use of additives
results in poor Coolant
property
Standard range of
additives was fixed
according to coolant
reports
Due to frequent change in
magnetic separator cycle,
operational efficiency
reduce.
Due to more ON and less
OFF time leads to more oil
losses along with iron
To overcome this, we
decided standard
ON/OFF time
To overcome this, we set
standard cycle time
Additives of
oil to be
maintained
Resistance - 4
Resistance - 3
111

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Improvement in HR to
CR yield
High Leader End in
Galvalume Line
Addition of
emulsifier to
improve oil
concentration
Mixing of pH
booster
maintained
Change of magnetic
separator cycle time
(ON/OFF) .
Overview of problem :
112

Shourya
Step – 10 :
Trial Implementation and Check
Performance
Tools used : SMART Analysis
PDCA cycle
5W-1H Technique
Control Chart
“Quality has to be caused, not controlled”
- Philip B. Crosby
113

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S SPECIFIC/ SIMPLE Yes, It can be possible to achieve
M MEASURABLE
Yes, we can monitor it on daily/shift basis to check abnormalities
for Improving HR to CR Yield
A ACCOUNTABLE Yes, it accounts for increase in Yield from 95% to 95.5%.
R REALISTIC
Yes, system is sophisticated by continual improvement and
monitoring at Mill
T TIME BOUND
High Leader End weight due to Black Patches is reduced within
time period of Nov-19 to June-20
 For Verifying the recommendation of solutions, we use PDCA analysis
Step 10 : Trial Implementation and Check Performance
114

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• Trial to be taken for quantity
added and results achieved will
be recorded, for emulsifier, pH
booster and additives addition
• Training and Knowledge
sharing
• Regular checking of oil
concentration
• Checking and maintaining the pH
Level
• Regular Checking the norms of
oil additives
• To monitor magnetic separator
cycle time
• For Reducing High Leader End
Generation
• Addition of Emulsifier
• Mixing of pH booster
• Additives of oil to be maintained
• Change in Magnetic Separator
Cycle time (ON/OFF)
• Take appropriate actions to fulfill
the regular implementations for
reducing weight of Leader End
PLAN DO
CHECK
ACT
 For
Effective
Trial and
Implementa
tion we used
PDCA Cycle
for reducing
Leader End
115

Shourya
PLAN Type Description
What is to be planned
for reducing Leader end
?
Maintaining roll coolant parameters by:
1. Addition of emulsifier
2. Mixing of pH booster
3 Additives of oil to be maintained
4. Change IN magnetic separator cycle time (ON/OFF) .
Why is to be planned ? To reduce black patch generation to achieve minimum
rate of leader End generation
Who is responsible ? QC Team
When to be planned ? 01 June 2020
Where to implement the
plan ?
Galvalume line
How to Implement the
plan ?
1. By studying properties of emulsifier which gives
better concentration
2. Standard range decided to add pH booster in
coolant to maintain pH range of emulsion
3. Standard range of additives was fixed to improve
anti staining properties of emulsion
4. Standard ON/OFF time of magnetic separator to
maintain iron content in emulsion
DO Type Description
What is to be done ? 1. To implement our plan of using standard
additives
2. Carryout proper training and education and
following proper guidelines
Why is to be done ? To maintain the required coolant properties for
minimizing black Patches.
Who is responsible ? Operation and Quality Assurance Team
When it is to be done ? 01 July, 2020
Where it is to be done ? At 6Hi Mill
How it is to be done ? With the help of Operation person and oil supplier we
have decided to increase the quality of Roll Coolant
and reduce black patch generation to reduce leader
end generation
 We Further used 5W-1H Technique for each of element of PDCA Cycle of the Oil Additives to be maintained:
116

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CHECK Type Description
What is to be checked ? Regular monitoring of Leader End generation at
galvalume End due to black patch
Why it is to be checked ? To achieve minimum Leader End regularly
Who is Responsible ? QC Members
When it is to be checked ? In Every shift ( A, B, C)
Where it is to be checked ? At galvalume
How to Check ? By doing regular follow-up with galvalume shift
Incharge
By collecting data for leader end generation due to
black patch on daily basis
ACT Type Description
What action is to be taken ? We will standardize the time and quantity for
addition of various additives in emulsion by making
SOP for each parameters
Why to act ? To sustain the results achieved
Who is responsible ? Operation and maintenance department
When to act ? After successful trial implementation & customer
feedback
Where to act ? Galvalume lines
How to act ? With the help of Operator, Shift In charge and
maintenance Crew and daily analysis of leader end
generation and emulsion parameters
 We Further used 5W-1H Technique for each of element of PDCA Cycle of the Oil Additives to be maintained:
117

Shourya
Plan : For reducing Leader End Generation
1.Addition of emulsifier
2. Mixing of pH booster
3 Additives of oil to be maintained
4. Change IN magnetic separator cycle time
(ON/OFF).
Act :
1.As satisfied results are observed, we have
decided to continue these roll coolant
parameters at mill.
2. Regular feedback taken from customer end
(Galvalume)
Check :
1.Black patch generation at galvalume end
(Below 400 kgs)
2.Checked Coolant Parameters such as Oil
conc., Iron content, pH Level
 PDCA (Plan-Do-Check-Act) Cycle :
Before After
Magnetic cycle time in HMI
Before After
For good surface of coil : Emulsifier, pH
Booster, Additives are used
Do :
118

Shourya
SR No Shift Coils
Weight of Leader
End at Mill (MT)
Weight of Leader End
at Galvalume (MT)
Remarks
1 A KM1A0G0448 0.25 0.34 No black patch found
2 B KM1A0G0447 0.21 0.38 No black patch found
3 C KM1A0G0405 0.24 0.35 No black patch found
 Trial performance Checklist of Leader End :
119

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 Oil parameters Shift Wise performance sheet :
Date Parameters
Shift Wise Data
Date
Shift Wise Data
Date
Shift Wise Data
Norms A B C A B C A B C
1-Sept-20
OIL % 1.5-3.5 2.2 1.6 3.1
11-Sept-20
2.36 2.99 3.45
21-Sept-20
1.89 1.79 2.86
Iron ppm 0-600 436 582 468 379 459 458 496 582 489
ph 5.5-6.5 5.7 6.1 5.9 5.89 5.49 5.72 6.2 5.89 5.73
2-Sept-20
OIL % 1.5-3.5 1.89 1.79 2.86
12-Sept-20
2.47 2.33 1.56
22-Sept-20
2.2 1.6 3.1
Iron ppm 0-600 496 582 489 273 269 386 436 582 468
ph 5.5-6.5 6.2 5.89 5.73 5.61 5.89 5.73 5.7 6.1 5.9
3-Sept-20
OIL % 1.5-3.5 1.94 2.96 3.42
13-Sept-20
2.2 1.6 3.1
23-Sept-20
1.94 2.96 3.42
Iron ppm 0-600 572 546 473 436 582 468 572 546 473
ph 5.5-6.5 5.84 6.39 6 5.7 6.1 5.9 5.84 6.39 6.45
4-Sept-20
OIL % 1.5-3.5 3.12 3.48 3.16
14-Sept-20
1.89 1.79 2.86
24-Sept-20
2.2 1.6 3.1
Iron ppm 0-600 329 426 548 496 582 489 436 582 468
ph 5.5-6.5 5.62 6.12 6.03 6.2 5.89 5.73 5.7 6.1 5.9
5-Sept-20
OIL % 1.5-3.5 2.2 1.6 3.1
15-Sept-20
1.94 2.96 3.42
25-Sept-20
2.36 2.99 3.45
Iron ppm 0-600 436 582 468 572 546 473 379 459 458
ph 5.5-6.5 5.7 6.1 5.9 5.84 6.39 6.09 5.89 5.49 5.72
6-Sept-20
OIL % 1.5-3.5 1.89 1.79 2.86
16-Sept-20
2.36 2.99 3.45
26-Sept-20
1.94 2.96 3.42
Iron ppm 0-600 496 582 489 379 459 458 572 546 473
ph 5.5-6.5 6.2 5.89 5.73 5.89 5.49 5.72 5.84 6.39 6.13
7-Sept-20
OIL % 1.5-3.5 2.36 2.99 3.45
17-Sept-20
2.2 1.6 3.1
27-Sept-20
2.2 1.6 3.1
Iron ppm 0-600 379 459 458 436 582 468 436 582 468
ph 5.5-6.5 5.89 5.49 5.72 5.7 6.1 5.9 5.7 6.1 5.9
8-Sept-20
OIL % 1.5-3.5 2.2 1.6 3.1
18-Sept-20
1.94 2.96 3.42
28-Sept-20
1.89 1.79 2.86
Iron ppm 0-600 436 582 468 572 546 473 496 582 489
ph 5.5-6.5 5.7 6.1 5.9 5.84 6.39 6.74 6.2 5.89 5.73
9-Sept-20
OIL % 1.5-3.5 2.2 1.6 3.1
19-Sept-20
2.36 2.99 3.45
29-Sept-20
2.2 1.6 3.1
Iron ppm 0-600 436 582 468 379 459 458 436 582 468
ph 5.5-6.5 5.7 6.1 5.9 5.89 5.49 5.72 5.7 6.1 5.9
10-Sept-20
OIL % 1.5-3.5 1.94 2.96 3.42
21-Sept-20
1.89 1.79 2.86
30-Sept-20
1.89 1.79 2.86
Iron ppm 0-600 572 546 473 496 582 489 496 582 489
ph 5.5-6.5 5.84 6.39 6.48 6.2 5.89 5.73 6.2 5.89 5.73
 We have shown here the data of Oil Parameters of September Month 120

Shourya
 Performance chart of Leader End generation :
Leaderend in feb, 2020
0
0.2
0.4
0.6
0.8
1
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29
Leaderend
Wt
(Ton)
Date
Leaderend generation performance chart
Leaderend in feb, 2020 Leaderend in Sept, 2020
121

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 Trial and Implementation of Oil 122

Shourya
Step – 11 :
Regular Implementation
Tools used : Data Collection
Line Graph
Bar Graph
Area Graph
“Cost is more important than quality but quality is the best way to reduce the cost”
-Genichi Taguchi
123

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 Month wise Production yield performance of leader end:
Month
Target
Yield
Actual
Yield
Total
Yield loss
% of Leader
end due to
Black patch
above 400 Kg
November-19 95.26% 95% -0.26 40%
December-19 95.26% 95.12% -0.14 38%
January-20 95.26% 94.98% -0.28 42%
February-20 95.26% 95.02% -0.24 35%
AVG. 95.26% 95.03% -0.23 93%
Month
Target Yield Actual Yield Total Yield loss
% of Leader end due to
Black patch above 400 Kg
March-2020 95.26% 95.49% 0.23 22%
April-2020 0 0 0 0
May-2020 95.26% 95.39% 0.13 20%
June-2020 95.26% 95.48% 0.22 15%
July-2020 95.26% 95.56 0.24 12%
August -2020 95.26% 95.86 0.16 8%
September - 2020 95.26% 95.77 0.17 10%
October -2020 95.26% 95.81 0.21 8%
AVG. 95.26% 95.44% 0.18 20%
 Month wise yield before QC  Month wise yield after QC
Step 11 : Regular Implementation
Lockdown
124

Shourya
Month
% of leader end
below 400 Kg
Month
% of leader
end below 400
Kg
Nov-19 76.00% May-20 79.00%
Dec-19 85.30% Jun-20 89.00%
Jan-20 83.12% July-20 85.00%
Feb-20 82.15% Aug-20 81.23%
Mar-20 84.23% Sept-20 86.89%
Apr-20 0 Oct-20 91.26%
 Data collection after regular implementation :
Lockdown
125

Shourya
 Line Graph : Showing Leader End of each months of previous shown data after regular
implementation :
0.00%
10.00%
20.00%
30.00%
40.00%
50.00%
60.00%
70.00%
80.00%
90.00%
100.00%
Nov-19 Dec-19 Jan-20 Feb-20 Mar-20 Apr-20 May-20 Jun-20 Jul-20 Aug-20 Sep-20 Oct-20
%
of
Leader
End
Month
% of leader end below 400 Kg
Lockdown
126

Shourya
Month HR to CR Yield
November, 19 85.89%
December, 19 87.77%
January, 20 84.68%
February, 20 80.13%
March, 2020 81.22%
April, 2020 0.00%
May, 2020 94.96%
June, 2020 95.48%
July, 20 95.56%
August, 20 95.86%
September, 20 95.77%
October, 20 95.81%
 Month Wise Yield Performance Chart :
85.89% 87.77%
84.68%
80.13% 81.22%
0.00%
94.96% 95.48% 95.56% 95.86% 95.77% 95.81%
0.00%
20.00%
40.00%
60.00%
80.00%
100.00%
120.00%
HR
to
CR
Yield
Month
HR to CR Yield
Before QC After QC
Lockdown
127

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 Month Wise Oil Concentration Chart :
Month
Oil Concentration (2-
3.5)%
November, 19 1.75%
December, 19 1.80%
January, 20 2.00%
February, 20 1.40%
March, 2020 1.68%
April, 2020 0.00%
May, 2020 1.88%
June, 2020 2.90%
July, 20 3.10%
August, 20 3.20%
September, 20 3.44%
October, 20 1.88%
1.75% 1.80%
2.00%
1.40%
1.68%
0.00%
1.88%
2.90%
3.10%
3.20%
3.44% 3.41%
0.00%
0.50%
1.00%
1.50%
2.00%
2.50%
3.00%
3.50%
4.00%
HR
to
CR
Yield
Months
Oil Concentration (2-3.5)%
After QC
Before QC
Lockdown
128

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 Month Wise pH Performance Chart :
4.65
4.9 5
2.89
4.89
0
5.1
5.77
5.89
6.2
6.09 6.15
0
1
2
3
4
5
6
7
November,
19
December,
19
January,
20
February,
20
March,
2020
April, 2020 May, 2020 June, 2020 July, 2020 August, 20 September,
20
October,
20
pH
Range
Months
pH range (5.5-6.5)
Month pH range (5.5-6.5)
November, 19 4.65
December, 19 4.9
January, 20 5
February, 20 2.89
March, 2020 4.89
April, 2020 0
May, 2020 4.7
June, 2020 5.1
July, 20 5.89
August, 20 6.2
September, 20 6.09
October, 20 4.65
Lockdown
Before QC After QC
129

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 Month Wise Chart of Iron Content :
Month
Iron Content (400
max)
November, 19 600
December, 19 589
January, 20 542
February, 20 789
March, 2020 550
April, 2020 0
May, 2020 443
June, 2020 402
July, 20 389
August, 20 351
September, 20 314
October, 20 335
600 589
542
789
550
0
443
402 389
351
314
335
0
100
200
300
400
500
600
700
800
900
Iron
Content
Month
Iron Content (400 max)
Lockdown
Before QC After QC
130

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 Cost Analysis after QC:
Cost analysis of Increasing Leader End due to
Black patches Before QC
Cost analysis of Increasing Leader End due to
Black patches After QC
Average coil end wt: 500 Kg
Target coil end: 400 Kg
Average coil end wt: 350 Kg
Target coil end: 400 Kg
A=Cost of prime material/ton (GP+CC)
= ₹ 70000
A=Cost of prime material/ton (GP+CC)
= ₹ 70000
B=Cost of leader end material/Ton
= ₹ 32000
B=Cost of leader end material/Ton
= ₹ 32000
C =Loss of material/Ton
C = A-B = 70000-32000
= 38000 ₹/Ton
C =Loss of material/Ton
C = A-B = 70000-32000
= 38000 ₹/Ton
D =Loss of material/Month
=0.10*500=50 Ton
D =Gain of material/Month
=0.15*500=75 Ton
E = Total loss = 50*38000
= 1900000 ₹/ Month
E = Total gain = 75*38000
= 2850000 ₹/ Month
131

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 Intangible benefits for the Quality circle members:
Befor…
After…
Before QC After QC
• Job Satisfaction
• Increased Co-operation
• Improved Self Confidence
• Increased Computer Knowledge
• Improved presentation Skills
• Increased Innovative spirit
• Communication Skills
• Problem Solving Skills
• QC Knowledge
5 S Improvement : Improved House Keeping
Safety : Developed Safe Work Atmosphere using Du-Pont Technique
132

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Step – 12 :
Follow Up and Review
Tools used : Gantt Chart
“Quality is fitness for intended use”
-Joseph M Juran
133

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 Checklist for important parameters to be maintained
 For maintaining Oil Parameters
1. Reporting in mail to everyone
2. Daily noting in Log Book
These parameters are to be
reviewed by QC members on
Regular basis at the end of every
shift as shown here.
Line Parameters checked Requirement
A - Shift B - Shift C - Shift
Result Remarks Result Remarks Result Remarks
6 Hi (M1)
Total Oil (%) 2.00 - 3.50 2.20 OK 2.00 OK 2.00 OK
Scum (%) 1.00 (Max) 0.20 OK 0.20 OK 0.20 OK
Iron (ppm) 400 (Max) 356 OK 334 OK 334 OK
pH 5.50 - 6.50 5.86 OK 5.90 OK 6.20 OK
Step 12 : Follow Up and Review
134

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Sr. No Sujhaav Title Sujhaav By
Submitted
On
HOD
Remarks
Closure
Status
1
Stand to be make to place the coil end/leader
end
Dhanesh
Vijayan
10/6/2020
Safety And
House Keeping
Approved
2
Wiper arrangement require at Mill-1 to wipe
out the coolant carry over
Mahesh
Werulkar
10/6/2020
Qms, Improved
Quality
Pending
with HOD
3
improve coolant quality at mill 1 by
installing oil skimmer
Rohit Gupta 9/7/2020 QMS Approved
4 coolant pipe line change Shraddha 11/8/2020
QMS, improved
utilization and
quality
Approved
5 Water Conservation
Dhanesh
Vijayan
11/8/2020 Closed Approved
6
safety barricade around coil storage and
Leader End area,
Rohit Gupta 15/9/2020 ok Approved
 We have also made some Sujhaav in our organization Sujhaav Portal as shown below :
135

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Format No: 08.16.01
QMP No.09
START DATE 1-Nov-19
QUALITY
OBJECTIVE:
SCOPE:
RESPONSIBILITY:
Responsibility Trgt Date Com pletion
Date
Expences Status / Rem arks
Shift
Incharge
Regular Regular Ok
Shift
Incharge
Regular Regular Ok
Shift
Incharge
Regular Regular Ok
Review Date: Remarks Section I/C: -
Sign - Unit I/C: - Sign - Section I/C: - Sign -HOD : -
Remarks HOD: -
Analyse the Coil ends coming above and below 400 kgs 56864
Maintaining Roll Coolant parameters
Maintaining Magnetic Seperator ON/OFF time
Reducing Leader end Generation at coating lines
Eliminating High weight leader end at coating line so as to improve HR to CR Yield
Shift Incharge
DESCRIPTION:
Coil leaderend welding to head end of HR at payoff,so that one side coil leaderend save.
List of activities to be performed by each dept.
JSW Steel Coated Products Limited,KLM
QUALITY MANAGEMENT PROGRAMME - 2020 Dept: Mill Operation
QMP/Mill/Opr/June-20/09
COMPLETION DATE Regular
 Made some QMP Programme as shown :
136

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CRM Operation Training
Dept
S. No.
Name Person /
Training
Roles & responsibilities
and dept. objectives.
Significant
Environmental
aspects and
initiatives
Significant
Hazards , HIRA
and initiatives
Dept.
Statutory
requirements
Emergency
Preparedness
Energy Saving
Total Tech Training
Planned / Attended
Total
Train
ing
Hour
s
Planned(P) ,
Attended(A)
P T A AT P T A AT P T A AT P T A
A
T
P T A AT P T A AT P T A AT P
MILL 1 1 Vinesh Dwivedi 1 0.5 1 0.5 2 0.75 1 0.75 2 2 0 1 1 1 1 2 1.5 0 2 0.5 1 0.5 14 6.55 8 3.55 24
MILL 1 2 Rajeev Bhramar 1 0.5 0 2 0.75 0 2 1 1 1 1 1 0 2 1.5 0 2 0.5 0 14 6.55 12 5.55 24
MILL 1 3 K C Sharma 1 0.5 1 0.5 2 0.75 0 2 1 0 1 1 0 2 1.5 1 1.5 2 0.5 0 14 6.55 8 3.55 24
MILL 1 4 D Malviya 1 0.5 1 0.5 2 0.75 1 0.75 2 1 1 1 1 1 0 2 1.5 0 2 0.5 1 0.5 14 6.55 11 5.05 24
MILL 1 5 D Kokate 1 0.5 1 0.5 2 0.75 0 2 1 1 1 1 1 0 2 1.5 0 2 0.5 1 0.5 14 6.55 7 3.05 24
MILL 1 6 C Ucchasare 1 0.5 0 2 0.75 0 2 2 0 1 1 1 1 2 1.5 1 1.5 2 0.5 1 0.5 14 6.55 5 2.5 24
MILL 1 7 S A Choudhari 1 0.5 0 2 0.75 1 0.75 2 1 1 1 1 1 1 1 2 1.5 0 2 0.5 1 0.5 14 6.55 5 2.5 24
MILL 1 8 Ajay Yadav 1 0.5 1 0.5 2 0.75 0 2 2 0 1 1 0 2 1.5 0 2 0.5 0 14 6.55 5 2.5 24
MILL 1 9 K V Srinivas 1 0.5 1 0.5 2 0.75 0 2 1 0 1 1 1 1 2 1.5 1 1.5 2 0.5 0 14 6.55 4 1.55 24
MILL 1 10 I M Dongre 1 0.5 1 0.5 2 0.75 1 0.75 2 1 1 1 1 1 0 2 1.5 0 2 0.5 1 0.5 14 6.55 7 3.05 24
MILL 1 11 N Palade 1 0.5 0 2 0.75 0 2 1 0 1 1 1 1 2 1.5 0 2 0.5 1 0.5 14 6.55 8 3.55 24
MILL 1 12 Dheeraj Thigale 1 0.5 1 0.5 2 0.75 0 2 1 1 1 1 1 0 2 1.5 0 2 0.5 1 0.5 14 6.55 9 4.5 24
MILL 1 13 Harshal Patil 1 0.5 0 2 0.75 1 0.75 2 1 0 1 1 1 1 2 1.5 1 1.5 2 0.5 0 14 6.55 9 4.5 24
MILL 1 14 Pradeep Singh 1 0.5 1 0.5 2 0.75 0 2 1 0 1 1 1 1 2 1.5 0 2 0.5 1 0.5 14 6.55 12 5.55 24
 P- Training Planned; Training Hrs; A-Training attended; AT-Total Training Completed Hrs
 Training taken of employees :
137

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 Training taken of employees :
138

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 We have also shown skit performance of quality circle and given safety trainings to
other employees :
Skit Performance Fire Safety Training
139

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 Kaizen of our Department 140

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 Appreciation Letter from our HOD 141

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SR No Activities 1 2 3 4 5 6 7 8 9 10 11 12-18 18-22 Remarks
1 Identification of Work related problems No Variation
2 Selection of Problems No variation
3 Define the Problems No variation
4 Analyze the problem
Due to absence of
members
5 Identification of causes Due to previous delay
6 Finding out the root causes Due to previous delay
7 Data analysis No variation
8 Developing solutions No variation
9 Foreseeing Probable resistance No variation
10 Trial Implementation and check performance
Delay due to
Breakdown
11 Regular Implementation No Variation
12 Follow Up/Review No variation
 Scheduled Gantt Chart :
Planned May-20 Actual June-20
142

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Steps
No
Steps Details
Flow
Diagram
Brain
Storming
Data
collection
Pareto
Diagram
Cause &
Effect
Diagram
Stratification Graphs
5 W-1 H
Technique
1
Identification of Work
related problems
2 Selection of Problems
3 Define the Problems
4 Analyze the problem
5 Identification of causes
6
Finding out the root
causes
7 Data analysis
8 Developing solutions
9
Foreseeing Probable
resistance
10
Trial Implementation
and check performance
11
Regular Implementation
12 Follow Up/Review
 Tools and
Technique
Used
while
solving
problems
Note :
Tools
Used
143

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 Members Views about the benefits they got from working in this quality circle:
I was totally mesmerised
by seeing how these small
tools helped us to solve this
problem so easily which
become fruitful for our
company too…
- Shraddha
The quality circle group
helped in enhancing my
presentation and
communication skills
along with managing
time.
- Rohit
I learnt a lot while making the
PPT presentation. Along with
other team members, I learnt
about time management.
- Sagar
I understood perfect meaning
of
teamwork and how to see the
problem in easy and
understandable way
- Dhanesh
I gained self confidence
and improved my
communication skills
while speaking to others
- Mahesh
144

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Future Plans
1. Regular feedback and monitoring of leader End generation at Galvalume
2. Pipe line will be change for avoiding coolant leakage
3. New air wiping system will be procured for better and efficient coolant
wiping
4. New oil supplier will be chosen for better emulsion performance
145

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Making Steel Is Our Profession
Generating Smile Is Our Passion…
146

Improvement in HR to CR yield at JSW STEEL kalmeshwar

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