Transcript Document

VIRENDER DHAWAN, DGM I/C (O) CCS, BSP
RAJEEV SEHGAL, DGM I/C (O) CS, BSP
STEEL DEFECTS IN PLATES




Non Metallic inclusions (NMI)
Longitudinal Crack
Spider Crack
UT Failure (NDT)
INTERNAL NORMS FOR DEFECTS
 DEFECTIVE DUE TO STEEL DEFECTS :
1.40 % max
 DEFECTIVE DUE TO MILL DEFECTS :
0.43 % max
YEAR WISE ANALYSIS OF STEEL DEFECT
YEAR
STEEL
DEFECTS
2010-11
2.23
2.67
2011-12
2.16
2.57
2.76
3
2.5
2012-13
2.76
3.1
2.23
2.16
2010-11
2011-12
%
2
1.5
1
0.5
0
2012-13 (Till Nov)
ANALYSIS OF STEEL DEFECT APRIL-NOV 2012
NCO
65.53
70
60
%
50
40
30
20
10
2.83
3.01
5.88
1.27
1.46
0
NMI
LCRK
SPCRK
NDT
PORO
SLSD
DEFECT WISE STEEL DEFECT
60
55.47
50
DEFECTIVE
%
40
30
16.45
20
10
3.83
6.96
3.47
0.67
0
NMI
LCRK
SPCRK
NDT
PORO
SLSD
IMPACT OF HIGH STEEL DEFECT
 Delay in order servicing
 Chocking of Plate Mill finishing
area
 Loss of market
CHALLENGE
Evolve a system which aligns
process capability with
customer needs
ROOT CAUSE ANALYSIS OF UT FAILURE
Major Reasons identified for UT Failure
 Hydrogen cracking
 Caster Condition
 Process route - Not aligned with customer
need
ACTION PLAN FOR REDUCING NDT FAILURES
1. DEFINING OF PROCESS ROUTE FOR DIFFERENT GRADES/THICKNESS
 Technological Process Route
Converter LF RH Caster
Plate Mill
NDT
This process route is to be followed for
 For all high tensile (with or without Cu) below 410 MPa YS,
steel plates of 32 mm and above thickness.
 For 2062 E410 and above grades this route shall be followed
for plate thickness 28 mm and above.
 Calcium treatment in LF for all high tensile, micro alloyed
heats and EME grades.
 All mild heats for plates of 32 mm and above thickness.
 All BQ heats irrespective of plate thickness
ACTION PLAN
2. APPROVAL OF INITIATIVES FROM GM
(QUALITY) ON 25.10.2012
3. INCORPORATING PROCESS ROUTE IN MES
ACTION PLAN
4. IMPROVING EFFICIENCY OF DIFFERENT STATIONS
IN PROCESS ROUTE
 Ensuring vacuum level of <3 mbar in 2 to 2.5 minutes and
achieving vacuum level of <1 mbar in 3.5 to 4 minutes
 Measurement of RH out hydrogen at least once in a day.
Aimed hydrogen less than 1.5 ppm in tundish
 RH Off take change/maintenance planned after 1500 heats.
IMPROVING EFFECIENCY OF DIFFERENT
STATIONS IN PROCESS ROUTE
5. CASTER MAINTENANCE
Timely segment changes at caster 6 based on logger
readings and feed back on UT results.
Increased frequency of manual inspection of Caster 3
Tightening of foundation bolts of caster by hydraulic
torque wrench up to 400 Kg/cm2
ACTION PLAN
6. PROCESS CONTROL
Initiatives taken under this are
 Minimum 15’ degassing for 1st heat of sequence / tundish
and ensuring a hydrogen level of less than 1.6 ppm.
 First heat of tundish / sequence planned only for thinner
plates and not for heavy plates.
 Use of MES for effective monitoring of quality feedback
and based on this feed back caster maintenance plan made.
 Diverting heats with less degassing to lower thickness
ACTION PLAN
 Leaner chemistry for lower segregation
 Inclusion rating on regular basis Aim
below 1.0 for EME grades
 Periodical Sulphur print of slabs for
monitoring caster condition
RESULTS OF IMPROVEMENT INITIATIVES
M/C # 6 Performance
Insp
NDT
Period
%
16599
13832
635
39
Before
After
3.8
0.28
Heat Number
From
To
149917
150685
150686
Till 24th
3.8
4
%
3
2
0.28
1
0
BEFORE
AFTER
RESULTS OF IMPROVEMENT INITIATIVES
M/C # 3 Performance
Insp
NDT
Period
%
12851
7649
428
63
Before
After
3.3
0.8
Heat Number
From
To
149917
150685
150686
Till 24th
%
3.3
3.5
3
2.5
2
1.5
1
0.5
0
0.8
BEFORE
AFTER
COST OF POOR QUALITY - FOR PLATES
Month
Oct-12
Nov-12 Dec-12 Jan-13 Feb-13 Mar-13
Defective (Ton)
3184
2068
1125
1033
933
1419
Opprotunity Loss (Cr)
4.67
2.76
1.21
1.14
0.86
1.27
Total Sales(Cr)
352.52
Opp Loss/Sales (%)
Opp. Loss/Sales %
1.4
1.33
304.46 327.39 333.67 313.99
0.91
0.37
0.34
0.27
1.33
1.2
0.91
1
0.8
0.6
0.4
0.37
0.34
Dec/12
Jan/13
0.27
0.38
0.2
0
Oct/12
Nov/12
Feb/13
Mar/13
333.06
0.38
YEAR WISE ANALYSIS OF STEEL DEFECT
2.5
2.23
2.16
2.11
2
%
1.5
1.01
1
0.88
0.5
0
2010-11
2011-12
2012-13
2013-14
2014-15 (Till
date)
BENEFITS
Timely servicing of orders
Increase in customer confidence
Capability to service S2E3 (NDT)
plate orders developed
REDUCED COST
5
4.67
4.5
4
COPQ in Cr.
3.5
3
2.5
2
1.5
0.51
1
0.5
0
OCT '2012
OCT '2013
CUSTOMER FEED BACK
TATA HITACHI
Subject: FW: feedback from Tata Hitachi (TELCON) Feed back
from customer is sent please Balu From:Ajay Kumar
[mailto: [email protected]] Sent: 03 April 2013
14:02 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 - 831010
INDIA
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: 9407981698 Dear
Sir, Please find the Details of Heat no.which we
receive after heat no. 150686. We find no complain
on these Heat nos. Regards, Manzar Alam
Sr.Manager (Materials) RSB Transmission (I)
LTD.Unit-II Jamshedpur( INDIA) Email :[email protected] M- 09334628226
Lowest ever steel
defects of 0.48 %
in May ‘2014
HIGHLIGHTS OF
2014-15
Overall steel
defect till Jan 0.88
%
From:
Sent:
To:
Cc:
Subject:
Manzar Alam [[email protected]]
26 February 2013 16:17
'KL Balasubramanian'
[email protected]; [email protected]; bmbok
Improvement in Plates Quality & Implementation of EME Grade.
Dear Sir,
As discussed during our Visit to SAIL CMO BOKARO, with Branch manager(Mr.Anil
Arora and Mr.Prbhat Kumar and
Subsequent telephonic discussion with you regarding the implementation of EME Grade.
As we are finding Improvement in the Quality of plates, we still needs the EME to be
mentioned in the T.C. as well as on the Plates,
to avoid any gap during lifting from Stockyard.
Regards,
Manzar Alam
Sr.Manager (Materials)
RSB Transmission (I) LTD.Unit-II
Jamshedpur (INDIA)
Email :- [email protected]
M- 09334628226
ANALYSIS OF STEEL DEFECTS FROM APRIL 2012 TO NOV 2012
DEFECTS
%
Ton
NMI
0.11
849
L CRK
0.19
1468
SCRK
0.45
3476
NDT
1.53
11819
1.80
1.53
1.60
1.40
1.20
1.00
0.80
0.60
0.45
0.40
0.20
0.11
0.19
0.00
NMI
L CRK
SCRK
NDT
Quality improvement initiatives
New initiatives adopted
• Minimum 15 minutes degassing for first heat of sequence /
Tundish
• Minimum 12 minutes for subsequent heats.
• First heat of Tundish/sequence will be planned only for
thinner sections and not for heavy plates even if the heat is
degassed for 15 minutes.
MONTHWISE ANALYSIS OF NDT (%) - LIGHT MEDIUM & HEAVY PLATES
2011-12
0.53
APR
0.87
MAY
1.07
JUN
1.46
JUL
0.92
AUG
2.42
SEP
1.15
OCT
2.24
NOV
2.15
3
2.42
2.5
2.24
2.15
2
1.46
1.5
1.15
1.07
0.92
0.87
1
0.53
0.5
0
2011-12
APR
MAY
JUN
JUL
AUG
SEP
OCT
NOV
MONTHWISE ANALYSIS OF SCRK (%) - LIGHT MEDIUM & HEAVY PLATES
2011-12
0.46
APR
1.10
1.2
MAY
0.61
JUN
0.54
JUL
0.20
AUG
0.28
SEP
0.36
OCT
0.21
NOV
0.29
1.10
1
0.8
0.61
0.54
0.6
0.46
0.36
0.4
0.29
0.28
0.21
0.20
0.2
0
2011-12
APR
MAY
JUN
JUL
AUG
SEP
OCT
NOV
MONTHWISE ANALYSIS OF LCRK (%) - LIGHT MEDIUM & HEAVY PLATES
2011-12
0.15
APR
0.19
MAY
0.17
JUN
0.22
JUL
0.19
AUG
0.17
SEP
0.26
OCT
0.26
NOV
0.05
0.3
0.26
0.25
0.26
0.22
0.19
0.2
0.19
0.17
0.17
0.15
0.15
0.1
0.05
0.05
0
2011-12
APR
MAY
JUN
JUL
AUG
SEP
OCT
NOV
MONTHWISE ANALYSIS OF NMI (%) - LIGHT MEDIUM & HEAVY PLATES
2011-12
0.14
APR
0.15
0.16
MAY
0.11
JUN
0.11
JUL
0.10
AUG
0.09
SEP
0.14
OCT
0.06
NOV
0.08
0.15
0.14
0.14
0.14
0.12
0.11
0.11
0.10
0.1
0.09
0.08
0.08
0.06
0.06
0.04
0.02
0
2011-12
APR
MAY
JUN
JUL
AUG
SEP
OCT
NOV
From:
Sent:
To:
Cc:
Subject:
Attachments:
Manzar Alam [[email protected]]
26 February 2013 17:02
'KL Balasubramanian'
[email protected]; bmbok; [email protected]
Tracking of Heat No. After 150686
Sail Heat no-bhilai.xls
Dear Sir,
Please find the Details of Heat no.which we receive after heat no. 150686.
We find no complain on these Heat nos.
Regards,
Manzar Alam
Sr.Manager (Materials)
RSB Transmission (I) LTD.Unit-II
Jamshedpur (INDIA)
Email :- [email protected]
M- 09334628226
From:
Sent:
To:
Cc:
Subject:
Ajay Kumar [[email protected]]
03 April 2013 14:02
KL Balasubramanian
Prabhat; Manoj Barik; Malay Palit
feedback
Dear sir.
We take this opportunity to thank you sincerely for the quality improvement done as
per our new TDC.
The quality of plates have been improved in all parameters .
And we expect further improvement in surface ( MINIMIZING THE SCALE
FOR FURNACE NORMALISED PLATES ).
We continue to look forward to similar support in the future also.
Regards
Ajay Kumar
Divisional Manager (Supply Chain Management)
TATA Hitachi Construction Machinery Co. Ltd.
Tata Motors premises, Telco
Jamshedpur - 831010
INDIA
From:
Shankar V - Axles India [[email protected]]
Sent:
28 January 2013 20:34
To:
[email protected]
Cc:
[email protected]; Madhusudhan.Surathi; [email protected]; [email protected]; [email protected]
Subject:
FW: sail plate feedback
Attachments:
SAIL PLATES FEED BACK.xls
Dear Mr K M Balasubramanian,
We thank you for your efforts in controlling the issue of inclusions and spot laminations.
We have checked the heats supplied in Nov and Dec 2012 and confirm that there are no
inclusions and laminations. There are no rejections on this account and Quality has
improved. We thank your effort and support extended SMS, Quality and plate mill for
achieving the mail stone.
Regards
Shankar
-----Original Message----From: K S Ravi Shankar [mailto:[email protected]]
To: KL Balasubramanian; 'ASHISH KUMAR SINGH'; [email protected]
Cc: Vijaya Vittala M
Subject: Fwd: Ultrasonic test Audit on Steel plates
Dear Mr. Ashish / Balasubramananian,
For your information and records.
Self and Mr.Ravishankar conducted ultrasonic test audit on steel plates at M/S
Model Infra Corporation today as a pro active measure to give periodic feed back to SAIL
on internal soundness. We have checked four plates along with three UT certified personnel
of MIC after explaining the Quality requirements of UT as per the standard ASTM A 578
Level B. The plates audited by UT are also verified with mill test certificate of SAIL and
confirmed plate procurement with relevant mill test certificates are in
place at MIC. Based on UT, We observed that all the plates are free from defects. This
confirms that the countermeasure taken by SAIL are effective.