QC_SPARK.pptx

2
Sr. No DESCRIPTION Slide No
1 Introduction 5-8
2 Awards and Certification 9-13
3 Process flow of Kalmeshwar works 14-16
4 Introduction of Quality Circle 18
5 Identification of problems 19-22
6
Selection of problem
 Categorization in A,B,C
 A,B,C Analysis
 3P Analysis
23-30
7
Definition of problem
 Milestone Chart
 Introduction of department
 Process Description through flow diagram
 Introduction of problem area
 Impact of problem
 Setting of Objectives
 Setting of Goals
31-42
8
Analysis of problem
 Data collection
 Cost analysis of problem
43-49
9
Identification of Cause
 Identification of Probable Causes
 Cause and effect analysis
50-53
10
Root cause analysis
 Validation of causes
 Why- Why analysis
54-61
11
Data analysis on the root cause
 Selection of Main root Causes
 Pareto Analysis
 Inspection through Checklist
62-68
12
Development of solution
 Development of solution through brain
storming
 ICITE Matrix
 Responsibility Chart
69-75
2

3
13 Foreseeing probable Resistance and points to overcome them 76-79
14
Trial implementation &
Check Performance
 PDCA analysis
 Comparative study of graphs before and after QC
80-90
15
Regular implementation
 Data collection after regular implementation.
 Comparative study before and after QC graphs.
 Tangible & Intangible gains
91-96
16
Follow up and Review and Recurrence Prevention
 Graphs
 Document for change
 Kaizen
 One Point Lesson
 Milestone chart
97-105
17
Conclusion
 Members review.
 Tools and Techniques used.
 Future Plans.
106-109
3

4
Steel making capacity of 18 MTPA
7 manufacturing facilities in India
Integrated Steel Plant
Downstream Plant
VISION
MISSION
VALUE
Global recognition
for Quality &
Efficiency while
nurturing Nature &
Society
Supporting India’s
growth in core
economic sector
with speed &
Innovation.
Transparency strive
for Excellence,
Dynamism, Passion
for learning
5
INTRODUCTION OF JSW STEEL

PROJECT THEME To Optimization Grey coating at CGL-2 line
THEME SELECTED ON 01-10-2020
PROJECT COMPLETED ON 20-08-2021
NO. QC PROJECT COMPLETED 2 ( GOT PAR EXCELLANCE AWARD IN NCQC VARANASI)
NO. OF MEETINGS FOR THIS PROJECT 26
ATTENDANCE 95%
PERIODICITY OF MEETINGS Thursday
Mr. Ashish Zalke
Facilitator
Mr. Vinay Patel
member
Mr.Mahesh Werulkar
Member
5
Mr. Vijayandra
Yadav
Member
Mr. Atul Deo
Leader

6
Mr. Babu Achmare
(DGM- Mechanical)
Mr. Rajesh Jain
(Plant Head)
Mr. Abhay Girhare
(HOD- Business Excellence)
Mr. Badam Singh
(AVP- Operations)

7
JSW
INFRASTRUCTURE
INFRASTRUCTURE
JSW
ENERGY LIMITED
POWER
GLOBAL BUSINESS
SOLUTIONS
SERVICES
JSW
FOUNDATION
JSW
CEMENT
CEMENT
Group
JSW
STEEL LIMITED
STEEL
Expanding Presence Across Key Infrastructure
Sectors
 JSW Group – 18 Bn USD
 JSW Steel – 13 Bn USD

8
VASIND / TARAPUR
DOLVI
VIJAYANAGAR
KALMESHWAR
SALEM
SALAV
Slabs
Cold Rolled
CA,GL
Coated
Products
Long
Products
HRPO
Coils
Hot Rolled
Plates
HR Coils HSM
Plates
Integrated Steel Plant Downstream Plant

1999
0.30 Mt
2004
0.33Mt
2011
0.35 Mt
2014
0.41 Mt
2017
0.65Mt
This is what we got
And this is what we made of it
2018
0.66Mt
Speed,
agility and
Innovation
at the core
9
2020
0.71Mt
9

10
Kalmeshwar
Location : Kalmeshwar
Area : 147 Acres
No. of Employees : 690
No. of Associates : 823
Capacity : 0.66 Million Ton / Year
Date of Start : 1st August, 1985
COMPANY LOCATION
Kalmeshwar

11
Products
Range (mm)
Features Form
Thick Width
GI
0.14 -
3.15
500-1350
 With spangles,
 Without spangles,
 Bright finish
 Coils
 Plain Sheets
Profiles
- Sinusoidal
- Trapezoidal
- Tile
GL® 0.20 -1.2
PPGI
0.25 -
1.20  Colours,
 Textures (Glossy, Matte)
PPGL® 0.30- 1.20
With
Spangle
Without
Spangle

13
Vehicle Parking
Solar power
panel stand
Grain Silos
Roofing
Pre Engineered
Building
Cold Storage End
Caps
Sandwich Panel
Trunk
Dome Roofing
Gutter
Porta cabin
GI/GL/PPGI/PPGL
Roofing, Cladding, Side Wall,
Construction, Door/Windows,
GI/GL –Solar panel, Grain Silos, Trunk,
Cooler

14
Product Application in Solar Power Plant

17
Sr.no STATE AWARDS Year
1 Own the IGMC award 2021
2 GHR (G H Raisoni) Award for innovative Practices in manufacturing 2019
3
Certificate of Merit at State Level Award for Energy Conservation &
Management in metal & steel Sector
2017-18
4 1ST Position, Best Domestic Customer, Concor Award 2017
5 3RD Position by MEDA for Energy Conservation 2016
6 2nd Position, Exporter Category, Concor Award 2015
7 3rd Highest Exporter of ICD, Concor Award 2014
Sr.no NATIONAL AWARDS 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

18
Prime
Minister’s
Trophy by
Ministry of
Steel for
the year
2012-13.
Porter Prize
for Creating
Shared
Value,
Leveraging
Unique
Activities -
Weathering
the Iron
Ore crisis
2015
National
Sustainabili
ty
Award: 1st
Prize by IIM
for the year
2017
Steel
Minister’s
Trophy for
the year
2014-15
and 2015-
16
Quality concept for Cultural Breakthrough

20
COLD ROLLING PROCESS
COLOR COATING PROCESS
Shear Joint
Press
Pretreatment
Tanks
PICKLING PROCESS
GALVANIZING/GALVALUME PROCESS
Uncoiler
Shear Welder Wet Loop Pit Pickling Tanks Exit Looper Side Trimmer Shear
Cold Rolling Mill Uncoiler 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

Methodology
21
12
11
10
9
8
7
6
5
4
3
2
1 Problem Identification
Follow-Up / Review
Selection of Problem
Definition of problem
Analyzing the problem
Identifying the causes
Finding out root cause
Data analysis
Developing solutions
Foreseeing resistance
Trial check performance
Regular implementation

22
TECHNIQUE USED
• BRAIN STORMING
(ROUND ROBIN
METHOD)

23
SR NO. Description Category
A B C
1 Black patches in CR. *
2 Scratches and RIS in CR coils. *
3 Rusty CR coils. *
4 Buckling and edge waviness in CR coils. *
5 Poor pickling of HR coils. *
6 Poor trimming of HR coils. *
7 Coil car tripping. *
8 Uncoiler snubber damage. *
9 Welding m/c diode failure. *
10 Air pressure drop. *
11 Scratches from looper roll *
12 Leakages from RTF Roll bearings. *
13 LOV Valves jamming. *
14 Propane balancing disturbing. *
15 combustion blower tripping. *
16 Hot well cold well level control problem. *
During QC meeting, Brainstorming sessions were conducted and problems
were identified and categorized into A,B,C category.

24
A B C
17 Burner block damage. *
18 Pick -up on Throat seal and RTF roll. *
19 Leakages from RTF and RCS manhole. *
20 Air and LPG line DPT Malfuctioning. *
21 Zinc pill off due PRV diaphragm punctured/damage. *
22 Pilot burner firing not proper *
23 Improper position of propane flow meter , difficult to read. *
24 Difficult to operate CPC#4 in manual mode. *
25 Bird waste deposition on furnace. *
26 Furnace glasswool fallen on sheet. *
27 Furnace hearth roll bending in running line. *
28 Furnace hearth roll coupler bolt shear *
29 Hearth roll chain sprocket allignment disturb. *
30 Water cooled hearth roll rotary union leakage. *
31 Difficult to fire 100% poilet burner. *
32 Radiant tube leakage. *

25
A B C
33 Coating variation on sheet as pot equipment constraint. *
34 Zinc pick-up on CAG roll. *
35 Difficult to remove pick -up zinc from CAG roll. *
36 CAG snubber roll alignment not proper. *
37 Sink roll bush worn out frequently. *
38 Sink and support roll pick-up. *
39 Quenching tank squeeze roll difficult to change in running. *
40 Quenching tank water level auto system not working. *
41 Heavy water leakage from quenching tank bearing seal. *
42 CR coil shifting delay. *
43 Level 2 system hang in running. *
44 Difficult to control TDS of quenching tank water. *
45 Tension leveller bearing damage. *
46 Heavy grease patches from leveller. *
47 Chromate carryover on G.P.Sheet *
48 Work roll frequently pick-up in skinpass mill. *

26
A B C
49 Difficult to control water carryover on edges after skin-pass. *
50 Wet sheet after skin-pass,dryer not effective. *
51 Logo m/c alignment disturbing. *
52 Logo m/c INK not proper. *
53 In thicker gauge scratches generated from briddle. *
54 Jerk was obesreved at briddle#7 at the time of coil cutting. *
55 Loop formation at Briddle #7 in thicker gauge. *
56 Chromate roll rubber damage in running. *
57 Chromate roll shaft broken in running. *
58 Greay surface of GP sheet *
59 Poor logo on GP sheet *
60 Temperature near logo m/c is vey high. *
61 Difficult to adjust back side roll of logo m/c . *
62 Looper capacity constraint for higher speed. *
63 Belt wrapper not operative. *
64 Chromate return line blockage. *

27
A B C
65 Every time setting needed for skin pass m/c. *
66 Poor house keeping near chromate tank. *
67 Payment clearing process time consuming. *
68 Pannel buttons in broken condition. *
69 Less manpower difficult to adjust shift. *
70 Pulpit roof in damage condition *
71 pulpit floor tiles in broken condition. *
72 Looper rolls not balanced. *
73 Difficult to change looper roll. *
74 Entry coil saddle foundation damage. *
75 Entry coil transfer trolly rail foundation damage. *
76 Exit looper railing damage condition. *
77 No proper walk out space from exit panel. *
78 Less coil stacking area for finish goods. *
79 Chromate pit pump not working. *
80 Quenching tank roll scaling. *

28
A B C
81 Difficult to plan material in campaign. *
82 Leakage zinc accumulation in pot cellar. *
83 Water leakages from walls of exit looper. *
84 Personal address system sound not clear. *
85 CAG sheet threading difficult. *
86 Radient tube fire roll gasket leakage. *
87 High stacking in packing area. *
88 Difficult to cut coil in lower weight at exit. *
89 Brazing and welding difficult in all loopers. *
90 Pressure regulating valve diaphram damage. *
91 Rain water leakage from roof. *
92 Very difficult to feed CR coil in uncoiler #2 mandril. *

29
TECHNIQUES USED
ABC ANALYSIS
ECT TECHNIQUES
RANKING METHOD
TOOLS USED
Stratification

30
We used A/B/C Analysis to decide the Nature of problems:-
Category -A Problem within our control & capacity.
Where we required help from resources of other
departments.
All under management purview/help.
All the problems are sorted in these three categories
Category -B
Category -C

31
All our problems are sorted into A,B,C categories as per
Quality Circle Decisions
For finding the % of every category ,we plotted PIE Graph
Category Problem No. Total Problems
A
7,8,9,11,13,14,17,19,22,24,29,30,31,32,
35,37,38,41,45,46,47,48,49,54,56,57,58
59,60,63,64,66,68,76,77,79,80,85,90.
39
B
1,2,3,4,5,6,10,15,21,25,26,36,40,42,44,5
1,52,61,65,67,69,70,71,72,73,75,81,82,8
3,84,86,88,89,91,92.
35
C
12,16,18,20,23,27,28,33,34,39,43,50,53,
55,62,74,78,87.
18

32
It requires huge
investment
C
Solved by
Our self
A
B
With help
of other
department
STRATIFICATION OF PROBLEMS - ABC ANALYSIS
 All 92 Problems were identified and they were categorized in
A, B, C categories.
Category Total Percentage
A 39 41.30%
B 35 39.13%
C 18 19.59%
Total 92 100%
41.30%
39.13%
19.57%
A B C

33
After A,B,C analysis we discussed over all the problems of Three
categories. We can solve these problems by ourselves and found
that A Category problem can be solved within our control.
So first of all , we decided to solve the problems
A category and listed separately.

34
S.N. Problem No. Description
1 7 Coil car tripping.
2 8 Uncoiler snubber damage.
3 9 Welding m/c diode failure.
4 11 Scratches from looper roll
5 13 LOV Valves jamming.
6 14 Propane balancing disturbing.
7 17 Burner block damage.
8 19 Leakages from RTF & RCS manhole.
9 22 Pilot burner firing not proper.
10 24 Difficult to operate CPC#4 in manual mode.
11 29 Hearth roll chain sprocket allignment disturb.
12 30 Water cooled hearth roll rotary union leakage.
13 31 Difficult to fire 100% poilet burner.
14 32 Radiant tube leakage.
A category Problems

35
15 35 Difficult to remove pick-up zinc from CAG roll.
16 37 Sink roll bush worn out frequently.
17 38 Sink and support roll pick-up.
18 41 Heavy water leakage from quenching tank bearing seal.
19 45 Tension leveller bearing damage.
20 46 Heavy grease patches from leveller.
21 47 Chromate carryover on G.P.Sheet
22 48 Work roll frequently pick-up in skin pass mill.
23 49 Difficult to control water carryover on edges after skin-pass.
24 54 Jerk was observed at briddle#7 at the time of coil cutting.
25 56 Chromate roll rubber damage in running.
26 58 Grey coating on GP sheet
27 59 Poor logo on GP sheet
A category Problems

36
28 60 Temperature near logo m/c is vey high.
29 63 Belt wrapper not operative.
30 64 Chromate return line blockage.
31 66 Poor house keeping near chromate tank.
32 68 Pannel buttons in broken condition.
33 76 Exit looper railing damage condition.
34 77 No proper walk out space from exit panel.
35 79 Chromate pit pump not working.
36 80 Quenching tank roll scaling.
37 85 CAG sheet threading difficult.
38 90 Pressure regulating valve diaphram damage.
A category Problems

37
Proprietary Grouping Stratification
All problems of A-Category are located against 4 Proprietary Groups.
To decide priority among the Proprietary Group, Ranking has been done
using ECT technique.
S.N Groups/Proprietary Problem no.
Total
Problems
1 Processing Related
14,19,22,24,29,35,47,48,
49,58,59
11
2 Resources Related
7,8,9,11,13,17,30,41,45,
54,56,57,60,63,31,32,37,
38,68,76,80,85,90
23
3 Administration Related 0 0
4 House Keeping Related 46,64,66,77,79 5
Stage Type of Analysis Purpose
P-I PROPRIETARY GROUPING
Grouping according to our company strategy
and requirements
P-II
PRIORITY
DETERMINATION
Selection of vital one from above on the basis
of "ECT TECHNIQUE" & departmental needs
P-III PREFERENCIAL LISTING
Final selection of one problem based on actual
data.
3P Analysis

38
Priority Determination
After Proprietary Grouping, we used “ECT Technique" to decide Priority of
Group by ranking .
Adverse effect on working
Cost of Manpower(Wastage)
Delay in processing
E ffect
C ost
T ime

39
Priority Determination
Priority has been given by all members to the problems in
Processing Related Group by Ranking and listed them .
Ranking by Q.C Member.
S.N. Group/Member B Yadav Vinay Akash Atul Moharana Total Stands
1 Processing Related 1 1 1 1 1 5 1
2 Resources Related 2 3 2 3 2 12 2
3 Administration Related 4 4 4 4 4 20 4
4 House keeping Related 3 2 3 2 3 13 3
Ranking(Out of five) of Proprietary Groups is done on the
basis of “E-C-T”.

40
Processing Related Problems
Before coming at preference among these problems, we
collected data for number of Occasions/Frequency .
S.N.
A Category
Prob.No.
Problems
1 14 Propane balancing disturbed.
2 19 Leakages from RTF and RCS manhole.
3 22 Pilot burner improper firing
4 24 Difficult to operate CPC#4 in manual mode.
5 29 Water cooled hearth roll chain sprocket alignment disturb.
6 35 Difficult to remove pick -up zinc from CAG roll.
7 47 Chromate carryover on GP sheet.
8 48
While skin -pass material processing work roll frequently pick-
up
9 49 Difficult to control water carryover on edges after skin-pass.

41
Preference Determination
Problem number ’58’ stands ‘1st’ in preference on maximum
Number of frequency.
S.N.
A Cate.
Prob.No.
Problems Aug-18 Sep-18 Oct-18 Nov-18 Dec-18 Jan-19
Total
Frequency
1 14 Propane balancing disturbed. 1 0 0 1 0 0 2
2 19 Leakages from RTF and RCS manhole. 0 0 1 0 0 0 1
3 22 Pilot burner improper firing 1 1 0 2 1 1 6
4 24 Difficult to operate CPC#4 in manual mode. 1 0 0 1 0 0 2
5 29
Water cooled hearth roll chain sprocket
alignment disturb.
1 4 3 2 2 3 15
6 35
Difficult to remove pick -up zinc from CAG
roll.
3 2 2 1 4 1 13
14 12 20 13 14 16 89
8 48
While skin -pass material processing work
roll frequently pick-up
1 1 0 2 0 0 4
9 49
Difficult to control water carryover on edges
after skin-pass.
1 0 0 0 1 1 3
10 47 Chromate Carryover 2 3 2 1 1 2 11
For Preference Determination we are having number of frequency data for six month listed below.

42
Preference Determination
2 1 6 2
15 13
89
4 3
11
0
10
20
30
40
50
60
70
80
90
100
NO.OF.FREQUENCY
PROBLEMS
A Category Problems VS Total Frequency

43
Pareto Graph Of A Category Problems
89
15 13 11 6 4 3 2 2 1
60.96
71.23
80.14
87.67
91.78 94.52 96.58 97.95 99.32
0
10
20
30
40
50
60
70
80
90
100
0
20
40
60
80
100
120
140
NO.
OF
OCCASIONS
PROBLEMS
A Cate.
Prob.No.
Problems
Total
Occasion
%
Frequency
Cumulative
%
58 Grey coating on GP sheet
89 60.96
60.96
29
Water cooled hearth roll chain
sprocket allignment disturb.
15 10.27
71.23
35
Difficult to remove pick -up
zinc from CAG roll.
13 8.90
80.14
59 Chromate carryover 11 7.53 87.67
22 Piolet burner improper firing 6 4.11 91.78
48
While skin -pass material
processing work roll
frequently pick-up
4 2.74
94.52
49
Difficult to control water
carryover on edges after skin-
pass.
3 2.05
96.58
14 Propane balancing disturbed. 2 1.37 97.95
24
Difficult to operate CPC#4 in
manual mode.
2 1.37
99.32
19
Leakages from RTF and RCS
manhole.
1 0.68
100.00
VITAL FEW
USEFUL MANY
From Pareto Analysis it is clear that the Grey coating on GP
sheet Problem covers major area of Vital Few..
C
u
m
m
%

44
Brain storming session conducted for Rating table analysis on
‘C-Q-L-S-E’ Technique.
QUALITY
LOSS
COST
SAFETY
ENVIRONMENT
C
E
S
Rating will be given on all 10 no. of problems .
Q
L

45
RATING TABLE ANALYSIS
From this rating table analysis Chromate carryover on GP sheet related problems has to be ranked as first. So, we
selected for Chromate carryover problem.
S.N.
A Cate.
Prob.No.
Problems C Q L S E Total Ranking
1 14 Propane balancing disturbed. 5 7 6 3 3 24 4
2 19 Leakages from RTF and RCS manhole. 4 6 5 3 2 20 6
3 22 Piolet burner improper firing 4 4 5 4 2 19 9
4 24 Difficult to operate CPC#4 in manual mode. 5 3 5 4 3 20 7
5 29 Water cooled hearth roll chain sprocket allignment disturb. 6 6 7 5 4 28 2
6 35 Difficult to remove pick -up zinc from CAG roll. 5 4 4 3 3 19 10
7 47 Grey coating on GP Sheet 8 8 9 7 8 40 1
8 48 While skin -pass material processing work roll frequently pick-up 6 5 5 3 2 21 5
9 49 Difficult to control water carryover on edges after skin-pass. 5 5 4 3 2 19 8
10 59 Logo m/c pump get jam. 6 6 5 5 4 26 3
C
.
 From the list of Processing Related problems Brain storming done and Ranking given
on C-Q-L-S-E Technique.

46
From rating table analysis Grey coating on GP Sheet having 1st
preference.
To reduced grey
coating on G.P.sheet
So we have to focused on this problem.
To Know the impact of the problem our members decided to
define the problem for which we had drawn the flow Diagram .

47
TECHNIQUES USED
FLOW DIAGRAM
TOOLS USED
DATA COLLECTION
GRAPH

QC Name: Spark Dept: CGL-2 Facilitator:Mr. Ashish Zalke
Member's Name:
A.Nikhade
V.yadav
V. Patel
Project No. 03 Project Leader : Mr.Atul Deo
Theme: ”To reduce Grey coating on G.P.
sheet” Date of Beginning :- Date of Complection :20-08-21
Meeting Day: Thursday
N
o.Activity Week 2 4 6 8 10 12 14 16 18 20 22 24 26 REMARKS
1 Defining Problem STARTED
2 Analyzing the problem 01/9/2020
3 Identifiying the causes
4 Finding out the root causes
5 Data analysis
6 Developing solutions
7 Foreseeing possible resistance
8
Trial implementation and checking
performance
9 Regular implementation
1
0 Follow-Up / Review COMPLETED
20/08/2021
Planned
 We make the Mile Stone Chart for Execution before QC.
48

49
Defining the problem
To study the impact of the problem we have Define the problem, it was defined by
using Process Flow Chart of continuous galvanizing line. ..
Continuous Galvanizing Line(CGL) Process Details
Hot-dip galvanization is a form of galvanizing, It is the process of coating iron and steel with zinc, which alloys
with the surface of the base metal when immersing the metal in a bath of molten zinc at a temperature of
around 449 °C (840 °F). When exposed to the atmosphere, the pure zinc (Zn) reacts with oxygen (O2) to form
zinc oxide (ZnO), which further reacts with carbon dioxide (CO2) to form zinc carbonate (ZnCO3), a usually dull
grey, fairly strong material that protects the steel underneath from further corrosion in many
circumstances. Galvanized steel is widely used in applications where corrosion resistance is needed without
the cost of stainless steel,
Zinc Pot –In Zinc pot section we applied zinc coating on G.P. sheet to increase corrosion
resistance properties.

50
CGL-2 PROCESS FLOW
We mark location of problem where Zinc Coating is applied on
G.P. sheet.
Problem
area

51
In Pot section Zinc applied on
G.P. sheet. There are two rolls
in Pot section these are Sink
roll & Support roll These rolls
are used to apply zinc on GP
sheet. Also Nozzle provided on
pot section for applying zinc on
G.P.sheet with proper pressure.
We can clearly see the Zinc coating applying process in block
Diag.

52
Defining the problem
Good Quality Sheet
Grey Coating Sheet
Process flow for acceptance & Non acceptance is explained in next slide
NOT OK SAMPLE OK SAMPLE
Grey
Coating

No
Input material(CR coil )transfer to entry
Annealing process carried out in furnace.
Zinc coating on CR coil.
Cooling of G.P. sheet
Online skin pass and shape correction of G.P.
sheet at Tension leveler.
G.P. coil ok for packing.
G.P. coil packed and
dispatch.
Chromate applied on G.P. sheet
Yes
G.P. coil
hold by
Q.C.
Grey coating
on GP sheet
Galvanized steel processing
Material down
graded/scrap
53

54
Impact of problem
40
38
35 36
34 33 34
0
10
20
30
40
50
Jan'21 Feb'21 Mar'21 Apr'21 May'21 June'21 July'21
Zinc
Loss(Mt)
Month
Month wise Zinc Loss

55
Impact of problem
97.16
96.46 96.56
93.65
94.73
92
92.4
89
90
91
92
93
94
95
96
97
98
Quality
Yield
(%)
Month
Quality Yield(%)

THEME OF “SPARK” QC CIRCLE PROJECT
To reduced zinc loss from Avg 35 Mt to 10 Mt .
Reduction in scrap generation by 0.50%
Increase the line stability
To reduced Grey Coating diversion from 100 Mt to 25 Mt.”
To increase overall finish yield from 94 % to 95 %
56
To analyze the problem we use 4W 1 H Technique to come across probable causes.
Reduction in grey coating from 100 Mt to 25 Mt in the
production of G.P. sheet By 31st Sept 2021 consider
avg production of 25000Mt/Month.

57
TECHNIQUES USED
4W & 1H ANALYSIS
TOOLS USED
DATA COLLECTION

58
Where does it
happen?
At Pot section of
Line
When it occurs?
During Zinc
application on sheet
How this is happen
?
High temperature at
pot section
Which areas
affected?
Zinc loss &
diversion increased
What is happen?
Zinc Coating not get
control as per
requirement of
customer.
Which
4W 1H
Analysis
How
Where
What When
4 W AND 1H TECHNIQUE

59
0
5
10
15
20
25
30
35
40
40
38
35 36
34 33 34
Zinc
Loss(Mt)
Month
Zinc loss

60
Impact of problem
Six months data collected for cost calculation
Month Zinc loss(Mt) Loss In Rs Lac
Jan'21 40 9.60
Feb'21 38 9.12
Mar'21 35 8.40
Apr'21 36 8.64
May'21 34 8.16
June'21 33 7.92
July'21 34 8.16

61
TECHNIQUES USED
BRAINSTORMING
TOOLS USED
AFFINITY DIAGRAM
CAUSE & EFFECT DIAGRAM

62
Brain storming done by all our Q.C. Members & following probable
causes are found out, which are responsible for the Zinc coating
variation on G.P. sheet.
1. Lack of skill.
2. Improper Nozzle pressure setting.
3. Defective Input material
4. Coating gauge not showing proper
reading
5. RCS fan not working properly
6. Heat Exchanger not working properly.
7. Zinc pot temperature is high
8. Leakage in RCS section
9. Error by Quality inspector in checking
zinc coating on G.P.Sheet.
10. Sink roll not properly working
11. RCS temperature is high
12. Nozzle gap not properly set
13. Heat exchanger tube chocked
problem
18.Heat exchanger water returned header
chocking problem
19.Grey coating problem
20.Zinc quality not proper
21.Pneumatic damper Actuator problem

63
Brain storming done following probable causes are found out,
which are responsible for Zinc coating variation shown in Affinity
Diagram
All the causes are studied by 4M Method using Cause & Effect diagram for Validation
MACHINE MATERIAL METHOD
MAN
ENVIRONMENT

Grey Coating on
sheet
Machine
Method
Material
Man
Coating gauge problem
64
Input CR Material
not proper
Improper nozzle gap
position setting
Environment
Error by Quality inspector
in zinc coating checking
Lack of skill
Heat exchanger not
working properly
Improper Nozzle Lip gap
setting
RCS fan not
working properly
Heat exchanger tube
chocked
No proper training.
Lack of Knowledge
Soil degradation
Zinc Material
Quality not proper
Wastage of water
Furnace & Pot hot fumes
Zinc Material Quality not proper
Lack of skill RCS fan speed setting
RCS section temperature control as
per sheet gauge
RCS fan suction & delivery ducting
Bellows leakage problem
Heat exchanger water returned header
chocking problem
Damper Pne Actuator problem
Heat exchanger cooling inlet
Temp problem
Heat exc water returned
flow problem

65
TECHNIQUES USED
5W -1H ANALYSIS
Why –Why Analysis

66
Why is it happening?
Due to temperature not
reduced in zinc bath pot
and JCS Section
How does it happen?
During RCS Fan Speed not
increased and temperature
not controlled
Where is the happening?
At RCS fan no -5 heat
exchanger
When does it happen?
During thicker gauge
and thinner gauge
material processing
What used to happen?
Which is the area?
Continuous galvanizing
line- 2 RCS section
Heat Exchanger not
working effectively

67
Identification of Root cause by WHY-WHY analysis & validation
Man
Related
Causes
Why Why Proper Justification
Judgement
Sub-cause
Sub-sub-
cause
Validation results
Lack of skill of pot
operator
Improper
working
knowledge
No proper
training Training given to workers
Error in zinc
coating checking
by QC inspector
Concentration
of HCL acid not
proper
HCL not
change from
long time
HCL concentration
properly checked &
Timely HCL replaced.
3. Lack of Coating
gauge standard
sample checking
Improper Skill
No Proper
technical
training
Training provided to
Electricians

68
Method
Related
Causes
Judgement
Sub-cause
Sub-sub-
cause
Validation results
Improper nozzle gap
position setting
Lack of
knowledge
No proper
training
All manpower well trained
Improper Nozzle Lip
gap setting
Poor planning
Unavailability
of material
Material was available
RCS Fan Speed
setting
Sheet Surface dull
Oxidation
taking place
Leakage arrested
RCS section
temperature control
as per sheet gauge
RCS fan speed not
increasing
Black spot on
sheet surface
coming
All leakages arested

69
Material
Related
Causes
Judgement
Sub-cause
Sub-sub-
cause
Validation results
Input Rolling CR
material not proper
Input CR material
shape not proper
Pickled coil
rolling not
proper
Pickling department
informed and quality
improved
Zinc Quality not
proper
Checked in quality
lab
Quality problem
identify and
informed
Improved vendor end

70
Machine
Related
Causes
Judgement
Sub-cause Sub-sub-cause Validation results
Coating gauge not
showing proper reading
Calibration not
done
Person not available Calibration done timely
RCS fan not working
properly
Above RCS 20% of
speed sheet surface
problem arise
During RCS fan
running outside air
inhaling
Leakages arrested
Heat Exchanger not
working properly
Heat transfer not
effective
Heat exchanger
water circulation
tubes chocked
Heat exchanger cleaning
done by outside vendor
Heat Exchanger inlet
water temperature
cooling problem
Not cleaned as per
schedule
Due to production
load
Ensured with production
team for Cooling tower
cleaning as per schedule
RCS fan suction &
delivery bellows
leakage problem
Due to aging of
bellows
Not changed as per
schedule
Ensured with production
team for bellows changing
as per schedule
Damper Pneumatic
Actuator problem
Due to internal seal
leakage
Due to high temp
and aging
New damper provided

71
Environment
Related
Causes
Judgement
Sub-cause Sub-sub-cause Validation results
Soil Degradation
Hot water sprayed
on floor
Leakaged from
returned line of
heat exchanger
Leakage arrested
Furnace & Pot Hot
Fumes
Due to high
temperature pf pot
from 460 deg cent
to 520 deg cent
Temperature controlled
after Heat exchanger
replacement

72
These are valid reasons to optimize zinc consumption
through grey coating obtained from why - why analysis
and validation process

73
TOOLS USED
PARETO DIAGRAM
SCATTER DIAGRAM

74
Smart Technique for Data Analysis

Date : 10-09-2020
Data collected person : vinay
Patel
Data verified person : A.Zalke
From this Frequency, Pareto Diagram was drawn
75
S.N Reasons of Grey coating Mar-21 Apr-21 May-21 June-21 July-21 Aug-21 No. of Occasions
1 Error in zinc coating
checking by Qc Team 1 1 2 1 2 1 08
2 Improper Nozzle gap
position setting
2 3 1 2 1 1 10
3 Improper Nozzle gap Lip
Setting
2 1 1 1 1 1 07
4 Input CR Rolling material
not proper 3 3 2 1 2 1 12
5 Coating gauge not showing
reading proper
3 2 1 1 1 1 09
6 Heat exchanger not working
properly 5 4 4 5 8 6 32
Data collection

Date : 10-09-2020
Data collected person : Vinay
Patel
Data verified person : A.Zalke
From this Frequency, Pareto Diagram was drawn
76
S.N Reasons of Grey coating
Mar-21 Apr-21 May-21 June-21 July-21 Aug-21 No. of Occasions
7 Heat Exchanger inlet cooling
water temperature high
1 3 2 3 4 3 16
8
RCS fan suction and delivery
bellows leakage problem 2 3 1 4 7 6 23
9
Heat Exchanger returned water
chocking problem
4 3 2 5 8 7 29
10
Soil degradation problem
2 2 1 1 2 1 9
11 Furnace and pot hot fumes 1 2 1 3 1 2 10
Data collection

77
19
37
51
61
68
74
80
85
91
96
100
0
10
20
30
40
50
60
70
80
90
100
0
20
40
60
80
100
120
140
160
Heat
exchanger
not working
properly
Heat
Exchanger
returned
water
chocking
problem
RCS fan
suction and
delivery
bellows
leakage
problem
Heat
Exchanger
inlet water
temperature
cooling
Input CR
Rolling
material not
proper
Improper
Nozzle gap
position
setting
Furnace and
pot hot
fumes
Coating
gauge not
showing
reading
proper
Soil
degradation
problem
Error in zinc
coating
checking by
Qc Team
Improper
Nozzle gap
Lip Setting
Cumm
Freq
Freq
Problems
Freq % of Cumm freq
VITAL FEW
USEFULL MANY

78
TECHNIQUES USED
BRAINSTORMING

79
Sl.
No
Suggested solution Suggested by No Trails
Accepted (or)
Rejected
Remarks
Error in zinc coating
checking by Qc Team Atul Deo
Coating
properly
checked by QC
person.
Improper Nozzle gap
position setting Akash Nikhade
Nozzle gap
position
properly set.
Improper Nozzle gap Lip
Setting
Vinay patel
Lip gap properly
set.
Input CR Rolling material
not proper
V. Yadav
Input CR coils
are proper.
Coating gauge not
showing reading proper
Akash Nikade
Coating is
proper.
1
2
3
4
5
0
0
0
0
0

80
Sl.
No
Suggested solution Suggested by No Trails
Accepted (or)
Rejected
Remarks
Heat exchanger not
working properly
Vinay Patel
It will be a one of
the reason.
Heat Exchanger inlet
cooling water temperature
high
V. Yadav Not Possible.
RCS fan suction and
delivery bellows leakage
problem
Atul Deo
It will be a one of
the reason
Heat Exchanger returned
water chocking problem Vinay Patel
It will be a one of
the reason
Soil degradation problem
Atul Deo Not possible
Furnace and pot hot fumes
Akash Nikhade
Not effected the
grey coating
1
0
6
1
1
0
0

81
Heat exchanger working make effective by
cleaning its chocked inside tubes for effective
Heat transfer
RCS fan suction and delivery bellows leakage
arrested by changing its gaskets and to provide
new bellows.
Heat Exchanger returned water line to main
header pipe line modification.

82
Root Cause Action Plan
Responsibi
lity
Target Date Results
Grey
coating on
G.P. sheet
 Heat exchanger working make
effective by cleaning its
chocked inside tubes for
effective Heat transfer
 RCS fan suction and delivery
bellows leakage arrested by
changing its Bellow with Gasket
 Heat Exchanger returned water
line to main header pipe line
modification.
Vinay patel
Atul Deo
B Yadav
20th June’20
15th July’20
25th June’20
Completed
Completed
Completed
Trial implementation is follows

Working on first probable solution
83
Heat exchanger working make effective by cleaning its chocked inside tubes
for effective Heat transfer
jet Cooling section system of furnace with Heat exchanger arrangement
JCS Heat Exchanger arrangement
 Sheet passes from entry section to Non ox furnace after
that it goes to RTF section and then finally entered to
JCS section
 After JCS section it goes to Zinc pot where zinc coating
applied
 Sheet temperature for average gauge 0.80x1220 mm in
nonox furnace about 1150 deg cent and in RTF section is
750 deg cent and 550 deg cent in JCS section
 After that sheet passes to pot where need to maintained
pot temperature 460-470 deg cent for proper zinc coating
on sheet surface
 Pot temperature play important roll for Zinc coating on
surface if temperature rises from 460 deg cent to 520 deg
cent then grey coating generated on sheet surface by
which material diverted
 For controlling pot temperature need to JCS section must
be working effectively means its heat exchanger must
work effectively along with its JCS fan.

84
Existing Drawing of JCS Heat Exchanger arrangement

85
Showing Existing Heat Exchanger after dismantling
 Jet Cooling Section removed Heat Exchanger
opened
 After opening found heavy scale deposited on
cover and tubes are chocked
 Tubes are chocked with hard layer of waste
material
 Tubes are of copper material with 5/8 inch and
120 no of tubes and Alluminium fins from
outside.
 Due to above chocking no water circulation and
heat transfer taking place.
 Even full speed of RCS fan no any temperature
drop of sheet so pot temperature rises.
Heat Exchanger inside tubes chocked

86
After that our team has decided to make in-house arrangement
for its cleaning
1. For in-house arrangement we have arranged one pump
with motor
2. We have done fabrication of piping
3. We have arranged chemical from our pickling plant for
tubes cleaning
4. We have take the help of electrical department for motor
connection and startup
5. We have keep the pump in start condition for forward and
reverse direction for tubes cleaning for at least two hrs
6. After that we have done tubes cleaning with high pressure
jet nozzle.
7. After that pressure testing done for any leakage of tubes at
6 kg/cm2
8. After pressure testing successful we have now ready for
changing existing heat exchanger with cleaned one
Heat Exchanger cleaning arrangement and its process
Working on First probable solution
Arrangement of Cleaning and Testing for
Heat Exchanger

87
Pump & Motor arrangement for
cleaning work
JCS Heat Exchanger cleaning with high
pressure nozzle

88
 As chocked JCS Heat exchanger outside
fins are cleaned
 As JCS Heat Exchanger inside chocked
tubes are cleaned
 JCS all pipe line connected with its flange
gaskets
 JCS Heat Exchanger Pressure Testing
arrangement done Hence, we decided to
take its pressure testing at 6kg/cm2 for
tube leakage and plan to put in JCS section
for performance checking
Conclusion
Jet cooling Heat Exchanger after cleaning process

89
 In RCS Section 5 nos RCS Fan provided with 10 nos bellows
 In RCS section Bellows are provided in Suction and Delivery ducting line of RCS Fan
 RCS Fan connected with these Suction and Delivery Bellows for smooth suction and Delivery process
 RCS fan must be running with 100 % efficiency for achieving JCS section Temperature of 550 deg Cent
 During Running of RCS Fan no any leakages must be accepted as it create black spot due to oxidation
on sheet surface after zinc coating in zinc pot.
 Bellows or any other leakages in JCS section must be checked by hyd leak detector instrument.
Existing arrangement of Bellows in RCS section
RCS fan suction and delivery bellow leakage arrested by changing its bellow with gaskets
Working on second probable solution

90
Existing arrangement of JCS fan with Expansion Bellows in suction and delivery Line
In Existing arrangement of JCS Section :-
 In JCS section, Jet Cooling Fan with Motor ,Ducting with bellows in Suction and Delivery Line, Pneumatic
Actuators in suction and delivery line and inlet and out let water piping arrangement to Heat Exchanger
installed.
 During running of line JC Fan running with its 100 % capacity of 2200 RPM for controlling the sheet
temperature to 550 deg cent
 Due to leakage in JC fan ducting or expansion bellows not possible to run the JC fan with its full capacity also
sheet temperature not controlled to 550 Deg cent which impact the Zinc Pot temperature rise.

91
RCS fan Suction expansion bellow cracked /leakage RCS fan Suction expansion bellow Ok Condition
RCS fan Suction expansion bellow found cracked due to that
not possible to increase the JC Fan speed as black spot coming
on sheet surface and JCS section temperature also not
controlled to 550 deg cent.
After RCS Fan Ok Bellow
RCS fan Suction expansion bellow new one fixed
on its suction ducting place and found after
running RC fan no any leakage and sheet surface
also ok at 100 % capacity and temperature also
controlled to 550 deg cent..
Before RCS Fan Bellow

92
Working on Third probable solution
Before RCS fan Heat Exchanger Return Line
connected to Header
Return Line to Header
 RCS fan heat exchanger returned line connected to main
header and main header to Hot Well tank
 Main Header having size of 10 inch and heat exchanger
return line 5 inch connected to main header
 Return 5 inch line connected point hole to main header
only 2 inch so return not effectively to main header which
also impact for controlling RCS section temperature
 RCS fan heat exchanger returned line connected to main
header and main header to Hot Well tank Modified for
each RCS fan heat exchanger, separate 5 Inch Line
provided for each RCS Heat Exchanger for free flow of
water without any restriction.
 Now return effectively to main Hot well tank which also
help for controlling RCS section temperature
After RCS fan Heat Exchanger Return Line
Connected separately to Hot Well Tank
Direct Return Line to Hot Well Tank

93
Foreseeing Probable Resistance
“If you can't describe what you are doing as a process, you don't know what you're doing”
- W. Edwards Deming
TECHNIQUES USED
BRAINSTORMING
FORCE FIELD ANALYSIS

94
S.No.
1
Difficulty in JCS section Heat
exchanger cleaning work
Mechanical
In house JCS Heat Exchanger
Cleaning done
2
Difficulty for checking pressure
heat exchanger leakage
Mechanical Heat Exchanger cleaning done
3
Difficulty for removing and fixing
Jet Cooling Heat exchanger and
expansion bellow on position due
to temperature
Mechanical Expansion Bellow changed by
new
4
Difficulty for modification of heat
exchanger return line to main
header due to space constraint
Mechanical
Return line modification done
Interacted
Dept
Resistance Overcome
 The following resistances were forecasted and they were overcame by the
appropriate solutions as described below.

Helping forces & Score Hindering forces & Score
1
0
9 8 7 6 5 4 3 2 1 1 2 3 4 5 6 7 8 9
1
0
Total score - 72 Total score - 52
Grey Coating Reduced
Zinc loss reduced
Production increased
Customer satisfied
Employees satisfied
Low implementation cost
Industry best practice
9
10
10
8
9
9
7
Accept level 10
Heat Exchanger P.M. in running line.
Need for training
Method understanding
SOP change
Skill necessary
Disrupt work flow
Accept level
9
8
7
5
6
6
4
Implementation time
7
 While implementing the solutions we may come across the resistances, so to
know those resistances and their magnitude we used Force Field Analysis
technique.
 Whereas Force Field analysis also explored the helping forces to trial implement our solutions. 95

96
TOOLS USED
DATA COLLECTION
PDCA
GRAPH

97
PDCA : Trial Plan 1
PLAN: We plan to replaced JCS section water Heat exchanger with
cleaned one at RCS fan no -5 position in SSD
DO: In SSD we replace the cleaned one JCS Heat exchanger at
JCS fan no -5 position with all water inlet and out let pipe line and
valve arrangement
CHECK : We check the JCS furnace after inserting Heat
exchanger at JCS fan no -5 position for effectively working and
reduction of temperature for JCS and pot section.
Check sheet for PDCA-1 JCS Heat exchanger performance
1st set JCS fan-5 Heat Exchanger
Heat
exchanger
inserting in
RCS section
at fan -5
position
Planned
Water
Inlet
pressure
Actual water
outlet
pressure
Planned
RCS
section
strip temp
Deg cent
Actual
RCS
section
strip
temperatur
e
Deg cent
Planned
Pot zinc
bath
temperatur
e Deg cent
Actual Pot
zinc bath
temperatur
e
Deg cent
A shift 5.0 bar 4.8 bar 550 505 460 465
B shift 5.0 bar 4.9 bar 550 503 460 462
C shift 5.0 bar 5.0 bar 550 500 460 461
JCS Heat Exchanger arrangement

PDCA : Trial Plan 1
98
ACT: PDCA methodology applied to minimise the JCS and POT section temperature has
been reduced successful. Below is the summary sheet.
SI. NO Actions planned Effect Observation Remarks
1
Heat exchanger Cleaning on
regular basis
Heat Exchanger fins and inside tubes
chocked and temperature of JCS and pot
section rise
Cleaning of Heat exchanager
before replacement Completed
2 Testing of heat exchanger leakage
Testing on regular basis to avoid any
leakage after inserting in JCS furnace
On regular interval pressure
testing done
Completed
3
Pressure checking on regular basis To make sure that system is running
smoothly without Internal leakage
Checklist on daily basis To be continued
4
Periodic checking of water
inlet and outlet
temperature
Ensures gasket and fasteners
tightened and base is seated
properly
Periodic monitoring carried
out
To be continued

PDCACYCLE
99
PDCA : Trial Plan 2
PLAN: We plan to insert JCS section suction bellow in place of
leakaged bellow at RCS fan no -5 position in SSD
DO: In SSD we inserted the new bellow at JCS fan no -5 position with
all fasteners, gasket and O ring cord silicon make material
CHECK : We check the JCS furnace after inserting Expansion Bellow
at JCS fan no -5 position for effectively working with maximum
running speed of fan ,reduction of temperature for JCS and pot section
and sheet surface without any black pin point.
Check sheet for PDCA-2 JCS Expansion Bellow performance
1st set JCS fan-5 Expansion Bellow in suction duct
Expansion
Bellow
inserting in
RCS section
at fan -5
position
Planned
RCS fan
no 5
speed
Actual RCS
fan no 5
Speed
Planned
RCS
section
strip temp
Deg cent
Actual RCS
section
strip
temperatur
e
Deg cent
Planned
Pot zinc
bath
temperatur
e Deg cent
Actual Pot
zinc bath
temperatur
e
Deg cent
A shift 2100rpm 2100 rpm 550 505 460 465
B shift
2100rpm 2100 rpm
550 503 460 462

PDCA : Trial Plan 2
100
ACT: PDCA methodology applied to minimise the JCS section bellow leakage has been reduced
successful. Below is the summary sheet.
1
Expansion bellow gasket and
fasteners checking on regular
basis
Expansion bellow suction side of fan no
-5 leakaged due to that fan speed not
increasing as sheet surface coming with
black spot/pin hole marks
Checking and replacing
expansion below in ssd Completed
2 Testing of Expansion bellow
leakage
testing done
Completed
3
smoothly without any leakage
4
Periodic checking of air inlet
and outlet leakages
Ensures bellow gasket is seated
properly
out
To be continued

PDCACYCLE
101
PDCA : Trial Plan 3
PLAN: We plan to modify JCS section heat exchanger returned water line to separate return line to hot well tank for each
JCS heat exchanger at RCS fan no -5 position in SSD
DO: In SSD we modified the heat exchanger returned line to separate return line to hot well tank from 2.5 inch size to 5
inch size for water free flow at JCS fan no -5 position
CHECK : We check the JCS furnace after placing modified heat exchanger returned line to main header at JCS fan no -5
position for effectively working with maximum running speed of fan and water inlet pressure of 5 kg/cm2 and found
reduction of temperature for JCS and pot section and temperature drop in outlet water
Check sheet for PDCA-3 JCS heat exchanger returned line performance
JCS fan-5 Heat exchanger return line water to main header Line
Heat
exchanger
return line
modification in
RCS section
at fan -5
position
Before
return line
pipe size
After
modification
return line size
Planned
RCS section
inlet water
temp
Deg cent
Actual RCS
section
outlet water
temperature
Deg cent
Planned Pot
zinc bath
temperature
Deg cent
Actual Pot
zinc bath
temperature
Deg cent
A shift
2.5 inch
5.0 inch 31 38 460 465
B shift
2.5 inch
5.0 inch
32 40 460 462
Separate Return line to
Hot well tank
After RCS fan Heat Exchanger
Return Line separate
Connected to Hot Well tank rom 2.5 to
5.0 inch

PDCA : Trial Plan 3
102
JCS Heat Exchanger No -5 Returned separate water Line ,water coming after
providing cleaned heat exchanger
PDCA CYCLE

PDCA : Trial Plan 3
103
ACT: PDCA methodology applied to modify the JCS section heat exchanger return line to main
header line flow has been increased successful. Below is the summary sheet.
1
Heat exchanger returned line
modified from 2.5 to 5.0 inch
and flow checking on regular
basis
Heat exchanger returned line flow not
properly drain to main header pipe so
heat exchanger heat transfer not taking
place and RCs section and Pot Zinc bath
temperature rising
Checking and modifying
returned line in ssd Completed
2 Testing of Return line leakages
leakage
testing done
Completed
3
smoothly with required pressure
4
Periodic checking of water
inlet and out let from heat
exchanger and leakages
Ensures bellow gasket is seated
properly
out
To be continued

Standard Chart for pipe selection
104
RCS fan Heat Exchanger Return Line
Modification fabrication work

Trial performance checklist
Material diversion reduced due to minimising of Grey Coating
on GP Sheet
105
Shift-A Shift-B Shift-C
COIL NO QUALITY
GRADE
COIL NO QUALITY
GRADE
COIL NO QUALITY GRADE
KG1A9H0001 P1 KG1A9H0011 P1 KG1A9H0021 P1
KG1A9H0004 P1 KG1A9H0014 S1 KG1A9H0024 P1
KG1A9H0007 P1 KG1A9H0017 P1 KG1A9H0027 S2
DATE :-08.06.2020

106
TOOLS USED
DATA COLLECTION
GRAPH

108
40
35 35 34 33 32
30
28
25
23
25 26 27
18 19
16
13
17
4 4
0
5
10
15
20
25
30
35
40
45
Sep-20 Jan-21 Apr-21 Jul-21 Oct-21 Feb-22 May-22 Aug-22 Dec-22
Zinc
Loss
(Mt)
Month
Zinc Loss(Mt)

After QC
 Achieved Average Grey
coating defects is 35 Mt/
Month
 Achieved Avg. Zinc loss is
24 Mt/ Month
109

110
• By the reduction in Grey coating on GP sheet ,
We save zinc .
BETTER EFFICIENCY AND BETTER WORKING ENVIRONMENT THROUGH
“SELF RELIANT THINKING”

111
TECHNIQUES USED
EQUIPMENT FAILURE MODE &
EFFECT ANALYSIS (EFMEA)
MILE STONE CHART
HORIZONTAL DEPLOYMENT
TOOLS USED
DATA COLLECTION
GRAPH (TREND CHART)
CHECK SHEET (CHECK LIST
TYPE)

QC Name: SPARK Dept: CGL-2
Member's Name:
Mr. V Yadav
Mr. V, Patel
Mr. A. Nikade
Project No. 04 Project Leader : Mr.Atul Deo
Theme::”To reduce Grey coating on
GP sheet Date of Beginning : 01/01/2020 Date of Complection : 20/08/2021
Meeting Day: Thursday
No. Activity Week 2 4 6 8 10 12 14 16 18 20 22 24 26 REMARKS
1 Defining Problem STARTED
2 Analyzing the problem 01/01/2020
3 Identifiying the causes
4 Finding out the root causes
5 Data analysis
6 Developing solutions
7 Foreseeing possible resistance
8 Trial implementation and checking
performance
9 Regular implementation
10 Follow-Up / Review
20/08/2021
Planned Actual
112

113
Potential Failure
Mode
Potential
Effects of
failure
Severity
Potential
Causes/mechanism
s of failure
Occurrenc
e
Current
Detection
Detec
tabilit
y
RPN
Heat Exchanger
Not working
properly
Grey coating on
GP sheet
Zinc Loss 5
Heat exchanger
tube chocked
32
Temp
Increase
3 160
RCS section leakage 23 Visual 4 115
Delivery bellow
leakage
23 Visual 4 115
Heat Exchanger return
water chocked
21 Visual 3 105
RPN NUMBER WAS HIGH

114
Potential
Failure Mode
Potential Effects
of failure
Severity
Potential Causes/mechanisms
of failure
Occurrence
Current
Detection
Detect
ability
RPN
Heat
Exchange
r Not
working
properly
Grey coating
on GP sheet
Zinc Loss 5
Heat exchanger tube chocked 20
Temp
Increase
3 100
RCS section leakage 8 Visual 4 40
Delivery bellow leakage 7 Visual 4 35
Heat Exchanger return water
chocked
5 Visual 3 25
RPN NUMBER IS LESS

 To sustain the effects and results of the implementation done, the need is to sustain it. For that
reason we make SOP & Check sheet for every shift
115

 To sustain the effects and results of the implementation done, the need is to sustain it. For that
reason we make SOP & Check sheet for every shift
116

Bypass pressure regulating valve installation at main
propane line
Water carryover wipping after skinpass mill
Water leakage arresting from quenching tank
main roll flange.
Sink roll life Enhancement
120

QC_SPARK.pptx

Recomendados

Recomendados

Más contenido relacionado

La actualidad más candente

La actualidad más candente (20)

Similar a QC_SPARK.pptx

Similar a QC_SPARK.pptx (20)

Más de MAHESH WERULKAR

Más de MAHESH WERULKAR (20)

Último

Último (20)

QC_SPARK.pptx