virender dhawan, dgm i/c (o) ccs, bsp rajeev sehgal, dgm i/c (o) cs, bsp

IMPROVING PLATE YIELD BY REDUCTION

OF STEEL DEFECTS

VIRENDER DHAWAN, DGM I/C (O) CCS, BSPRAJEEV 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

2010-11 2011-12 2012-13 (Till Nov)0

0.5

1

1.5

2

2.5

3

2.23 2.16

2.76

%

YEAR 2010-11 2011-12 2012-13STEEL 2.23 2.16 2.76

DEFECTS 2.67 2.57 3.1

ANALYSIS OF STEEL DEFECT APRIL-NOV 2012

NMI LCRK SPCRK NDT PORO SLSD0

10

20

30

40

50

60

70

2.83 3.01 5.88

65.53

1.27 1.46

%

NCO

DEFECT WISE STEEL DEFECT

NMI LCRK SPCRK NDT PORO SLSD0

10

20

30

40

50

60

3.836.96

16.45

55.47

3.47 0.670000000000002

%

DEFECTIVE

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 MAINTENANCETimely 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

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

ACTION PLAN

RESULTS OF IMPROVEMENT INITIATIVESM/C # 6 Performance

BEFORE AFTER0

0.51

1.52

2.53

3.54

3.8

0.28

%

Insp NDT Period % Heat NumberFrom To

16599 635 Before 3.8 149917 15068513832 39 After 0.28 150686 Till 24th

RESULTS OF IMPROVEMENT INITIATIVESM/C # 3 Performance

BEFORE AFTER0

0.51

1.52

2.53

3.53.3

0.8

%

Insp NDT Period % Heat NumberFrom To

12851 428 Before 3.3 149917 1506857649 63 After 0.8 150686 Till 24th

COST OF POOR QUALITY - FOR PLATES

Oct/12 Nov/12 Dec/12 Jan/13 Feb/13 Mar/130

0.2

0.4

0.6

0.8

1

1.2

1.41.33

0.91

0.37 0.34 0.27

0.380000000000001

Opp

. Los

s/Sa

les

%

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) 352.52 304.46 327.39 333.67 313.99 333.06

Opp Loss/Sales (%) 1.33 0.91 0.37 0.34 0.27 0.38

YEAR WISE ANALYSIS OF STEEL DEFECT

2010-11 2011-12 2012-13 2013-14 2014-15 (Till date)

0

0.5

1

1.5

2

2.5 2.23 2.16 2.11

1.010.88

%

BENEFITS

Timely servicing of orders

Increase in customer

confidence Capability to service S2E3 (NDT) plate

orders developed

REDUCED COST

OCT '2012 OCT '20130

0.5

1

1.5

2

2.5

3

3.5

4

4.5

54.67

0.51

COPQ

in C

r.

CUSTOMER FEED BACK

TATA HITACHISubject: 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 JAMSHEDPURSent: 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

HIGHLIGHTS OF 2014-15

Lowest ever steel defects of 0.48 % in May ‘2014

Overall steel defect till Jan 0.88 %

Thanks

From: Manzar Alam [[email protected]]Sent: 26 February 2013 16:17To: 'KL Balasubramanian'Cc: [email protected]; [email protected]; bmbokSubject: 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 AlamSr.Manager (Materials)RSB Transmission (I) LTD.Unit-IIJamshedpur (INDIA)

Email :- [email protected]

M- 09334628226

mailto:[email protected]

DEFECTS NMI L CRK SCRK NDT% 0.11 0.19 0.45 1.53

Ton 849 1468 3476 11819

ANALYSIS OF STEEL DEFECTS FROM APRIL 2012 TO NOV 2012

0.110.19

0.45

1.53

0.00

0.20

0.40

0.60

0.80

1.00

1.20

1.40

1.60

1.80

NMI L CRK SCRK NDT

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.

Quality improvement initiatives

2011-12 APR MAY JUN JUL AUG SEP OCT NOV0.53 0.87 1.07 1.46 0.92 2.42 1.15 2.24 2.15

MONTHWISE ANALYSIS OF NDT (%) - LIGHT MEDIUM & HEAVY PLATES

0.53

0.871.07

1.46

0.92

2.42

1.15

2.24 2.15

0

0.5

1

1.5

2

2.5

3

2011-12 APR MAY JUN JUL AUG SEP OCT NOV


MONTHWISE ANALYSIS OF SCRK (%) - LIGHT MEDIUM & HEAVY PLATES

0.46

1.10

0.610.54

0.200.28

0.36

0.210.29

0

0.2

0.4

0.6

0.8

1

1.2



MONTHWISE ANALYSIS OF LCRK (%) - LIGHT MEDIUM & HEAVY PLATES

0.15

0.190.17

0.22

0.190.17

0.26 0.26

0.05

0

0.05

0.1

0.15

0.2

0.25

0.3



MONTHWISE ANALYSIS OF NMI (%) - LIGHT MEDIUM & HEAVY PLATES

0.140.15

0.11 0.110.10

0.09

0.14

0.06

0.08

0

0.02

0.04

0.06

0.08

0.1

0.12

0.14

0.16


From: Manzar Alam [[email protected]]Sent: 26 February 2013 17:02To: 'KL Balasubramanian'Cc: [email protected]; bmbok; [email protected]: Tracking of Heat No. After 150686Attachments: 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 AlamSr.Manager (Materials)RSB Transmission (I) LTD.Unit-IIJamshedpur (INDIA)

Email :- [email protected]

M- 09334628226

mailto:[email protected]

From: Ajay Kumar [[email protected]]Sent: 03 April 2013 14:02To: KL BalasubramanianCc: Prabhat; Manoj Barik; Malay PalitSubject: 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. RegardsAjay KumarDivisional Manager (Supply Chain Management)TATA Hitachi Construction Machinery Co. Ltd.

Tata Motors premises, TelcoJamshedpur - 831010INDIA

From: Shankar V - Axles India [[email protected]]Sent: 28 January 2013 20:34To: [email protected]: [email protected]; Madhusudhan.Surathi; [email protected]; [email protected]; [email protected]: FW: sail plate feedbackAttachments: 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]: Vijaya Vittala MSubject: 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.

virender dhawan, dgm i/c (o) ccs, bsp rajeev sehgal, dgm i/c (o) cs, bsp

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