Reduction of Coke Rate from 428 kg/thm to 408 kg/thm at ‘I ...Blast Furnace 1 2 Reduction of Coke...
Transcript of Reduction of Coke Rate from 428 kg/thm to 408 kg/thm at ‘I ...Blast Furnace 1 2 Reduction of Coke...
-
1
Reduction of Coke Rate
from 428 kg/thm to 408
kg/thm at ‘I’ Blast Furnace
1
Vineet R TripathiHead Operation ‘I’ Blast Furnace
S. SubhachandharManager Operations & Support ‘I’ Blast Furnace
Tata Steel … values stronger than steel
2© Copyright 2017 Tata Steel. All Rights Reserved
1
5
500
81K28
110
First Integrated Steel Plant
in Asia
Over 28 Million tonnes of Steel
Produced p.a
Providing customized solutions across 5
continents
One of the few steel industries to
feature in FORTUNE500
Conglomerate with over 81,000
employee
110 Years of Successful operation
-
2
‘I’ Blast Furnace… Journey of Excellence : 2012 - 2017
3© Copyright 2017 Tata Steel. All Rights Reserved
2013 2014 2015 2016 2017Breaking the
Deadlock
• First breakthrough
in Operational
Efficiency – Tata
Steel benchmark
• Reduction of CO2
Emission to Indian
Benchmark
• Shram Bhushan
Award recipient
from Hon. President
of India
Outperforming
Ourselves
• Highest Ever Production
• Lowest Ever Coke Rate and
Highest Coal Injection –
Indian Benchmark
• Lowest Ever Utilities &
Consumable consumption
• Achieved Status of Power
Neutrality – We Consume
what we produce
Going Green
& Up skilling
Manpower
• Zero Effluent
Discharge for the first
time
• Highest Power
Generation
• 100% Involvement of
I BF manpower in
Improvement
Frameworks – TPM &
SGA
Pursuit of
Excellence in
Safety
• Centre for
Excellence in
Process Safety
• 1000 days of LTI
Free Operations
• Exemplar in Road
Safety Performance
in Tata Steel
World Class
Commissioning
• Benchmark Ramp
to the Rated
Capacity
• Leanest Man-
Power Blast
Furnace in Tata
Steel India &
EuropeCo
mm
issi
on
ing
of
I BF
–4
thA
pri
l 20
12
INDEX
4© Copyright 2017 Tata Steel. All Rights Reserved
Project and Team Selection 1 Slides – < 5 - 17 >
Current Situation and Improvement Opportunity Analysis 2
Solution / Improvement Development 3
Implementation and Results Verification 4
Sustaining Results Over Time 5
Beyond Results : Awards & Accolades 6
6’
7’
5’
6’
3’
3’
Slides - < 18 – 31>
Slides - < 32 – 48 >
Slides - < 49 – 59 >
Slides - < 60 – 63 >
Slides - < 64 – 66 >
-
3
Project and Team Selection1
5© Copyright 2017 Tata Steel. All Rights Reserved
Understanding the Context of the Project Selection
Project & Team Selection
Current Situation and Improvement
Opportunity Analysis
Improvement Development
Implementation & Result Verification
Sustaining & Communicating
Results
1.1.0
1
2
3
4
5
1.1.1.1 – Who was responsible for the selecting the project ?1.1.1.2 – What background information on the company or those who selected the project was provided to better understand the context of the project ?
6© Copyright 2017 Tata Steel. All Rights Reserved
Elaborate Project Selection Framework following ‘Top – Down’ ApproachTeam Responsible for
Selection of the project
Background Information for the selection of the project
1
2
-
4
The current position of I BF also states that there is scope of improvement
Project & Team Selection
Current Situation and Improvement
Opportunity Analysis
Improvement Development
Implementation & Result Verification
Sustaining & Communicating
Results
Project Selection Process1.2.0
1
2
3
4
5
1.2.1.1 – How was the gap or opportunity brought to the attention of the project identification group ?1.2.1.2 – What was the opportunity (process improvement) ?
7© Copyright 2017 Tata Steel. All Rights Reserved
Company Level Strategy
(Tata Steel)
Increasing the savings by INR
2000 Cr
Divisional Level Strategy
(Iron Making)
Reduce the Cost of Divisions
product
Departmental Level Strategy (Blast Furnace)
Reduction of Hot Metal Cost
Cost Break Up of Finished Steel60 % of Cost of Hot metal is
incurred through Coke & Coal consumption in Blast Furnace
70%
30%
Bringing the Opportunity to the Attention of Project Identification Group1 Opportunity
Scope
Project & Team Selection
Current Situation and Improvement
Opportunity Analysis
Improvement Development
Implementation & Result Verification
Sustaining & Communicating
Results
Project Selection Process1.2.0
1
2
3
4
5
1.2.1.3 – What area of the organization had the gap or opportunity ?
8© Copyright 2017 Tata Steel. All Rights Reserved
Opportunity
42% of the cost of Finished steel comes from the coke and
coal consumed in Blast Furnace – OPPORTUNITY TO REDUCE THE COKE CONSUMPTION & IMPACT
THE BOTTOMLINE
What ?
Area of Opportunity Identified
‘Blast Furnace’
Where ?2 3
60 % of Cost of Hot metal is incurred through Coke & Coal consumption in Blast Furnace ‘I’ Blast Furnace
-
5
To align the project to the strategic priority
To understand the current situation and scope for improvement
To identify the various cost affecting parameters
Project Selection Process
Project & Team Selection
Current Situation and Improvement
Opportunity Analysis
Improvement Development
Implementation & Result Verification
Sustaining & Communicating
Results
1.2.0
1
2
3
4
5
1.2.2.1 – What data was generated to help select the project ?1.2.2.2 – What methods and tools were used to assess or prioritize the need for the project ?1.2.2.3 – Why were these methods and tools used to select the project ?
9© Copyright 2017 Tata Steel. All Rights Reserved
Dat
a G
ener
ated Input from BO&S
Operational Data
From Business Analysis Group
List of projects shortlisted
Prioritization Method used‘Project Prioritization Matrix’
S.No Project Legend Ease of Implementation Business Impact Strategic Priority
1Elimination of Nut Coke Discharge from I
BF Stock HouseA 1.2 3.8 6.5
2 Reduction in cold blast humidity B 1.6 3.5 5.9
3 Increase Gas Utilisation by 2% C 2.8 3.1 4.5
4 Reducing Carbon Rate D 2.9 4 6
5 Reduction of Coke Rate E 2.1 5 10
6Increasing HM Si Compliance(0.6
-
6
Team Selection and Preparation
Project & Team Selection
Current Situation and Improvement
Opportunity Analysis
Improvement Development
Implementation & Result Verification
Sustaining & Communicating
Results
1.3.0
1
2
3
4
5
1.3.1.1 – How was the stakeholder groups identified ?1.3.1.2 – What or who were the stakeholder groups ?
11© Copyright 2017 Tata Steel. All Rights Reserved
1 All the Stakeholders were identified through the tool SIPOC
Raw Materials Management
Coke Plant
Sinter Plant
Pellet Plant
Fuel Management Division
Power House
Maintenance Team
Coke, Sinter, Pellet, Iron ore, Nut Coke, Fluxes, Cold
Blast, BF Gas, Humidity, Oxygen, Coal, Nitrogen
Blast Furnace Process
Hot Metal, Slag, BF Gas, Electric Power
Hot Metal Logistics
Steel Making Shop
Fuel Management Division
Slag Granulation and Drying Plant
Project Steering Committee
Project Mentor
Project Team Process Owner *Stakeholders2
Team Selection and Preparation
Project & Team Selection
Current Situation and Improvement
Opportunity Analysis
Improvement Development
Implementation & Result Verification
Sustaining & Communicating
Results
1.3.0
1
2
3
4
5
1.3.2.1 – What knowledge or skill sets were determined to be necessary for successful completion of the project ?1.3.2.2 – To what extent did the existing stakeholder groups have the required ?1.3.2.3 – What additional knowledge and skills were brought in to make the project successful ?
12© Copyright 2017 Tata Steel. All Rights Reserved
1
3
2 Stakeholder Knowledge assessment was made and accordingly training requirement was identifiedY – Already Trained, NA – Not Applicable, N – To be Trained
-
7
Team Selection and Preparation
Project & Team Selection
Current Situation and Improvement
Opportunity Analysis
Improvement Development
Implementation & Result Verification
Sustaining & Communicating
Results
1.3.0
1
2
3
4
5
1.3.3.1 – Before the project started, what specific training was done ?
13© Copyright 2017 Tata Steel. All Rights Reserved
1 Specific Training Imparted to specific Team Based on the Gaps identified
• Training were imparted based on the Gaps Identified, from the brainstorming sessions of the team. • Dedicated classroom sessions were organized with the help of Tata Management Development Centre & Total
Quality Management
Team Selection and Preparation
Project & Team Selection
Current Situation and Improvement
Opportunity Analysis
Improvement Development
Implementation & Result Verification
Sustaining & Communicating
Results
1.3.0
1
2
3
4
5
1.3.3.2 – Before the project started, what was done to prepare the team to work together as a team ?
14© Copyright 2017 Tata Steel. All Rights Reserved
2 Preparing the team, as a ‘Team’
Project Kick Off Meeting
Project Discussion with Team Lead
Workshop with the Project Members & Process Owners
Project Plan Formulation
Meeting of Project Steering
Committee to set business context and deliverables
Elaborating the project requirements to the Team
Leader and finalizing the Project Team Members
Workshop of Project Members & Process Owners with the Project Steering Committee where is context is set
and Team discussion of what each members can contribute and training needs were identified
The Team Brainstormed and planned the project ahead
To foster smooth functioning of the team thefollowing steps were taken• SharePoint – Common Repository was created
with access to all the stakeholders• A Group e-mail ID was created
-
8
Team Selection and Preparation
Project & Team Selection
Current Situation and Improvement
Opportunity Analysis
Improvement Development
Implementation & Result Verification
Sustaining & Communicating
Results
1.3.0
1
2
3
4
5
1.3.4.1 – What roles and expectations were determined ahead of the project ?
15© Copyright 2017 Tata Steel. All Rights Reserved
Role ProjectMentor
Project Leader
Team Member
Team Member
Team Member
TeamMember
Process Owners
Name Amit Singh Vineet R. Tripathi
Subhachandhar S
Basant Kr Singh
Sanjiv Kumar Samik Nag Ujjal Ghosh / RajkumarVishwakarma
Designation Chief, I BF Head Operation
Manager Operations
Process Analyst, I BF
Sr Mgr, BF Process Analysis, Technology Group
Head, BFResearch & Development
Sr Mgr & MgrOprns
Expectation Guide the Team for Successful completion of the project
Team the Lead,Collaborate with various stakeholders and Problem Solving Expert
Data Analysis, Quality Assurance and Customer Relations
Process Expert & Data Analysis
Data Analysis, Process Expert
Process Modeling and Blast Furnace Simulations
Owners of Process & Successful implementation
Roles & expectation from the Team Members1
Team Selection and Preparation
Project & Team Selection
Current Situation and Improvement
Opportunity Analysis
Improvement Development
Implementation & Result Verification
Sustaining & Communicating
Results
1.3.0
1
2
3
4
5
1.3.4.2 – What deadlines and deliverables did the team have to consider ahead of actually starting the project ?
16© Copyright 2017 Tata Steel. All Rights Reserved
2 Deadlines and Deliverables
Phase Deliverables Q1 Q2 Q3 Q4
DefineProject Selection , Project Charter Preparation, SIPOC
MeasureCause Effect Analysis, Root Cause Analysis, Data Collection Plan
AnalyzeIdentify and Validate the vital affecting kpis
ImproveGeneration of possible solution, prioritization and Validation through piloting
ControlProcess Control Analysis,Standardising the Procedure & Communication to the team
5th May 2015
20th Jun 2015
20th Oct 2015
31st Dec 2015
31st Mar 2016
-
9
Team Selection and Preparation
Project & Team Selection
Current Situation and Improvement
Opportunity Analysis
Improvement Development
Implementation & Result Verification
Sustaining & Communicating
Results
1.3.0
1
2
3
4
5
1.3.4.3 – Before the project started, what team routines, including communications, were established ?
17© Copyright 2017 Tata Steel. All Rights Reserved
3 Team Routines
S.No Meeting Frequency Chair Details
1 Group Internal Meeting Need Based - Lync Meetings(VC) & Discussion regd the progress of any analysis
2 Project Assessment by Team Lead
Weekly Team Leader Assessment of Progress
3 Meeting with the TeamMentor
Bi Weekly Team Mentor Assessment of Project Progress & Revisiting Charter
4 Meeting with Technology Group and R&D
Bi Weekly Team Leader Results Validation and Inputs for Analysis
5 Project Steering Committee Review
Monthly Project Steering Committee
Assessing Progress and revisiting targets and charter
6 VP Project Review Quarterly Vice President Review of Project
Current Situation & Improvement
Opportunity Analysis2
18© Copyright 2017 Tata Steel. All Rights Reserved
-
10
Key Measures Expected of the Project
Project & Team Selection
Current Situation and Improvement
Opportunity Analysis
Improvement Development
Implementation & Result Verification
Sustaining & Communicating
Results
2.1.0
1
2
3
4
5
2.1.1.1 – What specific goals and/or measures was the team trying to achieve with the project ?2.1.1.2 – What additional potential benefits, other than the specific goals and / or measures was the project expected to impact ?
19© Copyright 2017 Tata Steel. All Rights Reserved
Improvement Opportunity
Current Performance (kg/thm)
Target (kg/thm)
Coke Rate 428 408
Project Statement : Reduction of Coke Rate of ‘I’ Blast Furnace by 5%, thereby save INR 20 Cr in FY 16
1
Thereby the reduction of Cost of Hot Metal
Reduction of Coke Rate Reduction of Hot Metal Cost
Reduction of Carbon Footprint
Improvement in Productivity
2
*Additional Benefits
Project Benefit
Possible Root Causes / Improvement Opportunities
Project & Team Selection
Current Situation and Improvement
Opportunity Analysis
Improvement Development
Implementation & Result Verification
Sustaining & Communicating
Results
2.2.0
1
2
3
4
5
2.2.1.1 – What methods and / or tools used to identify possible root causes / improvement opportunities ?2.2.1.2 – Why were these methods and / or tools selected ?
20© Copyright 2017 Tata Steel. All Rights Reserved
Tools used to identify Improvement Opportunities
Tools Used
Process Mapping
Benchmarking
Brainstorming
Control Charts & Stability Charts
Ishikawa Diagram
Why
To understand the as-is process
To understand the scope for improvements and current gaps
To look for Opportunities for Improvement
To study the current capability and stability of the process
To map and group the various affecting parameters
1 2
-
11
Possible Root Causes / Improvement Opportunities
Project & Team Selection
Current Situation and Improvement
Opportunity Analysis
Improvement Development
Implementation & Result Verification
Sustaining & Communicating
Results
2.2.0
1
2
3
4
5
2.2.3.1 – How was the team prepared to use these methods and / or tools ?
21© Copyright 2017 Tata Steel. All Rights Reserved
3
3 hours of hands on training imparted on Creation of Process Maps
1 day training program on Benchmarking methodology
5 Hours training on Systematic Focused group discussion and brainstorming
3 day training program on Six Sigma Green Belt Program and use of Statistica
3 Hours hands on refresher training imparted on the 7 QC Tools and a 6 day six sigma training program was organised
Preparation of Team for using the Tools
Process Mapping
Benchmarking
Brainstorming
Control & Stability Charts
Ishikawa Diagram(Six Sigma Green Belt)Training Imparted to
1. Project leader2. Project Members &3. The Process Owner
The Effectiveness of training was verified byconducting Pre Course and Post Course Assessments
Possible Root Causes / Improvement Opportunities
Project & Team Selection
Current Situation and Improvement
Opportunity Analysis
Improvement Development
Implementation & Result Verification
Sustaining & Communicating
Results
2.2.0
1
2
3
4
5
2.2.2.1 – What data was generated and how was the data analyzed to identify the possible root cause / improvement opportunities ?
22© Copyright 2017 Tata Steel. All Rights Reserved
Tools used to identify Improvement Opportunities
Tools Used
Process Mapping
Benchmarking
Brainstorming
Control Charts & Stability Charts
Ishikawa Diagram
Data Generated
Process Inputs, Outputs, Sub Processes and Performance Indicators
In - Processes were also benchmarked along with the major KPIs
The various affecting parameters were jotted
The was found stable under 100 % availability
Various Affecting parameter were drilled down
How
Process Mapped through group discussion
KPIs Collected from various Blast Furnace and Studied
Dedicated Group discussion to answer what can improve the efficiency
Using Statistical Tool to predict
All the affecting Parameters that were operating in not optimized range were identified
1. What ?? 1. How ??
-
12
Possible Root Causes / Improvement Opportunities
Project & Team Selection
Current Situation and Improvement
Opportunity Analysis
Improvement Development
Implementation & Result Verification
Sustaining & Communicating
Results
2.2.0
1
2
3
4
5
2.2.2.2 – What were the possible root cause / improvement opportunities ?
23© Copyright 2017 Tata Steel. All Rights Reserved
Tools used to identify Improvement Opportunities
Tools Used
Process Mapping
Benchmarking
Brainstorming
Control Charts & Stability Charts
Ishikawa Diagram
Data Generated
Process Inputs, Outputs, Sub Processes and Performance Indicators
In - Process KPIs are also becnhmarkedalong with the major KPIs
The various affecting parameters were jotted
The was found stable under 100 % availabilty
Various Affecting parameter were drilled down
Raw Material• Sinter, Pellet, Coke – Chemical &
Physical Properties• Agglomerates• Moisture Input
In Process KPIs• Burden
Distribution• Slag
Composition• Blowing Rate• Oxygen
Enrichment• Coal Injection
Equipment KPIs• Availability• Interruptions
Human• Lack of
Knowledge Skill and Training
Final Root Cause / Improvement Opportunity
Project & Team Selection
Current Situation and Improvement
Opportunity Analysis
Improvement Development
Implementation & Result Verification
Sustaining & Communicating
Results
2.3.0
1
2
3
4
5
2.3.1.1 – What methods and / or tools were sued to identify the final root cause(s)/improvement opportunities ?2.3.1.2 – Why were these methods and / or tools selected ?
24© Copyright 2017 Tata Steel. All Rights Reserved
Tools used to identify Improvement Opportunities
Tools Used
Correlation Matrix
KPI Drill Down
Multiple Regression Analysis
Why
To figure out the most affecting parameter among the other KPIs
To drill down to final few important
To identify the most affecting parameter and impact of the every variable on the big Y
1 2
-
13
Final Root Cause / Improvement Opportunity
Project & Team Selection
Current Situation and Improvement
Opportunity Analysis
Improvement Development
Implementation & Result Verification
Sustaining & Communicating
Results
2.3.0
1
2
3
4
5
2.3.1.3 – How was the team prepared to use these tools ?
25© Copyright 2017 Tata Steel. All Rights Reserved
3
3 day training program on Six Sigma Methodology including Correlation Matrix
3 hours of hands on training imparted on building and conducting KPI Drill Down Analysis
6 days training program on Six Sigma Methodology including Multiple Regression Analysis
Preparation of Team for using the Tools
Correlation Matrix
KPI Drill Down
Multiple Regression Analysis(Six Sigma Green Belt)
Training Imparted to 1. Project leader2. Project Members &3. The Process Owner
The Effectiveness of training was verified byconducting Pre Course and Post Course Assessments
Correlations (Spreadsheet22 19v*297c)COKE_RATE
PRODUCTION
COAL_RATE
HMT
BGV
COLD_BLAST_FLOW_RATE
O2_FLOW
K
RAFT
ETA_CO
Total Agglomerates in Burden, Burden Distrbution, Slag Composition, Blowing Rate, Oxygen Enrichment, Coal Injection
Final Root Cause / Improvement Opportunity
Project & Team Selection
Current Situation and RC /
Opportunity Analysis
Improvement Development
Implementation & Result Verification
Sustaining & Communicating
Results
2.3.0
1
2
3
4
5
2.3.2.1 – What data was generated and how was the data analyzed to identify the final possible root cause / improvement opportunities ?2.3.2.2 – What are specified examples of data analysis that led to the final root cause ?2.3.2.3 – What were the final root cause/improvement opportunity ?
26© Copyright 2017 Tata Steel. All Rights Reserved
Tools used to identify Improvement Opportunities
Tools Used
Correlation Matrix
KPI Drill Down Analysis
Multiple Regression Analysis
Data Generated
The set of Variables with P
-
14
Final Root Cause / Improvement Opportunity
Project & Team Selection
Current Situation and RC /
Opportunity Analysis
Improvement Development
Implementation & Result Verification
Sustaining & Communicating
Results
2.3.0
1
2
3
4
5
2.3.3.1 – How was (were) the final root cause(s) / improvement opportunities validated ?2.3.3.2 – What evidence showed that the final root cause(s)/improvement opportunity(ies) were validated prior to solution development ?
27© Copyright 2017 Tata Steel. All Rights Reserved
ValidationCategory
Expert Validation – BF PIT Meeting
Modeling Software
Procedure Followed Advice from Experts Mr Ashok Kumar, CTOMr Tijuis Gerard, Tata Steel IjmuidenMr Uttam Singh, CoBF
Validation done through Static Dynamic Thermodynamic model
Evidence
1
2
Validation Impact of burden
Distribution and blowing rate
Current regime
Optimized regime
MOM of Blast Furnaces PIT Meeting
Meeting No. PIT/BF/07/16 Date: 09/10/2015 Time: 03.30 PM (India); 12.00 (NL); 11.00 (UK)
Chaired by Mr. Uttam Singh
Attendees :
Jamshedpur IJmuiden Port Talbot Scunthorpe
Uttam Singh Johannes de Lange Andrew McGregor No attendance
Sanjiv Kumar Mark van den Berg
AS Reddy Gerard Tijhuis (CoE)
Krishnendu Jan van der Stel (R&D)
Goutam Kr Raut
Vineet Tripathi
Sl. No
Item Discussed
Timeline / Action plan
Responsibility Status (Open /Closed/ Carry Forward)
Comment
A Share information on through life in Port Talbot Port Talbot (McGregor)
Open
B Share report on depressurising hose failure in IJmuiden coal preparation plant
IJmuiden (de Lange)
Open EBFC presen- tation on sharepoint
C Typical report on hearth temperature behaviour as presented in morning meeting
IJmuiden (de Lange)
Open PDF on sharepoint
D I BF Project on Coke Rate- Key Factors that affect Coke Rate
I BF, Jamshedpur
Closed Panel reached a conclusion
Pending points from previous meetings
3 Information on sealing material used to arrest tuyere leakage. Material, equipment, procedure, etc. Work in progress.
IJmuiden (Nugteren)
CF Separate lync to be set up in week 42
8 Information sharing on type of eyes and face protection safety gears at cast house
All Sites CF
Jsr & SCP info on share-point. Other sites to do.
MoM of BF Pit with the Point discussed about I BF
Coke Rate Project
Project Management Update
Project & Team Selection
Current Situation and Improvement
Opportunity Analysis
Improvement Development
Implementation & Result Verification
Sustaining & Communicating
Results
2.4.0
1
2
3
4
5
2.4.1.1 – How was the correctness of the initial project scope, deliverables, and timing confirmed (or what changes were made)?
28© Copyright 2017 Tata Steel. All Rights Reserved
Review of Progress with respect to the Project Charter1
Phase end review with the Project Steering Committee• Progress as per Charter• No Change of Scope Identified Plan
Actual
-
15
Project Management Update
Project & Team Selection
Current Situation and Improvement
Opportunity Analysis
Improvement Development
Implementation & Result Verification
Sustaining & Communicating
Results
2.4.0
1
2
3
4
5
2.4.1.2 – How were stakeholders involved and / or communicated with during root cause / improvement opportunity phase of the project ?
29© Copyright 2017 Tata Steel. All Rights Reserved
1. No change
2
Project Management Update
Project & Team Selection
Current Situation and Improvement
Opportunity Analysis
Improvement Development
Implementation & Result Verification
Sustaining & Communicating
Results
2.4.0
1
2
3
4
5
2.4.1.3 What stakeholder resistance was identified and / or addressed in this phase of the project ?
30© Copyright 2017 Tata Steel. All Rights Reserved
Category of Stakeholders
Stakeholders Resistance Identification Resolved
Suppliers
Raw Material Management None None None
Coke PlantThrottling of Production might be reqd
Feedback in MonthlyReview Meeting
Supply from Batt 10 &11 to top up A-F BF Bunkers
Sinter Plant None None None
Pellet Plant None None None
Fuel Management Division None None None
Maintenance None None None
Internal
Project Steering Committee None None None
Project Team None None None
Process OwnerRequirement of Fine coal wil increase leading to depletion of Buffer
Brainstorming sessionMeasures to improve throughput were taken
Customer
Steel Melting ShopsNew Trials may increase Quality deviations
Customer Visit Feedback
Management of Quality Change Procedure used
Slag Granulation and Drying Plant None None None
Hot Metal Logistics None None None
Fuel Management Division None None None
3
-
16
Project Management Update
Project & Team Selection
Current Situation and Improvement
Opportunity Analysis
Improvement Development
Implementation & Result Verification
Sustaining & Communicating
Results
2.4.0
1
2
3
4
5
2.4.1.4 – How was the appropriateness of the initial team membership and management routines confirmed ?
31© Copyright 2017 Tata Steel. All Rights Reserved
Team Membership & Management Routines
Confirming Appropriateness Changes needed
Team Membership • Project Charter Review –Completion as per timeline
• Stakeholder Matrix Analysis –Work done as per plan
No Change required
Management Routines • Documentations were found in place
• Procedures followed• Proper Communication to all
stakeholders were evident
No Change Required
4
Solution / Improvement Development3
32© Copyright 2017 Tata Steel. All Rights Reserved
-
17
Possible Solutions or Improvements
Project & Team Selection
Current Situation and Improvement
Opportunity Analysis
Improvement Development
Implementation & Result Verification
Sustaining & Communicating
Results
3.1.0
1
2
3
4
5
3.1.1.1 – What methods and / or tols were used to identify the possible solutions / improvements ?3.1.1.2 – Why were these methods and / or tools selected ?
33© Copyright 2017 Tata Steel. All Rights Reserved
Tools used to identify Improvement Opportunities
Tools Used
Expert Consultation - PIT
Benchmarking
Focused Group Discussion – LEO (Learning from Each Other)
Literature Review
Why
To facilitate cross learning among the European and Indian Opportunity
Comparing various in processes to identify the directionality towards solution
Experts views from Blast Furnaces in Jamshedpur were taken
To identify the best practices in the industry
1 2
Possible Solutions or Improvements
Project & Team Selection
Current Situation and Improvement
Opportunity Analysis
Improvement Development
Implementation & Result Verification
Sustaining & Communicating
Results
3.1.0
1
2
3
4
5
3.1.1.3 – How was the team prepared ot use these mehtods and / or tools ?
34© Copyright 2017 Tata Steel. All Rights Reserved
3
All the Root Causes identified were compiled and sent across to the experts from various Tata Steel Plants around the world
1 day training program on Benchmarking methodology
5 Hours training on Systematic Focused group discussion and brainstorming
Dedicated Topic Research were given to each member of the team and a period of 1 week to come up with solutions
Preparation of Team for using the Tools
Expert Consultation
Benchmarking
Focused Group Discussion
Literature ReviewTraining Imparted to 1. Project leader2. Project Members &3. The Process Owner
The Effectiveness of training was verified by conducting PreCourse and Post Course AssessmentsThe progress was also tracked in the Weekly review meeting
-
18
Possible Solutions or Improvements
Project & Team Selection
Current Situation and Improvement
Opportunity Analysis
Improvement Development
Implementation & Result Verification
Sustaining & Communicating
Results
3.1.0
1
2
3
4
5
3.1.2.1 – What data was generated and how was the data analyzed to determine the possible solutions / improvements ?
35© Copyright 2017 Tata Steel. All Rights Reserved
Tools used to identify Improvement Opportunities
Tools Used
Expert Consultation - PIT
Benchmarking
Focused Group Discussion – LEO (Learning from Each Other)
Literature Review
Data Generated
The Solutions Ideas
Key Gaps were identified
Various Ideas were collated
Some best practices across other blast furnace and process changes at higher
coal were noted
How
Translated into Actions in Team meetings
Used Necessity and sufficiency checks to translate into results to check validity
Translated into Actions in Team meetings
Used Necessity and sufficiency checks to translate into results to check validity
1 1
Possible Solutions or Improvements
Project & Team Selection
Current Situation and Improvement
Opportunity Analysis
Improvement Development
Implementation & Result Verification
Sustaining & Communicating
Results
3.1.0
1
2
3
4
5
3.1.2.2 – What are the possible solutions / improvements?
36© Copyright 2017 Tata Steel. All Rights Reserved
Tools used to identify Improvement Opportunities
Tools Used
Expert Consultation - PIT
Benchmarking
Focused Group Discussion –LEO (Learning from Each
Other)
Literature Review
Data Generated
The Solutions Ideas
Key Gaps were identified
Various Ideas were collated
Some best practices across other blast furnace and process
changes at higher coal were noted
In Process KPIs1. Opt for Flatter distribution2. Adjust the screening size3. Reduce the centre coke percentage4. Optimize slag composition5. Reduce the Wind Volume6. Reduce the Hot Metal Temperature7. Increase the Oxygen Enrichment8. Increase Coal Inecjtion9. Increase the Hot Blast Temperature10. Improve Cast House Operation
Raw Material1. Increase of Agglomerates2. Increase the size of Coke3. Increasing the Cold strength of Coke4. Improve the Reducibility of Sinter & Pellet5. Increase the Calorific value of coal
2
-
19
Possible Solutions or Improvements
Project & Team Selection
Current Situation and Improvement
Opportunity Analysis
Improvement Development
Implementation & Result Verification
Sustaining & Communicating
Results
3.1.0
1
2
3
4
5
3.1.2.3 – What evidence showed that the solutions / improvements identified were possible instead of final ?
37© Copyright 2017 Tata Steel. All Rights Reserved
Process No. Process Function
Product (Output)
Characteristics
Requirements
Potential Failure ModePotential Effect(s) of
Failure
A
Severity
(Out of 10)
Potential Cause (s) / Mechanism (s) of Failure
40.I1 Fluctuation in Wind Volume
40.I2 Raw material quality(Sn-RDI, C-Ash,
P-SI)
40.I3 Cooling water Flow
40.I4 Physical and Chemical Properties of
Raw Material
40.I5 Stock line
40.I6 Distribution of RM
40.I7 Fluctuation of Top Gas Pressure
40.I8 Variation in input coal quantity and
quality
40.I9 Variation in agglomerate percentage
40.I10 High input moisture load
40.I11 %Sn in burden
40.I12 Oxygen Enrichment
40.I13 Burden Distribution
40.I14 Low Sinter basicity
40.I15 High Al2O3 in raw material
40.I16 Phosphorus in input raw material
40.I17 Hot Metal Temperature
40.P1 SLC
40.P2 Coal Injection
40.P3 RAFT
40.P4 water Circuit make up
40.P5 Fuel rate
40.P6 Slag Chemistry
40.P7 ECO
40.P8 E H2
40.P9 Amount of dust dumped from dust
catcher
40.P10 Heat Flux (Circuit#3 Heat Loss)
40Furnace
Operation
Hot Metal Si (40.O1)
Hot Metal S (40.O2)
Hot Metal
Temperature (40.O3)
Slag Chemistry(MgO,
Al2O3 & B2) (40.O4)
Coke Rate (40.O5)
Hearth liquid level
(40.O6)
Si < 0.44%
Si >1.04%
S >0.065%
Coke Rate
-
20
Possible Solutions or Improvements
Project & Team Selection
Current Situation and Improvement
Opportunity Analysis
Improvement Development
Implementation & Result Verification
Sustaining & Communicating
Results
3.2.0
1
2
3
4
5
3.2.1.3 – How was the team prepared to use these methods and / or tools ?
39© Copyright 2017 Tata Steel. All Rights Reserved
3
Usage and creation of Affinity Diagram was instructed and activity was carried out by the Project team along with the process owners
4 hours session in hands on training of Pay off Matrix
Modelling of different scenario and its results analysis were imparted to the team in a 2 day training module
Preparation of Team for using the Tools
Affinity Diagram
Pay Off Matrix
Modelling
Training Imparted to 1. Project leader2. Project Members &3. The Process Owner
The Effectiveness of training was verified by conducting PreCourse and Post Course AssessmentsThe progress was also tracked in the Weekly review meeting
Final Solutions or Improvements
Project & Team Selection
Current Situation and Improvement
Opportunity Analysis
Improvement Development
Implementation & Result Verification
Sustaining & Communicating
Results
3.2.0
1
2
3
4
5
3.2.2.1 – How were the methods and / or tools used to determine the final solutions / improvement ?3.2.2.2 – What was (were) the final solution(s) / improvement (s) ?
40© Copyright 2017 Tata Steel. All Rights Reserved
Tools used to identify Improvement Opportunities
Tools Used
Affinity Diagram
Payoff Matrix
Modelling
How
Brainstorming helped categorizing the solutions
Categorized the available solutions
Validated various scenarios after building in the model
1
2
Increasing cold strength of coke, Adjusting Screening size, optimize the slag composition, reduce wind volume, increase oxygen enrichment, coal injection and hot blast temperature
and improve the cast house operation
Final Improvement Opportunities
-
21
Final Solutions or Improvements
Project & Team Selection
Current Situation and Improvement
Opportunity Analysis
Improvement Development
Implementation & Result Verification
Sustaining & Communicating
Results
3.2.0
1
2
3
4
5
3.2.3.1 – How were the final solutions / improvements validated ?3.2.3.2 – What evidence showed that the validation was performed prior to implementation ?
41© Copyright 2017 Tata Steel. All Rights Reserved
ValidationCategory
Expert Validation FMEA Pilot Scale Implementation
Procedure Followed Advice from ExpertsMr Ashok Kumar, CTOMr Tijuis Gerard, Tata Steel IjmuidenMr Uttam Singh, CoBF
Cross Referenced through the Failure Mode and Effect Analysis
Pilot Scale Implementation of Various actions were tried with a small change and monitored for one month to capture data
Evidence
1
2MOM of Blast Furnaces PIT Meeting
Meeting No. PIT/BF/09/16 Date: 04/12/2015 Time: 03.30 PM (India); 12.00 (NL); 11.00 (UK)
Chaired by Mr. Uttam Singh
Attendees :
Jamshedpur IJmuiden Port Talbot Scunthorpe
Uttam Singh Johannes de Lange Andrew McGregor No attendance
Sanjiv Kumar Mark van den Berg
AS Reddy Jan van der Stel (R&D)
Shambu Nath Gerard Tijhuis (CoE)
Padma Pal
Shantanu Mallick
Krishnendu Mukhopadhyay
Manish Pandey
Vineet Tripathi
Sl. No
Item Discussed
Timeline / Action
plan
Responsibility Status (Open /Closed/ Carry Forward)
Comment
A
Low CSR coke was charged to I BF from 10 to 20 Nov. (slide 4 in presentation). What are the actions taken in such a case at TSE furnaces ? Request to share our procedures.
All sites Open Discussion in next PIT meeting
B Damage to stove #2 at KPO during heat-up. What is recommendation of TSE for start-up ? Blow-in with only two stoves ?
All sites Open
Port Talbot and IJmuiden adviced not to start with only 2 stoves. Risk in case of failure of other stove is too big.
C The Action points identified for coke rate reduction in I BF were discussed and deliberated – More discussion to held in person
Jamshedpur Open
D
Document on trough discharge in Jsr is made available on sharepoint. All sites are requested to share their practices on this, including safety measures
All sites Open Share you practice
E Port Talbot mentioned an investigation on the torpedo collision (~one month ago) is still ongoing.
Port Talbot Open Outcomes to be shared for learnings.
MoM of BF Pit with the Point discussed about I BF
Coke Rate Project Results of Pilot Trials in I BFPFMEA
Final Solutions or Improvements
Project & Team Selection
Current Situation and Improvement
Opportunity Analysis
Improvement Development
Implementation & Result Verification
Sustaining & Communicating
Results
3.2.0
1
2
3
4
5
3.2.4.1 – What additional potential benefits were anticipated from the final solutions / improvements ?3.2.4.2 – Were the additional potential benefits anticipated prior to implementation ?
42© Copyright 2017 Tata Steel. All Rights Reserved
*Additional Benefits
Project Benefit
Additional Benefits anticipated from the final solutions1
2 These Benefits were anticipated from the implementation of solution
Reduction of Coke Rate Reduction of Hot Metal Cost
Reduction of Carbon Footprint
Improvement in Productivity
-
22
Final Solutions or Improvements
Project & Team Selection
Current Situation and Improvement
Opportunity Analysis
Improvement Development
Implementation & Result Verification
Sustaining & Communicating
Results
3.2.0
1
2
3
4
5
3.2.5.1 – What data was generated and how was the data analyzed to justify why the chosen final solutions / improvements should be implemented ?3.2.5.2 – What evidence showed that the justification was performed prior to the implementation of the solution ?
43© Copyright 2017 Tata Steel. All Rights Reserved
1 Final Solutions to be implemented
Method IncreasingCSR of Coke
Adjusting CokeScreen Size
Optimize Slag Composition
Softer Blowing Rate
Oxygen Enrichment
Coal Injection
Optimizing Cast House Operation
Hot Blast Temperature
Expert Consulta
ncyY Y Y Y Y Y N Y
Brainstorming
Y Y N Y Y Y Y Y
Correlation Matrix
N Y Y Y Y Y N Y
Final Decision
Y Y Y Y Y Y N Y
- Final implementable solutions were decided based on the matrix tabulated below
2 Evidence that the justification was performed
Evidence of Brainstorming session and its finalized MoM
Project Management Update
Project & Team Selection
Current Situation and Improvement
Opportunity Analysis
Improvement Development
Implementation & Result Verification
Sustaining & Communicating
Results
3.3.0
1
2
3
4
5
3.3.1.1 – How was the correctness of the initial or updated project scope, deliverables, and timings confirmed ?
44© Copyright 2017 Tata Steel. All Rights Reserved
Review of Progress with respect to the Project Charter1
Phase end review with the Project Steering Committee• Progress as per Charter• No Change of Scope Identified
PlanActual
-
23
Project Management Update
Project & Team Selection
Current Situation and Improvement
Opportunity Analysis
Improvement Development
Implementation & Result Verification
Sustaining & Communicating
Results
3.3.0
1
2
3
4
5
3.3.1.2 – How were the stakeholders involved and / or communicated with during the solution / improvement phase of the project ?
45© Copyright 2017 Tata Steel. All Rights Reserved
2
Project Management Update
Project & Team Selection
Current Situation and Improvement
Opportunity Analysis
Improvement Development
Implementation & Result Verification
Sustaining & Communicating
Results
3.3.0
1
2
3
4
5
3.3.1.3 – What stakeholders resistance was identified and / or addressed in this phase of the project ?
46© Copyright 2017 Tata Steel. All Rights Reserved
Category of Stakeholders
Stakeholders Resistance Identification Resolved
Suppliers
Raw Material Management None None None
Coke Plant None None None
Sinter Plant None None None
Pellet Plant None None None
Fuel Management DivisionReduction of Wind Volume to the Threshold of the Blower House
Feedback during Monthly Review
Maintained at the minimum rpm of the blower house
MaintenanceTRT Power Generation mayreduced at softer blowing rates
Reduction of Generation during pilot implementation
Inreased Top Pressure and Inlet pressure of TRT
Internal
Project Steering Committee None None None
Project Team None None None
Process Owner None None None
Customer
Steel Melting Shops None None None
Slag Granulation and Drying Plant None None None
Hot Metal Logistics None None None
Fuel Management Division None None None
3
-
24
Project Management Update
Project & Team Selection
Current Situation and Improvement
Opportunity Analysis
Improvement Development
Implementation & Result Verification
Sustaining & Communicating
Results
3.3.0
1
2
3
4
5
3.3.1.4 – How was the appropriateness of the initial or updated team membership and management routines confirmed ?
47© Copyright 2017 Tata Steel. All Rights Reserved
Team Membership & Management Routines
Confirming Appropriateness Changes needed
Team Membership • Project Charter Review –Completion as per timeline
• Stakeholder Matrix Analysis –Work done as per plan
No Change required
Management Routines • Documentations were found in place
• Procedures followed• Proper Communication to all
stakeholders were evident
No Change Required
4
Implementation and Results
Verification4
48© Copyright 2017 Tata Steel. All Rights Reserved
-
25
Stakeholders consideration in Implementation
Project & Team Selection
Current Situation and Improvement
Opportunity Analysis
Improvement Development
Implementation & Result Verification
Sustaining & Communicating
Results
4.1.0
1
2
3
4
5
4.1.1.1 – How were the stakeholders involved in planning the solution/improvement implementation ?4.1.1.2 – How were the stakeholders involved in implementing the solution / improvement ?
49© Copyright 2017 Tata Steel. All Rights Reserved
1 2
Stakeholders consideration in Implementation
Project & Team Selection
Current Situation and Improvement
Opportunity Analysis
Improvement Development
Implementation & Result Verification
Sustaining & Communicating
Results
4.1.0
1
2
3
4
5
4.1.2.1 – What was done to anticipate resistance before it occurred ?4.1.2.2 – What types of resistance were actually encountered during the course of solution / improvements implementation ? (1/2)4.1.2.3 – How was the actual resistance identified ? (1/2)
50© Copyright 2017 Tata Steel. All Rights Reserved
Anticipation of Resistance: As a measure to predict the resistance, dedicated brainstorming session were organized and detailed discussion was carried out against each element in the stakeholder matrix
1
1 2 3
-
26
Stakeholders consideration in Implementation
Project & Team Selection
Current Situation and Improvement
Opportunity Analysis
Improvement Development
Implementation & Result Verification
Sustaining & Communicating
Results
4.1.0
1
2
3
4
5
4.1.2.1 – What was done to anticipate resistance before it occurred ?4.1.2.2 – What types of resistance were actually encountered during the course of solution / improvements implementation ? (2/2)4.1.2.3 – How was the actual resistance identified ? (2/2)
51© Copyright 2017 Tata Steel. All Rights Reserved
2 31
Stakeholders consideration in Implementation
Project & Team Selection
Current Situation and Improvement
Opportunity Analysis
Improvement Development
Implementation & Result Verification
Sustaining & Communicating
Results
4.1.0
1
2
3
4
5
4.1.3.1 – How was the actual resistance addressed ? (1/2)4.1.3.2 – How did the team know it was successful in addressing the resistance ? (1/2)
52© Copyright 2017 Tata Steel. All Rights Reserved
1 2
-
27
Stakeholders consideration in Implementation
Project & Team Selection
Current Situation and Improvement
Opportunity Analysis
Improvement Development
Implementation & Result Verification
Sustaining & Communicating
Results
4.1.0
1
2
3
4
5
4.1.3.1 – How was the actual resistance addressed ? (2/2)4.1.3.2 – How did the team know it was successful in addressing the resistance ? (2/2)
53© Copyright 2017 Tata Steel. All Rights Reserved
1
2
1 2
Stakeholders consideration in Implementation
Project & Team Selection
Current Situation and Improvement
Opportunity Analysis
Improvement Development
Implementation & Result Verification
Sustaining & Communicating
Results
4.1.0
1
2
3
4
5
4.1.4.1 – What was the evidence of stakeholder group buy-in ?4.1.4.2 – What evidence showed that buy-in was obtained prior to implementation ?
54© Copyright 2017 Tata Steel. All Rights Reserved
Evidence of Stakeholder Buy-in: 1
Bu
y in
fro
m S
take
ho
lder
s Sign off at the end of each stage of the Project
Following the Management of Quality Change - MQC
Recording the Changes incorporated in the MoUs and VoCs –Inmprovement in Customer Satisfaction
Regular Communications in various Forums and recorded MoMs
Evidence That Buy-in was obtained: 2
MoM of Quality Council Meeting
MQC Raised for reduction of Coke Rate
-
28
Solution / Improvement Implementation
Project & Team Selection
Current Situation and Improvement
Opportunity Analysis
Improvement Development
Implementation & Result Verification
Sustaining & Communicating
Results
4.2.0
1
2
3
4
5
4.2.1.1 – What process or systems were changed or created to implement the solution / improvement ?4.2.1.2 – What systems were changed or created to measure and manage the performance of the implementation ?
55© Copyright 2017 Tata Steel. All Rights Reserved
Systems Processes
Implement Solution
Introduction of Modeling Software in Level 2 Automation : MOGADOR, Burden Distribution Model
ASAM Testing of Burden
HOSIM Testing of Burden
Enhancing the grinding system
Adjusting the screening rate in
stock house
Increasing the Size of laval tuyerefor higher injection
Optimize the casting rate to facilitate better
drainage
Creation of New SOPs
Updating Daily Management Checklist and documents
Measure / Manage the Implementation
Job Cycle Checks and updating the Old SOPs and Action Standards
FMEA , Control Plan and Risk Status Up-gradation
Increasing the Sampling frequency
Installation of Above Burden Probe with
Gas analyser to measure the Gas
Composition across the radial pattern
Training Process Strengthened and
change documents identified
1
2
Project Results
Project & Team Selection
Current Situation and Improvement
Opportunity Analysis
Improvement Development
Implementation & Result Verification
Sustaining & Communicating
Results
4.3.0
1
2
3
4
5
4.3.1.1 – What were the results ?4.3.1.2 – How did the results compare to the specific project goals / measures from item 2.1.1 ?
56© Copyright 2017 Tata Steel. All Rights Reserved
ResultsResults Exceeded the TargetIn the first step it was broughtdown to 353 which furtherreduced to 328 kg/thm
1 Improvement Opportunity
Current Performance (kg/thm)
Target (kg/thm)
Actual Achieved (kg/thm)
Coke Rate 428 408 353
2 Performance of Coke Rate
This resulted in a Overall Saving of INR 65 Cr
The coke rate performance of I BF and the improvement journey is illustrated hereThe biggest step Jump in the last 30 years in Tata Steel Blast Furnaces
-
29
Project Results
Project & Team Selection
Current Situation and Improvement
Opportunity Analysis
Improvement Development
Implementation & Result Verification
Sustaining & Communicating
Results
4.3.0
1
2
3
4
5
4.3.2.1 – What additional benefits were realized from the project ?
57© Copyright 2017 Tata Steel. All Rights Reserved
Coke Rate Reduction
Reduction of Carbon
Footprint
Q - Reduction of Mean HM
Si
Increase of Productivity
Reduction of Steam
Consumption
Additional Benefits Realized1
Two additional Benefits wererealized which were notanticipated earlier
Reduction from 1.52 tCO2/thm to 1.41tCO2/thm
Reduction of Mean HM Si from 0.84 to 0.72%
Increase of Productivity from 2.65 to 2.72 t/m3/day
Reduction of Steam Consumption from
17,000 tons/month to 1600 tons/month
Project Results
Project & Team Selection
Current Situation and Improvement
Opportunity Analysis
Improvement Development
Implementation & Result Verification
Sustaining & Communicating
Results
4.3.0
1
2
3
4
5
4.3.2.2 – How did the team measure any of the additional benefits that were “soft”?
58© Copyright 2017 Tata Steel. All Rights Reserved
Additional Soft Benefits Realized2
Soft Benefits
Customer Satisfaction
Increased Morale of
Team
Inspiration to other
departments
Awards and Accolades
Improved Customer Satisfaction and reduction of Customer Complaint by 35%
Becoming the Indian Benchmark gave motivation to the team to drive for excellence and change –Ripple Effect
Seeing the transformation of I BF other departments started
following the path of I BF –Sense of Pride to the Team
More Feathers were added to the cap of I BF – Recognitions, Awards
and Accolades
-
30
Coke Rate Reduction
Reduction of Carbon
Footprint
Q -Reduction of Mean HM Si
Increase of Productivity
Reduction of Steam
Consumption
Project Results
Project & Team Selection
Current Situation and Improvement
Opportunity Analysis
Improvement Development
Implementation & Result Verification
Sustaining & Communicating
Results
4.3.0
1
2
3
4
5
4.3.2.3 – How do the actual additional benefits that were realized compare to the expected additional benefits identified in item 3.2.4 ?
59© Copyright 2017 Tata Steel. All Rights Reserved
Realization of Additional Benefits3
Anticipated and Fully Realized
Not anticipated realized
All the four additionalbenefits were fullyrealized
Sustaining Results Over Time5
60© Copyright 2017 Tata Steel. All Rights Reserved
-
31
Sustaining Results Over Time
Project & Team Selection
Current Situation and Improvement
Opportunity Analysis
Improvement Development
Implementation & Result Verification
Sustaining & Communicating
Results
5.1.0
1
2
3
4
5
5.1.1.1 – What was done to make sure the process or system changes made during the implementation continued to be followed ?5.1.1.2 –What evidence showed that this became part of the organization’s culture/operating strategy ?
61© Copyright 2017 Tata Steel. All Rights Reserved
Steps to ensure the changes to be followed:
1
Step
s fo
r Su
cces
sfu
l Su
sten
ance
of
the
Im
pro
vem
en
t
Updating the SOPs and Action Standards and subsequent Training
Updating the Daily Management Documentation
Updating the FMEA & CP and subsequent communication
Evidence : 2
Process No. Process Function
Product (Output)
Characteristics
Requirements
Potential Failure ModePotential Effect(s) of
Failure
A
Severity
(Out of 10)
Potential Cause (s) / Mechanism (s) of Failure
B
Occurrence
(Out of 10)
Current process Controls - Detection/Prevention
C
Detectability
(Out of 10)
Risk Priority
Number (RPN)
AXBXC
Actions to reduce RPNResponsi
bility
Target
Date
40.I1 Fluctuation in Wind Volume 3 Online monitoring & follow up with supplier 5 135
40.I2 Raw material quality(Sn-RDI, C-Ash,
P-SI)3 Lab analysis 3 81 Information to supllier CR Opr w.i.e
40.I3 Cooling water Flow 2 Online monitoring & follow up 3 54
40.I4 Physical and Chemical Properties of
Raw Material3 HBT data from control room 1 27
40.I5 Stock line 2 Online monitoring & follow up 3 54
40.I6 Distribution of RM 4 Online monitoring & follow up 4 144
40.I7 Fluctuation of Top Gas Pressure 2 Online monitoring & follow up 3 54
40.I8 Variation in input coal quantity and
quality3 Online monitoring & follow up 3 81
40.I9 Variation in agglomerate percentage 4 Bin level monitoring & adjustment in burden 2 72
40.I10 High input moisture load 3 CRMT report and adjustment in fuel rate 3 81 Information to supllier CR Opr w.i.e
40.I11 %Sn in burden 2 Online monitoring 2 36
40.I12 Oxygen Enrichment 5 Online monitoring 1 45
40.I13 Burden Distribution 4 Online monitoring 2 72 Information to supllier CR Opr w.i.e
40.I14 Low Sinter basicity 1 Online monitoring 1 9
40.I15 High Al2O3 in raw material 3 Online monitoring & follow up with supplier 2 54
40.I16 Phosphorus in input raw material 3 Online monitoring(HM) & follow up with supplier 2 54
40.I17 Hot Metal Temperature 4 Online monitoring(HM) & follow up with supplier 2 54
40.P1 SLC 3 Online monitoring & follow up with supplier 3 81
40.P2 Coal Injection 4 RAFT set point and PV 4 144
40.P3 RAFT 3 Furnace DP and K value at control room 5 135 SOP CR Opr w.i.e
40.P4 water Circuit make up 2 Make up trend of cooling circuits in control room 5 90 SOP CR Opr w.i.e
40.P5 Fuel rate 4 Fuel rate at tuyere data of level2 system 1 36
40.P6 Slag Chemistry 2 Online monitoring 2 36
40.P7 ECO 3 ECO data from furnace overvie page 2 54
40.P8 E H2 3 E H2 data from furnace overviw page 2 54
40.P9 Amount of dust dumped from dust
catcher4 DM log sheet 2 72
40.P10 Heat Flux (Circuit#3 Heat Loss) 7 Heat flux data from staves structure page 1 63
Section: IBF (Operations) Date : 01.09.2016 Approved by: Chief IBF Rev. : 03
Doc. No.: OPR/DM/PFC/03 Effective Date : 01/04/2016
Department: I Blast Furnace Revision No.: 5 Prepared by: Head Operations IBF Form No. : TQM/DM/FMEA/003
40Furnace
Operation
Hot Metal Si (40.O1)
Hot Metal S (40.O2)
Hot Metal
Temperature (40.O3)
Slag Chemistry(MgO,
Al2O3 & B2) (40.O4)
Coke Rate (40.O5)
Hearth liquid level
(40.O6)
Si < 0.44%
Si >1.04%
S >0.065%
Coke Rate
-
32
Communication of Results
Project & Team Selection
Current Situation and Improvement
Opportunity Analysis
Improvement Development
Implementation & Result Verification
Sustaining & Communicating
Results
5.2.0
1
2
3
4
5
5.2.1.1 – How did the team communicate the results to the various stakeholder groups ?
63© Copyright 2017 Tata Steel. All Rights Reserved
Communication to Stakeholder1
Coke Rate Improvement
Suppliers
Internal
Customers
- TQM Council Meetings- RM Quality Meeting- Monthly Report Circulation
- Blast Furnace Process Review Meeting- I-Mirror Circulation- Monthly Report Circulation- Learning From Each Other – LEO – Meeting
- Customer Visits- TQM Council Meeting- War Room Meeting- Monthly Report Circulation
Apart from these forums, MD Online, Monthly Newsletter from VP and TQM Apex Project Review were also used to communicate across Tata Steel
Awards and Accolades6
64© Copyright 2017 Tata Steel. All Rights Reserved
-
33
Awards and Accolades
• Achieving the feat. of Indian Benchmark in Monthly Coke rate, coal Rate and carbon
footprint
• The Project was awarded in APEX Level by TQM Division
• Lauded by Senior Management and Ex Tata Steel Management and made them feel proud
of the achievement
• Won in Eastern region in Tata Groups Innovista Competition and represented in Tata Steel in
Finals of Innovista
65© Copyright 2017 Tata Steel. All Rights Reserved
Together We Can !!!
66© Copyright 2017 Tata Steel. All Rights Reserved