4i Case Study Pass Life Improvement 02082018

Steel Ltd, 4i -Sheet (Improvem
Vijayanagar
Project Title
40 Rb finishing pass life improvement from 710 ton per pass to 1000 ton per pass.
0.Business Case
In TMT bar rolling finishing pass will have ribs and logo on the TMT Bars,The finishing pass need to be changed
to maintain specified ribs, Logo & surface at every 710 tons (last 06 month avg)and every stoppage approximetly
takes 20 mins.If we improve the avg pass life to 1000 tons,approximetly 27 hours rolling time will be saved in a
year.The reduction pass life will ensure reduction in roll ring cost.
a) Problem Definition
Low pass life in 40rb rolling causes frequent pass changes which affecting milll utilization
b) Problem Goal- Improve pass life in 40 Rb

GOAL STATEMENT BASE LINE PERIOD CURREN BENCH TARGET
T VALUE MARK
KPI Apr 17 TO Dec 17 5.05% 4.75%
1. Identification
1.1 Probable Causes Identification
1.2 Root Cause Validation
4i -Sheet (Improvement Project Summary)
Team Details (Name, Department & Designation)
Leader Kiran Akkidasu BRM#02 Manager
Member1 Shripad Jirafe BRM#02 Sr Manager
Member2 Arun Kumar BRM#02 Engineer
ass need to be changed

y stoppage approximetly
time will be saved in a 2. Ideation & Evaluation
2.1 Idea Generation - Possible solutions for Problem
1 Roll Cooling Nozzle angle modification
2 Branding letter Electrode Profile Grinding
3 Roll Hardness change
milll utilization 2.2 Selection of Idea

I.C.I.T.E Solution Selection Matrix
Idea No Cost Of Impact Of Time Of Ease Of Total

Implemen Implemen Implemen Implemen
1 Low High Low Easy 36
2 Low High High Easy 28
3 High Low High Difficult 4
2.3 Risk assesment

Faster wear out roll pass will impact on logo and quality or Rebar for
export material.
TARGET DATE
4/30/2018
3. Implementation
3.1 Detailed Implementation plan & execution
Conclusion:- Nozzle cooling arrangement at 45 deg shows improvement in passs live over 10
Deg
Document No: Form No. VJNR/TQM/EE-008.01.20170403
YYYY/INNO/Department-XX
Start Date End Date
7/26/2017 8/3/2017
3.2 Project Standardization & Commercialization
4. Institutionalization
Impact On KPI
Documents for Institutionalization
OPL Y/N
Pokayoke Y/N
Revised SMP/SOPs/V-SOPs Y/N Yes
New SMP/SOPs/V-SOPs Y/N
FMEA Modification Y/N Yes
Material Machine
Rolls groove
turning as per
Using of HSS
& Composite standard profile skilled
Roll Cleaning Machine
roll and preparation operators
Roll material
Uniform
hardness Maintained
throughout uniform LOGO
usable dia depth
Branding
electrode
profile grinding
Nozzle Roll hardness Furnace billet

cooling checked in digital Temperature
arrangeme hardness testing
nt be in 45’ proper machine
supervision
of shift in-
charge
Production
Periodical checking targets
of notching and
proper cleaning Branding depth
of Water nozzles
Method Mother
Measurement
Nature
Man
Proper LOGO
depth on
skilled Groove
Machine
operators
Increased in
pass life
Proper
ntained alignment of
orm LOGO water
h cooling
manifold
Reduction in
Roll and TC
Ring Cost
Furnace billet
Temperature
Rolling speed
has been
Production achieved
targets
Mother
Nature
#
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
Probable Causes
Roll material
Roll hardness (Roll hardening depth)
Roll mechanical properties
Roll diameter (Usable dia)
Reduction % ge
Rolling speed
Cooling arrangement
Logo Depth and Branding parameters
Billet temperature
Groove type
Pass life improvement
Using of HSS and Composite rolls
Nozzle cooling arrangement with 45’ angle
Billet discharge temperature
Branding electrode profile grinding
Converting discard rings of lower sizes to highest sizes
Nozzle angle change

Branding parameter
Roll hardness
Rs/ton Target is 40.00rs but mean value is 45.00
Daily Till date

Statement : Rs/ton for Rolls & rings of June month
is better than previous year.
MONTH (JUN- Ring Avg
Roll avg (RS/MM)
NOV 2017) (RS/MM)
H0 : Rs/ton (July) <= Rs/ton (Pr. Year)
Ha: Rs/ton (July) > Rs/ton (Pr Year)
Oct-16 21.25 22.53
Nov-16 28.92 22.11
Using 2-proportion test:
Dec-16 9.64 38.86
P – value is 0.002 Jan-17 8.18 30.21
Feb-17 18.56 28.96
Since P –value is less than 0.05, reject H0 Mar-17 19.26 28.22
Apr-17 18.99 27.22
Rs/ton of July month is better than Rs/ton of May-17 11.55 22.55
Previous Year Jun-17 21.24 21.92
Jul-17 24 20.40
Aug-17 27.57 19.64
Sep-17 27.57 19.64
MEAN VALUE-44.94
Current
Potenti Control
Potenti al
Occurrence
Detection
Potenti
Severity
Item / al al Causes
Sl. No. Effect(s /Mecha
Process Failure ) of nisms
Mode Preven
Failure of
Failure tion/De
tection
Brandi
By
ng maintai
param ning
eter Letter High unifor
optimiz worn speed Excess m
01 ation out rolling stock depth
Nozzl
e
cooling Core
arrang surface
ement roughn Mill
with 45 Roll Low ess on checkin
02 angle damage cooling Rebar. g
Uneve
n shape By
Discard of measur
Rings Profile Ring ing in
Conver grindin breakag Excess Templa
03 sion g e depth tes
Till date
Ring Avg
S/MM) Total
(RS/MM)
22.53 43.78
22.11 51.03
38.86 48.50
30.21 38.39
28.96 47.52
28.22 47.48
27.22 46.21
22.55 34.10
21.92 43.16
20.40 44.40
19.64 47.21
19.64 47.21
Action Results
Recom
mende Respon
RPN d sibility
Action( &
s) Target Action
Occ.
Det.
Sev.
Comple Taken RPN

tion
Date
Proper
grindin
g the Machi
electro ne in- Apr-
des charge 2017
By
removi Shift
ng dirt in- June-
in holes charge 2017
Proper
master
Drawin Machi
g to be ne
provide operato
. r 17-Aug
FINISHING PASS CHANGE DETAILS 40RB JULY-17 T
Slno MONTH stand no. SECTION DATE SHIFT TIME REASON OF PASS CHAN
DUE TO GRADE CHANGE
7 JULY #14 40RB 7/25/2017 B 4:00PM
( 550D TO 500 CARES ST
8 JULY #14 40RB 7/25/2017 C DUE TO CORE SURFACE ROU
9 JULY #14 40RB 26/7/2017 A 10:00AM DUE TO CORE SURFACE ROU
DUE TO CORE SURFACE ROUG
10 JULY #14 40RB 26/7/2017 A 1:40PM
'N'LETTER WEAR OUT
11 JULY #14 40RB 26/7/2017 B 5:40PM DUE TO 'W''N'LETTERS WEA
12 JULY #14 40RB 26/7/2017 B 9:40PM DUE TO 'W''N'LETTERS WEA
15 JULY #14 40RB 27/7/2017 A 1:30PM
CYCLE GAPWEA
DUE TO 'W''N'LETTERS
16 JULY #14 40RB 27/7/2017 B 6:40PM
SURFACE ROUGHNES
17 JULY #14 40RB 27/7/2017 C 3:00AM DUE TO CORE SURFACE ROU
19 JULY #14 40RB 28/7/2017 A 1:30PM DUE TO SECTION CHAN
25 AUGUST #14 40RB 9/8/2017 B 7:00PM CORE SURFACE ROUGHN
26 AUGUST #14 40RB 9/8/2017 C 1:30AM
DUE TO CORELOGO DULL
SURFACE ROUG
27 AUGUST #14 40RB 9/8/2017 C 2:00AM
IMPRESION MARKOU
DUE TO 'W''N'LETTER WEAR
28 AUGUST #14 40RB 10/8/2017 A 8:30AM SURFACE ROUGHNES
DUE TO 'W''N'LETTER WEAR OU
29 AUGUST #14 40RB 10/8/2017 A 1:00PM SURFACE ROUGHNES
30 AUGUST #14 40RB 10/8/2017 B 3:00PM DUE TO 'W' LETTER WEAR
DUE TO 'W' LETTER WEAR OUT
31 AUGUST #14 40RB 10/8/2017 B 7:00PM
ROUGHNESS
32 AUGUST #14 40RB 10/8/2017 C 2:30AM DUE TO 'W' 'N' LETTER WEA
DUE TO 'W''N'LETTER WEAR OU
33 AUGUST #14 40RB 11/8/2017 A 9:30AM
SURFACE ROUGHNES
34 AUGUST #14 40RB 11/8/2017 A 2:00PM DUE TO SECTION CHAN
DUE TO GRADE CHANGE
35 AUGUST #14 40RB 18/8/2017 B 10:00PM
(500D TO 500 CARES STAN
36 AUGUST #14 40RB 18/8/2017 C 4:00AM DUE TO 'W''N'LETTER WEA
37 AUGUST #14 40RB 19/8/2017 A 9:30AM DUE TO 'W''N' LETTERS WEAR
38 AUGUST #14 40RB 19/8/2017 B 4:30PM DUE TO CORE
'W''N'SURFACE ROUGH
LETTERS WEAR
CORE SURFACE ROUGH
DUE TO 'W''N' LETTERS WEAR
39 AUGUST #14 40RB 19/8/2017 C 12:00AM
CORE SURFACE ROUGH
42 AUGUST #14 40RB 20/8/2017 C 10:30PM DUE TO CORE SURFAE ROUG
43 AUGUST #14 40RB 20/8/2017 C 4:00AM DUE TO 'W''N' LETTERS WEAR
CORE SURFACE ROUGHN
44 AUGUST #14 40RB 21/8/2017 A 9:30AM DUE TO CORE SURFAE ROUG
45 AUGUST #14 40RB 21/8/2017 B 5:30PM DUE TO DOWN TIME
47 AUGUST #14 40RB 22/8/2017 B 5:30PM DUE TO CORE SURFACE ROU
53 AUGUST #14 40RB 24/8/2017 B 3:30PM DUE TO CORE SURFACE ROU
54 AUGUST #14 40RB 24/8/2017 B 8:00PM DUE TO SECTION CHAN
DUE TO GRADE CHANGE 50
55 AUGUST #14 40RB 30/8/2017 B 8:00PM
500CARES STANDERD
64 SEPTEMBER #14 40RB 2/9/2017 B 6:00PM DUE TO CORE SURFACE ROU
72 SEPTEMBER #14 40RB 5/9/2017 A 8:00AM DUE TO SECTION CHAN
73 SEPTEMBER #14 40RB 14/9/2017 B 3:30PM DUE GRADE CHANGE (500D
CARES STANDERD)
78 SEPTEMBER #14 40RB 15/9/2017 C 3:00AM DUE TO CORE SURFACE ROU
79 SEPTEMBER #14 40RB 19/9/2017 B DUE TO GRADE CHANGE 500D
5:30PM
CARES STANDERD
80 SEPTEMBER #14 40RB 19/9/2017 B 1:00AM DUE TO CORE SURFACE ROU
81 SEPTEMBER #14 40RB 20/9/2017 A 6:30AM DUE TO CORE SURFACE ROU
84 SEPTEMBER #14 40RB 20/9/2017 C 1:00AM DUE TO CORE SURFACE ROU
85 SEPTEMBER #14 40RB 21/9/2017 A 7:30AM DUE TO SECTION CHAN
86 OCTOBER #14 40RB 9/10/2017 A 1:00PM DUE TO GRADE CHANGE 500D
87 OCTOBER #14 40RB 9/10/2017 B 5:30PM DUE TO CORE SURFACE ROU
88 OCTOBER #14 40RB 9/10/2017 C 10:30PM DUE TO CORE SURFACE ROU
89 OCTOBER #14 40RB 9/10/2017 C 1:30AM DUE TO CORE SURFACE ROU
90 OCTOBER #14 40RB 10/10/2017 A 8:00AM DUE TO CORE SURFACE ROU
91 OCTOBER #14 40RB 10/10/2017 A 12:30PM DUE TO CORE SURFACE ROU
93 OCTOBER #14 40RB 10/10/2017 C 12:20AM DUE TO CORE SURFACE ROU
94 OCTOBER #14 40RB 10/10/2017 C DUE TO CORE SURFACE ROU
4:00AM
&"N" LETTER WEAR
97 OCTOBER #14 40RB 11/10/2017 B 7:30PM DUE TO SECTION CHAN
98 OCTOBER #14 40RB 15/10/2017 A DUE TO GRADE CHANGE 500D
2:00PM
CARES
107 OCTOBER #14 40RB 17/10/2017 B 6:30PM DUE TO E W LWTTER WEA
110 OCTOBER #14 40RB 18/10/2017 A 11:00 AM DUE TO SECTION CHAN
111 NOVEMBER #14 40RB 9/11/2017 A DUE TO GRADE CHANGE 500D
12:30PM
CARES STANDERD
112 NOVEMBER #14 40RB 9/11/2017 B 6:00PM DUE TO CORESURFACE WEA
113 NOVEMBER #14 40RB 9/11/2017 C 11:30PM DUE TO CORE SURAFECE ROU
114 NOVEMBER #14 40RB 9/11/2017 C 5:00AM DUE TO CORE SURAFECE ROU
115 NOVEMBER #14 40RB 10/11/2017 A 10:30AM DUE TO CORE SURAFECE ROU
116 NOVEMBER #14 40RB 10/11/2017 B 6:00PM DUE TO CORE SURAFECE ROU
117 NOVEMBER #14 40RB 10/11/2017 C 11:30PM DUE TO DOWN TIME
119 NOVEMBER #14 40RB 11/11/2017 C 4:00PM #14 SHEAR PIN BROKEN (DOW
120 NOVEMBER #14 40RB 12/11/2017 A 9:30AM DUE TO CORE SURFACE ROU
121 NOVEMBER #14 40RB 12/11/2017 B 5:00PM DUE TO CORE SURFACE ROU
123 NOVEMBER #14 40RB 12/11/2017 C 10:15PM DUE TO CORE SURFACE ROU
124 NOVEMBER #14 40RB 12/11/2017 C 12:00AM DUE TO EXTRA METERIAL IN
127 NOVEMBER #14 40RB 13/11/2017 A 1:00PM DUE TO CORE SURFACE ROU
128 NOVEMBER #14 40RB 13/11/2017 A 2:00PM DUE TO CORE SURFACE ROU
130 NOVEMBER #14 40RB 13/11/2017 B 3:30PM DUE TO EXTRA METERIAL IN
131 NOVEMBER #14 40RB 13/11/2017 B 4:30PM DUE TO SECTION CHAN
132 NOVEMBER #14 40RB 17/11/2017 A 1:00PM DUE TO GRADE CHANGE 50
500CARES STANDERD
135 NOVEMBER #14 40RB 17/11/2017 C 4:00AM DUE TO CORE SURFACE ROU
136 NOVEMBER #14 40RB 18/11/2017 A 9.30AM DUE TO CORE SURFACE ROU
137 NOVEMBER #14 40RB 18/11/2017 B 4.0PM DUE TO CORE SURFACE ROU
140 NOVEMBER #14 40RB 19/11/2017 A 9:30AM DUE TO CORE SURFACE ROU
144 NOVEMBER #14 40RB 20/11/2017 B 9:30AM DUE TO CGRADE CHANGE 500
146 NOVEMBER #14 40RB 21/11/2017 A 9:30AM DUE TO SECTION CHAN
147 DECEMBER #14 40RB 15/12/2017 A 11:20AM DUEGRADE CHANGE
TO CORE 500DROUG
SURFACE TO C
148 DECEMBER #14 40RB 15/12/2017 B 5.30PM WATER FLOW & WATER
DUE TO CORE SURFACE ROUG HE
149 DECEMBER #14 40RB 15/12/2017 B 9.50PM WATER CONDITION
FLOW OK
& WATER HE
150 DECEMBER #14 40RB 15/12/2017 C 3:00AM WATER CONDITION
FLOW OK
DUE TO (W, N,E)&LETTER
WATERWEHE
151 DECEMBER #14 40RB 16/12/2017 A 07:30AM WATER CONDITION
FLOW & OK HE
WATER
152 DECEMBER #14 40RB 16/12/2017 A 01.10PM WATER CONDITION
FLOW OK HE
& WATER
153 DECEMBER #14 40RB 16/12/2017 B 4.50PM WATER CONDITION
FLOW OK HE
& WATER
FLOW & OK HE
WATER
FLOW OK HE
& WATER
156 DECEMBER #14 40RB 17/12/2017 B 3:10PM WATER CONDITION
FLOW & OK HE
WATER
FLOW OK HE
& WATER
FLOW & OK HE
WATER
FLOW OK HE
& WATER
FLOW & OK HE
WATER
FLOW OK HE
& WATER
FLOW OK HE
& WATER
FLOW & OK HE
WATER
FLOW OK HE
& WATER
165 DECEMBER #14 40RB 19/12/2017 C 11:40PM WATER CONDITION
FLOW & OK HE
WATER
166 DECEMBER #14 40RB 19/12/2017 C 5:40AM CONDITION
WATER FLOW OK HE
& WATER
167 DECEMBER #14 40RB 20/12/2017 A 7:30AM CONDITION OK
DUE TO SECTION CHAN
168 JANUARY #14 40RB 16/1/2018 B 5:20PM GRADE
DUE TO CORECHANGED
SURFACETO CA
ROUG
169 JANUARY #14 40RB 16/1/2018 C 10:40PM WATER FLOW & WATER
DUE TO CORE SURFACE ROUG HE
170 JANUARY #14 40RB 16/1/2018 C 4:30AM WATER CONDITION
FLOW OK
& WATER HE
171 JANUARY #14 40RB 17/1/2019 A 10:20AM WATER CONDITION
FLOW & OK HE
WATER
172 JANUARY #14 40RB 17/1/2019 C 12:00AM CONDITION
WATER FLOW OK HE
& WATER
173 JANUARY #14 40RB 17/1/2019 C 2:15AM N LETTER CONDITION
WEAR OUT (INOKDOW
174 JANUARY #14 40RB 18/01/2018 A 8:00AM DUEWATER FLOW
TO CORE & WATER
SURFACE HE
ROUG
175 JANUARY #14 40RB 18/01/2018 B 3:00PM WATER CONDITION
FLOW OK
& WATER HE
FLOW & OK HE
WATER
FLOW OK HE
& WATER
178 JANUARY #14 40RB 19/01/2018 A 8:30AM WATER CONDITION
FLOW & OK HE
WATER
179 JANUARY #14 40RB 19/01/2018 A 12:50PM WATER CONDITION
FLOW OK HE
& WATER
FLOW OK HE
& WATER
181 JANUARY #14 40RB 19/01/2018 C 11:30PM WATER CONDITION
FLOW & OK HE
WATER
FLOW OK HE
& WATER
FLOW & OK HE
WATER
184 JANUARY #14 40RB 20/1/2018 A 8.30AM WATER CONDITION
FLOW OK HE
& WATER
185 JANUARY #14 40RB 20/1/2018 A 1:10PM CONDITION
WATER FLOW & WATER OK HE
186 JANUARY #14 40RB 20/1/2018 B 3:00PM CONDITION
DUE TO SECTION OK
CHANGE
ILS 40RB JULY-17 TO DEC-17
TARGET ROLLED
REASON OF PASS CHANGE TONNAGE TONNAGE Remarks
DUE TO GRADE CHANGE
800 150 STAND CHANGE
( 550D TO 500 CARES STD )
DUE TO CORE SURFACE ROUGHNESS 800 662.5 PASS CHANGE
DUE TO CORE SURFACE ROUGHNESS &
800 507.5 PASS CHANGE
'N'LETTER WEAR OUT
DUE TO 'W''N'LETTERS WEAR OUT 800 492.5 PASS CHANGE
DUE TO 'W''N'LETTERS WEAR OUT 800 467.5 PASS CHANGE
DUE TO CORE SURFACE ROUGHNESS 800 785 PASS CHANGE
CYCLE GAPWEAR OUT&
DUE TO 'W''N'LETTERS
800 705 PASS CHANGE
SURFACE ROUGHNESS
DUE TO SECTION CHANGE 800 357.5 SECTION CHANGE
CORE SURFACE ROUGHNESS 800 472.5 PASS CHANGE
800 820 PASS CHANGE
DUE TO CORELOGO DULL
SURFACE ROUGHNESS &
800 15 PASS CHANGE
IMPRESION MARKOUT & CORE
DUE TO 'W''N'LETTER WEAR
SURFACE ROUGHNESS 800 627.5 PASS CHANGE
DUE TO 'W''N'LETTER WEAR OUT & CORE
SURFACE ROUGHNESS 800 427.5 PASS CHANGE
DUE TO 'W' LETTER WEAR OUT 800 620 STAND CHANGE
DUE TO 'W' LETTER WEAR OUT& SURACE
800 285 PASS CHANGE
ROUGHNESS
DUE TO 'W' 'N' LETTER WEAR OUT 800 615 PASS CHANGE
DUE TO 'W''N'LETTER WEAR OUT & CORE
SURFACE ROUGHNESS
DUE TO GRADE CHANGE
(500D TO 500 CARES STANDERD)
DUE TO 'W''N'LETTER WEAR OUT 800 807 PASS CHANGE
DUE TO 'W''N' LETTERS WEAR OUT AND 800 862.5 PASS CHANGE
DUE TO CORE
'W''N'SURFACE ROUGHOUT AND
LETTERS WEAR 800 985 PASS CHANGE
CORE SURFACE ROUGHOUT AND
DUE TO 'W''N' LETTERS WEAR
800 920 PASS CHANGE
CORE SURFACE ROUGH
DUE TO CORE SURFAE ROUGHNESS 800 865 STAND CHANGE
DUE TO 'W''N' LETTERS WEAR OUT AND 800 657.5 PASS CHANGE
CORE SURFACE ROUGHNESS
DUE TO CORE SURFAE ROUGHNESS 800 837.5 PASS CHANGE
DUE TO DOWN TIME 800 780 PASS CHANGE
DUE TO CORE SURFACE ROUGHNESS 800 1120 STAND CHANGE
DUE TO GRADE CHANGE 500D TO
500CARES STANDERD
DUE GRADE CHANGE (500D TO 500 800 205 PASS CHANGE
CARES STANDERD)
DUE TO GRADE CHANGE 500D TO 500 162.5 PASS CHANGE
800
CARES STANDERD
DUE TO GRADE CHANGE 500D TO 500 800 130 PASS CHANGE
DUE TO CORE SURFACE ROUGHNESS 377.5 PASS CHANGE
800
&"N" LETTER WEAR
DUE TO SECTION CHANGE 800 580 SECTION CHANGE
DUE TO GRADE CHANGE 500D TO 500 160 STAND CHANGE
800
CARES
DUE TO E W LWTTER WEAR OUT 800 757.5 PASS CHANGE
DUE TO SECTION CHANGE 800 527.5 SECTIONCHANGE
DUE TO GRADE CHANGE 500D TO 500 147.5 STAND CHANGE
800
CARES STANDERD
DUE TO CORESURFACE WEAR OUT 800 585 PASS CHANGE
DUE TO CORE SURAFECE ROUGHNESS 800 855 PASS CHANGE
DUE TO CORE SURAFECE ROUGHNESS 800 660 PASS CHANGE
DUE TO CORE SURAFECE ROUGHNESS 800 822.5 PASS CHANGE
DUE TO CORE SURAFECE ROUGHNESS 800 622.5 PASS CHANGE
DUE TO DOWN TIME 800 842.5 PASS CHANGE
#14 SHEAR PIN BROKEN (DOWM TIME) 800 607.5 PASS CHANGE
DUE TO EXTRA METERIAL IN REBAR 800 270 PASS CHANGE
DUE TO EXTRA METERIAL IN REBAR 800 237.5 PASS CHANGE
DUE TO EXTRA METERIAL IN REBAR 800 202.5 STAND CHANGE
DUE TO EXTRA METERIAL IN REBAR 800 122.5 PASS CHANGE
DUE TO SECTION CHANGE 800 137.5 PASS CHANGE
DUE TO GRADE CHANGE 500D TO 130 STAND CHANGE
800
500CARES STANDERD
DUE TO CORE SURFACE ROUGHNSS 800 712.5 PASS CHANGE
DUE TO CORE SURFACE ROUGHNSS 800 605 PASS CHANGE
DUE TO CORE SURFACE ROUGHNSS 800 920 STAND CHANGE
DUE TO CGRADE CHANGE 500 TO 500D 800 780 STAND CHANGE
DUEGRADE CHANGE
TO CORE 500DROUGHNESS
SURFACE TO CARES , 800 157.5 STAND CHANGE
WATER FLOW & WATER HEADER ,
WATER CONDITION
FLOW OK
& WATER HEADER , 800 560 PASS CHANGE
DUE TO CORE SURFACE ROUGHNESS
WATER CONDITION
FLOW OK 707.5 PASS CHANGE
DUE TO (W, N,E)&LETTER
WATERWEAR
HEADER
OUT, 800
WATER CONDITION
FLOW & OK HEADER
WATER 800 480 PASS CHANGE
DUE TO CORE SURFACE ROUGHNESS ,
WATER CONDITION
FLOW OK HEADER
& WATER 800 680 PASS CHANGE
WATER CONDITION
FLOW OK HEADER
WATER CONDITION
FLOW & OK HEADER
WATER CONDITION
FLOW OK HEADER
WATER CONDITION
FLOW & OK HEADER
WATER CONDITION
FLOW OK HEADER
WATER CONDITION
FLOW & OK HEADER
WATER 800 732.5 STAND CHANGE
WATER CONDITION
FLOW OK HEADER
& WATER 800 587.5 PASS CHANGE
WATER CONDITION
FLOW & OK HEADER
WATER 800 1037.5 PASS CHANGE
WATER CONDITION
FLOW OK HEADER
WATER CONDITION
FLOW OK HEADER
WATER CONDITION
FLOW & OK HEADER
WATER CONDITION
FLOW OK HEADER
WATER CONDITION
FLOW & OK HEADER
CONDITION
WATER FLOW OK HEADER
CONDITION OK
GRADE
DUE TO CORECHANGED
SURFACETO CARES
ROUGHNESS , 800 77.5 STAND CHANGE
WATER FLOW & WATER HEADER
DUE TO CORE SURFACE ROUGHNESS , 800 912.5 PASS CHANGE
WATER CONDITION
FLOW OK HEADER
WATER CONDITION
FLOW OK HEADER
CONDITION
WATER FLOW OK HEADER
N LETTER CONDITION
WEAR OUT (INOKDOWNTIME), 800 172.5 PASS CHANGE
DUEWATER FLOW
TO CORE & WATER
SURFACE HEADER ,
ROUGHNESS 800 762.5 PASS CHANGE
WATER CONDITION
FLOW OK
& WATER HEADER , 800 1002.5 PASS CHANGE
WATER CONDITION
FLOW & OK HEADER
WATER CONDITION
FLOW OK HEADER
& WATER 800 722.5 STAND CHANGE
WATER CONDITION
FLOW & OK HEADER
WATER CONDITION
FLOW OK HEADER
WATER CONDITION
FLOW OK HEADER
WATER CONDITION
FLOW & OK HEADER
WATER CONDITION
FLOW OK HEADER
WATER CONDITION
FLOW & OK HEADER
WATER CONDITION
FLOW OK HEADER
CONDITION
WATER FLOW & WATER OK HEADER 800 650 PASS CHANGE
CONDITION
DUE TO SECTION OK 28RB
CHANGE 800 247.5 …..

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Steel Ltd, 4i -Sheet (Improvem

b) Problem Goal- Improve pass life in 40 Rb

ass need to be changed

milll utilization 2.2 Selection of Idea

Idea No Cost Of Impact Of Time Of Ease Of Total

2 Low High High Easy 28

3 High Low High Difficult 4

2.3 Risk assesment

Start Date End Date

3.2 Project Standardization & Commercialization

Nozzle Roll hardness Furnace billet

Nozzle angle change

Daily Till date

Comple Taken RPN

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