INNOVATORS

QUALITY CIRCLE TEAM

WELCOMES YOU ALL

 COMPANY INTRODUCTION
VISA GROUP

VISA VISA STEEL VISA COKE

MINMETAL

 1,50,000 TPA Ferro Chrome  4,00,000 TPA Coke Plant

 Commodity Trading Plant  Equipped with environmental
 Shipping & Chartering  25x3 MW Captive Power Plant friendly Chinese technology.
 Structured Trading  2,25,000 TPA Blast Furnace  Major supplier for Blast
 Investment in Mining Plant Furnaces & Foundries.
 3,00,000 TPA DRI Plant
 5,00,000 TPA Steel Melting Shop
and Wire Rod & Bar Mill
 VISA Group is founded by Mr. Vishambhar Saran in April, 1994.

 VISA Steel Limited is a flagship company of the VISA Group with its Registered office in
Bhubaneswar; Corporate office in Kolkata, Branch offices across India and Manufacturing
Facility at Kalinganagar, Odisha.

 The Company is operating an integrated Special Steel Plant and Ferro Chrome Plant at
Kalinganagar Industrial Complex in Odisha.
 COMPANY PRODUCTS

Pig Iron Sponge Iron Billet

Wire Rod Round Bar Angle

TMT Flats Ferrochrome

 DRI PLANT FLOW DIAGRAM ALPHA

COAL

COAL
DOLO
GROUND IRON MITE
IRON HOPER

STACK CAP

DOLOMITE GROUND
HOPER
COAL COAL

COAL THROW PIPE SAF

ABC
KILN

SIZER
DSC

FINES LUMPS COOLER

MAGNETIC MAGNETIC
SEPARATOR SEPARATOR
WET SCRAPPER

Parameter Details

Capacity 300,000 TPA

SPONGE SPONGE
CHAR
IRON IRON
LUMPS
Description 2 x 500 TPD Rotary Kilns
FINES

Technology Partner Lurgi (Outokumpu) Germany

 INNOVATORS

QUALITY CIRCLE
TEAM INTRODUCTION
 TEAM MEMBERS

AMIT.MOHANTY
(FACILITATOR)

PRATYUSH.PARIJA DURGADATTA RAY BIMAL JENA JABAN.DHAL

(TEAM LEADER) (MEMBER) (MEMBER) (MEMBER)
 PROJECT INTRODUCTION

 Team Formation: Jan-2022

 Team Registration: VSL/QC/DRI/004
 Project Name: ELIMINATION OF FREQUENT FAILURE OF BAGGING MACHINES
AND SPILLAGE OF SPONGE IRON
 QCFI Registration No: 071504117761
 Project Started: 01/02/2022
 Project Completed: 31/03/2022
 Numbers of Meeting: 08
 Meeting Frequency: Weekly
 Attendance in Meeting: 100%
 Project Implementation: 01
 Project Running: 00
 QUALITY CIRCLE

TOOLS AND TECHNIQUES APPLIED

 TOOLS & TECHNIQUES

1. Brainstorming

2. Smart Method

3. Pie Chart

4. Ranking Method

5. Fish Bone Analysis

6. 4W+1H Technique

7. Pareto Analysis

8. Why-Why Analysis

9. PDCA Cycle

10. Mile Stone Chart

IDENTIFICATION OF PROBLEMS

PROBLEM IDENTIFICATION??
 BRAINSTORMING

Brainstorming session were carried out for identification of problems

 PROBLEMS

Problems
Sr. No Category
1 Support railing is missing near winch machine of Kiln-1 CB platform A
2 Dumping bin is absent at IBIN dust collection chute A
3 PA system is offline in some of the DRI plant area A
4 Frequent failure of bagging machines and spillage of sponge iron A
5 To mush dust emission from dedusting-02 side and water contamination A
6 Dumping bin is absent at coal fines junction dust collection chute A
7 Walkway is damaged near borewell area electrical shift room B
8 Kiln-1 Upper ABC fan platform is damage A
9 Product building 1st floor cable is not dressed properly in cable tray A
10 Industrial socket is missing near Bagging m/c-1 B
11 High dust emission in bagging area A
12 Ingression of water in electrical workshop A
13 High dust emission in DRI fines discharge belt during vibrator motor running A
 PROBLEMS

Sr.
Problems
No Category
14 Vibro feeder too much sound is present in bagging area A
15 Low illumination in bagging area A
16 Oil leakage in Kiln-1 auxillary drive gear box A
17 Oil ingression from gear box towards tacho assembly in kiln-2 Iron ore w/f A
18 Kiln-2 CB platform power cable of CB-1 fan & CB-2 fan protection cover is absent B
19 Too much dust emission at product JH-01 and high dust accretion at staircase A
20 BC-37 walkway platform is weak B
21 BC-21A walkway is too weak B
22 Leakage and overflow issue is present in dumping bin of daybin A
23 Oil leakage in kiln-2 auxillary drive gear box A
24 No name plate available of misc w/f of Kiln-1&2 B
25 No name plate available of feed coal w/f of Kiln-2 B
26 Too much dust emission from JH-02 coal fines A
27 welding m/c cable open & laying on staircase in PP building B
 PROBLEMS
Sr. Problems
No Category
28 Walkway absent in entrance of RMHS new DE MCC room B
29 Too much dust emission from secondary crusher building B
30 Too much material ingression present on walkway of BJ5-15 B
31 Belt conveyor roller found over DG roof shed B
32 Deposition & contamination of water near DRI compressor room B
33 Lighting JB near 3rd ABC kiln-2 cover is missing B
34 Landline phone of Intrumentation room is not working C
35 Char-1 bin level indication is not working A
36 IBIN-A level is not displaying on DCS system A
37 Frequent blockage of I/L hood pressure duct connected to flow transmitter A
38 Water filter not working properly and leakage in tap of the water filter C
39 Frequent damage of float switch/level sensor of wet scrapper water level A
40 ZSS controller of AJ5-15 not properly welded B
41 Oil leakage in Kiln-1 cooler main drive gear box A
 PROBLEMS

Sr. Problems
No Category

42 No cover fitting on counter weight of vibro feeder motor of iron B

43 Magnetic Vibrator Both LCS door hinges are damaged A

44 CD-1 motor protection cover is missing B

45 No proper dressing of lumps magnetic seperator motor cable A

46 No proper dressing of fines magnetic seperator motor cable A

47 Low illumination at AJ5-23 platform A

48 RAV-1&2 of DE system emergency stop push button is damaged A

49 Very low illumination near compressor 1,2,3 A

50 No proper cable dressing near CB fan 2 of kiln-1 A

51 LCS of kiln-1 transfer cute is not available and not covered properly B
52 No HMI system present for IOCP area A
 ABC CLASSIFICATION

 A-Category: To be solved by Quality Circle team members without assistance of any other
departments

 B-Category: For solving the problem assistance of other departments is required

 C-Category: For solving the problems help of top management is required

 ABC CLASSIFICATION

3%

34%

A-CATEGORY
B-CATEGORY
C-CATEGORY
61%
SELECTION OF PROBLEMS

SMART METHOD
 SELECTION OF PROBLEM

52 PROBLEMS

CLASS-A(32) CLASS-B(18) CLASS-C(2)

OPERATIONAL SAFETY ENVIRONMEMNT CUSTOMER MAINTENANCE

SATISFACTION PRACTICES
 FOLLOWING PROBLEMS ARE IDENTIFIED

Frequent damage of float switch/level sensor of wet scrapper water level

Char-1 bin level indication is not working

No HMI system present for IOCP area

Frequent failure of bagging machines and spillage of sponge iron

IBIN-A level is not displaying on DCS system

PROBLEM SELECTION

RANKING METHOD
 SELECTION OF PROBLEM..
Maximum Marks:10
Sr. No P. Parija D. Ray B. Jena J. Dhal Total Rank
Problem Description

Frequent damage of float

1 switch/level sensor of wet 7 7 7 6 27 3
scrapper water level

Char-1 bin level indication is

2 6 5 5 4 20 4
not working

No HMI system present for

8 8 7 8 31 2
3 IOCP area

Frequent failure of
4 bagging machines and 9 9 8 8 34
1
spillage of sponge iron
IBIN-A level is not
5 5 5 4 5 19 5
displaying on DCS system
 OBJECTIVE & GOAL

OUR CORE OBJECTIVE OF THIS PROJECT

 To minimize the Failure time of the system

 To create a safe working environment
 To eliminate damage of bags
 To eliminate use of hardware contactors & hardware timers
 To increase the bagging production
 Eliminate spillage of Sponge Iron.

OUR GOAL

Reducing the frequency of failure of Bagging Machine from 81 to 4 times.

 MILESTONE CHART
Target
Team Name : INNOVATORS Dept : DRI Facilitator: Members:
Amit Mohanty P. Parija, D. Ray, B.Jena, J. Dhal
Project: ELIMINATION OF FAILURE OF BAGGING Reason for selection : Unable to trace the fault and
MACHINES AND SPILLAGE OF SPONGE IRON eliminate spillage of sponge iron material
Project No : 01 Date of Beginning : 1/02/2022 Date of Completion : 31/03/2022

Meeting Day: Monday Time: 4 pm to 5 pm No. of Project Completed: 00

WEEKS
Sr. No Steps 1 2 3 4 5 6 7 8
1 Defining the problem

2 Analyzing the problem

3 Identifying the problem

4 Finding root cause

5 Data analysis

6 Developing the solution

7 Foreseeing problem resistance

8 Trail implementation

9 Regular implementation

10 Follow up/Review
SYSTEM OVERVIEW

SYSTEM OVERVIEW
AND
AREA OF PROBLEM
 BAGGING MACHINE OVERVIEW

SPONGE IRON
MATERIAL BIN MATERIAL

UPPER GATES

LOAD BUCKET

LOWER GATES

CLAMPS CLAMPING BUTTON

BAG
 PROBLEM FACED

 Spillage of sponge iron from bagging machine

Bagging
Machine

Sponge
Iron

Conveyor
belt
 AREA OF PROBLEM

 Main area of problem is not able to trace fault

during Failure of bagging machine and spillage of
sponge iron material
 Due to dense wiring, it becomes very difficult to
trace the problem in the bagging machine
 PROBLEM FACED

 It also causes damage of bags and also the bagging speed is slow (approx. 8 bags/min)
PROBLEM ANALYSIS

4W+1H TECHNIQUE
 WHAT?..

What is the problem??

Frequent failure of Bagging Machine and spillage of Sponge Iron.

 WHEN?..

When the problem occurs?

During the operation of bagging machine.

 WHERE?..

Where is the problem?

In Bagging Machine
 WHO?..

Who is affected by it?

Man, Machine, Process, Safety, Product parameters and its quality

 HOW?..

How the problem arises?

During operation of Bagging Machine sometimes bagging

machine sequence interrupt due to which spillage of S.I happens.
PROBLEM ANALYSIS
 DATA COLLECTION

Failure of machines & spillage of sponge iron material history

Month Frequency of Failure Frequency of spillage

OCT-21 22 19
NOV-21 19 16
DEC-21 24 20
JAN-22 16 14
IDENTIFICATION OF CAUSES
 FISH BONE DIAGRAM

• The fishbone diagram identifies many possible causes for an effect or problem.
 IDENTIFICATION OF CAUSES..

MAN MACHINE METHOD

Elimination
of frequent
failure of
Bagging
machines and
spillage of SI

MATERIAL MISCELLANEOUS
 IDENTIFICATION OF CAUSES..
Lack of training
Bag not fitted properly
MAN to machine

Misalignment of bag
Lack of knowledge with machine discharge
Lack of wiring Unable to trace
Wrong operation of
knowledge fault in electrical
clamp push button
panel wiring

Double pressing of Due to dense Elimination

button electrical wiring of frequent
failure of
Bagging
No interest to learn system machines and
Lack of interest spillage of SI
Operator not trained

Lack of process Poor system

knowledge awareness

MAN
 IDENTIFICATION OF CAUSES..
Upper gate contactor
malfunctioning MACHINE

Upper gate solenoid Problem in electrical

problem Fault in electrical panel
contactors

Dust in electrical panel

Upper proxy sensor
faulty
Problem in upper Loose wiring Elimination
gate wiring of frequent
failure of
Bagging
Lower gate contactor Jamming in cylinder piston machines and
malfunctioning spillage of SI
Problem in clamp
solenoid wiring
Problem in lower
gate wiring
Damaged holding
clamps Clamp cylinder
Lower gate solenoid solenoid problem
problem Clamp solenoid supply
MACHINE missing
 IDENTIFICATION OF CAUSES..

METHOD

Wrong approach
Wrong operation Lack of bagging
machine knowledge

Sequence breaking

Delay in process Dense hardware

Elimination
electrical wiring
of frequent
failure of
Bagging
machines and
Wrong operation of spillage of SI
clamp switch

Clamp switch
operation
METHOD
 IDENTIFICATION OF CAUSES..
Lower gate solenoid
faulty
Upper gate proxy MATERIAL
faulty
Problem in Lower
Problem in Upper gate
gate

Clamp solenoid faulty

Upper gate solenoid

faulty Problem in Bag
holding camps Elimination
of frequent
failure of
Bagging
machines and
High dust emission spillage of SI

Low illumination

Very dense wiring

Working condition not
good
MISCELLANEOUS
 VALIDATION OF CAUSES..

WITH PROPER
WHY WHY JUSTIFICATIO
CAUSE N
VALIDATION
SUB CAUSE SUB CAUSE
RESULT
Wrong operation of clamp push Lack of knowledge Rejected
button Double pressing of button Rejected
No interest to learn system Rejected
Lack of process knowledge
Operator not trained Rejected
Poor system awareness Lack of interest Rejected
MAN
Lack of training Rejected
Bag not fitting properly to machine
Misalignment of bag with machine discharge Rejected

Unable to trace fault in electrical Lack of wiring knowledge Rejected

panel wiring Due to dense electrical wiring Accepted
Upper gate contactor malfunctioning Accepted
MACHINE Upper gate solenoid problem Upper proxy sensor faulty Accepted
Problem in upper gate wiring Accepted
 VALIDATION OF CAUSES..

WITH PROPER
WHY WHY JUSTIFICATIO
CAUSE N
VALIDATION
SUB CAUSE SUB CAUSE
RESULT
Loose wiring Accepted
Problem in electrical panel Dust in electrical panel Accepted
Fault in electrical contactors Accepted
Lower gate contactor malfunctioning Rejected
Lower gate solenoid problem
MACHINE Problem in lower gate wiring Rejected
Jamming in cylinder piston Accepted
Problem in clamp solenoid wiring Accepted
Clamp cylinder solenoid problem
Damaged bag holding clamps Accepted
Clamp solenoid supply missing Accepted
 VALIDATION OF CAUSES..

WITH PROPER
WHY WHY JUSTIFICATIO
CAUSE N
VALIDATION
SUB CAUSE SUB CAUSE
RESULT
Sequence breaking Rejected
Wrong operation
Delay in process Rejected
METHOD Dense hardware electrical wiring Accepted
Wrong approach
Lack of bagging machine knowledge Rejected

Clamp push button operation Holding the clamp button to ON Accepted

Upper gate proxy faulty Rejected

Upper gate
Upper gate solenoid problem Accepted
MATERIAL
Lower gate Lower gate solenoid faulty Rejected

Bag holding camps Clamp solenoid faulty Rejected

 VALIDATION OF CAUSES..

WITH PROPER
WHY WHY JUSTIFICATIO
N
CAUSE`
VALIDATION
SUB CAUSE SUB CAUSE
RESULT
Low illumination Rejected

MISCELLANEOUS Working condition not good High dust emission Rejected

Very dense wiring Rejected

 VALIDATION OF CAUSES..

Problem in electrical panel

Clamp cylinder solenoid problem

Dense hardware electrical wiring

Upper gate solenoid problem

Holding the clamp button to ON

ROOT CAUSE ANALYSIS
 DATA ANALYSIS ON ROOT CAUSE

CAUSE Frequency in No's

Problem in electrical panel 45

Clamp cylinder solenoid problem 7

Dense hardware electrical wiring 17

Upper gate solenoid problem 3

Holding the clamp button to ON 4

 DATA ANALYSIS ON ROOT CAUSE

OCT-21 to JAN-22
Cumulative failure
Causes Failure frequency Failure in %
frequency

Problem in electrical
45 45 59
panel

Dense hardware
17 62 82
electrical wiring

Clamp cylinder
7 69 91
solenoid problem

Wrong operation of
4 73 96
clamp switch

Holding the clamp

3 76 100
button to ON
Total 76
 PARETO ANALYSIS

100
78 96 100
Failure frequency of bagging machines and spillage of SI

91

65 82
80

Cumulative failure in %age

52 Vital few 59
Breaking Point 60

39

40
26
Useful many
45

20
13
17

7
0 4 3 0

Holding the clamp

button to ON

CAUSES
 PARETO ANALYSIS

Pareto analysis clearly shows that the major contribution of problem faced in bagging machines
are;

1. Problem in electrical panel 2. Dense hardware electrical wiring

WHY WHY ANALYSIS
 WHY WHY ANALYSIS

1. PROBLEM IN ELECTRICAL PANEL

MALFUNCTIONING OF
WHY
HARDWARE CONTACTORS

WHY LOOSE WIRING OF CONTACTORS

HARDWARE BASED ELECTRICAL

WHY WIRING

WHY DESIGN WEAKNESS

RESULTS IN FREQUENT FAILURE

OF BAGGING MACHINES AND
SPILLAGE OF SPONGE IRON
 WHY WHY ANALYSIS

2. DENSE HARDWARE ELECTRICAL WIRING

WHY DENSE HARDWARE ELECTRICAL WIRING

MULTIPLE CONTACTORS AND

WHY HARDWARE TIMERS USED

WHY DESIGN WEAKNESS

RESULTS IN FREQUENT FAILURE

OF BAGGING MACHINES AND
SPILLAGE OF SPONGE IRON
DEVELOPING SOLUTION
 DEVELOPING SOLUTION

1. REPALCING OLD CONTACTORS WITH NEW ONE OVER FREQUENT PERIOD OF TIME

RESULT: NOT FEASIBILE TO REPLACE CONTACTORS EVERYTIME

 DEVELOPING SOLUTION

2. MAINTAINING THE ELECTRICAL PANEL NEAT AND CLEAN AND ENSURING THE
TIGHTNESS OF ELECTRICAL CONNECTIONS DAILY

RESULT: NOT FEASIBILE TO DO EVERYTIME AS IT BECOMES TOO

MUCH TIME CONSUMING RESULTING IN INCREASE IN
TROUBLESHOOTING TIME
 DEVELOPING SOLUTION

3. REPALCING THE ELECTRICAL PANEL WITH DCS SYSTEM

RESULT: VERY MUCH EFFECTIVE AND FAULT TRACING BECOMES EASY

AND HARDWARE ELECTRICAL CONTACTORS AND TIMERS WILL BE
COMPLETELY ELIMINATED
 FORESEEING PROBABLE RESISTANCE

SR.
FORESEEING PROBABLE RESISTANCE ACTION TO OVERCOME
NO

1 Non quality circle member opposed due to avoiding Theoretical presentation was
nature and extra work. given to non QC members to
explain the advantages

2 Doubts raised by operation personnel regarding new Presentation regarding new

system implementation. system is given and its ease of
use
3 Doubts raised by Mech HOD on new system accuracy Presentation regarding new
and reliability system with respect to mech
point of view was explained

4 Doubts raised by Plant HOD on new system accuracy Presentation regarding

and reliability advantages of using bagging
machine by DCS system was
explained

5 Doubt raised by other department personnel whether Presentation regarding

implementation into DCS system will be reliable or not advantages of using bagging
machine by DCS system was
explained
TRIAL IMPLEMENTATION
PDCA
 PLAN DCA CYCLE

1. ANALYSIS OF EXISTING SYSTEM

2. ARRANGEMENT OF REQUIRED MATERIALS

3. ACTION PLAN FOR EXECUTION OF THE PLAN

4. APPROVAL OF WORK BY SECTION HEAD AND OPERATIONAL INCHARGE

 ACTION PLAN FOR MODIFICATION WORK

Target Actual

DATE P. PARIJA D. Ray B. JENA J. DHAL JOB DESCRIPTION

01-02-2022 Study of system

Analysis of required
11-02-2022
materials

Arrangement of required
20-02-2022
materials

DI & DO tag creation and

06-03-2022
activation of tags

Cable schedule
10-03-2022
preparation
 ACTION PLAN FOR MODIFICATION WORK

Target Actual

DATE P. PARIJA D. Ray B. JENA J. DHAL JOB DESCRIPTION

Cable laying and loop

15-03-2022
checking

20-03-2022 Termination of cable

Logic & Graphics made

21-03-2022
in DCS

22-03-2022 Trail & Implementation

System handover to
25-03-2022
process
 P DO CA CYCLE

 Arrangement of master JB box

 Arrangement of Sub JB

 Arrangement of 2.5 sq.mm 12 pair instrument control cable

 Arrangement of 24V DC proxy sensor

 Arrangement of clamp ON push button

 Mounting of master JB box

 Mounting of sub JB near bagging machine

 Mounting and adjustment of proxy sensor in bagging machine

 P DO CA CYCLE

STUDY OF SYSTEM

Bagging machine operation flow is studied and analyzed

 P DO CA CYCLE

ARRANGEMENT OF REQUIRED MATERIAL

Arrangement of required material is done

 P DO CA CYCLE

DI/DO TAG CREATION IN DCS SYSTEM

Inputs & Outputs required in the bagging machine are defined and their tag creation is carried
out in DCS system
 P DO CA CYCLE

CABLE SCHEDULE PREPARATION

Cable schedule is prepared as per inputs & outputs used in the bagging machine.
 P DO CA CYCLE

CABLE LAYING

After cable schedule preparation, cable

laying from DCS FIM panel to bagging
machine area is done.
 P DO CA CYCLE

LOOP CHECKING

After cable laying is done, proper

loop testing is carried out
 P DO CA CYCLE

TERMINATION OF CABLE

After successful cable loop testing, with the

help prepared cable schedule the termination
bagging machine inputs & outputs is done
with the DCS FIM panel
 P DO CA CYCLE

LOGIC & GRAPHICS MADE IN DCS

After the termination is done, finally the

logic & graphics are made in the DCS
system as per the operation of bagging
machine

Special interlock is provided in logic to

eliminate spillage of sponge iron
 P DO CA CYCLE

LOGIC & GRAPHICS MADE IN DCS

 PD CHECK A CYCLE

 TO CHECK THE SUSTAINABILITY OF OUR PROJECT

 CHECK POINTS:

1. Checking the proxy sensor condition

2. Checking upper gate, lower gate, clamps
3. Inspecting master JB, sub JB condition
4. Checking if any spillage of sponge iron is present or not
 PD CHECK A CYCLE

1. Checking the proxy sensor condition

 PD CHECK A CYCLE

2. Checking upper gate, lower gate, clamps

 PD CHECK A CYCLE

3. Inspecting master JB & sub JB condition

 PD CHECK A CYCLE

4. Checking if any spillage of sponge iron is present or not

 PDC ACT CYCLE

 System handed over to process

 Examine the sustainability of modified system

 Note down any loop holes or errors found during examination

 CHECKLIST

SR. CHECKPOINT FREQUENCY OBSERVATION RESPONSIBILITY

NO

1 Checking the proxy sensor Daily for 1 All ok J.Dhal

condition month
2 Checking upper gate, lower Daily for 1 All ok B.Jena
gate, clamps month
3 Inspecting master JB, sub JB Daily for 1 All ok B.Jena
condition month
4 Checking if any spillage of Daily for 1 All ok J.Dhal
sponge iron is present or not month
 TRAINING CONDUCTED

With the help of department training co-ordinator, training program were conducted

After implementation of project, following training points are covered for smooth process of
bagging machine

SR. TOPICS DATE TRAINER PERSONS NO. OF

NO COVERED PARTICIPAN
T
1 Working on modified system 01-04- L.Khan Mech & 10
2022 Operation
2 Troubleshooting by DCS 01-04- L.Khan Electrical 4
system 2022
3 I/O checking by DCS system 01-04- P.Parija Electrical 4
2022
4 Checking of particular 01-04- P.Parija Electrical 4
solenoid, proxy sensor by 2022
DCS system
MILESTONE CHART
 MILESTONE CHART
Target Actual
Team Name : INNOVATORS Dept : DRI Facilitator: Members:
Amit Mohanty P. Parija, D. Ray, B. Jena, J. Dhal
Project: ELIMINATION OF FAILURE OF BAGGING MACHINES AND SPILLAGE Reason for selection : Unable to trace the fault and eliminate spillage of
OF SPONGE IRON sponge iron material
Project No : 01 Date of Beginning : 1/02/2022 Date of Completion : 31/03/2022
Meeting Day: Monday Time: 4 pm to 5 pm No. of Project Completed: 01
WEEKS
Sr. No Steps
1 2 3 4 5 6 7 8

1 Defining the problem

2 Analyzing the problem

3 Identifying the problem

4 Finding root cause

5 Data analysis

6 Developing the solution

7 Foreseeing problem resistance

8 Trail implementation

9 Regular implementation

10 Follow up/Review
 RESULT

Due to implementation of DCS system in Bagging machine

operation

90 81

Before Project: 80
Average frequency of failure of bagging machines
from Oct-21 to Jan-22 = 81 70

After Project: 60
Average frequency of failure of bagging machines
from April-22 to July-22 = 4 50 Before Project
40 After Project

30
20
4
10
0
 RESULT

Due to implementation of DCS system in Bagging machine

operation

80 69
Before Project: 70
Average frequency of spillage of sponge iron
from 60
Oct-21 to Jan-22 = 69
50
After Project:
Average frequency of spillage of sponge iron 40 Before Project
from
April-22 to July-22 = 3 After Project
30

20
3
10

0
Spillage of Sponge Iron
 RESULT

Due to absence of fault tracing system using DCS

198
200
Before Project: 180
Average time required to trace the fault
(Troubleshooting time) in the machine from Oct-21 160
to Jan-22 = 198 Hrs.
140
120
After Project:
Average time required to trace the fault from 100 Before Project
April-22 to July-22 = 4 Hrs.
After Project
80
60
40 4
20
0
Troubleshooting Hrs
PROJECT BENEFITS
 INTANGIBLE BENEFITS

 Safe working environment

 Development of team work
 Quality of life improved
 Job satisfaction
 House keeping improved
 Stress on workmen reduced
 TANGIBLE BENEFITS
 Damage of bags is drastically reduced

Before Project No. of bags damaged Cost

OCT-21 156 1248Rs/-
NOV-21 102 816Rs/-
DEC-21 87 696Rs/-
JAN-22 96 768Rs/-
Total 441 3530Rs/-
After Project No. of bags damaged Cost
APRIL-22 11 88
MAY-22 4 32
JUNE-22 6 48
JULY-22 10 80
Total 31 250Rs/-

Total Cost savings for bags= 3280Rs/-

 TANGIBLE BENEFITS

 Speed of bagging of sponge iron is increased

Before Project No. of bags

No. of bags per min 7-8
After Project No. of bags
No. of bags per min 14-15

Hence, delay in dispatch of sponge iron is reduced

 TANGIBLE BENEFITS

 Spillage of sponge iron is reduced

Before Project Avg. Frequency of Avg. SI material (Kg)

spillage
OCT-21 19 3000
NOV-21 16 2200
DEC-21 20 2400
JAN-22 14 1700
Total 69 9300 Kg’s
After Project Avg. Frequency spillage Avg. SI material (Kg)

APRIL-22 1 100
MAY-22 0 0
JUNE-22 1 120
JULY-22 1 100
Total 3 320Kg’s

Hence, spillage is reduced from 9300kg’s to 320kg’s

 TANGIBLE BENEFITS

 Spare consumptions and use of electrical timers, contactors is completely eliminated

Spare type Quantity (No) Total cost

Before Project Aux. Contactor 32 22400Rs/-
Timers 16 24000Rs/-
Total cost
Spare type Quantity (No)
After Project
No spares required - 0 Rs/-

Total Cost Savings: - Rs.49680 in 4 months.

 FUTURE PROJECT

No HMI system present for IOCP area

 ACKNOWLEDGEMENT

 We are thankful to CCQC Bhubaneswar chapter, for giving us opportunity to present

our project.

 We are thankful to Visa Steel management and ISO team for inspiring us to join the
quality circle team.

 We are thankful to our facilitator for guiding us at different stages during project

 We are thankful to Operation & Mech. department for their valuable support during
project

 We would like to express our special gratitude and thanks to senior management for
giving us such attention and time.
THANK YOU