overview of bhushan power and steel

7/30/2019 Overview of Bhushan power and steel

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MID-TERM EVALUATION REPORT OF

6 MONTHS INTERNSHIP AT

BHUSHAN POWER

& STEEL LTD.

Submitted byAbhishek Dhawan

b.e.(Mechanical)4

thyear

Sg 9904


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CONTENTSS.No Description Pages

1 ACKNOWLEDGEMENT 3

2 COMPANY PROFILE 4

3 MISSIONS AND VALUES 5-6

3 PRODUCTS 7-8

4 DESCRIPTION OF TUBE MILL 9

5 PROCESSES 10-11

6 PROJECT/ CASE STUDY 12

7 SIX SIGMA ANALYSIS 13-18


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ACKNOWLEDGMENT

I deem it as my proud privilege to express my sincerest regards and

gratitude to Mr. Goyal , GM , Bhushan Power And Steel Limited (BPSL) for

providing this valuable opportunity to pursue this work .

I would like to record with in deep sense of gratitude to:

Mr. Harkamal Preet Singh

H.O.D of B.E. (MECHANICAL) , PUSSGRC , Hoshiarpur.

My humble and sincere thanks to all the technicians and workers for

their unstilted guidance and direction , which helped in increasing my

practical knowledge.

I wish to express my thanks to all staff members of BPSL for their

cooperative attitude and valuable suggestions during the course of the

project work .

COMPANY PROFILE


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Bhushan Power & Steel Limited (BPSL), is a fully integrated 2.8 Million TPA

Steel Making Company having turnover of INR 5020 Crores (USD 1000

Million) FY11.

The Company is certified to ISO 9001:2008 & TS-16949 Quality Standards

and ISO 14001:2004 Environment Management Standards.

BPSL is a leading manufacturer of flat and long products and have state-of

the-art plants at Chandigarh, Derabassi, Kolkata and Orissa in India. These

plants manufacture value added products covering entire steel value chain

right from Coal Mining to manufacturing Pig Iron, DRI, Billets, HR Coils,

CR Coils, GP/GC Sheets, Precision Tubes, Black Pipe/GI Pipe, Cable Tapes,

Tor Steel, Carbon and Special Alloy Steel Wire Rods and Rounds conformingto IS and international standards.

The Company have successfully commissioned a 2.8 Million TPA Greenfield

Steel and Power Plant in Orissa with HR Coil making facility - First in

Private Sector in the State of Orissa. For this plant, technology and equipment

were sourced from leading world-renowned companies viz., Lurgi, ABB Ltd.,

SMS Siemag, SMS Meer Danieli, LOI Tenova, Kocks etc. BPSL has a wide

marketing network in both India (comprising 35 sales offices) and abroad for

selling its value added product range.

The rock-solid foundation combined with continuous up gradation and

innovation has enabled the Company to surpass its goals constantly. BPSL's

end-to-end portfolio has enabled it to offer a wide spectrum of products at

superior quality consistently surpassing customers' specifications. In addition

to export thrust, BPSL cater to the domestic steel requirements of fast-

growing sectors like automotive, white goods, construction / infrastructure,

furniture, fasteners, telecommunication, power etc. With a view to make its

presence in a big way in Special Alloy Steel Long Product business, BPSL has

commissioned a most modern state of the art Wire Rod-cum-Bar Mill and iscommissioning a host of downstream finishing facilities viz., Heat Treatment

facilities, Bright Bar manufacture etc.

MISSIONS AND VALUES


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Our Mission is to achieve clear identity and leadership globally in Steel

production and distribution by integration of complete chain of production

starting from captive iron ore to end user Steel products.

Our revolution in Steel production has helped us to carve a niche unique only

to a market leader. Every year passes by with new value additions and more

accolades from our customers - Locally and Globally. Our rising chart in

respect of all-important parameters of production and finance is a testimony

to our claim.

In pursuing our mission, we at Bhushan Power & Steel Ltd. are guided by the

following values

Quality - To be the best in quality. We aim and achieve excellence.

Technology - State of the art technology and product enrichment by

continuous Research and Development.

Customer Friendly - Our products are world class and more and more clients

are appreciating and using our products. We also undertake customized

products with values addition and enhancement.

Corporate Governance - We comply with all applicable laws and regulations.

We believe in maintaining clean environment and conservation of natural

resources. We contribute towards betterment of our staff and provide them

with best of facilities.

Environment Protection and Practice - We are adopting and implementing

pollution control measures as a matter of policy. (All our efforts are in

accordance with the laid down norms of Central Pollution Control Board for

Industrial and Mixed use areas).

OUR COMMITMENTS

To improve the quality of our products and complete integration of

various stages of production.


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To be conscious towards quality and pricing of our products. We strive

by continuous research and development to make our products world

class, having distinct identity and uniqueness. Our customers get best

value for their money.

To run the company profitably year after year.

A workforce motivated, skilled and well looked after.

A workplace safe, secure and hygienic.

To make our Environment Clean, Healthy and Hospitable.

productsFLAT PRODUCTS


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These Tubes are widely used for Power and Industrial boilers, Transformers,

Super heaters, Automobiles and Bicycles, Railway Electrification, Furniture and

General Engineering Applications etc.

Cable Tapes

GP Coils

Steel Coils

GP coil sheets

Corrugated sheets

Cold Rolled Sheets

Narrow CR coils

Galvanised Pipes

Black PipesPrecision Tubes

LONG PRODUCTS

With the introduction of most technologically advanced special and alloy steel

long product rolling complex for manufacture of value added bars and coils, a new

dimension has been added in BPSL's long history in the steel business. The Long

Product Rolling Complex consists of a most modern 0.5 million TPA multiproduct


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Wire Rod and Bar Mill (18 pass Horizontal & Vertical Continuous Mill) supplied

by Danieli Morgardshammar, Italy and KOCKS, Germany (4 pass mill).

Wire rod bar and mill

Mill Product RangeRaw and Finished Products

Dimensions and Quality

Plant facility

Mill Special Features

SPRING IRON

Sponge iron is a basic raw material for making primary steel products. Production

is at our Orissa Project.

PIG IRON

A product in solid (lumpy) form obtained upon solidification of hot metal in pigcasting machine. Pig Iron is used for production of cast iron casting and steel. PigIron is manufactured at our Orissa Plant.

POWERPLANT

376 MW Power Plant is operational at our Orissa Plant. The excess power

generated is being sold through state power grid.

DESCRIPTION OF TUBE MILL

RAW MATERIAL

Cold rolled steel coils


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PARAMETERS

Thickness (mm) 0.10-4.00

Width (mm) 10-1700 (Max)

Coil Weight (MT) Upto 30 MT (7-18 Kg/mm width)

Surface finish Super bright, Bright, Dull and Matte

Grades Specifications- As per

JIS/BIS/ASTM/EN standards

ERW TUBES CEW TUBES

OUTER DIAMETER

(MM)

6.00 TO 127.00 MM 09.00 TO 110.00 MM

THICKNESS(MM) 0.40. TO 6.00 0.80 TO 6.00

LENGTH UPTO 12 MTRS. UPTO 12 MTRS.

APPLICATIONS Automotive, Boiler & Heat

Exchangers ,Air Heater, GEN. EGG.,

Bicycle & Propeller Shafts

Automotive, Boiler, Shock Absorbers, Textiles, Gener

Engg. Propeller Shafts, Cylinder bore tubes for specia

applications & front fork tube for two wheeler.

PROCESSESFORMING

Entry pass Edge Forming

The most common and most simple roll design to form tubing is known as Simple

Radius. In this process a cylinder is formed in a series of rolls having single radius

contours in which the radius decrease progressively.


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WELDING

Precision welded tubes are manufactured by high frequency induction welding

process. Welding is done continuously by passing of electric current of high

frequency that is 4,50,000 cycles/second across the butting edges. The outside bead

is trimmed off by Tungsten carbide tool.

SIZING

After the welding station is usually a scarfing stand with or without an

accompanying iron pass following by an overlying guide to guide the tube into the

first sizing pass with three driven passes and idlers between each. After the sizing

is the single ordouble Turks head for straightening.

CUTTING

The clod saw flying cutting machine has the capacity to cut the tubes to desired

lengths with tolerance of +/- 1.55 mm. The tube ends generated by the flying saw

machine are absolutely straight (90 degree) and do not require any de-dimpling.

INSPECTION AND QUALITY CONTROL

The tube division is fully equipped with advanced integrated quality control system

to produce tube matching the national and international standards. The quality

control system is backed by an advanced testing laboratory for advanced physical

and chemical tests. Laboratory is equipped with:

Spectrometer

Universal testing machine

Vickering hardness tester

Rockwell hardness tester

Carbon Sulphur determination apparatus


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Microscope

Eddy current tester

Hydraulic press for weld ability test

Flattening test

PROJECT STUDYTIME STUDY DURING OPERATIONS AND CHANGOVERS

Time study is a direct and continuous observation of a task, using a timekeeping

device (e.g., decimal minute stopwatch, computer-assisted electronic stopwatch,

and videotape camera) to record the time taken to accomplish a task .Here we facethe problem of lost mill time during operations and changeovers. A lot of time is

lost during the loading and unloading of the coil. Despite the use of accumulator,

still a major fraction of time is lost during loading and unloading, tool

changeovers. During my study here a lot of reasons have been found out during the

time study of tube mill which lead to excessive downtime which are:


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There are no written procedures for setup. All mills should have fixed

written procedures for operators to follow. It is important to control the timeof the process

There is no setup chart. Tweaking the mill during setup loses valuable setup

time. Operators must work the tooling as required. Hence setup chart shouldbe there.

There is lack of formal training. Training helps operators performprocedures for tube mill in the same way.

If the tube mill has been setup according to the written procedures and setupchart, the operator can write down numbers from the digital readout on the

single point adjustment unit (SPA) allowing the next operator to setup from

where the first left. It saves about 75% of the total setup time. If the mill is in poor condition it costs valuable time and scrap during setup

and operation.

Tube misalignment, inaccurate setup accounts for 95% of all problems facedduring tube production.

If tooling is in poor condition, much time is wasted. Running the tool until it

cannot produce more tubing that is beyond its tool life wastes valuable time.

Hence measures are needed to be undertaken to reduce this time duringloading/unloading and changeovers so that the efficiency of mill is

increased. To improve all these factors, study is being done.


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PROJECT ON

ACHIEVING SIX

SIGMA QUALITY


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SIX SIGMA INTRODUCTIONSix Sigma is a business process improvement strategy, which essentiallychecks that a business is doing what its customers require, that the process

employed is the most effective known and that variation is removed from that

process to provide significantly improved consistency. Much of the initial

success in the application of Six Sigma was based on manufacturing

applications; however, Six Sigma can also be applied in the services and also

banking industries. As clients place a high value on consistent business

processes, which have been proven to be efficient, Six Sigma would meet their

requirements as it is a proven methodology for delivering consistentincremental improvement.

By reducing process variation, Six Sigma allows the organization to focus on

improving process capability and as Sigma levels increase, the cost of poor

quality decreases and profitability increases. The principal purpose of this

project is to review the Six Sigma implementation process and emphasize the

importance of this methodology in the quality area. For this reason, its main

framework is based on the description of the Six Sigma process.

The second chapter describes the significance of Six Sigma, its statistical

interpretation, the team members and their responsibilities and some of the

benefits and limitations of this methodology. The third chapter illustrates the

implementation process and the tools, which can be used in order to achieve

high-quality results. The fourth chapter is centered on showing the benefits

and difficulties that can occur in the implementation process in some

published case studies. In order to show that Six Sigma can be used in

different sectors, the last chapter presents the application of Six Sigma in the

financial services industry, with a focus on banking.


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SIX SIGMA DEFINEDIn order to introduce a Six Sigma definition it is necessary first to state the

meaning of sigma:For a manufacturing process, the sigma capability is a metric, which indicates

how well the process is performing. Sigma capability measures the capacity of

a process to develop without defects. A defect means an unsatisfied customer.

The quality scale of Six Sigma measures the number of sigmas between the

interval defined by the specification limits. The greater the number of Sigmas

between the specification limits the smaller will be the value of Sigma and the

lower the number of defects. The difference between the Upper Specification

Limit (USL) and the Lower Specification Limit (LSL) is divided by the

standard deviation to give the Sigma Level, z.The capability of a process for a Six Sigma Level is two, obtained by dividing

the difference between the USL and the LSL by Six Sigma.

Figure 1. Relationship between sigma, DPM, yield and the number of sigma.

Figure 1(a) shows a line with negative slope representing the relationship

between the standard deviation (sigma) and the number of sigmas between the


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specification limits. As the sigma value increases, the number of sigmas

reduces and vice versa.

The relationship between the number of sigmas and the yield (%) is shown in

Figure 1(b). It has a positive slope indicating that as the sigma level increases

the process yield also increases.

Figure 1(c) shows the relationship between the value of sigma and the

number of defects per million. It also has a positive slope, indicating that when

sigma increases, the number of defects per million also increases.

Figure 1(d) displays a line with a negative slope, which indicates that the

number of defects per million decreases, when the yield (%) Z increases.

Sigma measures demand a clear definition of what the customer

requirements are. This helps the company to realize what is important and

what need to be improved. With their focus on defects and defect

opportunities, sigma measure can be used to analyses and compare different

process inside an organization or between organizations. Once that have beenidentified the opportunity area and the requirement, the organization can

define the defect and the sigma level which wants to reach. Table 1 lists the

sigma level against the number of defects per million of opportunities, it shows

that the number of defects decreases exponentially as the sigma level

increases.

TOOLS OF SIX SIGMA


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Six Sigma statistical tools work like magic to uncover what you dont know.

Yet you dont have to be a statistician to use them:

You focus on selecting tools, using them, and analyzing data and let the

specific software do the calculations. The five-phase process of DMAIC,described earlier in this chapter, uses a collection of tools and is a logic filter

to lead you to the vital few factors affecting your process outcomes:

DefineDetermines the project goals and deliverables to customers (internal and

external).

MeasureIdentifies one or more product or service characteristics, maps the process,evaluates measurement systems, and estimates baseline capability.

AnalyzeEvaluates and reduces the variables with graphical analysis and hypothesis

testing and identifies the vital few factors for process improvement.

ImproveDiscovers variable relationships among the vital few, establishes operatingtolerances, and validates measurements.

ControlDetermines the ability to control the vital few factors and implementsprocess control systems.

Process for the study


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Till date, the following steps of the study have been completed :

Process Study

This includes the study of the overall process of manufacturing of tubes

and pipes.

Component Study

Each component of the study has been analyzed and studied separately.

Thorough study has been done on each component.

Data Collection

This step includes the collection of various data and the parameterswhich are required for the further process. This step has been followed

with fixed time intervals.

In the further study, following steps will be completed :

Data Study

Six Sigma Application

overview of bhushan power and steel

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