External factors

Melt shop has a low OEE of ~50% with ~85% losses due to
external factor
OEE analysis for Melt shop (Jan-Jun’12)
Percent, 100% = 7200 Hrs1
100.0 0.6 0.2 0.6 17.2

81.4 0.1 31.2

▪ Need to
deep-
0.3 49.8 0 49.8 dive to
identify
root
causes
for big
loss
buckets
▪
Material not available

Mould line stoppage

Identify
details of
Operating hours
Total available

Quality losses
Speed losses

unexplai
Unexplained

Running hrs
Minor stops
No Power

ned
losses

added
Value
losses
time

B/D

hrs
82% 60% 100%

Availability ratio Performance Quality ratio

ratio

1 Considering 150 working days and 24 hrs as operational hrs

SOURCE: Client data, Team analysis
0
 MELTING ISSUE TREE AND CA

Transfer cars (VW1 / VW 2 /VW

3 / VW4/TZ /ZL /Z6) / KEV2

1. Mould line Pattern change delays

Availability 2. Mould line B/D
stoppage
Shakeout/ Manipulator /
Flowtex problem

FM stop

Oil Temp High / Oil leakage /

Hydraulic motor

i. Power not available

(6500KW instead of
10000KW)

a. More Cycle time(77min

instead of 60min/heat)
Performance 1. Speed losses

a. Using of low density raw

matl
b. Time lost for slag removing
c. Time to adjust chemistry for
high alloy items,
d. More slag build up on
furnace linings decreases
furnace efficiency

1
 MELTING ISSUE TREE AND CA
Mould line stoppage
S. LOSS
POTENTIAL ROOT CAUSES IDEAS / LEVERS
NO REASON
1. Due to failure in the proportional card the 1. Additional Protection circuit provided to prevent the failure
replacement of cards and downloading of Proportion cards
the program to the proportional cards. 2. The pallet plate broken is the main reason for the box
2. Box derailment in the transfer car and also derailment and hence the all broken pallet plates are
Transfer cars welding in support cylinder replaced and welding done in support cylinder
(VW1 / VW 2
1. The cable connecting to VW1 transfer car 1. Identified the faulty cable and the same has been insulated
/VW 3 /
1. got grounded properly. Rerouting of cable done to avoid the reccurence
VW4/TZ /ZL
2. Oil leak in cushioning cylinder of DZ1-6 2. Replaced the piston rod with hard chrome plating to avoid
/Z6) / KEV2
cylinder the leak
( 5.5%)
1. Magnet guide got bend due to metal
piece struck 1. Removed the metal piece and adjusted the bend.
2. JVH 19 hydraulic lock piston rod got 2. Broken area welded and made ready
broken
Pattern 1. Replaced the drive with motor and PLC program modified.
1. The Drives in AR1 and AR5 failed and
change Drastic Reduction in time observed however the drive
2. hence the delay also on occasion pattern
delays needs to be obtained to eliminate the delay. P.O for drive
changing done manually
( 3.5%) raised and material expected by II week of Aug12
1.Manipulator Hydraulic hose damaged Replaced the hydraulic hose and fittings

Shakeout/ 1. The potentiometer value got disturbed and hence the value
1. Manipulator horizontal movement
Manipulator / adjusted as per the instruction provided in the manual
problem.
Flowtex 2. The seals of the pitch cylinder in the roll shaft arrangement
3. 2. Pitch cylinder not working
problem replaced
( 3.5%) Hydraulic hose got cut New hydraulic hoses are replaced
Shakeout motor failure due to failure in
New motor replaced.
bearings

2
 MELTING ISSUE TREE AND CA

Mould line stoppage

S. LOSS
POTENTIAL ROOT CAUSES IDEAS / LEVERS
NO REASON
Due to Oil contamination in the FM squeezing
The hydraulic valves replaced and oil filtration decided to be
zone hydraulic valve pressure did not develop
done once in 2 months.
leading to breakdown

FM hopper gate cable got grounded Faulty cable replaced

FM stop
4. Fm multi-piston squeezing cylinder and turn
( 2.5%) Replaced the oil seal for both the multi-piston and turntable
table oil seal failure due to aging factor

FM multi-piston hydraulic cylinder seal failure Replaced the oil seal

Oil got bypassed in FM squeezing station and

Operated the valve manually and valve replaced
hence pressure did not develop
Oil Temp
1. Replaced the cable with armored type to eliminate the root
High / Oil
1. Cable short in Cooling tower fan cause
5. leakage/Hydr
2. Multi-piston hydraulic cylinder seal failure 2. Replaced the oil sea
aulic motor
( 1.5%)

3
 MELTING ISSUE TREE AND CA
Speed losses

S.
LOSS REASON POTENTIAL ROOT CAUSES IDEAS / LEVERS
NO

i. Ensure the availability of 10000KW power for

Power not available (6500KW melting
1 Speed losses
instead of 10000KW) ii. Ensure Cupola furnace to be operated on regular
basis
High Density steel scrap should be procured.
Using of low density raw matl Eg: Bundle steel & rolling Mill end cuttings instead of tar
More Cycle steel
time(77min
2
instead of Time lost for slag removing Runner & riser can be Shot blasted / Tumblasted
60min/heat)
Time to adjust chemistry for high Planning of high alloy items/ same grade group items
alloy items continuously will reduce the time