Step 1 : Preparation of a QA Matrix. STEPS Investigate the types of defects occurring in each process.

s. Classification of product quality characteristics precisely and identify the all defect modes related to each characteristics. Rank the defect modes according to their seriousness and indicate which one have caused problems in the past as frequent or occasional. Divide the process in to the smallest possible units or (sub processes) and indicate the relationship between these and the defect modes. Step 2 : Analyze the production input (4M) conditions and organize the data in a table format. For each defect mode in each sub process, identify all conditions for equipments, materials, people and methods which established do not give rise to defect. Determine the whether the standards for those quality conditions exist whether follow them. Step 3 : Prepare the problem chart. Prepare the problem chart by listing any irregularity not covered in the process by problem type. Note how it is investigated and the results and use this information as a basis for proposing counter measures. Also consider any sub processes which the production input conditions analysis revealed were not properly standardized. Investigate the problems noted and propose counter measures. Express the result quantitatively. For simple problems decide what action to take, assign responsibility act immediately. For more difficult problems clearly record the investigation methods and results dont jump to hasty conclusions about solutions. For these problems, use FMEA analysis to rank defect modes in terms of the seriousness of their effects and priorities the problems for actions. Then take time to develop the appropriate counter measures through P-M analysis. Step 4 : Evaluate seriousness Perform FMEA Examine the problems on the problem chart and them in terms of their effects on the defect modes. Priorities the problems by scoring their frequency of occurrence, effect and difficulty of detection. Determine the assessment criteria in advance. Multiply the scores for each problem together and use the results to priorities the improvement effort. Step 5 : Use PM analysis to devise improvement measures. For more challenging problems, use P-M analysis to clarify the observed.

QM PILLAR

Theme: To improve FeM in fines Sponge Iron. Area: Kiln 3 section Problem: 1. Product material getting discharge from cooler after separation of magnetic and non magnetic analyzed that FeM of sponge iron fines was less than 80% (not acceptable) not ok. 2. All sponge fines from bunker was unloaded to trucks and stacked in to the sponge shed and could not be dispatched to the customer in time. 3. Manual labs were engaged for mixing of the material with good quality material. 4. Cost of production got increased due to poor quality material production.

Root cause analysis :- (4M Method)

Met hod

Man

Mat erial

Mac hine

1. Man 1.1. Lack of knowledge of operator to maintain process parameter 1.2. poor attitude 1.3. Inadequate supervision 1.4. Poor training 1.5. Poor skill 2. Machine 2.1. Malfunctioning of thermocouple 2.2. Improper discharge of material through weigh feeder 2.3. Variation of kiln RPM 2.4. Improper screened of iron ore fed to kiln 2.5. Interruption of feeding system. (WFs showing indication of running but actual not running) 2.6. Interruption of Injection coal. 2.7. High fines generation inside cooler. 2.8. Improper separation of material by magnetic separator. (MS-2) 2.9. Ingress of outside air through sealing. Kiln outlet & Cooler inlet. 3. Method 3.1. Improper testing of product material. 3.2. Maintaining high temperature in the reduction zone. Zone creating oxidation atmosphere. 3.3. Improper C/Fe ratio maintained. 3.4. Improper time, temperature turbulence maintained. 3.5. Improper mix up of coal source. 4. Materials4.1. More fines in feed coal 4.2. More fines in Injection coal 4.3. More shale in feed coal 4.4. Bad quality iron ore 4.5. More laterite in Tisco Khandabandha ore. 4.6. Mix up of different sources of iron ore. Tisco Khandbandha & Joda east ore. 4.7. Less carbon for Injection coal. 4.8. Contamination char , laterites and other material in iron yard as the stock has

Chec ks
1. Man 1.1. Kiln operator are experienced in this field 1.2. Attitude was normal. No abnormality noticed. 1.3. Close supervision in process control 1.4. Trained man powers are available. 1.5. Skill was ok. 2. Machine 2.1. Cross checking of thermocouples were done. QRT measurements were also done and four only TC10 & TC7 temperatures were exceeding limit. (Air control was done on those points) 2.2. All weigh feeders were calibrated and found ok (variation / error specified limit) 2.3. Physically kiln RPM was checked by stop watch in every 4 hours interval and found watching with the RPM set in PLC. 2.4. Screening of iron ore in iron ore circuit (VS-6) was normal. No abnormal fines come to weigh feeder /bins. (-5mm size was 5% maximum) It is as per specification limit. 2.5. No interruption has taken place in feeding system during that period. 2.6. Interruption of injection coal has take place 6 times at long intervals. On 18.05.2011 at 12:00 noon due to entrapped of wooden pieces coming along with injection coal. On 19.05.2011 at 00.12 - both coal injection system jamming due to jamming of over size coal in side rotary feeder. On 24.05.2011 B Shift - 2 times rotary feeder jammed due to over size coal and some wooden pieces along with South Africa coal. On 25.05.2011 Injection coal interruption twice due to over size coal. 2.7. Cooler discharge material was found sometimes normal and some times the -3mm fraction was more high decrepitation noticed (-3mm magnetic lowest = 22%, highest = 38.9%, normal = 25% and -1mm in sponge fines normal = 30% , lowest = 24.7 %, Highest = 55.1%) 2.8. Magnetic separator (MS-2) separation was found ok. Not a single time the charcoal content in sponge iron fines has gone > 1.0% (specified limit) 2.9. Ingress of out side air to the system through cooler inlet seal is still continuing.

3. Method 3.1. Testing procedure for product material has been done as per SOP made by Quality Assurance department. No deviation was noticed. Many samples were reanalyzed and cross checked jointly by Q.A, Operation and process control persons and QM pillar members and found no deviation with previous readings. 3.2. Temperatures particularly at TC10, TC7 area were found abnormal and action was taken to reduce from 1130 to <11000C or 1135-40 to < 10800C respectively in between 25.05.2011 to 27.05.2011. 3.3. C/Fe ratio was maintained 0.450, 0.488,0.460, 0.458, 0.440, 0.425, 0.470, 0.440 in between (0.425 0.488) but average is 0.455. 3.4. kiln Rpm and retention time of material inside kiln was 11Hrs 30mins to reduce the retention time inside kiln. KilnRPM was increased further keeping constant feed rate. It was noticed that both FeM lumps and fines further dropped . Lumps dropped to < 74% and fines < 72 to 73% range. In this case both 100% of sponge iron found non despatchable. 3.5. Coal source wise was checked through even at coal yard and cross checked. Many analysis for coal was done and found no abnormalities. Since there was only 3 sources of coal available in the yard and single kiln was in operation there is hardly any change of coal mixing found in the coal yard. Coal mix up for feeding to kiln Talcher < 35% Fc 25% to 30% POCP > 40% Fc 40% to 35% S. Africa >55% Fc 35% to 35% All parameter for kiln fed was found OK. 4. Material 4.1. Fines in feed coal was > 10% till 22.05.2011 as because (0-20)mm size of south african was feeding from inlet side along with ECL lumpy coal. (Min 10.5%, max 17%) On 26.05.2011 C shift fines % from inlet side had gone up to 30.17% even through lumpy coal was being fed. Till 31.05.2011 inlet from feed side was remaining in between 25 30% 4.2. Injection coal fines was kept controlled in between 30 35% as (o-5)mm and (520)mm coal was being fed to kiln separately from injection coal side. 4.3. Shale % in feed coal was also less since we are feeding 60% S. Africa coal and 40% Talcher coal. 4.4. Quality of Iron ore : Fe Metallic 4.5. Laterite in Iron ore was physically observed to be more than 15% as there were

Ore quality Size +18mm +15mm +8mm +5mm

%

FeT=54.3%
% FeM

Product Size & quality Size +20mm Nil +18mm Nil +15mm 3.2 +10mm 11.0 +8mm +5mm +3mm +2mm 16.2 27.5 11.7 7.6 66.4 63.5 63.7 70.5 75.1 76.8

5% 20% 60% 15%

Composition FeM is 68.7% Lumps = 68.4% Fines = 69.4% Fines generation = 30.4%

4.6. 4.7. 4.8.

+1mm 9.4 74.4 We did not found any mix up of Joda East ore with Tisco khandabandha ore. C/Fe from13.4 let (Injection coal side) was maintained as per norms. out -1mm 61.6 No contamination of char coal with Iron ore was found.

Root Cause: The above data of salvice test shows that FeM fines is coming less. This is because of lateritic ore, Generated more times inside kiln or the fines getting reoxidised as lower FeM Action Plan: When ever laterite I ore exceeds > 5% at that time it will kept separately and it will be fed to kiln with laterite free ore to get max 2% in the ore mix before charging to kiln. Monitoring: Tisco Khandabandha ore was fed to kiln -1 after litup in this campaign and found the sponge fines quality remained > 85% FeM. On the laterite in ore was analysed to be 3%.