IIL - Kalmeshwar Plant Visit

25 – 27 AUGUST 2008
FLORANTE C. LEE, Division
Head, CRM
ARTURO B. del AYRE, SiC,
CRM-Finishing
 Plant Location

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 Major Equipment

Acid Pickling Tanks Cold Rolling 6 Hi Mill Furnace in Galvanizing

Zinc Pot in Cold Rolling Skin Pass Coater in Color Coating Line
Galvanizing Mill
3 1st Hitachi Cold Rolling 6 Hi Mill in India 1st Thin Gauge Galvanizing Line from Nippon Denro Japan
1st Color Coating Line with Reverse Coating Technology
 IIL-KLM Organizational Structure

4 GSPI T/O

Note: Sr. VP (Projects) also heads MPICC

 Agenda and Points of Discussion
• I. Maintenance Systems
Part 01
• Functional Organization
• Maintenance Methodologies
• II. Operations Systems and
Part 02

Procedures
• Operational Processes
• Mill Generated Scrap Management
• Energy Management System
Part 03

• III. Management Initiatives

• Total Productive Maintenance
[including SHE/EMS]
5 • QMS (ISO 9001:2000, TS 16949, ISO
 Suggestions for

Kalmeshwar Complex
 Suggestions for IIL Operations
• Quality: Arrest roof leaks at Mill Bays
to prevent wetting CRFHs (Works-in-
Process) in Storage Area and up-
ended newly-Annealed coils from BAF
during heavy downpour [Water + Air
on Steel = Rust].
GSPI’s Initiative: Use of Kraft Packaging
Paper for CRFH WIPs and Lawanit Eye-
Blanks for upended CRCAs. This could also
address coils being subject to bird
droppings.
• Annealing Process: Use a fine-mesh
7 ceramic fiber as sealant for Inner
 Suggestions for IIL Maintenance
• Why-Why: Incorporate actionable
results of Why-Why Analysis to SAP’s
PM database. Presently, IIL uses Lotus
Notes to distribute scanned/soft
copies of WWA reports.
• SAP: Include Calibration in SAP Task
List. Calibration is a mandatory
requirement for ISO 9001.
• SAP: Include Standard/Actual (man-
8 hours) for each activity in the PM’s
 Suggestions for IIL Maintenance
• Predictive Maintenance:
Procurement of Thermography
instrument and / software. This could
aid in breakdown prediction for
certain equipment and respective
components.
• Spares Management: Classify
maintenance spares by Policy, such
as Operate-to-Failure (OTF), Fixed-
Time Replacement (FTR), Condition-
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Based Replacement (CBR), in addition
 Suggestions for IIL Mgt. Initiatives
• TPM-PM: Document all Mill
Equipment revisions or improvements
using MP Sheets and/or appropriate
Engineering/Schematic diagrams.
• TPM-JH: Apply GSPI’s TPM good
practices as recommended by AGM
Anil B. Sarwate [TPM] last Nov
* During2005.
the plant
visit, no objective
These practices* include: evidence at Mill
 Office TPM Makigami Sheet. floor were visible
for these practices.
 Kaizen Tree at JH machines.
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
 Suggestions for IIL Mgt. Initiatives
• 5-S: Encourage IIL-KLM regular
employees to perform 5-S activities
in their respective areas:
• Cleaning, Seiso, at RM’s Floor (currently
by Contractors),
• Sorting, Seiton, at Continuous Pickling

Line Spares Room

• Housekeeping, Seiketsu, on all Mill areas.

• Safety: Rain Water Downspout near

Col. C10/PPIC splashes to nearby PDB
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panel; drenching power cables for
 Suggestions for IIL Mgt. Initiatives
• Safety: Provide portable convenience
outlet for Floor Polisher used by
Contractor at 6-Hi Storage Area.
During the visit, Floor Polisher was
temporarily connected to a convenience
outlet inside the 6-Hi Rolling Mill Pulpit,
power cable laid on the stairs then through
the CRFH Staging Area with operational
crew hopping their way over the cable.
[Trip Hazard]
12 • Safety: Publicize “No. of Days
Other Activities

27 – 28 August 2008
Kalmeshar, Nagpur, India
Dolvi Plant, Alibaug, India
 27 Aug 2008: TPM Sharing at KLM

Microsoft
PowerPoint Presentation

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 28 Aug 2008: Tour at Dolvi Plant
Blast Furnace Jetty

15 HSM Facade HSM Stands