KAIZEN Replacement of wiper Assembly

KAIZENOBJECTIVE:RE-ARRANGEMENT OF WIPER ASSEMBLY AS A INDEPENDENT SOURCE TO INCREASE PRODUCTIVITY AND SAVE COST.Pictorial Representation:Constraints during and after Skin PassWiper worn out causes damages surface of Backup Roll.Wiper worn out frequently 5 times/month.Tension rod losses which causes abnormal sound from Backup Roll.Downtime occur almost 4Hrs for changing wipers till system resume.After Changing wiper we cant switch to skin pass due to dryness of wiper. So we must switch on Rolling. After Skin pass when switch to rolling then rolling emulsion carry over on sheet which causes black patches or dark shade after annealing process and quality affected. Wiper worn out causes damage Backup RollCalculationWiper cost which incurred due to this issue : 4000 Rs/PcPer set wiper Assy= 3pcsTwo sets wiper Assy=6 pcsCost per changing in wiper=6x4000=24000Rs5times wiper changing in a month=5x24000=120,000/monthPictorial Representation

Tension rod losses causes abnormal soundEffect:Pictorial Representation:Abnormal sound observed from the Mill.Causes severe accident.

Downtime Occur almost 4Hrs/ Week which causes production lossCalculation Production loss:Time Changing wiper assembly till system resume=4HrsFrequency of wiper changing=5 times/monthTotal down time=4hrs x 5times/month=20 Hrs/monthStd. production=46.3 MT/HrsTotal Production Loss per month=46.3MT/Hrs x 20Hrs/monthTotal Production Loss=926 MTHRC-CRC price difference = 15000/MTOperational Cost = 8775 Rs/MTProfit Margin = 6225Total Cost =926MT x 6225 Rs/MT=57,64,350 Rs/month

After Changing of wiper we couldnt switch to skin passEffect & Calculation:Due to the wipers dryness which damages surface of Backup Roll.Scratches marks on circumferential length of BUR by dry wiper.Grinding cost of BUR due to this issue=400,000Rs/month

Pictorial Representation:

After SPM when switch to rolling Causes:Wipers worn out which causes emulsion carry over on sheet and affect quality (black patches after annealing) Pictorial Representation:

How to overcome this issue?ReasonThis can over come by independent the wiper assembly by Backup Roll and assembled with the Mill stand because it has enough space in that area which shown:Pictorial Representation

This type of arrangement only for Backup Roll.

Advantages of this arrangement of wiperWe can save production loss which cost=57,64,350Rs/monthDuring skin pass Wipers not contact with the Back up roll which saves our surface of Backup Roll.Emulsion not carry over during rolling so quality become good.If we want to change wiper then it can easily change with sliding system in the Mill Stand hardly 30mins activity.

Estimated Cost of this arrangement:Calculation:Cylinder x 2=100,000 x 2=200,000/=Electrical Instruments=100,000/=Overhead cost=100,000/=Almost total lump sum amount would be =400,000/=

Total Cost incurred due to this issue:Saving:Total cost incurred due to this issue: Production Loss+ wiper Assy + Grinding of backup rollTotal cost = 57,64,350+120,000+400,000=62,84,530 Rs/monthProposal Cost:Total Estimated cost of independent source of wiper=400,000 Rs/monthConclusionAfter the analysis by cost we can easily see that it will be fruitful for the company to achieve good quality and meet the production targets.