CARLOS THAFENI

CANDIDATE TECHNICIAN INDUSTRIAL ENG

SLAB MANAGEMENT

2016-02-03

CONTINOUS IMPROVEMENT PROJECTS

Outline

Reducing Post Mortem Slabs

• Post Mortem Outcome

• Post Mortem Quality Deviations

• Current Process Flow

• Enhanced Process Flow

• Current vs New Practices

• Current Process Steps(KC03 Admin)

• New Process Steps(1.3 Quality Inspector)

• New Process Steps(1.1 Quality Inspector)

• New Process Steps(1.2 Quality Inspector)

• New Process Steps(Quality Inspector)

• New Process Steps(1.4 Quality Inspector)

• Important Notes and Conclusion

2016/05/10 1 CARLOS THAFENI

Outline

Elimination of Slab Beards

• Beards Removing Prototype Tool(s)

• Scarf Torch Method

• Scarf Torch Method Safety

• Conclusion and Remarks

2016/05/10 1.1 CARLOS THAFENI

Reducing Post Mortem Slabs

2016/05/10 2

Problem Statement • Slab Management(Yard05) is experiencing high

volumes of rejected slabs from Plate Mill due to

quality deviations.

Current Condition(Before Implementation) • Yard05 continuously retrieve red tag(Non-

conforming) slabs from Plate Mill.

Goal

• Minimize/Reduce high quantity of slabs

rejected from Plate Mill

Countermeasures • Discouraged workers/Unwilling

Employees

• Semi-Skilled Labor

• Equipment Breakdown

• Workforce Pressure

• Lack of discipline(Employees)

• Lack of manpower

Follow-up Action • Monitor not charges due to quality

deviations

CARLOS THAFENI

Post Mortem Outcome

Total YTD Est Rejected Slabs = 159

Total Est Rejected = 715.5Tons

0

2

4

6

8

10

12

14

16

18

20

22

24

Oct-15 Nov-15 Dec-15 Jan-16

Nu

mb

er

of

Sla

bs

Retu

rned

Months

Post Mortem Shifts Performance

A B C D

2 per. Mov. Avg. (A) 2 per. Mov. Avg. (B) 2 per. Mov. Avg. (C) 2 per. Mov. Avg. (D)

2016/05/10 3 CARLOS THAFENI

Post Mortem Quality Deviations

2016/05/10 4 CARLOS THAFENI

2016/05/10

Current Process Flow

5 CARLOS THAFENI

2016/05/10

Enhanced Process Flow

6 CARLOS THAFENI

-Print F/C Slabs (F SSQ)

-Search & Identify F/C Slabs

- Command Crane Driver to Pack Slabs on F/C Floor

- Submit Identified F/C Slabs to KC04

-Print 2xActions for Identified F/C Slabs (My

Phoenix)

- Provide Actions to F/C Sup & Quality Inspector

-Measure & Mark F/C Slabs According to Actions

-Start-Up F/C Operation on Marked Slabs

-Turn & Clean Finished F/C Slabs

- He or She Check Finished F/C Actions & Verify Slab

Dimensions(L x W x T) & Sign Off Action

-Submit Actions to KC03 with New Dimensions

- Sign Off F/C Action as Per Individual Task/Operation

- (Supervisor/Senior) Oversee F/C Process and

Ensuring Correct Dimensions are Taken

- Slabs are set to status ‘S” – Inspection for treatment

- Slab must be declared ‘Prime’ and if necessary

- Check-size to correct sizes (F,SCHEK)

Current vs. New practices

2016/05/10

Current New

7

-Print F/C Slabs (F SSQ)

-Search & Identify F/C Slabs

- Command Crane Driver to Pack Slabs on F/C Floor

- Submit Identified F/C Slabs to KC04

-Print 1xActions for Identified F/C Slabs (Phoenix)

- Provide Actions to F/C Supervisor

-Measure & Mark F/C Slabs According to Actions

-Start-Up F/C Operation on Marked Slabs

-Turn & Clean Finished F/C Slabs

- He or She Check Finished F/C Slabs & Verify Slab

Dimensions(L x W x T) & Sign Off Action

-Submit Actions to KC03 with New Dimensions

- Sign Off F/C Action as Per Individual Task/Operation

- (Supervisor/Senior) Confirm F/C Action Dimensions

& Sign Off.

- Cut Slabs With New Sizes-SPSNY

- SPSNY – call SRP ‘OPLN’ and Plan slab against the

Order (If sizes are correct), if not

- Slabs are Prime & Ready to be Planned manually

- By Planners ( MPLN)

CARLOS THAFENI

-Print Tags

- Stencil Tags on Finished Slabs on Floor

- Determine Slab Quality if “OK”? (YES) if Size Change

Required? 1.3 (NO) Prime Slab Include Row on

(F, SCHEK) Therefore SRP call F,MPLN

-Determine Slab Quality if “OK”? (YES) if Size Change

Required? 1.1(YES) Prime Slab Include Size,

Reason and Row on (F, SCHEK) Therefore SRP call

F,MPLN

- Determine Slab Quality if “OK”? (NO) if Size Change

Required? (NO) Set Slab Next Action, Scarf, F/C side

trimming, Scrap etc use I-Treat on F,INS

-Determine Slab Quality if “OK”? (NO) if Size Change

Required? 1.2(YES) Checksize with no Prime

Declaration, slab allocation is Unschedulable Stock

Inspect for Treat Light/Heavy

- Withdraw List of Inspect for Treat Slabs on (F,SSQ)

- Declare Slab Prime by Including Row

-

Current vs. New practices

2016/05/10

Current New

8

-Print tags

- Stencil tags on Finished Slabs

- Planned Slabs can be scheduled for rolling.

- Prime (Unplanned) & Prime(Planned) Slabs are

Allocated in Yard05 (ST56) & Planned Slabs are

Ready to be Transferred to Yard03.

- Plate Mill Receiving Transferred Planned Slabs

- Plate Mill Measure, Inspect & Reject Poor Quality

Slabs(Red Tags) to Yard05

- Check size - if Size is wrong Order will be removed

automatically .

- Check sized and Prime Slabs would be Planned

(F,MPLN)

-Scrap Slabs out of Quality Specification

- Set Next Treat Action e.g Hold, Scarf, F/C, Scrap if

Required

-Request Planning

CARLOS THAFENI

2016/05/10

Current Process Steps -

KC03 Admin – Print Actions For Identified Slabs

Entries for Navigation

Options (Phoenix)

• Press Slab Tracking-

• Program PSLB – Press PSLB

box to navigate to Yard05 and

Yard 06 options

• Select Yard05 – is for Plate Mill

material scheduled for F/C

• Schedule 05 Material –select

one option criteria Both, Heavy

or light material. In this example

heavy material was selected.

• Click Cast- to withdraw F/C

action and print two actions

9 CARLOS THAFENI

New Process Steps -

KC03 Admin – Print 2xActions for Identified Slabs

2016/05/10

Compulsory Entries

for Supervisor or

Senior F/C

Supervisor and

Quality Inspector)

• New Dimensions– F/C

Supervisor fill up new

dimensions

• Quality Check- Slab

Overall Inspection must be

completed by Quality

Inspector to determine the

quality of slab. Check slab

Identification(ID) if is

correct.

• Signature –Supervisor/

Senior, F/C Supervisor

,Flame Cutter and KC

must therefore sign off by

adhering to and

understanding instructions

provided on the F/C Action

sheet

10 CARLOS THAFENI

2016/05/10

Current Process Steps -

KC03 Admin – Cutting New Slab Dimensions(After

Cutting Slab Remain STAT “S”)

Compulsory Entries:

• OPTION – insert letter “S” for

Slab Management South Yards

• SER – insert daughter slab serial

number or ID that consist of four

digits from F/C action sheet.

• CASTNO – Type in Cast number

of Mother slabs

• FLOOR- for Yard04 material 41

or 44 can be inserted and for

Yard05 option 51 or 54.

• New Dimensions – .Record

new daughter slab dimensions,

LENG(Length), WID(Width) &

THK(Thickness)

11

51

CARLOS THAFENI

New Process Steps -

1.3 Quality Inspector – Prime Slab Including Row

2016/05/10

05 12JA25

S

Compulsory Entries:

• CAST – Insert Slab cast number

as required.

• AREA –– insert letter “S” for

Slab Management South Yards

•

• SERIAL- Insert slab serial

number

• REAS – use reason “05” for

Plate Mill schedulable slabs

• - No need for reason with Prime

declaration only

• Row-LOCATION- Provide slab

row and location to declare slab

prime

• - Row may be enough

12 CARLOS THAFENI

New Process Steps -

1.1 Quality Inspector – Prime Slab

(F,SCHEK) include slab Size, Reason and Row

2016/05/10

05 12JA25

S

Compulsory Entries:

• CAST – Insert Slab cast number

as required.

• AREA –– insert letter “S” for

Slab Management South Yards

•

• SERIAL- Insert slab serial

number

• REAS – use reason “5” for Plate

Mill schedulable slabs

• Row-LOCATION- Provide slab

row and location to declare slab

prime

• Dimensions – Fill in slab

checksized dimensions

13 CARLOS THAFENI

New Process Steps -

1.2 Quality Inspector – Checksize Slab

(F,SCHEK) include slab new Size(s).

2016/05/10

S

Compulsory Entries:

• CAST – Insert Slab cast number

as required.

• AREA –– insert letter “S” for

Slab Management South Yards

•

• SERIAL- Insert slab serial

number

• Dimensions – Fill in slab

checksized dimensions

14 CARLOS THAFENI

New Process Steps -

Quality Inspector –Inspect For Treat Slabs Directory

Ref ST56

2016/05/10

• Outstanding

Inspect for Treat

Slabs

• Row 7- all

outstanding light

material awaiting for

inspect for treat

would reflect on row 7

• Row 8- all

outstanding heavy

material awaiting for

inspect for treat

would reflect on row 8

15 CARLOS THAFENI

New Process Steps -

1.4 Quality Inspector – Withdraw List of Inspect

For Treat Slabs Ref ST56

2016/05/10

05 12JA25

S

Compulsory Entries:

• E-mail –Provide user work email

address to export inspect for

treat slabs

• PRINT – Provide user work

email address to export inspect

for treat slabs

• REPTYPE – Means Report Type

therefore insert “4“

• ORDNO Y/N – insert Y for

slabs awaiting Inspection with

orders

• STAT – use “S” for inspect for

treat

• NB- Either use E-mail or Print

to retrieve inspect for treat

slabs.

16 CARLOS THAFENI

New Process Steps -

Quality Inspector – Prime Slab Including Row

2016/05/10

S

05 12JA25

S

Compulsory Entries:

• CAST – Insert Slab cast number

as required.

• AREA –– insert letter “S” for

Slab Management South Yards

•

• SERIAL- Insert slab serial

number

• REAS – use reason “05” for

Plate Mill schedulable slabs

• - no need for reason

• Row-LOCATION- Provide slab

row and location to declare slab

prime - not necessary

17 CARLOS THAFENI

Important Notes and Conlusion

• When will the changes be implemented ?

The anticipated implementation date is 02 February 2016 time 11;00am

• Which parties will be affected by the changes ?

Yard 05 Phoenix users, initiating new process and approving service(s) rendered to Slab Management(Yard

05).

• What are the benefits of changing the process ?

o Eliminate slabs rejected due to incorrect dimensions,Swopped Tags from Yard03

o All PM material would be declared prime before planning

o Minimize double handling of Slabs from Yard03 to Yard05

o Slab would be transferred to Yard03 with good quality.

• Where will the process be implemented ?

The implementation will be done as a pilot per shift in Yard 05 Slab Management.

• Who can be contacted for support ?

- Maryna Raguz, Phone 0833843492, Office 2x4675, Short C 6041

- Gert Marais, Phone 0832878020, Office 2x8693, Short C 5905

- Carlos Thafeni, Phone 0839486109, Office 2x4118, Short C 5347

2016/05/10 18 CARLOS THAFENI

Elimination of Slab Beards

2016/05/10 19

Problem Statement

• Find a tool or methodology that can

remove slab beards.

Current Condition(Before Implementation) • Beards cause build up in the reheating furnaces

and could be rolled into the slab.

• Slab are not charged due beards

Goal • Eliminate slabs with beards as to improve our

quality level of <0.22%

Countermeasures • Lack of Finance

• Turning Table

• Water Injector System

• Unskilled Labor

• Insufficient Plant

Capacity(Yard99)

CARLOS THAFENI

Follow-up Action • Monitor not charged slabs

from HSM due to slab

beards.

Beard Removing Prototype Tools

• Rating Criteria

1-3 =Poor

4-6 = Moderate

7-10= Good

2016/05/10 20

Tool Beard remover hand Rating Scarf torch Rating Hummer Rating

Rating Criteria made tool (1-10) (1-10) (1-10)

Form of Energy Human Stregnth 3 Heat Energy(Gas & Oxygen) 8 Human Stregnth

Estimated Price/Cost® Affordable 7 Affordable 7 Cheap 9

Safety Risk Harzadous 2 Safe 8 Unsafe 6

Required Operators 1 Operator/Slab 9 1 Operator/Slab 9 3 Operators/Slab 2

Operator Posture Acceptable 6 Acceptable 6 Unacceptable 3

Removing Beard Duration 55min 2 5min-10min max 7 7min-20min max 4

Equipment Set-Up time 15min/Slab 5 20min/Slab 4 20min/Slab 4

Quality finish Moderate 5 Meet 7 Good 6

Assurance of Removing Beards Cannot remove all 4 Can Remove all 8 Cannot remove all 4

Efficiency Semi Efficient 4 Efficient 7 Semi Efficient 4

Flexibility Flexible 6 Not Flexibel 4 Not Flexible 4

Reliability Reliable 5 Reliable 8 Reliable 9

Accuracy 75% 6 85% 7 60% 6

Fatigueness Experinced 5 Experienced 4 Experienced 4

Ease of use Unfriendly 4 Heavy 3 Unfriendly 4

Consistency Not maintained 5 Not maintained 5 Not maintained 5

Total Rating 78 102 74

Scarf Torch Method

• Slab length is stacked

perpendicular to billet length and

released by crane grab

• By default slab tilt at an acute

angle to see underneath beards

• Scarf excessive gas is released

and ignite nozzle head to

produce flame.

• Scarf nozzle pipe face beard

thickness

.

2016/05/10 21 CARLOS THAFENI

Scarf Torch Method

2016/05/10 22

• Moderate pressure/oxygen is

released

• Beard would generate sparks

due to its low melting point

compared to slab

• Constant movement is required

to maintain beard melting point

until the process is

accomplished.

• Finished slab is removed on the

basement.

CARLOS THAFENI

Scarf Torch Method Safety

• Proper HIRA was done

• Safe Working Procedure (Including Scarf Torch SWP)

• Recommended PPE was supplied

• Scarf torch operators were trained

CARLOS THAFENI 2016/05/10 23

Conclusion and Remarks

2016/05/10 24

• Slab beards are treated with scarf torch method

• Quality Management approved scarf torch methodology

• Not charged from Hot Strip Mill due to slab beards is eliminated

CARLOS THAFENI

2016/05/10 25 CARLOS THAFENI