Root cause analysis procedure
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The document outlines a root cause analysis procedure for addressing liquid metal loss during continuous casting, aiming to reduce losses from 0.98% to below 0.2% in two months. It includes details on team formation, data collection, potential causes identified through brainstorming and fishbone diagrams, as well as recommendations for immediate and long-term actions. The report emphasizes monitoring and further investigation of certain factors, such as chocking and temperature drop during casting.
Root cause analysis procedure
- 1. Root Cause Analysis Procedure Sample presentation Prepared by: Sambeet Panda 1
- 2. Process Flow Project Charter Team formation Brain storming Cause & Effect model Data collection Segregation as per major heads Prioritize of loss category Analysis of all potential causes Elimination of causes as per effect Identification of causes to initiate W-W Why-Why analysis of major cause of problem Finding the Root Cause Preparation of CAPA Piloting the CAPA Final implementation Monitoring 2
- 3. Project Charter Project Title: Root Cause Analysis of Tundish Loss Problem Statement Loss of Liquid metal(LM) during continuous casting which is around 9.89 MT out of 1000 MT. Which is 0.98% Goal Statement Eeliminate the factors to reduce loss of LM to less than 0.2% with in next 2 months Data collection Source of data Location Area Data considered for last 6 months (Sept'20 to Mar’21) Log sheet SMS CCM 3
- 4. Team Members • Mr. Shiv Das (Team Leader) • Mr. Rajesh Tiwary (E&I) • Mr. G.S Kanungo (Team member - Mechanical) • Mr. Ramesh Pal (Team member - Process) • Mr. Ajay Chaturbedi (Team member - Process) • Mr. C. Behera (Team member - QA) • Mr. Anurag Thakur (Team member - CCM) • Mr. Soumya Mohanty (Team member - CCM) • Mr. Abhya Narayan (Team member – LSS Project Coordinator) 4
- 5. Brain Storming ideas • Problem is happening in any particular shift • Un skilled operator • Non-Adherence of SOPs • Due to power failure • Due to choking • High qty. of LM tap • Due to hydraulic power pack tripped. • Life span of equipment • Environment effect 5
- 6. Finding Possible causes through Fishbone diagram --- Cause Loss of Liquid Steel during casting Man Method Material Material Choking Life span of equipment Effect Un skilled operator Power failure dummy bar insertion problem Non-Adherence of SOPs •6 SAMPLE In any particular shift Machine Measurement Mother nature LM Qty. Environment effect
- 7. Data collected & segregation as per major heads(Category wise) Summary Loss Qty Cumulative Cumulative(%) Chocking 7.0 7.0 77.78 Power failure 1.3 8.3 92.22 Hydraulic power pack trip 0.7 9.0 100.00 Total 9.0 80-20 Analysis 7
- 8. Root Cause Analysis of LM loss Sr. No Possible Causes Observation Leading to loss 1 Problem is happening in any particular shift No such pattern is observed × 2 Un skilled operator Skilled manpower deployed for casting × 3 Non-Adherence of SOPs SOP complied × 4 Due to choking Loss due to choking is high √ 5 High qty. of LM tap LM qty. is as per design × 6 Due to hydraulic power pack tripped. Maybe consider in next why-why √ 7 Life span of equipment Found ok × 8 Power failure Maybe consider in next why-why √ 9 Environment effect No such effect × Note:- × - Not Observed √ - Observed Analysis of potential causes through Simulation Method 8
- 9. Why - Why analysis ROOT CAUSE ANALYSIS REPORT # Due Date Signature Shift Supervisor (Ops.) Mech Maintenance Electrical Maintenance Sr. Manager Signature: Manager's Comments These suggested ideas willl be under observation for a period of 1 month to obtain more clarity regarding the issue. After confirmation these will be implemented on long term basis. Production Manager Signature: Short term 1. Temperature lance accuracy to validate. 2. LM casting qty should not proceed 40 MT Long Term 1. Lifting temperature in 2nd heat of sequence to lift with 6-7 deg. more super heat. Equipment: Strand I/II Observation: From analysing last 6 months data this is observed that there was chocking tendency,which is insequence 2nd heat. Actions Taken: Lance was calibrated. Discussed with shift personregarding abnormality found. Why chocking happened ? Due to temperature drop in 2nd heat of sequence. Why temperature drop ? Due to loss of super heat during ending of casting. Why loss of super heat ? Due to less temperature content in 2nd heat. 1 2 3 4 WHY ANSWER Action Type Action Resp. CM not effective Problem Illustration(Pics/sketches may be included) Date & Shift * CM - Corrective Measure Reoccurence CM Not Taken CM not maintained Trouble No. Trouble Classification: Person who took action: Steel Division Team Process: Continuos Casting(SMS) New Description of Problem: Loss of LM during casting due to chocking tendency. Facility: 31.03.2021 9
- 10. Any Query?? 10