Safety provision in rubber mill & autoclave unit entry for 33rd CCQC 2022 (Nagpur chapter)

1. #Better Everyday
1
JSW Steel Coated
Products Ltd,Kalmeshwar
33rd Chapter Convention on Quality Concepts by QCFI
Nagpur Chapter
Kaizen Group

2. Kaizen Group
“UDAAN”
By Mechanical
Department

3. PROJECT THEME RUBBER MILL SAFETY IMPROVEMENTY
KAIZEN PROJECT TITLE SAFETY PROVISION IN RUBBER MILL & AUTOCLAVE UNIT
Project completed Date 30.8.2022
NO. OF MEETINGS 9
ATTENDANCE 94%
PERIODICITY OF MEETINGS THRICE MONTHLY
Team Charter
3
Team Leader
Mahesh Werulkar
Member
Niraj Vithalkar
Facilitator
Mr.Gajanan Ghughal
Member
G.N.BAWANE

4. Presence Across Key Infrastructure Sectors
4
STEEL
INFRASTRUCTURE
CEMENT
FOUNDATION
GLOBAL BUSINESS SOLUTION
POWER

5. VISION PURPOSE VALUES
Vision, Purpose and Values

6. 6
JSW Steel – Awards

7. 7
JSW SALEM WON DEMING AWARD -2019

8. 8
JSW Steel – Awards
Prime
Minister’s
Trophy by
Ministry of
Steel for the
year 2012-
13.
Porter Prize f
or Creating
Shared Value,
Leveraging
Unique
Activities -
Weathering
the Iron Ore
crisis 2015
National
Sustainabili
ty
Award: 1st
Prize by
IIM for the
year 2017
Steel
Minister’s
Trophy for
the year
2014-15
and 2015-
16

9. JSW Steel - At A Glance In India
Steel making capacity of 22 MTPA
9 manufacturing facilities in India
VASIND / TARAPUR
DOLVI
VIJAYANAGAR
KALMESHWAR
SALEM
Integrated Steel Plant Downstream Plant
Slabs
Cold Rolled
CA,GL
Coated
Products
Long
Products
HRPO
Coils
Hot Rolled
Plates
HR Coils HSM
Plates
India’s largest
Steel
manufacturer
SALAV
6

10. 0.30
1999
0.33 0.35
2004 2011
0.41
2014 2017
0.65
2019
0.68
12
CAPACITY RAMP –UP
(MTPA)
2022
1.00
0.72
2021
Acquisition by JSW
Galvanizing 1 - 1984
Color Coating -1988
Galvanizing 2 - 2003
Galvalume 1 - 2007
Color Coating 2 – 2013
Color Coating 3 - 2021
Financial Year
YEAR
MTPA
Milestones of Kalmeshwar

11. 0757: Shop Floor Mantra For Continuous Improvement
11
Our project is based on
eliminating UNSAFE
condition

12. Selection of problems
Definition of problems-
Measurement of the data on Problem-
Analysis of the problem for root causes-
Implementation of the Solution
Gain from the solution
Control /Follow Up

13. Step 1: Selection of the Problem
13
LIST OF VARIOUS PROBLEMS IDENTIFIED AT RUBBER MILL
SL NO PROBLEMS CATG. TYPE
1 Vulcanizer roll trolley rusting A
2 Vulcanizer trolley in/out required 4-5 manpower A
3 Overhead crane derail from track B
4 1060 mm Dia. roll cannot be lifted by crane C
5 B32 lathe gear worn out ,slow speed of operation C
6 B32 lathe machine bed worn-out A
7 Rubber mixing mill unsafe condition A
8 Mixing mill side guide worn-out A
9 Vulcanizer door gasket groove damaged chances of leakage C
10 Volcanizer lower steam pressure leads to improper curing B
11 Improper chemical composition of rubber C
12 Emergency braking system at rubber mill A
13 Cloth wrapping inside rmixing mill A
14 Oil lubrication problem in rubber mill B
15 Rubber cutting knife of lower quality B
16 Error in weighing scale B
17 Rubber area working hand gloves not good A
18 Improper arrangement of chemical oil removal from tank A
CATEGORY TYPE:
A: Problems which
can be solved
by our QC team
B: Cross functional
projects
C: Management
help

14. A
B
C
Step 1 : Selection of problems – ABC analysis
14
9
5
4
0
1
2
3
4
5
6
7
8
9
10
A B C
Frequency
Category

15. Step 1 : Selection of problems
15
All Unsolved Problems in A category Studied
A' Category Problems
Sr. No Problems Cat. Type
1 Vulcanize roll trolley rusting A
2 Vulcanize trolley in/out required 4-5 manpower A
3
1060 mm Dia. roll cannot be lifted by crane
A
4 Rubber mixing mill unsafe condition A
5 Mixing mill side guide worn-out A
6
Emergency braking system at rubber mill A
7 Cloth wrapping inside rmixing mill A
8 Rubber area working hand gloves not good A
9 Improper arrangement of chemical oil removal from tank A

16. Step 1 : Selection of problems Through Severity & No of occurrence
16
Data collection for A category problems
Sr. No Problems Sevirity
No of
occrance
(RPN)
1 Vulcanizer roll trolly rusting 3 2 6
2
Vulcanizer trolly in/out required 4-5
manpower
3 2 6
3 B32 lathe machine bed wornout 3 2 6
4 Rubber mixing mill unsafe condition 4 5 20
5 Mixing mill side guide wornout 4 2 8
6
Emergency braking system at rubber
mill
4 4 16
7 Cloth wrapping inside rmixing mill 4 4 16
8
Rubber area working hand gloves
not good
3 2 6
9
Improper arrangement of chemical
oil removal from tank
3 2 6
0%
10%
20%
30%
40%
50%
60%
70%
80%
90%
100%
0
5
10
15
20
25
No of occrance Cu %
Useful many
Vital few

17. Selection of problems
Definition of problems
Measurement of the data on Problem
Analysis of the problem for root causes
Implementation of the Solution
Gain from the solution
Control /Follow Up

18. 18
Step 2 : Definition of Problem
PROCESS DESCRIPTION OF JSW STEEL COATED PRODUCTS LTD. KALMESHWAR
Utilities : Rubber mill provides
rubber coating on used rolls for CPL,
GAL1,2 ,CGL 2lines

19. 19
Step 2 : Definition of Problem
RUBBER MILLAREA
RUBBER MILL
CPL
MILL
CGL 2
GAL 1 & 2
CCL 1,2
CCL 3
CRS 1,2,3
BOILER
 Rubber mill provides rubber rolls to these lines

20. 20
Step 2 : Definition of Problem
PROCESS DESCRIPTION OF RUBBER MIXING MILL
Old roll
threading on
lathe
Adhesive
pasting on
roll
Turning of
rubber roll
on lathe m/c
Coting rubber
strip from
extruder
machine
Tension strip
packing on
lathe
Vulcanizing
of Rubber roll
Rubber
Mixing
Mill

21. Step 2 : Definition of Problem
Rubber mixing mill:
There is a chance of crush injury while mixing the
different component of rubber.
Rubber
Mixing Mill
Mixing
Rolls

22. Unsafe condition at
Rubber Mill
Safety
Production
Cloths may stuck at rotating parts of
machine
Fatal accident while feeding rubber with
hand
Loss of production of rubber mill &
accordinlgy GAL 1&2 CCL 1,2,3
High MTTR of mixing machine
Damage to mixing rollers
22
Step 2 : Impact of Problem

23. TO PROVIDE PADDLE BRAKE.
TO REDUCE UNSAFE ACT & CONDITION AT RUBBER MILL
TO PROVIDE MACHINE GUARDING & SAFETY BAR AT MIXING ROLLLERS
TO PROVIDE BUSH BUTTON EMERGENCY SWITCH
“TO ELIMINATE UNSAFE CONDITION AT RUBBER
MILL”
Step 2 : Objectives
23
TO PROVIDE SAFETY LOCK AT VULCANISER DOOR

24. Start Date of Project
2
June
2022
Target Date of Project
30
Aug
2022
Coordinator : Narendra Kumar
Facilitator : Gajanan Ghugal
Team Mechnova
1. Mahesh Werulkar(Leader)
2. Niraj Vitthalkar
3. G N Banve
Kaizen Name: UDAAN Tittle : Safety Provision at Rubber Mill &Autoclave Unit
24
Step 2 : Schedule Gantt Chart
Sl no Activities/No of weeks 1 2 3 4 5 6 7 8 9 10 11 12 REMARKS
1 Selection of problem
2 Definition of problem
3 Measurement of the problem
4 Analysis of the problem for root cause
5 Implementation of the problem
6 Gain from the problem
7 Control /Follow Up

25. Selection of problems
Definition of problems
Measurement of the data on Problem
Analysis of the problem for root causes
Implementation of the Solution
Gain from the solution
Control /Follow Up

26. Step 3 : Measurement of the data on Problem
26
9
12
10
8
11
0
2
4
6
8
10
12
14
Jan/22 Feb/22 Mar/22 Apr/22 May/22
NO.OF
OBSERVATION
MONTH
SO observation for Rubber Mill
10
11
10
7
9
0
2
4
6
8
10
12
Jan/22 Feb/22 Mar/22 Apr/22 May/22
No
of
Near
miss
MONTH
Near miss occurred Rubber Mill

27. 4W 1 H
Analysis
What
Where
How
Which
When
What is the problem
Unsafe condition at
mixing roller
When does it happened
While feeding rubber
to mixing mill
Where is the problem
At rubber mixing
mill
Which agency
affected
Rubber mill
How to Reduce it
By Providing Guarding and
emergency braking system
Step 3 : Analysis of the problem by 4W and 1H Technique
27

28. Selection of problems
Definition of problems
Measurement of the data on Problem
Analysis of the problem for root causes
Implementation of the Solution
Gain from the solution
Control /Follow Up

29. Step 3 : Analysis of problem for root causes
29
Sr No Probable Causes
1 Cloth stuck at rollers
2 Palm/ fingers may stuck at nipping point in rollers
3 Delay in operation of OFF switch
4 Slippery arear around mixing rollers
5 Angle of feeding the raw material
6 Output Rubber cutting
7 Improper position of operator
8 Required PPE’s not used
9 Unskilled operator
10 Emergency braking system not working
11 Speed of machine is very high
12 Improper guarding of rollers/nipping point
13 MOC of rubber mixing mill
14 Operator palm/fingers can stuck between rollers
Causes are studied
with Ishikawa
Diagram

30. Unsafe working
condition at Rubber
Mixing Mill
Step 4 : Fishbone diagram
Dr. K. Ishikawa
30
Improper position of operator
Required PPE’s not used
Unskilled operator
MAN
Emergency braking system not
working
Improper guarding of
rollers/nipping point
MACHINE
Speed of machine is very high
Chemical composition of rubber
MOC of rubber mixing mill
MATERIAL METHOD
Improper way of rubber feeding
Operator palm/fingers can stuck between
rollers

31. 31
Step 4 : Validation of the causes
Sr No Probable Causes Validation results Judgement
1 Cloth stuck at rollers
Valid cause
2 Palm/ fingers may stuck at nipping point in rollers
Valid cause
3 Delay in operation of OFF switch Not Valid
4
Slippery arear around mixing rollers Not Valid
5 Angle of feeding the raw material Valid cause
6 Output Rubber cutting
Not Valid
7 Improper position of operator Not Valid
8 Required PPE’s not used
Not Valid
9 Unskilled operator Not Valid
10 Emergency braking system not working Valid cause
11 Speed of machine is very high Not Valid
12 Improper guarding of rollers/nipping point Valid cause
13 MOC of rubber mixing mill Not Valid
14 Operator palm/fingers can stuck between rollers Valid cause

32. 32
Step 4 : List of Valid Causes
Sr No Probable Causes Solution
1 Cloth stuck at rollers
Tight uniform and safetyguard
2
Palm/ fingers maystuck at nipping point in
rollers
SafetyGuard to be provided
5 Angle of feeding the raw material
Support bar required to feed the raw
material
10
Emergencybraking system are awayfrom
working area
Emergrybreakaing system to be provided at
hand/feet diatance.
12 Improper guarding of rollers/nipping point
14 Operator palm/fingers can stuck between rollers
Proper Guard to be provided at mixing
roller meshing points

33. Selection of problems
Definition of problems
Measurement of the data on Problem
Analysis of the problem for root causes
Implementation of the Solution
Gain from the solution
Control /Follow Up

34. 34
Step 5 : PDCA Cycle for Implementation
• Trial taken by feeding
rubber in mixing rollers
& applying hand or
peddle brakes
• No unsafe condition
observed while working on
Mill.
• Install Nip guard
• Provide safety bar
• Install emergency push
button
• Install peddle operated
brake system
• Take appropriate actions
to eliminate Unsafe
condition
PLAN DO
CHECK
ACT

35. Step 5 : Validation of Results
Sevirity
No of
occrance
(RPN) Sevirity
No of
occrance
(RPN)
1 Cloth stuck at rollers 4 5 20 2 3 6
2
Palm/ fingers maystuck at nipping
point in rollers
4 4 16 2 2 4
3 Angle of feeding the raw material 4 4 16 2 2 4
4
Emergencybraking system are away
from working area
4 3 12 2 2 4
5
Improper guarding of rollers/nipping
point
5 5 25 2 3 6
6
Operator palm/fingers can stuck
between rollers
5 5 25 3 2 6
Before Modification After Modification
Problems
Sr. No

36. BEFORE AFTER
Step 5 : Implementation of the Solution
 Nip Guard Arrangement For Mixing Rollers

37. Step 5 : Implementation of the Solution
 Nip Guard Arrangement For Mixing Rollers

38. BEFORE AFTER
Step 5 : Implementation of the Solution
 Emergency Brake Switch at Rubber Mixing Machine

39. BEFORE AFTER
Step 5 : Implementation of the Solution
 Safety Bar Rubber Mixing Machine

40. BEFORE AFTER
Step 5 : Implementation of the Solution
 Safety lock-Vulcanizer Door
Safety Lock
Sling locking
to bolts

41. Step 5 : Implementation of the Solution
 Safety lock-Vulcanizer Door
Adjustable toggle
Broken Bolt

42. Selection of problems
Definition of problems
Measurement of the data on Problem
Analysis of the problem for root causes
Implementation of the solution
Gain from the solution
Control /Follow Up

43. Step 6 : Comparative study before and after
Kaizen Implement
43
Sr no Before After
1
Clothe wrapping possibility due non availability of
the safety bar
Safety bar is provide from both the operating ends
2 No paddle operated braking system
Both operator side, given paddle operated braking arrangement
for emergency stoppage within after of influence.
3 ON/OFF switch was at JB
On both operator sides, right hand side push button given for
emergency braking
4 Angle feeding was not proper
By providing the safety bar, hand supported on the bar and easy to
feed the raw material.
5 Nip guard absent
Nip guard provided above the mixing rollers to avoid hand
contact.
6
Production of Rubber Mixing Mill reduced due to
safety factor
Rubber Mill Production increases by 5 Kg/Hr

44. Step 6 :Tangible benefits/Cost Saving
044
Saving Calculation
SR.No Particulars Uom Value Total Saving
1 Productivity Loss Kg 5 30,000 / Day
2 Project Cost Rs 20000/-
Major saving in terms of Human Life

45. Mutual understanding
Self confidence
Enhancement in
computer skill
Enriched knowledge
Enhanced problem
solving capability
Enhanced presentation
skills
Unsafe condition eliminated
Near miss and Unsafe SO
reduced
Step 6: Intangible benefits
45

46. Selection of problems
Definition of problems
Measurement of the data on Problem
Analysis of the problem for root causes
Implementation of the solution
Gain from the solution
Control /Follow Up

47. Control and follow up
Step 7 :
Rubber mixing mill:
There is a chance of crush injury while mixing the different component of rubber. Before the audit ,only one
hand operated mill stopping was given which is found not enough to avoid possible crush injury. So as per
the plant head suggestions three different arrangement provided on the machine to avoid possible hazards.
1. Hand pull emergency brake provide for immediate stopping rotating rollers. (Old arrangement)
2. Safety bar is provide from both the operating ends which will avoid possible contact of cloth with the
rotating rollers. (Newly installed)
3. Both operator side, given paddle operated braking arrangement for emergency stoppage. (Newly
installed).
4. On both operator sides, right hand side push button given for emergency braking. (Newly installed )
5. Hand pull emergency brake provide for immediate stopping rotating rollers. (New installed )
6. Nip guard provided above the mixing rollers to avoid hand contact.

48. Step 7 : Revision of Work Instruction
48
JSW STEEL COATED PRODUCTS
LIMITED,KALMESHWAR No.: 50-03-01
DEPARTMENT: RUBBER MILL
SECTION : RUBBER MIXING MILL ISSUE: 04: REV.: 01
WORK INSTRUCTION FOR RUBBER MILL
OPERATORS Date: 10.01.2022
JSW STEEL COATED PRODUCTS
LIMITED,KALMESHWAR No.:50-03-01
DEPARTMENT: RUBBER MILL
SECTION : RUBBER MIXING MILL ISSUE: 04: REV.: 02
WORK INSTRUCTION FOR RUBBER MILL
OPERATORS Date:30.8.22
BEFORE AFTER
1. TITLE : Work Instructions for rubber mill Operators.
2. PURPOSE : Rubber mixing at mixing mill
3. SCOPE : Proper mixing of rubber & cutting rubber strips
1. TITLE : Work Instructions for rubber mill Operators.
2. PURPOSE : Rubber mixing at mixing mill
3 SCOPE : Post treatment section to Finish Dryer
.
5. RESPONSIBILITY : Operator,Line In charge.
6. TOOLS & GUAGES : Cutting knife for rubber
7. WORK INSTRUCTIONS:
A. Operators and associates should use mandatory PPE while working on
mixing mill
B. Apply emergency brake (hand operated) in case of emergency
5. RESPONSIBILITY : Operator, Line In charge.
6. TOOLS & GUAGES : Cutting knife for rubber
7. WORK INSTRUCTIONS:
A. Operators and associates should use mandatory PPE while working on mixing mill
B. Apply emergency brake (hand/peddle operated) in case of emergency
C. Feed the rubber from top side of Nip guard to avoid unsafe condition

49. 49
LIST OF VARIOUS PROBLEMS IDENTIFIED AT RUBBER MILL
Sr.No PROBLEMS CATG.TYPE
1 Vulcanizer roll trolley rusting A
2 Vulcanized trolley in/out required 4-5 manpower A
3 B32 lathe machine bed worn out A
4 Mixing mill side guide worn out A
5 Emergency braking system at rubber mill A
6 Cloth wrapping inside rmixing mill A
7 Rubber area working hand gloves not good A
8 Improper arrangement of chemical oil removal from tank A
Step 7 : Future project

50. THANK YOU
Delivering Growth in Challenging Times
61
22 MTPA