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TATA STEEL
 The origins and ascent of Tata Steel, which has culminated into the century
long history of an industrial empire, emerge from the illustrious efforts of
India's original iron man and the remarkable people who thereafter, have
kept the fire burning.
 The story of Tata Steel is a century old. And so is the story of steel in India.
Etched with the visions and hardships of a single man, the story has flowed
through ages to redefine steel in every way. The saga, which started in 1907,
completes a century of trust in 2007. Over the years this one company has
exposed the various shapes and forms in which steel can be applied for
effective utilization. The story of Tata Steel: defines and redefines
conventional wisdom in myriad ways.

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 The modern iron and steel industry in India owes its
origin to the grand vision and perseverance of Jamsetji
Nusserwanji Tata, who was born in 1839 in Navsari, a
small town in Gujarat, into a family of priests.
 The Tata Iron and Steel Company Limited (Tata Steel)
was registered in Bombay on 26th August 1907. The
construction of the steel plant was then taken up in
earnest with the first stake being driven in February
1908. R.G. Wells, an American with steel plant
construction experience took over as the General
Manager in 1909.
The Beginning

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SUBMITTED BY:-
CHANDRA SEKHAR SAHOO
VT20161414
MECHANICAL ENGINEERING
COLLEGE OF ENGINEERING BHUBANESWAR
ODISHA
UNDER GUIDANCE OF:-
MR. RAKESH PRASAD
MANAGER EQUIP. MAINT.SERVICES
REDUCTION OF RE SLEEVING TIME BY
ZETKO MACHINE IN LD2

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BUSINESS CASE
 ZETKO tap hole Drill machine is an important equipment for LD-2 vessel
resleeving. so, there should be zero breakdown .Time consuming by drill
m/c at the time of resleeving is directly impacting the vessel operation.
 The average no of heat in LD2 is 73 at present. There is an opportunity
to increase the no of heat by reducing the downtime of the vessel.
Resleeving of the vessel is the major contributor for downtime of the
vessel. It is required to study the process of resleeving so that the
downtime can be reduced.
D M A I C

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BRIEF DESCRIPTION OF EQUIPMENT
D M A I C
 The Tap hole drill machine (ZKO) is a heavy duty drilling machine
featuring diesel-hydraulic drive.
 ZKO machine is used in steel making operation at LD =2 shop.
 There is 2 machines to perform drilling operation in LD2 .One is TML
drill machine another is ZKO drill machine.
 Working of ZKO drill machine:-Tap hole drilling & resleeving of vessel.
 The machine design incorporates the following subassemblies:
 Wheeled undercarriage (chassis)
 Superstructure(slewing platform)
 Operator’s cab with controls
 Cradle
 Diesel-hydraulic drive(main drive)
 Hydraulic system
 Electrical control system.

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TAP HOLE DRILL MACHINE( ZKO)
D M A I C

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Working of ZKO machine
D M A I C

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TECHNICAL DATA OF HYDRAULIC HAMMER FOR ZKO MACHINE
D M A I C

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Resleeving time of LD=2 shop
D M A I C
DATE
EQPT.
CODE
DEPT
VESSEL
NO.
DRILLING
START
DRILLING
FINISH
DURATION
(MIN)
TAP
START
NEXT TAP
START
JAN'15
04-01-2015 809 LD2 2 1.03 1.05 2.00 21:50 2:40
10-01-2015 809 LD2 2 4.56 4.58 4.00 4:40 8:10
16/1/2015 809 LD2 2 1.20 1.25 5.00 12:50 16:40
21/1/2015 809 LD2 2 7.32 7.35 3.00 6:45 10:10
31/1/2015 809 LD2 2 5.27 5.3 3.00 5:05 7:45
FEB'15
05-02-2015 809 LD2 1 9.32 9.34 2.00 20:45 2:05
06-02-2015 809 LD2 2 2.28 2.30 2.00 14:00 16:40
20/2/2015 809 LD2 2 12.10 12.12 2.00 11:35 16:10
24/2/2015 809 LD2 1 9.17 9.20 3.00 19:50 23:35
25/2/2015 809 LD2 2 5.05 5.11 6.00 15:50 20:05
MARCH'15
02-03-2015 809 LD2 1 5.40 5.42 2.00 17:10 20:25
07-03-2015 809 LD2 2 11.58 11.59 1.00 23:30 2:30
11-03-2015 809 LD2 3 11.08 11.16 8.00 9:50 14:15
12-03-2015 809 LD2 2 9.06 9.07 1.00 20:45 23:40
13/3/2015 809 LD2 1 3.53 4.00 7.00 3:00 7:40
16/3/2015 809 LD2 3 10.35 10.46 11.00 10:05 13:25
17/3/2015 809 LD2 2 3.14 3.15 1.00 2:55 5:45
19/3/2015 809 LD2 1 9.14 9.15 1.00 8:50 12:05
22/3/2015 809 LD2 2 8.56 8.57 1.00 20:33 1:00
25/3/2015 809 LD2 1 8.58 9.12 4.00 8:15 11:40
27/3/2015 809 LD2 3 11.11 11.15 4.00 10:20 13:40
27/3/2015 809 LD2 2 12.15 12.16 1.00 23:50 2:25
APRIL'15
01-04-2015 809 LD2 2 8.32 8.37 5.00 8:00 11:55
05-04-2015 809 LD2 2 4.20 4.25 5.00 3:50 7:25
21/4/2015 809 LD2 1 5.47 5.50 3.00 17:25 20:00
MAY'15
02-05-2015 809 LD2 1 6.45 6.50 5.00 6:25 9:05
08-05-2015 809 LD2 1 1.05 1.06 1.00 12:45 15:25
09-05-2015 809 LD2 3 9.30 9.34 4.00 9:00 11:40
13/5/2015 809 LD2 2 8.54 8.57 3.00 20:15 23:35
14/5/2015 809 LD2 1 6.10 6.14 4.00 5:35 9:10
15/5/2015 809 LD2 3 9.57 10.00 3.00 08:30 13:05
18/5/2015 809 LD2 2 4.02 4.05 3.00 3:40 6:30
19/5/2015 809 LD2 1 5.51 5.56 5.00 17:30 21:40
23/5/2015 809 LD2 2 12.27 12.30 3.00 23:50 04:35
24/5/2015 809 LD2 1 9.40 9.43 3.00 20:55 00:25

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D M A I C
Resleeving time of LD=2 shop
DATE
EQPT.
CODE
DEPT
VESSEL
NO.
DRILLING
START
DRILLING
FINISH
DURATION
(MIN)
TAP
START
NEXT TAP
START
JUNE;15
02-06-2015 809 LD2 2 3.35 3.39 4.00 3:05 06:00
04-06-2015 809 LD2 1 1.45 1.50 5.00 1:15 4:25
07-06-2015 809 LD2 3 1.13 1.15 2.00 12:50 15:30
08-06-2015 809 LD2 2 1.20 1.23 3.00 00:50 4:30
10-06-2015 809 LD2 1 7.00 7.03 3.00 18:30 21:30
13/6/2015 809 LD2 2 5.10 5.15 5.00 4:35 9:00
17/6/2015 809 LD2 1 10.24 10.34 10.00 9:50 13:25
18/6/2015 809 LD2 3 2.27 2.29 2.00 1:10 4:55
19/6/2015 809 LD2 2 6.20 6.22 2.00 17:35 21:00
22/6/2015 809 LD2 1 3.40 3.45 5.00 15:00 18:30
23/6/2015 809 LD2 3 3.26 3.3 4.00 05:45 7:20
29/6/2015 809 LD2 2 1.38 1.40 2.00 1:20 3:55
30/6/2015 809 LD2 3 1.22 1.26 4.00 12:40 16:15
JULY'15
03-07-2015 809 LD2 1 8.50 8.52 2.00 8:20 11:40
04-07-2015 809 LD2 2 4.55 4.58 3.00 4:30 8:05
06-07-2015 809 LD2 3 9.00 9.02 2.00 20:35 23:50
07-07-2015 809 LD2 1 3.23 3.27 4.00 2:55 5:40
11-07-2015 809 LD2 2 3.45 3.48 3.00 15:25 18:30
12-07-2015 809 LD2 3 10.28 10.30 2.00 9:55 13:55
14/7/2015 809 LD2 1 11.15 11.17 2.00 10:50 14:00
16/7/2015 809 LD2 2 12.21 12.27 6.00 11:35 15:55
17/7/2015 809 LD2 3 3.38 3.41 3.00 15:10 18:35
22/7/2015 809 LD2 2 11.00 11.03 3.00 10:25 13:25
AUGUST' 15
01-08-2015 809 LD2 2 6.29 6.33 4.00 6:00 8:45
12-08-2015 809 LD2 2 7.31 7.34 3.00 6:45 10:05
18/8/2015 809 LD2 2 5.25 5.27 2.00 16:30 20:15
22/8/2015 809 LD2 2 5.25 5.27 2.00 5:00 7:40
28/8/2015 809 LD2 2 8.30 8.39 9.00 7:50 11:25
28/8/2015 809 LD2 1 4.25 4.30 5.00 15:45 18:30

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PROCESS FLOW DIAGRAM OF TAP HOLE DRILL & RESLLVING IN LD=2,
TOTAL TIME- 100 Min
Step - 1
Tap hole cover Bolt cutting job.
Time: 18Mints
Step - 2
Gradlle placing for vessel cleaning
Time: 5Mints
Step – 3
Vessel mouth cleaning by Gradlle .
Time: 13Mints
Step – 4
Vessel ready for drill job.
Time: 2Mints
Step - 5
Tap hole drilling .
Time: 2 Mints
Step – 6
Vessel cleaning & ready for resleeving
Time: 6 Mints
Step - 7
Sleeve bring & ready for resleeving.
Time: 12Mints
Step – 8
Sleeve fitting
Time: 8 Mints
Step – 9
Cover plate fix &Bolt tightening
Time: 4 Mints
Step – 10
Stand removing by fork lift & Gradlle
removing from vessel after resleeving job.
Time: 6Mints
Step – 11
Preparation for gunning .
Time: 6Mints
Step – 12
Vessel gunning .
Time: 20 Mints
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D M I CA

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D M A I C
Resleeving Time break up of ZETKO Machine
0.00
2.00
4.00
6.00
8.00
10.00
12.00
14.00
16.00
18.00
20.00
Drill Vessel cleaning
& ready for
resleeving
Sleev bring &
ready for
reslleving
Sleeve fitting Bolt tighteening Area ready for
gunning
TIME(MIN)
JOB DETAILS OF RESEELVING
Job wise time taken
Time
Good
The above trend shows that Sleeve bring & ready for resleeving with sleeve fitting is taking maximum time of
resleeving , which is cause of concern and to be analysed further.

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D M A I C
Problem Details Phenomenon observation Causes
HIGH DOWN TIME OF
VESSEL FOR RESLEEVING
1.Bring sleeve at vessel by forklift.
1.No other option to carry sleeve & this is very
unsafe job.
2.Drill machine don’t have this arrangement to
carry sleeve.
3.By hand this material can not carry as it is
heavy .
2. Stand fix in front of vessel for re-sleeving
1.Stand fixing is necessary for re-sleeving
which is very unsafe job.
2.Dril machine don’t have stand for fixing or
handling sleeve .
3.Sleeve hold & fixing process with graddle &
forklift.
1. No other option to hold & fixing sleeve & this
is very unsafe job.
2.Drill machine don’t have holding & fixing
arrangement of sleeve.
3.Forklift use to support graddle which is very
unsafe job.
4.Graddle bring & Graddle take back from
vessel area
1.Graddle is required for re-sleeving..
2.No other option or drill machine don’t have
re-sleeving arrangement.
5.Stand bring & keep it back at its place.
1. No other option to re-sleeving with out stand
& this is very unsafe job.
Phenomenon observation of problem

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Sl
No
Causes Check Status
1
No other option to carry sleeve & this is very
unsafe job.
Checked option to make the job safe. OK
2
Drill machine don’t have this arrangement to carry
sleeve.
Discussion with OEM to fix resleeving
arrangement.
OK
3 By hand this material can not carry as it is heavy Checked this is very unsafe handling manually. NOT OK
4
Stand fixing is necessary for resleeving which is
very unsafe job.
Discussion with operational dept for proper
vessel preparation.
NOT OK
5
Drill machine don’t have stand for fixing or handling
sleeve .
Checked proper Arrangement for machine.. OK
6
No other option to hold & fixing sleeve & this is
very unsafe job
Checked option to make the job safe. OK
7
Drill machine don’t have holding & fixing
arrangement of sleeve
Discussion with OEM to fix resleeving
arrangement.
Ok
8
Forklift use to support graddle which is very unsafe
job.
vessel preparation
NOT OK
10 Graddle is required for reslleving..
vessel preparation
NOT OK
11
No other option or drill machine don’t have
resleeving arrangement.
Checked option to make the job safe. ok
12
No other option to resleeving with out stand & this
is very unsafe job
Checked option to make the job safe. ok
VALIDATION OF CAUSES
D M A I C

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D M A I CD M A I C
WHY-WHY ANALYSIS
High down time of vessel for resleeving
WHY
Time loss to transport working platform & sleeve
WHY
Forklift & gradlle used for handling of working
platform & sleeve.
No working platform available to reach vessel hole &
no sleeve handling arrangement .
WHY
There is no provision of working platform & sleeve
handling on M/C.
WHY

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D M A I CD M A I C
IDENTIFIED ROOT CAUSES
There is no provision of working platform & sleeve handling on M/C

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• ALTERNATIVE ADVANCE make machine with all facility to be provided.
• EXISTING machine with working platform to be provided.
• EXISTING procedure & safely resleeving job with existing M/C to be
provided.
• EXISTING machine with working platform & sleeve handling arrangement
to be provided.
• EXISTING OEM advance higher model M/C to be provided.
BRAINSTORMING FOR DEVELOPING ALTERNATE RESOURCES
D M A I C

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DECISION MATRIX
Ideas Feasibility Sustainability Maintainability
Cost
effective
Safety
Accepted/
Rejected
ALTERNATIVE ADVANCE
make machine with all facility to
be provided.
Yes Yes No No Yes Rejected
EXISTING machine with
working platform to be provided.
Yes No Yes Yes No Rejected
EXISTING procedure & safely
resleeving job with existing M/C
to be provided.
Yes No Yes No No Rejected
EXISTING machine with
working platform & sleeve
handling arrangement to be
provided.
Yes Yes Yes Yes Yes Accepted
EXISTING OEM advance
higher model M/C to be
provided.
Yes Yes No No Yes Rejected
D M A I C

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ACCEPTED SOLUTION
EXISTING machine with working platform &
sleeve handling arrangement to be
provided.
D M A I C

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