2009-10 Team Project Summaries

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Sterlite Industries Ltd
Tuticorin, Tamilnadu, India

SPARKLERS

Presentation: Tuesday, May 25, 3:00 p.m. – 3:45 p.m.
Room: 266

Type of Team: Improvement Team

The objective of the project was to improve the converter cranes reliability from 56% to 88%. Tools used in the project were, historic data collection, Pareto analysis, brain storming, Ishikawa (Fishbone) diagram, Why-Why analysis, Time Feasibility study, and Economic Feasibility study.

The crane improvement project was executed as an improvement Project using Juran Quality Improvement (JQI) methodology -TQM (Total Quality Management). The data on crane reliability was analyzed for past one year before the start of the project and Pareto analysis was done subsequently, to prioritize the issues. Brain storming was carried out to identify various causes and hypothesis developed and tested for its validity. Based on the conclusions, the root causes were identified. Alternate solutions were identified and evaluated based on economic/time criteria. Final solutions were implemented.

During the period 2006-07, 2007-08 production loss due to crane breakdown was 1053 MT and 2379 MT respectively. The Project has successfully reduced the downtime of cranes and in turn the production loss to a larger extent. By successful implementation of the project, the crane reliability is increased from 56% to 94.54%.

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