Iil-klm Visit Complete Version

IIL - Kalmeshwar Plant Visit 25 – 27 AUGUST 2008 FLORANTE C. LEE, Division Head, CRM ARTURO B. del AYRE, SiC, CRM-Finishing

Plant Location

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Major Equipment

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Acid Pickling Tanks

Cold Rolling 6 Hi Mill

Furnace in Galvanizing

Zinc Pot in Galvanizing

Cold Rolling Skin Pass Mill

Coater in Color Coating Line

1st Hitachi Cold Rolling 6 Hi Mill in India

1st Thin Gauge Galvanizing Line from Nippon Denro Japan 1st Color Coating Line with Reverse Coating Technology

IIL-KLM Organizational Structure

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GSPI T/O

Note: Sr. VP (Projects) also heads MPICC

Agenda and Points of Discussion • I. Maintenance Systems

Part 01

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Functional Organization Maintenance Methodologies

• II. Operations Systems and Procedures

Part 02

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Operational Processes Mill Generated Scrap Management Energy Management System

• III. Management Initiatives

Part 03

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Total Productive Maintenance [including SHE/EMS] QMS (ISO 9001:2000, TS 16949, ISO

Suggestions for

Kalmeshwar Complex

Suggestions for IIL Operations • Quality: Arrest roof leaks at Mill Bays to prevent wetting CRFHs (Works-inProcess) in Storage Area and upended newly-Annealed coils from BAF during heavy downpour [Water + Air on Steel = Rust]. GSPI’s Initiative: Use of Kraft Packaging Paper for CRFH WIPs and Lawanit EyeBlanks for upended CRCAs. This could also address coils being subject to bird droppings.

• Annealing Process: Use a fine-mesh 7 ceramic fiber as sealant for Inner

Suggestions for IIL Maintenance • Why-Why: Incorporate actionable results of Why-Why Analysis to SAP’s PM database. Presently, IIL uses Lotus Notes to distribute scanned/soft copies of WWA reports. • SAP: Include Calibration in SAP Task List. Calibration is a mandatory requirement for ISO 9001. • SAP: Include Standard/Actual (manhours) for each activity in the PM’s 8

Suggestions for IIL Maintenance • Predictive Maintenance: Procurement of Thermography instrument and / software. This could aid in breakdown prediction for certain equipment and respective components. • Spares Management: Classify maintenance spares by Policy, such as Operate-to-Failure (OTF), FixedTime Replacement (FTR), Condition9 Based Replacement (CBR), in addition

Suggestions for IIL Mgt. Initiatives • TPM-PM: Document all Mill Equipment revisions or improvements using MP Sheets and/or appropriate Engineering/Schematic diagrams. • TPM-JH: Apply GSPI’s TPM good practices as recommended by AGM * During the plant Anil B. Sarwate [TPM] last Nov 2005. visit, no objective These practices* include: evidence at Mill 

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Office TPM Makigami Sheet. floor were visible for these practices. Kaizen Tree at JH machines.

Suggestions for IIL Mgt. Initiatives • 5-S: Encourage IIL-KLM regular employees to perform 5-S activities in their respective areas: Cleaning, Seiso, at RM’s Floor (currently by Contractors), • Sorting, Seiton, at Continuous Pickling Line Spares Room • Housekeeping, Seiketsu, on all Mill areas. •

• Safety: Rain Water Downspout near Col. C10/PPIC splashes to nearby PDB 11 panel; drenching power cables for

Suggestions for IIL Mgt. Initiatives • Safety: Provide portable convenience outlet for Floor Polisher used by Contractor at 6-Hi Storage Area. During the visit, Floor Polisher was temporarily connected to a convenience outlet inside the 6-Hi Rolling Mill Pulpit, power cable laid on the stairs then through the CRFH Staging Area with operational crew hopping their way over the cable. [Trip Hazard] 12 • Safety: Publicize “No. of Days

Other Activities 27 – 28 August 2008 Kalmeshar, Nagpur, India Dolvi Plant, Alibaug, India

27 Aug 2008: TPM Sharing at KLM

Microsoft PowerPoint Presentation

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28 Aug 2008: Tour at Dolvi Plant Blast Furnace

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HSM Facade

Jetty

HSM Stands