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REDUCE

FALSE ALARM

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What is False Alarm?Regular Graph

False Alarm, Not actual defect

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TEAM ACITVITY

Material Machine

Steel Grade, Bar Size, RR, Ovality, Grinding, Super Heat,

Scale, Cooling Condition, Bend,

Scale in water, Water Filtration,

Probe identification

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*Data Collection

Activity

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*Data Analysis

23.67

2.44

0

5

10

15

20

25

B L OOM P R ODUC T AV G . F A %

B R E C O P R ODUC T AV G . F A %

S eries 1

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Trial -1 Press Straightened Vs Roller Straightened

F A %

9.6

87.3

0

20

40

60

80

100

R oller S tr P res s S tr

F A %

Two Roll straightener

Press straightener

F A

21

12

7 7

31

31

0

5

10

15

20

25

0.5 -1.0

1.0 -1.5

1.5 -2.0

2.0 -2.5

2.5 -3.0

3.0 -3.5

3.5 -4.0

4.0 -4.5

F A

Bend wrt No. of bars in Press Straightened.

Same Heat, Size,Rolling Condition.

Conclusion: Scale can be the reason for FA

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Trial-2 Scale

Ring Grinding Acid Wash MPI Before conditioning

After conditioning

Conclusion: Scale is the reason for FA.2Roll St. will Solve this

100%

0

0.2

0.4

0.6

0.8

1

1.2

1 2

After conditioning

Before conditioning

Before & After conditioning

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Trail 3Comparison between Dirty V/s Fresh water

Dirty water

Fresh water

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Improvement Plan in Machine

• Improve Water Filtration

Steel Tank

Water Pit

UT Tank

Wire Mesh Filter

Water Filter existing

Proposed filter

Wire Mesh Filter proposed

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False Alarm Probe Identification

• Maximum FA observed in probe 3 & 4

9 8

35

53

11

00

10

20

30

40

50

60

P robe 1 P robe 2 P robe 3 P robe 4 P robe 5 P robe 6

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Action Plan

• Trial to be taken after changing Probe location..• Water Filtration strengthening.

Next Step• Install two roll straightener• Study temporary counter measures until the installation of two roll straightener.