Improvement Status B-13 Class-O:-

Date:- 06/05/2013

1) Density reduced from 42~45 to 38~40 of class O sheets. Due to this productivity increased by 14%. 2) Close (small) cell structure like Italy. In Italy they are making it with 3 micron blowing agent but in our plant we are managing it by 5 micron blowing agent. 3) Line speed increased by 40% as compare to previous. With the help of this we have increased productivity by 40%. 4) Pine hole removed from the back side of sheet (especially from 19mm & 25mm). 5) Solved the elephant skin and soft feel of material (in 19mm, 25mm & 32mm). 6) Removal of Zeon in 25 mm and 32 mm for cost reduction. That will effect Rs.40, 500 in 32 mm out off 1000 nos. and Rs. 45,000 out off 1000 nos. of rolls approximately. 7) Sheet width increased by 20 cm for increase the productivity which give us 20% hick. Previously we are making our sheet width by 1m but currently we are making it by 1.2m in all sizes of class O sheets. 8) 50 density class-O sheet made for BARC 9) Lowered the scrap. 10) WIP reduction N-5 Class-O Pipe:1) Removal of soft pipe problem. 2) Line speed increased by 25%. Due to this productivity is increased by 25%. 3) WIP reduction which was very high in Class O pipe. Now we are gradually decreasing our WIP percentage. B-2 Class 1:1) Line speed increased by 10-15% (variable in different sizes) in pipe. Through this productivity increased by 10% 2) Removal of Zeon from the pipe for low cost (in 9mm & 13mm in some sizes which are fast moving). 3) Added white filler (Talcum powder) for cost reduction in pipe and all together its effected Rs.6/Kg. Currently we are using approximately 1200 kg/month in place of Zeon. 4) After removal of Zeon feeling same of the pipe. 5) Scrap reduction by removing of bubble problem. 6) In the shortage of B2, started blending with B13 in class-1 sheets. Through this we have also achieved improver line speed 14% more. Through this productivity increased by 14%. 7) 6mm, 65 density class-1 sheet made for CMS tape skiving. 8) Density low of pipe 60 to 55. 9) Density low of sheet 55 to 45. 10) WIP reduction. Cladding:1) Solved the wrinkle problem in cladding. 2) Scrap reduced.

Process and General:1) Mixing time increased in open roll mill for better and homogenous mixing.(4.5 min to 5 min) 2) Setting time reduction. Previously our per change over time was approximately 1.5hr (90 min) but currently we are doing it in 25-35 min. On an average we have 3-4 change over in a day. Through this we are creating approximately 3 days extra time for our production. 3) Scrap reduction from 8.5% to 3.2%. 4) Daily meeting for problem solving and exact status of our work. 5) Down time recording started. Previously there is no any account about the down time; from July12 we started down time calculation (recording). 6) Material efficiency(production efficiency) increased by 80%-85% to 90%-100+%. 7) Powder applicator for outside powder application in our pipe. 8) Now no need to cut the line (stop production) for bubble (splitting), material soft, pin hole, density. 9) WIP reduction.

Effect of these points will be Rs. 1 Cr. Approximately per month.