7/29/2019 POOGI of CCPM promotion at Tata Steel
1/42
www.tocpractice.com Sixth International TOCPA Conference
18-19 May, 2013, Moscow, Russia
Theory Of Constraints Practitioners Alliance TOCPA
Training Institute
Happy employees
Patronizing sports
Empowering womenAdult literacy
Providing waterin rural areas
Medical aid in remote areas
POOGI of CCPM Promotion The Tata Steel Experience
Prasanna Kumar Jha Tata Steel Ltd.
TATA NANO
A century ofTrust
7/29/2019 POOGI of CCPM promotion at Tata Steel
2/42
www.tocpractice.com Sixth International TOCPA Conference
18-19 May, 2013, Moscow, Russia
Theory Of Constraints Practitioners Alliance TOCPA
21 years of experience in Steel Operations andSupply Chain Management.
TOCICO Certified Practitioner in Supply Chainand Project Management. Additionally a certifiedSix Sigma Black Belt
Involved in implementation and
institutionalisation of Supply Chain, Logistics andProject Management solutions at Tata Steel.
Instrumental in implementing Replenishmentsolution in Flat Products Division of Tata Steel.
Also involved in execution of around 300maintenance and sustenance projects usingCCPM.
Holds a post graduate degree in Business
Management with specialisation in Systems andMarketing
Prasanna Kumar Jha
Head TQM TOC (Tata Steel Ltd.)
7/29/2019 POOGI of CCPM promotion at Tata Steel
3/42
www.tocpractice.com Sixth International TOCPA Conference
18-19 May, 2013, Moscow, Russia
Theory Of Constraints Practitioners Alliance TOCPA
Agenda:
Organisation Profile
Project Management - The TOC way
History of CCPM Implementation in Tata Steel
Problems in promotion of CCPM
Project Environment at Tata Steel
Classification of projects
Needs to apply CCPM
Issues and obstacles to Buy-In and ExecutionApproach at Tata Steel
Effects
Example Case Primary Crusher Erection
7/29/2019 POOGI of CCPM promotion at Tata Steel
4/42
www.tocpractice.com Sixth International TOCPA Conference
18-19 May, 2013, Moscow, Russia
Theory Of Constraints Practitioners Alliance TOCPA
Tata Group - Pioneers in Nation Building(established in 1868)
In a free enterprise,the community is notjust another stake
holder in the business,but in fact the very
purpose of itsexistence.
Jamsetji Tata(1839 1904)
Founder
Guiding Philosophy: Customer focus, Innovation, giving back to Society
Governed by the Tata Code of Conduct and Tata Group Values
144 year old professionally managed Business Group.
TATA Group
TataSteel
Tata SteelIndia
Nat SteelTata SteelThailand
Tata SteelEurope
Tata Motors TCSTata
PowerTata
Chemicals
1902 Hotels
1907 Steel
1910 Power
1911 Education
1932 Airlines
1945 Motors
Many first in India
No. of companies: 114 in 80 countries
Revenue: US $ 100 billion (FY12)
Employees: 425,000
4
TSL is Groups 2nd largest revenue earner: Turnover US $ 26.13 billion (FY12)
7/29/2019 POOGI of CCPM promotion at Tata Steel
5/42
www.tocpractice.com Sixth International TOCPA Conference
18-19 May, 2013, Moscow, Russia
Theory Of Constraints Practitioners Alliance TOCPA
Tata Steel India Organisational Profile
Indias first steel plant; 100 years old
Turnover US $ 8 Billion (FY12)
Believes that society is an important
stake holder in business 5 to 13% of
net profit is spent on society
Own raw material
Unique Industrial Corporation; oftencited as a global benchmark in
Corporate Social Responsibility1000 KM
7/29/2019 POOGI of CCPM promotion at Tata Steel
6/42
www.tocpractice.com Sixth International TOCPA Conference
18-19 May, 2013, Moscow, Russia
Theory Of Constraints Practitioners Alliance TOCPA
Tata Steel Value Chain
Flat Products Division
LD-2 Hot StripMill
Cold Rolling
Mills
Flat ProductMarketing &
Sales
Steel
Steel Products
Customers
Ore Mines&
QuarriesDivision
WestBokaroDivision
JhariaDivision
Raw MaterialsDivision
Long Products Division
LD-1
Merchant Mill
New Bar Mill
Wire Rod Mill
Long ProductMarketing &
Sales
Steel Steel Products
Customers
Long Products Division
Iron MakingSteel
MakingRolling
Marketing &Sales
Shared Services (Provides Maintenance Services and Operates Utilities)
Raw
Materials
Hot Metal
SinterPlant
CokePlant
Blast
Furnaces
Coke, Sinter & Iron Division
Lumps
Coal
Purchased
Materials
Fines
7/29/2019 POOGI of CCPM promotion at Tata Steel
7/42
www.tocpractice.com Sixth International TOCPA Conference
18-19 May, 2013, Moscow, Russia
Theory Of Constraints Practitioners Alliance TOCPA
TQM the binding glue - from Mining to Finished Products
ImprovementAccelerators
ISO System, Deployment of IT Systems for Business Initiation of Quality Circles
Introduce TQM, TPM pillars Training & Education
Value Engineering, AQUIP
Start usage of basic TQM tool, Total OperationalPerformance
Revisit Vision,
Measuring effectiveness by TBEM
Customer awareness to customer delight -
RVM, SVM, CVM, Theory of Constraints Integrated TQM framework (complete value
chain)
Benchmarking, Innovation, Expert creation Introduction of TQM promotion departments
(CQA, CS&P) Introduction of KVHS : a focused problem
solving methodology Codifying the Tata Steel Way of creating and
sustaining change
Seeking
world class2009 &
beyond
Global outlook,
Growth2005-2008
Cost competitiveness
1997-2004
Modernization of mind
1992-1996
Standardization1988-1992
Key TQM Response
2
3
4
5
BusinessNeed
1
DemingApplicatio
n Prize-2008
TQMDiagnosis
for DAP2005
TBEMAssessment
DemingGrandPrize -2012
7/29/2019 POOGI of CCPM promotion at Tata Steel
8/42
www.tocpractice.com Sixth International TOCPA Conference
18-19 May, 2013, Moscow, Russia
Theory Of Constraints Practitioners Alliance TOCPA
Agenda:
Organisation Profile
Project Management - The TOC way
History of CCPM Implementation in Tata Steel
Problems in promotion of CCPM
Project Environment at Tata Steel
Classification of projects
Needs to apply CCPM
Issues and obstacles to Buy-In and ExecutionApproach at Tata Steel
Effects
Example Case Primary Crusher Erection
7/29/2019 POOGI of CCPM promotion at Tata Steel
9/42
www.tocpractice.com Sixth International TOCPA Conference
18-19 May, 2013, Moscow, Russia
Theory Of Constraints Practitioners Alliance TOCPA
History of CCPM application in Tata SteelFirst application in December 2005 E Blast Furnace top repair
Since the
10 Projects in Mines
74 Projects in BlastFurnaces
109 Projects in Steel Melting& Casting
83 Projects in Rolling Mills
Strip Mill, Wire Rod Mill
Hot Rolling Mill, Cold Rolling Mill
132 Projects in Sinter Plants
12 Projects in Power Plants
Blast Furnaces
Mines
Steel Melting & Casting
Hot & Cold Rolling Mills
Over 400 Major Shutdowns &Upgrade Projects
7/29/2019 POOGI of CCPM promotion at Tata Steel
10/42
www.tocpractice.com Sixth International TOCPA Conference
18-19 May, 2013, Moscow, Russia
Theory Of Constraints Practitioners Alliance TOCPA
He will cutmy task
times inhalf
Let us applyCCPM in
your project
With all good intentions.
CCPM Facilitator
Project Manager1
The belief: In order to complete the project on
time each task must complete on time
2
.. We needmanagementcommitment
3Implement
CCPMWe have hiscommitment
Project Manager
CCPM will get implemented .
. Will the results be there ??
4
Problems in promotion of CCPM
7/29/2019 POOGI of CCPM promotion at Tata Steel
11/42
www.tocpractice.com Sixth International TOCPA Conference
18-19 May, 2013, Moscow, Russia
Theory Of Constraints Practitioners Alliance TOCPA
Project Environment at Tata Steel (1/2)
Definition
MaintenanceProjects
Maintenance to overcome normal wear & tear ofequipment
Inspect the components which need repair orchange (CDT)
Cleaning and painting
SustenanceProjects
Based on the need, equipment need to be upgraded for
- Higher production
- Meet certain quality requirement of enriched productmix
- Modification to reduce cost of operation
- Modifications to comply with new environmental andsafety regulations.
7/29/2019 POOGI of CCPM promotion at Tata Steel
12/42
www.tocpractice.com Sixth International TOCPA Conference
18-19 May, 2013, Moscow, Russia
Theory Of Constraints Practitioners Alliance TOCPA
Project Environment at Tata Steel (2/2)
Maintenance projects Sustenance & Expansion Projects
Project teams are independent takes own decision on how to manage projects
Some common resources used as expertise. Free to seek external support.
BELIEFS
Done similar projects earlier
Continuously improved
More time spent,
better the quality of work.
BELIEFS
Many groups can influence
Majority external agencies. Very less control
Penalty clauses help complete on time
Management tools cannot help
Challenges
Identifying potential losses
Convincing - times estimates are variable
Minimize transfer batch (improve flow in planning)
Protect uncertainties with Buffers (placements)
Synergizing different groups towards
common goal
There is time - increase scope of work Project getting delayed trim content
7/29/2019 POOGI of CCPM promotion at Tata Steel
13/42
www.tocpractice.com Sixth International TOCPA Conference
18-19 May, 2013, Moscow, Russia
Theory Of Constraints Practitioners Alliance TOCPA
Need to apply CCPM
When was the last time some one came and said,
Thank you very much for Toilets that Flush
Maintenance is an interesting professionHard work Highly skilled Rarely recognized
The goal seems to be:
Keep everything running all the time
Ridiculous!! (from a maintenance point of view)
Do you know of anyone who buys a new car and says,
Oh, I cant wait to get the first repair done
As Dr James Holt (WSU) says:
7/29/2019 POOGI of CCPM promotion at Tata Steel
14/42
www.tocpractice.com Sixth International TOCPA Conference
18-19 May, 2013, Moscow, Russia
Theory Of Constraints Practitioners Alliance TOCPA
Need to apply CCPM (Performance Gap)
Maintenance - In terms of statistics:
We have about 10% down time / year
About 8% to 9% of which is Planned
Industry Benchmark ??
1% increase in availability 38 Mil USD in Sales
Sustenance
Huge demand
Need to augment capacities to meetdemand
Capture desired market segments
All this would lead to higher down time
7/29/2019 POOGI of CCPM promotion at Tata Steel
15/42
www.tocpractice.com Sixth International TOCPA Conference
18-19 May, 2013, Moscow, Russia
Theory Of Constraints Practitioners Alliance TOCPA
Classification of Maintenance andSustenance Projects
Project Management
1. Manage & execute ourselves some contractor labor used for low end jobs.
2. Manage ourselves but use
external expertise forexecution
3. Offload the entire project
including project management
4. Work coordinated by us
executed by petty contractors
but offload project
management & engineering
A. Short term project
- 5 days to 1 month
B. Long Term Project
- 1 month to 1 year
We have not applied CCPM in
projects spanning more than 1
year
Time
7/29/2019 POOGI of CCPM promotion at Tata Steel
16/42
www.tocpractice.com Sixth International TOCPA Conference
18-19 May, 2013, Moscow, Russia
Theory Of Constraints Practitioners Alliance TOCPA
Issues in applying CCPM- Buy In
There is a need for the whole project team to complete
the project within (a) Budget, (b) Content & (c) Time
If project team becomes job less if project is completed early, then Budget and
Content may be okay, but finishing early may not be important.
NecessaryAssumption
Getting a Buy-in
Time is NOTdeterministic
Skewed distribution
In a series of dependentactivities some will happen
early, some will be late
Taking advantage
of early finishes
7/29/2019 POOGI of CCPM promotion at Tata Steel
17/42
www.tocpractice.com Sixth International TOCPA Conference
18-19 May, 2013, Moscow, Russia
Theory Of Constraints Practitioners Alliance TOCPA
Issues in applying CCPM - Execution
Components of execution
Planning
as per CCPM
Execution
as per CCPMPreparation
Issues
Staggering
Buffering
Issues
Buffermanagement
7/29/2019 POOGI of CCPM promotion at Tata Steel
18/42
www.tocpractice.com Sixth International TOCPA Conference
18-19 May, 2013, Moscow, Russia
Theory Of Constraints Practitioners Alliance TOCPA
Issues in applying CCPM - Execution
Planning - Issues
Resources are never well defined : most resources are often men
India with its 1 Billion + : men appear to be limitless
- Very skilled manpower has been a constrained
Equipment resources can be considered : In these environments it is not
very difficult to add another resource if required
Multi tasking of resource is often invisible
Buy-in of aggressive times : Task managers need to plan how to achieve
these new times
Reorganize people if required
7/29/2019 POOGI of CCPM promotion at Tata Steel
19/42
www.tocpractice.com Sixth International TOCPA Conference
18-19 May, 2013, Moscow, Russia
Theory Of Constraints Practitioners Alliance TOCPA
Issues in applying CCPM - Execution
Execution Taking advantage of early finish
Short duration projects : Less than 10 days
In most cases all resources are available
Since the belief in themselves is not there: the resource may not be
present when needed.
Planning to make sure resource is available is essential
When the project starts, facilitator should point out the early finishes
that were not capitalized on
Long duration projects
Resources are not planned as per aggressive schedules
The conflict is If resources are brought in early and incase activity is
delayed it will increase cost
7/29/2019 POOGI of CCPM promotion at Tata Steel
20/42
www.tocpractice.com Sixth International TOCPA Conference
18-19 May, 2013, Moscow, Russia
Theory Of Constraints Practitioners Alliance TOCPA
Issues in applying CCPM - ExecutionExecution
Short duration projects : Less than 10 days
Scheduling within a shift is very important
Major time lost in shift changer over
Problems faced during trials remain the same whether the project is
short or long The time taken to diagnose the root cause
is difficult to crush
The problems faced are common to projects whether CCPM applied or not.
Believe in aggressive schedules
As long as progress is good people have no
issues with aggressive schedules
The moment the curve rises steeply up
instant reaction: crushing time did not help
7/29/2019 POOGI of CCPM promotion at Tata Steel
21/42
www.tocpractice.com Sixth International TOCPA Conference
18-19 May, 2013, Moscow, Russia
Theory Of Constraints Practitioners Alliance TOCPA
Common Promotion Practices
EducationOnce people understand the
concept they will adopt
INITIATIVEINITIATIVEINITIATIVEINITIATIVE AssumptionAssumptionAssumptionAssumption
Brochures & Pamphlets Once peers discuss the conceptpeople will try to adopt
Mandate from topManagement decisions are
always adopted
NONE of these techniques were adopted to promote CCPM
Competition betweenpeer groupsNo one wants to be last in therace.
Senior ManagementReview
Review - forces people topractice, even if they do notbelieve in it.
Slogans & DrivesIf demand is created, people willbe eager to try the new concept.
Reward & RecognitionPeople will do anything to earn a
few extra bucks
7/29/2019 POOGI of CCPM promotion at Tata Steel
22/42
www.tocpractice.com Sixth International TOCPA Conference
18-19 May, 2013, Moscow, Russia
Theory Of Constraints Practitioners Alliance TOCPA
Approach at Tata Steel
Developedexpertise
Checkedappropriate
ness ofmeasure
Sanitized
presentplan
Protected Plan:
Interruptions
Variability
Covariance
Changed priorityof measurements
Maintenance
1. Content
2. Budget3. Time
Expansion
1. Budget
2. Time
3. Content
New priority of
measures1 Content
2 Time
3 Budget
BuildInfrastructure
Formed ateam of
facilitators
Trained onTOC
Trained onCCPM
Made technicalschedule usingconcept of flow
1. Planning Finishto Start
2. Maximizeproduction batch
minimize
transfer batch3. Stagger tasks
prevent resourcecontention
Helped teams identify &agree on cause that limit
their performance
1. Interruptions2. Variability in tasks
3. Covariance
4. Exploit the above problems
4.1 Aggressive scheduling
4.2 Buffering
4.3 Buffer management
When problems really got solved, people adopted the concept.
Proposed solutions specific to the project. Not suggest generic concepts
7/29/2019 POOGI of CCPM promotion at Tata Steel
23/42
www.tocpractice.com Sixth International TOCPA Conference
18-19 May, 2013, Moscow, Russia
Theory Of Constraints Practitioners Alliance TOCPA
Analysis
Why was the approach effective?
1. Teams which saw value, adopted the concept.
2. There was no pressure to adopt the process like a religion.
Assumptions:
If a new concept helps people achieve their goals they will adopt it.
Belief:
Implementing the new concept cannot be a goal in itself. It is only a means to the goal.
3. Early project completion was celebrated.
4. The concept became popular by word of mouth.
Project teams were encouraged to share their experiences.
People were encouraged to discuss the pros and cons of the process.
t ti
7/29/2019 POOGI of CCPM promotion at Tata Steel
24/42
www.tocpractice.com Sixth International TOCPA Conference
18-19 May, 2013, Moscow, Russia
Theory Of Constraints Practitioners Alliance TOCPA
Effects
3 2031 31
44
9786
101
4932
41 41
40
2027
15
15
35 4045
80
8590
0
20
40
60
80
100
120
FY06 FY07 FY08 FY09 FY10 FY11 FY12 FY13
Numberofpro
jects
CCPM Projects undertaken - FY06 to FY13
Actual CCPM Projects Actual Other Projects Plan CCPM Projects
70 7075 75 85
90 90 90
33
5058
67
90
8287 88
20
30
40
5060
70
80
90
100
FY06 FY07 FY08 FY09 FY10 FY11 FY12 FY13
Perce
ntage
Compliance to plan time - Completed CCPM Projects
Plan Actual
New areas of CCPM application were tried
(proj < 48 hrs and IT/NPD projects). Some
new projects delayed because of people
not trained enough
Execution of CCPMprojects more than
doubled in last threeyears
Due date performance of projects hasimproved by 32% over last five years
88% of projects completed withinplanned time in last two years
Savings Rs 157 Crores
(US $ 30.2 Million) in FY13
tocp actice com
7/29/2019 POOGI of CCPM promotion at Tata Steel
25/42
www.tocpractice.com Sixth International TOCPA Conference
18-19 May, 2013, Moscow, Russia
Theory Of Constraints Practitioners Alliance TOCPA
Flat Products Division
LD-2 Hot StripMill
Cold Rolling
Mills
Flat ProductMarketing &
Sales
Steel
Steel Products
Customers
Ore Mines&
QuarriesDivision
WestBokaroDivision
JhariaDivision
Raw MaterialsDivision
Long Products Division
LD-1
Merchant Mill
New Bar Mill
Wire Rod Mill
Long ProductMarketing &
Sales
Steel Steel Products
Customers
Long Products Division
Iron MakingSteel
MakingRolling
Marketing &Sales
Shared Services (Provides Maintenance Services and Operates Utilities)
Raw
Materials
Hot Metal
SinterPlant
CokePlant
BlastFurnaces
Coke, Sinter & Iron Division
Lumps
Coal
Purchased
Materials
Fines
CCPM Case on Primary Crusher Replacement inNoamundi Iron Ore Mines : Business Case
Case area described in this presentation
www tocpractice com Si h I i l TOCPA C f
7/29/2019 POOGI of CCPM promotion at Tata Steel
26/42
www.tocpractice.com Sixth International TOCPA Conference
18-19 May, 2013, Moscow, Russia
Theory Of Constraints Practitioners Alliance TOCPA
CCPM Case on Primary Crusher Replacement in
Noamundi Iron Ore Mines : Business CaseBackground : Crusher was installed in 1967 and it was running at high risk
due to many defects and at reduced capacity (70% of rated capacity)
Model : T.C./S. NO. -86555
Make : Fuller KCP
Weight : 238 T
Capacity : 1800 TPH
Max Feed Size : 900 mm
Lump size: 175 ~200 mm
Motor Capacity :450 HP
Model : CG-820 .
Make : SANDVIK
Weight : 262 T
Capacity : 1600 -3500 TPH
Max Feed Size : 1200 mm
Lump size: 130 ~200 mm
Motor Capacity :600HP
Hydraulic Not in operation
Weight increased due to
welding at many places
Capacity : 1200 TPH
Max Feed Size : 200 mm
Lump size: 175 ~200 mm
Motor capacity :450 HP
1967 2009 New Crusher
Welded body at very high risk
www tocpractice com Si th I t ti l TOCPA C f
7/29/2019 POOGI of CCPM promotion at Tata Steel
27/42
www.tocpractice.com Sixth International TOCPA Conference
18-19 May, 2013, Moscow, Russia
Theory Of Constraints Practitioners Alliance TOCPA
CCPM Case on Primary Crusher Replacement inNoamundi Iron Ore Mines : Business Case
upstream
www.tocpractice.com Sixth International TOCPA Conference
7/29/2019 POOGI of CCPM promotion at Tata Steel
28/42
www.tocpractice.com Sixth International TOCPA Conference
18-19 May, 2013, Moscow, Russia
Theory Of Constraints Practitioners Alliance TOCPA
Current Conditions - Challenges
www.tocpractice.com Sixth International TOCPA Conference
7/29/2019 POOGI of CCPM promotion at Tata Steel
29/42
www.tocpractice.com Sixth International TOCPA Conference
18-19 May, 2013, Moscow, Russia
Theory Of Constraints Practitioners Alliance TOCPA
Strategy Option evaluation and project planning
Shutdown planning using various focused methodologies
www.tocpractice.com Sixth International TOCPA Conference
7/29/2019 POOGI of CCPM promotion at Tata Steel
30/42
p Sixth International TOCPA Conference
18-19 May, 2013, Moscow, Russia
Theory Of Constraints Practitioners Alliance TOCPA
Strategy Option evaluation and project planning
Dismantling of Bottom shell 10 hours
Dismantling of Apron feeders 12 hours
Liner removal - 12 hours
Erection of Apron feeders 24 hours
Erection of crusher - 24 hours
Trial and commissioning 12 hours
Total reduction in plan through
Incorporation of past learning - hours 4 days
Example -Erection methodology of Apron feedermodified and saved 24 hours in critical path .
Monitoring and recording of Time and Quality
Qualityparameters
Time
Scheme Approval withClient
Study of time and implication
Consultant andsupplier supervision
Comparison of duration in IstApron feeder
Sign off protocol Assessment for next feeder
and carried forward
Application of past learning for reducing S/d time
Total Saving of 24 hours in Apron feeder erection
Task Initial Plan Revised planbased onlearnung
Lowering of Apron in
single pieces
24hours 16hours
Positioning 24 hours 12hours
Alignment 12 hours 8 hours
Total 60 hours 36 hours
www.tocpractice.com Sixth International TOCPA Conference
7/29/2019 POOGI of CCPM promotion at Tata Steel
31/42
p Sixth International TOCPA Conference
18-19 May, 2013, Moscow, Russia
Theory Of Constraints Practitioners Alliance TOCPA
ExecutionBuffer management and Task prioritisation
Work centers and cross functioning
Apron feeder
Fifth floor
Primary Crusher
3rd /2nd floor
Civil Works
Ist floor/Zerofloor
Hydraulic, Luboil and water
Fouth floor
Electrical andautomation
Zero and 2nd
29th April`10 NightShift
Alignment of Apronfeeders
Motor alignment andHanding over toelectrical
Grouting of Primarycrusher and
Hopper beam ofcrusher
Cooling towerInstallation
30th April`10 DayShift
Fixing of Chain ,pan and Drivealignment
Lowering of eccentric,MPS unit
Power cabletermination forcrusher motor
30th April `10
Night Shift
Fixing of Eccentric andMPS
Balance Hilti of pipelines
Lub oil unit piping forcrusher
Scaffolding for fixingof control cables
1st May`10
Day shift
ID Run Hydro set unit piping Control deskinstallation
1st May`10
Night shift
Motor trials Fixing of main shaft and
spider
Crusher Inlet/Out let
piping flushing
Cabling and crusher
motor trial
2nd May`10 Fixing of skirts Fixing of sensors TIMS checking I/O Checks
Criticalstage ofproject
www.tocpractice.com Sixth International TOCPA Conference
7/29/2019 POOGI of CCPM promotion at Tata Steel
32/42
Sixth International TOCPA Conference
18-19 May, 2013, Moscow, Russia
Theory Of Constraints Practitioners Alliance TOCPA
ImplementationDaily Evening Meeting to finaliseresource and buffer recovery plans
Evening Meeting in progress
www.tocpractice.com Sixth International TOCPA Conference
7/29/2019 POOGI of CCPM promotion at Tata Steel
33/42
Sixth International TOCPA Conference
18-19 May, 2013, Moscow, Russia
Theory Of Constraints Practitioners Alliance TOCPA
Pictorial Recap Dismantling of old crusher
www.tocpractice.com Sixth International TOCPA Conference
7/29/2019 POOGI of CCPM promotion at Tata Steel
34/42
18-19 May, 2013, Moscow, Russia
Theory Of Constraints Practitioners Alliance TOCPA
Pictorial Recap Erection of new crusher
www.tocpractice.com Sixth International TOCPA Conference
7/29/2019 POOGI of CCPM promotion at Tata Steel
35/42
18-19 May, 2013, Moscow, Russia
Theory Of Constraints Practitioners Alliance TOCPA
Pictorial Recap Erection of new crusher
www.tocpractice.com Sixth International TOCPA Conference
7/29/2019 POOGI of CCPM promotion at Tata Steel
36/42
18-19 May, 2013, Moscow, Russia
Theory Of Constraints Practitioners Alliance TOCPA
Pictorial Recap Erection of new crusher
www.tocpractice.com Sixth International TOCPA Conference
7/29/2019 POOGI of CCPM promotion at Tata Steel
37/42
18-19 May, 2013, Moscow, Russia
Theory Of Constraints Practitioners Alliance TOCPA
Pictorial Recap Erection of new crusher
www.tocpractice.com Sixth International TOCPA Conference
7/29/2019 POOGI of CCPM promotion at Tata Steel
38/42
18-19 May, 2013, Moscow, Russia
Theory Of Constraints Practitioners Alliance TOCPA
Pictorial Recap Erection of new crusher
www.tocpractice.com Sixth International TOCPA Conference
7/29/2019 POOGI of CCPM promotion at Tata Steel
39/42
18-19 May, 2013, Moscow, Russia
Theory Of Constraints Practitioners Alliance TOCPA
Achievement
First time in World, Crusher and Apronfeeders replaced in 18 days
Sandvik, the supplier, published this in
Bulk Handling Journal, Australia
ZERO Accident .
The plant reached its rated capacity in oneweek
Savings about
US $ 4.2 Million
www.tocpractice.com Sixth International TOCPA Conference
7/29/2019 POOGI of CCPM promotion at Tata Steel
40/42
18-19 May, 2013, Moscow, Russia
Theory Of Constraints Practitioners Alliance TOCPA
Way Forward: Sustaining improvement andensuring irreversibility
Project CCPM Plan Actual achieved
LD#1 Vessel #2 relining ,Mar10 8.67 days 8.33 days
LD#1 Vessel# 1 relining, June 10 7.6 days 7.6 days
LD#1 Vessel# 2 relining, Sept 10 7.33 days 6.83 days
LD#1 Vessel# 1 relining, Dec10 7 days 6.08 days
LD#1 Vessel# 2 relining March11 6.8 days 5.56 days
LD#1 Vessel# 1 relining, Dec12 5.5 days 5.1 days
After five iterations and incorporating continuous learning from thepast, LD#1 vessel relining shutdown has now reached near touch time level- Best in the world
many more projects have reached this status today
www.tocpractice.com Sixth International TOCPA Conference
18 19 M 2013 M R i
7/29/2019 POOGI of CCPM promotion at Tata Steel
41/42
18-19 May, 2013, Moscow, Russia
Theory Of Constraints Practitioners Alliance TOCPA
Way Forward: Sustaining improvement andensuring irreversibility
www.tocpractice.com Sixth International TOCPA Conference
18 19 M 2013 M R i
7/29/2019 POOGI of CCPM promotion at Tata Steel
42/42
18-19 May, 2013, Moscow, Russia
Theory Of Constraints Practitioners Alliance TOCPA
Route was difficult . initial progress was slowresult was inspiring
Thank you
Welcome to Jamshedpur, India