Work Roll Consumption

Topics: Roughness, Tensile strength, Steel Pages: 28 (5804 words) Published: January 10, 2012
Reduction in Work Roll Consumption of Skin Pass Mill
Using six sigma-A case study

A Thesis Submitted to the Ranchi University in partial fulfilment of the requirement for the award of the degree

Master of Science Engg.


ROLL NO: 20/M/PM/2002

Under the guidance of
Mr K.D.P.Singh
Department of Mechanical Engineering


September -2008



I here certify that the work which is being presented in this thesis entitled “Reduction in Work Roll Consumption of Skin Pass Mill using six sigma-A case study” in partial fulfilments for the award of degree of Master of Science Engg. In Production Management, & Submitted in the Department of Mechanical Engineering NIT, JAMSHEDPUR is an authentic record of my own work carried out under the Supervision of Mr K.D.P Singh Lecturer, Department of Mechanical Engineering. National Institute of Technology, Jamshedpur.

The matter embodied in this thesis has not been submitted by me for the award of any other degree.

Signature of candidate

This is to certify that above statement made by the candidate is correct to the best of my knowledge.

Mr K.D. P Singh
Mechanical Engineering Department
NIT, Jamshedpur

Dr J.N.Yadav
Professor & HOD
Mechanical Engineering Department

Signature of internal examiner Signature of external examiner


First of all I would like to express my gratitude to Mr. C.M.Verma Head, BAF/SPM/ECL Cold Rolling Mill, Tata Steel for allowing me to be a owner of this case study matching to my area of work where I could really apply and develop my technical skills in practical aspect.

I am extremely grateful to Mr K.D.P.Singh (Lecturer NIT, JSR), Mr Vivek (Sr Manager, BAF & Six sigma Co-ordinator CRM), and Mr.Dharmendra Kumar (Manager Roll shop) for guiding this case study. They have guided me at every step, clearly explained the objectives, the problems statements, technical concepts and terminology to make my case study a success. They always extended a helping hand and spent their valuable time to explain the problems that ever obstructed my path.

Working in Tata Steel has not only been a learning experience on technical aspects but there were many other things, which could only be experienced in organization of such repute. Their work culture, discipline, employee’s devotion towards their job and company are extraordinary.

Thanks a lot to all those who helped me directly or indirectly during the completion of this case study and special thanks to the associates of Skin Pass Mill and Roll Shop of cold rolling mill Tata steel.

Chandra Prakash


This case study deals in reducing Work Roll consumption of Skin Pass Mill of cold rolling Mill. Cold Rolling is a Process by which hot rolled strip or stock is introduced between rollers and squeezed or compressed to the desired thickness. The quality of work rolls that come into direct contact with the steel product has a direct effect on product quality and mill operation.

At the time of taking up this case study, Roll cost was one of the major operational cost element for Skin pass Mill & due to increase in global Roll prices its contribution increases from 15 % of total conversion cost to 22 % of total conversion cost .In the mean time there were some additional problem associated with work roll grinding & operational practices at Skin pass mill which showing variability in the process of Roll grinding & Skin passing.

This case study deals in bringing improvement in the...
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