Award for TPM Excellence Category – “A”

Jayaswal NECO Industries Limited
Rolling Mills & Bright Bar Unit

1. Organization Profile:
Jayaswal NECO Industries Limited, Steel Plant Division (JNIL-SPD) is a unit of the "NECO"
group of Industries. JNIL-SPD is situated at Raipur in Chhattisgarh state, India. It is theflagship unit of NECO group, having an Integrated Steel Plant of 1 Million Ton installedcapacity.
The JNIL-SPD was established in the year 1996. It is a successful and fast-growing Steel Plant,
under the leadership of Mr. Ramesh Jayaswal, Managing Director. It is spread over 1600 acresof land (39% Green Belt) in the industrial belt of Raipur.
Rolled and Bright Bar Products of JNIL- SPD mainly cater to the needs of the Automobile,Power, Railways, Engineering, and other Manufacturing sectors. Sale-volume wise, JNIL isamong the Top 3 Alloy Steel producers in India.
Under the Iron-making, Steel-making and Rolling Mills divisions JNIL-SPD has various
production units. TPM Excellence Award Category-A assessment was conducted for Rolling
Mills and Bright Bar Unit.
Iron Making

Steel Making

Rolling MillsBlast Furnace

Steel Melting Shop 1 (SMS-1) Light Bar Mill (LBM)

Sinter Plant

Steel Melting Shop 2 (SMS-2) Wire Rod Mill (WRM)

Coke Oven

Oxygen Plant

Pellet Plant

Heavy Bar Mill (HBM)
Bright Bar (BB)

Direct Reduced Iron (DRI1&2)

Power Plants: (PP1 to PP5)JNIL has 5,606 employees, out of which Rolling Mills and Bright Bar has 1,136 employees(Executives 100, Non-executives 565, Contractor employees 471).

Product & Size Range of Rolling Mills & Bright Bar:Rounds

23 to 200 mm

Round Corner Square (RCS)

55 to 200 mm

Flat

63.5 x 6.35 mm to 100 x 28 mm

Wire Rod Coils

5.5 to 32 mm in Coil Shape

Coil Annealing- Soft/ Spherodized

5.5 to 32 mm

Bar Annealing- Soft / Spherodized

Rounds 20 to 140 mm & RCS up to 150 mm

Drawing Coil to Bar

Round 5 to 27 & Hex 6 to 14 mm a/f

Drawing Bar to Bar

Round 24 to 52 & Hex 18 to 40 mm a/f

PeelingRound 20 to 80 mm

Centerless Grinding

Round 6 to 78 mm

Process Technology:

Product Grades:
Steel Grades as per IS, JIS, SAE, EN, DIN,and Customer Specifications.

Forging, Cold Holding Quality, MicroAlloy, Spring Steel, Free Cutting Steel,Bearing, Electrode Quality, High CarbonTire Bead & Cord.



JNIL is One Stop shop for all the needs ofAlloy Steel: Rolled and Bright BarProducts.

 JNIL has the highest Bloom size of 340
x400 mm in India, it offers a maximum
reduction ratio of Rolled products.

2. Milestone on the Journey to Manufacturing Excellence:
Jayaswal NECO Industries Ltd. is certified for the following Integrated Management Systems(QMS, EMS & OHSAS)•

ISO 9001:2015 (Quality Management System)•IATF 16949:2016 (Automotive Quality Management System)•ISO 14001:2015 (Environmental Management System)•ISO 45001:2018 (Occupational Health & Safety Assessment System)

Major challenges during the quality journey include improving equipment reliability andpeople competencies at all levels. JNIL adopted TPM to meet these challenges.
TPM was launched in JNIL on 26th January 2019. The main benefits of adopting TPM are:

Drastic improvement in Quality in WRM to 99.9 %,Productivity increased in HBM by 53%,

Availability increased in LBM by 9.4%.

Cost Reduction in WRM by 30%

Improvement in Safe working environment- Zero LTI in last one year.

Ensure 100% on-time delivery as per order quantity.

Increase in the morale of the team members through participation and a sense of ownership
The TPM journey continued through the difficult times during the Covid period.

Pillar Wise major items introduced in our TPM journey.

PillarMajor Items introduced.

KK

Loss elimination and Cost reduction activities. Focus on the quick changeoverin view of the increase in product varieties.

JH

Improvement & sustenance of Equipment Basic condition by developing
Equipment competent Operators. Focus on quality defect sources and minor
stoppages.

PMElimination of Equipment Breakdown by Shifting from Reactive Approachto Proactive approach in Equipment maintenance. Preventive Maintenance
was revolutionized by the development of JMS (JNIL Maintenance System).

QM

Reduction in Customer complaints and Establish a Defect-free Production
system. The focus was on the complete elimination of surface defects likescratches.

DMNew product development activity was systematized with the DM pillar
concepts. Development of new product grades has become streamlined withlower lead time.

E&T

Skill mapping & Proactive training to eliminate Breakdowns, Accidents &Defects due to Poor Knowledge & Skill. Training Dojo was developed withcut models for Step 4 training, as well as for faster training of functional skills
to recruits.

OTPM

Improvement in office work environment and process. Apply cost reduction
techniques. Office Losses were identified department-wise and connectedwith office work pain areas. IT-based processes were introduced to reduce
office work lead time.
Shifting from Reactive to Proactive approach to eliminate Accidents.

SHE

KYT drill implemented in everyday practice to reduce First Aid cases.
Proactive Approach for Health Hazards.
Improve and sustain Green Belt coverage.

3. Benefits Achieved:
Tangible Business Benefits:
Productivity

Improvement in Productivity, Availability, Reduction in Breakdown.

Quality

Reduction in Customer complaints,
In-House rejection, Rework.

Cost

Reduction in Conversion cost, Improvement in material yield.

Delivery

100 % achievement in delivery.

SafetyReduction in Incidents/ Accidents,Development of a safe working environment.

MoraleIncreases employee engagement.

Employee involvement, motivation, and other intangible improvements
Employee Involvement

Change in attitude.
Improved level of communication.

Structured and focused way of solving problems.
Safe way of working.
Motivation

Fun and joy to work.
Positive change in Sense of Ownership.
Motivated and higher skilled workforce.
Cleaner Greener & Environment friendly plant.

4. Key of our Manufacturing Excellence:
JNIL is known as the shortest delivery time supplier in the Alloy Steel market of India.

JNIL can match diverse customer needs in terms of Quality, Cost, and Delivery.

JNIL offers physical and metallurgical properties as per customer requirements with thelowest ppm of complaints.

JNIL developed critical grades of Alloy steel as an Import substitute.

Use of Green Power for production using Waste Heat Recovery.

5. TPM Award Assessment Achievement Sheet (Index Table)

2023 TPM Award -Achievement Sheet
Company
Plant name
TPM Slogan/Objectives
Year when TPM started
CategorySSPPPPPPPJAYASWAL NECO INDUSTRIES LIMITED
Rolling Mills & Bright Bar Unit (RM & BB)
Manufacturing Excellence Through TPM
2019Benchmark2019-20
TPMIndex
MillUnit
Started(Calculation Formula)
Name
FY-2019-20
Number of work-related accidents
RM &requiring days off work
Cases/ year6BB(Loss Time Injury)
Number of work-related accidents
RM &not requiring days off work
Cases/ year
152BB
(First-Aid incident)
Productivity for main products
HBMMT/Hrs.
33.9
OEE
LBM
%
68.0
(or Overall Plant Efficiency)
Availability
LBM%
71.7
Performance RateBB%
96.6
Quality Products Rate
WRM%
99.4
Monthly
Number of breakdowns
LBM
16
Avg. no’s
MTBFLBM
Hour
45

Status2022-23(Till Dec-23)
05
51.9
78.7
81.1
98.6
99.9
2364

PMTTR

WRM

Q

Number of customer complaints

HBMQC
DDHourNumber/year

0.92

0.67

51

In-line defect rate
Rejection + Non-Prime
Cost index (Conversion Cost)
Production Lead time (Planning toinspection)

HBM%

0.71

0.03

WRM

Rs./MT

4194

2920

BBDays87

Delivery performance

RM &BB%

91100

2.92

0.00

46298

S

Safety-index(ex-Lost Time Incident Rate)

RM &BBM

Number of Employee Suggestions

HBM

Accidents
per1,000,000
operatorhours
Number/year