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Company |
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Sterlite Copper, Silvassa |
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Industry |
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Copper |
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Year of Submission |
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2006 |
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Status |
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Finalist |
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| Sterlite Industries operates an electro copper refining plant at Silvassa. Their project focuses on improving the efficiency of the production process. Precious metal slime gets generated during copper electro refining. This slime is subjected to the copper leaching process to remove any residual copper prior to sale. The mission of their project was to increase the leaching rate from14 kgs/hr to 20 hours resulting in a 30 percent reduction of steam and also less than 3 MT inventory as monthly closing stock by 30th April 2006. Several theories were formulated and tested. Using structured Continuous Quality Improvement tools such as brainstorming, cause & effect diagrams and data collection, a cross functional team formulated and tested several theories. Four of the tested theories were validated and acted upon. The tangible benefits realized were a saving of nearly Rs 51.84 lakhs per annum, man hours involved in the operation were reduced as well as maintenance activities were reduced due to reduced batch time. The intangible benefits were a boost in team confidence and considerable reduction in customer complaints. |
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