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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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2005 |
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Status |
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Winner |
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| Vedanta Resources plc is a diversified and integrated FTSE 250 metals and mining group with annual sales of $1.9bn. Sterlite Industires (I) Ltd. is the Copper division of Vedanta. The copper electro refining plant is located at Silvassa. De-Tellurisation is a critical process in copper slime treatment. During the copper leaching process, unwanted impurity i.e. Tellurium also gets leached out along with the copper. De-Tellurisation (De-Te) process is used to remove tellurium from copper solution prior to sending it back to electro-refining cells. If not removed it may create quality problems in electro-refining. Pareto analysis of total slime treatment plant cost showed that De-Tellurisation process cost is around 29 %. This cost was mainly due to high De-Tellurisation batch time. Higher the batch time, higher was the steam and power consumption. Calculations showed that the annual additional expenditure due to the excess batch time was estimated at Rs 12.0 Lacs/annum. Using the DMAIC methodology and quality tools such as Brainstorming, Cause and Effect Diagram and Hypothesis Testing, the team identified three vital and significant root causes for high batch time. Subsequent remedial actions lead to reduction of De-Tellurisation batch time from an average of 48 hours to 22 hours, much below the target of 30 hours. Resultanf=t savings from this project were Rs 22.6 lakh. |
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