Strategic Process Optimization YieldsSubstantial Savings
The Roll Shop Department of SAIL's RourkelaSteel Plant (RSP) has demonstrated exceptional performance in cost optimizationduring the 2024-25 financial year through targeted process improvements andtechnical innovations. By implementing sustained optimization strategies andenhanced operational practices in Hot Strip Mill-2 (HSM-2), the departmentsuccessfully reduced roll consumption from 0.50 kg/T to 0.44 kg/T. Thisseemingly modest improvement in efficiency has generated impressive results,translating to annual cost savings of ₹11 crore ($1.32 million). Theachievement underscores RSP's commitment to maximizing productivity whilesimultaneously minimizing input costs, all without compromising the qualitystandards that SAIL's products are known for in the market. The systematicapproach to process refinement reflects a broader organizational culturefocused on continuous improvement and resource efficiency.
Indigenous Engineering Solutions EnhanceEquipment Reliability
In a demonstration of technical ingenuity, theRoll Shop team designed and fabricated a protective hood for the bottom back-upchock of the MHI Mill in HSM-2 entirely in-house. This custom-engineeredsolution addresses a persistent maintenance challenge by effectively preventingchronic water ingress into critical components. The innovation hassignificantly improved equipment reliability while extending componentlifespan, directly contributing to reduced maintenance requirements andoperational downtime. By developing this solution internally rather than relyingon external vendors, RSP has not only achieved cost savings but alsostrengthened its self-reliance capabilities. This initiative exemplifies howindigenous engineering expertise can be leveraged to solve complex technicalproblems, creating value through applied innovation and reducing dependency onimported solutions or external technical support.
Resource Recovery Initiatives Amplify CostBenefits
The department's focus on resource efficiencyand waste minimization is further highlighted by its successful salvaging of 20leveller rolls in the Plate Mill that had previously been classified asunserviceable. This recovery effort generated additional cost savings of ₹3crore ($360,000), demonstrating the significant financial impact of targeted resourcerecovery initiatives. The achievement reflects the department's commitment tosustainable practices by extending the useful life of existing equipment ratherthan defaulting to replacement. By reimagining what was once considered wasteas a valuable resource, the Roll Shop team has created a model for howindustrial operations can simultaneously pursue economic and environmentalobjectives. This approach aligns with global best practices in circular economyprinciples, where maximizing the utility of existing resources takes precedenceover continuous consumption of new materials.
Technical Excellence Drives OperationalPerformance
Operational excellence in the Roll ShopDepartment is further evidenced by the achievement of zero roll neck bearingfailures across multiple mills during the fiscal year, including the PlateMill, New Plate Mill (NPM), HSM-2, and the Silicon Steel Mill. This perfectreliability record represents a significant milestone in equipment maintenanceand operational stability. Additionally, the team developed new technicalcapabilities by adapting conventional roll grinding machines at Roll Shop-1 toprocess NPM work rolls, demonstrating both technical versatility andproblem-solving skills. These achievements highlight how specialized knowledgeand attention to detail in maintenance practices can dramatically improveoperational outcomes. The department's focus on preventing failures rather thansimply responding to them has created a more stable and efficient productionenvironment across multiple mill operations.
Workplace Enhancement ComplementsTechnical Achievements
Beyond its technical and economicaccomplishments, the Roll Shop team has also contributed to improving theworkplace environment by developing a beautifully landscaped garden within thedepartment premises. This initiative reflects a holistic approach to workplaceexcellence that recognizes the importance of aesthetics and environmentalquality in industrial settings. The garden serves multiple purposes: enhancingthe visual appeal of the industrial space, providing employees with a morepleasant work environment, and demonstrating the department's commitment toenvironmental consciousness. This attention to workplace quality complementsthe technical achievements and suggests a comprehensive understanding oforganizational excellence that extends beyond purely economic or technicalmetrics to include human and environmental factors.
Benchmarking Excellence in SteelManufacturing
The collective achievements of the Roll ShopDepartment establish new benchmarks for techno-economic performance in steelmanufacturing. By simultaneously pursuing cost optimization, technicalinnovation, and operational excellence, the department has created a templatefor success that could be replicated across other units within SAIL andpotentially throughout India's steel sector. The emphasis on self-reliance andin-house engineering solutions is particularly relevant in the current economicclimate, where supply chain resilience and indigenous capabilities have takenon increased importance. These achievements demonstrate how Indianmanufacturing can combine technical expertise with innovative thinking toovercome challenges and improve competitiveness. The Roll Shop's performanceduring FY 2024-25 thus represents not just departmental success but acontribution to the broader goals of manufacturing excellence in India's steelindustry.
Strategic Alignment with NationalManufacturing Objectives
The achievements of RSP's Roll Shop Departmentalign closely with India's national objectives of strengthening domesticmanufacturing capabilities and reducing import dependence. By developingindigenous solutions to technical challenges and extending the life of existingequipment, the department contributes to the broader goals of the "Make inIndia" initiative. These efforts also support sustainability objectives byreducing resource consumption and waste generation, demonstrating how economicand environmental goals can be pursued simultaneously. The cost savingsachieved—totaling ₹14 crore ($1.7 million)—directly enhance the competitivenessof Indian steel in global markets at a time when the industry faces significantinternational competition. This strategic alignment between departmental initiativesand national priorities highlights the role that operational excellence at theunit level can play in advancing broader industrial policy objectives.
Key Takeaways:
• SAIL's Rourkela Steel Plant Roll ShopDepartment achieved ₹11 crore ($1.32 million) in annual savings by reducingroll consumption in Hot Strip Mill-2 from 0.50 kg/T to 0.44 kg/T throughprocess optimization and improved operational practices.
• The team designed and implemented an in-housefabricated protective hood for HSM-2's MHI Mill, preventing water ingressissues and extending component life while reducing dependency on externalvendors.
• The department successfully salvaged 20previously unserviceable leveller rolls in Plate Mill, saving an additional ₹3crore ($360,000), and achieved zero roll neck bearing failures across multiplemills during FY 2024-25.
