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| Innovation
makes a clean sweep |
In the Refractories Production Department, limestone is
received in wagons that are unloaded by a wagon tippler. After unloading, cleaning of the
wagons is carried out manually to remove any residual limestone particles. While cleaning
the wagons, these particles used to fall on the railway tracks, thereby causing track
jamming, which resulted in derailment of the wagons and ultimately increased demurrage
cost.
In July 2002, a “Zero Derailment” campaign was
launched in the Works. This provided the challenge that this Department wanted. To reduce
the demurrage cost, Quality Circle “Lagan” led by Mr. N. K. Biswas, Foreman and
facilitated by Mr. Avijit Bose, Manager, Lime Calcining Plant, resolved to solve this
perennial problem. This team changed their basic way of thinking — they adopted an
“out of the box” approach. After detailed study and brainstorming, the Team came
out with an innovative but simple idea of using an “easy-to-use” tackle during
cleaning. The tackle was deigned and fabricated. It provided a means of supporting the
open wagon doors in order to make them remain in an inclined position. This helped to
change the projectile of the falling limestone particles so that they fell 0.75 metres
away from the rail track. This avoided track jamming altogether.
This brilliant (but extremely simple) idea yielded a saving
of Rs. 12.18 lakhs in FY 2003 in demurrage credit alone. It also contributed towards
achieving the goal of zero derailment. Such is the power of Small Group Activities.
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