PROCESS ANALYSIS - CRITICAL TASKS DEFINITION AND A

PROCESS: ROLLING MILL - REHEATING AND ROLLING

DATE:
TASK: Change rolls and setup in accordance to the flow sheet - RM
PROCESS STEP: Reversing Mill

PRODUCT IN PROCESS: Rough bar

1. 5x5 MATRIX RESULTS

A - Critical PROBAB
B - Medium
RARE LOW
C - Minimum
5 10
Catastrophic
HS - HEALTH AND SAFETY, Q - QUALITY, C = COST,

4 8
D = DELIVERY, E = ENVIRONMENT

Critical
SEVERITY CATEGORIES:

3 6
Mediuim

2 4
Marginal

1 2
Low

2. 5x5 KPI ANALYSIS

Health & Safety Environment Quality
 Complaint due to
QUA - Customer
Conformity Rate

Product Quality
Environmental
OSHA

(ECR)
LTA
Low

Medium

Critical -> High

3. ADDING SAFETY HAZARDS AND ENVIRONMENTAL ASP

Fall, Slip, Trip Caught In / On (Snagged, Hung, Pinch)

Flammable, Explosive
Overexertion, Ergonomic, Heat Fatigue
Material/Environment
Caught Between or Under (Crushed or
Struck Against / By
Amputated)
Contact (Heat, Cold, Radiation, Energy: Electrical, Pneumatic,
Caustics, Toxics, Biological, Noise) Hydraulic, Steam, Springs, Gravity
Oxygen enrichment or deficiency,
Cut / Sharp tools or objects
other contaminants

OTHER SAFETY HAZARDS / MORE DETAILS IF NEEDED:

4. IF THE TASK WAS RANKED CRITICAL (5X5 OR KPI), GO

Effects / Impacts (What can happen) - Ideas to Improve / Reduce criticality of the
Only for Critical Activities activity
4. FOR CRITICAL TASKS - IDENTIFY CRITICAL ACTIVITIES
 Is it a Critical
Activities (step by step) to execute the critical task
Activity
ION AND ANALYSIS
LLING
RANKED BY:
eet - RM

AREA LEADER CHECK:

PROBABILITY or FREQUENCY CATEGORIES

LOW MEDIUM HIGH EXT. HIGH

15 20 25

12 16 20

9 12 15

6 8 10

3 4 5

Quality Cost Delivery

 Conversion Costs
Complaint due to
QUA - Customer

EBITDA (Impact
GAP (Met Loss,
Product Quality

Costs/Profit)

Rolling Mill -

Complaint
Utilizaton)

Customer
to overall

Logistics
Therms,

ASO
ENTAL ASPECTS

CRITICAL LOTOTO RAIL MATERIAL HANDLING

5:
CONFINED SPACE FALL PROTECTION

ENVIRONMENTAL ASPECTS:
Spills Emissions Water contamination Scale Scrap

Trash Paperwork Dust Grease Noise

OTHER ENVIRONMENTAL ASPECTS / MODE DETAILS IF NEEDED:

R KPI), GO TO PAGE 2. OTHERWISE, STOP HERE.

CTIVITIES, IMPACTS AND IDEAS TO REDUCE THE CRITICALITY
ITICALITY