10th Planet (11th nov)

8/15/2019 10th Planet (11th nov)

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Name Of QC.:-10th PlanetName of Dept:-O&M(operation)TEAM LEADER:-MR.R.R.NAIK MEMBER:-MR.H.K. UDANMEMBER:-MR.JADUMANI SAHOO

MEMBER:-MR.N.K.PRADHANMEMBER:-MR.SANJAY KU. SAHOOFACILITATER:- MR.M.K.JANADY.FACILITATER:MR.A.K.PASWAN


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Formation & RegistrationFormation &

Registrationof our Quality Circleof our

Quality Circle

Officially formed on 03/06/2003.

Meeting on every alternateevening shift of the rota.

Total Nos. of meeting:73

Attendance (%) 85.96


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Methodology adopted :-Brain Storming MethodMethodology adopted :-Brain Storming Method

TEP- 1 :

1) Boiler tube leakage.2) Low condenser vacuum in unit#1.3) Checking of ESP hopper throat due to dump formation.4) Poor evacuation of mill,jamming problem.5) Mill motor bearing temperature going high.6) Main PA dampers of mill jamming problem.7) Mill feeder jamming problem.8) LRSB not retracted.9) Water logging at cable gallery.10)Waste coal at feeder floor .


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11. Hot line to ERLDC not functional.12. Power consumption in cable gallery, high (SWGR) lighting.

13. Seal oil filter venting problem.

14.Wastage of condenser sump pit water.

15. Bottom ash drain pump over load.16. LRSB drain temp. not maintaining high in U # 2.

17) Energy meters in MS SWGR not visible.

18) Diesel tank location for DG set is out side DG set building.

19) Air ingress through CEP suction line drain .20) VC not effective.

21) During LRSB to HRSB C/o water particles trapped inside cancause tube leakages.


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36)Coal accumulation near TP area.37)tripping of compressor when DMCW pump trip.

38)clinker grinder jamming.

39)air coolers for GT is not temperature operated.

40) water logging at 0mtr. ESP area.

41) DM water wastage on D/A level high.

42) Ash accumulation near PAPH & SAPH oil tank.

43) Mill#1C classifier temperature low during rainy season.44)Reducing Aux. Power consumption.

45) Reducing DM makeup water.


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46)Ash water leakage from hoppers.47)flue gas leakage from ID fan inspection manhole.48)passing of fire hydrant valve.49)parking of vehicles near service building.50) noise pollution in mill area.51)service pump sunction line choking.52)valve identification problem.53)vacuums pump choking.54) Ash dyke overflow.

55) Low line vacuum in fly ash evacuation system.56)problem in PHE change over.57)Bearing damage of series pumps.58)High vibration in FAHP pump.


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AFTER BRAINSTORMING THE PROBLEMSARE CATAGORISED AS UNDER

08

32

18

TYPE-B

TYPE-C

TYPE-A


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WE HAVE SOLVED ALLWE HAVE SOLVED ALL A TYPE PROBLEMSA TYPE PROBLEMS

TEP- 2 :


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THE BCATAGORISED PROBLEMS ARE PRIORITISEDTHE BCATAGORISED PROBLEMS ARE PRIORITISEDBY NOMINAL GROUP TECHNIQUE. (NGT)BY NOMINAL GROUP TECHNIQUE. (NGT)

WEIGHTAGE BASIS : 1. SAFETY 2. PRODUCTIVITY 3. HOUSE KEEPING4. QUALITY 5. ENVIORNMENT

SCALE : 1 - 10

PROBLEM NO.

MEMBERS

1 2 3 4 5 6 8 9 10 11 12

R.R. NAIK 8 8 9 8 5 6 9 6 8 6 7 6

J. SAHOO 9 7 8 7 9 9 10 5 6 5 7 5

N.K. PRADHAN 8 9 8 8 10 6 9 7 8 7 6 7

H.K. UDAN 9 8 7 7 9 4 8 5 7 8 9 6

S.K. SAHOO 8 7 6 6 7 5 9 6 8 6 6 7

TOTAL 42 39 38 36 40 30 45 29 37 32 35 31

RANKS 2 4 5 7 3 11 1 12 6 9 8 101

7


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NO. ACTIVITY TIME in weeks

123

4567

89

10

Defining problem

Analysing the problem

Identifying the cause

Finding out root cause Data analysis

Developing solutions

Foreseeing probableresistance

Trial implementation andChecking performance

Follow-up / Review

Regular implementation

TARGET (12WEEKS )

1 2 3 4 5 6 7 8 9 10 1112 13


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Feeder

Bunker

Conveyor Belt

Mill # 1 C

Glass Window

Drain line

DESIGN BYMR R.R.NAYAK


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FEEDER FEEDER

To supply coal to the mill forpulverization .

To regulate coal supply to mill . ymuch sought internationally.


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BUNKER FLOOR BUNKER FLOOR

Unload the coal from conveyor .Bunker feeding .


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START

FLOW CHART FOR

MILL#1C CLASSIFIER

TEMPERATURE LOW

ARRANGE PROPER

DRAINAGE

END

YES

By using Flow Diagram

C&IPROBLE

M

VERY MUCH WETCOAL COMING

YES

NO

NO

MILL # 1CCLASSIFIER

TEMP LOW

IS HOT AIR DAMPER

FULLY OPEN

IT IS RAINING

WET COAL COMINGFROM CHP


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STEP- 4 :MONTH MILL#1C classifier temp lo.

JANUARY 0FEBRUARY 0MARCH 3APRIL 4MAY 6JUNE 10JULY 7AUGUST 3SEPTEMBER 4OCTOBER 1NOVEMBER 0DECEMBER 0TOTAL 38

DATA SHEET BASED ON OPERATION LOG SHEET

DATA COLECTED BYMR.H.K.UDAN & MR.S.K.SAHOO


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VALIDATION OF ROOT CAUSES THROUGH COLLECTINGDATA FROM OPERATION LOG SHEET

STEP- 6 :

MALFUNCTIONOF C&I EQUIPEMENT.

HOT PA DAMPER NOT OPENING.

WATER INGRESS AT BUNKERFLOOR.

VERY MUCH WET COAL.

FREQUENCY TYPES OF CAUSE SL.NO

55

77

44

11

11

22

33

44DATA COLECTED BY

MR.N.K.PRADHAN & MR.JADUMANI SAHOO


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CONTRIBUTION OF CAUSES TO THEPROBLEM ( SHOWN IN %)

CAUSE NO-1CAUSE NO-2CAUSE NO-3

CAUSE NO-4

41. 2 %29. 4 %

23. 6 %5. 8 %


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PARETO ANALYSIS

DEVELOPING SOLUTIONS

100 %87.5%

50 %

F R E Q U E N C Y

C U M I L A T I V E %

1 2 3 4

8.5

6.325

2.125

STEP-8 :

4.25

17

14.825

12.75

10.625

75%

62.5%

37.5%

25%

12.5%

CAUSE NO

41.2

70.6

94.2


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( TOOLS USED BRAIN STORMING )

OF CAUSE NO.1


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TOOLS USED BRAIN STORMINGTOOLS USED BRAIN STORMINGOF CAUSE NO.1


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TOOLS USED BRAINSTORMING

OF CAUSE NO.2


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TOOLS USED BRAIN STORMINGTOOLS USED BRAIN STORMING

OF CAUSE NO.4


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FORSEEING THEPROBABLE RESISTANCESTEP-9 :

Discussed about the problem, itscauses and analysis with our

HOD (O&C)

The proposed solution was

conveyed to him, got verbalapproval to go ahead for trialimplementation .


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INTANGIBLE BENEFITS

BY THE END, WE HAVE ASSESED THE BENEFITS TO THEMEMBERS SUCH AS:

IMPROVEMENT OF SELF CONFIDENCE. KNOWLEDGE REGARDING QC TOOLS/TECHNIQUES SPEAKING UP AT MEETING INCREASED. CREATIVITY HAS INCREASED. IMPROVEMENT IN ABILITY, TEAM WORK AND INTERACTION WITH

OTHERS. USING COMPUTERS . STAGE FEAR REMOVED. TIME MANAGEMENT IMPOVED.

ABOVE ALL OUR CIRCLE HAS INSPIRED THE NON MEMBERS

AND NEW CIRCLES ARE FORMED IN OUR DEPARTMENT.


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Mill#1C classifier temperatureduring rainy Season can beadequately maintained &Feeder floor will not be dirty.


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FLOW DIAGRAM

BRAINSTORMINGDATA COLLECTION

CHARTS & GRAPHS

CAUSE AND EFFECT DIAGRAM

PARETO ANALYSIS


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CREATED BY JADUMANI SAHOO

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10th Planet (11th nov)