Buland Soch final 15-01-2023 NCQC Final.pptx

NCQC presentation

1. 1 Integrated quality concepts – the gateway to global leadership “Optimizing of Cement Mill by reducing down time of Crusher, through Quality concepts” 36th NCQC-2022 At AURANGABAD JK LAKSHMI CEMENT LTD. DURG-UNIT (C.G) Buland Soch India, ab soch karo buland

2. Toran Kumar Facilitator Pradeep Kumar Team Leader Mahendramani Deputy Leader D K Soni Member Ukesh Sahu Member Bipin Chandrawanshi Member Our Quality Circle Team 2

3. Group Profile :- J.K. Organisation is multinational group head-quartered in India with a heritage of more than 1 34 years. The Group has multi-business, multi-product and multi-location operations, with its foot prints in various countries across the globe. It has overseas manufacturing operations in Mexico, Indonesia, Romania, Belgium, Portugal and UAE. Products of the JK Group have a strong brand recall and enjoy a significant market share in their respective segments. The strong brand equity of the Group has been built through use of latest technologies, continuous research & development and innovation. The Organisation has set up highly reputed Research and Development Institutes in various fields. Bharat Hari Singhania President, J.K. Organisation "Our founders believed in sustainable development and so apart from contributing to industrial growth we have always been committed to enhance the quality of life of people in general and cared for the social well-being of communities we work with."

4. The Group Reputed and diversified group in business for over 1 34 years with a Turnover of $ 4.0 billion . A strong orientation towards innovation and R&D through dedicated centres for different businesses. Sales and Service network of 10,000+ distributors and retailers. Multi - business operations; footprint across 6 continents, 100 countries & 22 manufacturing facilities across India . Committed to excellence, driven by a mission to serve the Society with integrity, fairness and trust. A team of 40,000+ committed and motivated managers and workers. Our Vision & Values We Are A dynamic business organisation A Socially-valued conglomerate Our Core Values Caring for people Integrity, openness, fairness & trust Commitment to Excellence

5. 1982 - 1st Integrated Plant at Sirohi , Total Capacity - 0.5 Mn MT 1982 2009 Capacity addition at Sirohi Capacity - 4.2 Mn MT Kalol Grinding Unit 2009 2nd Integrated Plant at Durg - 1.8 Mn MT Total Capacity - 7.8 Mn MT 2014 2017 Surat GU Commissioned - 1.4 Mn MT Total Capacity - 10.0 Mn MT 2017 Successfully Commissioned Company’s Subsidiary - UCWL - 1.6 Mn MT 2018 2019 Odisha Grinding Unit Total Capacity - 15 Million MT 2019 Our Organization Journey 6

6. 7 Award received by our JK Lakshmi cement Durg Unit Received awards in different categories of CII Energy Circle Competition 2020-21 Winner of Best Implementation of ISO 50001 / ENMS Runner up in Best Energy Efficient Unit & Runner up in DCs under PAT sector Specific Circle Competition

7. 8   BRIEF HISTORY OF THE ORGANIZATION: - NAME OF QC TEAM "BULAND SOCH" REGISTRATION NO  H4212 ORGANISATION JK LAKSHMI CEMENT LTD. DEPARTMENT CEMENT MILL SECTION ADDRESS JK LAKSHMI CEMENT LTD. VILLAGE MALPURI KHURD,KHASADIH, PHONE NO. 8966909152,896690253 DATE OF FORMATION 10/3/2016 DAY OF MEETING SATURDAY NUMBER OF MEETINGS 18 ATTENDANCE 90.00% IDENTIFIED PROBLEMS 76 PROBLEM SOLVED 5 QC PROJECTS IN HAND 1 PERIOD OF PROJECT 05-04-2022 to 05-07-2022

8. 9 Brief History of our completed QC Project :   1. Enhanced self - reliant the quality process through digitalization. - Gold and Par-Excellence Award 2.Hopper Level transmitter Fine material coating removing through air purging.- Gold and Par-Excellence Award   3.Enhancing the capacity of weigh feeders at Cement mill grinding section.- Gold and Par-Excellence Award 4. Modification in conveyors of Cement Bag Transport Circuit - Gold and Par-Excellence Award 5. Enhancing the efficiency of Raw mill by increasing the availability of Classifie r - Gold and Par-Excellence Award

9. 12/28/2022 10 Step Quality Circle Steps Page. No. 1 Identification of the problem 11-19 2 Selection of problems 20-29 3 Define the problem 30-40 4 Analysis of the problem 41- 45 5 Identification of causes 46-52 6 Root causes Analysis 53-57 7 Data Analysis on root causes 58- 63 8 Developing solution 64 - 66 9 Foreseeing probable resistance 67-68 10 Trial implementation and checking performance 69 - 74 11 Regular implementation 75 - 83 12 Follow-up and review 84 - 92 Our team has completed this project by following the 12 steps of problem solving technique by J.M.JURAN

10. STEP-1 : IDENTIFICATION OF PROBLEMS

11. IDENTIFICATION OF PROBLEMS Using the Round Robin Method of Brainstorming , we have identified the main problems in the Cement mill section. CATEGORY OF PROBLEMS

12. S. No. Problems Category 1 Material Jamming in Belt. A 2 Material jamming in chute A 3 Approach problem during rainy season A 4 Quality of fine material is not adequate. A 5 Cement Mill main drive tripping A 6 Puncturing Of feeding hopper A 7 Getting Poor Quality Of different types of additives (Slag/Gypsum/ Dolachar ) A 8 Vehicle approach in feeding hopper way A 9 Feeding of wrong additives into the feeding hopper A 10 Increase In Fines Percentage In Charged Slag/Gypsum/ Dolachar A 11 Higher Percentage Of Ash In Gypsum A 12 Increase In Fines Percentage In Charged Slag A 13 Higher Percentage Of Ash and dust In Dolachar . A 14 Increase In Fines Percentage In Charged Slag A 15 Pull cord and BSS problem in belt A

13. S. No. Problems Category 16 Failure Of belt and shaft Coupling Belt A 17 Problem In Attaching And Detaching Of wires in lines A 18 Reject material extraction increases due to improper grinding because of material quality. A 19 Overload of motor and its failures A 20 Sticky material makes the belt slipped A 21 Problem In hopper chute Leakage A 22 Belt idler jamming and breaking A 23 Chute jamming in belt discharge A 24 Take pulley jamming and load dismantle A 25 Tail pulley ZSS failure A 26 Trouble In belt looseness and screw take up point break A 27 Diverter jamming due to sticky material A 28 Diverter chute leakage problem A 29 Diverter flap breaking and rusty problem A 30 Failure Of heading belt Conveyor discharge A

14. S. No. Problems Category 31 Diverter SOV exhaust point, silencer jamming A 32 Inadequate mill inlet and outlet temperature A 33 Crusher hammer rubbing problem A 34 Material approach problem A 35 Quality Degradation Of gypsum/slag/ dolachar A 36 Getting Totally Full Of Upper And Lower Bin A 37 Chocking Problem in Bin discharge A 38 Diverter gate PRV closing problem A 39 Diverter gate PRV opening problem A 40 Belt selection problem for different materials A 41 Feedback of different additives belt problem A 42 Feedback of different additives hopper problem A 43 Feeding of wrong material selection due to communication problem A 44 Level sensor malfunctioning of raw mix hopper A 45 Proxy cable cut down of belt conveyor A

15. S. No. Problems Category 46 Slackness problem in belt conveyor A 47 Over tension of belt conveyor and reduce in strength A 48 Cement mill vent fan product transport issues A 49 Air slide issues due to moisture content in product A 50 Stacker &Reclaimed travel guide issue A 51 Cement Mill crusher motor direction changing B 52 Wear out or rubbing of crusher hammer B 53 Classifier gear box vibration problem B 54 Cement mill classifier tripping problem B 55 Failure Of bag filter level system B 56 Fall In Compressed Air Pressure B 57 Unbalancing Of Temperature And Pressure in bag filter B 58 Leakage In bag filter hopper. B 59 Rotary airlock jamming due to sticky material B 60 Cement mill silo feed Bucket elevator jamming problem B

16. S. No. Problems Category 61 Diverter operation SOV coil failure B 62 Diverter SOV air pipe break B 63 Diverter SOV air pipe jamming due to moisture B 64 Cement Mill Weigh feeder overload problem B 65 Cement Mill conveyors jamming problem B 66 Cement mill reject bucket elevator jamming problem B 67 Cement Mill classifier bottom bearing RTD pipe wear out. B 68 Cement Mill Classifier getting tripped due to RTD malfunctioning B 69 Take high current From belt conveyor B 70 Delay In Frequent Changing Of fly ash Pipes And Puncturing Of It C 71 Burning vast grasses at site C 72 Taking Work From Untrained And Newly Appointed C 73 Unavailability Of Safety Equipment’s C 74 Poor visibility problem C 75 High noise area near feeding hopper C 76 Product blending issue C

17. 18 Total nos. of problems identified Category A B C 76 50 19 7 Problem Categorized by ABC Method We have chosen ´B ´category problems for our quality circle project...

18. 19 Fig.1 Pie chart for problem selection:-

19. 12/28/2022 20 STEP-2 : SELECTION OF PROBLEMS

20. 21 S. No. Problems Category No. Of Occurrence Jan-22 Feb-22 Mar-22 1 Mill down time increase due to crusher direction change B 1 2 1 2 Classifier bottom bearing RTD problem B 1 1 4 Classifier gear box vibration problem B 1 2 1 5 Cement mill classifier tripping problem B 1 1 6 Failure Of bag filter level system B 1 7 Fall In Compressed Air Pressure B 1 1 8 Unbalancing Of Temperature And Pressure in bag filter B 1 1 9 Leakage In bag filter hopper. B 1 1 1 10 Rotary airlock jamming due to sticky material B 1 1 1 Frequency of the problem are listed below –

21. 12/28/2022 22 S. No. Problems Category No. Of Occurrence Jan-22 Feb-22 Mar-22 12 Diverter operation SOV coil failure B 3 3 3 13 Diverter SOV air pipe break B 3 3 2 14 Diverter SOV air pipe jamming due to moisture B 1 1 15 Cement Mill Weigh feeder overload problem B 1 1 1 16 Cement Mill conveyors jamming problem B 2 2 2 17 Cement mill reject bucket elevator jamming problem B 1 1 1 18 Cement Mill classifier bottom bearing RTD pipe wear out. B 1 1 19 Cement Mill Classifier getting tripped due to RTD malfunctioning B 4 3 3 Frequency of the problem are listed below –

22. 23 Stratification of the problem: We are stratified the problem in descending order. Top 08 problems are covering near about 91% of occurrences and they are nominated A to H in alphabetic series and left other problems are named as K (Other) Sr. No Name of Problem Problem Categorisation No. Of occurrence in descending order 1 Mill down time increase due to crusher direction change A 10 2 Classifier bottom bearing RTD problem B 9 3 Classifier gear box vibration problem C 8 4 Cement mill classifier tripping problem D 6 5 Failure Of bag filter level system E 4 6 Fall In Compressed Air Pressure F 3 7 Unbalancing Of Temperature And Pressure in bag filter G 2 8 Leakage In bag filter hopper. H 3 9 Rotary airlock jamming due to sticky material I 2 10 Cement mill silo feed Bucket elevator jamming problem J 2

23. 24 Sr. No Name of Problem Problem Categorisation No. Of occurrence in descending order Percentage of Occurrence Cumulative Percentage 1 Mill down time increase due to crusher direction change A 10 21.28 21.28 2 Cement Mill Weigh feeder tripping problem B 9 19.15 40.43 3 Cement Mill conveyors jamming problem C 8 17.02 57.45 4 Mill Vibration high problem D 6 12.77 70.22 5 Failure Of bag filter level system E 3 6.38 76.6 6 Fall In Compressed Air Pressure F 3 6.38 82.98 7 Unbalancing Of Temperature And Pressure in bag filter G 2 4.26 87.24 8 Leakage In bag filter hopper. H 2 4.26 91.48 9 Rotary airlock jamming due to sticky material I 2 4.26 95.76 10 Cement mill silo feed Bucket elevator jamming problem J 2 4.26 100 Total 47     Cumulative Percentage of the Problem-

24. 12/28/2022 25 Vital few 77% Useful many Problems No. Of Occurrences Cumulative Percentage Pareto Chart

25. 26 After Pareto Analysis we found that 5 problems are vital few. To select one among these vital few, These are

26. 27 S.N. Criteria Reasons 1 Safety To ensure 100% safe work with respect to man , machine and tools 2 Environment To ensure better Work Environment 3 Quality To get better quality of Raw mix FINES (microns) regarding fines and moisture content. 4 Production To sustain productivity by improving / updating technical standards to stay ahead in the competitive business environment. 5 Equipment Availability To ensure smooth production, equipment availability plays an important role. It also affects the process break. Ranking Table Criteria

27. 28 S. No Problems Members   Total Pradeep Kumar Mahendra Mani Bipin Kumar DK Soni Ukesh Sahu 1 Cement mill classifier tripping problem 2 3 3 5 3 16 2 Cement Mill Weigh feeder tripping problem 3 5 2 4 4 18 3 Cement Mill conveyors jamming problem 4 1 4 1 5 16 4 Mill Vibration high problem 5 4 5 3 2 19 5 Mill down time increase due to crusher direction change 1 2 1 2 1 7 Ranking Table By ranking method we select problem-5 for this project since it got the highest priority. So, finally our project is: Problem- 5 :- Mill down time increase due to crusher direction change

28. 12/28/2022 29

29. STEP-3 : DEFINE THE PROBLEM

30. 12/28/2022 31 Quality Circle Name : "BULAND SOCH" Department:- Cement mill Project :-“Optimizing of Cement Mill by reducing down time of Crusher through quality concept Reason for selection : Effect on Production efficiency of Cement mill Facilitator : Mr.Toran Yadav  Project No. :- 06 Date of Beginning: 05/04/2022 Date of Completion 05/07/2022 Meeting Day : Saturday No. of project completed : 05 Time : 16:30 to 17:30                       S. NO Activity Week 1 2 3 4 5 6 7 8 9 10 11 12 1 Define the Problem W1                       2 Analysis the Problem   W2                     3 Identification of Causes     W3                   4 Finding out the root causes       W4                 5 Data Analysis         W5               6 Developing Solution           W6             7 Fore-seeing probable resistance             W7           8 Trial implementation/Checking performance               W8-W10     9 Regular Implementation                     W11   10 Follow up Review                       W 12 Milestone chart(Plan)

31. Mines LS CRUSHER Stacker & Reclaimer Raw Material Hopper Kiln Clinker Silo Raw & Coal Mill (V.R.M) Raw Meal Silo Pre-heater Cement Mill Cement Silo Packing Plant (Packer & Truck Loading) Flow Sheet of Plant Problem area

32. 12/28/2022 33 Problem area Fig.Flow diagram of Cement mill section

33. 12/28/2022 34

34. 35 Output crushed material Fig-2. Impact hammer jaw crusher full operation Input Coarse material Crusher Capacity-100TPH Crusher motor rating-160 KW

35. 36 Wear out of hammer Fig 3. Impact hammers jaw crusher full and rubbed from one side

36. 37 SETTING GOAL ( What we will achieve?) SETTING OF OBJECTIVES (What we want to do?) To get maximum production of the Cement mill without any disturbance Increase the availability of the Cement mill and maintained the quality of cement Improve working conditions at the Cement mill Improve safety and build healthy environment To reduce the Cement Crusher direction changeover time up to 100% To sustain the availability of Cement mill by 100 % To reduce Unsafe conditions for achieve zero incidents. To reduce power loss of CM up to 0%

37. STEP-4 : ANALYSIS THE PROBLEM

38. 39 What is the Problem? Cement mill production loss due to clinker crusher rotation direction change When the problem does arise? When Clinker crusher not working with full efficiency Where does the problem occur? Problem occur in Cement mill crusher Who is affected by the problem? The production and quality of Cement mill product How does this problem affect the production of Cement mill ? Cement mill need to stop whenever clinker crusher direction change To analyze the problem the group decided to use the (4W+1H) technique. ANALYSIS THE PROBLEM

39. 40 CEMENT PRODUCTION LOSS No. of stoppage/Year 24 Stoppage duration (Hrs) 3 CM TPH 110 Production loss/stoppage 3x110=330 Production loss/year(Ton) 330X24=7920 Total Loss/Month(RS) 198,000 Total Loss /Year(RS) 2,376,000 Losses Production los s(A) :- During Cement mill grinding operation cement mill crusher tripped due wear out of hammer so we need to stop the Cement mill and change the hammer of crusher. This cause the loss of production whenever crusher hammer replaced .

40. 41 Power consume during re-start of Cement mill 1500 KWH Stoppage of Cement mill 24 NO. Total Loss /Year (1500x24) 36,000 KWH Total Loss /Year(36000x7.5) 270,000 Rs Power loss(B) : - Frequently coming of above problem increases the power consumption. Again starting and stopping of the Cement mill circuit results in increased power consumption for the same amount of production. (Note: Power consumption at the time of starting is 5-6 times higher than the power consumption during the operation in flow.)

41. 12/28/2022 42 Required Man power 3 No. One man power cost for (3 hours) 150 Rs Three man power cost for (3hours) 450 Rs Man power cost during stoppage 450 Rs Cement mill stoppage numbers/year 24 Rs Man power cost per year (600x6) 10,800 Rs Man power loss (C)- Total Loss (A+B+C)-26,56,800

42. STEP-5 : IDENTIFICATION OF CAUSE

43. Fish bone diagram Man Material Machine Method Mill down time increase due to crusher direction change

44. Man Don’t have basic knowledge of crusher Excusing of workers Ego problem Unsafe work practice Poor decesion making Unskilled operator Awareness Irritation Don‘t have technical knowledge Communication Decision not given in time Decision in anger Main operator on leave Operator selected wrong No tool box meeting Local language issue Feedback is not proper Less experience Lack of proper training For water drinking For natural call Lack of information flow New joining Lack of proper knowledge Neglecting others instructions Negative approch towards work Lack of PPE´S Absent in training Short tempered attitude Mill down time increase due to crusher direction change

45. Machine ZSS malfunctioning Crusher availability Flange bolt missing Unsafe condition of work Coupling broken Belt surface getting smooth Difference in conveyors speed Bearing failure Breakdown in crusher hammer Motor overload of Crusher Gear box low RPM Difficult to problem solving No proper alingment Bush wear out Dust accumulation Motor rpm difference No preventive maintenance Crusher hammer running continue one direction Wear out of hammer Continous bag transport Due to cement abrasion Due to Dust accumulation Due to confined space Looseness of hammer bolt Broken of hammer bolt Poor lubrication of motor Excess material feed Need to cooling time more Due to Dynamic & confined area Poor lubrication Uneven load on rollers Oil quality lost Heavy load Wear rate of threads Due to high vibration Mill down time increase due to crusher direction change

46. Material Low quality product Quality of crusher hammer product Unavailability of spares Quality of material used Low strenth of crusher hammer Mixing of dust with grease Moisture content in feed material Holding down bolts thread damage Damaged cables High grade of lime stone Used out side pile Weigh feeder chute jamming Fall of foriegn particles Improper handling Metallurgical problem friction rate is high Tripping due ZSS switch High frequency of breakdown of conveyors Improper planning Poor quality management Improper handling Dusty environment Poor quality material used During maintenance Standard types by vendors Failure of testing equipments Negligency of operators Uneven impact in Roller During Running High Vibration arises some times Mill down time increase due to crusher direction change

47. Method Operating Principle Safety bypass Methodology High dust emission Continous operation Delay in operation interlock Difficult approach Operating issue Selection of material Supplier carelessness Emergency switches in one side Wrong methodology Poor maintenance projection Market demand Poor bags quality Bag filter not working As per design High vibration area Provided as per vendors Not given wear rate calculation and maintenance planning Unavailability of spares Dispatch pressure Poor maintenance Wrong data setting Frequent tripping of mill Current and speed mismathed Skid of bags Mill down time increase due to crusher direction change Due to confined space Both side hammer to be used Utilizing to the hammer by rotated motor direction Crusher direction change in manual mode

48. 49 Fig. Fishbone attached at site Onsite display of fish-bone diagram

49. STEP-6 : ROOT CAUSE ANALYSIS

50. 51 Man Don't have basic knowledge of Raw materials Less experience substitute are available Invalid Lack of proper training Proper Training required Invalid Don't have technical knowledge New joining Training required Invalid Lack of proper training due to shortage supply Invalid Proper communication Due to confined space Safety issues Valid More time required to communicate between inter departments As per SOP time required more Valid Decision making problem Negligence of root causes FRL system checklist should be followed Invalid avoiding standard rules Cleaning schedule should be follow acc. to SOP Invalid Don’t have basic awareness No tool box talk It is necessary Invalid lack of information flow can be eliminate by using more hard materials Invalid Failure Of bag filter level system Approach is improper Maintenance schedule to be follow Invalid confined and hot place to work It is a process of Cement mill . Invalid

51. 12/28/2022 52 Machine More time required change crusher direction Re-termination required frequently Motor cable size too high Valid Cable lug damaged Fall In Compressed Air Pressure Continuous running Cement mill efficiency can be increased, can be checked by taking shutdown Invalid less time to be given for maintenance It happens rarely Invalid Classifier gear box vibration problem wear rate of threads Due to high vibration area Invalid Due to vibration is high Training can be given for this Invalid Unsafe Condition /work due to confined space can be avoid by adjusting the lines Invalid   To be inform to supplier and our purchase team Invalid Cement mill silo feed Bucket elevator jamming problem due to dynamic and confined area Standard design of equipment Invalid need to cooing time more Lubrication schedule to be followed Invalid Improper communication of bearing temperature dynamic machine it is in confined area Guide supports to be adjust Invalid improper route design Can be eliminate by changing it duly scheduled Invalid Dynamic Crusher Lack of tools and tackles It happens rarely Invalid Torsion effect during running According to approved drawing Invalid

52. 12/28/2022 53 Cause Sub-cause Sub-sub cause Observation Validation Material High volume of course Particle return Speed of CM fan is increases Found it can be happened some time Invalid High Draft It is a continuous process Invalid Moisture content in feed material Used outside pile Not always, sometimes Valid Weigh feeder chute jamming for getting high production Valid Quality of feed materials Hardness of clinker As per material available Valid High lime in clinker As per standard by vendors Valid Material fineness is high Low demand quality of material volatile Invalid Poor quality It happens rarely Invalid Cement mill crushing problem friction rate is high Always happens, it have as per design Valid Tripping due to Zero speed switch Operation of crusher interrupted Valid unavailability of spares High frequency of failure rate due to confined area poor observation Invalid improper planning According to situation Invalid Uncontrolled of material Temperature Failure of testing equipment It can happened some time Invalid Negligence of operators as per supplier guidelines Invalid Quality of Hammer crusher material Standard type by vendors during rainy seasons Valid Poor quality material used It is depend on as per mines material Valid

53. 54 Method Operating Issue Frequent tripping of mill Rollers can be adjusted again Invalid Speed and current is not matched in CCR desk Information to condition monitoring team Invalid Material feeding More material feeding Information to Production department for controlling the feed Invalid course material rejected more Raw material quality is poor Invalid Methodology High temperature area SOP to be follow Invalid More time required to change Crusher Direction change Manual method Valid Compatible system not available System not design Valid Supplier carelessness wrong Methodology to interrupt can be eliminate, penalty to be set for this Invalid poor maintenance projection Maintenance to be done acc. to schedule Invalid Selection of Material MS pipe only for the protection It is normal technique cable laying Invalid not given wear rate calculation and maintenance planning Don’t have any calculation Invalid Operating principle Motor is running in one direction only material handling training can be improved Invalid impacted directly to the clinker As per approved material it is erected Invalid Utilizing to the hammer by rotate motor direction As per equipment available given details are same Invalid Cement mill crusher motor Direction changing. need to need to improve as per application Invalid

54. STEP-7 : DATA ANALYSIS OF ROOT CAUSE

55. 56 S. No. Cause Validation Jan-22 Feb-22 March-22 Total 1 Crusher motor rotational direction change by conventional method Valid 16 14 13 43 2 Crusher starting feeder not compatible Valid 15 10 12 37 3 Motor cable size too high Valid 13 13 8 34 4 Quality of feed materials due to Hardness of clinker Valid 12 11 8 31 5 More time required to communicate between inter departments Valid 12 10 6 28 6 Moisture content in feed material due to Weigh feeder chute jamming Valid 11 9 6 25 7 Quality of feed materials due to High lime in clinker Valid 4 3 1 8 8 C rusher availability due to Wear out of hammer because material impacted to the same. Valid 3 3 1 7 9 Cement mill crushing problem because of friction rate is high Valid 2 1 2 5 10 Quality of Hammer crusher material due to Poor quality material used Valid 2 1 1 4 DATA ANALYSIS OF ROOT CAUSE

56. 57 S.No . Cause Total no. of Occurrences 1 Crusher motor rotational direction change by conventional method 43 2 Crusher starting feeder not compatible 37 3 Motor cable size too high 34 4 Quality of feed materials due to Hardness of clinker 31 5 More time required to communicate between inter departments 28 6 Moisture content in feed material due to Weigh feeder chute jamming 25 7 Quality of feed materials due to High lime in clinker 8 8 C rusher availability due to Wear out of hammer because material impacted to the same. 7 9 Cement mill crushing problem because of friction rate is high 5 10 Quality of Hammer crusher material due to Poor quality material used 4 Stratification of Causes

57. 12/28/2022 58 S.No . Cause Categorisation Validation Total Occurrences Percentage of Occurrence Cum. Percentage 1 Crusher motor rotational direction change by conventional method A Valid 43 21.39 21.39 2 Crusher starting feeder not compatible B Valid 37 18.41 39.8 3 Motor cable size too high C Valid 34 16.92 56.71 4 Quality of feed materials due to Hardness of clinker D Valid 31 15.42 72.14 5 More time required to communicate between inter departments E Valid 17 8.46 80.59 6 Moisture content in feed material due to Weigh feeder chute jamming F Valid 12 5.97 86.56 7 Quality of feed materials due to High lime in clinker G Valid 8 3.98 90.54 8 C rusher availability due to Wear out of hammer because material impacted to the same. H Valid 7 3.48 94.03 9 Cement mill crushing problem because of friction rate is high I Valid 6 2.99 97.01 10 Quality of Hammer crusher material due to Poor quality material used J Valid 6 2.99 100

58. 12/28/2022 59 No. of Occurrences Cumulative Percentage Vital few 81% Causes Pareto chart Useful many

59. 60 Pareto Analysis on root causes data analysis- So, finally our Root cause is : A Crusher motor rotational direction change by manual method

60. STEP-8 : DEVELOPING SOLUTION

61. 62 S.No Possible/Acceptable Solution Suggested by Evaluation Of Suggestion 1 CM Crusher hammer physically direction can be changed Ukesh Sahu This suggestion was already in line, but its will take to much time and man power 2 Feed from CM crusher can be reduced Bipin Kumar This suggestion was appreciated but it will affect the cement mill production. 3 Hammer material quality can be changed D.K.SONI This suggestion is appreciated but it very costly 4 CM Crusher can be operated in both direction with changeover switch Mahendra Mani It is also appreciated but it is unsafe because anyone can change direction manually 5 CM crusher hammer rotation can be made in both direction by auto mode Pradeep Kumar It is appreciated by all the group members because it will decrease changeover time of crusher direction DEVELOPING SOLUTION

62. 63 DEVELOPING SOLUTION Time required for direction change over of Crusher will be within seconds

63. STEP-9 : FORESEEING PROBABLE RESISTANCE

64. 65 S. No FORESEEING PROBABLE RESISTANCE ACTION TO OVERCOME 1 Non Quality Circle members opposed due to avoiding nature and extra work. Theoretical presentation before implementation and practical training after implementation will be given to non-QC members by the group. 2 Doubts raised by the Operation personal on new system’s accuracy and reliability. Presentation regarding its working was given in front of operation and mechanical personal by the group. Once the scheme is clear to them their all resistance converted into positive support. 3 Cement mill production in charge objected on additional work they are wanted to complete solution. Giving presentation and training to the Cement mill production in charge after that they are satisfied for the RDOL feeder. 4 Shift engineer, technician and operator wanted to know for the implementation work and how to handle and inspected during shift operation. Site visit arranged with Sift engineer, technician and operator explained by the Group. 5 E & I people felt that it will require additional spares for power contactors required for the fixing on feeder. The Group explained them the simplicity and single time nature of job. Foreseeing and Probable Resistance

65. STEP-10 : TRIAL IMPLEMENTATION AND CHECK PERFORMANCE

66. 12/28/2022 67

67. 68 SL. No. Name of Materials Size/ Nos Total Cost in Rs. 1. Power contactor 1 48000/- 2. Power cable 3 meter 3000/- 3. Push button and relay 1 lot 5000/- 4. Man power cost 3 8400 Total cost in Rs. 64,400/- PLAN Target: - To install RDOL feeder in place of DOL feeder Man power requirement- Electrician : 1 Fitter : 1 Worker/Helper : 1 Welder : 1 REQUIRED MATERIAL AND COST

68. 69 S. No. Activity Day Day Day Day Day 1 Manpower and material arrangement 3 2 Drawing and designing for the modification 4 3 arrangement the equipment and tools 4 4 Fixing and installation 7 5 Inspection 3 Activity Chart Time schedule: - Our Three week plan of activity, with the help of table is given below:-

69. 12/28/2022 70 SL.No . Work Responsibility Date of completion 1 To take approval from management Pradeep Kumar 01/0 5 /22 2 To arrange manpower and matrials Bipin Kumar 04/0 5 /22 3 arrangement the equipment and tools Mahendra mani 6 /0 5 /22 4 Fixing and installation Ukesh Sahu 12 /0 5 /22 5 Inspection Facilitator 18 /0 5 /22 6 Trial Run of the mill crusher direction change All members 02/0 6 /22 DO Responsibilities are given to each member as per their area of work, and time schedule is also given them to complete their assigned work.

70. 71

71. 12/28/2022 72 Saving in cost of extra manpower which had been involved for changing direction of motor in panel/feeder side .

72. STEP-11 : REGULAR IMPLEMENTATION

73. 74 Regular Implementation: Objective plan For crusher motor feeder, installing RDOL feeder by in-house modification, in place of DOL feeder and rotate hammer crusher in both direction as required in auto mode. Method plan We have completed the process of developed solution in 3 stages- In first stage we have provided changeover switch for operating in manual mode, whenever we required changing the direction of crusher motor. After then we have done brain storming session in between our team members and finally we have got the solution for these particular problem we have decided to replace the existing DOL feeder with RDOL feeder. We have arranged the system in such a way we have provided separate command for separate direction of motor rotation in control system.

74. 75 Power Supply Contactor for only one direction Power Supply Contactor for reverse direction Power Supply Contactor for forward direction Fig 4. Before project implementation Fig 5. After project implementation

75. 76 Fig. Electrical Modification in power & control drawing of crusher motor feeder

76. 12/28/2022 77 Fig. Before project crusher motor direction changed by manually changing the supply cable

77. 12/28/2022 78 Fig.Flow diagram of Cement mill section Forward direction Reverse direction CCR Selection

78. 12/28/2022 79 Crusher Direction change over switch Fig. 6 No any provision for reversible rotational direction change of crusher motor Fig. 7 Reversible Provision for rotational direction change of crusher motor After project there is one selection made for auto changeover of crusher hammer direction in CCR (CENTRAL CONTROL ROOM) for ball mill operator, earlier there was no such provision. Before After

79. 80 Tangible Benefits – S. No Description Unit Total Cost Saving/Per Year 1 Idle run Rs 270,000 2 Production saving Rs 23,76,000 3 Manpower Cost saving Rs 10,800 Total Saving Rs 2,656,800

80. 81 Intangible Benefits of this project Strengthen Team Work During the whole project we worked together as a team, a team sprit developed among us and now we are confident to take up any more challenging project Improved Self Confidence Successfully completion of the project developed self-confident among us. Improvement in Working condition There is no overflow of material now and hence working environment is improved, Job Satisfaction All the team members are now satisfied with our job, we are taking responsibility to the job assigned to us. An ownership feeling developed among us. Safe Working Practice Working in the area is become much easier and safer now.

81. 82 Training session organised after the regular implementation of the project to management and workers .

82. STEP-12 : FOLLOW UP / REVIEW

83. 12/28/2022 84 S.NO TERMINOLOGY BEFORE IMPLEMENTATION AFTER IMLEMENTATION 1 PRODUCTION SAVING(Ton) NIL 7920 3 POWER SAVING (KWH) NIL 36,000 4 MAN POWER COST (In Rs) 10800 NIL 5 UNSAFE CONDITION YES NO 6 CRUSHER DIRECTION CHANGEOVER TIME (Minute) 180 Within second 7 TOTAL SAVING(Rs) NIL 26,56,000 Comparative data after/before implementation:-

84. 12/28/2022 85

85. 86 Final milestone chart (Actual VS Planned) Actual Planned

86. 87 Weekly check list SR. NO. Component Status of Components     05-07-202 2 12-07-202 2 19-07-202 2 26-07-20 2 1 02-08-202 2 1 Power contactor condition √ √ √ √ √ 2 Power cable connection and termination √ √ √ √ √ 3 Heating and insulation on cables √ √ √ √ √ 4 Crusher hammer condition √ √ √ √ √ 5 Working of selection switch   √ √ √ √ √ 6 Any abnormality of DCS communication √ √ √ √ √

87. 88 Safe Work Permit

88. 89 Work Notification and Order for the implementation

89. 90 Tools Used

90. 91 “Increasing efficiency of cement mill output to minimizing breakdown of product transport bucket elevator.” Our next Quality circle project will be..........

91. 92 ACKNOWLEDGEMENT We are highly indebted to Shri Mukul Srivastava Vice President (Works) For motivating us throughout this project. We express our deep sense of gratitude to, Shri Sanjay Sud guidance , JN Chakraborty For his valuable in completing the project. Our sincere thanks to, Shri Saket Rajoria Shri Shirish Shukla for the support extended during the project. We take this opportunity to extend our thanks to all our colleagues in the department and other departments for successful completion of the project.

92. 93