Anil Kumar-Year 2016, Gagal Works

Process Improvement Project
Systematic Problem Solving methodology

Project Title- SO3 optimization and Usage of Low Purity Gypsum
at Asian Cement
Gagal Cement Works
Project
Plan
Actual
Start Date
4 April2016
4 April2016
Completion
Date
30 Oct2016
Current Status: Completed
1
ACC/ Plant name
SPC- Process Improvement Project of Year2016
2016
Team Information: Cross Functional

N
o
Description
Name
Designation
Dept
Email
Project Leader
Anil Kumar
Sr. Analyst
Quality
anilk.kumar@acclimited.com
Mentor
Ramesh Kumar
Gupta
Chief Manager
Quality
Ramesh.gupta@acclimited.com
Member 1
Deepak Jasuja
GM Production
Production
Deepak.jasuja@acclimited.com
Member 2
Ashok Kumar
Dwivedi
Manager
Quality
Ashokkumar.dwivedi@acclimit
ed.com
Member 3
Shaikh Abdul
hamid
Asst.Manager
Quality
Shaikh.hamid@acclimited.com
Member 4
Saurabh Srivastava
Production
Manager
P&QC
saurabhsrivastava@asianceme
nts.com
Member 5
Hunar Singh
Sr.Analyst
P&QC
Hunar.singh@asiancements.co
m
3
4
5
2
ACC/ Plant name
2016
Group photo: Cross Functional
3
ACC/ Plant name
2016
Step 1: - Problem Definition
4
ACC/ Plant name
2016
Step 1:- (a) Problem Definition

1.1) Brief description of Problem
1.
At present, We are using High Purity Imported Gypsum at Asian Cements due to
which we are facing less mill availability due to shortage of fly-ash in 2015 (500
hrs), hence it is considered that during less fly ash availability, usage of Low Purity
gypsum will be beneficial as it helps to reduce clinker factor as well as increase
productivity.
a)
Tangible Benefit A. 3.60 Crores Rs saving annually(50 Rs/T) cement in Asian By

reducing 2% Clinker Factor
B. 6 % plant availability will improve in poor fly ash availability
C. Powdery nature of Low Purity gypsum will increase mill
productivity.
D. Energy saving will get down.
a)
Intangible Benefit:-1) Improvement in Quality Product

2) Good Customer Satisfaction
Present Level:
Target:
Uses of High Purity Imported Gypsum

Uses of Low Purity Gypsum in case of less fly ash availability
and Optimization of SO3 as per type of Gypsum Used.
5
ACC/ Plant name
2016
Cost Benefit Analysis

Present: Cost Analysis For PPC Cement (With Imported Gypsum)
Asian
%
Jan-16
Consum
Rate/Cemen
Qty
ption
Amount
Rate
Cement t
Flyash
16,918
27.29
12,011,780
710
61,996
194
Imported Gyp
2,116
3.41
5,634,908
2,663
61,996
91
Clinker
42,962
69.30
143,922,700
3,350
61,996
2,321
Total
61,996.00 100.00
161,569,388
2,606
Year
Target :Cost Analysis For PPC Cement (With Low Purity Gypsum)
Asian
%
Consum
Rate/Cemen
Qty
ption
Amount
Rate
Cement t
Flyash
Low Purity
Gypsum
16,918
27.29
12,011,780
710
61,996
194
3,410
5.50
6,734,316
1,975
61,996
109
Clinker
41,668
67.21
139,588,537
3,350
61,996
2,252
Total
61,996.00 100.00
158,334,633
2,554
ACC/ Plant name
6
2016
Gypsum Consumption %
By using Low Purity
gypsum
Y2015 Clinker produced with normal coal

Present Level & Target-2016 by using
petcoke clinker.
7
ACC/ Plant name
2016
% Clinker Factor
By using Low Purity
Gypsum
Y2015 Clinker produced with normal coal

Present Level & Target-2016 by using
petcoke clinker
ACC/ Plant name
8
2016
Summary of Problem Definition step

Summary of above slide:
1)Poor mill availability due to less fly-ash available in market.
2)Low productivity due to imported gypsum and pet coke clinker.
3)Cost optimization by lowering down clinker factor by using
Low Purity gypsum in period of low fly-ash availability.
9
ACC/ Plant name
2016
2. Observation
Cement Mill Circuit block Diagram
Clinker
RC Fan
Gypsum
Fly-Ash
Bag Filter
Separator
Cyclone
Elevator
Hammer
Crusher
Weigh
Feeders
Grinding Mill
Bag Filter
PG
Conveyor
Fly mixing at
mill outlet
ACC/ Plant name
2016
2. Observation
Imported Gypsum Sieve Analysis
Sive Size in
mm
88.9
Wt.
% Residue
2.12
7.61
% Cum
Residue
7.61
76.2
1.89
6.78
14.39
85.61
63.5
2.76
9.90
24.29
75.71
50.8
6.27
22.50
46.79
53.21
38.1
1.92
6.89
53.67
46.33
25.4
3.12
11.19
64.87
35.13
19.05
0.22
0.79
65.66
34.34
12.7
2.23
8.00
73.66
26.34
6.35
1.23
4.41
78.07
21.93
3.18
0.912
3.27
81.34
18.66
5.2
18.66
100.00
27.87
100.00
ACC/ Plant name
% Passing
92.39
1.
2.
3.
Large lumps are found which is above 50 mm

(47%).
Cause of Gypsum Hopper Jamming
Difficult to grind as compare with Low Purity
gypsum
2016
2. Observation
Low Productivity Due To Pet Coke Clinker
Asian-1
Month
Jan-15
Run Hours Production

282.67
Asian-2
TPH
Run Hours Production
12644
44.73
314.2
47017
149.64
After using pet coke clinker, there

is significant drop in mill
productivity 29 TPH in Asian-2 and
11.5 TPH in Asain-1.
2.
To ensure the pet-coke impact,

clinker grind-ability test carried out
for Gagal-1 and Gagal-2
TPH
Feb-15
117
5224
44.65
337.95
51641
152.81
Mar-15
285.6
13048
45.69
364.07
56412
154.95
Apr-15
312.9
14219
45.44
360.7
56238
155.91
May-15
331.38
15726
47.46
460.25
69275
150.52
Jun-15
410.17
19374
47.23
483.62
68609
141.87
Jul-15
443.46
18809
42.41
424.97
57865
136.16
Aug-15
481.05
19567
40.68
444.6
61516
138.36
Sep-15
485.81
20804
42.82
500.1
69201
138.37
Oct-15
500.05
21558
43.11
552.43
78542
142.18
Nov-15
430.26
18155
42.2
442.57
62527
141.28
Jan-Nov 15
4080.35
179128
43.9
Coal
Clinker
4685.46
678843
144.88
Dec-15
536.64
18699
34.84
Pet Coke
Clinker
564.6
65103
115.31
Jan-16
558.47
16969
30.38
559.01
61996
110.9
Feb-16
567.36
17734
31.26
558.89
64286
115.02
Mar-16
510.34
16135
31.62
459.88
55540
120.77
Apr-16
283.75
10486
36.96
361.3
43613
120.71
May-16
348.8
13532
38.80
404.9
49386
121.97
Jun-16
311.2
10124
32.53
334.22
40821
122.14
Dec-15 To
June-16
3116.56
103679
33.2
3242.8
380745
117.4
ACC/ Plant name
1.
Microsoft Office
Word 97 - 2003 Document
3.
Low Purity gypsum is easier to

grind as compare to imported
gypsum.
2016
2. Observation
Clinker Factor Optimization In Low Fly-Ash Availability Period
FA Unavailbilit
y
Jan-15
Feb-15
Mar-15
Apr-15
May-15
1.
2.
3.
Asian-1
Asian-2
Asian-1
Asian-2
Clinker
Gypsum
Fly-Ash
Total
Clinker
Gypsum
Fly-Ash
Total
0
50.9
17.83
35.50
63.9
64.45
5.78
5.34
30.32
30.21
100
100
63.93
64.59
5.82
5.30
30.25
30.11
100
100
115.6
224.35
25.54
58.98
140.82
32.63
65.93
69.93
64.15
5.25
5.16
5.14
28.82
24.9
30.71
100
100
100
Imported
67.47
71.85
64.86
5.28
5.13
5.14
27.25
23.02
30
100
100
100
Jun-15
0.00
63.61
5.61
30.78
100
63.77
5.63
30.61
100
Jul-15
Aug-15
Sep-15
4.65
17.93
0
13.62
27.40
13.35
63.94
63.8
64.7
5.4
5.51
5.22
30.67
30.68
30.08
100
100
100
63.96
64.03
64.66
5.44
5.37
5.22
30.6
30.6
30.12
100
100
100
Oct-15
Nov-15
Dec-15
16
0
13.30
0.00
64.46
63.59
65.47
5.29
6.92
6.27
30.24
29.49
28.26
100
100
100
64.53
64.69
66.05
5.11
4.84
5.72
30.36
30.47
28.23
100
100
100
Jan-16
Feb-16
0
6
4.53
3.95
100
100
100
Jun-16
July-16
5.65
100
Aug-16
Sept-16
0
0
0
0
0
16.33
Oct-16
68.46
69.05
69.75
64.42
64.67
64.96
65.66
63.52
64.67
65.2
4.25
3.45
3.62
7.54
7.20
6.94
6.99
8.31
7.09
6.42
27.29
27.50
26.63
28.04
28.13
28.10
27.35
28.17
28.24
28.39
100
100
5.05
4.10
0.00
27.40
27.53
27.01
27.55
28.25
28.14
28.25
0
28.13
0
55.61
0
0
4.71
3.76
3.56
7.27
7.47
6.88
7.22
0
6.87
0
100
100
Mar-16
Apr-16
May-16
67.89
68.71
69.43
65.18
64.28
64.98
64.53
0
65
0
100
0
100
0
100
100
100
100
100
100
100
100
In Month of April-15, Asian-1 and Asian-2 were running at low fly-ash absorption (24.90% in Asian-1 and 23.02 % in Asian-2) due to less availability in
market.
In year of 2015, there is 455 hrs of plant unavailability due to fly-ash shortage in Asian-1 and 354 hrs for Asian-2.
Low Purity gypsum will help in clinker optimization and to make the plant available.
ACC/ Plant name
2016
Summary of Observation step

Summary of above slide:
1) In case of Imported Gypsum, Very big boulders present in
Gypsum cause jamming of gypsum weigh feeder and harder
to grind.
2) Less mill output due to high grind-ability of clinker when pet
coke is used as fuel which can be improved by using easy to
grind Low Purity gypsum.
3) Very high Clinker factor during less fly ash availability which
can be compensated by using Low Purity gypsum of low
purity.
14
ACC/ Plant name
2016
Analysis
15
ACC/ Plant name
2016
Brain Storming has been done and following point have been identified
Gypsum granulometry--(Mr.Prem Sagar)
Weigh Feeder Performance(Mr.Pradeep Singh)
Crusher/Grizzly Reliability (Mr. Hardeep Singh)
Unskilled Labour (Mr.Hunar)
Unavailability of SOP (Mr.Abhishek)
Inappropriate Training (Mr.Prem Sagar)
Higher Moisture Content leads hopper jamming (Mr.Abhishek)
Fly-Ash Availability (Mr.Chhabra)
Improper Sampling (Mr. Anil)
XRF calibration(Ms.Charu Lata)
Gypsum purity variation(Mr. Hunar Singh)
SO3 variation in Clinker (Mr.Anil)
ACC/ Plant name
2016
Root Cause Analysis

Man
Machine
Weigh Feeder Performance
Unskilled
Labour
Crusher/Grizzly
Reliability
Improper sampling
Higher Cement Cost

Due to use of
imported gypsum
and To improve
customer satisfactory
index
Fly-Ash Unavailability
Unavailability of SOP
Higher Moisture Content

leads hopper
jamming
SO3 variation in Clinker

Gypsum purity variation
Inappropriate Training
Gypsum granulometry
XRF Calibration
Method
Material
17
ACC/ Plant name
2016
3. Analysis
Confirm the probable cause: TEST OF HYPOTHESIS

Conclusion
No
Probable Cause
Testing and Observations
1.
Due to improper size of grizzly,

gypsum feed size is not under
control
Feed size of gypsum at weigh feed is abnormal (more than 50%

on 50 mm Sieve)
2.
In month of April-15 , fly-ash was at 23-24% which increase

clinker factor resulting per ton cost of cement increased
Valid
Gypsum supplier of imported gypsum provided coarser gypsum

which is above 50 mm
Valid
3.
4.
Gypsum Granulometry
In year of 2016 , Low Purity Gypsum purity variation from 40%

to 75%.
Valid
Ref Slide no.22
Valid
Microsoft Office
Excel Worksheet
Microsoft Office
Excel Worksheet
Microsoft Office
Excel Worksheet
18
ACC/ Plant name
2016
3. Why-why analysis
3.3 . Identify the root Causes

No.
1.
Valid Probable causes
why
why
Gypsum feed size is not under

control at Plant Site
Grizzly size is not uniform
Grizzly was made with scrap

material (Scrap Utilization)
Market scenario for power demand is not

under control of Cement Plant Power
demand is fluctuating in market
2.
3.
Gypsum Granulometry (at
Supplier End)
4.
Variation of gypsum size from the supplier
a)Crusher unavailability at mine
site;
b)Different source of mines
Low Purity gypsum supplied by vendor.
--
19
ACC/ Plant name
2016
Action
ACC/ Plant name
2016
4. ACTIONS
4.1 Actions Decided
Sl.No.
1
Root
Cause
Cause
Action Plan
Grizzly was
made with
scrap material
Prone of
damage its
screen
Gypsum
granulometr
y
New Grizzly material has been ordered

and fabricate at site to make well
designed grizzle to arrest bolder
Fly-Ash
Unavailab
ility
Increased
clinker factor
and per ton
cement cost.
Gypsum
blockage due
to higher
particle size at
grizzly and
other feeding
points
Resp.
25 July2016
Status
Mr.
Hardeep/Mr.Pre
m Sagar
Completed
Gypsum
Granulometr
y
Low purity
Low Purity
gypsum
supplied by
ACC/ Plant namevendor.
Gypsum purity
variation
Target
Date
-Increase Liaisoning with logistic to
enhance the fly-ash availability

-Asian has been requested to enhance the
fly-ash storage capacity new fly-ash silo
(1000 MT)
Low Purity Gypsum has been introduced

which has fine powder and does not
block the passage in flow at weigh
feeders
30-June2016
30-Nov2016
Mr.Anil/Mr.Saura
bh
In progress
Adobe Acrobat
Document
30-June2016
Mr.Anil/Mr.Saura
bh
Completed
30-Sept2016
Mr.Anil/Mr.Hunar
In Progress
Mail to purchase section.
Adobe Acrobat
Document
21
2016
New Grizzly for Gypsum
Before
After
New Grizzly made to arrest bolder Gypsum

22
ACC/ Plant name
2016
Low Purity Gypsum Usage
Action:
To start the Low Purity gypsum, trial has been done at Asian
Trial Results:
Trail with Low Purity Gypsum at Asian
Trial No.
Clinker %
Gypsum %
Fly-Ash %
Low Purity /
Imported Ratio
Chemical
Parameter
CaO
SO3
LOI
Blaine
Residue (R45 mic)
1 Day
3 Days
7 Days
28 Days
Normal (100%
imported)
Trial-1
Trial-2
Trial-3
Trial-4
UOM
64.20
5.00
30.80
63.40
5.80
30.80
62.50
6.70
30.80
61.10
8.10
30.80
59.00
10.20
30.80
%
%
%
0:100'
25:75'
50:50'
75:25'
100:0'
Averag
e
42.30 42.25
Normal PPC
Set-1
42.80
42.50
2.52
2.48
1.96
381
10.6
14.9
27.9
36.6
Awaited
Averag
Set-1
e
41.60 42.05 42.40
Set-2
2.62
2.55
2.40
Averag
Set-1
e
41.50 41.95 42.89
Set-2
2.42
2.41
2.57
Averag
Set-1
e
42.34 42.62 42.20
Set-2
2.34
2.46
2.38
Set-2
2.47
2.43
1.96
2.53
2.2
2.16
1.95
2.06
1.70
1.78
1.74
1.88
1.66
1.77
398
386
392
396
390
393
383
398
391
395
380
388
10.8
10.2
10.5
10.8
11.8
11.3
10.0
10.0
10.0
10.0
10.5
10.3
14.2
14.6
14.4
14.4
14.0
14.2
14.2
13.8
14.0
12.7
12.4
12.6
25.0
27.5
26.3
26.5
26.0
26.3
24.2
24.8
24.5 Awaited Awaited Awaited
31.8
34.0
32.9
32.0
33.5
32.8
31.8
34.2
33.0 Awaited Awaited Awaited
Awaited Awaited Awaited Awaited Awaited Awaited Awaited Awaited Awaited Awaited Awaited Awaited
Microsoft Office
Word Document
%
%
m2/kg.
%
MPa
MPa
MPa
MPa
23
ACC/ Plant name
2016
5. Check
ACC/ Plant name
2016
ACC/ Plant name
2016
ACC/ Plant name
2016
ACC/ Plant name
2016
SO3 Optimization
SO3 optimization has bee done for both type of clinker and gypsum.
a) - With Coal and High Purity Gypsum:- SO3 Range: 2.1-2.6%
b) - With Pet coke and Low Purity Range:- SO3 Range: 2.44-2.67%
Microsoft Office
Excel 97-2003 Worksheet
Coal and High Purity Gypsum
Microsoft Office
Excel Worksheet
Pet coke and Low Purity Gypsum
28
ACC/ Plant name
2016
BENEFITS
Asian Cement Works
SPC- Process Improvement Project of 2016
Tangible saving validation sheet
Project Title:- SO3 optimization and Usage of Low Purity Gypsum at Asian Cement
Saving through:- Systematic Problem Solving Methodology
Project period:- 4 April 2016 to 30 Oct 2016
Improvement by reducing clinker factor by 3.52% with the use of low purity gypsum and
consequently, productivity, plant availability and per ton power consumption has been improved by
3 TPH productivity, 2874 MT PCC per month and 5-6 kWhr. Per ton of cement respectively.
Details of saving:-Calculation
a) Annual Saving in Clinker Consumption @3.52% Clinker Factor Reduced = 18837 MT = 4.20
Crore @ Rs. 2252 /MT of Clinker.
b) Annual Saving in Production By increasing Plant Availability in Low Fly-Ash Availability = 34488
MT cement produced = 8.99 Crore @ Rs. 2606 /MT of PPC
Annual Saving in Crore = 13.19

Remarks:Validated By:Project Leader
ACC/ Plant name
Mentor
Head Finance
Director Plant
2016
6. Standardization
6.1 Updation of documents:
1.
Gypsum sampling & testing is done truck wise.
2.
SOP for SO3 Optimization .
6.2 Training:
Training given to Site Lab testers and CCR regarding SOP of SO3 Optimization and monitoring of
abnormal lumps received from low purity gypsum and checking of Grizzly Size.
6.2 Additional Audit / Check

1.
Proper Monitoring of Purity of incoming gypsum and clinker SO3%.
2.
Follow up for SO3 Optimization (twice in a year at least)
ACC/ Plant name
2016
7. Conclusion
7.1 Horizontal Deployment:
Cost reduction approach can be deployed to other department like minimization of waste
material/recycling to regenerate the product efficiently.
7.2 Lessons Learnt:

Learnt about importance of PSD, Route Cause Analysis, Cause & Effect Diagram (Fish bone
diagram), Why-Why analysis etc.etc.
How to optimize the clinker factor and to make system more profitable.
Importance and usage of low purity gypsum .
ACC/ Plant name

ACC Gagal
2016
Thank You
32
ACC/ Plant name
2016

Anil Kumar-Year 2016, Gagal Works

Diunggah oleh

Informasi Dokumen

Judul Asli

Hak Cipta

Format Tersedia

Bagikan dokumen Ini

Bagikan atau Tanam Dokumen

Opsi Berbagi

Apakah menurut Anda dokumen ini bermanfaat?

Apakah konten ini tidak pantas?

Hak Cipta:

Format Tersedia

Anil Kumar-Year 2016, Gagal Works

Diunggah oleh

Hak Cipta:

Format Tersedia

Process Improvement Project

Systematic Problem Solving methodology

Gagal Cement Works

Current Status: Completed

SPC- Process Improvement Project of Year2016

Team Information: Cross Functional

SPC- Process Improvement Project of Year2016

Group photo: Cross Functional

SPC- Process Improvement Project of Year2016

Step 1: - Problem Definition

SPC- Process Improvement Project of Year2016

Step 1:- (a) Problem Definition

Tangible Benefit A. 3.60 Crores Rs saving annually(50 Rs/T) cement in Asian By

Intangible Benefit:-1) Improvement in Quality Product

Uses of High Purity Imported Gypsum

ACC/ Plant name

SPC- Process Improvement Project of Year2016

Cost Benefit Analysis

ACC/ Plant name

SPC- Process Improvement Project of Year2016

Y2015 Clinker produced with normal coal

SPC- Process Improvement Project of Year2016

Y2015 Clinker produced with normal coal

SPC- Process Improvement Project of Year2016

Summary of Problem Definition step

SPC- Process Improvement Project of Year2016

ACC/ Plant name

SPC- Process Improvement Project of Year2016

ACC/ Plant name

Large lumps are found which is above 50 mm

SPC- Process Improvement Project of Year2016

Run Hours Production

Run Hours Production

After using pet coke clinker, there

To ensure the pet-coke impact,

ACC/ Plant name

Low Purity gypsum is easier to

SPC- Process Improvement Project of Year2016

ACC/ Plant name

SPC- Process Improvement Project of Year2016

Summary of Observation step

SPC- Process Improvement Project of Year2016

SPC- Process Improvement Project of Year2016

Gypsum granulometry--(Mr.Prem Sagar)

Weigh Feeder Performance(Mr.Pradeep Singh)

Crusher/Grizzly Reliability (Mr. Hardeep Singh)

Unskilled Labour (Mr.Hunar)

Unavailability of SOP (Mr.Abhishek)

Inappropriate Training (Mr.Prem Sagar)

Higher Moisture Content leads hopper jamming (Mr.Abhishek)

Fly-Ash Availability (Mr.Chhabra)

Improper Sampling (Mr. Anil)

XRF calibration(Ms.Charu Lata)

Gypsum purity variation(Mr. Hunar Singh)

SO3 variation in Clinker (Mr.Anil)

ACC/ Plant name

SPC- Process Improvement Project of Year2016

Root Cause Analysis

Higher Cement Cost

Higher Moisture Content

SO3 variation in Clinker

ACC/ Plant name

SPC- Process Improvement Project of Year2016