Business Excellence Dolvi

Deming Cycle

Identify work
Follow up related
And Review problems
Selection of
1 problem

Regular 2
Implementation
Define the
3 problem

4
Analyze
5
Trial
Implementation 6
9 7
8

Foresee Resistance
And Prepare

Business Excellence Dolvi 3

 Step-1 Identification of Problem

Technique-Brainstorming(Group Passing)
Step-1
Identification of Problem 4
 Identification of Problem
S.No Problems S.No Problems
1 Lack of sludge disposal system. 26 DCP2&3RC Vertical pump gland leak
2 Manpower required for safe and timelyexecution of maintenance activities. 27 DCP2&3RA ARV valve gland leak

Problems 3
4
Addition pump standby requirement for backwash water pump.
For reutilisation of CT blowdown water additional pipeline required.
28
29
DCP2&3RC Discharge valve gland leak
SP-1 Poor lighting

Bank 5
6
New PLC required for filtration plant.
All pumps ICW/DCW and Scale pit Flow and Pressure display should be on VNCC.
30
31
SP-1 Incomplete barrication
SP-1 Improper ladder for bia-pass valve
7 SSPF Filtration Plant "F" valve malfunctioning. 32 Scale pit 1 Oil collection area slippery
8 Failure of Backwash Pump 33 Scale pit 1 Oil collection tank not functioning properly
9 SP 1,2,3 Vertical pump maintenance area not available for spare pump maintenance. 34 Scale pit 1 Oil Skimmer boom not rotating for maintenance
10 CT-1 overflow water optimization. 35 Scale pit 1 No pressure gauge on pump discharge
11 IC-3 diesel pump oil pressure is low. 36 Scale pit 1 pump discharge flow transmitter not working
12 ECRW-1 cable trench height is low. 37 Scale pit 2 Otoklin filter motor shed not available
13 Scale pit 2 online filter backwash water optimization. 38 Scale pit 2 Otoklin filter backwash reading not working
14 ECR W-1 drainage water optimization. 39 Dcp 4RC/D Discharge current get reduced after some interval
15 Scale pit -1 flooding . 40 Scale pit 2 Unwanted material in pump pit
16 No Coupling guard to DCP2&3RA 41 Scale pit 2 Unwanted Material in MCC room
17 No Coupling guard to DCP2&3RA 42 No coupling guard for Dcp 4RC
18 No Coupling guard to DCP2&3RA 43 No coupling guard for Dcp 4RD
19 DCP 2&3RC discharge valve problem 44 Dcp 4RA Pump Heavy gland leakage
20 DCP 2&3RB NRV leak 45 Dcp 4RB Pump Heavy gland leakage
21 Dcp 2&3RA/RC NRV get stuck 46 Dcp 4RC Pump Heavy gland leakage
22 DCP 2&3RA Dischage valve hard to operate 47 Dcp 4RD Pump Heavy gland leakage
23 SP-1 Bia-Pass valve gland Leak 48 Dcp 4RA discharge valve gland leakage
24 DCP2&3RA Discharge valve gland leak 49 Dcp 4RB discharge valve gland leakage
25 DCP2&3RC ARV valve pass 50 Dcp 4RC discharge valve gland leakage

Step-1 Identification of Problem 5 Business Excellence Dolvi

 Identification of Problem
S.No Problems S.No Problems
51 Dcp 4RD discharge valve gland leakage 76 Dcp 1RA NRV valve problem
52 Scale pit 2 Oil collection area slippery 77 Scale pit 3 Amaid filter tripping frequently
53 Scale pit 2 Oil collection tank not available 78 SSPF dosing point was correded
Problems 54 Scale pit 2 Oil Skimmer boom not rotating for maintenance 79 SSPF "F" Valve problem
55 Scale pit 2 Amaid online filter trip indication not available 80 SSPF "F" Valve NRV pass
Bank 56 Scale pit 2 Otoklin online filter trip indication not available 81 SSPF Air Blower NRV pass
57 Scale pit 2 pump discharge flow transmitter not working 82 SSPF pnuematic Valve Malfunctioning
58 Dcp 1RA discharge valve problem 83 SSPF wash water pump gland leak
59 Scale pit 3 Unwanted material in pump pit 84 Spare SSPF filter not available
60 Scale pit 3 water level increase quickly 85 SSPF Filling valve gear box pass
61 Scale pit 3 No proper Walkway direct to PRV 86 SSPF wash water tank level indicator not available
62 DCP1RB Pump Gland Leak 87 Spare SSPF PLC not available
63 DCP1RC Pump Gland Leak 88 SSPF Air Blower Belt not available
64 DCP1RD Pump Gland Leak 89 SSPF Valve No Visual marking for "Open/Close" coil
65 DCP1RE Pump Gland Leak 90 SSPF No proper Railing for ladder
66 DCP1RC Discharge valve gland leak 91 CT-1 Makeup Flow transmitter not working
67 No Coupling guard for DCP1RA Pump 92 CT-1 hot basin nozzles get choked with sand
68 No Coupling guard for DCP1RB Pump 93 CT-1 some blowdown valve not working
69 No Coupling guard for DCP1RC Pump 94 No proper collection tank for blowdown water
70 No Coupling guard for DCP1RD Pump 95 CT-1/2 Water parameter keep on changing
71 No Coupling guard for DCP1RE Pump 96 Cold basin walkway area slippery
72 DCP 1RA Pump ARV Valve Passing 97 CT-1 water temp display not on PLC
73 DCP 1RB Pump ARV Valve Passing 98 No proper Walkway for checking CT-1 Fan inside oil level
74 DCP 1RD Pump ARV Valve Passing 99 CT-1 Hot basin isolation valve gear box jam
75 DCP 1RE Pump ARV Valve Passing 100 CT-1 Suction strainer condition not proper

Step-1 Identification of Problem 6 Business Excellence Dolvi

 Identification of Problem
S.No Problems S.No Problems
101 DCP1 PRV valve not working 126 DCP 4 Flow/Pressure not available on PLC screen
102 DCP1E NRV need to be lift 127 ICP 1 Standby Pump not available

Problems 103
104
DCP1B Discharge valve flange joint heavy leak
DCP1E Pumps Bearing failure
128
129
ICP 1 Pumps discharge valve cannot open 100%
ICP 1 Pumps gland leakage

Bank 105
106
DCP1D/E Header recirculation valve jam
All DCP1 Pipeline are interconnected need isolation according to zone
130
131
ICP 2 Flow/Pressure not available on PLC
ICP 2 Pumps Discharge valve cannot open 100%
107 DCP1C NRV need to be lift 132 ICP 2 Pressure frequent complaint from caster
108 DCP1G Current less in caster break 133 ICP 2B Pumps casing leakage.
109 Pressure Transmitter required for all DCP1 pumps Discharge and suction pipeline 134 No suction strainer in ICP 2D
110 Caster 1/2 all zones individual flow transmitter required 135 ICP 2D tripping Frequently without indication/Alarm
111 DCP 1 Pumps heavy leakage 136 DCP1C High Vibration
112 All DCP Pump current not showing on PLC 137 ICP 2 MM30 display in very low need to bend to take reading
113 DCP 1F Pump not available 138 Filtration plant All Pneumatic valve malfunctioning
114 DCP 2 Pump back pressure in roll change 139 ICP 3 Flow/Pressure not available on PLC
115 DCP 2D Pump Abnormal Noise from NRV 140 ICP 3 NRV Passing
116 DCP 2 Gland Cooling Hose broken from last 2 month 141 ICP 4A Discharge valve problem
117 DCP 2B Discharge valve gear box tight 142 ICP 4 Gland leakage
118 DCP 2 individual and header Pressure Transmitter Required 143 ICP 4 Flow/Pressure not available on PLC
119 DCP 3A Pump starting problem occurs 2 times 144 No suction strainer in ICP 4 Pumps
120 DCP 3A Motor Fan guards damaged 145 No ICP 5 standby Pump available in Higher width casting
121 DCP 3A Pressure complaint from descaler 146 Scale pit 2 Amaid filter motor shed not available
122 DCP 3 Pumps on starting descaler Pump get tripped 147 ICP 5 Flow/Pressure not available on PLC
123 DCP 3 Pumps flow/pressure not available on plc screen 148 ONLINE PH/Turbidity/TSS Meter not Available
124 DCP 4 Flow transmitter Malfunctioning 149 Wash water tank dosing risky
125 DCP 4 Discharge valve cannot open 100% 150 Water sample bottle are not clean

Step-1 Identification of Problem 7 Business Excellence Dolvi

 STEP-2 SELECTION OF PROBLEMS

Step-2 Selection of Problem 8 Business Excellence Dolvi

 Problem Selection (A/B/C Stratification)
Impact
Complexity
S.NO Problems (A/B/C)
(P/Q/C/D
/S/M/E)
1 All pumps ICW/DCW and Scale pit Flow and Pressure display should be on VNCC. B P
2 SSPF Filtration Plant "F" valve malfunctioning. A Q
3 Failure of Backwash Pump A P
4 SP 1,2,3 Vertical pump maintenance area not available for spare pump maintenance. A S
5 ECRW-1 cable trench height is low. A S
6 Scale pit 2 online filter backwash water optimization. A E
7 ECR W-1 drainage water optimization. A C
8 DCP 2&3RB NRV leak A P
9 Dcp 2&3RA/RC NRV get stuck A P
10 DCP 2&3RA Dischage valve hard to operate A P
11 SP-1 Poor lighting B E
12 SP-1 Improper ladder for bia-pass valve A S
13 Scale pit 1 Oil collection area slippery A S
14 Scale pit 1 Oil collection tank not functioning properly A E
15 Scale pit 1 Oil Skimmer boom not rotating for maintenance A M
16 Scale pit 1 pump discharge flow transmitter not working B P
17 Scale pit 2 Otoklin filter backwash reading not working B P
18 Dcp 4RC/D Discharge current get reduced after some interval A P
19 Dcp 4RA Pump Heavy gland leakage A E
20 Dcp 4RB Pump Heavy gland leakage A E
21 Dcp 4RC Pump Heavy gland leakage A E
22 Dcp 4RD Pump Heavy gland leakage A P
23 Dcp 4RA discharge valve gland leakage A E

Step-2 Selection of Problem 9

 Problem Selection (A/B/C Stratification)
Impact
Complexity
S.NO Problems (A/B/C)
(P/Q/C/D
/S/M/E)
AK
24 Dcp 4RC discharge valve gland leakage A E
25 Scale pit 2 Oil collection area slippery A S
26 Scale pit 2 Oil collection tank not available A E
27 Scale pit 2 Oil Skimmer boom not rotating for maintenance A M
28 Scale pit 2 Amaid online filter trip indication not available B Q
29 Scale pit 2 Otoklin online filter trip indication not available B Q
30 Scale pit 2 pump discharge flow transmitter not working B P
31 Scale pit 3 water level increase quickly A P
32 Scale pit 3 No proper Walkway direct to PRV C S
33 DCP1RB Pump Gland Leak A E
34 DCP1RD Pump Gland Leak A E
35 DCP1RE Pump Gland Leak A E
36 DCP1RC Discharge valve gland leak A E
37 Dcp 1RA NRV valve problem A P
38 SSPF "F" Valve problem C P
39 SSPF "F" Valve NRV pass C P
40 SSPF Air Blower NRV pass C P
41 SSPF pnuematic Valve Malfunctioning A P
42 SSPF wash water pump gland leak A E
43 Spare SSPF filter not available A P
44 SSPF Filling valve gear box pass A P
45 SSPF wash water tank level indicator not available B P
46 Spare SSPF PLC not available B Q

Step-2 Selection of Problem

10
 Problem Selection (A/B/C Stratification)
Complexi Impact
S.NO Problems ty (P/Q/C/D
(A/B/C) /S/M/E)

47 SSPF Valve No Visual marking for "Open/Close" coil B P

48 SSPF No proper Railing for ladder A S
49 CT-1 Makeup Flow transmitter not working B P
50 CT-1 hot basin nozzles get choked with sand A P
51 CT-1 some blowdown valve not working A Q
52 No proper collection tank for blowdown water A E
53 CT-1/2 Water parameter keep on changing A Q
54 Cold basin walkway area slippery A S
55 CT-1 water temp display not on PLC B P
56 No proper Walkway for checking CT-1 Fan inside oil level A M
57 CT-1 Hot basin isolation valve gear box jam A P
58 CT-1 Suction strainer condition not proper C P
59 DCP1E NRV need to be lift A P
60 DCP1E Pumps Bearing failure A C
61 DCP1D/E Header recirculation valve jam A P
62 All DCP1 Pipeline are interconnected need isolation according to zone A P
63 DCP1C NRV need to be lift A P
64 Pressure Transmitter required for all DCP1 pumps Discharge and suction pipeline B P
65 Caster 1/2 all zones individual flow transmitter required B P
66 All DCP Pump current not showing on PLC B P
67 DCP 2 Pump back pressure in roll change A P
68 DCP 2 Gland Cooling Hose broken from last 2 month C P
69 DCP 2 individual and header Pressure Transmitter Required B P

Step-2 Selection of Problem 11

 Problem Selection (A/B/C Stratification)
Complexi Impact
S.NO Problems ty (P/Q/C/D
(A/B/C) /S/M/E)

70 DCP 3A Pump starting problem occurs 2 times B P

71 DCP 3A Pressure complaint from descaler A Q
72 DCP 3 Pumps on starting descaler Pump get tripped A Q
73 DCP 4 Flow transmitter Malfunctioning B P
74 DCP 4 Discharge valve cannot open 100% A Q
75 ICP 1 Standby Pump not available C Q
76 ICP 1 Pumps discharge valve cannot open 100% A Q
77 ICP 2 Pumps Discharge valve cannot open 100% A P
78 ICP 2 Pressure frequent complaint from caster A P
79 ICP 2B Pumps casing leakage. A P
80 No suction strainer in ICP 2D C Q
81 ICP 2D tripping Frequently without indication/Alarm B P
82 DCP1C High Vibration A p
83 ICP 2 MM30 display in very low need to bend to take reading B M
84 Filtration plant All Pneumatic valve malfunctioning A p
85 ICP 3 Flow/Pressure not available on PLC B P
86 ICP 3 NRV Passing A P
87 No suction strainer in ICP 4 Pumps C Q
88 No ICP 5 standby Pump available in Higher width casting C P
89 ONLINE PH/Turbidity/TSS Meter not Available A Q
90 Wash water tank dosing risky A S

Step-2 Selection of Problem 12

 ABC Analysis after problems solved

40% 39%

A(Within Dept.)
B(Cross Functional)
C(Management Support)
7% 14%
Problems Solved

Complexity No. of Problems

A(Within Dept.) 59
B(Cross Functional) 21
C(Management Support) 10
Solved 60
Total 150
Step-2 Selection of Problem 13
 Complexity Solved
A(Within Dept.) 59
B(Cross Functional) 21
C(Management Support) 10
Total 90

Step-2 Selection of Problem 14 Business Excellence Dolvi

 Problem Selection ‘A’ Complexity selected
(Theme based classification)
Impact
Complexity
S.NO Problems (A/B/C)
(P/Q/C/D AK/QC
/S/M/E)
1 SSPF Filtration Plant "F" valve malfunctioning. A Q
2 Failure of Backwash Pump A P
3 SP 1,2,3 Vertical pump maintenance area not available for spare pump maintenance. A S
4 ECRW-1 cable trench height is low. A S
5 Scale pit 2 online filter backwash water optimization. A E
6 ECR W-1 drainage water optimization. A C
7 DCP 2&3RB NRV leak A P AK
8 Dcp 2&3RA/RC NRV get stuck A P
9 DCP 2&3RA Dischage valve hard to operate A P
10 SP-1 Improper ladder for bia-pass valve A S AK
11 Scale pit 1 Oil collection area slippery A S
12 Scale pit 1 Oil collection tank not functioning properly A E
13 Scale pit 1 Oil Skimmer boom not rotating for maintenance A M
14 Dcp 4RC/D Discharge current get reduced after some interval A P
15 Dcp 4RA Pump Heavy gland leakage A E AK
16 Dcp 4RB Pump Heavy gland leakage A E AK
17 Dcp 4RC Pump Heavy gland leakage A E AK
18 Dcp 4RD Pump Heavy gland leakage A P AK
19 Dcp 4RA discharge valve gland leakage A E AK
20 Dcp 4RC discharge valve gland leakage A E AK

Step-2 Selection of Problem 15

 Problem Selection ‘A’ Complexity selected
(Theme based classification)
Impact
Complexity
S.NO Problems (A/B/C)
(P/Q/C/D AK/QC
/S/M/E)

21 Scale pit 2 Oil collection area slippery A S

22 Scale pit 2 Oil collection tank not available A E
23 Scale pit 2 Oil Skimmer boom not rotating for maintenance A M
24 Scale pit 3 water level increase quickly A P
25 DCP1RB Pump Gland Leak A E AK
26 DCP1RD Pump Gland Leak A E AK
27 DCP1RE Pump Gland Leak A E AK
28 DCP1RC Discharge valve gland leak A E AK
29 Dcp 1RA NRV valve problem A P AK
30 SSPF pnuematic Valve Malfunctioning A P
31 SSPF wash water pump gland leak A E AK
32 Spare SSPF filter not available A P
33 SSPF Filling valve gear box pass A P AK
34 SSPF No proper Railing for ladder A S AK
35 CT-1 hot basin nozzles get choked with sand A P
36 CT-1 some blowdown valve not working A Q AK
37 No proper collection tank for blowdown water A E
38 CT-1/2 Water parameter keep on changing A Q
39 Cold basin walkway area slippery A S AK
40 No proper Walkway for checking CT-1 Fan inside oil level A M

Step-2 Selection of Problem 16

 Problem Selection ‘A’ Complexity selected
(Theme based classification)
Impact
Complexity
S.NO Problems (A/B/C)
(P/Q/C/D AK/QC
/S/M/E)

41 CT-1 Hot basin isolation valve gear box jam A P

42 DCP1E NRV need to be lift A P
43 DCP1E Pumps Bearing failure A C AK
44 DCP1D/E Header recirculation valve jam A P AK
45 All DCP1 Pipeline are interconnected need isolation according to zone A P
46 DCP1C NRV need to be lift A P
47 DCP 2 Pump back pressure in roll change A P
48 DCP 3A Pressure complaint from descaler A Q
49 DCP 3 Pumps on starting descaler Pump get tripped A Q
50 DCP 4 Discharge valve cannot open 100% A Q
51 ICP 1 Pumps discharge valve cannot open 100% A Q
52 ICP 2 Pumps Discharge valve cannot open 100% A P
53 ICP 2 Pressure frequent complaint from caster A P
54 ICP 2B Pumps casing leakage. A P
55 DCP1C High Vibration A p
56 Filtration plant All Pneumatic valve malfunctioning A p
57 ICP 3 NRV Passing A P AK
58 ONLINE PH/Turbidity/TSS Meter not Available A Q AK
59 Wash water tank dosing risky A S

Step-2 Selection of Problem 17

 A Type :Productivity Theme Problems
Theme based Categorization
'A' type problems
25%
P(Productivity)
24% Quality Circle
41% Q(Quality)

5% C(Cost) 75% Kaizen

D(Delivery)
14%
S(Safety)
13%
3% M(Morale)

0% E(Environment)
Type of Problem No. of Problems
Impact
P(Productivity)
No of Problems
24 Quality Circle 18
Q(Quality) 8
C(Cost) 2 Kaizen 6
D(Delivery) 0
S(Safety)
M(Morale)
8
3
Total 24
E(Environment) 14
Total 59
Step-2 Selection of Problem 18
 Problem Summary
Theme Based
Complexity
Categorization for A-type
Complexity No. of Problems Impact No of Problems
A(Within Dept.) 59 P(Productivity) 24
B(Cross Functional) 21 Q(Quality) 8
C(Management 10 C(Cost) 2
Support)
D(Delivery) 0

S(Safety) 8
A-type (Productivity)
M(Morale) 3

Type of Problem No. of Problems E(Environment) 14

Quality Circle 18
THEME SELECTED
Kaizen 6
PRODUCTIVITY
Step-2 Selection of Problem 19
 Prioritization of Problem(Rating Method)

Harinarayana

Ashirwad

Prashant
Shirke
Rajam

Amar
Atish

Total
S.No

Ajit
Problems

1 Failure of Backwash Pump 8 9 9 8 7 6 7 6 60

2 Dcp 2&3RA/RC NRV get stuck 8 8 7 7 6 6 7 7 56
3 DCP 2&3RA Dischage valve hard to operate 8 7 8 6 6 6 6 6 53
4 Dcp 4RC/D Discharge current get reduced after some interval 6 7 7 7 6 6 7 7 53
5 Scale pit 3 water level increase quickly 8 7 7 6 6 6 6 6 52
6 SSPF pnuematic Valve Malfunctioning 8 8 7 7 6 6 5 5 52
7 Spare SSPF filter not available 7 7 7 7 7 6 5 5 51
8 CT-1 hot basin nozzles get choked with sand 7 7 7 7 6 6 5 5 50
9 CT-1 Hot basin isolation valve gear box jam 8 8 8 7 6 5 8 8 58
10 DCP1E NRV need to be lift 7 7 7 7 6 6 5 5 50
11 All DCP1 Pipeline are interconnected need isolation according to zone 7 7 7 7 7 6 4 4 49
12 DCP1C NRV need to be lift 7 7 7 7 5 5 5 5 48
13 DCP 2 Pump back pressure in roll change 5 7 7 5 5 5 7 7 48
14 ICP 2 Pumps Discharge valve cannot open 100% 9 8 7 8 7 7 6 6 58
15 ICP 2 Pressure frequent complaint from caster 5 7 6 5 6 5 5 5 44
16 ICP 2B Pumps casing leakage. 7 7 5 5 5 5 5 5 44
17 DCP1C High Vibration 8 9 9 8 8 8 7 7 64
18 Filtration plant All Pneumatic valve malfunctioning 8 8 8 8 8 8 7 7 62

Step-2 Selection of Problem 20

 Project Charter

Department: Utility Project Regn. No.

Project Title Improvement in operational reliability of caster direct spray cooling pump DCP #1C

Project
Quality Cost Productivity Delivery Safety Morale
Classification

Need for project: Define the problem & impact of problem:

Pump ha vi ng Hi gh vi bra ti on a nd Re pe a te dl y fa i l ure of NDE be a ri ng
High vibration in pump.

Impact:
*Re pe a te dl y fa i l ure of pump NDE be a ri ng
*Non a va i l a bi l i ty of pump ma y ha mpe r producti on proce s s

Goal D C P 1 C V ib ra tio n R e a d in g B e f o r e
25
Characteristic Target date of completion
20
Sl. No. under Current Level Goal

Vibration reading in mm
42491
15 42552

improvement 42644
10 42675

1 Vi bra ti on 10.74mm/s e c 3 to 4mm/s e c 7/16/2017 5

Good
S a tisfa c to r y

Process identified for improvement: 0

S e r ie s7

1 2 3 4 5 6 7 8 9 10 11 12

Di re ct s pra y cool i ng wa te r ci rcui t a t CSP uti l i ty Trend of the problem:

R e ad in g s

Team Time plan

Sr. No. Name Deptt. Role Sr. No. Step Start Date End Date
1 Aji t Moka l Uti l i ty Fa ci l i ta tor 1 I de nti fy Probl e m 15/3/2017 22/3/2017
2 S.D. Ra ja m Uti l i ty Le a de r 2 Se l e cti on of Probl e m 22/3/2017 29/3/2017
3 M.M. Shi rke Uti l i ty Me mbe r 3 De fi ne the Probl e m 29/3/2017 5/4/2017
4 As hi rwa d Pa ti l Uti l i ty Me mbe r 4 Ana l yze 5/4/2017 12/4/2017
5 Ha ri na ra ya na Uti l i ty Me mbe r 5 I de nti fy Ca us e s 12/4/2017 19/4/2017
6 Ati s h Bhoi r Uti l i ty Me mbe r 6 I de nti fy root ca us e s 19/4/2017 19/4/2017
7 Pra s ha nt Moka l Uti l i ty Me mbe r 7 Da ta Ana l ys i s 19/4/2017 26/4/2017
8 Ama r Ma ne Uti l i ty Me mbe r 8 De ve l op s ol uti on 26/4/2017 3/5/2017
9 Fore s e e Re s i s i ta nce a nd Pre pa re 3/5/2017 10/5/2017
10 Tri a l I mpl e me nta ti on 10/5/2017 24/5/2017
11 Re gul a r I mpl e me nta ti on 24/5/2017 7/6/2017
12 Fol l ow Up a nd Re vi e ws 7/6/2017 28/6/2017
Champion's comments:

21
Business Excellence Dolvi
 PLANNED MONTH
Sr.No STEPS ------ Mar April May June
----- 15/3/2017 22/3/2017 29/3/2017 5/4/2017 12/4/2017 19/4/2017 26/4/2017 3/5/2017 10/5/2017 17/5/2017 24/5/2017 31/5/2017 7/6/2017 14/6/2017 28/06/2017
P
1 Identify Problems
A
P
2 Selection of problem
A
P
3 Define Problem
A
P
4 Analyze
A
P
5 Identify Causes
A
P
6 Identify Root Causes
A
P
7 Data Analysis
A
P
8 Develop Solution
A
P
9 Foresee Resistance
A
P
10 Trial Implementation
A
P
11 Regular Implementation
A
P
12 Follow up and Reviews
A
P-PLANNED Prepared By Rajam S D
A-ACTUAL Approved By Ajit mokal

Step-2 Selection of Problem 22

 DCW-1 SYSTEM

COOLING T OWER - 1 COOLING T OWER - 1A

D C-1 D D C-1 E D C-1A D C-1B DC-1C D C-1 G

PUMP PUMP PUMP PUMP PUMP PUMP
360 360 665 665 665 665
CuM/Hr CuM/Hr CuM/Hr CuM/Hr CuM/Hr CuM/Hr
@16.5 @16.5 @16.5 @16.5 @16.5 @16.5
b ar b ar b ar b ar b ar b ar

CASTER PHASE -I CASTER PHASE CASTER PHASE -2

1 & 2 BOTH

BOOSTER PUMPS
ZONES 4 TO 8 ZONES 1 TO 3 ZONES 4 TO 8

PRV
SCALE PIT - 3

DC-1R E
D C-1RD DC-1R A/B/C PUMP
PUMP PUMP 665 CuM/Hr
360 CuM/Hr 665 CuM/Hr @ 4.7 b ar
@ 4.5 b ar @ 4.5 b ar

FILTRATIO N PLANT AMAID ONLINE

PF 3-1 TO PF 3-3
PF 3-4 FILTERS 1/2/3

Step-3 Define Problem

Step-3 Define Problem 24
 DCP1C pump water is used
for Caster I & II secondary
cooling zone 1 to 3 where it
is in direct contact with the
newly solidified surface of the
metal. Water cooling affects
the product quality by (1)
controlling the heat removal
rate that creates and cools
the solid shell and (2)
generating thermal stresses
and strains inside the
solidified metal.
https://www.researchgate.net/
publication/225927363_The_
use_of_water_cooling_during
_the_continuous_casting_of_
Step-3 Define Problem
steel_and_aluminum_alloys
25
 Diagnostics Journey : Process Flow Diagram (PFD)

Step-3 Define problem 26

 25

Chart Title
20

Vibration reading mm/sec

15 May-16
Jul-16
Oct-16
Nov-16
Good
10
Satisfactory

0
1 2 3 4 5 6 7 8 9 10 11 12
Monthwise

Step-3 Define Problem 27

 Step-3 DEFINE PROBLEM :High Vibration in Caster Spray cooling pump DCP1C

Problem Location Vibration Reading Required Vibration Reading Actual

High Vibration of
HSM CSP Vibration reading Vibration reading
Caster Direct Spray
Utility 1.8mm/sec to 4.5mm/sec 10.74mm/sec
cooling Pump DCP 1C

Symptom Effect Impact Goal

Non Drive End side Caster Spray Reduction of Vibration
Caster Breakout with HSM
Pump Bearing Failure Cooling Pump Reading from 10.74mm/sec
production loss @21.5 Lacs
and Mislaginment Breakdown to 3-4mm/sec in 3 months

Step-3 Define Problem 28

Reduction of Vibration Reading of DCP1C
from 10.74 mm/sec to 3-4 mm/sec
29
 STEP-4 ANALYZE CAUSE

• Premature Pump failure

WHAT

Problem
Statement • Non Drive End side bearing failure
WHERE
Very High
Vibration
In DCP1C • Over an period of a year
WHEN
Pump
• DCP 1 Caster Spray cooling Circuit
WHO Reduction of
Vibration
Reading from
• Very high Vibration Reading of 10.74mm/sec 10.74mm/sec
HOW
to
3-4mm/sec

Step-4 Analyze Cause 30

STEP-5 IDENTIFY CAUSE

31
 Brainstorming Points (Identifying possible causes)
1 Unbalanced rotating components 15 Impeller relief hole obstructed/choked
2 Bent Shaft{Shaft Straightness) 16 Debris/Foreign particulates in impeller
3 Sleeve Damage 17 Clogged suction Line
4 High vibration 18 Partially/Plugged strainer
5 Cavitation 19 Insufficient Suction
6 Improper mounting of bearing 20 Pump base shim packing deteriorate
7 Bearing wear out prematurely 21 Improper pump assembly
8 Bearing Housing damage 22 Misalignment
9 Bearing quality 23 Base Frame deteriorate
10 Worn or loose bearing 24 Coupling bushes worn
11 Clearance of bearing 25 Coupling pin hole damaged
12 Internal Recirculation 26 Pipe Strain
13 Impeller Imbalance 27 Pipe Stress
14 Maximum size impeller 28 Pipe Support deteriorate

Step-5 Identify Cause 32

 Ishikawa (Fishbone) Diagram

Step-5 Identify Cause 33

 Problem • High Vibration in DCP1C pump
Why • Unbalanced Rotating Assembly
Why • Bearing Failure
Why • Misalignment
Why • Coupling Damage
Why • Base Frame Deteriorate
Why • Pipe Strain

Step-5 Identify Cause 34

 *Pipe strain is
unwanted pressure or
movement in piping
systems

Step-5 Identify Cause 35

STEP-6 IDENTIFY ROOT CAUSE

36
Step-6 Identify Root Cause 37
 Validation of possible Causes
Validating
Sr.No Probable Causes Valid Invalid
Techniques
1 Base Frame Deteriorate Observation √
2 Bearing wear out prematurely Data base √
3 Pipe Strain Expert Advice √
4 Frequency of Greasing is low Database √
5 Coupling Damaged Observation √
6 Misalignment Observation √
7 Improper Pump Assembly Database √
8 Bent Shaft Observation √
9 Bearing quality Data base √
10 Cavitation Observation √
11 Contaminated grease Observation √
Step-6 Identify Root Cause 38
 List of Validated Cause

Sr.No. Validated Causes

1 Base Frame Deteriorate
2 Premature Bearing wear
3 Misalignment
4 Coupling Damaged
5 Bent shaft
6 Pipe Strain
Step-6 Identify Root Cause 39
 Damaged Motor Old rusty and
coupling, deteriorated
coupling hole support plates
became oblong

Cause Cause
No 4 Rusty shim packing taken out No 1
Cause No 3
Step-6 Identify Root cause 40
 Cause
No 6
PUMP SUCTION /DISCHARGE PIPELINE WAS FIND OUT BY 3-4 MM

Pump suction
pipe cutting
done find out Pump discharge
by pipe cutting
approximately done find out by
5mm approximately
6mm

Step-6 Identify Root Cause 41

Step-6 Identify Root Cause 42
STEP-7 DATA ANALYSIS

43
 DCP#1 Pump bearing failure
25
DCP1A/B/C/D

20

Bearing Failure DCP1B/D/E

15
Record DCP1A/B/C/D/E DCP1A/B/C/E
DCP1C/E

10

No of bearing 5
Year Bearing failure
changed 0
2012 2013 2014 2015 2016
2012 9 DCP-1A/1B/1C/1D/1E

2013 9 DCP-1C/1E

2014 10 DCP-1A/1B/1C /1E

2015 10 DCP-1B/1D/1E

2016 20 DCP-1A/1B /1C/1D

Step-7 Data Analysis 44

 12-May-2016 23-July-2016

DCP-1C - DIRECT COOLING WATER PUMP-1C (12-May-16)

11-Oct-2016 06-Nov-2016

Step-7 Data Analysis 45

 25

Chart Title
20

Vibration reading mm/sec

15 May-16
Jul-16
Oct-16
Nov-16
Good
10
Satisfactory

0
1 2 3 4 5 6 7 8 9 10 11 12
Monthwise

Step-7 Data Analysis 46

Step-7 Data Analysis 47
STEP-8 DEVELOP POSSIBLE
SOLUTION

48
 Step-8 Develop Possible Solutions
Sr. Causes
No. Possible solutions
validated
1.1 Rusty portion of frame to be cleaned new
support plates should be welded and painted.
1.2 Base shim packing of brass material to be fitted
to avoid rusting and Deterioration
1 Pipe strain
1.3 Pipe supports fabrication to be done.
1.4 Suction and delivery pipe cutting/welding to be
done properly to Align pipe in line so that stresses
were not developed
2.1 New Coupling to be fitted
Coupling
2 2.2 Coupling Bushes to be replaced with new
Damaged
2.3 Coupling pin hole to be checked regularly in
preventive
3.1 Watermaintenance
Collecting Funnel to be fitted to avoid
Base
water spillage on base platform and foundation bolt
3 Frame
3.2 Proper housekeeping to be maintain
Deteriorate
3.3 Base frame to be painted
3.1 New Rotating Assembly to be Kept ready
4 Bent shaft 3.2 New Bearing to be fitted
3.3 Proper Alignment to be done

Step-8 Develop solution 49

 Solution Matrix

Impact
Sr. Cost of Time
No. Solution on Reversibility
implementation Impact
Total
quality
Suction and delivery pipe cutting/welding to
1 8 9 8 6 31
be done properly to Align pipe in line
Rusty portion of frame to be cleaned new
2 support plates should be welded and 3 9 6 9 28
painted
New coupling to be made ready with
3 9 9 9 9 36
boring the hole and keyway
New rotating assembly made ready with
4 9 9 9 9 36
new bearings
Base shim packing of brass material made
5 9 6 8 2 25
ready to avoid rust
Scale-on: 1 for weak relation, 3 for moderate relation, 9 for strong relation.
Step-8 Develop solution 50
STEP-9 FORESEE RESISTANCE AND PREPARE

51
Step-9 Foreseeing Probable 52
STEP-10 TRAIL IMPLEMENTATION

53
 Step-10 TRIAL IMPLEMENTATION PLANNING

Start Due
Causes Solutions Resp person Status and Actions
Date Date
To avoid New coupling to be made ready with boring New Coupling fabricated from CRS to avoid
Shirke/Rajam 3/5/2017 10/5/2017
Misalignment the Pinhole and keyway in Central Repair Shop Delivery delay
New rotating assembly made ready with new New Rotating assembly fitted which help to
Bent shaft Shirke 5/5/2017 6/5/2017
bearings and fitted to Pump solve misalignment due to bent in shaft
DCP1C Pump Base shim packing of brass material made Base frame Shim not get rusted so
Shirke/Rajam 07/05/2017 08/05/2017
Alignment ready to avoid rust Alignment Accuracy sustain
DCP1C Pump
Due to funnel Base frame deterioration
Gland leak water collecting funnels fabricated Ashirwad/ Mane 10/5/2017 12/05/2017
avoided and Housekeeping Maintain
spillage
Suction and Discharge Pipe cutted found
To remove Pipe Suction and delivery pipe cutting to Align
Rajam/Mane 14/05/2017 14/05/2017 suction pipe Out by 3mm and Discharge out
Strain pipe in line
by 4mm
Pump Rusty portion of frame to be cleaned new
New Support plate welded to base frame for
foundation support plates should be welded and Shirke/Mane 14/05/2017 14/05/2017
Strengthening
Strengthening painted
To avoid Piping Pipe and Pump Flanges aligned parallel
Pipe and Pump Flanges alignment Shirke/Prashant 14/05/2017 14/05/2017
Strain before tightening the bolts
Patch ring Fabricated and welded to pipe
DCP1C Pump Suction and delivery pipe welding to be
Rajam/Mane 15/05/2017 15/05/2017 joint to avoid stress development in pipeline
Pipeline Strain done properly
due to welding the pipe joint.
DCP1C Pump
Alignment to be done of Pump Suction and Helps to Know the Actual deflection in two
Pipeline Shirke/Prashant 15/05/2017 15/05/2017
Discharge Pipe Pipe joint
Alignment
New fabricated Coupling with New Bushes
To avoid New coupling with New Bushes to be fitted to
Shirke/Prashant 16/05/2017 16/05/2017 fitted which helps to maintain Alignment
Misalignment Pump & Motor
Accuracy
DCP1C Pump
Final Alignment to be done of Pump & Motor Shirke/Prashant 17/05/2017 17/05/2017 final Alignment done
Alignment

Step-10 Trial Implementation 54

 Gantt Chart for Implementation Activities
Commencing Date: 03/05/2017 Completion Date: 17-05-2017
Actual Pump Shutdown Date: 15/05/2017 - 16/05/2017

10/5/2017

11/5/2017

12/5/2017

13/5/2017

14/5/2017

15/5/2017

16/5/2017

17/5/2017
3/5/2017

4/5/2017

5/5/2017

6/5/2017

7/5/2017

8/5/2017

9/5/2017
Sr
.No
Activity

New coupling to be made ready with boring the Pinhole and

1
keyway in Central Repair Shop
New rotating assembly made ready with new bearings and
2
fitted in Pump

3 Base shim packing of brass material made ready to avoid rust

4 water collecting funnels fabricated

5 Suction and delivery pipe cutting to Align pipe in line

Rusty portion of frame to be cleaned new support plates

6
should be welded and painted

7 Pipe and Pump Flanges alignment

8 Suction and delivery pipe welding to be done properly

9 Alignment to be done of Pump Suction and Discharge Pipe

10 New coupling with New Bushes to be fitted to Pump & Motor

11 Final Alignment to be done of Pump & Motor

Step-10 Trial Implementation 55

 Cause
No 1
PUMP SUCTION /DISCHARGE PIPELINE WAS FIND OUT BY 3-4 MM

Pump suction
pipe cutting
done find out Pump discharge
by pipe cutting
approximately done find out by
5mm approximately
6mm

Step-10 Trial Implementation 56

 PROPOSED
PUMP SUCTION AND DELIVERY PIPELINE ALIGN INLINE SOLUTION
No 1

Suction and Discharge Suction and Discharge pipe Patch Ring

pipe Align in line Welding done after Alignment
Step-10 Trial Implementation 57
 PROPOSED
Motor foundation base support plate welded SOLUTION
No 3

Step-10 Trial Implementation 58

 PROPOSED
SOLUTION
PUMP DISCHARGE PIPELINE SUPPORT WELDED No 2

Support Painted
Support Rusted New Support Pipe Welded
Step-10 Trial Implementation 59
 PUMP ALIGNMENT DONE BEFORE AND AFTER WELDING OF PROPOSED
SOLUTION
SUCTION &DISCHAGE PIPELINE
No 4

Copper shim
fitted to base
plate for
Alignment

Step-10 Trial Implementation 60

 PAINTING DONE TO SUCTION & DISCHAGE PIPELINE AND PROPOSED
SOLUTION
SUPPORTS AFTER WELDING
No 4

Copper shim
fitted to base
plate for
Alignment
To avoid gland water leakage spillage
water collecting funnels fabricated

Step-10 Trial Implementation 61

 STEP-11 REGULAR IMPLEMENTATION

Preventive Maintenance of Pump should

Regular check in Each shift while in
be done monthly checking following
operation and note Variation/Abnormalities
parameter

2
a Coupling condition a Pump flow
b Coupling gap b Pump pressure
1 c Coupling Bushes condition c Motor current
d Gland follower status d Pump Noise
e Gland leak if change gland e Pump Vibration
f While gland replacement check sleeve condition Shutdown Check
g Pump/Motor foundation bolts a Pump Alignment
3
h Suction and Discharge valve operation b Pump Base Shim condition
i Flange joint bolts c Bearing Condition

Step-11 Regular Implementation 62

 Control Plan
Spec.
Input Decision
What's Limits / Measurement Control Sample Who/What Where
or Frequency Rule/Correctiv SOP #
Controlled? Require Method Method Size Measures Recorded
Output? e Action
ments
DCP#1
Water Gland Change the
Output ---- Visual ------ ------ ------ ---- Start/Stop
Spillage packing gland packing
SOP-01
Back If PRV not
PRV
pressure on Operation operated in DCP#1
operation In caster
pump due to Output 16 Kg/Cm2 ------ Pressure control automatically Start/Stop
break
which gland room operate it SOP-01
checking
leak. manually
Water If Funnel
CLIT DCP#1
spillage Choked clean
Output ---- Visual schedule ------- Every Shift Operator Log book Start/Stop
funnel and if broken
followed SOP-01
cleaning refabricate

Step-11 Regular Implementation 63

STEP-12 FOLLOW UP AND REVIEW

64
 28-Jun-2017

25
Vibration Analysis of DCP1C After QC
Vibration reading mm/sec

20

May-16
15
Jul-16
Oct-16
10 Nov-16
Good
Satisfactory
5 Jun -17

0
1 2 3 4 5 6 7 8 9 10 11 12

Readings

Step-12 Follow up and Reviews 65

 28-Jun-2017

5
Vibration reading after QC
4.5

4
Vibration Reading in mm

3.5

2.5 Good
Satisfactory
2
Jun-17
1.5

0.5

0
1 2 3 4 5 6 7 8 9 10 11 12
Readings

Vibration Reading is Satisfactory below Max 4.5mm

Step-12 Follow up and Reviews 66

 DCP1C Vibration Reading Before DCP1C After Quality Circle
Quality circle 25
25

Vibration Reading in mm
20
Vibration reading in mm

20 May-16
May-16 15 Jul-16
15 Jul-16 Oct-16
Oct-16 10 Nov-16
10 Nov-16 Good
Good 5 Satisfactory
5 Satisfactory Jun-17
#REF!
0
0 1 2 3 4 5 6 7 8 9 10 11 12
1 2 3 4 5 6 7 8 9 10 11 12 Readings
Readings

Vibration Reading was very High Max 10.74 mm /sec Vibration Reading is Satisfactory below Max 4.5 mm/sec

Step-12 Follow up and Reviews 67

 Self Evaluation by Team
What went well?
No more Base Frame deterioration
Water Spillage prevented by Funnel
Bearing life increased
No more Coupling Damaged
Pipe Strain removed
Alignment Accuracy increase
Reduction in stuffing box leakage
Increase the life of Pump rotating assembly
Pump Vibration decreased
Step-12 Follow up and Reviews
What could have been better?
Individual pump pressure/flow data should be
available on PLC
DCP1 Header strengthening to be done
Online Vibration checking Instrument should be
installed
Repair of caster zone 1 to 3 PRV
Suction Strainer should be installed on DCP1
pump
Individual caster zone wise pipeline Isolation
Pump changeover Schedule should be
followed strictly
Pump Non Return Valve should be
Repaired(Hydraulic Cylinder Rod need to lift)
Preventive Maintenance Schedule should be
followed
68
 PLANNED MONTH
Sr.No STEPS ------ Mar April May June
----- 15/3/2017 22/3/2017 29/3/2017 5/4/2017 12/4/2017 19/4/2017 26/4/2017 3/5/2017 10/5/2017 17/5/2017 24/5/2017 31/5/2017 7/6/2017 14/6/2017 28/06/2017
P
1 Identify Problems
A
P
2 Selection of problem
A
P
3 Define Problem
A
P
4 Analyze
A
P
5 Identify Causes
A
P
6 Identify Root Causes
A
P
7 Data Analysis
A
P
8 Develop Solution
A
P
9 Foresee Resistance
A
P
10 Trial Implementation
A
P
11 Regular Implementation
A
P
12 Follow up and Reviews
A
P-PLANNED Prepared By Rajam S D
A-ACTUAL Approved By Ajit mokal

Step-12 Follow up and Reviews 69

 Saving on Utility Maintenance Cost of Vendor for Pump
Overhauling(Rs30,000)Fabrication Service Charge(Rs40,000)Reduction in Bearing
Financial
Consumption(Rs13,802)and New Rotating Assembly replacement cost(Rs3,60,904)
Benefits Rs 4,44,706.54

Saving By avoiding Caster Breakout cost if Pump Failure

Rs17,00.000

Saving
@21.5 lacs

Step-12 Follow up and Reviews 70

 Milestone Chart
Data Collection
Brain Storming

Deming Wheel
C & E Diagram

4W-1H /5W-1H
Validity Chart
Flow Diagram

Pareto graph
Check Sheet

Graphs
Sr.
Problem solving Steps
No

1 Identification of Probem
2 Selection of Problem
3 Define the problem
4 Analyze the problem
5 Identification of causes
6 Root Cause Analysis
7 Data Analysis
8 Development of the solution
9 Foreseeing prob. Resistance
10 Trial impl/Check performance
11 Regular Implementation
12 Follow up/Review

71
 Project Completion sheet
QC Circle Project Completion Sheet
Name o f the QC Circ le : Missio n

De partme nt:Utility QCC Re g. No .:

Pro je c t Title :- High V ibration in DCP1C pump

Pro je c t Pr oje ct Clas s ification:

Classific ati P( ), Q( ),C( ),D( ),M ( Enviro nme
on ),S( ) Pro d uc tivity Quality Co st De live ry Safe ty Mo rale nt Othe rs

Te am Time plan
Sl. No . Name De ptt. Ro le Sl. No . Ste p Start Date End Date
1 M r. A jit S. M o kal U t ilit y F aci l i t at o r 1 D e f i ne 15.03.2017 29.03.2017
2 M r. S.D.Rajam U t ilit y Le a d e r 2 O b ser vat i o n 05.04.2017 12.04.2017
3 M .M .Shirke U t ilit y M e mb e r 3 A na l y s i s 19.04.2017 03.05.2017
4 M r. Harinrayan U t ilit y M e mb e r 4 A ct i o n 03-05-2017 17.05.2017
5 M r. A t ish B ho ir U t ilit y M e mb e r 5 C he c k 24.05.2017 31.05.2017
6 M r. A shirvad Pat il U t ilit y M e mb e r 6 S t a nd a r d i z a t i o n 28.06.2017 28.06.2017
7 M r. Prashant M o kal U t ilit y M e mb e r 7 C o nc l us i o n 28.06.2017 28.06.2017
Tre nd o f ac hie ve me nt, Be fo re A fte r graph
A c hie me nt:Id ent if y Perf o rmance o f DCP# 1 p ump s f o r Cast er d irect sp ray co o ling , f o und t hat it s
b earing f ailure and hig h vib rat io n d ue t o d et erio rat io n o f p ump s b ase f rame and p ip e st rain , So st ud y t he
vib rat io n read ing and t ake t he d ecisio n t o rep air b ase f rame and p ump shim rep lacement as well as remo ve t he
p ip e st rain, result b reakd o wn o f DCP# 1 p ump s is red uced .

Sl. No . Charac te ristic Base line Targe t A c hie ve d

impro ve d

1 Pump Vibr at ion 10.74 mm/s 3 t o 4 mm/s 4.1mm/s

Pump r ot at ing assembly

2 failur e 1 0 0
3
S.No Reason Cost in Rupees
Quotation from Vendor of pump for Overhauling ,
1 30,000.00
Financial Benefit (I f any ) installation and dial gauge alignment of pump
2 Fabrication service charges 40,000.00
(At t ach calculat ion sheet ) 3 Reduction in bearing consumption 13,802.00
4 Reduction in new rotating assembly replacement 360904.54
T otal Cost 444706.54

Ot her I nt angible Benefit s

Sign : Leader Sign: QC Cir cle Cor dinat or Sign: HOD

Business Excellence Dolvi 72

Business Excellence Dolvi