1

FLUID POWER
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 SGA CIRCLE “FLUID POWER”

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 ABOUT TATA STEEL

Established in 1907 at Jamshedpur, India and one of Asia's first integrated private
sector steel companies, the Tata Steel group is among the top-ten global steel
companies with an annual crude steel capacity of over 28 million tones per annum
(mtpa).A Fortune 500 company, it produces a spectrum of steel products and
mainly feeds the market sectors of construction, automobiles and engineering.

Post its globalization initiatives that established its presence in Europe and South
East Asia, Tata Steel is the world’s second-most geographically-diversified steel
producer, with operations in 26 countries and a commercial presence in over 50
countries.

The Group’s vision is to be the world’s steel industry benchmark in “Value

Creation” and “Corporate Citizenship” through the excellence of its people, its
innovative
4 approach and overall conduct.
FLOW SHEET OF AN INTEGRATED STEEL PLANT

O2 IGD
BOC

Blast
Furnaces

Slag

Hot metal

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QUALITY CIRCLE MEMBERS INTRODUCTION

Jaydeep Rathod - leader Shubhadip Nandi-Member

Facilitator-Srinivas Rao

Shruti Subhashini-Member
Kanhu Charan Swain- Member

Upendra nath Mahanta - Member Vishal Kumar Rajak-Member Shubham kumar giri - Member
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 QUALITY CIRCLE DETAILS

Department- Maintenance Engineering department.

Section - Hydraulic Group
Registration No - SG00007859 ,
No of Kaizen till date- 97
Saving from Kaizen till date – 50 lakhs
Start date of present case study - 05/03/16
Date of completion of present case study -28/07/16
Circle meets on every - Friday 4.00 PM
Average % of attendance - 96%
No's of meeting for this project - 10

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 FUNCTIONS OF HYDRAULICS GROUP
WE ARE THE CENTRALISED EXPERT SERVICE PROVIDER
Blast Furnaces Coke Plant Sinter Plant
Lime Plant

New Bar Mill

Merchant Mill
MED
Wire Rod Mill MECHANICAL
HYDRAULIC
GROUP Hot Strip Mill
Pellet Plant

Cold Rolling Mill

Machine Shop

LD#3 & TSCR L D Shop # 1 L D Shop # 2 8

PROBLEM SELECTION

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 PROBLEM IDENTIFICATION
Catg.
SL.NO Problem
A/B/C
1 Excessive time consumption for cleaning of hydraulic cylinders externally during repair. A
2 Problem in assembly of hydraulic cylinders vertically in time efficient manner A
3 Problem in testing of big hydraulic cylinder at high pressure. B
4 Problem in testing of LD#1 CC#1 Turret lifting hyd. cylinder A
5 Problem in handling of Hand Pump on shop floor. C
6 Failure of silo gate power pack at Slag granulation plant . B
7 Frequent failure of band saw at Bar Mill. A
8 Frequent failure of Hyd. cylinder of wheel on boom reclaimer at Sinter plant. B
9 Failure of Mud gun cylinder at 'F' Blast Furnace . C
10 Problem of loading unloading in Skoda machine power pack at Engg. Shops. B
11 Problem due to contaminated oil in Test Rig Power Pack. A
12 Problem of testing of hydraulic cylinders in any intermediate position in the barrel A
13 Frequent failure of valves of 1000T press at Machine shop. A
14 Centring problem of hot metal filled ladle during emergency situation of Combined car . B
15 Frequent failure of Gas reversing cylinders at coke plant. C
16 Contamination problem of wagon tippler power pack oil at M.H.S B
17 Problem in use of the intensifier, where Air supply is not available. A
18 Problem in over travel of Tundish cover plate at LD # 1 , CC # 1, Tundish Car # 2. B
19 Failure of coal bunker gate hyd. cylinder at coke plant. C
20 Problem of compactor hydraulic system at WRM B
21 Problem of handling of heavy components inside the hydraulic lab. B
22 Frequent failure of motion control valve at Bar Mill C
23 Frequent failure of Hyd. Pump at Refractories production department B
24 Frequent failure of DS Door cylinder of LD#3 A
25 Failure of silo gate power pack at Slag Granulation Plant C
26 Frequent failure of band saw at Bar Mill B
27 Frequent failure of hyd. Cylinder of wheel on boom reclaimer at Sinter Plant B
28 Life enhancement of Withdrawal & Straightener cylinder at LD # 1,CC#1 from 1month to 6 months. A
29 Problem of loading unloading in Skoda machine power pack at Engg. Shop B
30 Jerky motion of combined hot metal car hyd. Cylinders at Ld Shop # 2 C
 PROBLEM IDENTIFICATION
Catg.
SL.NO Problem
A/B/C
31 Failure of skirt hyd. Cylinder at LD Shop # 2 B
32 Failure of coal bunker gate hyd. Cylinder at Coke Plant A
33 Frequent failure of valves of 1000T press at Machine Shop B
34 Failure of hyd. Motor of down coiler at Hot Strip Mill C
35 How to minimise customer complaint regarding repaired pumps at hydraulic lab. A
36 Contamination problem of Wagon tippler power pack oil at M. H. S. B
37 Wastage of Nitrogen gas during accumulator charging C
38 Frequent failure of Rexroth make A10VSO Pumps B
39 Frequent failure of withdrawal winch of SCP machine at Coke Plant B
40 Frequent failure of pump at CMH machine trolley power pack C
41 Frequent failure of CNC lathe at WRM C
42 Failure of mobile wall cylinder at Coke Plant B
43 Oil Contamination problem of Merchant Mill breaking device at power pack B
44 Problem of oil flow measurement at test rig at Hydraulic Lab. C
45 Frequent failure of solenoid voltages of test rig at Hyd Lab. C
46 Problem of oil leakage at D. S. Slag racking machine A
47 Frequent failure of direction control valve at surface grinding machine B
48 Problem of excess vibration at D. S. Slag racking machine of Ld Shop # 2 B
49 Problem of high oil temperature at CMH machine at Bar Mill B
50 Problem of oil leakage at Rotary joint at LD Shop # 1 C
51 Problem of high oil temperature of damage blower power pack at Power Engg. B
52 Frequent failure of Vicker’s make CM-11 valve at Coke Plant B

A : Minimum Involvement of other Department.

B : Involvement of other Department is a Necessity .
C : Management Sanction may be Needed in Implementing the Solution.
 PROBLEM PRIORITIZING AND SELECTION
Categorization of the total 52 no's of problem statements.

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23

18

A B C

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 Sorting of Group-A problems
We have successfully resolved all 23 ‘A’ category problems in FY 17 through
our Quality circle activities. Only selection of case study for presentation in
higher forum is to be carried out.
our team has distributed these 23 problems in accordance to criteria like;
Productivity, Quality, Cost, Delivery, Safety and Moral(PQCDSM).

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12
No. of problem

10

3 4
5 2

1 1
0
Quailty cost Delivery Safety Production Moral
our Production criteria is ‘Number of cylinders repaired‟ and Quality means ‘Quality
of repaired cylinder to provide necessary reliability of the hydraulic equipment‟. So
that after installation it should run trouble free in its full span of life.
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 PROBLEM SELECTION

Implementati
Availability
Costumer

Potential
on cost

saving
Safety
Need

Rank
Total
S.No Problem

LAYING OUT STEEL PIPING TO ENSURE MINIMUM USAGE OF HOSES AT

1 HYDRAULIC LAB
3 5 10 2 6 26 9th

PLACING BIG CYLINDERS AND HEAVY HYDRAULIC EQUIPMENTS ON

2 THEIR PROPER STANDS IN CYLINDER SHOP.
3 7 3 7 5 25 10th

ARRANGEMENT OF SLIDING WINDOW IN STAFF ROOM OF HYDRAULICS

3 MED (M)
2 2 10 2 4 20 11th
PROBLEM OF FREQUENT FAILURE OF DS DOOR CYLINDER AT LD # 3 DUE
4 TO DAMAGE IN ROD
12 10 12 11 12 57 1st
PROBLEM OF FREQUENT FAILURE OF SHEAR FRAME MOVEMENT
5 CYLINDER OF TSCR AREA#3
8 12 11 3 10 44 2nd
MAKING PROPER ARRANGEMENT FOR DISMANTLING THE PISTON ROD
6 OF BELT CONVEYOR CYLINDER OF PELLET PLANT.
6 1 9 8 2 30 6th

PROBLEM OF DAMAGE OF PISTON ROD DURING TESTING OF CYLINDER

7 IN ‘HYDRAULIC CYLINDER REPAIR SHOP’
10 5 10 9 9 43 3rd

8 DRILLING MORE SAFELY ON SHOP FLOOR 1 4 5 2 6 18 12th

9 OPENING OF THE GRUB SCREW IN PISTON HAVING DAMAGED THREAD 5 10 9 3 9 36 4th

TO IMPROVE WORK PLACE SAFETY DURING TESTING OF HYDRAULIC
10 MOTOR AT CYLINDER REPAIR SHOP.
11 8 7 1 7 34 5th

11 OPENING THE WATER JACKET OF BILLET LIFTER CYLINDER 9 3 3 5 9 29 7th

12 OPENING THE PISTON OF TURRET CYLINDER 2 2 10 2 4 27 8th

‘thro’ Nominal Group Technique Scale 1 12

Low High
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 LINKAGE OF THE IDENTIFIED PROBLEM WITH
DEPARTMENTAL & ORGANISATIONAL GOAL
EFFECT ON DEPT. ORGANISATION VISION
OPERATION GOAL GOAL 2018

Zero
Increased
Life of cylinder Accident
Availability Reduce
of DS DOOR in maintains
LD#3 Low cost
Cost
Reduce
PROBLEM OF Cost
FREQUENT Clean
FAILURE OF DS Value
Environment Creating
DOOR CYLINDER
AT LD # 3 DUE TO Partnership
DAMAGE IN ROD.
Increase
availability Happy
Safe working Employee
condition Improve
Quality

Customer Sustainable
Growth
Satisfaction

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 Case - Problem of Frequent failure of DS Door
cylinder at LD#3 due to damage in rod.

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 DS FRONT DOOR DOOR CYLINDER IN OPERATION

Definition of problem
The front door of each DS in LD#3 operated with the help of 2 hydraulic cylinders
which are placed vertically. Due to leakage in the cylinders, operational difficulties
are encountered and safety hazard is created. The objective of the project is to
achieve zero leakage failures for uninterrupted DS process . Changing of each
20 20
hydraulic cylinder need 4hrs plant down.
 IMPACT OF PROBLEM
Due to DS Front Door Cylinder.
1.Chance of Fire because of oil leakage from hydraulic cylinder.

2. If Cylinder fails, Door will not move. Environment will be polluted by the
fumes and hot metal spatter may create safety hazard.

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 OBJECTIVE OF THE PROJECT

1. Elimination of hydraulic cylinder failure in between campaign of DS.

2. Improvement in reliability and hence availability of DS door cylinder ,

3. Elimination of production interruption.

4. Eliminate the hot metal spatter for making safe workplace

5. Eliminate environment pollution due to fumes generated during

process.

6. Reduce maintenance cost.

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 ANALYZING OF PROBLEM

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 ANALYSIS OF PROBLEM
4W & 1H Analysis
Study of the problem was done by using 4W 1H (except Why) and problem was
analysed.
When Who is How does
What is Where is
the responsible it cause
the the
problem for the the
problem ? Problem?
arises ? problem? problem?
When door
Delay or No  No
lower/lift
production Door lifting movement
Door lifting interrupt by
due to front hydraulic in door
Mechanism. two
door cylinder .
hydraulic
cylinders.

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 IDENTIFY THE CAUSES

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 FINDING OUT CAUSES (C & E DIAGRAM)
To draw cause effect and diagram we have done brain storming to find out all probable
causes for cylinder failure & fire incident due to oil leakage problem. We have organised
causes in to main cause, sub cause and made the fish bone diagram.
Sl no PART OF SYSTEM CAUSE SUBCAUSES (SUGGESIONS)

01 Man 1. poor maintenance practice. a. Improper mounting skill

2. Knowledge gap b. Lack of training
c. Uncomfortable working area

02 Machine 1. Problem in design of cylinder. a. Much longer stroke length.

2. Fire b. Misalignment.
3. Problem in operation of cylinder.. c. Unbalance due to position of cylinder.
d. Gland seal Failure.
e. Electrical spark
f. Loosen of piston
g. Cylinder seal burn due to heat area.

03 Material 1. Cylinder material . a. Oil quality.

2. Gland seal failure. b. High temperature.
c. Seal material is not proper for application.

04 Method 1. Wrong assembly of cylinder a. SOP not followed.

2. Wrong or loose mounting of cylinder. b. Not aware of job steps.
c. Assembly Process not proper

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 CAUSE-EFFECT ANALYSIS
Cylinder failure, Chance of fire due to oil leakage

MAN MACHINE
Lack of Long stroke length Cylinder
training unbalance due to
Problem in design of Misalignment
Knowledge mounting
gap cylinder
Uncomfortable
working area Gland seal Problem in operation
Poor Maint. failure Loosen of of cylinder
Practice piston Seal burn due to high heat area
Fire
Improper External leakage
Mounting SKILL form hydraulic Electrical spark
cylinder Cylinder failure,
Cylinder life over
SOP not followed Seal life over
Cylinder
Wrong assembly of
material High Temp.
hydraulic cylinder
Not aware of job steps
Loose mounting material not compatible with
of cylinder application
SOP not followed Gland seal material not
material compatible with
environment

METHOD27 MATERIAL
FEASIBILITY TEST OF C&E DIAGRAM THROUGH S.L.D. TABLE

Sl PART OF CAUSE SUBCAUSES (SUGGESIONS) LIMITATIONS DECISION

no SYSTEM
01 Man 1. poor maintenance practice. a. Improper mounting skill a. Trained operator a. Not accepted
2. Knowledge gap b. Lack of training b. Trained operator b. Not accepted
c. Uncomfortable working area c. Not feasible c. Not accepted
02 Machine 1. Problem in design of a. Much longer stroke length. a. Checked OK a. Not accepted
cylinder. b. Misalignment. b. Checked OK b. Not accepted
2. Fire c. Unbalance due to position of c. Checked OK c. Not accepted
3. Problem in operation of cylinder.
cylinder.. d. Gland seal Failure. d. Found damaged d. Accepted
e. Electrical spark e. Checked OK e. Not accepted
f. Loosen of piston f. Checked OK f. Not accepted
g. Cylinder seal burn due to g. Checked OK g. Not accepted
heat area.
03 Material 1. Cylinder material . a. Oil quality. a. Checked OK a. Not accepted
2. Gland seal failure. b. High temperature. b. Checked OK b. Not accepted
c. Seal material is not proper c. Checked OK c. Not accepted
for application.

04 Method 1. Wrong assembly of cylinder a. SOP not followed. a. Trained operator a. Not accepted
2. Wrong or loose mounting b. Not aware of job steps. b. Checked OK b. Not accepted
of cylinder. c. Assembly Process not proper c. Checked OK c. Not accepted

Outcome of above analysis:

After validating all causes and sub causes our team have concluded that Gland seal
failure is main cause of concern. So we have to collect data on gland seal failure problems
only. 28
 IDENTIFY ROOT CAUSES

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 ROOT CAUSE IDENTIFICATION
Gland seal failure: why-why technique
Gland Seal Failure

Why Why
Why
Burning of gland Oil contamination and
Scoring on piston rod
seal low viscosity

Why
Why
Piston rod come in touch
with metal male header of
gland seal
Due to high temperature
Why

Design defect
Why

Checked and found

temperature within range

Check with particle count machine found OK-

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CROSS SECTION OF HYDRAULIC CYLINDER

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HYDRAULIC CYLINDER SEAL ARRENGEMENT
BEFORE

Old Gland seal profile

 DEVELOPING SOLUTION

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 ROOT CAUSE
Design insufficiency was the root cause. It comprised of the
component:
1. Metallic male header which is used in V-pack gland seal.

BRAINSTORMING FOR FEASIBLE IDEAS

FEASIBILITY TEST THROUGH S.L.D. TABLE
S.NO SUGGESTIONS LIMITATION DECISION
To replace metallic male header with
1 Feasible and economical Accepted
other softer material.
Not feasible as V-Pack design Not
2 To modify gland seal profile. is proper for this application Accepted
To increase clearance between Not feasible due to sealing Not
3
Piston rod and gland. purpose not fulfilled Accepted

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FORESEEING PROBABLE
RESISTANCE

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 FORESEEING PROBABLE RESISTANCE
Implemented
S.No Resistance to implement Remedial solution
solution

Finding out material which can

give proper strength for Discuss with Design
application and better life of group and seal
cylinder. manufacturer

To replace metallic
male header with
1
other softer
material.

Filtering out the Supplier who

can give this chosen material Taking help of our expert
gland seal of same profile and and approved vendors.
correct dimensions.

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TRIAL IMPLEMENTATION
PLAN

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 SOLUTION IMPLEMENTATION BY PDCA CYCLE

PLAN

Action plan for job allocation

S.NO JOB DESCRIPITION TARGET DATE REPONSABILITY REMARKS
Dimension measurement for Jaydeep , Done
1 15-03-2016
gland seal male header Shruti
Drawing development for new
2 18-03-2017 Shubhadip Done
male header.
To polishing and buffing on piston 22-03-2016 Shubham,
3 Done
rod Vishal,
To assemble with new brass male Shubham ,
4 26-03-2016 Done
header gland seal and test . Kanhu

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 Replace metallic male header with brass
male header.

Steel male header of V-Pack gland Brass male header of V-Pack gland
seal seal
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 CHECK
•Checked and found no gland seal leakage after 20 times operation in
test bench.

•Mark on modified cylinder and Send cylinder to LD-3 DS for use.

•Life of modified cylinder achieved more than 3 months but after that
again gland seal failure was identified

ACT
• Standardization :- Nil

•Conclusion :- Further improvement required.

Team members started brain storming for probable cause of gland seal failure,
All probable cause set in the cause and effect diagram for finding of root cause.

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Data Collection of Cylinder failure From March-16 to July-16

Sl.no Date Problem

1 07-03-2016 Gland seal damaged

2 07-03-2016 Piston rod Scoring

3 22-06-2016 Piston Scoring

4 22-06-2016 Piston Sealing problem

5 25-06-2016 Gland seal damaged

6 25-06-2016 Piston rod Scoring

7 25-06-2016 Piston Sealing problem

8 12-07-2017 Gland seal damaged

9 12-07-2017 Piston Scoring

10 13-07-2017 Piston Sealing problem

11 13-07-2017 Piston Scoring

12 13-07-2017 Gland seal damaged

 Pareto analysis
Category No .of problem Cumulative data in %
Gland seal damaged 4 33.3
Piston Scoring 3 58.3
Piston sealing problem 3 83
Piston rod Scoring 2 100

12 100
Vital few
90 1. Gland seal damaged.
10
80
2. Piston scoring.
70
8
3. Piston sealing Problem
60

6 50
Use full many
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4 1. Piston Scoring.
30

20
2
10

0 0
Gland seal damaged Piston Scoring Piston sealing Piston rod Scoring
problem
 FINDING OUT CAUSES (C & E DIAGRAM)
To draw cause effect and diagram we have done brain storming to find out all probable cause
of Gland Seal failure,. We have organised causes in to main cause, sub cause and made the
fish bone diagram.
Sl no PART OF CAUSE SUBCAUSES
SYSTEM
01 Man 1. poor maintenance practice. a. Improper mounting skill
2. Knowledge gap b. Lack of training
c. Uncomfortable working area

02 Machine 1. Misalignment of cylinder. a. Misalignment.

2. Problem in seal design of cylinder.. b. Unbalance due to position of cylinder.
c. Gland seal design .
d. Long stroke length

03 Material 1. Piston rod material . a. Cylinder seal burn due to heat area ,High
2. Gland seal material. temperature.
b. Gland seal is not proper.

04 Method 1. Wrong assembly of cylinder . a. SOP not followed.

2. Improper mounting of cylinder b. Not aware of job steps.
c. Assembly Process not proper.

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 CAUSE-EFFECT ANALYSIS
Cylinder failure, Chance of fire due to oil leakage
MAN MACHINE
Lack of Cylinder
training unbalance due to
Problem in design of Misalignment
Knowledge mounting
cylinder
gap
Uncomfortable Misalignment of
working area Gland seal
design
cylinder
Poor Maint. Long stroke length
Practice
Improper
Mounting SKILL
Gland seal failure
Cylinder life over
SOP not followed
Piston rod
Wrong assembly of Seal life over
material
hydraulic cylinder
Not aware of job steps Gland seal
Improper material not compatible with material
mounting of application
cylinder SOP not followed Seal burn due to Improper seal
high heat area

METHOD44 MATERIAL
 FEASIBILITY TEST OF C&E DIAGRAM THROUGH S.L.D. TABLE
Sl PART OF CAUSE SUBCAUSES
no SYSTEM
01 Man 1. poor maintenance practice. a. Improper mounting skill a. Trained operator a. Not accepted
2. Knowledge gap b. Lack of training b. Trained operator b. Not accepted
c. Uncomfortable working area c. Not feasible c. Not accepted
02 Machine 1. Misalignment of cylinder. a. Misalignment. a. Checked OK a. Not accepted
2. Problem in seal design of b. Unbalance due to position of b. Checked OK b. Not accepted
cylinder.. cylinder.
c. Gland seal design . c. Checked OK c. Not accepted
d. Long stroke length d. Checked OK d. Not accepted

03 Material 1. Piston rod material . a. Cylinder seal burn due to heat a. Checked OK a. Not accepted
2. Gland seal material. area ,High temperature.
b. Gland seal is not proper. b. Not equipped b. Accepted

04 Method 1. Wrong assembly of cylinder . a. SOP not followed. a. Trained operator a. Not accepted
2. Improper mounting of b. Not aware of job steps. b. Trained operator b. Not accepted
cylinder c. Assembly Process not proper. c. Checked OK c. Not accepted

Outcome of above analysis:

After validating all causes and sub causes our team have concluded that Gland seal is
not proper is main cause of concern. So we have to collect data on gland seal material
problems only. 45
 ROOT CAUSE IDENTIFICATION
Gland seal failure: why-why technique
Improper gland
seal
Why
Why

Gland seal material Gland seal design

Why Why
Brass chips are coming out
and damage gland seal Why
Burning of gland
Why seal material

Brass male header is Why

rubbed with piston rod,

Why Due to high temperature

Brass male header is

used in gland seal
Checked OK

Why
Metallic Male Checked and found OK
header

46 Why
Design defect
 ROOT CAUSE
1. Metallic male header of gland seal was the root cause.
2. Piston sealing Problem (Solved by JDI process)
3. Scoring on Piston (Solved by JDI)

BRAINSTORMING FOR FEASIBLE IDEAS

FEASIBILITY TEST THROUGH S.L.D. TABLE
S.NO SUGGESTIONS LIMITATION DECISION
To replace Metallic male header
1 Feasible and economical Accepted
with reinforced fabric material.
Not feasible as V-Pack design Not
2 To modify gland seal profile. is proper for this application Accepted
To increase number of piston seal
for better life of Cylinder and
3 Feasible and economical Accepted
prevent damage of piston seal
from misalignment
To replace PTFE bearing strip with
4 fiber reinforced PTFE material Feasible and economical Accepted
47 for better sealing in heat area
 FORESEEING PROBABLE RESISTANCE
Implemented
S.No Resistance to implement Remedial solution
solution
Finding out the reliability and
other properties of new seal Discuss with Design
material for better life of group , expert and seal
To replace Brass cylinder. manufacturer
male header with
1
other sealing Filtering out the Supplier who
material. can give this chosen material Taking help of our expert
gland seal of same profile and and approved vendors.
correct dimensions.

Space is a constraint for Discuss with expert and

2 To increase no of piston
increasing no of seal in piston. approved vendor for
seal.
selecting less width seal

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 PDCA CYCLE-2

2 PLAN
Action plan for job allocation
S.NO JOB DESCRIPITION TARGET DATE REPONSABILITY REMARKS
Dimension measurement for Jaydeep,
1 12-07-2014 Done
gland seal male header Shruti
Drawing development for new Done
2 15-07-2014 Shubhadip
male header.
To assemble with new fiber
reinforced material male header Shubham,
3 26-07-2014 Done
gland seal and other new Kanhu
designed seals

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 DO

Check sheet for design and

dimension

50
 DO
Before After

Metallic male header of

Fibre reinforced male
V-pack seal
header in V-pack seal

51
 DO
Before After

Dual point piston seal for

Single point piston seal
better sealing

52
 DO

PTFE bearing strip

Fabric Reinforced Bearing strip

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 CHECK
•Checked and found no gland seal leakage after 20 times operation in test bench.

•Mark on modified cylinder and Send cylinder to LD#3 DS for commissioning.

•Life of modified cylinder achieved more than 10 months.

ACT
•Standardization :- Modified the Standard Operating Procedure of cylinder
repairing.

•Conclusion:- Eliminate Cylinder Failure of LD#3 DS door cylinder.

•Horizontal Deployment- Seal modification of all

Cylinders of DS front door.

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 PERFORMANCE ANALYSIS
List of Before
S.no After implementation
problem implementation

1 Gland seal Gland seal failure Problem eliminated.

2 Piston rod Piston rod Scored Problem eliminated.

Safety and Unsafe and Safe and clean work

3
environment pollution condition

Customer Satisfied performance

4 Unsatisfied
satisfaction reported

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FOLLOW UP AND REVIEW

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 Follow up/Review & Recurrence Prevention
•Standardised the safe operating procedure MED(M)/HYD/SOP/HD/03/14

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Follow up/Review & Recurrence Prevention
•Training given on SOP to improve skill and knowledge.

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 Follow up/Review & Recurrence Prevention

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 TANGIBLE &INTANGIBLE BENEFITS

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 QC Tools and Techniques

Techniques QC Tools
Brain Storming Cause And Effect Diagram
Why-Why Analysis Pareto Analysis
 Decision Matrix PDCA Cycle
Data Collection
 Graphs and Charts

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 Future Plan

We are working on :
To develop correct procedure to
reconditioning and testing of TCSR
caster segment cylinder.

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 OUR DEDICATION

FLUID POWER
“Innovation is creativity with a job to do.”

- John Emmerling

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