Ankur Final Ppt

8/7/2019 Ankur Final Ppt

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Welcomes You All


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Status ReportStatus ReportDATE OF INAUGURATION 18/01/2011

WORKING AREA ANP PLANT

TOTAL NO. OF MEETINGS 10

MEETINGS THIS YEAR 10

DAY OF MEETING MONDAY, FRIDAY

ATTENDANCE 90 %

TIME OF MEETING 02:00 P.M. & 7:00 P.M

MEETING VENUE WELFARE BLOCK

PROBLEMS IDENTIFIED 20

PROBLEMS SOLVED 01

PROBLEMS IMPLEMENTED 01


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AnkurAnkurQuality Circle TeamQuality Circle Team

Leader : Mr. D.K.Wagh.

Dy. Leader : Mr. Mahesh Jadhav.

Members : Mr. S.P.Wagh.Mr. V.D Gadekar.

Mr. Sunil Auti.

Mr. Nilesh Babar

Mr. S.R. Mane.


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Facilitator P.D.KHAIRNAR

Plant Coordinator P.K. BHOWMICK

Q.C. Coordinator SAGAR BOREKAR

Chief Coordinator SURLI KUMAR

Operation Manager R.K. BANSAL

AnkurAnkurQuality Circle TeamQuality Circle Team


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Brain StormingBrain Storming


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1) FREQUENT V RI TI N IN IZE F RANUALUESAT

RANULATI NSECTI N. >>> A

2) SCALEFORMATION INSI E ALLMILL URINGTHEUSEOF

ETROCK HOSPHATE. >>>

3) UN-UNIFORM ISTRI UTIONOFMATERIALON VI RATORY

SCREENSATGRANULATIONSECTION. >>>4) SETTLINGOFSAND INSIDENEUTRALIZERHEADTANK. >> A

5) FREQUENTCHOKINGANDRESTRICTION INEVAPORATOR

FEEDLINE. >>> C

6) MOREAMOUNTOFEFFLUENTGENERATEDDURINGHIGH

LOADOFPLANT. >>> C

7) SCRUBBERNOZZLECHOKING. >>> B8) SPILLAGESATFINESCONVEYOR >>> A

9) CYCLONECHOKING >>> A

10) CHOKINGOFFILLERBINHOPER >> A

Contd.

Identification of ProblemsIdentification of Problems


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Identification of ProblemsIdentification of Problems11) EXCESS DUST AT 7MTR RECYCLE BELT AT

GRANULATION C

12) REMO AL OF WET MATERIAL FROM COOLER WHEN IT IS

SHUTDOWN FOR LONGER PERIOD B

13) RIGIDITY OF SCREEN FEED ELE ATOR DAMPER B

14) NO PROPER PLACE FOR TOOLS SUCH AS LE ER. A

15) INEFFICIENCY OF IBRATORY SCREENS AT GRANULATIONSECTION. >> C

16) WASTAGE OF TIME IN DECHOKING OF INLET CHUTE OF

DRYER INLET. B

17) SCALING FORMATION INSIDE THE GRANULATOR. B

18) LOW CONCENTRATION OF UREA SOLUTION TO

DISSOL ER A

19) FREQUENT TENDENCY TO GO OFFCENTER OF FILTER

CLOTH C

20) NO FREE FLOW OF ROCK FEEDING TO BC-1 WHEN ROCK

IS WET C Total Problems identified = 20


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Categorization of ProblemsCategorization of Problems((A,B,CAnalysisA,B,CAnalysis))

A >>>> PROBLEMS CAN BE SOLVED BY QC MEMBERS

B >>>> PROBLEMS CAB BE SOLVED BY TAKING HELP FROM

OTHER DEPARTMENT.

C >>>> PROBLEMS THAT CAN BE SOLVED BY TAKINGHELP FROM TOP MANAGMENT


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Problems from ACategoryProblems from ACategorySr.No Problems

1 FREQUENT ARIATION IN SI E OF GRANUALUES AT

GRANULATION SECTION.

2 SETTLING OF SAND INSIDE NEUTRALI ER HEAD TANK.

3 DUSTING AT RECYCLE BELT CON EYOR.

4 CYCLONE CHOKING.

5 CHOKING OF FILLER BIN HOPER.

6NO PROPER PLACE FOR TOOLS SUCH AS LE ER.

7 LOW CONCENTRATION OF UREA SOLUTION TO

DISSOL ER.


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Problems from BCategoryProblems from BCategory

Sr.No Problems

1 UN-UNIFORM DISTRIBUTION OF MATERIAL ON

IBRATORY SCREENS AT GRANULATION SECTION.

2 SCRUBBER NO LE CHOKING.

3 REMO AL OF WET MATERIAL FROM COOLER

WHEN IT IS SHUTDOWN FOR LOOGER PERIOD.

4 WASTAGE OF TIME IN DECHOKING OF INLET

CHUTE OF DRYER INLET.

5 RIGIDITY OF SCREEN FEED ELE ATOR DAMPER

6 SCALING FORMATION ON CANOPY INSIDE THE

GRANULATOR.


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Problems from CCategoryProblems from CCategorySr.No Problems

1 SCALE FORMATION INSIDE BALL MILL DURING THE USE

OF WET ROCK PHOSPHATE.

2 FREQUENT CHOKING AND RESTRICTION IN

E APORATOR FEED LINE.

3 MORE AMOUNT OF EFFLUENT GENERATED DURING

HIGH LOAD OF PLANT.

4 EXCESS DUST AT 7MTR RECYCLE BELT AT

GRANULATION

5 INEFFICIENCY OF IBRATORY SCREENS AT

GRANULATION SECTION.6 FREQUENT GOING OF OFFCENTER OF FILTER CLOTH

7 NO FREE FLOW OF ROCK FEEDING TO BC-1 WHEN

ROCK IS WET .


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5.4

5.6

5.8

6

6.2

6.4

6.6

6.8

7

7.2

C ategory A C ategory B C ategory C

Total Problems identified = 20

Categorization of ProblemsCategorization of Problems((A,B,CAnalysisA,B,CAnalysis))


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Brain stormingBrain storming


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Selection from BCategorySelection from BCategory

Sr.

No

Problems Frequency/

month

B1 RIGIDITY OF SCREEN FEED ELE ATOR DAMPER. 4

B2 SCRUBBER NO LE CHOKING. 3

B3 REMO AL OF WET MATERIAL FROM COOLER WHEN IT

IS SHUTDOWN FOR LONGER PERIOD.

2

B4 WASTAGE OF TIME IN DECHOKING OF INLET CHUTE OF

DRYER INLET.

4

B5 UN-UNIFORM DISTRIBUTION OF MATERIAL ONIBRATORY SCREENS AT GRANULATION SECTION

5

B6 SCALING FORMATION ON CANOPY IN GRANULATOR. 8


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Selection from BCategorySelection from BCategory

(Priority given to frequency)(Priority given to frequency)

0

1

2

3

4

5

6

7

8

B1 B2 B3 B4 B5 B6

Frequency/month


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Problem IdentifiedProblem Identified


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crystallisation

Neutral-

isation

Evapo-

rationB.M.T.

CN

Reactor

AN Conc.Unit

80 % ANCentri-fugation

Ground

RockDissolution

Calcium

carbonateML-I

ML-II

ML-III

Vap. Amm.

CN

CRYSTALS

ML60 % NAP.A.

60 % NA

Biproduct

Biproduct

60 % ANFilter

Vap. Amm.

Co2

Granulation

Plant

Bagg.

Plant

ANPPl ntPr cess Fl w di grANPPl ntPr cess Fl w di gr


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Dryer Exit

BeltScreen Feed

Elevator

Screen

Crusher

Recycle

Elevator

Cooler

NP slurry

NH3

Recycle

Conveyor

CoaterTo Bagging

DryerGranulator

Proper

sizeOver

size

Under

size

Flo diagram ofgranulation sectionFlo diagram ofgranulation section


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Problem inside GranulatorProblem inside Granulator

Scales & lumps formed

NP Slurry

NH3

Recyclegranules

To Dryer


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Brain StormingBrain Storming


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Lumps

formation on

Canopy in

granulator

Man Material

MachineMethod

Very busy

Negligence

No care ofimproving

Productivity

De-scaling and

Removal of scale

is difficult taskActivity needs

more time

laziness

Negativeattitude

Defective

MOC

Tendency toform lumps

Manufacture

defect

Affinity tomoisture

Hygroscopicnature

Confined

space

Less area formovement

Entering the Granulator

for cleaningLess

illumination

Less

ventilation

Area to be keptsealed

It is a path for

granules

No Online

de-scaling

Triangular

surface for

canopy

Removing scale

after de-scaling

Cant

change

Cause & effect DiagramCause & effect Diagram

Low concentration

of slurry


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Validity Chart for findingroot causeValidity Chart for findingroot cause

Sr Causes Observation Remark

1. Negligence inwork Nonegligence invalid

2. Attitude ofstaff Attitude is positive Invalid

3 Lumps formationon

canopy

No Online arrangementfor

descaling

Valid

4. Triangular surface of

canopy

Suitable foroperation

Requiredto protect lines

invalid

5. Stationary canopy It cannot be rotatory invalid

6. Hygroscopic slurry Nature cannot be change invalid


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Root CauseRoot Cause


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Brain stormingBrain storming


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SolutionSolution -- 11

Online hammering of

Canopy

No proper approach


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Providing air hose over

canopy surface

More dust formation


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Provision of vibrators over

canopy

Not feasible/ No space

available


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Providing steam line to

flush from top of canopy to

remove scaling

Online flushing is possible &

will reduce lumps formation

Accepted


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Scales & lumps formed

NP Slurry

NH3

Recycle

granules

To Dryer

Steam

flushing

Suggested Modification(Online Steam flushing)


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Implementation StatusImplementation Status

IMPLEMENTATION ON22th JANUARY 201122th JANUARY 2011


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Cost ofImplementationCost ofImplementation

1. MATERIAL COST Rs. 25,000/-

2. FABRICATION Rs. 5,000/-

---------------

TOTAL COST : Rs. 30,000/-


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Data collection analysisData collection analysis

Before modificationBefore modificationSr.no month Average time required

For de-scaling

granulator canopy

1 Sept10 5.5 hrs

2 Oct10 4.2 hrs

3 Nov10 4.8 hrs

4 Dec10 5.6 hrs


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Data collection analysisData collection analysis

after modificationafter modificationSr.no month Average time required

For descaling

granulator canopy

1 Jan11 2.5 hrs

2 Feb11 2.2 hrs


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0

1

2

3

4

5

6

sep'10 oct'10 nov'10 dec'10 Jan'11 Feb'11

Avg time required for descaling canopy


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Avgtime requiredfordescaling

canopy(sept10 todec10)= 4.8 hrs

Avgtime requiredfordescalingcanopy(jan11tofeb11)= 2.2 hrs

Reduction intime fordescaling=4.8 - 2.2 = 2.6 hrs.

TANGIBLEBENEFITSTANGIBLEBENEFITS


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Productionsaving@10MT/hrs= 2.6 x 10 = 26 MT

Annual saving basedon50 shutdown/ yr

= 26 x50 =1300 MT/yr Annual cost [email protected]/ MT=

=1200 x 1300

=15.6 Lakh/annumPay back period=0.3/15.6x330days= 7days

TANGIBLEBENEFITSTANGIBLEBENEFITS


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Easy and quick cleaning.

Satisfactionofsolving problems.

Encouragementfrom colleagues &

superiors.

Increasedteam spirit.

Enhancedour knowledge.

Better interpersonal skills.

Safety inoperation.

INTANGIBLEBENEFITSINTANGIBLEBENEFITS


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TMP PRESENTATION7

FOLLOWUP/REVIEW6

REGULAR IMPLEM.

TRIAL IMPLEMENTATION.5

FORESEE. RESISTANCE

DEVELOP SOLUTION4

ROOT CAUSES

IDENTIFY.CAUSES3

ANALYZE PROBLEM

DEFINE PROBLEM2

SLECTION OF PROBLEM

IDENT. OF PROBLEMS/1

ACTIVITY121110987654321

MEETINGSN

O

Activity ChartActivity Chart

5/2/11


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1 BRAIN STORMING

2 CAUSE AND EFFECT DIAGRAM

3 VALIDITY CHART4 ACTIVITY CHART

5 ABC ANALYSIS

6 DATA COLLECTON

Tools & TechniquesTools & Techniques


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OurNextPr leOurNextPr le


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Ankur Final Ppt

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