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    Kaizen PF6

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    Jeniffer Rayen
    The project aimed to address issues with identifying which pellet car wheel was missing or having problems at the indurating machine by installing a digital distance sensor to track the position of each wheel. A distance sensor was installed on top of each wheel at the machine discharge end and wired to the control room to allow continuous monitoring of wheel positions and identification of any faulty cars. This improvement allows faulty cars to be accurately identified and removed, improving productivity, quality, and safety.

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    © All Rights Reserved
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    Kaizen PF6

    Uploaded by

    Jeniffer Rayen
    90 views10 pages
    The project aimed to address issues with identifying which pellet car wheel was missing or having problems at the indurating machine by installing a digital distance sensor to track the position of each wheel. A distance sensor was installed on top of each wheel at the machine discharge end and wired to the control room to allow continuous monitoring of wheel positions and identification of any faulty cars. This improvement allows faulty cars to be accurately identified and removed, improving productivity, quality, and safety.

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    KAIZEN PF6

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    The project aimed to address issues with identifying which pellet car wheel was missing or having problems at the indurating machine by installing a digital distance sensor to track the position of each wheel. A distance sensor was installed on top of each wheel at the machine discharge end and wired to the control room to allow continuous monitoring of wheel positions and identification of any faulty cars. This improvement allows faulty cars to be accurately identified and removed, improving productivity, quality, and safety.

    Copyright:

    © All Rights Reserved
    Download as XLSX, PDF, TXT or read online from Scribd
    Download as xlsx, pdf, or txt
    90 views10 pages

    Kaizen PF6

    Uploaded by

    Jeniffer Rayen
    The project aimed to address issues with identifying which pellet car wheel was missing or having problems at the indurating machine by installing a digital distance sensor to track the position of each wheel. A distance sensor was installed on top of each wheel at the machine discharge end and wired to the control room to allow continuous monitoring of wheel positions and identification of any faulty cars. This improvement allows faulty cars to be accurately identified and removed, improving productivity, quality, and safety.

    Copyright:

    © All Rights Reserved
    Download as XLSX, PDF, TXT or read online from Scribd
    Download as xlsx, pdf, or txt
    You are on page 1of 10

    Form No. VJNR/TQM/QC/001.01.

    20150109
    Kaizen Project Department Quality Circle Name
    Project No: Date
    Format PP-1 14/11/2022
    Title of Project: PF-6 WEIGH FEEDER CONTROLLER PANEL UPGARDTION FROM TUC-2 TO GDC CONTROLLER .

    Category: (√) Productivity, (√ ) Quality, (√ ) Cost, (√ ) Delivery, ( ) Safety, (√ ) Morale, ( ) Environment

    Before (Situation) Root Cause Analysis Improvement Measures After (Situation)

    PF-6 weigh
    feedeer set
    point and feed
    back not
    matching
    properly and
    Checked the controller and
    getting
    try to reset by removing Planned to go with new controller(GDC
    hanged some
    E-PROM and entering new controller ) and new ABB drive with wiring
    times due to
    program but also problem modification
    old type of
    was not resolving
    controller
    (TUC-2),and
    some times Replaced the controller (GDC
    controller was Controller) by modificating all wirings
    going to china and programming done now set point
    language and feed back matching with accurate
    values and working fine.this
    modification was done by in house
    PP-1 TEAM
    Benefits: a) Weigh feeder set point feed back matching Member Details: Team leader- Mr. Vivek Jain,Mr. shreeshail
    (b)Better operation working . Team Member- Mr.Krishna ,Mr. Basavraj,Mr.Hussain,Mr.Imran,Mr.Khaza, Mr. shiv
    (c) increasec accuracy of weigh feeder readings

    Standardization: any sop/smp change or new sop along with any


    training given regarding this project to concern people

    Single Point Lesson: Accuracy of weigh feeder will improved Remarks of evaluator:

    Date of Completion:
    Date of Starting: 15-11-2022 Name: vivek jain Signature:
    20-11-2022
    Kaizen Project Department Quality Circle Name
    Format
    Title of Project: Thickner arm rotation running condtion sensing

    Category: (√) Productivity, (√ ) Quality, (√ ) Cost, (√ ) Delivery, (√ ) Safety, (√) Morale,

    Problem Statement: Solution: Implementation:


    To prevent the damage and
    overloading of the thickener,
    The current a zero speed switch was
    monitoring installed and linked to the
    system for the shaft bolt. This change will
    thickener's allow for proper monitoring of
    rotating arm the arm's rotation, giving an
    was not indication when the arm is not
    providing rotating.
    proper
    indication of
    the arm's
    rotation,
    leading to
    potential The zero speed switch was insta
    damage and linked to the shaft bolt on the thi
    overloading of rotating arm. Every time the sh
    the thickener. passes, the switch will give a r
    indication, providing a clear and
    status of the arm's rotatio
    Benefits: a) Thickner arm rotation online monitoring. Member Details: Team leader
    b) any Team Member- Mr. Manj
    abonrmility of rake will identified. Mr.Devaraj

    Standardization: any sop/smp change or new sop along with any Horizontal Deployment Oppor
    training given regarding this project to concern people

    Single Point Lesson: Thickner arm rotation online monitoring Remarks of evaluator:

    Date of Completion:
    Date of Starting: 27-01-2023 Name: Jeniffer
    30-01-2023
    Form No. VJNR/TQM/QC/001.01.20150109
    rcle Name Project No: Date
    PP-1 11/15/2022

    Safety, (√) Morale, (√ ) Environment

    Implementation: Monitoring and Evaluation: Continuous Improvement:

    The monitoring system will be


    regularly reviewed to ensure that the
    zero speed switch and shaft bolt link The monitoring system for the
    are functioning properly and thickener's rotating arm will be
    providing accurate information on continually reviewed and improved as
    the arm's rotation. Any issues or necessary, using the Kaizen
    failures will be identified and philosophy of continuous
    peed switch was installed and addressed promptly to maintain the improvement. The goal is to provide
    he shaft bolt on the thickener's proper functioning of the monitoring accurate and reliable information on
    rm. Every time the shaft bolt system. the arm's rotation, to prevent
    he switch will give a running damage and overloading of the
    providing a clear and accurate thickener, and to maintain the highest
    us of the arm's rotation. level of process efficiency.
    etails: Team leader- Mr. Jeniffer,Mr.Shreshail
    m Member- Mr. Manjunath CB , Mr.Ankith , Mr. Mahesh , Mr. Dheeraj ,Mr.Manju (Elect),
    j

    Deployment Opportunities (Replication):

    of evaluator:

    niffer Signature:
    1.01.20150109
    Kaizen Project Department Quality Circle Name
    Format
    Title of Project: Distance Sensor fixing at pellet car(Wheel) return side .

    Category: (√) Productivity, (√ ) Quality, (√ ) Cost, (√ ) Delivery, (√ ) Safety, (√) Morale,

    Before (Situation) Root Cause Analysis Improvement Measure


    Indrduced new digital
    distance sensor for identified
    the car wheel postion with the
    help of distance masure
    and
    Indurating planned to installed the
    Machine pellet distance sensor on top of the
    car wheel wheel
    missing and
    tracking
    problem was
    more and we
    are not able
    to identify
    from which
    car its having
    problem

    We have installed the D


    sensor at machine discharge en
    side and cable laying done from
    control room and commissionin
    Benefits: a) We can measure the Distance of car whhel and Member Details: Team leader
    removed faulty car. Team
    (b)Better indtification of missing car . imran, Mr. Anji, Mr. Rudresh
    C) any abonrmility of car wheel will identified.

    Standardization: any sop/smp change or new sop along with any Horizontal Deployment Oppor
    training given regarding this project to concern people

    Single Point Lesson: car wheel missing will identified Remarks of evaluator:

    Date of Completion:
    Date of Starting: 01-11-2022 Name: Shreeshail
    15-11-2022
    Form No. VJNR/TQM/QC/001.01.20150109
    rcle Name Project No: Date
    PP-1 11/15/2022

    Safety, (√) Morale, ( ) Environment

    provement Measures After (Situation)

    After installing the Distance sensor


    e have installed the Distance signal given to control room and
    machine discharge end returs critical alarm also enabled in DCS for
    able laying done from field to identified of pellet car wheel missing
    om and commissioning done. or some abnormility of car.
    etails: Team leader- Mr. BB Patro, Mr. Shreeshail Mr. Vivek Jain,
    Team Member- Mr. shiv Kumar ,Mr.Ankith , Mr. Krishna , mR. Basvraj ,Mr.
    Anji, Mr. Rudresh

    Deployment Opportunities (Replication):

    of evaluator:

    eeshail Signature:
    1.01.20150109

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