STATUS OF CIRCLE

QUALITY CIRCLE INAUGURATION : 12th

Dec.1991
NO. OF PROBLEMS IDENTIFIED : 60

 NO. OF PROBLEMS SOLVED : 12

 NO. OF SOLUTION IMPLEMENTED : 12

 NO. OF MEETINGS HELD :7

FOR THIS PROBLEM

 AVERAGE ATTENDANCE : 94%

 MEETING DAY & TIME : TUESDAY 14.00 to 15.00

 INTRODUCTION

V.G.PATIL LEADER

R.G.GUNJAL DY.LEADER

A.C.PATIL MEMBER

N.S.GOKHALE MEMBER

KRISHAN A.MEENA FACILITATOR

1. Frequent failure of cooling tower motors in DMF plant
2. High energy consumption & Unsafe Maintenance in
Loading shed area of DMF plant
3. Energy Conservation of lighting in Formic Acid & CO
Plant Area.
4. Frequent burning of incoming cable instrument air dryer
heater panel
5. Difficulty in greasing to L.T.Motors.
6. Unsafe condition while checking of control supply in
formic MCC
7. Failure to auto start the instrument air compressor.
8. Difficulty in drum filling in DMF loading shed area.
9. Unsafe condition while checking DMF and DMAC Street

light
10 .Malfunctioning of motor module in MAP MCC.
11. Frequent Failure of CO/FORMIC PCC
SR. No. Problem Category A/B/C
1 Frequent failures of cooling tower motors. A
2 Energy conservation in loading shed area. B
3 Trouble while maintenance of MAP lighting A
4 Wastage of water from well & from dewatering pumps near DMF plant. C
5 Unsafe condition while checking of control supply in MAP & DAMC MCC. A
6 Unsafe condition at the time of inserting or removing the fuses in CO MCC. A
Maintenance problem on motors due to narrow passage between A/B motors in CO
7 B
plant.
8 Energy conservation of air conditioner in Co-Formic office. B
9 Unsafe condition for maintenance on cooling tower motors in Formic Acid plant. C
10 Maintenance problem of heater in Formic Acid plant. A
11 Energy conservation in Rasayan Bhavan – I C
12 Reuse of various types contractors having minor faults. A
13 Unsafe & improper way of unloading of Methanol. C
14 Frequent melting of lugs in MAP plant heater. B
15 Energy conservation at storage tank in Nitrogen plant. B
16 Problem of frequent damages to L.T.Motors fan covers. B
17 Problem while working on L.T. Motors fan. A
18 C.T. Fan trips at the time of starting in DMF plant. C
19 Burning of incoming cables in Instrument Air Compressor Heater panels. A
20 No greasing arrangement externally to some L. T. motors. A
 C, 8

B, 17 A, 35
1.Malfunctioning of DG Auto Operation
1.Malfunctioning of DG Auto Operation

‘A’ category
Stratifying every problem with respect to its
priority

Frequent failure of Old Methyl Amine Plant’s Heater.

Difficulty in greasing at Nitrogen Plant.

Maintenance problem of heater in Formic Acid plant

Cooling Tower Fan trips at the time of starting

in Dimethyl Formamide Plant

Malfunctioning of DG Auto Operation

SR. NAME OF THE PROBLEM AFFECTING
NO. AREA
1 Frequent failure of Old Methyl Total Methyl
Amine Plant’s Heater. Amine Plant

Maintenance problem of heater in Formic Methyl Format

2 Acid Plant. section of formic acid
plant.
3 Malfunctioning of DG Auto Operation Unsafe shut down
activities at
time of black out.

Cooling Tower Fan trips at the time of Delay in startup of

4 starting in Dimethyl Formamide Plant. Dimethyl Formamide
Plant
5 Difficulty in greasing at Nitrogen N2 plant
compressor
 ACTIVITY CHART (BEFORE)

MEETING
10/08/10 17/08/10 24/08/10 31/08/10 07/09/10 21/09/10 28/09/10
DATES

Data collection

Define the problem

Problem analysis

Brainstorming

Development of
solution
Reverse brain
storming
Cost and benefit
analysis
 DMF
2500 MT
DMAC
PER YEAR
5000 MT
CO PER YEAR
1200 nm3
PER HOUR

OLD MAP
CHEMICAL 5000 MT
GROUP OF PER YEAR
NITROGEN PLANT
1200 nm3
PER HOUR

ARGON
45
FORMIC MT/D
10000 MT
NEW MAP
PER YEAR
6400 MT
PER YEAR
Methyl Amine Plant
Methyl Amine Plant’s Heater
HEATER TERMINAL BOX
 PROBLEM DEFINITION

MOTOR CONTROL CENTRE OF METHYL

AMINE PLANT’S
 PROBLEM DEFINITION

HEATER MODULE
 MOTOR NOT RUNNING
YES

CONTROL SUPPLY OK
NO

CHECK CONTROL FUSE PROCESS FLOW

YES DIAGRAM
NO
CHECK OVER LOAD TRIP
OVER LOAD RESET
YES

NO
CHECK STOP PUSH IF PRCISED RELESE
BUTTON POSITION
YES

NO
CHECK DCS STOP
RESET FROM DCS
STATUS
YES

NO
CHECK SUPPLY AT LCS CHECK CABLE
YES

NO

MAKE LCS AUTO & CHECK AUTO CONTACT

CHECK SUPPLY
YES

NO
CHECK FEEDER ON ON SWITCH PROBLEM
CONTACT
YES

NO
CHECK FEEDER MAIN REPLACE COIL
COIL
YES
NO

CHECK FEEDER NUTRAL MAKE OK

LINK
YES

CONTROL SUPPLY OK
 P
Ø 24 S1

Fuse
Over load relay
N/O N/C
8
LINE DIAGRAM

Stop push button

9
Ø 4

Stop DCS (remote)

Ø 5
off On
auto
Ø 6

Hold on

Ø
7

D2 Process trip
D2

Main contactor C

Aux
contactor
N 25
ON OFF
O/L TRIP PROCESS
PROBLEM DEFINITION

INSULATION RESISTANCE TEST

231.4.
TO
5.
TO
TOTO
6.REMOVE
TIGHTEN
LIFT
ISOLATE ALLEN
COVER
HEAVY
PLACE
ENERGISE 440 BOLTS
COVER
HEAVY PLATE
VOLTS
HEATER AND
SUPPLY
COVER
OF
KEEP COVER
WITH
PLATE WHICH
ALLEN
ASIDE.
ON THE NUTIS ATREQUIRED
2PERSONS
HEATER HEIGHT
Impact of the problem is either total
plant shut down or partial shut
down of individual section of MAP
and delay in dispatch of finished
product.
“TO IMPROVE THE RELIABILITY OF
ELECTRICAL HEATING SYSTEM”.

“TO
TOMINIMIZE
“MINIMIZETHE
THE
BREAKDOWNS
BREAKDOWNS
CAUSED
CAUSEDBYBY
ELECTRICAL
ELECTRICAL
HEATING
HEATINGSYSTEM”
SYSTEM”
 4W & 1H

WHAT WHERE WHEN WHO HOW

How
Who
When
Whatthese
Whereisdoes
isresponsible?
are
istheproblem
the affecting
problem?
problem?occur?
the activity?

At
Location
Problem
the time
occurs
ofofthestartup
Heater
in between
orterminals.
normal
the
running
running
Frequentconditions
hours
Electrical of Heater
failure
Heating interruption
of electrical in
Equipment
plant activities,
Heater in old MAPmeans direct or
indirectly production loss.
 DATA COLLECTION FREQUANCY OF THE JOB.

NO DATE EQUIPMENT PROBLEM

1 20/08/07 31 HE-103 A1 BURNING OF R-PHASE
2 25/08/07 31 HE-103 C2 BURNING OF Y-PHASE
3 04/09/07 31 HE-103 A2 BURNING OF B PHASE
4 08/10/07 31 HE-103 B1 BURNING OF R- B PHASE
5 22/12/07 31 HE-103 B2 BURNING OF B-PHASE
6 20/01/08 31 HE-103 A2 BURNING OF R-PHASE
7 20/03/08 31 HE-103 C1 BURNING OF B-PHASE
8 21/04/08 31 HE-103 C1 BURNING OF R-PHASE
9 15/06/08 31 HE-103 C1 C. T BURNING IN MCC.
10 20/09/08 31 HE-103 C1 BURNING OF YPHASE
11 21/11/08 31 HE-103 C1 BURNING OF B-PHASE
12 26/12/08 31 HE-103 C1 BURNING OF R-PHASE
 DATA COLLECTION FREQUANCY OF THE JOB.

NO DATE EQUIPMENT PROBLEM

13 21/01/09 31 HE-103 B1 BURNING OF Y-PHASE
14 27/03/09 31 HE-103 A2 BURNING OF R-PHASE
15 21/06/09 31 HE-103 B2 BURNING OF B PHASE
16 20/08/09 31 HE-103 C2 BURNING OF R- R PHASE
17 14/10/09 31 HE-103 B1 BURNING OF Y-PHASE
18 07/12/09 31 HE-103 C2 BURNING OF B-PHASE
19 05/02/10 31 HE-103 B2 BURNING OF R B-PHASE
20 13/04/10 31 HE-103 A2 BURNING OF R-PHASE
21 16/05/10 31 HE-103 C2 BURNING OF B-PHASE.
22 11/06/10 31 HE-103 A2 BURNING OF C T
 MAN MACHINE

Improper cooling of
Negligence heater terminal box

Sudden rise in temperature High temp inside the terminal box

Loose
Continuous Running of a Particular Heater Connection

Traditional method used Distance between

supplies is very less Frequent failure of Old
Methyl Amine Plant’s
Distance between supplies is Heater
very less Bad
Bad Quality
Quality of
of cable
cable

Two
Two power
power cables
cables entry
entry inside
inside
the
the single
single terminal
terminal box
box Congested Terminal box

Improper Size of lug Low Rating Elements

440V and 440V supply in

same cabinet

METHOD MATERIAL
 Root causes analysis from valid causes
NO CAUSES VALID INVALID REASON
1 Negligence  Trained manpower

2 Bad quality of cable  Design is original

3 Congested Terminal box  Design is original

4 Improper Size of lugs  Design is original

5  Trained manpower
Loose connection

6  Trained manpower
Traditional method is used

7 Two power cables entry inside  Design is original

the single terminal box

8 Distance between supplies is  Design is original

very less
 Root causes analysis from valid causes

NO CAUSES VALID INVALID REASON

9  Design in original
Low Rating Elements

10 High temperature inside the  Design in original

Terminal Box

11 Continuous Running of a  Plant requirement

Particular Heater
12 Improper cooling of heater  Nitrogen air is
terminal box continuous inside the
TB
13 Sudden rise in 
Plant requirement
temperature .
 DATA ANALYSIS FOR ROOT CAUSE.

NO DATE EQUIPMENT PROBLEM REASON

1 20/08/07 31 HE-103 A1 BURNING OF R-PHASE
High temperature inside the TB
2 25/08/07 31 HE-103 C2 BURNING OF Y-PHASE High temperature inside the TB
3 04/09/07 31 HE-103 A2 BURNING OF B PHASE High temperature inside the TB
4 08/10/07 31 HE-103 B1 BURNING OF R- B High temperature inside the TB
PHASE
5 22/12/07 31 HE-103 B2 BURNING OF B-PHASE High temperature inside the TB
6 20/01/08 31 HE-103 A2 BURNING OF R-PHASE High temperature inside the TB
7 20/03/08 31 HE-103 C1 BURNING OF B-PHASE High temperature inside the TB
8 21/04/08 31 HE-103 C1 BURNING OF R-PHASE High temperature inside the TB
9 15/06/08 31 HE-103 C1 C. T BURNING IN MCC. High temperature inside the TB
10 20/09/08 31 HE-103 C1 BURNING OF YPHASE High temperature inside the TB
11 21/11/08 31 HE-103 C1 BURNING OF B-PHASE High temperature inside the TB
12 26/12/08 31 HE-103 C1 BURNING OF R-PHASE High temperature inside the TB
 DATA ANALYSIS FOR ROOT CAUSE.

NO DATE EQUIPMENT PROBLEM REASON

13 21/01/09 31 HE-103 B1 BURNING OF Y-PHASE High temperature inside the TB
14 27/03/09 31 HE-103 A2 BURNING OF R-PHASE High temperature inside the TB
15 21/06/09 31 HE-103 B2 BURNING OF B PHASE High temperature inside the TB
16 20/08/09 31 HE-103 C2 BURNING OF R- R High temperature inside the TB
PHASE
17 14/10/09 31 HE-103 B1 BURNING OF Y-PHASE High temperature inside the TB
18 07/12/09 31 HE-103 C2 BURNING OF B-PHASE High temperature inside the TB
19 05/02/10 31 HE-103 B2 BURNING OF R B- High temperature inside the TB
PHASE
20 13/04/10 31 HE-103 A2 BURNING OF R-PHASE High temperature inside the TB
21 16/05/10 31 HE-103 C2 BURNING OF B-PHASE. High temperature inside the TB
22 11/06/10 31 HE-103 A2 BURNING OF C T High temperature inside the TB
 Why – Why technique

1.Why job is affected by time?

Because job is to open the cover of heater which
is hot, heavy and also on height. We have to
wait for at least 4 hrs to cool down the
temperature of heater.

2. Why the cover of heater is to be opened?

To check elements and its connections. For that
cover is to be removed and kept aside.
 Why – Why technique
3. Why cover plate is so heavy?

Because flame proof enclosure is required

for operation.

4. Why above activities are required for

maintenance?

Because location of the terminals are inside the

heater and the temperature of the terminal box
is more than 330 Degree Celsius itself.
..
“Temperature inside the terminal box”

HEATER TERMINAL BOX

 REJECTED

HEATER SECTION MAP MCC

 Increase the
height of
terminal box

REJECTED
 To improve the insulation
quality inside the terminal box
and heating elements:
REJECTED
ACCEPTED
FORSEEING PROBABLE RESISTANCE
 Whether extended cable will also work in the
environment of our plant. We insert these leads in
spiral flexible pipe and these leads come with a
certificate for the use of hazardous zone itself.

Spiral flexible pipe

After Implementation

Cu Leads

Junction
Box

PVC Power Cable

 After Implementation

HEATER TERMINAL

JUNCTION BOX
 To isolate heater
electrically.

To take reports from prod. To remove cover

Department. ACT plate of heater.

PLAN

CHECK
To remove the connection of the
cable and connect the Leads to
the terminals.
To observe the current DO
and temperature of To connect the leads and the
heater. cable to the junction box..
 Measure distance of
module from contact
TRIAL IMPLEMENTATION AND CHECK
Put the module in to the MCCPERFORMANCE To make available
and check the function. ACT
channel with roller 50 no.

PLAN

CHECK
Check the distance
To take module out.
between each module
of channel. 05/09/2010
DO
To make drills to each MCC that
We check that channel is 25 no
supplied by supplier is of
Fixing of channel
correct size or not
 REGULAR IMPLEMENTATION

20/09/2010 and 27/09/2010

Implementation Schedule

Date Heater Remark

20/09/10 105 B1 & B2 OK
27/09/10 105 C1 & C2 OK
 FOLLOW UP REVIEW

For the proper functioning of

heaters we are checking all the
heaters one by one monthly by
opening the cover and checking
tightness of the connections, as
well as we check the condition of
the cooper leads also.
 1. Junction Box No 6
2. Fire Retardant Fiber Insulated Copper Leads

For the implementation we required 36m of

Copper leads `162.00 price of per meter
36 x ` 162.00 = ` 5832.00
This is the actual cost for
implementation
The Junction Box was collected from scrapped old CO Plant. So
cost of implementation is ` 5832.00 only.
Saved valuable man-hours & manpower

Reduction in time for maintenance

Healthy working condition achieved

Easy maintenance is possible

Reduction in unwanted breakdowns.

 * Appreciation from superiors and colleagues
* Increased team spirit.

* Strengthening of quality circle movement.

* Enhanced friendship and cooperation among

members & non members.

* Commitment towards ISO-14000

 Q.C. TOOLS & TECHNIQUES

1. BRAINSTORMING

2. DATA COLLECTION

3.ACTIVITY CHART

4.FISH BONE DIAGRAM

 Q.C. TOOLS & TECHNIQUES

5. FLOW CHART

6. 4 W & 1 H

A P
7. PDCA Chart
C D

C, 7

8. ABC Classification B, 17 A, 30
 DATA DEVELOP
ABC 4W&1H
ANALISIS 1 5

PROB. DATA DATA

FORSEEING
1 ANALISIS 2
SEL

ACTIVITI DATA ROOT

PDCA
CHART 2 CAUSE

DEVELOP
PROBLEM
1 BENEFIT-1
NAME

DIFINE CAUSE & DEVELOP

BENEFIT-2
PROBLEM EFFECT 2

DEVELOP QC
FLOW VALID &
3 TOOLS 1
DIAGRAM INVALID 1

OBJECT VALID & DEVELOP QC

4
GOAL INVALID 2 TOOLS 2