ph quality circle - 2011
TRANSCRIPT
-
7/28/2019 PH Quality Circle - 2011
1/7
PROBLEM PRIORITIZATION MATRIX
LIST OF PROBLEMSCRITERIA
TOTALPOINTS
RANKINGCost Controllability
Availabilityof Data
Seriousness/Urgency
UNWANTED MATERIALS 2 1 1 3 7
a.) welding rods
b.) broom sticks
c.) paper bags from recycling
d.) small pieces of wood
EXCESSIVE MATERIAL SPILLAGES:
1. SLIDE GATE AT SILOS 1 TO 6DURING ADJUSTMENT
1 3 2 1 7
2. SCREW CONVEYOR UNDERSILOS 3 AND 6 INSPECTION HOLE
1 3 3 1 8
3. DRAG CHAIN BOTTOM CASING2 3 3 1 9
4. MAIN FEED SCREW CONVEYORINSPECTION HOLE
3 3 3 3 12 1
5. BUCKET ELEVATOR (FLUXOAUXILIARY) INSPECTION HOLE
3 3 2 1 9
6. FEED VALVE SHAFT BUSHING3 2 2 3 10 2
7. SENSOR COVERS OVERFLOWDURING FEED VALVE
MALFUNCTION
1 3 3 3 10 3
8. RETURN SCREW CONVEYORDRIVE SIDE OVERFLOW
2 3 2 2 9
9. RECYCLING SCREW CASING1 3 2 1 7
10. DRAG CHAIN CONVEYOR @2ND FL (BULK LOADING
AUXILIARY)
2 3 3 1 9
Rating Scales:
Low - 1
Medium - 2High - 3
-
7/28/2019 PH Quality Circle - 2011
2/7
-
7/28/2019 PH Quality Circle - 2011
3/7
PROCESS ANALYSIS
OPERATION CONDITION OUTCOME
1. Start up Normal NPOF
2. Withdrawal of cement
- Silo #1, @ 50% SG Normal NPOF100% SG Abnormal (boulders) POF
Stuck up bin
valve
Abnormal (pebbles) POF
- Silo #2, @ 50% Normal NPOF
DC trip-off Abnormal (equipmentproblem)
NPOF
MFS trip-off Abnormal (equipmentproblem)
POF
100% bin valve Abnormal (pebbles/boulders) POF
- Silos 1 & 2 (blending)
DC trip-off Abnormal (equipmentproblem)
NPOF
MFS trip-off Abnormal (equipmentproblem)
POF
100% bin valve Abnormal (pebbles/boulders) POF
- Volume of withdrawal,
50/50
Normal NPOF
25/75
Normal NPOF
75/25
Normal NPOF
3. Running- Blending/silo withdrawal Normal NPOF
- Fluxo packer stoppage Abnormal (stuck up nozzle) POF
- Feed valve stuck Abnormal (clog-up, defective
pneumatic cylinder)
POF (Coordination /
flexibility problem
between
tender/operator
- Cement silo, discharge
hopper aeration
Abnormal (gate valve left
open)
POF
- Power outage, withdrawal
at silo 2
Abnormal (cement discharge
due to gravity)
POF
- Stoppage sequence Abnormal POF
-
7/28/2019 PH Quality Circle - 2011
4/7
ROOT CAUSE VALIDATION
ROOT
CAUSE
VERIFICATION
METHOD
IN-
CHARGEFINDINGS
CONTROLLA-
BILITY
CONCLUSION
True Cause/
Not True
Cause
1. Training Training Needs
Analysis
JMP/AAC Not significant High Not True Cause
2. No reliable
means/facilityof monitoring
cementwithdrawal byTenders
Site Inspection Switchboard
Operator / Tender
Tenders has no
reliable means ofdetermining volume
of cementwithdrawn resultingto overflow in the
MFS inspectionhole
High Not True Cause
3. No provision
for
automatically
stopping
cement
withdrawal
when the
system stops
Site Inspection Switchboard
Operator /
Tender / PH
Mechanic
Even if drag
chain
underneath
cement silos 1 &
2 and MFS
conveyor is
stopped, cement
still continues to
flow to the drag
chain and MFSconveyor out to
the inspection
hole
Cement
withdrawal is
operated
manually
Medium True Cause
-
7/28/2019 PH Quality Circle - 2011
5/7
PROPOSED ALTERNATIVE SOLUTIONS TO PROBLEM #1
OBJECTIVE: Provide facility for automatically/immediately stopping cement withdrawal when the system
stops
1. MAN
1.1. Highly motivated personnel
1.2. Additional manpower1.3. Vigilance
2. MACHINE
2.1. Replace with cellular feeder2.2. Replace with rotary feeder
2.3. Replace with vari-drive
2.4. Modulating gate
2.5. Reactivate roots blower2.6. Control aeration system
2.6.1. Install solenoid valve at aeration system2.7. Replace gate valve with ball valve
2.7.1. Replace air hose with GI pipe and relocate to most accessible area
2.8. Install turbo blower
2.9. Replace MFS cover2.9.1. Provide snap-on/wing nut
2.9.1.1. Extend steel casing
3. METHOD
3.1. Install alarm system
3.2. Packer to coordinate with Switchboard operator
4. MATERIAL
5. MILIEU
5.1. Ergonomics
-
7/28/2019 PH Quality Circle - 2011
6/7
ALTERNATIVE SOLUTION CRITERIA
Advantage DisadvantageTOPO
Doability Economical Relevance/ Impact Safety
AN
1) Highly motivated personnel 2 2 1 3
2) Additional manpower 2 1 1 2
3) Vigilance 2 3 1 3
ACHINE
1) Replace with cellular feeder 1 2 3 3Pebblesproblem
2) Rotary feeder 1 1 3 3 Not available
3) Vari-drive 1 1 3 3 Not available
4) Modulating gate 1 1 3 3
5) Reactivate roots blower and aeration system 1 1 3 3
5.1) Control aeration system 3 3 3 3
6) Install solenoid valve at aeration system (@WBD)
1 1 1 3
7) Replace aeration gate valve with ball valve, installmergency shut-off ball valve and relocate the valves
3 3 3 3
8) Install turbo blower 1 1 2 3
9) Replace MFS cover 3 2 3 3
9.1) Provide snap-on / wing nut 3 2 3 3
9.1.1) Extend steel casing 3 2 1 1 ETHOD
1) Install alarm system 2 3 3 3
2) Coordination among SWBD Optr, Packer andnder
3 3 3 3
LIEU
1) Ergonomics 2 2 3 3
ATERIAL
TERNATIVE SOLUTION MATRIX
JECTIVE: Provide facility for immediately stopping cement withdrawal when the system stops
-
7/28/2019 PH Quality Circle - 2011
7/7
LIST OF ACTIVITIES FOR THE TWO BEST ALTERNATIVE SOLUTIONS
(For Gantt chart)
Best Alternative Solution #1 - Replace aeration gate valve with ball valve, install emergency shut-off ball valve
and relocate the valves
Activities/Tasks:
1. Sketch relocation piping
2. Determine bill of materials3. Prepare purchase requisition for needed materials
4. Check quantity and specifications of purchased materials
5. Layout, connect pipes and install valves
6. Tap new piping to existing air source and remove old aeration system7. Test new aeration system
8. Utilize new aeration system
9. Evaluate effectiveness and standardize
Best Alternative Solution #2 Install alarm system (buzzer) and establish coordination procedure among
switchboard operator, packer and tender
Activities/Tasks:
1. Draft procedure flow chart
2. Prepare purchase requisition for alarm system (buzzer and switch)3. Check specifications of buzzer
4. Prepare SWO for installation of buzzer
5. Conduct orientation with concerned personnel on the procedure6. Implement procedure
7. Evaluate effectiveness and standardize