This is about Winning Anywhere - the Power of See
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This is about Winning Anywhere - the Power of See

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This was a presentation I gave in Mumbai for Quality Circle Forum of India. This is based on a recent book, I published -- Winning Anywhere -- the Power of See. Though the presentation was tailored to ...

This was a presentation I gave in Mumbai for Quality Circle Forum of India. This is based on a recent book, I published -- Winning Anywhere -- the Power of See. Though the presentation was tailored to top managers of Manufacturing the principles of the book can be similarly applied to any field of human activity, which starts with the power of see. The book is the first in the series -- NEME (noticeornot, engageornot, mullornot, exchangeornot), which form the cornerstone of the discipline of Nemetics.

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This is about Winning Anywhere - the Power of See This is about Winning Anywhere - the Power of See Presentation Transcript

  • R A P © Rapidinnovation™
  • N E M E (Solving ‘Wicked’ Problems & Improving Performance) Zero Breakdown through Minimal Design Interventions dibyendu de See E M EN E M E Nemetics N
  • INNOVATION R A P I DDesign Thinking for Serious Play © Rapidinnovation™
  • “ In a high-growth period, productivity can be raised by anyone. But how many can attain it during more difficult circumstances induced by low- growth rate? This is the deciding factor in the success or failure of an enterprise. ” Taiichi Ohno – Toyota © RMCPL All rights reserved
  • See E M EN E M E Nemetics N
  • INNOVATION R A P I DDesign Thinking for Serious Play © Rapidinnovation™
  • INNOVATION R A P I DDesign Thinking for Serious Play © Rapidinnovation™
  • INNOVATION R A P I DDesign Thinking for Serious Play © Rapidinnovation™
  • R A P © Rapidinnovation™
  • # Audit Parameters Previou s After1.5 y After 2.5 y 1 Production (units) 200 2000 3000 2 Production (Tons) 4500 8000 10168 3 Quality rejection 20% 7% 5% 4 Capacity < 100% = 100% >100% Effects of Strategies– Process Plant © RMCPL All rights reserved
  • Case Study on System Thinking Problem: Frequent bearing failure of ID Fan 2 in 25 MW Power Plant The bearing fails once in 3 months… See E M EN E M E Nemetics N
  • Fan NDE Bearing that fails often Fan Motor Example – Emergence & Essence See E M E Nemetics N
  • Ask questions to explore the context • Why ID fan 2 NDE bearing is failing & not the DE bearing? • There are 2 identical fans close to each other but the problem is with only one of the fans and not the other. • Why outer race bearing gets affected, why not other parts? • Why motor bearings did not fail even once? • The expected life of the bearing is minimum 2 years but fails once in 3 months! Similar Symptoms: Different Problems See E M E Nemetics N
  • Outer Race damaged bearing Nature of the Bearing Failure. Notice the fine flute marks across the outer race of the bearing. Emergence See E M E Nemetics N
  • The surface of the rollers also show fine damages See E M E Nemetics N
  • Vibration Data of ID Fan2 (does not improve even after bearing replacement: so the problem is not the bearing) POINT POINT AFTER BEARING BEFORE BEARING ID DESCRIPTION REPLACEMENT REPLACEMENT UNITS ----- ----------------------------- ------- ----- ------- ------- ---- --- ID FAN-02 (03-Jul-10) (03-June-10) M1H=Motor Outboard Horizontal .390 .471 mm/Sec M1P=Motor Outboard Horz Peakvue .289 .265 G-s M1V=Motor Outboard Vertical .748 .151 mm/Sec M1A=Motor Outboard Axial .365 .311 mm/Sec M2H=Motor Inboard Horizontal .418 .531 mm/Sec M2P=Motor Inboard Horz Peakvue .375 .352 G-s M2V=Motor Inboard Vertical .199 .231 mm/Sec M2A=Motor Inboard Axial .607 .579 mm/Sec F1H=Fan Inboard Horizontal 1.353 1.049 mm/Sec F1P=Fan Inboard Horz Peakvue .602 1.115 G-s F1V=Fan Inboard Vertical .850 .548 mm/Sec F1A=Fan Inboard Axial 1.883 1.294 mm/Sec F2H=Fan Outboard Horizontal .448 .932 mm/Sec F2P=Fan Outboard Horz Peakvue .598 1.660 G-s F2V=Fan Outboard Vertical .234 .443 mm/Sec F2A=Fan Outboard Axial .449 .640 mm/Sec ------------------------------------------------------------------------- Example – Emergence & Essence See E M E Nemetics N
  • Challenge the assumptions: Start with a Zen mind Assumptions we Tried, Checked & Failed were • Bearing failed due to misalignment of shaft. • Lubrication condition. • Looseness of bearing. • Over damped System. • Level of the shaft. • Bearing design is the problem Challenge the assumptions See E M E Nemetics N
  • (Think by observing & Zooming Out – check the interrelationships. From Emergence to Essence). • Fault arising in outer race of Fan NDE bearing (emergence of the system). • Frequent failure is only in one fan not in both fan. • Both fans are operating at same speed, load & handling the same material. • The gas temperature is same for the both fans. • Electric cable passing near the ID fan 2 NDE bearing (essence of system that causes the emergence) Observe the whole – Energy Interactions See E M E Nemetics N
  • Cable passing near the affected bearing creates Electromagnetic flux that causes the ‘mess’ Aluminium cover provided for shielding the affected Fan NDE bearing Interactions See E M E Nemetics N
  • Create & Choose responses that eliminate the set of imperfections that create the set of problems • The electric cable of the 220 KW motor of the adjacent fan & passing near the NDE bearing generates electromagnetic flux. • This is the essence of the problem that causes the bearing to often fail. • Solution  Protect the affected bearing from the electromagnetic flux (shield by aluminum sheet). Simplest solution Interactions See E M E Nemetics N
  • Vibration Spectrum of fan NDE Horizontal Direction (The Magic Effect – Constraint removed) PKVelocityinmm/Sec Frequency in CPM FANS - ID FAN-02 ID FAN-02 -F2H Fan Outboard Horizontal 0 20000 40000 60000 80000 0 0.04 0.08 0.12 0.16 0.20 0.24 0.28 0.32 Max Amp .30 09:07:51 03-Jul-10 10:26:49 03-Jun-10 Before Bearing Replacement without Aluminum cover After Bearing Replacement & providing Aluminum cover Energy Inteactions See E M E Nemetics N
  • Vibration Spectrum of fan NDE Axial Direction (The Magic Effect – Constraint removed) PKVelocityinmm/Sec Frequency in CPM FANS - ID FAN-02 ID FAN-02 -F2A Fan Outboard Axial 0 20000 40000 60000 80000 0 0.05 0.10 0.15 0.20 0.25 Max Amp .24 09:08:49 03-Jul-10 10:28:01 03-Jun-10 Before Bearing Replacement without Aluminium cover After Bearing Replacement & providing Aluminum cover Example – Emergence & Essence See E M E Nemetics N
  • Whole picture  imperfection/ Insight See E M E Nemetics N
  • Case of Diaphragm failure 1200 failures of Diaphragms/year See E M E Nemetics N
  • Whole picture  interactions -> Insight See E M E Nemetics N
  • Aluminum Plant - Charging Car See E M E Nemetics N
  • a case study on minimal Design intervention Case Study See E M E Nemetics N
  • • production not more than 60 packet a min • vibration between 50 to 60 microns • variation of quantity in packets – 6 to 8 ml • rat tailing – wastage of material • horizontal sealing problem • vertical sealing problem • new German machine = 1Cr • workers’ problem! The pain …. See E M E Nemetics N
  • • Variation in fill • Horizontal seal • Vertical seal The sachet See E M E Nemetics N
  • • Observe that the machine is like a tall column  pitching effect. • The width at the base (c to c of cushy foot) = 0.7 m. Length is 1 m • Note the sensitive directions shown by the red arrows. 0.7 m Principles of Sensitive Direction, Proportions & Structures See E M E Nemetics N
  • • The paper reel unit, the stair case are attached to the main unit. (Left hand side of the red line) • It shifts the centre of mass and induces vibration which is amplified by the low stiffness of the staircase • The yellow line more-or-less shows the centre of mass • Note that the machine has two regions of stiffness. One the left hand side of the red line it is the region of low stiffness and on the right is the region of high stiffness. 1 M Low Stiff region High Stiff region Principles of Centre of Mass & Stiffness See E M E Nemetics N
  • • This slider mechanism is critical for the operation. • Here the linear bearing can’t be lubricated by any means. • Moreover, the L/D ratio of the bearing is also not ideal. This would lead to accelerated wear & misalignment Linear Bearings Principle of centre of friction & proportion See E M E Nemetics N
  • • Imperfection: the temperature of the heaters are not equal. So a steady state temperature can’t be reached. • Solution: provide more feedback to control temperature uniformly. Principle of Centre of Temperature See E M E Nemetics N
  • • Imperfection: variable heat distribution. Principle of heat distribution See E M E Nemetics N
  • • The shampoo feed pipe is attached to the machine. Hence pipe vibrations are easily transferred to the machine. • Solution: Detach the pipe to isolate pipe vibration. And pipe hangers should be at unequal distance Principle of Pipes See E M E Nemetics N
  • • Imperfection: Heat gets trapped because of enclosure • Solution: redesign without covers no machine there – natural convection current to take away heat. Principle of Heat Distribution See E M E Nemetics N
  • • Imperfection: Heat is trapped because of the stainless steel cover. This heats up other elements in the working zone and reduces life. • Solution: replace SS cover by Aluminum to efficiently radiate heat Stainless Steel cover Principle of Heat Transfer See E M E Nemetics N
  • The new machine See E M E Nemetics N
  • the pains……… the gains • < 60 packets a min • 60 microns vibration • 6 to 8 ml per packet • rat tailing • horiz seal problem • vertical seal problem • foreign mac > 1 Cr • workers’ problem • 80 packets a min • < 5 microns vibration • 8 ml per packet • no rat tailing • no problem • no problem • new machine = 7.5L • workers’ cooperation Pain to Gains See E M E Nemetics N
  • learning to live by minimal design intervention scaling learning – the ultimate competitive advantage! Personal Mastery – 6th Principle See E M E Nemetics N
  • Story of the Poor PIG! See E M E Nemetics N
  • Energy flow; Interactions; Sync See E M E Nemetics N
  • Pain is the starting point... 1.Yield = 92% , International Benchmark = 97% 2.Weight variation, Ideal weight  9 to 11 kg, presently 7 to 14 kgs 3.% of Poor Pigs > 30% 4.Availability < 95% 5.Tried different models and techniques for 4 years without success See E M E Nemetics N
  • BEAS River: Insights – POV! See E M E Nemetics N
  • Design Intervention: 1.Change the speed and synchronize 2.Change the dimensions of the molds 3.Change the height of discharge of molten metal 4.Spray less water See E M E Nemetics N
  • 94 96 98 100 102 99.9 YIELD % International BM Results: See E M E Nemetics N
  • 15 20 25 30 35 40 25 15 30 35 21 35 13 WEIGHT DISTRIBUTION A B C D E % Results See E M E Nemetics N
  • 10 15 20 25 30 35 40 26.3 36.3 20 24.6 34.9 15.4 PPP Target Achieve% PPP Results See E M E Nemetics N
  • 95 96 97 98 99 100 101 95 100 AVAILABILITY % Results See E M E Nemetics N
  • 6% 99%+ After 1 yrAfter 1 yr World Class -Additional Profit2 RemarksRemarks PreviouPreviou ss Audit ParametersAudit Parameters## 6 Sigma, Internatio nal Benchmar k 92%Yield1 Effects of RAPID - Process Plants See E M E Nemetics N
  • “We broke new grounds in achieving high yield levels…. One thing which remains hidden…is the manner in which the opportunities for improvement are addressed. A systematic fact-based analysis followed by out-of-the box thinking to arrive at creative solutions lead to dramatic improvements … make positive changes irreversible & long lasting.” Harsh K. Jha, M.D. Tata Metaliks ‘Metalogue’, Vol 4, Number 2, Feb 2005 (newsletter) This says it all See E M E Nemetics N
  • Right Strategy was applied to 3 process plants % of equipment covered: 62 (most critical + critical) # Audit Parameters Previou s After 1 yr After 2 yrs 1 No of breakdowns/year 57 19 3 2 % of breakdown hours 25 12 5 Effects of Strategies– Process Plant © RMCPL All rights reserved
  • # Audit Parameters Previou s After 1 yr After 2 yrs 3 Design Out maintenance cases Nil 28 Further done 4 % of increase in monitoring activities 18 42 5 Capacity < 100% > 100% 6 Cost Leadership 3 1 Effects of Strategies– Process Plant © RMCPL All rights reserved
  • -- Reliability -- Cost 0 10 20 30 40 15 20 25 1 2 3 4 5 6 7 8 9 10 11 12 Reliabilityvs. Cost Reliability v/s COST - Cement Plant © RMCPL All rights reserved
  • Cement Plant See E M E Nemetics N
  • Effects of Strategies– Chemical Co. when STRATEGY was applied to 46 critical machines in a chemical company, the results were impressive. 0 5 10 15 20 25 30 1st Yr 2nd Yr 3rd Yr 4th Yr Number Years No. of Breakdowns(Avg/month) © RMCPL All rights reserved
  • # Audit Parameters Before ‘98 After May ‘01 8 Annual Mean Maintenance Labour Hours in a year 4675.66 hours 3108.87 hours 9 Maintenance Budget Rs 3.4 Cr Rs 1.41 Cr 10 Production rate 1.66 T/hr 1.87 T/hr 11 Quality 3.5 σ 6σ 12 Leadership Position 4th 1st (sells at premium) Effects of Strategies– Chemical Co. © RMCPL All rights reserved
  • Effects of RAPID – Aluminum PlantEffects of RAPID – Aluminum Plant ## AuditAudit ParametersParameters PreviousPrevious After 6 mAfter 6 m RemarksRemarks 1 Availability 80% 90% 10 % productivity 2 Rolls/hour 20 23 15% productivity
  • Effects of RAPID – Aluminum PlantEffects of RAPID – Aluminum Plant ## Audit ParametersAudit Parameters PreviousPrevious EffectEffect 3 Energy 17% reduction 4 Profits 16% increase
  • • Leadership • People Ingredients of Success See E M E Nemetics N
  • Once done the company gains permanent on- going benefits. Prof. Tim Henry, Manchester University, U.K Benefit See E M E Nemetics N