1. Ashwamedh is a Sanskrit text that details the ancient Vedic horse sacrifice ritual performed by rulers in India. 2. The ritual involves releasing a horse to wander for an entire year as a demonstration that the ruler's territory is properly administered and no enemies remain who could harm the horse. 3. If the horse returns unharmed after a year, it is a sign that the ruler's realm is secure and fit to perform the ultimate horse sacrifice ritual involving slaughtering the horse.

1. Ashwamedh
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Cat C, Cat B
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5 Productivity
Wastage Reduction
Health/Safety
4 Wastage Reduction
Cost Reduction
Health/safety
Fatigue
Productivity
3 Cost Reduction
Fatigue
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Weightage Chart
Sr RM SR PK VS SH AV SU PK
No Theme B G M M H M B M TOTAL
1 Productivity 3 4 5 3 2 1 2 2 22
2 Health and safety 2 1 3 4 3 5 3 1 22
3 Wastage Reduction 5 5 4 5 4 4 5 4 36
4 Fatigue 1 2 2 1 1 3 4 5 19
5 Cost Reduction 4 3 1 2 5 2 1 3 21
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Problem
no Problem Description Detail
Frequent damage of
15 Wastage of belts due to stones & metal pieces in coal feeders,
the coal mill belt
belt damage due to improper storage, effect of climate etc.
Scrapping of high
20
value parts Wastage of High cost items like shafts, actuators, valves etc
Oil wastage due to leakages, oil changes and maintenance
22 Wastage of oil
activities.
Wastage of Compressed air wastage due to various leakages and improper
27
compressor air use of compressed air.
Man hours getting waste due to improper planning of work,
28 Wastage of Man-hours
transportation activities and plant emergencies.
Water wastage due to leakages, passing valves and improper
47 Wastage of water
usage.
Fuel wastage during transportation, leakages and improper
68 Wastage of fuel
usage.
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Problem Problem Weightage Chart
no Description RMB SRG PKM VSM SHH AVM SUB PKM TOTAL
Frequent damage of
15 the coal mill belt 4 6 7 2 1 5 1 1 27
Scrapping of
20 high value parts 7 7 6 7 7 6 7 6 53
22 Wastage of oil 5 1 4 6 2 7 2 7 34
Wastage of
27 compressor air 4 2 1 5 5 3 5 3 28
Wastage of Man-
28 hours 2 4 2 1 6 1 6 5 27
47 Wastage of water 1 3 5 4 4 4 4 4 29
68 Wastage of fuel 6 5 3 3 3 2 3 2 27
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Scrapp
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PIE CHART in Lakhs
COMPRESSOR COMPRESSOR
VALVE, 1.82, 3% VALVE
HIGH PRESSURE
VALVE, 3.25, 6%
* ; ACTUATORS ,
HIGH PRESSURE
2.18, 4%
; ; VALVE
Segregating
' valve, 2.75, 5%
#
ACTUATORS
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TWS Head shaft (
Scrapping of high
value parts (5 Items)
Problem Selected by Rating
Method is 1
Problems falling under
Theme “wastage reduction” is 7
Problems falling under
Category “A” is 31
Number of Problems identified are 72
15

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no Activity Week 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20
3 Defining Problem
4 Analyzing Problem
5 Finiding the Causes
6 Root Cause analysis
7 Data analysis
8 Developing Solution
Foreseeing
9 Resistance
10 Trial Implementation
Regular
11 Implementation
12 Follow up and review
20

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TWS he ad shaft Scrapping DATA
4.5 2006-07
4
Nos. scrapped
3.5
3
2.5
2
1.5 2005-06 2007-08 2008-09
1
0.5 2009-10
0
2005- 06 2006- 07 2007- 08 2008- 09 2009- 10
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27. 5) Finding the causes
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28. 5) Finding the causes
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34. 3E 9 '
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Interference fit
di 0 L 130 Ei 77 vi 0.3
mm mm GPa
d 120.00 0.03 Eo 77 0.3
mm mm GPa vo
do 124.80 µ 0.12
mm
Modulus of Elasticity, E for SS 316= 77 Gpa, - Interference in mm, µ- coefficient of friction
for steel contacts dry between 0.1 and 0.15, vi and vo – surface roughness in µm
Interference pressure p 0.73
MPa
Friction force F 4.27
kN
Transmission torque T 256.23
Nm
% ; 1 :#:, +
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34

35. 3E 9 '
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Sr No ACTION POINTS WHO WHEN STATUS
Job Planning for availability and
GVB
machining of shaft and sleeve.
1 SRG 22/05/09
Procurement of Material for
SD
sleeve.
SRG,
Design of sleeve and material PKM,
2 24/05/09
collection for the same PKN,
SHH
PKM,
3 Machining of sleeve and shaft RMB, 27/05/09
AVM
PKM,
Installation, trials and SUB,
4 2/6/2009
implementation SHH,
VSM
AVM,
RMB,
5 Performance monitoring
PKM,
VSM
%
35

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37. 0:E %
DT : 19/05/2009
37

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39. 0:E %
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43. 00E ' %
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PIE CHART in Lakhs
COMPRESSOR COMPRESSOR
VALVE, 1.82, 3% VALVE
HIGH PRESSURE
$
VALVE, 3.25, 6%
ACTUATORS ,
HIGH PRESSURE
2.18, 4%
VALVE
Segregating
valve, 2.75, 5%
ACTUATORS
Segregating
valve
Travelling w ater
screen Head
shafts, 44, 82% Travelling w ater
screen Head
shafts
PIE CHART in lakhs
TWS Shaft repair
Travelling w ater cost, 0.19518, 2%
screen Head
shafts, 0, 0%
COMPRESSOR COMPRESSOR
VALVE, 1.82, 18% VALVE
HIGH PRESSURE
VALVE
Segregation
Valve, 2.75, 27% ACTUATORS
Segregation Valve
HIGH PRESSURE
VALVE, 3.25, 32%
Travelling w ater
ACTUATORS , 2.18, screen Head
( ; # 21% shafts
TWS Shaft repair
cost
43

44. $ *
:. ; # * ; ( ; @
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% B' DT .E
,02 9
0 Q0,, % Q003 Q.0: .385#23 05/03#84
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( $ Travelling
BAR Chart
w ater
50
screen Head
• # shafts, 44 Travelling
•
45
% 9 ( * 9 water screen
; # 40 Head shafts
% ( ( 35
Cost in Lakhs
30
TWS Shaft
repair cost
• $ ; 1 25
; 1 # 20
' ) ( ; 1
15
#
10
TWS Shaft
• =' ; 5 repair cost,
0.1951872
' ' ' 0
Tr avelling wat er screen Head TWS Shaf t repair cost
# shaf t s
Items
$ - (
• $ ' - =' #
• % 9 ; 1 & #
• % 9 " 9 #
• #
44

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45

46. 04E 6 ; ' 9 ;
9 9 ( ; ( ; # 1 ; 1
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4: ; 1 @
Sr Activity
no Week 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21
3 Defining Problem
4 Analyzing Problem
5 Finding the causes
6 Root Cause analysis
7 Data analysis
8 Developing Solution
9 Foreseeing Resistance
10 Trial Implementation
11 Regular Implementation
12 Follow Up and Review
46

47. Actual Planned
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47

48. Reward and Recognition
- ' * * ' ( *
48

49. 49