Innovative reconditioning of degaussing system INS Betwa IDDQC2022.pptx

Established in 1735 by the East India
Company.
Asia’s first dry dock, the Bombay dock
was build in the year 1750.
Notable creation the HMS Trincomalee
built in 1878 is presently berthed at
Hartlepool (U.K)
Naval Dockyard has nearly 9,000
employees
Yard has intrinsic capabilities and
capacities, to carter the maintenance
needs of naval platforms.
2
Bombay Dock
Brief about Naval Dockyard
2
HMS Trincomalee

3
Skills at a Glance
Docking of IN Ships
Rewinding of Stator & Rotor
3

4
Skills at a Glance
Overhauling of Valves
Complete maintenance of GT engines
4

5
Skills at a Glance
Overhauling various Motors
Overhauling of IC Engines
5

Name : Drishti
Born On : 03 Jan 1998
We Meet : Fortnightly
For : One Hour
(Wed-15.30 to 16.30)
Projects Implemented : 27
Our Circle
6

7
Coordinator : TM Passi TA/L
Facilitator : MB Panda, F/M(G)
Leader : Uttam Singh
Members : Shaju Jacob C
: Deepak Kumar
: Satish Mohan
: Surendra Sahu
: Ankit Gupta
Organization of Drishti

TM Passi TA/L
Coordinator
Uttam Singh
Leader
Ankit Gupta
Member
Deepak kumar
Member
Shaju Jacob
Member 8
Surendra Sahu
Member
Satish Mohan
Member
Organization of Drishti
MB Panda
Facilitator

9
Our Objective
• Study the facets of “Quality Circle” & analyse them
from the Yard’s perspective
1
• Highlight the importance of incorporating Kaizen
techniques in shop floor processes
2
• Identify problem areas & propose practical &
feasible solutions
3
• Demonstrate through a case study, the success of
QC in innovation
4
9

10
• Cabling onboard ships and submarines.
• Ty. Lighting assistance to other centers.
• Reconditioning of galley and control panels in
Ships & Submarines.
• Gland packing, vulcanization of cables at various
places.
• Degaussing system.
• Department maintenance.
Roles & Responsibilities

Requirement of new
water purifier at
shop floor
Disposal of waste item
Regular Choke up in
drainage pipes of ECI
Dept. Time consumption in
repairing of
navigational light
fitting
Leakages in ceiling
at various places in
department
Brainstorming
12

Problems Identified By Brainstorming :
Identification of The Problem
13

14
S.No Problems Identified A B C
1 Accumulation of DO-SSRR items B
2 Leakage of roof at shop floor B
3 Shortage of man power C
4 Shortage of spares C
5
Innovative reconditioning of degaussing cable onboard
INS Betwa
A
6 Shortage in hydraulic crimping tools C
7 Shortage of water in dept A
8 Repairing of shore charging mast of INS Shalki A
9 Requirement of training for all personnel A
10 Frequent choking of wash basin B
Problem Stratification

15
11 Limited availability of lister for transportation A
12 Limited realization of demands raised by store B
13 Personality development in workers A
14 Poor washing of overalls B
15 Missing of lead lamps from on board ships. B
16 Shortage of personnel protective equipments. B
17 Non-availability of certain parts of portable power tools
B
18 Disposal of waste items A
19 Shortage of different sizes of drill bits B
20 Fire in Galleys of Indian Naval Ships A

16
21 Irregular clean ship of bathrooms and workers changing rooms
A
22 Cramped workers changing room A
23 Communication gap between workers and management
A
24 Requirement of pest control to be done on a regular basis
A
25 Mishandling of computers A
26 Frequent long leave by workers A
27 Difficulty in getting assistance from other centre's in time B
28
Insufficient qty of electrical extension boards for working onboard
ships/submarines
A

17
29 Requirement of dot matrix printers at shop office C
30
Timely availability of printer cartridges for dot matrix, laser
and inkjet printers
C
31 Motivation corner for workers A
32 Insufficient sanitation facility B
33 Monsoon gear not made available in time C
34 Bathroom and terrace seepage B
35 Lack of safety awareness A
36 Requirement of new water purifier at shop floor C
37 Frequent failure of lift A
38 Out-station training of workers C
39 Improper space for dining hall and changing room B
40 Insufficient safety gears C

18
41 Shortage of fire fighting equipment at working place C
42 Inadequate medical facility C
43 Lack of anti-glare screen for computer c
44 Deficiency of hydraulic tools C
45 Non availability of a turner B
46 No training programs scheduled for QC members B
47 No energy conservation at shop floor A
48 Lack of hygiene consciousness amongst the workers A
49 Electrical hand saw for plywood cutting are not available C
50 Electrical planer for carpenters are not available C

51 Medical assistant is not available B
52 Lack of ratchet cutters B
53 Lack of safety belts B
54 Pest control in shop floor B
55 Shortage of lister C
56 Cleaning of water cooler A
57 Shortage of lockers in worker’s changing room C
58 Alcoholism among workers B
59 Ladies changing room A
60 Evenly distribution of workers among groups A
61 Updating of service documents on time C
62 Non receiving of personal pension order on time C
19

ABC Analysis (Bar graph)
Category
No.
of
problems
20
0
5
10
15
20
25
Category " A" Category " B" Category " C"
Series 1
Category " A"
Category " B"
Category " C"

• There were 24 problems in category ‘A’, 20 in category ‘B’ and
18 in category ‘C’
• Category ‘A’ problems could be resolved by using in house
resources and expertise
• Category ‘B’ problems could be resolved with the assistance of
other centers
• Category ‘C’ problems could be resolved after approval and
support from top management
21
ABC Analysis

• Problems identified in ‘’A’’
category : 24
• Solved Problems : 14
• Unsolved Problems : 10
Selection Of Problems
23
0
2
4
6
8
10
12
14
16
SOLVED UNSOLVED
14
10
No.
of
problems
Status of problems

Theme Based Stratification Of
Unsolved 'A’ Category Problems
Sl.No Problems Experienced Group
1
Innovative reconditioning of degaussing
cable onboard INS Betwa
Production
2 Shortage of water in Dept Production
3
Requirement of advanced training for all
personnel
Production
4 Limited number of listers available Service
5
No space available for accumulation of
emergency cables at shop floor
Production
24

Sl.No Problems Experienced Group
6
Communication gap between workers and
management
Service
7 Lack of safety awareness in workers Safety
8
Insufficient quantity of electrical extension
boards for work onboard ships
Service
9
SOP not being followed while working on
Galley onboard Indian Naval Ships
Safety
10
Repairing of shore charging Sockets of
Indian Naval Submarines
Production
25

26
50%
20%
30%
Production
Safety
Service

Production Related Problems
 Innovative reconditioning of degaussing cable onboard INS
Betwa
 No space available for accumulation of emergency supply
cables at shop floor
 Shortage of water in department
 Requirement of advance training for all personnel
 Repairing of shore charging Sockets of Indian Naval
Submarines
27

SN List of problems
QC Members Total
Score
SJ US DK AG SM SS
1
Innovative reconditioning
of degaussing cable
onboard INS Betwa
9 9 8 7 9 9 51
2
No space available for
accumulation of
emergency cables
7 7 7 6 8 8 43
3
Shortage of water in
department
8 8 7 6 8 8 45
4
Requirement of training for
all personnel
5 5 4 3 5 7 29
5
Repairing of shore
charging sockets of Indian
Naval Submarines
6 6 5 4 6 6 33
Problem Selection
(Rating Table)
28

Graphical Presentation of
Rating Table
0
10
20
30
40
50
60
Innovative
reconditioning of
degaussing cable
onboard INS
Betwa
Accumulation of
Emr. Cable Shortage of water
in Dept. Requirement. of
training Repairing of
Shore charging
Socket
PROBLEM
POINTS
29
51
43 45
29
33

Activity Plan Chart
(01 July 20- 04 Aug 20)
Activity
01July-04 August
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35
1. Identification of problems
2. Selection of problem
3. Define the problem
4. Analysis of problem
5. Identification of causes
6. Root cause analysis
7. Data analysis
8. Developing solutions
9. Foreseeing probable
resistance
10. Trial implementation
11. Regular implementation
12. Follow up/Review
PLAN

Problem Definition
33
 Unprecedented accident caused extensive damage to the Indian Naval ship Betwa causing
entire degaussing systems of the ship to non ops.
 A steel–hulled ship is like a huge floating magnet a large magnetic field surrounding it . As
the ship moves through the water, this field also moves which add or subtracts from the
earth’s magnetic field. Because of its distortion effects on earth magnetic field. The ship can
act as a trigger device for magnetic sensitive devices. So to reduce the ships effects on the
earth magnetic field. Degaussing system has to be installed.
 Degaussing is a process in which system of electrical cables are installed around the
circumference of ships hull running from bow to stern on both sides. A measured electrical
current is passed through these cables to restrict the ships induced magnetic field. To avoid
the distortion on magnetic sensitive devices
 OEM was unavailable and Shipbuilder refused to take the task.
 The entire refit schedule of the ship was affected.

34
Problem Definition
34
Degaussing Coil position of INS Betwa

Problem Definition
Impact of the problem:
 Degaussing systems will remain non-ops
 Vital equipment of ship was unprotected
 Other departments work also affected
 Ultimately, hamper the refit schedule of the ship
35

37
Problem Analysis
(4W-1H Method)
Activity Elaboration
What is the problem ?
Low insulation in degaussing
cables.
Where is the problem ? Onboard INS Betwa.
When is the problem ? After it slipped from docking blocks.
Who faces the problem ? Ship’s crew and Indian Navy.
How it happened ?
Due to ingress of sea water in
cables.

38
Problem Analysis
JOB: Restore of Degaussing system.
Period: Within a month defect raised .
Data taken from: Ships Defect Reporting System
Total Cables length to get replace : 2230 mtrs.
Data Collection
38

39
Goal of Our Team
(Bar Graph)
Goal: To restore whole Degaussing system with in limited period of
time.
0
500
1000
1500
2000
2500
2230
0
Repaired
Defective
Length
of
cables
in
mtrs.

Identification of Causes
(Fishbone Diagram)
Shortage of Manpower
Negligence
Untrained Manpower
Environment
Material Method
Improper Dismantling
Lack of modern tools Improper Assembling
Failure of
degaussing
system
Ageing of material
Deposit of Salt
on Material
Non Hygienic Condition
Congested space
41
Non-availability of material
Absenteeism
Quality of material
Poor Maintenance
Man
Position of Cable route
Fire proof cable not used

(Fishbone Diagram)
Man
Failure of degaussing
system
High retirement rate
Low recruitment
Unaware of advance technology
Inadequate training
Traditional mind set
Lack of awareness
42
Shortage of Manpower
Untrained Manpower
Negligence
Family Problem
Absenteeism
Low of morale
Health issues

Method
No responsibility
(Fishbone Diagram)
Time
constraints
Priority not set
Lack of
encouragement
43
Poor Maintenance
Water Tight Compound
Lack of Experience
Limited Expertise
Improper assembling
Complicated
Part
Lack of modern tools
Not available in
store
Lack of experience
Demand not raised
Failure of
degaussing system

Material
Substandard Material
Lack of timely inspection Not Contracted from OEM
Identification of causes
(Fishbone diagram)
Unavailability of Spares
44
Failure of
degaussing system
Not frequently used
Improper inspection
Ageing of material
Obsolete material
Long Time for drafting Contract
Old stock
Improper Storage
Corroded Components
Ingress of sea water

Environment
No proper ventilation
(Fishbone Diagram)
Closed compartments
Difficult to access
Non availability of assistance
Long running cables
45
Failure of degaussing
system
Congested space
Lots of machineries
Manufacturing Design
Lack of maintenance
Placing of cable bunches
Frequent Failure

46
Finding Out The Probable Root Causes

Finding Out Probable Root Cause
(Why – Why Analysis)
Failure of power distribution system
Traditional mind set
Lack of awareness
Shortage of Manpower Negligence
Low Recruitment
Govt. policy
MAN
Untrained Manpower
Inadequate training
Lack of Motivation
why
why
why why
why
why
why why
why
47

48
METHOD
why
why
why
why
Improper Assembling
Hastiness
Time constraint
Not available in store
Lack of modern tools
Unavailability of spares
why
Demand not raised
why
why
why
why
High import cost from OEM
Reuse of existing spares
Obsolete Material
why
Failure of Degaussing system
why

ENVIRONMENT
why
why
No Proper Ventilation Long running cables
Placing of cable bunches
Major activities involves
for cable replacement
Closed compartments
why
why
why
why
Congested space
Lots of machineries
Manufacturing Design
why
why
why
49

MATERIAL
why
why
why why
why
why
why
Corroded Components
Ingress of Sea Water
Kneeling of ship
Demand not raised Poor Insulation
Lack of timely Inspection
why
50
Ageing of material
Obsolete Spare
why
Spares unavailability

Probable Root Cause
51
Ingress of sea water in degaussing JB’s & cables
which led to corrossion of JB’s.
Cable length around ships circumference of ships
hull running from bow to stern on both sides approx.
length 2230 mtrs.
Cable replacement involves several major activities .

53
JOB: Defects in Degaussing cables & Jb’s.
Period : Apr 19 – Mar 20
Data taken from : Ships Defect Reporting
System & Maintenance Record
Ship
Unavailability of spare
Degaussing
Cables
Degaussing JB’s
Brahmaputra 1 -
Gomati 1 1
Beas 1 -
Delhi - 1
Mysore 1 -
Total 4 2
Data Analysis
0
0.2
0.4
0.6
0.8
1
1.2
Cables JB's
Ships
Defects
in
Cables
&
JB’s

55
Total
Quality
Improvement
How to do?
Who will do?
What to do ?
Where to do ?
When to do?
Developing Solution
5W-1H method
Onboard INS Betwa Our department workers
After clearance from IHQ and
Ship staff
Why to do ?
To restore degaussing
system.
Repair of affected degaussing
cables & JB’s

56
Developing Solutions
ROOT CAUSE SUGGESTIONS CONCLUSION REMARKS
• Long running
cables
•Major activities
involves for
cable
replacement
Approach OEM
Approach
Shipbuilder
• OEM not found
•Refused to repair
Cable
replacementchase
• Cables length were too long and
runs through various
compartments which makes it
lengthy process
•Time consuming
•High cost &high volume
•Uncertainty about required
available quantity
Cables insulation
improvement &
Reconditioning of
JB’s
•Design/diagram
•Material Accepted
Not
Accepted
Not
Accepted

57
Foreseeing probable resistances

Foreseeing Probable
Resistances
58
Management approval
Ship staff & co-workers
Safety Department
Availability of material

Overcome Probable
Resistance
Probable Resistance Solution
Management Approval For
Innovative method
After briefing management agreed for the
Innovative method
Ship staff & co-workers
How the innovative method will ease the
operation and maintenance of the system
explained to them
Safety Department
Certified Modern tools and insulating materials
to ensure safety.
Availability of material Material was arranged in-house.
59

61
1. After innovative solution was approved from higher authority our team had isolated
the supply and degutted the cable from clamp and also disconnected degaussing
connection in Jb’s.
Trial Implementation & Check
Performance

62
2. Before proceeding for the innovative solution of Degaussing system , circuit drawings
were collected from the design & documentation cell of the ship to ensure the rating and
quantity cables and JB’s onboard.
Performance
Degaussing diagram

63
Performance
3. As per innovative solution first we did a trail on a single cable by
cutting the cable outer insulation at the loop cylindrically and
hanged the cable for whole day so that water can be drained out.

64
Performance
4. After cutting the outer layer insulation. Cable was left for dry out
the moisture.
Water draining
from cable
Cable left for dry
out moisture

65
Performance
5. To remove total moisture of cable hot air was blowned on
innercore of cable. Once the insulation was improved with
satisfactory results. we started wrapping the cable with cotton tape.

66
6. We also insulated the outer layer of cable and Jb’s cable gland
with heat shrinking sleeve so that water can not renter in the cable
through Jb’s again.
Performance

67
Performance
BEFORE AFTER

Before commencement of work the
S.O.W was projected to the IHQ
(Navy) & DGM (L) for approval .
The QC team was permitted to
carry out the work.
The same was also registered in
QA division.
68
Management Approval

 INS Betwa had not reported any defect related to
degaussing JB’s and cables since this system was
energized.
This type of modifications was carried out for similar defects
70
Regular implementation

Appreciation letter
71
 The innovative method not only
helped us in restoring major
accident but also ensured the safe
operation of the vital equipments
and degaussing system in time.
 Management appreciated our QC team’s splendid effort.
 Our team was also honored by DGM(L) and GMR, which will
keep motivating us to continue to do this in future.

72
• Repairing started –10 July
20
• Onboard Trial – 29 July 20
• Completion of project – 4
Aug 20
• Management
Reviewed – 4 Aug 20
• Study on existing system –
3 July 20
• Demand initiated – 6
July 20
• All material received
– 9 July 20
• Implemented – 4 Aug 20
Act Plan
Do
Check
PDCA Cycle
72

Milestone Chart
(Gantt Chart
Activity
01July-04 August
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35
1. Identification of problems
2. Selection of problem
3. Define the problem
4. Analysis of problem
5. Identification of causes
6. Root cause analysis
7. Data analysis
8. Developing solutions
9. Foreseeing probable
resistance
10. Trial implementation
11. Regular implementation
12. Follow up/Review
PLAN ACTUAL

Cost Benefit Analysis
75
Rate Sheet as per Market
Sl Item Qty Unit
Unit
Price
Total
1
Degaussing cables (14x25
Sq.mm)
2230 Mtr 3100 6913000
2 Mandays for degutting 300 No 2224 667200
3 Mandays for regutting 350 No 2224 778400
Grand Total
83,58,600

76
Project Expense Sheet
Sl Item Qty Unit
Unit
Price
Total
1
Cotton Insulation tapes (18
mtrs)
450 No 380 171000
2 PVC Tape (25 mtrs) 120 No 15 1800
3
Shrinking Sleeves for
cables.(50 mm)
430 Mtr 625 268750
4
Man days for degutting and
regutting
350 No 2224 778400
Grand Total
12,19,950

 Mandays will be consumed for Degutting and Regutting of
cables(650X 2224) = Rs 14,45,600 /-
 Material expenses = Rs 69,13,000/-
 Total project expense = Rs 12,19,950/-
 Market value = Rs 83,58,600/-
 Saving = Rs 83,58,600 – Rs 12,19,950 = Rs 71,38,650/-
(Approx 71 Lakhs)
77

 Money saved approx Rs. 68 Lakhs
 Goal Achieved
 Platform available for exploitation.
78
Tangible Benefits
0
500
1000
1500
2000
2500
Defective Repaired
Defective
Cables
0
500
1000
1500
2000
2500
Defective Repaired
Defective
Cables
Before After
2230 2230
0 0

 Increased confidence amongst workers.
 Co-ordination among workers towards team building
 CBM Amongst ship staff/user .
 Inspiration for thought towards in house indigenous
solutions with quality concepts.
79
Intangible Benefits

0
20
40
60
80
100
Confidance
Coordination
Inspiration
Knowledge
Experience
Self satisfaction
Before
After
80
Special Gains

82
Follow-up and Review
Job : Innovative reconditioning of degaussing system onboard INS Betwa.
Period : 1 July 2020 to 4 Aug 2020
Data : Ships Defective Reporting System
Remark:
 Degaussing system working successfully
 Regular audit and inspection
 Documentation and practiced as standard operating procedure
 Display and training

• Pie chart
• Bar graph
• Data collection
• Process chart
• Fishbone diagram
• 4W-1H
• Brain storming
• PDCA cycle
• Milestone chart
• Radar Chart
QC Tools & Technique Used
83

In-house
Drawing Office
&
QA Division
84
Special Thanks

Our Achievement-2018
87
NCQC-2018
PAR EXCELLENCE

88
NCQC-2019
PAR EXCELLENCE

89
IDQCC-2021
PAR EXCELLENCE

90
ICQC-2021 HYDERABAD
PAR EXCELLENCE

91
NCQC-2021 COIMBATORE
PAR EXCELLENCE

92
Naval Dockyard, Mumbai
Integrated Quality Concepts – “The
Gateway to Global Leadership”

Innovative reconditioning of degaussing system INS Betwa IDDQC2022.pptx

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