TQM process implementation to increase hydraulic oil recovery in Heavy earth Moving Machinery of a mining company

1. 1

2. 2

3. INTRODUCTION
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4. 4

5. TQM PROJECT
ON
“Reduction Of Loss Of
Hydraulic Oil During
Used Oil Recovery.”

6. PROJECT DOCUMENT-1
TITLE: Reduction of loss of Hydraulic oil during used oil recovery in Wheel Loaders
from 3437 liters to 2000 liters.
FACILITATOR : Laxman Aldonkar.
TEAM LEADER : Vijayanand Chakrasali
MEMBERS : Arindam Das (Maintenance)
Subhajit Sen (Maintenance)
Shrinivas Pattar(Mining)
Azad Kadkade (Plant Operations)
Start Date: 11th
April ‘10
COMPLETION DATE: 31st
October‘11
Number of Meetings held so far: 16
Average Attendance of the Team: 84.5%
DATE: 11th
December ‘11
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7. STEP 1: DEFINE PROBLEM
The following Trend Chart displays overall loss of oil during oil recovery (month wise)
for the year 2010-11
TOOL USED: TREND CHART
Month 10-Apr 10-May 10-Jun 10-Jul 10-Aug 10-Sep 10-Oct 10-Nov 10-Dec 11-Jan 11-Feb 11-Mar
Total Oil
loss in
liters
1206 1238 1562 1514 1422 1434 1849 1874 1656 120 1347 808
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8. The following data displays the trend of oil recovery for the year 2010-11 (monthwise)
STEP 1: DEFINE PROBLEM
TOOL USED: STRATIFICATION AND CHECK SHEET
Loss during recoveryENGINE HYDRAULIC TRANSMISSION OTHERS
MONTH
Apr-10 541 513 80 72
May-10 243 746 224 25
Jun-10 252 930 269 111
Jul-10 170 1064 230 50
Aug-10 204 1021 92 105
Sep-10 142 969 313 10
Oct-10 346 1222 197 84
Nov-10 301 1346 190 37
Dec-10 291 896 413 56
Jan-11 26 84 10 0
Feb-11 39 975 308 25
Mar-11 126 173 492 17
TOTAL 2681 9939 2818 592
Monthly oil recovery 10-11
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9. The following data displays the trend of oil recovery for the year 2010-11 (monthwise)
STEP 1: DEFINE PROBLEM
TOOL USED: Pareto Graph
Loss during recoveryHYDRAULIC TRANSMISSION ENGINE OTHERS
TOTAL 9939 2818 2681 592
Loss in oil recovery 10-11 (April - March)
Hydraulic Oil is considered for study
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10. STEP 1: DEFINE PROBLEM
Trend Chart displays overall loss of Hydraulic oil during oil recovery (month wise) for
the year 2010-11
TOOL USED: TREND CHART
Month Apr-10 May-10 Jun-10 Jul-10 Aug-10 Sep-10 Oct-10 Nov-10 Dec-10 Jan-11 Feb-11 Mar-11
Hydraulic 513 746 930 1064 1021 969 1222 1346 896 84 975 173
Loss in Hydraulic oil Recovery
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11. The following data displays the trend of oil recovery for the year 2010-11 (monthwise)
STEP 1: DEFINE PROBLEM
TOOL USED: STRATIFICATION AND CHECK SHEET
Hydraulic Oil April May June July August SeptemberOctober NovemberDecemberJanuary February March Total
WHEEL LOADER 320 265 385 281 324 175 685 307 345 25 305 20 3437
EXCAVATOR 60 224 259 430 300 342 281 501 280 33 397 145 3252
DUMPER 133 243 246 303 292 442 172 501 215 26 239 0 2812
DOZER 0 14 40 50 105 10 84 37 56 0 34 8 438
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12. TOOL USED: PARETO CHART
STEP 2: OBSERVATION
The following chart displays the trend of hydraulic oil recovery as per unitwise
HEMM Wheel Loaders Excavator Dumper Dozer
Loss of oil (ltr) 3437 3252 2812 438
Prioritized for the project
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13. TOOL USED: STRATIFICATION AND CHECK SHEET
STEP 2: OBSERVATION
The following trend chart displays the trend of hydraulic oil recovery in wheel loaders for 2010-11
MONTH ISSUE(in liters) RECOVERY(in liters) OIL LOSS(in liters)
Apr-10 430 110 320
May-10 465 200 265
Jun-10 385 0 385
Jul-10 281 0 281
Aug-10 564 240 324
Sep-10 385 210 175
Oct-10 905 220 685
Nov-10 627 320 307
Dec-10 545 200 345
Jan-11 65 40 25
Feb-11 635 330 305
Mar-11 220 200 20
TOTAL 5507 1860 3437
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14. TOOL USED: TREND CHART
STEP 2: OBSERVATION
The following trend chart displays the trend of hydraulic oil recovery in wheel
loaders.
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15. Drain oil from
damagepart of
machine
Transferring of
drained oil to barrel
STEP 3(a): ANALYSIS
Periodic draining of oil
from machines
Collection of drain oil
Measurement of oil
TOOL USED: FLOW CHART
Oil issued for
Topping
Collected oil
returned Stores
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16. STEP 3(b): ANALYSIS
TOOL USED: BRAINSTORMING
Total No.Of outcome:55
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17. STEP 3(b): ANALYSIS
The following causes are obtained after brainstorming session:
Spillage during collection of oil.
Spillage during topping up of oil
Delay in attending b/ds
Machine can’t be attended instantly as it is heated up due to operation.
Irregular Trend monitoring
Wrong Accountability on issue/return & data recording.
No replacement of critical hoses till failure
Unable to identify non-performing m/c & replace the same
Premature failure of spares.
Poor quality of material
Faulty report from operator
Less awareness among staff
Hoses in abrasive condition.
Report obtained at the end of the shift.
TOOL USED: BRAINSTORMING
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18. STEP 3(b): ANALYSIS
TOOL USED: BRAINSTORMING
 Accidents.
 Poor Packing.
 Loose plug.
 Hydraulic filter replacement.
 Seal leakage.
 Lack of communication.
 Overfilling of oil in tank.
 Loss during transportation.
 Lack of manpower
 Lack of planning
 Late report of breakdown
 Flaw in operation.
 Very minute leakage which is very rarely visible.
 Hydraulic pump failure
 Improper report from operator
 Lack of supervision.
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19. TOOL USED: CAUSE AND EFFECT DIAGRAM Controllable Causes
STEP 3(c): ANALYSIS
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20. STEP 3(b): ANALYSIS
TOOL USED: GENBA OBSERVATION
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21. STEP 3(b): ANALYSIS
TOOL USED: GENBA OBSERVATION
Lead distance of around 2kms from Workshop to Mines increases
the response time to attend any kind of Breakdown.
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22. STEP 3(b): ANALYSIS
TOOL USED: CHECKSHEET
MONTH SEAL/O-RING FAILURE HOSE FAILURE
PUMP/ CONTROL VALVE
FAILURE
APRIL ’10 70 202 0
MAY ’10 50 186 0
JUNE ’10 107 190 48
JULY ‘10 79 176 0
AUGUST ’10 60 169 65
SEPTEMBER ’10 56 89 0
OCTOBER ’10 112 410 65
NOVEMBER ’10 30 257 0
DECEMBER ’10 97 235 0
JANUARY ’11 5 20 0
FEBRUARY ’11 87 178 0
MARCH ’11 20 0 0
TOTAL LOSS 773 2112 178
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23. STEP 3(b): ANALYSIS
Probable
causes
confirmed
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24. Proper and accurate collection of oil
STEP 4: ACTION
(IDENTIFICATION OF POSSIBLE COUNTER MEASURE)
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25. Proper and accurate collection of oil
STEP 4: ACTION
(IDENTIFICATION OF POSSIBLE COUNTER MEASURE)
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26. STEP 4: ACTION
Sl.
No.
Root Cause Counter measure Responsibility Method Target
Date
Remarks
1 Spillages Oil suction pump for
topping up & draining
Uddesh/
Himanshu
30/10/11 Implemented
2 Spillages Collection of oil from
replaced filter via use of
oil screening tray
Laxman
Aldonkar
Installation of
used oil
collecting screen
15/09/11
3 Does not follow
regular monitoring
of m/c leakages
Replacement of hoses in
advance as per
conditional monitoring
Rajesh/
Subhajit
Conditional
Monitoring
01/07/11 Put into practice in
for New H-series
Wheel Loaders
4 Delay in attending
b/ds
By attending leakage
source instantly
Ranjan/
Arindam
Mobile service
vehicle at mines
In practice
5 No replacement of
critical hoses till
failure
Replacement of all critical
hoses during scheduled
overhaul
Ashok/
Subhajit
Scheduled
Overhaul
In practice
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27. Trend Chart displays overall loss of Hydraulic oil in Wheel loader during oil recovery (month wise) for the
year 2010-11
TOOL USED: TREND CHART
APR '10 MAY '10 JUN '10 JUL'10 AUG '10 SEP '10 OCT'10 NOV'10 DEC '10 JAn'11 FEB '11 MAR '11 APR '11 MAY '11 JUN'11 JUL '11 AUG '11 SEPT'11 OCT '11
320 265 385 281 324 175 685 307 345 25 305 20 180 197 120 109 102 79 146
AfterBefore
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STEP 5: CHECK

28. STEP 5: CHECK
MONTH ISSUE(in litres) RECOVERY(in litres) OIL LOSS(in litres)
11-Apr 485 305 180
11-May 680 483 197
11-Jun 565 445 120
11-Jul 189 80 109
11-Aug 182 80 102
11-Sep 229 150 79
11-Oct 455 309 146
TOTAL 2785 1852 933
The following chart displays the trend of hydraulic oil recovery as per unitwise for 2011-2012
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TOOL USED: PARETO CHART

29. STEP 5: CHECK
MONTH APR'10 MAY'10 JUN'10 JUL'10 AUG'10 SEP'10 OCT'10 NOV'10 DEC'10 JAN'11 FEB'11 MAR'11 APR'11 MAY'11 JUN'11 JUL'11 AUG'11 SEP'11 OCT'11
HYDRAULIC
OILLOSS
513 746 930 1064 1021 969 1222 1346 896 84 975 173 1061 497 336 239 269 299 451
Trend Chart displays overall loss of Hydraulic oil during oil recovery (month wise) for the year 2010-11
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TOOL USED: TREND CHART

30. STEP 5: CHECK
MONTHLY OIL LOSS FOR THE YEAR 2011-12 (IN LITRES)
MONTH HYDRAULIC TRANSMISSION ENGINE OTHERS
11-Apr 1061 128 421 102
11-May 497 151 591 12
11-Jun 336 120 419 0
11-Jul 239 128 181 0
11-Aug 269 144 221 0
11-Sep 299 84 197 0
11-Oct 451 263 238 70
TOTAL 3152 1018 2268 184
The following table displays the trend of oil reduction as per oil classwise for the year 2011-2012
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TOOL USED: PARETO CHART

31. Tools used; ---------------------------------
Other Area for implementation
STEP 5: CHECK
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32. STEP 5: CHECK
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33. BENEFITS OBTAINED
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34. BENEFITS OBTAINED
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35. A
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Acknowledgement
We are grateful for the guidance, support &
motivation provided in completion of our first TQM
project of SRL & SMCL
 Mr.P. D. Kulkarni ( TQMConsultant)
Mr. M. K. Reddy (Bussiness Head)
Mr. Shrishaila Gouda (AGM)
Mr. Govindaraj (GM Bussiness Excellence)

36. THANK YOU
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