Six Sigma Project - Enhancement availability of UBH Furnace

1. Six Sigma Project
Availability Enhancement of UBH Furnace
Define
Measure
Analyze
Improve
Control
Project Leader : Ashish Mishra
Project Start :15 Aug 2023
Project Complete :17 Oct 2023
Cost Saving (Rs/year) :1890000

2. Phase 1: DEFINE
Define
Measure
Analyze
Improve
Control
DEFINE
2

3. Identify Project
Develop Project
Charter
Identify CTQ
Parameter
Map Current
Process
DEFINE PHASE
3

4. Identify Project
VOB:UBH AVALABILITY DATA FY21-22
UBH AVAILABILITY DATA FY21-22
Loss (Hrs) Total Loss (Hr) Planned (hr) Available time(Hr) Availability %
Apr-21 480 720 240 33.33
May-21 240 744 504 67.74
Jun-21 552 720 168 23.33
Jul-21 96 744 648 87.10
Aug-21 144 744 600 80.65
Sep-21 408 720 312 43.33
Oct-21 144 744 600 80.65
Nov-21 312 720 408 56.67
Dec-21 360 744 384 51.61
Jan-22 96 744 648 87.10
Feb-22 360 672 312 46.43
Mar-22 360 744 384 51.61
Monthly 296 730 434 59.45

5. Identify Project
Daily shift report (source of loss data )

6. Identify Project
UBH FURNACE: PLANNED VS AVAILABLE TIME FY 21-22
720
744
720
744 744
720
744
720
744 744
672
744
730
240
504
168
648
600
312
600
408
384
648
312
384
434
0
100
200
300
400
500
600
700
800
Apr-21 May-21 Jun-21 Jul-21 Aug-21 Sep-21 Oct-21 Nov-21 Dec-21 Jan-22 Feb-22 Mar-22 Monthly
TIME(HRS)
MONTH
Planned (hr) Available time(Hr)

7. Identify Project
UBH AVAILABILITY % TREND FY 21-22
Project: To
enhance
availability
33.33
67.74
23.33
87.10
80.65
43.33
80.65
56.67
51.61
87.10
46.43
51.61
59.45
0.00
10.00
20.00
30.00
40.00
50.00
60.00
70.00
80.00
90.00
100.00
Apr-21 May-21 Jun-21 Jul-21 Aug-21 Sep-21 Oct-21 Nov-21 Dec-21 Jan-22 Feb-22 Mar-22 Monthly
%
MONTH
Availability %

8. Identify project
Develop Project
Charter
Identify CTQ
Parameter
Map Current
Process
DEFINE PHASE
8

9. Voice of Customer (Kano Classification)
 VOC translated in CTQ 9
VOB Business
issues
CBR CTP
KANO
CLASSIFIC
ATION
UBH Furnace
downtime is
high/unavail
able for
production
Output
Unable to
meet the
demand &
Maintenance
cost is high
Improve
availability of
furnace &
increase
output
Increase
availability from
59% TO 83%
MUST BE

10. Identify problem
Statement
Develop Project
Charter
Identify CTQ
Parameter
Map Current
Process
DEFINE PHASE
10

11. PROJECT CHARTER
11

12. Business Opportunity
12
Cost
Direct Cost Indirect Cost
Description/Calculations Value INR Description/Calculations Value INR
Current
Spares consumption & Cost:
1. Inner door(4037271/4024216): 1 per year
2. Inner Rail: 0.5 per year(4014390) (12-8/4*2)
3. RC FAN (4014395) : 0.75 per year (6/4*2)
4. Inner Handler(4015323): 0.375 per year (3/4*2)
5. Repairing cost
(po:400441/406925/422658/423601/428972): per year:
1.Rs. 350000/pc *1 = Rs350000
2.Rs. 548000/pc *0.5= Rs274000
3.Rs. 1335000/pc *0.75=Rs.1000000
4.Rs. 719000*0.375= Rs.269000
5.Rs.524000
Planned time= 730 hrsper month
Current availability = 59.45%
CT=20 HRS
Production per batch =384 cups
Monthly production= (384/20)*0.5945*730=8332
cups
Proposed
Spares consumption & Cost:
1.New Inner door Material change for better life: 0.5 per
year
2.Inner Rail indigenisation :0.5 per year
3.RC FAN indigenisation: 0.75 per year
4.Inner Handler indigenisation : 0.375 per year
5.Repairing cost after increased availabilty 40%
1.Rs.588500/pc*1/2 =Rs.294250
2.Rs.135000*0.5=Rs.67500
3.Rs.315000/pc*0.75=Rs236250
4.Rs.261000*0.375=Rs.97875
5.Rs.524000*0.6=Rs.314000
Planned time= 730 hrsper month
New availability =83.23 (40% increase)
CT=20 HRS.
Production per batch =384 cups
Monthly production= (384/20)*0.8323*730=11665
cups
Monthly increase in production: 11665-8332=3333
cups
Estimated Saving
1.Inner door per year
2.Inner rail per year
3.RC Fan per year
4.Inner Handler per year
5.Reduction in Repairing cost per year
1.Rs350000-294250=RS.55750
2.Rs.274000-67500=Rs.206500
3.1000000-236250= Rs.976350
4.Rs.269000-97875=Rs.171125
5.Rs.524000-314000=Rs.210000
Production cost per batch = Rs 58351
Production cost per cup=58351/384
Considering 10% profit, profit per cuP
Monthly increase in profit=(3333*15.1)
Annual increase = Rs.607939
Rs 58351
Rs152
Rs15.2
Rs50661
Rs.607939
Actual Considering factor of safety: 0.9
Total saving per
year:Rs55750+206500+976350+17112
5+210000=Rs.1619725*0.9=Rs.145700
0
Annual increase Rs.607939
Actual Saving Round off(10-12% price hike) Saving per year:Rs1282000 Round off Rs.608000
Annual saving Rs.1282000+Rs.608000=Rs1890000

13. Indirect cost (CONSUMABLES)
13
Running Cost
Rating Qty
Consumptio
n
Running
time(hrs) in
one cycle
Total
consumption(
kwh&cubmt&
KG)
Unit
cost(Rs/uni
t
Running
cost per
cycle(Rs)
TOP COOL RC FAN 2HP 1.5KW 2 3 4 12 7 84
FURNACE RC FAN 5HP 3.75KW 2 7.5 16 120 7 840
BLOWER 5HP 3.75KW 1 3.75 16 60 7 420
BURNER LPG 3.2CUBMT/HR 6KG/HR 6 36 16 576 60 34560
ATMOSPHERIC LPG 3CUBMT/HR 5.67KG/HR ….. 5.67 16 90.72 60 5443.2
ENDO 45CUBMT/HR 45CUBMT/HR ….. 45 16 720 23 16560
NITROGEN 24CUBMT/HR 30KG/HR ….. 30 4 120 6.15 738
58645.2 Total cost
58000 Roundoff
n2 1cubmt/hr 1.25kg/hr
lpg 1cubmt/hr 1.89kg/hr

14. Indirect cost (CONSUMABLES)
14
ENDO COST CALCULATION
CATALYST LPG Electricity Total
Cons(kg/Year) 800 320 Cons (cubmt/hr) 11 Rs/kwh 7 Rs/hr 2099.858
Quaterly
consumption
200 80 Rs/kg 60.25 Cons (kw per hr) 90 flow(cubmt
/hr
90
Rs/Kg 1985 985 Density (kg/cub mt) 1.89 Rs/hr 630 Rs/cubmt 23.33175
Rs/YR 1588000 315200 Cons (kg/hr) 20.79
Rs/DAY 4350.685 863.5616 Rs/hr 1252.5975
Rs/HR 181.2785 35.98174
Total (rs/hr) 217.260274
Rs.1985/kg
Rs.985/kg
Ni catalyst cost Catalyst bed cost

15. Indirect cost (CONSUMABLES)
15
Rs.61.24/kg
Rs.11.6/cubmt
or Rs.6.1per kg
LPG cost
Nitrogen cost

16. Indirect cost (flowmeter reading)
16
Nitrogen reading
Endo reading

17. Direct Cost (Inner door)
17
Old inner door New inner door

18. Direct Cost (Roller Rail)
18
Inner rail imported
This amt is for 8 pc

19. Direct Cost (fan assembly)
19
RC Fan assly imported
This amt is for 4 pc

20. Direct Cost (inner Handler)
20
Inner Handler imported

21. 21
Direct Cost(Indian Quotation)

22. 22
Direct Cost(Indian Quotation)

23. Identify problem
Statement
Develop Project
Charter
Identify CTQ
Parameter
Map Current
Process
DEFINE PHASE
23

24. PROCESS MAP
24

25. PROCESS MAP
25

26. SIPOC Diagram
26
Production.
1.Information of failure
from production dept.
2.Probable reason from
operator/supervisor
3.Manpower
4.Tools
5.Spares
6.Checksheet
Maintenance Furnace available for
production
Production
COOLING DISASSEMBLY/CL
EANING
SPARES CHANGE FABRICATION ASSEMBLY COLD DUMMY
TRIAL

27. Top-down chart
27
Cooling Disassemb
ly/Cleanin
g
Spares change Fabrication/Bri
ck lining
Cold trial
Assembly
 Step by
step
temp
reductio
n
 Inner
door
open-
close at
interval
of 1hr
 RC FAN
RUNNIN
G
 Removal of
Pnm cyl,
Housing &
then door
 Removal of
damaged
bricks
 Removal of
Roller, Rail,
chain guide
& HANDLER
 Cleaning of
gas pipes &
Flowmeters
& Burner
spark plugs
 Change of
cylinder/cyl
seal kit
 Filling of
ceramic
blanket into
door for
insulation
 Change of
Roller/pin
 Change of Rail
 Change of
spark plugs if
required
 Removal of
bend from
door
 Gas & water
Leakage
correction by
fabrication
 New brick
lining for door
sealing
 Fitment of
Handler,
Guide, Rail
&Roller-pin
 Fitment of
Inner door,
Housing, &
then Pnm
cyl
 Joining of
door with
Cyl
 Mechanical
movement
of Chain,
Handler,
Roller
 Opening/cl
osing of
door
 Sealing
check from
inside
furnace

28. Quick Wins Identification
28

29. Quick Wins implementation status
29

30. Quick Wins impact
30
UBH AVAILABILITY DATA JULY22-OCT22
Loss (Hrs) Total Loss (Hr) Planned (hr) Available time(Hr) Availability %
Jul-22 288 744 456 61.29
Aug-22 200 744 544 73.12
Sep-22 200 720 520 72.22
Oct-22 200 744 544 73.12
Total 888 2952 2064 69.92
Monthly 222 738 516 69.92

31. Quick win Impact
UBH AVAILABILITY % TREND (BEFORE QW VS AFTER QW)
Increase
from 59 %
to 69.92%
61.29
73.12
72.22
73.12
69.92
54.00
56.00
58.00
60.00
62.00
64.00
66.00
68.00
70.00
72.00
74.00
76.00
Jul-22 Aug-22 Sep-22 Oct-22 Monthly
% MONTH
Availability %
33.33
67.74
23.33
87.10
80.65
43.33
80.65
56.67
51.61
87.10
46.43
51.61
59.45
0.00
10.00
20.00
30.00
40.00
50.00
60.00
70.00
80.00
90.00
100.00
%
MONTH
Availability %
BEFORE AFTER

32. Phase 2 :- MEASURE
Define
Measure
Analyze
Improve
Control
MEASURE
32

33. List & screen X’s
Measurement
system analysis
Plan for Data
collection
Define baseline
performance
MEASURE PHASE
33

34. PARETO CHART FY 21-22
80% LOSSES
BECAUSE OF
THREE FACTORS
1.INNER DOOR
FAILURE
2.BURNER
FAULT
3.HANDLER
ISSUES
FACTORS PARETO FY21-22

35. 35
Brain storming: Probable causes (INNER DOOR FAILURE)
1.Air supply failure
2.Pnm cylinder malfunctioning
3.Leakage of compressed air
4.Misalignment of door with
cylinder
5.Sudden pressure drop
6.Door stucking with furnace body
7.Door bend/bulged
8.Cracks in door
9.Overusage of door
10.Bricks damaged
11.Incomplete movement of door
12.Limit switch failure
13.Batch interlocking failure
14.Blanket failure
15.Valve failure
16.Excess loading
17.Programming error
18.Excess Glass wool filling
19.Overusage of glass wool
Participants::
Mechanical Maintenance Electrical Maintenance Production Metallurgy
1.Ashish Mishra 1.Anurag sharma 1. Prabhat Kumar 1.ShivamGupta
2. Vikash Sharma 2.Kunj Bihari Chhipa
3.Virendra choudhary
20.Bypass of output devices (Pressure/flow
switches, timers )
21.Malfunctioning flow controls for door
speed
22.Housing sealing rope failure
23.Housing bend
24.Failure of locking mechanism for sealing
25.Arch failure
26.Poor heat heat capacity of door at
950deg cel

36. 36
All Probable Causes
prioritized to get
Potential Causes
based on the severity
ratings given by Cross
Functional Team
Potential
causes X’s
CE MATRIX 0F PROBABLE CAUSES (INNER DOOR FAILURE)

37. 37
Brain storming: Probable causes (X’s) for BURNER FAULT
1.LPG supply failure
2.Air supply failure
3.Valve malfunctioning
4.Burner line choking
5.Air Blower failure
6.Spark rod failure
7.Falme sensor failure
8.Air Gap disturbed
9.Pre-mix air failure
10.Seal failure
11.Controller issue
12.Exhaust choking
13.Carbon deposition
14.Recuperator damage
15.Mounting issue
16.Radiant tube leakage
17.Insufficient air through
proportional valve
Participants
Mechanical Maintenance Electrical Maintenance Production
1.Ashish Mishra 1.Vinod Mahto 1. Prabhat Kumar
2.Abhishek sharma 2.Kunj Bihari Chhipa
3.Virendra choudhary
18.Unfiltered air
19.Unequal distribution of air
20.Programming issue
21.Spark/flame rod insulation failure
22.Sequence (air-lpg-spark-flame-repeat)
timing failure
23.Abnormal voltage supply: Transformer
failure
24.Lance tube failure

38. 38
All Probable Causes
prioritized to get
Potential Causes
based on the severity
ratings given by Cross
Functional Team
Potential
causes X’s
CE MATRIX 0F PROBABLE CAUSES (BURNER FAULT)

39. 39
Brain storming: Probable causes (X’s) for HANDLER ISSUES
1.Motor failure
2.Gear box failure
3.Main chain damage
4.Handler Dog damage
5.Guide Disturbed
6.Misalignment of chain/dog/guide
7.Locking pin damage
8.Interlocking failure
9.Tray Position out
10.Cup falling
11.Drive failure
12.Cam failure
13.Rollers misaligned
13.Roller rail bend
14.Rail joining bolts damaged
15.H-bricks damaged
16.H-Bricks cap damaged
17.Rollers Missing
Participants::
Mechanical Maintenance Electrical Maintenance Production Metallurgy
1.Ashish Mishra 1.Anurag sharma 1.Prabhat Kumar 1.ShivamGupta
2.Vikash Sharma 2.Kunj Bihari Chhipa
3.Virendra choudhary
18.Welding defect
19.Overusage of HANDLER
20.Handler Dog tilting failure
21.Handler Dog Fitment issue
22.Level of rollers disturbed
23.Marginal gap between tray &
radiant tube

40. 40
All Probable Causes
prioritized to get
Potential Causes
based on the severity
ratings given by Cross
Functional Team
Potential
causes X’s
CE MATRIX 0F PROBABLE CAUSES (HANDLER ISSUES)

41. MEASURE PHASE
List & Screen X’s
Plan for Data
Collection
Measurement
System Analysis
Define Baseline
Performance
Plan for Data
Collection
41

42. Data Collection Plan
Ashish
Ashish
Ashish
Ashish
Ashish

43. Data Collection Plan
Ashish
Ashish
Ashish

44. Data Collection Plan
Ashish
Ashish
Ashish

45. MEASURE PHASE
List & Screen X’s
Plan for Data
Collection
Measurement
System Analysis
Define Baseline
Performance
45
MEASURE

46. Baseline Performance
Data Period: Apr’21-Mar’22
 As per Yield, Current Sigma level : 1.2 46
Current Level
Target Level
336
264
600
96
168
408
192
312 312
96
408
360
296
720 744 720 744 744 720 744 720 744 744
672
744 730
0
100
200
300
400
500
600
700
800
Total Loss (Hr)
Planned (hr)
Month
Time
(Hrs)
Loss % =
Loss hrs
Total planned hrs
X 100
X 100
Yield = 100-40.54 = 59.45 %
730
296
Loss % =
Loss% = 40.54 %
From
above
graph

47. 47
Phase 3: Analyze
Define
Measure
Analyze
Improve
Control
Analyze

48. 48
PROCESS FAILURE MODE & EFFECT ANALYSIS
Process
Step
Function
Requirement
s
Potential
Failure
Mode
Potential
Effect(s)
of Failure
Severity
Classification
Potential
Causes(s)
of Failure
Occurrence
Current
Process
Controls
Prevention
Current
Process
Controls
Detection
Detection
RPN
Severity
Zone
Detection
Zone
Priority
Level
Recommended
Action
Responsi
bility
& Target
Completi
on
Date
Action Results
Actions
Taken
& Effective
Date
Severity
Occurrence
Detection
RPN
Furnace
Heating/
Cooling
Gradual/unif
orm
heating/cooli
ng & all 6
burners must
be working
Abnormal/non
uniform
heating/coolin
g & all burners
not working
Inner door
bending due to
thermal shocks
3
1.Burner failure
during heating
cooling process.
2.Operator
Negligence
3
Burner servicing
during preventive
maintenance &
recipe fed to avoid
dependency on
operators
Burner failure is
detected by
flame sensor
which generates
alarm on
controller
9 81 3 1 2
Pipeline choking
& air gap will be
checked now
onwards as
identified from
CE matrix
Operato
r+superv
isor
10.01.2023 3 1 6 18
Furnace
Heating/
Cooling
Gradual/unif
orm
heating/cooli
ng & all 6
burners must
be working
Abnormal/non
uniform
heating/coolin
g & all burners
not working
Cracks in Brick
lining specially if
new brick lining is
done. Arch failure
can happen
3
1.Burner failure
during heating
cooling process
2.Operator
negligence
6
Burner servicing
during preventive
maintenance &
recipe fed to avoid
dependency on
operators
Burner failure is
detected by
flame sensor
which generates
alarm on
controller
9 54 3 3 3
Pipeline choking
& air gap will be
now onwards
checked as
identified from
CE matrix
Operato
r+superv
isor
10.01.2023 1 2 5 10
Furnace
Heating/
Cooling
No
atmospheric
gas leakage
should
happen in
main furnace
Gas leakage in
main furnace
atmosphere &
accumulation
inside
Explosion can
happen if lpg is
accumulated
inside main
furnace
10
Valve internal
leakage
1
Interlocks of valves
with temperature
& multiple valves
for safety
In case of major
leakage , lpg gets
detected easily
because of its
pungent smell, in
minor leakage its
undetected
3 30 3 3 3
Servicing of lpg
valve in preventive.
Point missing in
sheet. Added..And
before heating,
operator to check
manually for
leakage
Maintena
nce
supervior
and fittee
10.01.2023 10 0 2 0
Disassembly
Identify
damaged
furnace parts
to replace &
repair
Critical areas
for furnace
operation
missed & fails
during
operation
Breakdowns &
poor availability
& mean time
between faiure.
6
Fitters Negligence
or lack of
checkpoints in
preventive
checksheet
3
Disassembly is
done as per
checkpoints in
preventive
checksheet
Checksheet is
filled by fitter in
Sap section iw41
& cross verified
technically
completed by
manager in iw32
5 90 3 3 3
Preventive
checksheet to be
throughly
checked &
updated to cover
each & every
part of furnace.
Maintena
nce
superviso
r
10.01.2023 6 0 3 0

49. 49
PROCESS FAILURE MODE & EFFECT ANALYSIS
Process
Step
Function
Requirements
Potential
Failure
Mode
Potential
Effect(s)
of Failure
Severity
Classification
Potential
Causes(s)
of Failure
Occurrence
Current
Process
Controls
Prevention
Current
Process
Controls
Detection
Detection
RPN
Severity
Zone
Detection
Zone
Recommend
ed
Action
Responsibili
ty
& Target
Completion
Date
Action Results
Actions Taken
& Effective
Date
Severity
Occurrence
Detection
RPN
Spares/consu
mables
change
Glass wool
change to attain
perfect sealing
Sealing rope
change to avoid
air
suction.Above
two are most
important & are
done in each
preventive.
Other spares
done on the
basis of
condition
Sealing failure
can happen
either through
door blanket or
housing sealing
rope. Spares if
not corrected
or changed can
fail during
operation.
This can result in
backfires if
excessive air is
sucked within the
main furnace.
Increased
breakdown & loss
time
8
Spares/consumables
not available. Or
Housing or door
fitment was not
correct. Lack of
expertise during
assembly.Sometimes
because of limited
time & production
urgency the activity
is skipped
5
All consumables
are changed as
per Preventive
checksheet
Checksheet is
filled by fitter in
Sap section
iw41(sap pm
module
transaction) &
cross verified
technically
completed by
manager in
iw32(sap pm
module
transaction)
5 200 1 3
As resulted
from RCA
(slide no.53)
high density
blanket will
be packed
now
onwards
Maintenanc
e supervisor
11.01.2023 8 1 5 40

50. 50
Validation of X1: Door bend/bulged: Using one sample t-test
Suspicion statement :
Bend in door is more than 30 mm (≥30
not permissible)
Statistical statement :
Ho : µ (Bend amount) < 30
Ha : µ (Bend amount) ≥ 30
Analysis :
We will use 1 sample t Test.
P Value is 0.019
Statistical Conclusion :
As the value of p<0.05, so Ho (Null
hypothesis ) is rejected.
Conclusion :
Bend in door is more than 30 mm
Thus Door bend/bulge is an important
factor

51. Validation:: X2, X3 USING WHY-WHY ANALYSIS
Blanket failure Sealing Rope failure
Inner Door Failure
Heat leakage through blanket to
door body
Inter Blanket gap
Blanket width is 25mm & blankets
are packed manually differently
under different supervision
Blanket packing is not dense enough
Exact No of blankets not decided
Air suction through sealing
Gap generated between the
joining parts
Sealing rope compressed fully
so that metal to metal
contact is there
Strength deteriorates in quick
time
Property of sealing rope: 10
mm dimension & 800 deg
X2 X3

52. 52
Validation of X4: Housing bulged: Using one sample t-test
Suspicion statement :
Bulging in housing is more than 30
mm (≥30 not permissible)
Statistical statement :
Ho : µ (Bend amount) < 30
Ha : µ (Bend amount) ≥ 30
Analysis :
We will use 1 sample t Test
P Value is 0.690
Statistical Conclusion :
As the value of p>0.05, so Ho (Null
hypothesis ) cannot be rejected.
Conclusion :
Bend in door is less than 30 mm
Thus Door bend/bulge is not an
important factor

53. Validation:: X5, X6 USING WHY-WHY ANALYSIS
Burner Line choking Air Gap disturbed
Burner fault
Pipe from entry to final exit from
exhaust is not cleaned in preventive
Activity is time taking, slow,
complicated & high manpower &
therefore skipped. Number of
manual & solenoid valves,
regulators and fine holes are in
path. And work is to be done for six
burners with radiant tubes
Lack of manpower during
preventive
Electrodes position out
Electrodes getting earth with
body
Insulation failure of spark rod
X5 X6
Electrodes developing gap
more than 1.8 mm or
touching the burner body
Loosening or breaking of
ceramic support
Spark rod loose from
mounting or spark rod
damaged from tip
Carburised tip making it weak
Explosions because of
failure of ignition
Cleaning of rod tip is required
at regular interval
Carburised tip fails to
generate flame

54. Validation:: X7, X8 USING WHY-WHY ANALYSIS
Handler dog tilting failure Level of rollers disturbed
Handler issues
Handler dog gets stuck at one
position
Either Dog bore stucks with pin OD
or Dog sides stuck side handler
Metal expands at 950 deg and
overcome the current allowance left
Vestibule & main furnace
rollers are on different
platforms
Main furnace roller’s H-bricks
& packing gets damaged.
Vestibule rollers platform
supports on screw gets
damage
X7 X8
Levels not checked with
thread or straight beam &
difference keeps on
increasing
Current Clearance of 5- 8 mm is low
in bore & sides as well
Roller rails are bend & H-
bricks are damaged.

55. Summary of Validation : X1,X2,X3,X4,X5,X6,X7,X8
55
Sr. No. Parameter Tools Usedfor Validation p value Inference
X1 Door Bend 1-Sample t Test 0.019 Valid
X2 Blanket Failure Why-Why Analysis - Valid
X3 Sealing Rope Failure Why-Why Analysis - Valid
X4 Housing Bulged 1-Sample t Test 0.69 In-valid
X5 Burner line Choking Why-Why Analysis - Valid
X6 Electrode Air Gap disturbed Why-Why Analysis - Valid
X7 Handler Dog tilting failure Why-Why Analysis - Valid
X8 Level of Rollers disturbed Why-Why Analysis - Valid

56. 56
Phase 4 :- Improve
Define
Measure
Analyz
e
Improv
e
Control
Improve

57. Solution Generation
57
IMPROVE

58. Solution implementation:X1
58
IMPROVE
Existing Door: MS
MATERIAL
Implemented solution:
New door: BOILER
MATERIAL:PO 445397
Old door: Bend & Distorted New door: Boiler material

59. Solution implementation: X2 IMPROVE
Implemented solution: New door:
112 PCS STRIPS STACKING DONE
Door fitted with 112 pcs strips :
sealing checked from inside furnace
Sealing checked from all four sides
No of strips checked:: 112 pcs

60. Solution implementation: X3
60
IMPROVE
Existing Sealing rope: 10 mm
& 800 deg
Implemented solution:
New sealing rope:20 mm
& 1400 deg

61. Solution implementation: X5
61
IMPROVE
All 6 Burner lines cleaned All 6 Burner are working

62. Solution implementation: X6
62
IMPROVE
Existing condition:Carburized
Spark rod tip
Implemented solution:
Emery cleaned spark rod
trip
Carburised dull tip
Emery cleaned
shining tip

63. Solution implementation: X7
63
IMPROVE
Handler dog
Clearance:
Bore: 12mm
Sides:12 mm
Bore clearance: 12
mm
Sides clearance: 12
mm

64. Solution implementation: X8
64
IMPROVE
New Rails changed
Old rails : Bend & Distorted

65. 65
Phase 5 :- Control
Define
Measure
Analyze
Improve
Control
Control

66. 66
Standardization: X1 :BOM updation
BOM: BOILER PLATE INNER DOOR ADDED
X1 PO.462991
Older codes removed

67. 67
Standardization: X2,X3,X5,X6,X7,X8::Preventive check sheet updation
All important points out of RCA added in
Preventive checksheet
X2
X3
X6
X6
X8
X7
X5

68. 68
Standardization: X3 :BOM updation
BOM: High temp Seal 20 SQCS included
X3

69. Results
69
UBH AVAILABILITY % TREND (BEFORE VS AFTER)
33.33
67.74
23.33
87.10
80.65
43.33
80.65
56.67
51.61
87.10
46.43
51.61
59.45
0.00
10.00
20.00
30.00
40.00
50.00
60.00
70.00
80.00
90.00
100.00
%
MONTH
Availability %
61.29
73.12
72.22
73.12
69.92
54.00
56.00
58.00
60.00
62.00
64.00
66.00
68.00
70.00
72.00
74.00
76.00
%
MONTH
Availability %
75.45
80.34
85.00
86.00
88.50 88.50
65.00
70.00
75.00
80.00
85.00
90.00
95.00
Nov'22 Dec'22 Jan'23 Feb'23 Mar'23 Apr'23
Availability %
MONTH

70. Cost saving (APR’23)
70
Cost saving for APR’23
Planned time= 730 hrs per month
Old availability = 59.45% (from slide no.7)
CT= 20 HRS
Production per batch = 384 cups
Monthly production= (384/20)*0.5945*730=8332 cups
Planned time= 730 hrs per month
New availability = 88.5 (from slide no.70)
CT= 20 HRS.
Production per batch = 384 cups
Monthly production= (384/20)*0.885*730=12404cups
Monthly increase in production: 12404-8332=4072cups
Production cost per batch = Rs 58645 (from slide no.12)
Production cost per cup= 58645/384=Rs.152.72
Considering 10% profit, profit per cup= Rs.15.27
Monthly increase in profit= (4072*15.27)=Rs.62179*0.9(sf)=Rs.55961
Old monthly
production
Current
monthly
production
April Cost
saving

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