QUALITY CIRCLE TEAM

ACHIEVERS
“High Achievers Spot Rich Opportunities Swiftly,
Make Big Decisions Quickly
And Move Into Action Immediately”
-Robert H Schuller
 TEAM MEMBERS

• Gaurish G Dalal
• Swaraj Mohapatra
• Satish Sasamal
• Manoj Parua
• Manoj Pradhan
• Jatinder Bhoi

• Nilesh Nagose (Facilitator)

Aditya Aluminium
 INTRODUCTION

COMPANY : Aditya Aluminium, Lapanga

DEPARTMENT : Carbon Maintenance, Smelter

NO. OF MEMBERS : 07

PROJECT NO. : 01

DATE OF FORMATION : 15/05/2016

TARGET TIME : 12 months

MEETING DAY : Saturday

MEETING TIME : 12:00 Hrs.

NO. OF MEETINGS : 14

ATTENDANCE : 92%

Aditya Aluminium
 INTRODUCTION

12
11 Follow Up /Review
10 Regular Implementation
9 Trial Implementation & Check performance

8 Foreseeing Probable Resistance

7 Developing Solution

6 Data Analysis
5 Finding out the root causes
4 Identification of Causes

3 Analyse the Problem

2 Define the Problem
1 Selection of Problem
Identification of Work Related Problems

Aditya Aluminium
 INTRODUCTION

CAUSE
KNOWN UNKNOWN
KNOWN

(STEPS: 1,2,3,10,11, 12) (STEP: 1,2,3,5,6,7,8,9,10,11,12)

SOLUTION

UNKNOWN

(STEP: 1,2,3,8,9,10,11,12) (STEP: 1,2,3,4,5,6,7,8,9,10,11,12)

Aditya Aluminium
PROBLEM IDENTIFICATION

STEP 1
brainstorming

Aditya Aluminium
 WORK RELATED PROBLEMS
SR No PROBLEM
Anode Joining in Central Conveyor of Aditya & Hirakud Baked
1
line.
Frequent breakage of roller conveyors drive shaft in Anode
2
Handling System.
AD-20 & AD-30 rollers coming out of its mounting frame in
3
Anode Handling System.
Frequent wear and tear of flexible bellow in Fume Treatment
4
Centre Vibrating Screen(Reacted Alumina & Fresh Alumina).
5 Alumina leakages from Air Gravity Conveyor vent lines.
6 Stacking Crane-1 Auxiliary Hoist not working.
7 Uncleaned anodes coming out of Aditya Cleaning Machine.
8 HFO Feed pump 5,6 & 7 bearing failure.
9 HFO Quick release coupling leakage.
10 FTA crane grab vibration.
11 AHS Central conveyor target plate damage.
Stacking crane-3 positioning fault above BG and BC
12
conveyor.
13 AD-30 guide wheel mounting assembly cracked.
14 AC-440 pallet chain liner plate wear.
15 AC-440 pallet coming out of chain
16 AD-90 locking arm guide roller play.
17 Aditya cleaning machine reamer assembly play.
18 FTA crane filling pipe wire rope damage.
19 AHS Roller conveyor chain looseness.
Aditya Aluminium
 WORK RELATED PROBLEMS

SR No PROBLEM
20 AD-30 Stopper plate getting bend.
21 Heating ramp injector nozzle getting jam.
22 FTA crane sliding gate valve coke leakage.
23 FTA crane dust discharge line leakage.
24 FTA Filling Pipe Flexible Bellow Deterioration
25 Aditya ACM Reamer-2 bolts shear.
26 BD-30 Packet discrepancy.
27 FTA all SOV sluggish movement
28 AD-30 tilting after packet movement.
29 Slot not getting cleaned in Aditya and Hirakud ACM.
30 Aditya and Hirakud dedusting system not efficient.
31 Aditya and Hirakud ACM frequent rail damage.
32 FTC-2 Treatment bypass damper passing.
FTC-1 and FTC-2 treatment and gen. bypass damper sluggish
33
movement.
34 Water dripping from FTC-1 and FTC-2 conditioning tower.
35 FTC-1 and FTC-2 VRI duct alumina leakage.
36 FTC-1 and FTC-2 RA airlift alumina leakage.
37 BG-30 and BG-80 turn table positioning fault.
Stacking crane-2 positioning fault above BG and BC conveyor.
38

39 Aditya Core sampling machine not working.

Aditya Aluminium
SELECTION OF PROBLEM

STEP 2

Aditya Aluminium
 ABC ANALYSIS

Sr Cate
No Problems gory
Anode Joining in Central Conveyor of Aditya & Hirakud Baked
1 B
line.
Frequent breakage of roller conveyors drive shaft in Anode
2 A
Handling System.
AD-20 & AD-30 rollers coming out of its mounting frame in Anode
3 A
Handling System.
Frequent wear and tear of flexible bellow in Fume Treatment
4 A
Centre Vibrating Screen(Reacted Alumina & Fresh Alumina).
5 Alumina leakages from Air Gravity Conveyor vent lines. A
6 Stacking Crane-1 Auxiliary Hoist not working. B
7 Uncleaned anodes coming out of Aditya Cleaning Machine. A
8 HFO Feed pump 5,6 & 7 bearing failure. A
9 HFO Quick release coupling leakage. A
10 FTA crane grab vibration. A
11 AHS Central conveyor target plate damage. B
12 Stacking crane-3 positioning fault above BG and BC conveyor. B
13 AD-30 guide wheel mounting assembly cracked. A

Aditya Aluminium
 ABC ANALYSIS

Sl.No. Problems Category

14 AC-440 pallet chain liner plate wear. A
15 AC-440 pallet coming out of chain A
16 AD-90 locking arm guide roller play. A
17 Aditya cleaning machine reamer assembly play. A
18 FTA crane filling pipe wire rope damage. A
19 AHS Roller conveyor chain looseness. A
20 AD-30 Stopper plate getting bend. B
21 Heating ramp injector nozzle getting jam. A
22 FTA crane sliding gate valve coke leakage. A
23 FTA crane dust discharge line leakage. A
24 FTA Filling Pipe Flexible Bellow Deterioration. A
25 Aditya ACM Reamer-2 bolts shear. A
26 BD-30 Packet discrepancy. B
27 FTA all SOV sluggish movement A
28 AD-30 tilting after packet movement. A
29 Slot not getting cleaned in Aditya and Hirakud ACM. B
30 Aditya and Hirakud dedusting system not efficient. A
31 Aditya and Hirakud ACM frequent rail damage. A
32 FTC-2 Treatment bypass damper passing. A
FTC-1 and FTC-2 treatment and gen. bypass damper
33 A
sluggish movement.

Aditya Aluminium
 ABC ANALYSIS
Sl.No. Problems Category
34 Water dripping from FTC-1 and FTC-2 conditioning tower. B
35 FTC-1 and FTC-2 VRI duct alumina leakage. A
36 FTC-1 and FTC-2 RA airlift alumina leakage. A
37 BG-30 and BG-80 turn table positioning fault. B
Stacking crane-2 positioning fault above BG and BC
38 B
conveyor.
39 Aditya Core sampling machine not working. A

Aditya Aluminium
 ABC ANALYSIS

No. of Problems

‘A’ Category:-Minimum
involvement of other
departments in solving them.
10

‘B’ Category:-Involvement of
other departments is a
necessity.
29
‘C’ Category:-Management
sanction may be needed in
implementing the solution.
A Class B Class
Aditya Aluminium
 STRATIFICATION OF ‘A’ CATEGORY
WORK RELATED PROBLEMS

Sr No PROBLEMS C S T M TOTAL
Frequent breakage of roller conveyors drive
1 4 4 4 4 16
shaft in Anode Handling System.
AD-20 & AD-30 rollers coming out of its
2 1 3 4 2 10
mounting frame in Anode Handling System.
Frequent wear and tear of flexible bellow in
3 Fume Treatment Centre Vibrating 4 1 2 1 10
Screen(Reacted Alumina & Fresh Alumina).
Alumina leakages from Air Gravity Conveyor
4 2 3 4 4 13
vent lines.
5 Heating ramp injector nozzle getting jam. 5 4 1 2 12
Uncleaned anodes coming out of Aditya
6 4 3 4 3 14
Cleaning Machine.
7 HFO Feed pump 5,6 & 7 bearing failure. 4 4 3 3 14
8 HFO Quick release coupling leakage. 4 4 2 2 12
9 FTA crane grab vibration. 2 4 2 2 10
10 AD-30 guide wheel mounting assembly cracked. 2 5 4 3 14
11 AC-440 pallet chain liner plate wear. 4 2 3 3 12
12 AC-440 pallet coming out of chain 1 1 3 2 7
13 AD-90 locking arm guide roller play. 1 1 4 4 10

Aditya Aluminium
 STRATIFICATION OF ‘A’ CATEGORY
WORK RELATED PROBLEMS
Sr No PROBLEMS C S T M TOTAL
14 Aditya cleaning machine reamer assembly play. 2 2 4 4 12
15 FTA crane filling pipe wire rope damage. 4 4 4 3 15
16 AHS Roller conveyor chain looseness. 1 1 2 2 6

17 FTA crane sliding gate valve coke leakage. 3 2 4 3 12

18 FTA crane dust discharge line leakage. 2 4 4 3 13

Tearing of Flexible Bellow in Filling Pipe of
19 5 3 4 4 16
FTA.
20 Aditya ACM Reamer-2 bolts shear. 4 2 4 2 12
21 FTA all SOV sluggish movement 1 1 1 1 4
22 AD-30 tilting after packet movement. 2 5 3 3 13
Aditya and Hirakud dedusting system not
23 3 4 2 2 11
efficient.
24 Aditya and Hirakud ACM frequent rail damage. 4 2 4 3 13
25 FTC-2 Treatment bypass damper passing. 3 4 4 4 15
FTC-1 and FTC-2 treatment and gen. bypass 2 3 1 1
26 7
damper sluggish movement.
27 FTC-1 and FTC-2 VRI duct alumina leakage. 4 4 3 3 14
28 FTC-1 and FTC-2 RA airlift alumina leakage. 4 4 3 3 14
29 Aditya Core sampling machine not working. 1 1 2 2 6

Aditya Aluminium
DEFINE THE PROBLEM

STEP 3

Aditya Aluminium
 DEFINE THE PROBLEM

The Furnace tending assembly (FTA) is a crane dedicated to fill

several function above anode furnaces.

The FTA crane moves over furnaces by mean of a long travel

motorization. An embedded trolley with several tools moves
along crane beams with tools necessary to fill functions attached
to the crane.

Aditya Aluminium
 DEFINE THE PROBLEM

Green Anodes Picking Up From Anode Handling System Conveyors, In

Order To Fill Pit.
And
Baked Anodes Picking Up From Pits To Fill Conveyors.

Aditya Aluminium
DEFINE THE PROBLEM

Coke Removing From Pits

Aditya Aluminium
 DEFINE THE PROBLEM

Dust Discharge (Recover From Coke Suction)

Aditya Aluminium
DEFINE THE PROBLEM

Coke Filling Into Pits

Aditya Aluminium
 DEFINE THE PROBLEM

Two Dedicated Telescopic Pipes Are

Intended For
Performing The Coke Filling Function
Into The Pits.

Wire Rope Hoist Drives The Telescopic Pipes.

An Expandable Flexible Bellow Envelopes

The Pipes For
Sucking Coke Dust While Filling.

Aditya Aluminium
 DEFINE THE PROBLEM

Tearing Of Flexible Bellow

In Filling Pipe Of
Furnace Tending Assembly

Aditya Aluminium
ANALYSIS OF PROBLEM

STEP 4

Aditya Aluminium
ANALYSIS OF PROBLEM

4W 2H

Aditya Aluminium
 ANALYSIS OF PROBLEM

4W 2H
What ? Tearing Of Flexible Bellow
Filling Pipe Of Furnace Tending
Where ?
Assembly
When ? During Filling Pipe Operation

Who ? FTA Operator

HOW Functional Failure & Environmental
effect? factors

How solve? By using QC Tools and Techniques

Aditya Aluminium
ANALYSIS OF PROBLEM

WHAT??

Tearing Of Flexible
Bellow

Aditya Aluminium
 ANALYSIS OF PROBLEM

WHERE??

Filling Pipe Of Furnace

Tending Assembly

Aditya Aluminium
 ANALYSIS OF PROBLEM

WHEN??

During FTA Filling Pipe

Operation

Aditya Aluminium
ANALYSIS OF PROBLEM

WHO??
FTA Operator

Aditya Aluminium
 ANALYSIS OF PROBLEM

HOW??

HOW IT AFFECTS: (1) Functional Failure

(2) Environmental Effects

Aditya Aluminium
 ANALYSIS OF PROBLEM

HOW??

HOW TO SOLVE: By Using QC Tools and Techniques

• Brainstorming
• Stratification
• Cause and Effect
• 4W & 2H
• Flow Chart
• Pie Chart

Aditya Aluminium
IDENTIFICATION OF CAUSE

STEP 5

Aditya Aluminium
 CAUSE AND EFFECT DIAGRAM

MAN MACHINE

TEARING OF FLEXIBLE
Operating Knowledge Tension on Bellow Fabric
Mounting
Clamps

BELLOW
Material of Bellow
Stiching of Bellow Fabric
Fabric
METHOD MATERIAL

Aditya Aluminium
FIND THE ROOT CAUSE

STEP 6

Aditya Aluminium
 VALIDATION OF ROOT CAUSES

Sr Brainstorming CHANCE CAUSE ASSIGNABLE VALIDATION

No Point CAUSE
1 Operating Knowledge √ No

2 Mounting Clamps √ No

3 Tension on Bellow √ Yes

Fabric
4 Stiching of Bellow √ No
Fabric
5 Material of Bellow √ No

Aditya Aluminium
 FINDING THE ROOT CAUSE

The Root cause of problem

is
Tension On Bellow Fabric

Aditya Aluminium
 DATA ANALYSIS

FAILURE HISTORY:

There Have Been Three Instances Of Bellow Failure Due To

Tearing In Past 18 Months.

All Three FTA (FTA-1, FTA-2, FTA-3) Have Witnessed Flexible

Bellow Failure Due To Tearing.

Aditya Aluminium
 DATA ANALYSIS

FAILURE CONSEQUENCE :
Functional Failure: Tearing of flexible bellow leads to
unbalancing of Filling pipe Mouthpiece, thus stopping coke filling
application.

Aditya Aluminium
 DATA ANALYSIS

FAILURE CONSEQUENCE :

Environmental effects: Tearing of flexible bellow leads to Coke

Dusting outside filling pipe.

Aditya Aluminium
 DATA ANALYSIS

FAILURE COST:

Cost of flexible bellow(NKM NOELL): 525884 Lac INR

Flexible Bellow Replacement:

Manpower: 6
Equipment Shutdown: 8 Hrs
Man-hours: 48

Aditya Aluminium
Development of solution

STEP 8

Aditya Aluminium
 Development of solution

TENSION ON BELLOW FABRIC

TENSION TO BE
TENSION TO BE ELIMINATED
MINIMIZED

TO ELIMINATE TENSION, SOMETHING

HAS TO TAKE THE TENSION ON BEHALF UNDER PRESENT SET
OF BELLOW UP TENSION CANT BE
MINIMIZED

PROPOSED CHAIN ARRANGEMENT FOR

TAKING UP TENSION

SELECTED
Aditya Aluminium
 FORESEEING PROBABLE RESISTANCE

STEP 9

NO DIFFICULTIES OBSERVED FOR

IMPLEMENTING THE SOLUTION

Aditya Aluminium
 TRIAL IMPLEMENTATION

Trail chain arrangement was done in Filling Pipe-2

of FTA-1.
And the results were as per our expectations.
Tension in bellow was completely eliminated.

Aditya Aluminium
 REGULAR IMPLEMENTATION

An In-house Designed Chain Arrangement Was Implemented In

Filling Pipe-2 Of FTA-1.

Aditya Aluminium
 REGULAR IMPLEMENTATION

Its Performance Was Monitored For A Period Of

Two Months And After Satisfactory Results,
The Same Setup Was Deployed In FTA-2 And
FTA-3.

Aditya Aluminium
 REGULAR IMPLEMENTATION

BEFORE AFTER

Aditya Aluminium
 REGULAR IMPLEMENTATION
Tangible Benefits

1) Switching to Indigenized developed flexible bellow.

Price of Imported Bellow- 525884 Lac (INR)
Price of Indigenized bellow- 92000 Lac (INR)
Total Saving- 433884 Lac (INR)

2) Filling Pipe functional failure has stopped Completely as now

chain holds the mouthpiece during filling.

3) Coke dusting due to bellow tearing has been stopped.

Aditya Aluminium
 REGULAR IMPLEMENTATION

Intangible Benefits

Presentation Skills Decision Making

INTANGIBLE
GAINS

Improved Team Work/ Skill

Increased Process Knowledge
Development

Aditya Aluminium 78
 REVIEW

Activity Responsibility Frequency

Ensure equal chain

Satish/Jatinder Weekly
Tensioning

Graphite Lubrication at
Manoj Pradhan Weekly
Fittings

Visual Checking of Fabric Manoj Pradhan Weekly

Aditya Aluminium
Thank You.