You are on page 1of 23

Ravi is a shift manager in Coke Dry Quenching units.

He is working on an improvement project utilising the lea


Ravi wants to check the relation between Circulating Gas Volume ( measured using the flow transmitterFT 123)
1 plot to analyse his data. Also find the correlation coefficient between Circulating Gas Volume (Independent Var
the same regarding the nature/e

Process Parameters

Circulating Gas Volume, Boiler Inlet Temperature, TE-


Time FT-123 (in Nm3) 120 (in °C)
00:00 177659 920
00:10 177058 921
00:20 175680 925
00:30 173746 926
00:40 172991 928
00:50 172660 929
01:00 171742 934
01:10 169255 935
01:20 167886 939
01:30 167448 941
01:40 165047 943
01:50 158953 943
02:00 158680 947
02:10 156148 949
02:20 154963 951

TE-120 (in °C)


02:30 147053 952 990
02:40 145628 953 980
02:50 143946 954 970
03:00 143455 955 960
950
03:10 143420 956 Boiler Inlet Temperature,
940
03:20 143272 964 930
03:30 141288 966 920
03:40 140913 968 910
03:50 139997 970 900
04:00 138234 970 890
120000 13
04:10 137194 971
04:20 137024 973
04:30 135070 974
04:40 130861 975
04:50 130059 975
05:00 128667 977
05:10 128550 978
nt project utilising the learnings from the TQM trainings to increase the Steam generation from the Waste Heat Recovery Boiler.
flow transmitterFT 123) and Boiler Inlet Temperature (measured using the thermocoupleTE 120). Help Rahul construct a scatter-
Volume (Independent Variable) and Boiler Inlet Temperature (Dependent Variable) and mention your one line interpretation from
e regarding the nature/extent/type of correlation.

CORRELATION COEFF. -0.979473


nature strong negative
extent high
type of correlation negative

Scatter plot
TE-120 (in °C)

990
980
970
960
950
Boiler Inlet Temperature,

940
930
920
910
900
890
120000 130000 140000 150000 160000 170000 180000 190000
Circulating Gas Volume, FT-123 (in Nm3)
Heat Recovery Boiler.
hul construct a scatter-
ne interpretation from
Total Charge WeiCount - Total Charge Weight ( in tons)
175-183 4
184-192 6
193-201 12
202-210 23
211-219 46
220-228 63
229-238 89
Total Result 243
Total Charge WeiCount - Total Charge Weight ( in tons)
175-181 3
182-188 4
189-195 5
196-202 10
203-209 23
210-216 25
217-223 47
224-230 57
231-238 69
Total Result 243
Pankaj is a section-head in SMS 3. He underwent a 4i-J3 TQM training session recently. This has helped him in analy
2 Weight in the Steel making process. The Total Charge Weight (in tons) equals the added weight of HDRI, CDRI, Scra
determine the number of classes and the Class Intervals. Also find out the nature of the frequency distribution plo

Total Charge Weight


( in tons)

222
222 max 238
219 min 175
224 range 63
223 no of class 7
219 mean 221.33
221
218
Count of Total Charge
218 Row Labels Weight ( in tons)
223 175-183 4
220 184-192 6
218 193-201 12
222 202-210 23
218 211-219 46
220 220-228 63
218 229-238 89
220 sum 243
222
223
224
222
223
224
222
219
220
222
223
219
220
224
222
221
223
221
222
218
218
221
219
219
223
218
221
236
237
235
237
235
233
232
234
236
232
236
232
237
234
232
232
235
236
233
232
238
232
232
234
236
234
235
233
233
233
232
238
232
235
233
235
238
233
233
236
234
232
235
234
232
238
235
234
238
235
235
232
235
238
236
237
237
233
237
232
238
238
233
235
217
216
215
211
213
216
215
212
215
213
212
216
213
214
217
214
215
211
215
217
211
217
211
215
214
215
213
211
217
212
217
217
226
228
226
229
225
226
229
226
229
225
231
226
229
230
228
229
225
225
227
230
227
225
227
227
226
228
228
227
227
229
226
227
229
230
230
227
231
230
231
229
229
230
226
225
231
230
226
227
231
225
230
227
225
229
230
227
225
230
201
200
200
200
199
203
201
201
201
199
201
207
206
204
208
205
206
208
209
204
206
209
205
209
207
209
204
207
209
207
204
204
204
192
195
192
191
193
187
185
183
186
180
175
176
his has helped him in analysing his process data better. For the BTP (Break Through Project), he is studying the variations in the Total Charg
weight of HDRI, CDRI, Scrap and Hot Metal. Help him construct a histogram to analyse his data better. Use the attached Reference Table to
frequency distribution plot and your inference from the same.

Reference Table
No. of Data Points
20-50
51-100
101-200
201-500
501-1000
Above 1000

Count of Total Charge Weight ( in tons)


100
Count of Total Charge Weight ( in tons)

89
90
80 mean
70
60 221.33 63

50 46
40
30 23
20 12
10 4 6
0
175-183 184-192 193-201 202-210 211-219 220-228 229-238

Row Labels
ying the variations in the Total Charge
Use the attached Reference Table to

Reference Table
Recommended No. of Classes
6
7
8
9
10
11 to 20

s)
89

ean
21.33 63

219 220-228 229-238


Siddalingappa ia a manager in PDQC taking care of the customer complains in the flat products segement. In one of
3 to prioritise his complaints in order to take care of the major pain areas first. Help Siddalingappa construct a Pareto
basis.

Serial no. Defects No. of Cases

12 Thickness/Width/Length Variation 71

6 Rolled in Scale 55

7 Pitting 48

8 Snaky line 28

2 Telescopicity 26

4 Coil Break Line (CBL) 15

1 Sliver Holes 11

10 Strip Breakage 11

9 Tail Chew 7

5 Tiger Mark 6

3 Nozzle Scale 5

11 Scab 2

sum 285

250
200 vital view
Axis Title

150
100
50
0
Thi cknes s /Wi dth/Length Vari ation Pi tting
vital few for following cases

Defects
Thickness/
Width/Leng
th Variation
Rolled in Scale
Pitting
Snaky line
Telescopicity
e flat products segement. In one of the TQM trainings, he was introduced to the Pareto concept of prioritisation. He wants
p Siddalingappa construct a Pareto chart. Also list out the Vital Few cases that should be taken care of on a higher priority

cumullative cumullative %

71 25%

126 44%

174 61%

202 71%

228 80%

243 85%

254 89%

265 93%

272 95%

278 98%

283 99%

285 100%

Chart Title
100%
250
80%
200 vital view 60%
Axis Title
150
100
50
usefull many 40%
20%
0 0%
s s /Wi dth/Length Vari ation Pi tting Tel es copi ci ty Sl i ver Hol es Tai l Chew Nozzl e Scal e
Axis Title

No. of Cas es cumul l ative %


No. of Cas es cumul l ative %

or following cases

No. of Cases

71

55
48
28
26
100%
80%
Axis Title

60%
40%
20%
0%
Heeranya is a manager working in Coke Ovens #4. He looks after the battery process. After the TQM training he
Ram of Battery #5 Pusher Car using some tools related to Statistical Process Control. He collects the data from t
4 same. Help him draw a control chart (Individual Plot) using the data and find out if there are any assignable(or
special cause(s) if any.

Oven No. Time Pushing Current (in ampere) mean hcl lcl
509 00:00:00 122 122 144 99
519 00:15:00 98 122 144 99
529 00:30:00 114 122 144 99
539 00:45:00 124 122 144 99
549 01:00:00 113 122 144 99
559 01:15:00 118 122 144 99
569 01:30:00 134 122 144 99
579 01:45:00 113 122 144 99
502 02:00:00 119 122 144 99
512 02:15:00 121 122 144 99
522 02:30:00 122 122 144 99
532 02:45:00 122 122 144 99
542 03:00:00 117 122 144 99
552 03:15:00 128 122 144 99
562 03:30:00 115 122 144 99
572 03:45:00 145 122 144 99
504 04:00:00 126 122 144 99
514 04:15:00 135 122 144 99
524 04:30:00 115 122 144 99
534 04:45:00 124 122 144 99
544 05:00:00 115 122 144 99
554 05:15:00 125 122 144 99
564 05:30:00 126 122 144 99
574 05:45:00 122 122 144 99
506 06:00:00 123 122 144 99
516 06:15:00 115 122 144 99
526 06:30:00 123 122 144 99
536 06:45:00 122 122 144 99
546 07:00:00 123 122 144 99
556 07:15:00 135 122 144 99
566 07:30:00 121 122 144 99
576 07:45:00 125 122 144 99
508 08:00:00 118 122 144 99
518 08:15:00 122 122 144 99
528 08:30:00 115 122 144 99
538 08:45:00 124 122 144 99
548 09:00:00 130 122 144 99
558 09:15:00 117 122 144 99
568 09:30:00 124 122 144 99
578 09:45:00 116 122 144 99
501 10:00:00 121 122 144 99
512 10:15:00 122 122 144 99
522 10:30:00 132 122 144 99
532 10:45:00 124 122 144 99
542 11:00:00 128 122 144 99
552 11:15:00 123 122 144 99
562 11:30:00 114 122 144 99
572 11:45:00 118 122 144 99
504 12:00:00 113 122 144 99
After the TQM training he feels he can better analyse the variations in the current drawn by the Pusher
He collects the data from the records for every pushed oven and wants to plot a control chart for the
ere are any assignable(or special) causes in the system. Also mention the Oven No(s). related to the

mean 121.63
sd 7.4345786
Ucl 143.93374
lcl 99.326264

Chart Title
150 144
140
Pushing Current (in ampere)

130
120
110
99
100
90
80
0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0
:0 :0 :0 :0 :0 :0 :0 :0 :0 :0 :0 :0 :0 :0 :0 :0 :0 :0 :0
:00 :30 :00 :30 :00 :30 :00 :30 :00 :30 :00 :30 :00 :30 :00 :30 :00 :30 :00 :3
00 00 01 01 02 02 03 03 04 04 05 05 06 06 07 07 08 08 09 09

Time

Pushi ng Current (i n a mpere) mean hcl l cl

assignable cause

time oven no.


0:15:00 519
3:45:00 572
tle

0 0 0 0 0 0 0 0 0 0 0 0
:0 :0 :0 :0 :0 :0 :0 :0 :0 :0 :0 :0
:30 :00 :30 :00 :30 :00 :30 :00 :30 :00 :30 :00
06 07 07 08 08 09 09 10 10 11 11 12

mean hcl l cl