A QUALITY CIRCLE PROJECT

BY
" NEW SHINE "
" MODIFICATION IN TELESCOPIC CHUTE "

Date of start : 10-01-2018

Date of completion : 10-07-2018
 ACKNOWLEDGEMENT

We are highly indebted to

Shri D K MEHTA,
Sr. Vice President (Works)
for motivating us throughout this project.

We express our deep sense of gratitude to,

Shri Mukul Shrivastava (VP Technical)
for their valuable guidance in completing the project.

Our sincere thanks to,

Shri Deepak sharma
Shri Sanjay Sud
Shri Jatindranath Chakraborty
Shri Saket Rajoria
Shri Jannishar akhtar
for the support extended during the project.
 We also take this opportunity to extend our thanks to all our colleagues who contributed
directly or indirectly successful completion of the project.

QUALITY CIRCLE INFORMATION

Started : 10/01/2018
QC Name : “NEW SHINE”
Organization : JK LAKSHMI CEMENT LIMITED, DURG (C.G.)

QCFI MEMBERSHIP NO : 070615102675

Title of case study : "Modification in telescopic chute"

Our QC consists of 4 members (All Males)

Average age of our QC members is 27yrs (Youngest : 23 / Oldest :
36)
QC meeting takes place : During working hours

Meeting Day / Frequency : Monday

QC Team Details :

Sl No. Name Designation

1 Amarnath tiwari Leader

2 Gyan bardhan Deputy Leader

3 Manoj kumar Singh Member

4 Manoj kumar vishwakarma Member

 PROFILE OF QC "NEW SHINE"

NAME OF QC TEAM : "NEW SHINE "

REGISTRATION NO : 06

ORGANIZATION : JK LAKSHMI CEMENT LTD. DURD (C.G)

DEPARTMENT : CLINKER LOADING AREA

JK LAKSHMI CEMENT LTD.

ADDRESS : VILLAGE-MALPURI KHURD, KHASADIH,
POST-AHIWARA DIST-DRUG(C.G.) 490036.

PHONE NO : 08966909216, 8966909220

DATE OF FORMATION : 10-01-2018

DAY OF MEETING THURSDAY AND SATURDAY

TIME OF MEETING : 3:00 pm – 4:30 pm

NUMBER OF MEETING : 56

ATTENDANCE : 90.00%

IDENTIFIED PROBLEMS : 72

PROBLEM SOLVED : 5

QC PROJECTS IN HAND : 1

PERIOD OF PROJECT : 01/03/2017 - 05/07/2017

 COMPANY PROFILE

INTRODUCTION :

Group Companies

J.K. Organisation, one of the leading Private Sector Groups in India, was founded over 100
years ago. With a century of multi-business, multi-product and multi-location business
operations, the Group has Companies with a diverse portfolio including Automotive Tyres &
Tubes, Lakshmi Cement & Pulp, Cement, V-Belts, Oil Seals, Power Transmission Systems,
Hybrid Seeds, Woolen Textiles, Readymade Apparels, Sugar, Food & Dairy Products,
Cosmetics, etc. All products of the Group are not only strong brand names but also reputed
market leaders in their respective segments.
With its operations spread in almost every state of India, the Group employs over 30,000
people along with a nationwide sales and service network of over 10,000 distributors and a
large number of retailers and service centers.

Some of the leading Group Companies

includes:

JK Tyre & Industries

 JK Paper
 JK Lakshmi Cement
 Fenner India.
 JK Seeds.
 JK Insurance.
 Umang Dairy.
 CliniRix Research.
JK LAKSHMI CEMENT LIMITED:- JK Lakshmi Cement, a renowned and
well-established name in the Indian cement industry, now in its 35th year, has a formidable
presence in North & Western India’s cement markets. Its current capacity stands at 12.0
million MT per annum.

ABOUT JK LAKSHMI
CEMENT LTD.

JK Lakshmi Cement Ltd. is among India’s foremost Cement manufacturers. It is part of one of
India’s leading Business Houses – JK Organization, which has a significant presence in
Automotive Tyres, Cement, V-Belts, Oil-Seals, Agri-seeds and Pulp & Paper.

The plant has an installed capacity of nearly 2.7 million tonnes per annum (mtpa). Following
commissioning, installed cement making capacity of the company now stands at 12.0 mtpa.
A part of the USD 4 billion JK Organisation, JK Lakshmi's greenfield Durg unit producing
various grades of Cement such as ordinary portland cement, portland pozzolana
cement and slag cement.

The commencement of the Durg plant is in line with the concept of inclusive growth and
Prime Minister's "Make in India" campaign to boost economy and growth of the region, the
company said.

Company Vision :-
To be A Profitably growing innovative and Caring Company, Aspiring to Double the market
share and Be among top 7 in the Indian Cement Industry

Company Mission:-
 Double Sales every 4 years, Profit every 5 years
 Achieve Operational Excellence
 Create superior value for customer through Premium Products & Brand Positioning
 Be a workplace of choice-Attract, Retain and grow Talent Pool
 Continuously enhance shareholders’ wealth and be a preferred portfolio among
investors
 Socially Responsible Corporate Decision
Core Values:-

 Caring for People.

 Integrity, including intellectual honesty, Openness, fairness

& Trust.

 Commitment to excellence
 Table of Contents

S.No. Description Page no.

1 IDENTIFICATION OF PROBLEMS 8
2 SELECTION OF PROBLEM 10
3 DEFINING THE PROBLEM 16
4 ANALYSIS THE PROBLEM 18
5 IDENTIFICATION OF THE CAUSES 19
6 FINDING OUT THE ROOT CAUSE 22
7 DATA ANALYSIS OF ROOT CAUSE 23
8 DEVELOPING THE SOLUTION 24
9 FORE-SEEING PROBABLE RESISTANCE 25
TRIAL IMPLEMENTATION / CHECKING THE
10 26
RESULT
11 REGULAR IMPLEMENTATION 28
12 FOLLOW-UP AND REVIEW 32
STEP-1 : IDENTIFICATION OF THE PROBLEMS
Using the Round Robin Method of Brainstorming we have identified 64 problem in the
crusher area.

CATEGORY OF THE PROBLEMS

‘A’ Category problems: Require minimum involvement of other department's / agencies.
‘B’ Category problems: Other department's involvement is necessary.
‘C’ Category problems: Management's approval may be required.

S.NO. Description Category

1 Heavy dust in environment C
2 Motor gear box damage due to dust B
3 Repaired Motor keep in Electrical workshop was also effected due to heavy dust B
4 Many compressor was effected due to dust because our compressor room was in B
Near by of clinker extraction system
5 Rotary feeder Motion fault due to ZSS malfunctioning A
6 Bag filter Purging sequence problem due SOV malfunctioning A
7 Nearby area motor cooling system effected due to dust B
8 WHR cooling Tower efficiency low due dust A
9 WHR cooling tower Fins cleaning frequency increases A
10 Extra material spillage in ground B
11 Bag filter diff. Pressure switch malfunctioning A
12 Pull chord showing alarm. A
13 LPBS was not work due to heavy dust B
14 Control supply problem due to contact problem because of dust A
15 Motor was overheated due to failure of motor cooling system B
16 Vision problem due to heavy dust B
17 Purging stopped due to air shortage of bag filter A
18 Accumulation of water in silo bottom so we not check properly nearby equipment A
19 Weighbridge sensor problem due to dust A
20 Unnecessary time delay in truck loading B
21 Dust accumulated on DPC so it was tripped due to overload B
22 Problem in identifying cable due to dust accumulated on it A
23 Material losses B
24 Overload problem in DPC B
25 Pneumatic gate not work properly A
26 Hooper full due to level switch malfunctioning A
27 Bag filter not work properly B
28 opacity monitor blower filter dust jamming A
29 HAG instrument also affected by dust. A
30 511DG1-3 showing limit fault due to dust stiks on the limit switch A
31 Motorised diverter showing runtime due to proxy loose A
32 All field instrument showing unhelthy due to control supply mcb trip due to short A
circuit
33 Diverter overload due to jammed A
34 Diverter trip due to open torque A
35 Diverter trip due to close torque A
36 DPC trip due to motion fault found zss damage due to DPC tail pulley shifted . A
37 DPC trip due to motion fault due to dust stick on DPC bucket wheel A
38 DPC trip due to motion fault due to DPC bucket wheel shifted A
39 Dpc trip due to dpc pull chord damage due to hot clinker fall A
40 Diverter trip due to over current A
41 Diverter trip due to limit switch cable ground fault A
42 DPC trip due to pull chord switch cable ground fault A
43 Clinker loading hopper level switch unhealthy due to hot clinker fall on switch cable A
44 Pull chord rope damage A
45 DPC bucket wheel fall. A
46 Bag filter zss ground fault A
47 Dpc trip due to zss ground fault A
48 Dpc trip due to overload B
49 DPC bucket damage due to clinker hip in hopper B
50 Bag filter SOV damaged so we replace it. A
51 Material fall from truck due excess loading because operator was unable to see the exact A
position of truck
52 Material was not extract from silo due to jamming of extraction gate B
53 Opacity monitor blower was not working properly due to heavy dust A
54 Bag filter rotary feeder motor overload due to highly dust particle A
55 Bag filter fan motor was overload. A
56 511CG1-9 inductive proximity switch required change with new flap limit switch C
because when
dust was sticks on proximity then it was not work
57 511DG1-3 inductive proximity switch required change with new flap limit switch C
because when
dust was sticks on proximity then it was not work
58 Opacity monitor shutter was closed due to blower not work properly A
59 Problem in identifying cable due to dust accumulated on it A
60 Dust accumulated on DPC so it was tripped due to overload A
61 Wire rope damage A
62 Pulley misalign A
63 Tilt switch damage A
64 Up and down limit fault A

STEP-2 : SELECTION OF THE PROBLEM

 Once all the problems were listed down we categorized them as per their respective criteria

into 3 categories. This Categorization and it's result is shown below:-

Categorisation of Problems:-

Total nos. of problems

Category (A) Category (B) Category (C)
identified

72 47 20 5

We have analysed all the problems in the clinker loading area. Then we categorized all the

problems

into three categories A, B and C as shown above. Then out of all the B type problems we

selected one Problem. To select the problem we collected data of all the B type problems then

stratified the data. After that we did Pareto Analysis in which we found that 4 problems are

covering 63% of the total B-type problems. We used ranking method to select one problem

among these 4 problems.

Finally, we have selected one problem for this project and all the procedure is discussed
below:-

Settings of Objective
1. We can stopped unwanted malfunctioning of equipments.
2. We should use proper interlock for protection of motor
3. To control the damaged of equipment.
4. To improve the efficiency of WHR generation.
5. To control man power, production losses.

Outcome:-
1. Improvements of clinker production .
2. System was simplified.
3. Reduce time of loading of clinker truck .
4. Achieved clean environment.

STEP 4 : ANALYSIS THE PROBLEM

We analyse the problem and the impact of area to using 4W & 1H technique which is given
below:-

S.No. Criteria Description

Motorized chute overload

1 What is the problem?
problem.

Problem occurred in clinker

Where does the problem
2 loading area telescopic
occur?
chute system.

When does the problem

3 During chute operation.
arises?
Near by equipment, WHR
Who is affected by the
4 Kiln feed, Raw Mill and Coal
problem?
Mill
How does the problem Some equipment's are
5
arises? malfunctioning

Impacts of the problem:-

 production loss and also WHR generation reduced.

 Man power loss

 Power loss

 Man & Machine from heavy dust

 Production loss
When Telescopic chute having problem, extraction of clinker from clinker silo was stopped
hence silo level was increased and the time came when silo level was full,we reduce the kiln
feed then we loss the production of clinker

 Man power loss

When Telescopic chute having problem then huge material was spillage on the ground for
cleaning those materials extra man power are required

 Power loss

When kiln feed was reduced due to problem in telescopic chute Outlet temperature was also
reduced hence inlet temperature of WHR was not enough so generation was reduced upto 1.5
MW

To deeply understand the power loss first we understand our production and consumption of
clinker

Our total clinker production per day is around 5500 ton, and our consumption is around 4000
ton so the difference is 1500 ton, it is extra clinker which is stored in our clinker silo. If outside
loading of clinker stop so our silo level increase, in this condition We have to down our kiln
feed which is normally running in 375 to 380 TPH reduce to 300 to 305 TPH, in this condition
our WHR generation is reduce which is normally running at 8.5 to 9.0 MW is reduce from 7 to
7.5 MW, other calculation is given bellow.

 Avg clinker production per day :- 5500 ton.

 Avg consumption per day :- 4000 ton.
 difference in clinker stored in silo :- 1500 ton.
 In this condition kiln feed reduce around 65 ton.
 Reduce in kiln feed WHR generation reduce around 1500 unit per day.
 Per day unit :- 1500*24 = 36000 unit per day
 per unit cost is :- Rs. 6.5/-
 Total cost of power per day is 36000*6.5 = Rs. 234000/-

Our kiln feed already reduce for 72 hrs. due to silo level full.
If we calculate power loss in reduced kiln feed in 72 hrs. then loss is 702000/-Rs

 Man & Machine from heavy dust

When Telescopic chute having problem then environment was heavy dusty which is very
dangerous for Man as well as Machine
STEP 5 : IDENTIFICATION OF THE CAUSES
By brainstorming, we found plenty of causes for Overload in motorized Telescopic chute For
root- cause analysis we made a cause and effect diagram (Fish-bone diagram) by dispersion
analysis method involving all the causes as shown in below:-
 STEP 6 : FINDING OUT THE ROOT CAUSES
After finding root causes by step 5 we are observing the peoblem and doing the validation of
the root causes is as follows:-

S.No. Cause Observation Remarks

The clinker loading telescopic
chute playing main role to
1 By Nature of Job dispatch outside clinker. Its Valid
main function is control the dust
from environment.
Production Due to requirement of plant
2 Valid
Requirement continuous production is must.
During telescopic chute rising its
What is problem up limit was operated due to
3 on proximity and low sensing range, and tilt Valid
tilt switch. switch gives continuous
command to motor
Poor quality of Due to production requirement
4 invalid
rope telescopic chute is must.
 STEP 7 : DATA ANALYSIS OF ROOT CAUSES
We analyse the vailid root causes and the observation is given below:-

Cause Observation Remarks

S.No.
The clinker loading telescopic
chute playing main role to
NOT
1 By Nature of Job dispatch outside clinker. Its
SELECTED
main function is control the dust
from environment.
Production Due to requirement of plant NOT
2
Requirement continuous production is must. SELECTED
During telescopic chute rising its
What is problem up limit was operated due to
3 on proximity and low sensing range, and tilt SELECTED
tilt switch. switch gives continious comand
to motor

The root cause no. 3 "What is problem on proximity and tilt switch." is
selected because of other two root causes are eliminated:-
 STEP 8 : DEVELOPING THE SOLUTION
By brainstorming we found the following probable solutions:-

S. Evaluation of
Solution Suggested by Elimination
No Suggestion
1 Manually up and Gyan In manual operation Eliminated
down of telescopic Bardhan chance to damage of
chute man or machine
2 Chute in up position Manoj Singh In chute up position Eliminated
the dust emission in
the environment it is
very harmful
3 Bypass tilt switch If tilt switch bypass Eliminated
Amarnath
Tiwari
the protection of
motor will also
bypass it is
dangerous for man
and machine
4 Proximity sensitivity Manoj Increase the Selected
& Tilt switch Vishwakarma sensitivity of up limit
feedback proximity to and give
tilt switch feedback in
to the motor interlock
to avoid the overload
the motor
Responsibilties shared activities:-

Sr. ACTIVITY RESPONSIBILITY Time

No Bound
1 Taking approval from Gyan Bardhan 10/5/2018
concerned authority
2 Drawing and designing for the Amarnath Tiwari 15/05/2018
modification
3 Making a list of required Manoj Kumar 22/05/2018
material for the modification
4 Requisition for the required Manoj 5/6/2018
material Vishwakarma
5 Receiving the material Facilitator 10/6/2018
6 Shifting the material Manoj Kumar 12/6/2018
7 Installation All member 9/7/2018
8 Inspection Facilitator 10/7/2018
STEP 9 : FORE-SEEING PROBABLE
RESISTANCE

Person
SL.
PROBABLE RESISTANCE / SOLUTIONS/ MEASURES TAKEN
No.
agency

Members who are not the Theoretical presentation before

part of quality circle may Non QC implementation and practical training after
1.
oppose due to avoiding Member implementation to be given to non-QC
nature and extra work. members by the group.

What is the effect on

operation after using both The loads are distributed and uniform load
2. Management
ends gear and increasing will be taken both gear.
size of bolts.

This implementation is one time

What will be the cost of
3. Management investment of cost and get long life of the
implementing this solution?
Telescopic chute

What will be the effect on Production raised exponentially after

4. Management
production? implementation of this project.

We would convience them by explaining

Will there be any fluctuations
5 Management about the quality and design both end gear
in the gear and bolts?
and size of bolts.
STEP 10 : TRIAL IMPLEMENTATION /
CHECKING THE RESULT
After getting the approval from management we are doing comparative study for trial
implimentation is given below:-

We are using PDCA technique to check the result after implimentation and take it in daily
practice.

Plan:-
Target:- To change the higher range proximity of up limit of DLS motor and change the wiring
of tilt switch feedback.

Do
Tilt switch feedback drawing modification
Check:-
 Trial implementation and checking the working performance
of telescopic chute.
 Checking the Up limit proximity feedback.
 Checking the tilt switch operation with motor .

Act:-

 Site-visit by facilitator.
 Site-visit by HOD.
 Departmental presentation.
 Preparation of check-list.
 Review:- checking the production performance.

Material requirement on this project

S. Name of Materials Size/ Nos

No.
1 Limit Switch 2 No `
2 Looping cable (1.5 Sqmm) 5 Metre
3 Cutting set 1 Set
4 Welding set 1 Set
5 Tools & Tackles 1 Set
11 : REGULAR IMPLEMENTATION

BEFORE THIS PROJECT:-

The telescopic chute regularly damage due to up limit of DLS motor not sense properly and tilt
switch feedback not connected in to the DLS motor contractor due to this our production loss
as well as our kiln feed down and WHR generation down.

AFTER THIS PROJECT:-

After the project implementation our production loss stopped as well as WHR generation
high .

Tangible Benefit

 Achieved clean environment.

 Power consumption reduced .

 Loading time minimized.

 System is simplified by modification in telescopic chute hence less

 maintenance near by equipment.

 Minimize of spares consumption.
Intangible benefits:-

Strengthen Team Work During the whole project we

worked together as a team, a
team sprit developed among us
and now we are confident to take
up any more challenging project.
Improved Self Successfully completion of the
Confidence project developed self confident
among us.
Improvement in There is no overflow of material
Working condition now and hence working
environment is improved, no
much dust is generating in the
area.
Job Satisfaction All the team members are now
satisfied with our job, we are
taking responsibility to the job
assigned to us. An ownership
feeling developed among us.
Safe Working Working in the area is become
Environment much easier and safer now.
STEP 12 : FOLLOW-UP AND REVIEW

Frequency of Review:-
We are decided to do bimonthly review of this check-list to check the result and we found no
damaged.

Recurrence prevention measures:-

For prevention of recurrence we are checking all points as per above given checklist in our daily
routine.
After success we kept on monitoring to check the performance.

DLS Tilt
Loss of
S .No. Date
Production
motor switch
overload damage
1 15/06/18 NIL NIL NIL
2 20/06/18 NIL NIL NIL
3 23/06/18 NIL NIL NIL
4 30/06/18 NIL NIL NIL
5 5/7/2018 NIL NIL NIL
Project in Hand: “To Control dust
generation in truck loading hopper"