Densh plant product failure in quality test consistently for months

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Densh plant product failure in quality test consistently for months

This case study focuses on a mechanical brickett manufacturing plant in chemical plant, known as the Densh Ash Plant, which faced significant challenges resulting in the accumulation of rejected finished products. Despite various attempts by experts, the problem persisted, hampering production. The objective of this case study is to present a systematic and professional approach to resolving the issues at the plant.
 
The Densh Ash Plant experienced a halt in the production of sellable products, leading to an accumulation of rejected finished products. Despite equipment experts certifying the machinery as functioning properly, the rejection was caused by a higher powder percentage in the final product than the design specifications allowed this problem was for more then a year.
 
The plant management sought assistance from BiC, promoter, to address the issues. With no prior experience in briquetting machines or Dens ash plants, BiC's founder was entrusted with the responsibility of resolving the problem. A comprehensive data collection process was initiated, involving stakeholders such as employees, laborers, officers, and engineers.

Investigation

Through thorough analysis, conflicting information emerged. Investigations revealed the following key findings:
  • The mechanical maintenance team identified bearing failures as a major issue.
  • The electrical engineering department reported no significant problems but mentioned changes in electrical distribution due to disturbances in the power plant.
  • The instrumentation department noted a drop in voltage to the vibrators, which convert voltage into pulses.

Approach

By connecting the findings, it was discovered that the electrical distribution system had undergone changes, resulting in a 30-35% increase in the distance from the original setup. This change caused a 5% drop in voltage to the vibrators, leading to decreased vibration and quality issues. The quality failures observed aligned with the data from the inspection department.

Actions

By connecting the findings, it was discovered that the electrical distribution system had undergone changes, resulting in a 30-35% increase in the distance from the original setup. This change caused a 5% drop in voltage to the vibrators, leading to decreased vibration and quality issues. The quality failures observed aligned with the data from the inspection department.
 
To address the identified issues, the following actions were taken:
  • Transformer tap change to boost voltage and restore it to the designed circuit.
  • Testing confirmed that the voltage reached the required 240V AC.
  • Vibrator dummy trials showed significantly improved vibration quality.
  • Maintenance and corrective measures were implemented for conveyance, disintegration units, vibrators, and associated machinery.

Results

The implemented actions resulted in outstanding product quality, with a 1/10th reduction in fine particles compared to the allowable limit. Production records improved significantly, achieving tenfold growth over three months. Automated billing systems were introduced to handle the increased production efficiency.
 

Conclusion

This case study highlights the importance of managing change processes in an organized and expert-driven manner. Departments should not be allowed to make changes based on individual comfort, and multi-level approval from a team of experts is essential. The deviation in voltage by the instrumentation department had cascading effects on the vibrators, underscoring the need for standardized quality measurements and adherence to design specifications.
 
The entire findings were driven by the BiC promoter and he has received appreciation from the head of the organization.

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1978 - 1988 Tata Chemicals, Mithapur.
Challenge Instrumentation frequent failure, trappings due to air line failure. Business Impact Profitability. Solutions implemented after RCA and study I took responsibility to set right Entire airline and associated like air filters etc converted to SS316 and atlas copco with MD 6 Dryer to avoid moisture in air line.Outcome No instrument failure thuse, loss preventes.
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21978 - 1988 Tata Chemicals, Mithapur.
Challenge Instrumentation frequent failure, trappings due to air line failure. Business Impact Profitability. Solutions implemented after RCA and study I took responsibility to set right Entire airline and associated like air filters etc converted to SS316 and atlas copco with MD 6 Dryer to avoid moisture in air line.Outcome No instrument failure thuse, loss preventes.
Next
31978 - 1988 Tata Chemicals, Mithapur.
Challenge Instrumentation frequent failure, trappings due to air line failure. Business Impact Profitability. Solutions implemented after RCA and study I took responsibility to set right Entire airline and associated like air filters etc converted to SS316 and atlas copco with MD 6 Dryer to avoid moisture in air line.Outcome No instrument failure thuse, loss preventes.
Next
41978 - 1988 Tata Chemicals, Mithapur.
Challenge Instrumentation frequent failure, trappings due to air line failure. Business Impact Profitability. Solutions implemented after RCA and study I took responsibility to set right Entire airline and associated like air filters etc converted to SS316 and atlas copco with MD 6 Dryer to avoid moisture in air line.Outcome No instrument failure thuse, loss preventes.
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