LNT HE Quality

L&T Heavy Engineering
Quality
a Way of Life
Commitment to Quality
From Staff, Technicians and Contractors in Labour Intensive Sector

012 Larsen & Toubro Limited : All rights reserved
16th May 2013, Conference on
Quality Systems for Sustainable Manufacturing Growth
Case Study: S R Ramanujam

JGM Manufacturing, Powai
SR.RAMANUJAM@larsentoubro.com
Atul Paranjape, GM, QA

Powai, Talegaon, Coimbatore
Atul.Paranjape@Larsentoubro.com
16 May 2013
Larsen & Toubro Limited
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Topics
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L&T Businesses
Heavy Engineering
Infrastructure
& Construction
Hydrocarbon
E&C
Industrial
Machinery
16 May 2013
Power E&C
Electrical
& Automation
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Quality & EHS Certifications
ISO 9001 : 2008

ISO 14001 : 2004
OHSAS 18001 : 2007
IQRS Level 8
L&T Hazira
16 May 2013
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Manufacturing locations
Ranoli :
Exotic Materials
Hazira :
Super Heavy, Forging
Powai :
Heavy Engg
Talegaon :
Defense
Oman :
Heavy Engineering
Bengaluru :
Avionics
Coimbatore :
Precision Mfg
16 May 2013
Kattupalli :
Ship Building
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Manufacturing Locations
Year established : 1987

Area (Sq. m)
: 36,00,000
Capacity (MT p.a) : 2,00,000
Hazira Manufacturing Complex

Sohar, Oman
Year established
Area (Sq. m)
Capacity (p. a)
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: 2009
: 400,000
: 10,000 MT
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L&T Ship Building
Workshops
Cross transfer
Area
Ship Lift
Finger Jetty
Ship Lift
16 May 2013
Platform Raised
with Ship
Platform Lowered
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L&T Special Steels & Heavy Forgings Pvt Ltd
Covered Shop area: Approx. 65,000 m2
JV (74: 26)
Special Steel
100,000
MT/annum
16 May 2013
Single piece Ingot

up to 600 MT
Forgings Up to
Diameter : 6.5 m
Height : 5.0 m
Nuclear grade
Alloy
Stainless steel
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Products: Process Equipment
2010
Heaviest Hydrocracker Reactor : KNPC
KNPC Hydrocracker Reactor

1540 MT, 308mm
1999
2007
RPL Jamnagar FCC Regenerator

1320 MT, 16.3 M Diameter
16 May 2013
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Site Assembly
2009
Nuclear Power: Fast Breeder

Reactor Safety Vessel (13 m Dia)
with Reflective Insulation
2009
Coal Gasifier: Hebi, China
16 May 2013
Weight 1300 MT
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Weapon Systems & Radars
Pinaka Multi Barrel Rocket Launcher
Trishul Launcher
Namica
Akash Air force Launcher

16 May 2013
Platform for Radar Rohini

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Ship Building
Defense:
Indias 1st Nuclear Submarine INS Arihant
Commercial:
Special Purpose Vessel
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Challenges
Labour Intensive:
Custom Built:
Large Workforce
Engineer-to-order
Wide Range of Skill Levels
Wide Range of Standards
Multi-skilling
Modular Manufacturing
Quality in
ETO Industry
Project Industry:
Mission Critical:
Multi-location
Critical Application Areas
Multi-Site
Severe Operating Conditions
Complex Supply Chain
High Risk on Failure
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Topics
16 May 2013
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Quality Formula
P
Q = -----E
Performance
----------------Expectation
>1
What Customers want?

Cheaper! Better!! Faster!!!

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Is there a Conflict?
Reliability
Business
Need
Cost
16 May 2013
Delivery
Q
U
A
L
I
T
Y
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Accuracy OR Speed?
Long term Needs
Product
Reliability
Work
Carefully
Meet
Customers
Needs
&
Work
Fast
Speed
As per
QUALITY SYSTEM
Short term Needs
The & Paradigm

16 May 2013
Quality
&
Speed
&
Cost Effective
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Topics
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Journey towards Proactive Safety/ Quality

Incident & Injury Rate
No System,
Individual Dependent
Number of Incidents
Reactive Era (Incident Based)

Accident Reports, Analysis, Correction
Preventive Era (Process Based)

Unsafe Condition Report, Improve
ZEROonly through
Behavioral Aspects
Human Side of Safety
1940
1950
1960
1970
1980
1990
2000
IIF (Incident and Injury Free) by JMJ Associate
Incident & Injury

16 May 2013
Nonconformity
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Quality Control Paradigms

Proactive
Preventive
Reactive
Specification
Stage-based
Inspection
QC
Product Control
16 May 2013
Design Intent
In-Process
Audit
QA
User Need
Natural
Behaviour Based
BBQ
Process Control
Mind Control
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Daag se Darna Manaa Hain!

Dont be afraid of the dark !
ISO 9001 8.5.2 Corrective Action
The organization shall take action to:

Eliminate the cause of nonconformities in order to
Prevent recurrence.
Corrective Actions: Appropriately address effects of nonconformities.
Image of NC
Penalize the Doer

More NCR, Worse Quality
Reluctance to issue NCR

Need
to Remove
Negative Image of NC
NC Analysis is a Tool for improvement

16 May 2013
Plan
Act
Do
Chk
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CAQs (New Observation System)
No Sab Chalta hain
Dont tolerate Non-sense !
1
Incident
MajorMajor
Nonconformity
29
Minor
Incident
Minor
Nonconformity
Observation or Alert
Based on:
Actual Event or Condition
For Avoiding:
POTENTIAL Damage/ Re-work
Enhancing:
Sensitivity to Quality
300
Near Misses
CAQ: Conditions
Adverse to Quality
Heinrichs law for Incident
Major Incident :Minor Incident: Near Misses =1 : 29: 300

16 May 2013
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KLEPPA
Pride in your Work !
Real Motivation for Quality

Knowledge
Love
Enjoy KLEPPA
Pride
Participation
Awareness
Product is workers baby.

Where his baby goes/ works?
How his baby functions?
What his baby contributes to?
More KLEPPA More care of baby!!
Quality Improvement
Confucius:
Knowing is012not
as good as Loving;
Larsen & Toubro Limited : All rights reserved
Loving is not as good as Enjoying
Know whats Required

Pride in my Output
Source: JGC Quality System

16 May 2013
BBQ:
Love my work
Enjoy Doing It
Part of Winning Team Aware of Big Picture
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Topics
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Organization
Quality
Quality Management
(QM)
QMS, WMS, Audits, MRMs

ISO Certifications
Control of QMS
ISO Manual & Procedures
Monitor Organizational
Quality Objectives
Planning & Arranging Audits
Monitoring CAQs
Monitoring CARs
Management Review
Quality MIS
16 May 2013
Quality Planning
(QP)
QA, QRMs, Vendor Quality

Project Specific Certifications
Quality Control
(QC)
Inspection, Documentation
Interface with TPI/ Customer
ASME Quality Manual

Inspection as per CTQs & ICL
Align to Customer Requirement
PT/ MT/ Visual/ Dimensions
Study Advance Drawings
Self Verification/
& Process Plans
Dimensions Formats
Compilation
of CTQ/ QAP
In-process documentation
Inspection Procedures/ Checklist Raising & Validating NCR
Co-ordinate for Customer Audits Verification of Correction
Conducting Job Audit
Shop wise NCR analysis
QRM, RCA, CAPA
Final documentation
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Key Processes
Quality Circles &
Six Sigma Projects
QC Tools Training
Fortnightly Review
Structured Evaluation & Recognition
Major-Minor
Severity & Frequency Analysis
Monthly QRMs
Participation: Workers/ Supervisors

Unnati at Hazira
Navneet Teams at Powai
733 Teams in 14 Years of QC Journey
Rigorous NCR Analysis: RRCA
Quality Circles
Customer Feedbacks,
Top NCRs, RCA results
Six monthly MRMs
Review: Quality Objectives

Audit Findings
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Key Processes
Aligning Quality Objectives
Department Purpose Analysis

Functional Measures
Organisation Goals
Quality Planning:
Critical To Quality
Identification at Project Start
QA Plan, Procedures & Check Lists
Larsen & Toubro Limited : All rights reserved

Awareness Programs012for
Workmen
In Local language
Intranet based CAQ System

16 May 2013
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Topics
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Zero Repair Drive SGA

Champion
Team Leader
Team members
: S. R. Ramanujam (Production Center Head)
: Ganesh Badgujar (Production & Maintenance)

: Production: Jayesh Patel, Salim Mulani, Balkrishna Doke, Girish Sagare,
Karan Kosambi, Welding Engg: Avinash Abnave, QC: John Pinto
Object of
Concern
(Item, Process,
Area, Machine)
Effect
(What is wrong)
Size
(Extent, Occurrences,
Frequency, Severity)
16 May 2013
Item
: Weld Joints in Gasifier Coils
Process : Manual Welding
Shops
: Mulund Shop (Contract
welders)
High level of defects after

Radiographic &
Ultrasonic
Testing
85 Repairs in 1612 Spots

in August 2009 (5.3%)
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Monitoring: Limited Results

Sr.No
1
2
3
4
5
Monthly Spot wise repair % from Aug 2009 to Dec 2009.
Month/Year
Aug-09
Sep-09
Oct-09
Nov-09
Dec-09
Total No of RT Spots
1612
1286
1297
1656
2910
Monthly Repair %
% RT Repair
6
5
4
3
Total No of Repairs
85
57
45
57
67
Repair %
5.27
4.43
3.46
3.44
2.3
Continuous Monitoring gave

only Limited Results
Decided to Implement
Philip Crosby Philosophy
2
1
0
16 May 2013
Aug/09 Sep/09 Oct/09 Nov/09 Dec/09

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Quality Management Maturity Grid

III
Enlightenment
I
Uncertainty
II
Awakening
Quality
Department
Valuable, But
No resources
Management
Driven
Management
Participation
Everyone
Quality
Function
Hidden
Support
Function
Line
Function
Business
Function
Quality
Director
on Board
Problem
Solving
Fire
Fight
Short term
Focussed
Methodical
Approach
Early Problem
Identification
Preventive
Action
COPQ
Unknown
Maybe >20%
Reported 3%
Maybe >18%
Reported 8%
Maybe >12%
Reported 6%
Maybe >8%
Reported 3%
Really is 3%
Responsibility
for Quality
Quality
Improvement
No Formal
System
What you
hear ?
Why do
we GET
Problems?
16 May 2013
IV
Wisdom
Measurement Fourteen Step

Continual
& Motivation
Program
Improvement
Why do
we HAVE
Problems?
We Identify
& Resolve
Problems
Defect
Prevention
is our motto
V
Certainty
Continual
Improvement
We do not
have Quality
Problems !
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14 Step Methodolgy
1
Management
Commitment
2
Cross-Functional
QI Team
3
Measurement
Philosophy:
Full commitment & support from Top Management
ZERO is Possible and Will be achieved
No Shortcuts to Quality
No Quick fixes
Cross Functional Approach:
All are responsible for welding 012
defects
and not the welding engineer or Quality Engineer
Participation of all employees is a MUST
: All rights reserved
Measurement of Problem & Status of Improvement

Track and Monitor each Weld on daily basis
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14 Step Methodolgy
4
Cost of Quality
Evaluation
5
Quality
Awareness
6
Habit: Identify
& Correct
Cost of Poor Quality

Production Loss (Hours), Delay Penalty
Awareness
Supervisors : Impact of Poor Quality on Profitability
Welders
: Loss of earnings
(Payment based on CLEARED Welds)
Habit
Daily Feedback is a must
(Before, During & After Welding)
Elimination of all possible reasons before welding
Mantra: Knowledge & Attention

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14 Step Methodolgy
7
Zero
Defect
Task-force
Action Plan
1. Analysis
2.
3.
4.
5.
Interaction
Training
Checklist
Recording
6. Feedback
7. Solve
8
Supervisor Trg:
Understanding
Problems
9
Zero
Defects
Day
: Past data Collection & Monthly Repair

Brain storming session with workmen:
100+ Conditions resulting in repairs identified
Act
: With welder, contractor, supervisor every month
: Weekly sessions conducted by zero Repair Team.
: Standard Preparations for repair prevention
: By every welder: 012
Pocket
Details
seam
welded
LarsenDiary
& Toubro Limited
: Allof
rights
reserved
(Date, shift , Seam no, Process, Thk, Material & status)
: Weekly problem sharing sessions
: All Problems/ Difficulties highlighted by Welders
10
Goal
Setting
Plan
Do
Chk
Zero Defect Policy Announced

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14 Step Methodolgy
11
Act on Problems
told by Workers
12
Recognition
Actions Taken (based on feedback from Welders):

Electrode brand changed
Ban mobile usage during working hours
Eye check-up for all workmen (welders, grinders,
fitters & supervisors)
Monthly appreciation of welders who have
produced zero defects.
Target Zero Repair message beside every seam
Depth chart (more than 30thk) for012
Accountability
End-to-end Task completion by one welder
Daily RT / UT status update at Production Center
Heads Cabin
Display Boards, Pocket cards: Quality instructions
Frequent spot check by Shop supervisor
16 May 2013
13
Quality
Council
14
Do it again!
: All rights reserved
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Weekly Training Sessions: All Welders
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Active Interactions
Appreciation:
Zero Defect
Welders
Eye Check-up Camp
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Result
Statement of Cost Saving due to improved process of RT/UT
Period
Aug 08 to July 09
Total
Red in no. Cost per
Total Repair Repair Reduction in
Spots RT
of defects defect in
Spots (Nos) Spot % Repair %
Rs
(Nos)
(Nos)
25755
1091
4.2%
FY 10-11
24469
330
1.3%
2.9%
FY 11-12
19925
107
0.5%
3.7%
Cost per defect calculated based on Through-put per hour saved
Cost Saving in
Lacs Rs
<< Reference Point >>
707
737
6,582
6,976
46,50,005
51,41,877
= ZERO Defects
16 May 2013
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Summary
Plan
Dont be afraid of the dark !
Act
Do
Chk
Dont tolerate Non-sense !
Observation
System
Pride in your Work !

16 May 2013
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Strategic System Complex

L&T Talegaon
16 May 2013
Thank you
40 of 40

LNT HE Quality

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L&T Heavy Engineering

From Staff, Technicians and Contractors in Labour Intensive Sector

16th May 2013, Conference on

Quality Systems for Sustainable Manufacturing Growth

Case Study: S R Ramanujam

Atul Paranjape, GM, QA

Larsen & Toubro Limited

L&T Heavy Engineering

012 Larsen & Toubro Limited : All rights reserved

Larsen & Toubro Limited

L&T Heavy Engineering

012 Larsen & Toubro Limited : All rights reserved

Quality & EHS Certifications

L&T Heavy Engineering

ISO 9001 : 2008

012 Larsen & Toubro Limited : All rights reserved

Larsen & Toubro Limited

L&T Heavy Engineering

Super Heavy, Forging

012 Larsen & Toubro Limited : All rights reserved

L&T Heavy Engineering

Year established : 1987

Hazira Manufacturing Complex

L&T Ship Building

L&T Heavy Engineering

012 Larsen & Toubro Limited : All rights reserved

L&T Special Steels & Heavy Forgings Pvt Ltd

L&T Heavy Engineering

Covered Shop area: Approx. 65,000 m2

012 Larsen & Toubro Limited : All rights reserved

Single piece Ingot

Larsen & Toubro Limited

Products: Process Equipment

L&T Heavy Engineering

Heaviest Hydrocracker Reactor : KNPC

KNPC Hydrocracker Reactor

012 Larsen & Toubro Limited : All rights reserved

RPL Jamnagar FCC Regenerator

Larsen & Toubro Limited

L&T Heavy Engineering

Nuclear Power: Fast Breeder

012 Larsen & Toubro Limited : All rights reserved

Coal Gasifier: Hebi, China

Larsen & Toubro Limited

Weapon Systems & Radars

L&T Heavy Engineering

Pinaka Multi Barrel Rocket Launcher

012 Larsen & Toubro Limited : All rights reserved

Akash Air force Launcher

Platform for Radar Rohini

L&T Heavy Engineering

012 Larsen & Toubro Limited : All rights reserved

Larsen & Toubro Limited

L&T Heavy Engineering

Wide Range of Skill Levels

Wide Range of Standards

012 Larsen & Toubro Limited : All rights reserved

Critical Application Areas

Severe Operating Conditions

Complex Supply Chain

High Risk on Failure

Larsen & Toubro Limited

L&T Heavy Engineering