Form No. VJNR/TQM/QC/001.01.

20150109
Kaizen Project Department Quality Circle Name
Project No: Date
Format PP-1 14/11/2022
Title of Project: PF-6 WEIGH FEEDER CONTROLLER PANEL UPGARDTION FROM TUC-2 TO GDC CONTROLLER .

Category: (√) Productivity, (√ ) Quality, (√ ) Cost, (√ ) Delivery, ( ) Safety, (√ ) Morale, ( ) Environment

Before (Situation) Root Cause Analysis Improvement Measures After (Situation)

PF-6 weigh
feedeer set
point and feed
back not
matching
properly and
Checked the controller and
getting
try to reset by removing Planned to go with new controller(GDC
hanged some
E-PROM and entering new controller ) and new ABB drive with wiring
times due to
program but also problem modification
old type of
was not resolving
controller
(TUC-2),and
some times Replaced the controller (GDC
controller was Controller) by modificating all wirings
going to china and programming done now set point
language and feed back matching with accurate
values and working fine.this
modification was done by in house
PP-1 TEAM
Benefits: a) Weigh feeder set point feed back matching Member Details: Team leader- Mr. Vivek Jain,Mr. shreeshail
(b)Better operation working . Team Member- Mr.Krishna ,Mr. Basavraj,Mr.Hussain,Mr.Imran,Mr.Khaza, Mr. shiv
(c) increasec accuracy of weigh feeder readings

Standardization: any sop/smp change or new sop along with any

training given regarding this project to concern people

Single Point Lesson: Accuracy of weigh feeder will improved Remarks of evaluator:

Date of Completion:
Date of Starting: 15-11-2022 Name: vivek jain Signature:
20-11-2022
 Kaizen Project Department Quality Circle Name
Format
Title of Project: Thickner arm rotation running condtion sensing

Category: (√) Productivity, (√ ) Quality, (√ ) Cost, (√ ) Delivery, (√ ) Safety, (√) Morale,

Problem Statement: Solution: Implementation:

To prevent the damage and
overloading of the thickener,
The current a zero speed switch was
monitoring installed and linked to the
system for the shaft bolt. This change will
thickener's allow for proper monitoring of
rotating arm the arm's rotation, giving an
was not indication when the arm is not
providing rotating.
proper
indication of
the arm's
rotation,
leading to
potential The zero speed switch was insta
damage and linked to the shaft bolt on the thi
overloading of rotating arm. Every time the sh
the thickener. passes, the switch will give a r
indication, providing a clear and
status of the arm's rotatio
Benefits: a) Thickner arm rotation online monitoring. Member Details: Team leader
b) any Team Member- Mr. Manj
abonrmility of rake will identified. Mr.Devaraj

Standardization: any sop/smp change or new sop along with any Horizontal Deployment Oppor
training given regarding this project to concern people

Single Point Lesson: Thickner arm rotation online monitoring Remarks of evaluator:

Date of Completion:
Date of Starting: 27-01-2023 Name: Jeniffer
30-01-2023
 Form No. VJNR/TQM/QC/001.01.20150109
rcle Name Project No: Date
PP-1 11/15/2022

Safety, (√) Morale, (√ ) Environment

Implementation: Monitoring and Evaluation: Continuous Improvement:

The monitoring system will be

regularly reviewed to ensure that the
zero speed switch and shaft bolt link The monitoring system for the
are functioning properly and thickener's rotating arm will be
providing accurate information on continually reviewed and improved as
the arm's rotation. Any issues or necessary, using the Kaizen
failures will be identified and philosophy of continuous
peed switch was installed and addressed promptly to maintain the improvement. The goal is to provide
he shaft bolt on the thickener's proper functioning of the monitoring accurate and reliable information on
rm. Every time the shaft bolt system. the arm's rotation, to prevent
he switch will give a running damage and overloading of the
providing a clear and accurate thickener, and to maintain the highest
us of the arm's rotation. level of process efficiency.
etails: Team leader- Mr. Jeniffer,Mr.Shreshail
m Member- Mr. Manjunath CB , Mr.Ankith , Mr. Mahesh , Mr. Dheeraj ,Mr.Manju (Elect),
j

Deployment Opportunities (Replication):

of evaluator:

niffer Signature:
1.01.20150109
 Kaizen Project Department Quality Circle Name
Format
Title of Project: Distance Sensor fixing at pellet car(Wheel) return side .

Category: (√) Productivity, (√ ) Quality, (√ ) Cost, (√ ) Delivery, (√ ) Safety, (√) Morale,

Before (Situation) Root Cause Analysis Improvement Measure

Indrduced new digital
distance sensor for identified
the car wheel postion with the
help of distance masure
and
Indurating planned to installed the
Machine pellet distance sensor on top of the
car wheel wheel
missing and
tracking
problem was
more and we
are not able
to identify
from which
car its having
problem

We have installed the D

sensor at machine discharge en
side and cable laying done from
control room and commissionin
Benefits: a) We can measure the Distance of car whhel and Member Details: Team leader
removed faulty car. Team
(b)Better indtification of missing car . imran, Mr. Anji, Mr. Rudresh
C) any abonrmility of car wheel will identified.

Standardization: any sop/smp change or new sop along with any Horizontal Deployment Oppor
training given regarding this project to concern people

Single Point Lesson: car wheel missing will identified Remarks of evaluator:

Date of Completion:
Date of Starting: 01-11-2022 Name: Shreeshail
15-11-2022
 Form No. VJNR/TQM/QC/001.01.20150109
rcle Name Project No: Date
PP-1 11/15/2022

Safety, (√) Morale, ( ) Environment

provement Measures After (Situation)

After installing the Distance sensor

e have installed the Distance signal given to control room and
machine discharge end returs critical alarm also enabled in DCS for
able laying done from field to identified of pellet car wheel missing
om and commissioning done. or some abnormility of car.
etails: Team leader- Mr. BB Patro, Mr. Shreeshail Mr. Vivek Jain,
Team Member- Mr. shiv Kumar ,Mr.Ankith , Mr. Krishna , mR. Basvraj ,Mr.
Anji, Mr. Rudresh

Deployment Opportunities (Replication):

of evaluator:

eeshail Signature:
1.01.20150109