Statistical Process Control

SPC as tool to achieve reduced variability at each stage of operations for improved clinker / cement quality.

ACC Limited

Statistical Process Control-Q&PD

Nov2012

SPC sectional approach

Flow of Cement manufacturing Process
Process Control Variables Process Control Variables Process Control Variables

Quality Assuanrance Interface

Output Input Raw Mix Input Pyro

Output Input Cement Grinding Output

Each stage Quality Parameters set for which Cpk value to be measured monthly
Raw Material LSF Preparation R90 Mic/ R212 Mic

Kiln Feed LSF R90 Mic / R212 Mic

MgO

Clinker

Free Lime
LSF

Cement

SO3 R45 Mic

ACC Limited

Statistical Process Control

Nov2012

SPC tools & Project methodology

Basic problem solving tools 1. Check Sheet SPC project methodology 1. Problem Identification

2. Stratification/

2. Observation
3. Analysis 4. Action (Action plan with date/Resp.) 5. Check (*Saving validation by FICO )

Classification

3. Pareto analysis 4. Brain Storming

5. Cause & effect diagram

6. Histogram 7. Scatter plot, Correlation

6. Standardization
7. Conclusion & final

submission

* Reward & Recognition for best project

For each SPC project:a) Adherence of Project methodology is mandatory. b) Data base support is mandatory for a Valid cause in Analysis step. c) Project saving must be validated by Plant FICO.
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ACC Limited

Statistical Process Control

Nov2012

SPC Project identification approach

SPC Project identification approach from 2009 to 2012 Project scrutiny by Sectional head and final approval by Director Plant. Identified project is presented by Project leader during Training session for importance of Sectional developmental project. Road map for completion of each step & finalization date freeze. Regional review meeting with RO- coordinator for their guidance & help for implementation of identified job as per action plan. 24x7 availability of Project mentor, SPC Core team & MIQ team for discussion over Project. SPC Project approach for 2013: Project identification approach yet to be finalized.
Can included as a part of Sectional improvement under I Excellence?.

ACC Limited

Statistical Process Control

Nov2012

SPC Project 2009

Training imparted with support of MIQ-Nasik, for total 20 Participants (Only Production section). 20 SPC projects taken in 2009. 19 Projects Implemented & Saving through SPC project Rs. 2.7 Cr. 9 SPC Projects are related to improvement in Cement grinding & Clinker factor. Project Saving Rs 1.6 Cr.
S No 1 2 3 4 5 6 7 8 9 Name Mr.Pramod Sharma Mr.Amit Kumar Mr.Jelin Edvin Mr.Viswajeet Mitra Mr.Vishad Agrawal Mr.Subhajit Banerjee Mr.Atul Sharma Mr.Sumeet Srivastava Mr. Kumud Ranjan Sinha CMU Bargarh Chaibasa Chanda Damodhar Jamul Kymore Lakheri Sindri Tikarai Project Title To increase the Cpk Value of Cement mill from 0 to 0.5 Bring down the residue at R-45 . in CM-5 Minimise the variation of 45 micron (PPC) in Cement Mill -1 TO minimise the variation on R45 mic. Bring down the variations in residue on R-45 mic. in CM-1 Increase of %Flyash absorption in CM1&8 by reducing the variation in cement lime SO3 Variation in Cement Grinding Optimization in SO3 content in cement Bring down the residue at R-45 . in CM-3. Annual Saving (Lacs) 31 1.5 17 14 17.3 9.8 42 17 13

Out come from Feed back. a) Project saving must be validated by Plant FICO. b) Cross functional team involvement in SPC Project for next year. c) All these projects report are uploaded and now are available on shared folder for Reference at all plants. Path For access SPC- Projects folder: \\10.234.3.10\SPC- Projects. - Folder SPC Batch wise (Region wise folder)
ACC Limited Statistical Process Control

5
Nov2012

SPC Project 2010

Based on past feed, We have involved Cross functional function team i.e Process , Quality, Mines, Maintenance, E&I. Training Imparted with support of MIQ-Nasik. 29 SPC projects taken in 2010. Saving through SPC project is Rs. 11 Cr.
Function Process Quality Mines E&I Maintenance No of Participants 15 2 9 2 1

9 Projects are related to improvement in Cement grinding & Clinker factor. Saving through Cement grinding & CF is Rs 5 Cr.
S No 1 2 3 4 5 6 7 8 9 Name Sumersingh Tata Arvind K Dixit Asit Parui Vivek Gupta Anil Popuri P K Sharma Hemant Sahu Sanjeev Prasad Pintoo Sarkar CMU Lakheri Tikaria Kymore Wadi 2 Thondebhavi Bargarh Kudithini Sindri Damodhar Department Process Quality Process Process Process Process Quality Mechanical Process Project - Grinding section & CF Minimizing the flushing of fly ash in close circuit Cement mill no. 6 Maximization of phospho gypsum percentage in cement Improvement in Cpk of % residue on 45 micron of kymore cement mill 1 product ppc (from 0.32 to 0.80) To improve the process capability of SO3 in cement mill -06 To minimize the variation in cement residue on 45 mic Improvement in Res-45 of Cement mill-3 Minimization of variation of 1 Day compressive strength in PSC Improvement in cpk value of cement mill # 4 residue To improve the cpk of cement mill 45 micron residue by maintaining consistency of cement mill feed by reducing feed cut of CM-1 Annual Saving 36 432 44.9 3 5 10.8

6
Nov2012

ACC Limited

Statistical Process Control

SPC Project 2011

Refresher course on SPC organized for batch 2009 & new entrance with support of MIQ-Nasik, in two batch in March and April for total 51 Participants. 50 SPC developmental projects taken in 2011. 46 Projects Implemented, validated savings for 42 projects. Distribution and Classification of SPC projects-2011 Discipline 1.Quality & Productivity 2. Maintenance 3. Quarry 4. Power / Energy 5. Material 6. Process Numbers 35 02 05 04 01 01

Total

50

ACC Limited

Statistical Process Control

Nov2012

SPC Project2011 related to Clinker factor

19 Projects out of 46 related to improvement in Cement grinding & Clinker factor. Project Saving Rs 7.8 Cr
S.NO 1 Gagal 2 3 4 5 6 Thondebhavi 7 8 9 10 11 12 13 14 15 Sindri 16 17 18 19 Damodhar Encore Mr. Sumeet Srivastava Mr.Roshan Tailor Reducing the variation in one day strength to improve CpK 0.2 to 0.4. Reduction in variation of Residue on 45 mic in Cement Mill # 2 . 41.46 6.3 19.5 Chaibasa Bargarh Jamul Kudithini Mr. M Reddy Chintangal Mr.Gadilingappa Karur Mr. Pinaki Dutta Mr. Kundlesh Jha Mr. Tapabrata Mallik Mr. Krishna Ram Mr. Ravi Kant Tiwari Mr. Amlan Shyam Mr. Alok Bharti Kymore Tikaria Chanda Mr. Deepak Jasuja Mr. Qazi Mushtaque Mr. Rishikant S Baghel Mr. G VVaraprasad Mr. V. Sundararajan Plant Name Mr. S.A Hamid Project Title Annual Saving (Lacs) Reduce the Flyash consumption variation & increase the Cpk of R-45 micron residue 35.6 in G-I. Optimization of Cement Residue Improve Cpk in G-2 Cement mills. 95.8 To Control and Minimize the SO3 variations at cement grinding stage in CM 1. Reduction in cube to cube variation in cement strength Reduction in R45 variation in Cement Mill # 1 (Cpk improvement from 0.65 to 0.9) Improving Flyash absorption without sacrificing quality . Increase % Flyash absorption from 23.5 to 27.0 % To minimise the variation in SO3 content in cement.to improve Cpk 0.1 to 0.25 Optimization of SO3 in ground clinker for production of PSC. From current level of 3.10-4.32 5 to 4 +/- 0.2 % Improving Cpk of R45 of CM#3 from current level of 0.21 to 0.33 Reduction of Slag VRM product residue on 45 mic from current average level of 7% to 5%. Improvement in clinker factor from 0.453 to 0.442 Improvement of clinker factor by 0.5 % by reducing variation in kiln feed LSF ( CpK value from 0.18 to 0.4) Improve the process capability of clinker LSF from 0.18 to 0.45. Reduction in variation of clinker 1 day strength COV 6.1 to COV <4.0 thus reduce clinker factor by 0.5% Improvement in Cpk of residue on 45 micron of cement mill # 3. From 0.18 to 0.40 . 25.75 114 27.37 TRedn in COV from 6 < 4.5 133.8 141.45 16.68 17.9 25.92 33.48 44.4

Mr. Sudipta Sinha Reduction in SO3 variation in Cement Mill # 1 . Mr. Basudev Chakrabarty Improvement of Cpk value of So3 in cement from 0.04 to 0.5 .

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Nov2012

ACC Limited

Statistical Process Control

Reward & Recognition for Best SPC Projects 2011

Region: North

Best SPC Projects were awarded by our CEO & MD

Prize First Second Third

Works Gagal Lakheri Tikaria

Name of the project

Name of the project leader

Annual Saving (Rs.Lacs) 95.74 60.94 Quality

Optimization of Cement Residue Improve CpK in Mr.Deepak Jasuja G-2 Cement Mills Process and capacity optimization of wobbler from 260 tph to 320 tph Reduction in cube to cube variation in cement strength Mr.Rajesh Kushwaha Mr.Rishikant Baghel

Region: South West

First Thondebha vi Improving Flyash absorption without sacrificing quality. Increase % Flyash absorption from 23.5 to 27% To increase VRM output in optimum level and maintaining residue 45 & 20 micron 14.4% to 10% and 43% to 30% respectively Mr.V. Sunderarajan 141.45

Second

Kudithini

Mr.Ajoykumar Deka

74.46

Third

Madukkarai Improvement in CpK of% Free lime in Clinker by process optimization of the system

Mr.SP Rameshbabu

14.08

Region: East
First
Second Third Third

Jamul
Jamul Chaibasa Chaibasa

Reduction in grinding power consumption

Optimum utilization of low grade limestone from Jamul mines for better mineral management Reduction in variation of clinker 1-day strength COV 6.1 to COV <4.0 thus reduce clinker factor by 0.5% Improvement of clinker factor by 0.5% by reducing variation in kiln feed LSF (CpK value from 0.18 to 0.4

Mr.Pinaki Samanta
Mr.Devendra Kumar Mr.Amlan Shyam Mr.Krishna Ram

67.80
48.76 47.54 47.54

9
Nov2012

ACC Limited

Statistical Process Control

SPC Projects Summary of Savings Accrued till Dec11

2011

2009 to 2011

Year 2009 2010 2011 Total

ACC Limited

Project Saving from SPC project Cement Grinding & CF saving (Rs. Cr ) (Rs. Cr) 2.7 1.6 11 5 17.05 7.8 30.75 14.4
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Statistical Process Control

Nov2012

SPC Project2012
79 SPC Developmental projects identified for 2012, to be executed by Systematic Methodology of Problem solving. Necessary Training for new participants and project leaders being arranged through MIQNasik in March & April for 50 Persons in two batches.

Create Forum for cross learning thru SPC implementation (Safety, Logistics, Environment,
FICO & Sales-RO). 75 SPC project were reviewed in Aug-Sep12 (Region-wise) through MIQ and RO-coordinator. All developmental Project are completed by 15th of Nov12.
Section Safety Quality Productivity/Quality Energy/Power Packing/ Logistics Quarry Logistics Cost/Finance Lubricant Environment HR Procurement AFR HR-Thane Sales-RO Delhi Other/ Maintenance Total

North 0 4 5 3
3

South West 2 7 3 4 2 1 3 2 1 3 2 2 1

East 1 9 6 3 3 1 1
1

RO/Thane

1 1 1

1 18 33 26 2

Total 3 20 14 10 5 5 4 2 4 3 2 2 2 1 1 1
79

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Nov2012

ACC Limited

Statistical Process Control

SPC Project2012 related to Clinker factor

18 SPC developmental Projects are related to improvement in Cement grinding & CF. SPC developmental Project are completed by 15th of Nov12 and updated in SPC folder.
S. No 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 Name

Mr. Gagandeep singh

Mr. Manavjot Singh Mr.Kumud Ranjan Sinha Mr. Kumud Ranjan Sinha Mr Arun Kumar Garg Mr Mohan Raj Mr. B Ramaswamy Mr. Ajoy Kumar Deka Mr. Surendra Hegde Mr Tushar Goel Mr. P K Jain Mr. Pinaki Dutta Mr. pramodkumar.sharma Mr. Kundlesh Kr. Jha Mr. Narendra K Sahu Mr Swapan Roy Mr. Susanta Banejee Arijit Bandyopadhyay

SPC Project- CM Grinding & CF To improve Clinker factor by using low purity gypsum & increase in Fly ash % in Cement Mill Gagal II.

Plant

Dept. Process

To Improve the Specific Power Consumption of Gagal 1 Cement Mills (CM#1, CM#2, CM#5)
Increasing Fly ash absorption up to 35 %". Reduce specific energy consumption up to 32.0 KWH/T Establishing the +R45 of PPC in CM #03 Cpk : 0.84 Minimize the variation of % SO3 in PPC grinding to achieve the CpK value >= 0.70 Reduce Cement Mills Process Power from 42.65 to 40.51 KWh/T of Cement Reduction of the Specific power consumption in VRM grinding from 48 kwh/MT to 45 kwh/MT Reduction in oil consumption Lit. / Tn of cement. Improvement in Hourly TPH Reduction in clinker factor of PSC from 44% to 41%. Improving flyash absorption in PPC from 22% to 25%. Reducing PPC 3 days strength COV from 8.4 to 4.9 Complying 100% internal quality norms for F2R. Improvement in cement SO3 cpk from 0.13 to 0.3 Additives consumption optimization & hence reduction by Rs3/t cemt. Reduction in strength variation in 1 Day and 3 Day strength Reduction in clinker factor by optimizing PSC quality

Gagal
Power Quality Power Quality Quality Power Power Lubricant Productivity Productivity Productivity Quality Quality Quality Productivity Quality Productivity

Tikaria Chanda Madukkarai

Wadi Kudithini Thondebhavi

Bargarh

Jamul
Sindri

Damodhar

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ACC Limited

Statistical Process Control

Nov2012

SPC at ACC Way Forward

2012
Standardization of improvements. Horizontal deployment in other disciplines. SPC-SAP system for Encore/ New.Chanda Development of Culture- Way of Life at ACC Involvement of all SPC trained /for projects

2011

Sustainability of of Performance by involvement of 2009 batch Plant SPC Champion for coordinating development project. Reward & recognition for Best project (Region- wise) SAP system hookup with Excel Breakthrough improvements. Multiplication of projects by all yet trained participants Expand to Process parameters like BZT, Separator RPM

2008

SAP Implementation Expand the horizon of SPC (Mines, Maint , E& I Added) SPC plant champion & Regional coordinator. Breakthrough improvements. Development of Control Plan 2009 SPC Project share folder (Region- wise) Performance analysis based on Cpk achieved Review of Specification limits & Target setting Synergy between PQM and SPC Analysis of control charts Shift wise , Development of trainers at plant level Multiplication of projects at all stages, Implementation of SPC at extraction stage Implementation of MSA and SSP (statistical sampling plan)

2010

Flavor to Top Management on the Concept Team Formation , Training & Project assign Projects review and support with MIQ (Nasik )

2013:- Can SPC a part of I. Excellence???...

Statistical Process Control

13
Nov2012

ACC Limited

Outcomes from SPC ..

Excellence through implementation of SPC as a tool in Cement manufacturing
process through data based & systematic problem solving methodology.

Sustainable improvement by imparting Training for new participant and Project

leaders through MIQ-Nasik. Project review & support by Mentor , SPC core team, MIQ- Nasik.

SPC Champion at each Plant & RO-Coordinator to support the Project Leader
& his Team for pursuing of sectional developmental project.

Monthly SPC report for sectional review & improvement. Tangible benefit: Cpk improvements by reduced variability at each stage of operation.

Savings in cost of reprocessing .

Productivity improvement.

Intangible benefits: Team work

Ability to solve problems.

Habit of continuous improvements.
ACC Limited Statistical Process Control
14
Nov2012

THANK YOU

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ACC Limited

Statistical Process Control

Nov2012