Name Of QC.

:-10th Planet
Name of Dept:-O&M(operation)
TEAM LEADER:-MR.R.R.NAIK
MEMBER:-MR.H.K. UDAN
MEMBER:-MR.JADUMANI SAHOO
MEMBER:-MR.N.K.PRADHAN
MEMBER:-MR.SANJAY KU. SAHOO
FACILITATER:- MR.M.K.JANA
DY.FACILITATER:MR.A.K.PASWAN
 Formation & Registration
of our Quality Circle

Officially formed on 03/06/2003.

Meeting on every alternate

evening shift of the rota.

Total Nos. of meeting:73

Attendance (%) 85.96

STEP- 1 :

Methodology adopted :-Brain Storming Method

1) Boiler tube leakage.

2) Low condenser vacuum in unit#1.
3) Checking of ESP hopper throat due to dump formation.
4) Poor evacuation of mill,jamming problem.
5) Mill motor bearing temperature going high.
6) Main PA dampers of mill jamming problem.
7) Mill feeder jamming problem.
8) LRSB not retracted.
9) Water logging at cable gallery.
10)Waste coal at feeder floor.
11. Hot line to ERLDC not functional.
12. Power consumption in cable gallery, high (SWGR) lighting.
13. Seal oil filter venting problem.
14.Wastage of condenser sump pit water.
15. Bottom ash drain pump over load.
16. LRSB drain temp. not maintaining high in U # 2.
17) Energy meters in “MS SWGR” not visible.
18) Diesel tank location for DG set is out side DG set building.
19) Air ingress through CEP suction line drain .
20) VC not effective.
21) During LRSB to HRSB C/o water particles trapped inside can
cause tube leakages.
22) Solidification of CO, during the H2 purging.
23) Tools for isolation not properly insulated.
24) Draining system of stator CW system not secure.
25) CT sump overflow.
26)Tripping of ash evacuation system.
27)Soot blower flange leakage.
28)Improving Ash slurry series availability.
29)Leakage oil pump (TG)failure.
30)Jamming of material handling valve.
31)Hot air leakage throw PAPH&SAPH.
32)ESP isolation,one key for each field at unit#2.
33) Drain valves of BFPs passing.
34)Oil pit adulterated in FOPH.
35 BADV opening problem. 35 BADV opening problem.
36)Coal accumulation near TP area.
37)tripping of compressor when DMCW pump trip.
38)clinker grinder jamming.
39)air coolers for GT is not temperature operated.
40) water logging at “0”mtr. ESP area.
41) DM water wastage on D/A level high.
42) Ash accumulation near PAPH & SAPH oil tank.
43) Mill#1C classifier temperature low during rainy season.
44)Reducing Aux. Power consumption.
45) Reducing DM makeup water.
46)Ash water leakage from hoppers.
47)flue gas leakage from ID fan inspection manhole.
48)passing of fire hydrant valve.
49)parking of vehicles near service building.
50) noise pollution in mill area.
51)service pump sunction line choking.
52)valve identification problem.
53)vacuums pump choking.
54) Ash dyke overflow.
55) Low line vacuum in fly ash evacuation system.
56)problem in PHE change over.
57)Bearing damage of series pumps.
58)High vibration in FAHP pump.
AFTER BRAINSTORMING THE PROBLEMS
ARE CATAGORISED AS UNDER

TYPE 08
-A
TYPE-B 32

TYPE-C 18
STEP- 2 :

WE HAVE SOLVED ALL

“A” TYPE PROBLEMS
 AFTER BRAIN STORMING OUR TEAM MEMBERS
SELECTED THE FOLLOWING PROBLEMS FROM THE
ABOVE “B”TYPE PROBLEMS
1.Wastage of condenser sump pit water
2. Bottom ash drain pump over load.
3. LRSB not retracted.
4. Low condenser vacuum in u#1
5. High vibration in FAHP pump.
6. Mill motor brg. Temp. going high.
7. Mill#1C classifier temperature low during rainy season.
8. Soot blower flange leakage.
9. Jamming of material handling valve.
10.Drain valve of BFPs passing.
11. Tripping of ash evacuation system.
12.Ash leakage from hoppers.
 THE “B”CATAGORISED PROBLEMS ARE PRIORITISED
BY NOMINAL GROUP TECHNIQUE. (NGT)
SCALE : 1 - 10
WEIGHTAGE BASIS: 1. SAFETY 2. PRODUCTIVITY 3. HOUSE KEEPING
4. QUALITY 5. ENVIORNMENT

PROBLEM NO.
1 2 3 4 5 6 7 8 9 10 11 12
MEMBERS
R.R. NAIK 8 8 9 8 5 6 9 6 8 6 7 6
J. SAHOO 9 7 8 7 9 9 10 5 6 5 7 5
N.K. PRADHAN 8 9 8 8 10 6 9 7 8 7 6 7
H.K. UDAN 9 8 7 7 9 4 8 5 7 8 9 6
S.K. SAHOO 8 7 6 6 7 5 9 6 8 6 6 7
TOTAL 42 39 38 36 40 30 45 29 37 32 35 31
  RANKS 2 4 5 7 3 11 1 12 6 9 8 10
 TIME in weeks
NO. ACTIVITY
1 2 3 4 5 6 7 8 9 10 11
12 13
1 Defining problem
2 Analysing the problem
3 Identifying the cause
4 Finding out root cause
5 Data analysis
6 Developing solutions
Foreseeing probable
7 resistance
Trial implementation and
8 Checking performance
9 Regular implementation
10Follow-up / Review
TARGET (12
WEEKS )
Glass Window

Conveyor Belt

Bunker

Feeder

Drain line

Mill # 1 C
DESIGN BY
MR R.R.NAYAK
COAL BUNKER

Storage of coal .
No need of continuous feeding
through conveyers .
Total capacity is 1600Tone.
 FEEDER

• To supply coal to the mill for

pulverization .
• To regulate coal supply to mill .y
much sought internationally.
MILL

Pulverizing the coal to desired

fineness .
Supply pulverized coal to boiler .
BUNKER FLOOR

Unload the coal from conveyor .

Bunker feeding .
 By using Flow Diagram
START

NO
IT IS RAINING
MILL # 1C
CLASSIFIER
TEMP LOW
YES

VERY MUCH WET

COAL COMING WET COAL COMING
FROM CHP
IS HOT AIR DAMPER YES
FULLY OPEN ARRANGE PROPER
DRAINAGE

NO
END FLOW CHART FOR
C&I
PROBLE MILL#1C CLASSIFIER
M TEMPERATURE LOW
 DATA SHEET BASED ON OPERATION LOG SHEET
STEP- 4 :
MONTH MILL#1C classifier temp lo.
JANUARY 0
FEBRUARY 0
MARCH 3
APRIL 4
MAY 6
JUNE 10
JULY 7
AUGUST 3
SEPT EMBER 4
OCT OBER 1
NOVEMBER 0
DECEMBER 0
TOTAL 38

DATA COLECTED BY
MR.H.K.UDAN &
MR.S.K.SAHOO
STEP- 5 :
MACHINE MAN FACILITY NOT
PROVIDED
PA HEADER MIXED AIR GATE
MISTAKE BY OPERATOR
TEMPERATU OPENING PROBLEM
RE LOW
INSUFFICIENT TRAINING
MALFUNCTIONING OF
HOT PA DAMPER INADQUATE KNOWLEDGE
C&I EQUIPMENT
NOT OPENING

BYPASS PA FLOW LO MILL 1C

CLASSIFIER TEMP
LOW
COLD AIR GATE
NO PROPER
ERRODED HEATING AT NO GLASS AT THE
MIXING BOX WALL WINDOWS

DAMPER TO RAIN WATER INGRESS

ACTUATOR AT BUNKER FLOOR
VERY WET
DELINKED COAL

NO BARRIER SURROUNDING
MATERIAL PROCEDURE BUNKER TOP OPENING

(CAUSE & EFFECT DIAGRAM)

STEP- 6 : VALIDATION OF ROOT CAUSES THROUGH COLLECTING
DATA FROM OPERATION LOG SHEET

SL.NO TYPES OF CAUSE FREQUENCY

VERY MUCH WET COAL.

1 5

2 WATER INGRESS AT BUNKER

FLOOR.
7

MALFUNCTION
3 4
OF C&I EQUIPEMENT.

4 HOT PA DAMPER NOT 1

OPENING. DATA COLECTED BY
MR.N.K.PRADHAN &
MR.JADUMANI SAHOO
 PARETO TABLE
CAUSE  TYPE OF CAUSE NO OF  CUMMULATIV % TO TOTAL COMULATIVE
NO OCCURENCE E          %

WATER INGRESS 07 07 41 . 2 41 . 2
1 AT BUNKER
FLOOR.

VERY MUCH 05 12 29 . 4 70 . 6
2 WET COAL.

MALFUNCTION 04 16 23 . 6 94 . 2
3 OF C&I
EQUIPEMENT.
HOT PA DAMPER 01 17 5.8 100
4 NOT OPENING.

TOTAL 17 100
CONTRIBUTION OF CAUSES TO THE
PROBLEM ( SHOWN IN %)

5. 8 %
23. 6 %
CAUSE NO-1
41. 2 % CAUSE NO-2
29. 4 %
CAUSE NO-3
CAUSE NO-4
 STEP-8 : DEVELOPING SOLUTIONS

PARETO ANALYSIS

17
94.2 100 %

14.825
87.5%
70.6 75%
12.75
FREQUENCY

62.5%

CUMILATIVE %
10.625

41.2 50 %
8.5
37.5%

6.325
25%

4.25 12.5%
2.125

1 2 3 4
CAUSE NO
 OF CAUSE NO.1
( TOOLS USED BRAIN STORMING )
 OF CAUSE NO.1
TOOLS USED BRAIN STORMING
 OF CAUSE NO.2
TOOLS USED BRAIN
STORMING
 OF CAUSE NO.3
TOOLS USED BRAIN STORMING
 OF CAUSE NO.4
TOOLS USED BRAIN STORMING
 FORSEEING THE
STEP-9 : PROBABLE RESISTANCE

Discussed about the problem, its 
causes and analysis with our    
HOD (O&C)

The proposed solution was 
conveyed to him, got verbal 
approval to go ahead for trial 
implementation.
 COMPARATIVE
MILESTONE
NO. ACTIVITY
CHART
TIME in weeks
1 2 3 4 5 6 7 8 9 10 11
12 13 14
1 Defining problem
2 Analysing the problem TARGET ( 12
WEEKS )
3 Identifying the cause ACTUAL ( 13 WEEKS )

4 Finding out root cause

5 Data analysis
6 Developing solutions
Foreseeing probable
7 resistance
Trial implementation and
8 Checking performance
9 Regular implementation
10Follow-up / Review
 INTANGIBLE BENEFITS

BY THE END, WE HAVE ASSESED THE BENEFITS TO THE

MEMBERS SUCH AS:
→ IMPROVEMENT OF SELF CONFIDENCE.
→ KNOWLEDGE REGARDING QC TOOLS/TECHNIQUES
→ SPEAKING UP AT MEETING INCREASED.
→ CREATIVITY HAS INCREASED.
→ IMPROVEMENT IN ABILITY, TEAM WORK AND INTERACTION WITH
OTHERS.
→ USING COMPUTERS .
→ STAGE FEAR REMOVED.
→ TIME MANAGEMENT IMPOVED.

ABOVE ALL OUR CIRCLE HAS INSPIRED THE NON MEMBERS

AND NEW CIRCLES ARE FORMED IN OUR DEPARTMENT.
Mill#1C classifier temperature
during rainy Season can be
adequately maintained &
Feeder floor will not be dirty.
 FLOW DIAGRAM
BRAINSTORMING
DATA COLLECTION
CHARTS & GRAPHS
CAUSE AND EFFECT DIAGRAM
PARETO ANALYSIS
CREATED BY
JADUMANI SAHOO