PH Quality Circle - 2011

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    PROBLEM PRIORITIZATION MATRIX

    LIST OF PROBLEMSCRITERIA

    TOTALPOINTS

    RANKINGCost Controllability

    Availabilityof Data

    Seriousness/Urgency

    UNWANTED MATERIALS 2 1 1 3 7

    a.) welding rods

    b.) broom sticks

    c.) paper bags from recycling

    d.) small pieces of wood

    EXCESSIVE MATERIAL SPILLAGES:

    1. SLIDE GATE AT SILOS 1 TO 6DURING ADJUSTMENT

    1 3 2 1 7

    2. SCREW CONVEYOR UNDERSILOS 3 AND 6 INSPECTION HOLE

    1 3 3 1 8

    3. DRAG CHAIN BOTTOM CASING2 3 3 1 9

    4. MAIN FEED SCREW CONVEYORINSPECTION HOLE

    3 3 3 3 12 1

    5. BUCKET ELEVATOR (FLUXOAUXILIARY) INSPECTION HOLE

    3 3 2 1 9

    6. FEED VALVE SHAFT BUSHING3 2 2 3 10 2

    7. SENSOR COVERS OVERFLOWDURING FEED VALVE

    MALFUNCTION

    1 3 3 3 10 3

    8. RETURN SCREW CONVEYORDRIVE SIDE OVERFLOW

    2 3 2 2 9

    9. RECYCLING SCREW CASING1 3 2 1 7

    10. DRAG CHAIN CONVEYOR @2ND FL (BULK LOADING

    AUXILIARY)

    2 3 3 1 9

    Rating Scales:

    Low - 1

    Medium - 2High - 3

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    PROCESS ANALYSIS

    OPERATION CONDITION OUTCOME

    1. Start up Normal NPOF

    2. Withdrawal of cement

    - Silo #1, @ 50% SG Normal NPOF100% SG Abnormal (boulders) POF

    Stuck up bin

    valve

    Abnormal (pebbles) POF

    - Silo #2, @ 50% Normal NPOF

    DC trip-off Abnormal (equipmentproblem)

    NPOF

    MFS trip-off Abnormal (equipmentproblem)

    POF

    100% bin valve Abnormal (pebbles/boulders) POF

    - Silos 1 & 2 (blending)

    DC trip-off Abnormal (equipmentproblem)

    NPOF

    MFS trip-off Abnormal (equipmentproblem)

    POF

    100% bin valve Abnormal (pebbles/boulders) POF

    - Volume of withdrawal,

    50/50

    Normal NPOF

    25/75

    Normal NPOF

    75/25

    Normal NPOF

    3. Running- Blending/silo withdrawal Normal NPOF

    - Fluxo packer stoppage Abnormal (stuck up nozzle) POF

    - Feed valve stuck Abnormal (clog-up, defective

    pneumatic cylinder)

    POF (Coordination /

    flexibility problem

    between

    tender/operator

    - Cement silo, discharge

    hopper aeration

    Abnormal (gate valve left

    open)

    POF

    - Power outage, withdrawal

    at silo 2

    Abnormal (cement discharge

    due to gravity)

    POF

    - Stoppage sequence Abnormal POF

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    ROOT CAUSE VALIDATION

    ROOT

    CAUSE

    VERIFICATION

    METHOD

    IN-

    CHARGEFINDINGS

    CONTROLLA-

    BILITY

    CONCLUSION

    True Cause/

    Not True

    Cause

    1. Training Training Needs

    Analysis

    JMP/AAC Not significant High Not True Cause

    2. No reliable

    means/facilityof monitoring

    cementwithdrawal byTenders

    Site Inspection Switchboard

    Operator / Tender

    Tenders has no

    reliable means ofdetermining volume

    of cementwithdrawn resultingto overflow in the

    MFS inspectionhole

    High Not True Cause

    3. No provision

    for

    automatically

    stopping

    cement

    withdrawal

    when the

    system stops

    Site Inspection Switchboard

    Operator /

    Tender / PH

    Mechanic

    Even if drag

    chain

    underneath

    cement silos 1 &

    2 and MFS

    conveyor is

    stopped, cement

    still continues to

    flow to the drag

    chain and MFSconveyor out to

    the inspection

    hole

    Cement

    withdrawal is

    operated

    manually

    Medium True Cause

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    PROPOSED ALTERNATIVE SOLUTIONS TO PROBLEM #1

    OBJECTIVE: Provide facility for automatically/immediately stopping cement withdrawal when the system

    stops

    1. MAN

    1.1. Highly motivated personnel

    1.2. Additional manpower1.3. Vigilance

    2. MACHINE

    2.1. Replace with cellular feeder2.2. Replace with rotary feeder

    2.3. Replace with vari-drive

    2.4. Modulating gate

    2.5. Reactivate roots blower2.6. Control aeration system

    2.6.1. Install solenoid valve at aeration system2.7. Replace gate valve with ball valve

    2.7.1. Replace air hose with GI pipe and relocate to most accessible area

    2.8. Install turbo blower

    2.9. Replace MFS cover2.9.1. Provide snap-on/wing nut

    2.9.1.1. Extend steel casing

    3. METHOD

    3.1. Install alarm system

    3.2. Packer to coordinate with Switchboard operator

    4. MATERIAL

    5. MILIEU

    5.1. Ergonomics

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    ALTERNATIVE SOLUTION CRITERIA

    Advantage DisadvantageTOPO

    Doability Economical Relevance/ Impact Safety

    AN

    1) Highly motivated personnel 2 2 1 3

    2) Additional manpower 2 1 1 2

    3) Vigilance 2 3 1 3

    ACHINE

    1) Replace with cellular feeder 1 2 3 3Pebblesproblem

    2) Rotary feeder 1 1 3 3 Not available

    3) Vari-drive 1 1 3 3 Not available

    4) Modulating gate 1 1 3 3

    5) Reactivate roots blower and aeration system 1 1 3 3

    5.1) Control aeration system 3 3 3 3

    6) Install solenoid valve at aeration system (@WBD)

    1 1 1 3

    7) Replace aeration gate valve with ball valve, installmergency shut-off ball valve and relocate the valves

    3 3 3 3

    8) Install turbo blower 1 1 2 3

    9) Replace MFS cover 3 2 3 3

    9.1) Provide snap-on / wing nut 3 2 3 3

    9.1.1) Extend steel casing 3 2 1 1 ETHOD

    1) Install alarm system 2 3 3 3

    2) Coordination among SWBD Optr, Packer andnder

    3 3 3 3

    LIEU

    1) Ergonomics 2 2 3 3

    ATERIAL

    TERNATIVE SOLUTION MATRIX

    JECTIVE: Provide facility for immediately stopping cement withdrawal when the system stops

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    LIST OF ACTIVITIES FOR THE TWO BEST ALTERNATIVE SOLUTIONS

    (For Gantt chart)

    Best Alternative Solution #1 - Replace aeration gate valve with ball valve, install emergency shut-off ball valve

    and relocate the valves

    Activities/Tasks:

    1. Sketch relocation piping

    2. Determine bill of materials3. Prepare purchase requisition for needed materials

    4. Check quantity and specifications of purchased materials

    5. Layout, connect pipes and install valves

    6. Tap new piping to existing air source and remove old aeration system7. Test new aeration system

    8. Utilize new aeration system

    9. Evaluate effectiveness and standardize

    Best Alternative Solution #2 Install alarm system (buzzer) and establish coordination procedure among

    switchboard operator, packer and tender

    Activities/Tasks:

    1. Draft procedure flow chart

    2. Prepare purchase requisition for alarm system (buzzer and switch)3. Check specifications of buzzer

    4. Prepare SWO for installation of buzzer

    5. Conduct orientation with concerned personnel on the procedure6. Implement procedure

    7. Evaluate effectiveness and standardize