PH Quality Circle - 2011

7/28/2019 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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3/7

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

Documents

PH Quality Circle - 2011