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Statistical Process Control

SPC as tool to achieve reduced variability at each stage

of operations for improved clinker / cement quality.

Statistical Process Control-Q&PD Nov2012ACC Limited

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ACC Limited Nov2012Statistical Process Control

SPC sectional approach

Raw Mix PyroInput

OutputCement

GrindingInput

Output

Input

Process Control

VariablesProcess Control

Variables

Process ControlVariables

Output

Q

ualityAssuanranceInterface

Flow of Cement manufacturing Process

Each stage Quality Parameters set for which Cpk value to be measured monthly

Raw Material

Preparation

LSF

R90 Mic/ R212 Mic

Kiln FeedLSF

R90 Mic / R212 Mic

MgO

ClinkerFree Lime

LSFCement

SO3

R45 Mic

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SPC tools & Project methodology

Basic problem solving tools

1. Check Sheet

2. Stratification/Classification

3. Pareto analysis

4. Brain Storming

5. Cause & effect diagram

6. Histogram

7. Scatter plot, Correlation

SPC project methodology

1. Problem Identification

2. Observation

3. Analysis

4. Action (Action plan with date/Resp.)

5. Check (*Saving validation by FICO )

6. Standardization

7. Conclusion & finalsubmission

*Reward & Recogni t ion for best project

For each SPC project:-

a) Adherence of Project methodology is mandatory.

b) Data base support is mandatory for a Validcause in Analysis step.

c) Project saving must be validated by Plant FICO.

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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 fordiscussion 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?.

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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. 9SPCProjects are related to improvement in Cement grinding & Clinker factor.

Project Saving Rs 1.6 Cr.

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)

S No Name CMU Project TitleAnnual Saving

(Lacs)

1 Mr.Pramod Sharma Bargarh To increase the Cpk Value of Cement mill from 0 to 0.5 31

2 Mr.Amit Kumar Chaibasa Bring down the residue at R-45 . in CM-5 1.5

3 Mr.Jelin Edvin Chanda Minimise the variation of 45 micron (PPC) in Cement Mill -1 17

4 Mr.Viswajeet Mitra Damodhar TO minimise the variation on R45 mic. 145 Mr.Vishad Agrawal Jamul Bring down the variations in residue on R-45 mic. in CM-1 17.3

6 Mr.Subhajit Banerjee KymoreIncrease of %Flyash absorption in CM1&8 by reducing the variation in

cement lime9.8

7 Mr.Atul Sharma Lakheri SO3 Variation in Cement Grinding 42

8 Mr.Sumeet Srivastava Sindri Optimization in SO3 content in cement 17

9 Mr. Kumud Ranjan Sinha Tikarai Bring down the residue at R-45 . in CM-3. 13

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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.

S No Name CMU Department Project - Grinding section & CF Annual Saving

1 Sumersingh Tata Lakheri Process Minimizing the flushing of fly ash in close circuit Cement mill no. 636

2 Arvind K Dixit Tikaria Quality Maximization of phospho gypsum percentage in cement 432

3 Asit Parui Kymore ProcessImprovement in Cpk of % residue on 45 micron of kymore cement

mill 1 product ppc (from 0.32 to 0.80) 44.9

4 Vivek Gupta Wadi 2 Process To improve the process capability of SO3 in cement mill -06

5 Anil Popuri Thondebhavi Process To minimize the variation in cement residue on 45 mic 3

6 P K Sharma Bargarh Process Improvement in Res-45 of Cement mill-3 5

7 Hemant Sahu Kudithini Quality Minimization of variation of 1 Day compressive strength in PSC 10.8

8 Sanjeev Prasad Sindri Mechanical Improvement in cpk value of cement mill # 4 residue

9 Pintoo Sarkar Damodhar ProcessTo improve the cpk of cement mill 45 micron residue by maintaining

consistency of cement mill feed by reducing feed cut of CM-1

Function No of Participants

Process 15

Quality 2

Mines 9

E & I 2

Maintenance 1

9 Projects are related to improvement in Cement grinding & Clinker factor.

Saving through Cement grinding & CF is Rs 5 Cr.

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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 Numbers

1.Quality & Productivity 35

2. Maintenance 02

3. Quarry 05

4. Power / Energy 04

5. Material 01

6. Process 01

Total 50

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SPC Project2011 related to Clinker factor

19 Projects out of 46 related to improvement in Cement grinding & Clinker factor.

Project Saving Rs 7.8 CrS.NO Plant Name Project Title Annual Saving (Lacs)

1 Mr. S.A Hamid Reduce the Flyash consumption variation & increase the Cpk of R-45 micron residue

in G-I.35.6

2 Mr. Deepak Jasuja Optimization of Cement Residue Improve Cpk in G-2 Cement mills. 95.8

3 Kymore Mr. Qazi Mushtaque To Control and Minimize the SO3 variations at cement grinding stage in CM 1. 27.37

4 Tikaria Mr. Rishikant S Baghel Reduction in cube to cube variation in cement strength TRedn in COV from 6 < 4.5

5 Chanda Mr. G VVaraprasad Reduction in R45 variation in Cement Mill # 1 (Cpk improvement from 0.65 to 0.9) 133.8

6 Mr. V. Sundararajan Improving Flyash absorption without sacrificing quality . Increase % Flyash

absorption from 23.5 to 27.0 %

141.45

7 Mr. M Reddy Chintangal To minimise the variation in SO3 content in cement.to improve Cpk 0.1 to 0.25 16.68

8 Kudithini Mr.Gadilingappa Karur Optimization of SO3 in ground clinker for production of PSC. From current level of3.10-4.32 5 to 4 +/- 0.2 %

17.9

9 Mr. Pinaki Dutta Improving Cpk of R45 of CM#3 from current level of 0.21 to 0.33 25.92

10Mr. Kundlesh Jha

Reduction of Slag VRM product residue on 45 mic from current average level of 7%

to 5%.

33.48

11 Jamul Mr. Tapabrata Mallik Improvement in clinker factor from 0.453 to 0.442 44.4

12Mr. Krishna Ram

Improvement of clinker factor by 0.5 % by reducing variation in kiln feed LSF ( CpK

value from 0.18 to 0.4)

13 Mr. Ravi Kant Tiwari Improve the process capability of clinker LSF from 0.18 to 0.45.

14 Mr. Amlan Shyam Reduction in variation of c linker 1 day strength COV 6.1 to COV

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Reward & Recognition for Best SPC Projects 2011

Prize Works Name of the project Name of the projectleader

Annual Saving(Rs.Lacs)

First Gagal Optimization of Cement Residue Improve CpK in

G-2 Cement Mills

Mr.Deepak Jasuja 95.74

Second Lakheri Process and capacity optimization of wobblerfrom 260 tph to 320 tph

Mr.Rajesh Kushwaha 60.94

Third Tikaria Reduction in cube to cube variation in cementstrength

Mr.Rishikant Baghel Quality

First Thondebhavi

Improving Flyash absorption without sacrificingquality. Increase % Flyash absorption from 23.5 to27%

Mr.V. Sunderarajan 141.45

Second Kudithini To increase VRM output in optimum level andmaintaining residue 45 & 20 micron 14.4% to 10%and 43% to 30% respectively

Mr.Ajoykumar Deka 74.46

Third Madukkarai Improvement in CpK of% Free lime in Clinker byprocess optimization of the system

Mr.SP Rameshbabu 14.08

First Jamul Reduction in grinding power consumption Mr.Pinaki Samanta 67.80

Second Jamul Optimum utilization of low grade limestone fromJamul mines for better mineral management

Mr.Devendra Kumar 48.76

Third Chaibasa Reduction in variation of clinker 1-day strength COV6.1 to COV

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SPC Projects Summary of Savings Accrued till Dec11

2011

2009

to

2011

YearSPC project

saving (Rs. Cr )

Project Saving from

Cement Grinding & CF

(Rs. Cr)

2009 2.7 1.62010 11 5

2011 17.05 7.8

Total 30.75 14.4

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Section North South West East RO/Thane Total

Safety 0 2 1 3

Quality 4 7 9 20

Productivity/Quality 5 3 6 14

Energy/Power 3 4 3 10

Packing/ Logistics 2 3 5

Quarry 3 1 1 5

Logistics 3 1 4

Cost/Finance 2 2

Lubricant 2 1 1 4

Environment 3 3

HR 2 2Procurement 2 2

AFR 1 1 2

HR-Thane 1 1

Sales-RO Delhi 1 1

Other/ Maintenance 1 1

Total 18 33 26 2 79

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 MIQ-

Nasik 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 ofNov12.

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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 ofNov12 and updated in SPC folder.

S. No Name SPC Project- CM Grinding & CF Plant Dept.

1 Mr. Gagandeep singhTo improve Clinker factor by using low purity gypsum & increase in Fly ash

% in Cement Mill Gagal II.Process

2 Mr. Manavjot SinghTo Improve the Specific Power Consumption of Gagal 1 Cement Mills

(CM#1, CM#2, CM#5)Power

3 Mr.Kumud Ranjan Sinha Increasing Fly ash absorption up to 35 %". Quality

4 Mr. Kumud Ranjan Sinha Reduce specific energy consumption up to 32.0 KWH/T Power

5 Mr Arun Kumar Garg Establishing the +R45 of PPC in CM #03 Cpk : 0.84 Chanda Quality

6 Mr Mohan RajMinimize the variation of % SO3 in PPC grinding to achieve the CpK value

>= 0.70

Madukkarai Quality

7 Mr. B RamaswamyReduce Cement Mills Process Power from 42.65 to 40.51 KWh/T of

CementWadi Power

8 Mr. Ajoy Kumar DekaReduction of the Specific power consumption in VRM grinding from 48

kwh/MT to 45 kwh/MTKudithini

Power

9 Mr. Surendra Hegde Reduction in oil consumption Lit. / Tn of cement. Lubricant

10 Mr Tushar Goel Improvement in Hourly TPH Productivity

11 Mr. P K Jain Reduction in clinker factor of PSC from 44% to 41%. Productivity

12 Mr. Pinaki Dutta Improving flyash absorption in PPC from 22% to 25%. Productivity

13Mr. pramodkumar.sharma

Reducing PPC 3 days strength COV from 8.4 to 4.9 Quality14 Mr. Kundlesh Kr. Jha Complying 100% internal quality norms for F2R. Quality

15 Mr. Narendra K Sahu Improvement in cement SO3 cpk from 0.13 to 0.3 Quality

16 Mr Swapan Roy Additives consumption optimization & hence reduction by Rs3/t cemt. Productivity

17 Mr. Susanta Banejee Reduction in strength variation in 1 Day and 3 Day strength Sindri Quality

18 Arijit Bandyopadhyay Reduction in clinker factor by optimizing PSC quality Damodhar Productivity

Jamul

Thondebhavi

Bargarh

Gagal

Tikaria

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Flavor to Top Management on the Concept

Team Formation , Training & Project assign

Projects review and support with MIQ (Nasik )

2008

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)

SAP Implementation

Expand the horizon of SPC (Mines, Maint , E& I Added)

SPC plant champion & Regional coordinator. Breakthrough improvements.

Development of Control Plan

SPC Project share folder (Region- wise)2009

2010

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

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

2012

SPC at ACC Way Forward

2013:- Can SPC a part of

I. Excellence???...

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Outcomes from SPC ..

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

Sustainable improvement by imparting Training for new participant and Projectleaders through MIQ-Nasik. Project review & support by Mentor , SPC coreteam, 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.

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THANK YOU

Documents

SPC-CF _Nov'12.ppt