1. BIRLA CELLULOSIC , KOSAMBA, GUJARAT
WELCOME TO
CASE STUDY PRESENTATION ON
DOWN TIME REDUCTION
AT DRYER#1
By Team : GOAL
BIRLA CELLULOSIC , KOSAMBA, GUJARAT

2. CONTENTS Prioritization of root cause Unit introduction
Team Detail
Meeting detail
Identification of Problem
Selection of Problem
Definition of Problem
Analysis of Problem
Process flow diagram
Brain Storming
Cause and effect diagram
Prioritization of root cause
Data Collection and analysis
Problem faced if any
Trial result
Before & After sketches
Action taken / Team working
Cost Involved
Results achieved
Sustenance of result
Acknowledgement

3. UNIT INTRODUCTION Name of the Unit : BIRLA CELLULOSIC
Location : Kharach , Gujarat
Year of Commissioning : 1997
Installed Capacity : 77 TPD Viscose Staple Fibre
200 TPD H2SO4 (Sulphuric Acid)
24 TPD CS2 (Carbon di Sulphide)
Present Capacity : 175 TPD Viscose Staple Fibre
200 TPD H2SO4
48 TPD CS2
Main Products : Viscose Staple Fibre,H2SO4,CS2
Value Added Products : Sodium Sulphate

4. UNIT INTRODUCTION Prestigious Awards Bagged in Last Two Years :
Deming Quality Award (Japan)
Aditya Birla Group’s Highest Award (Gold Medal) for Manufacturing Excellence
CII-Exim Bank Award for Business Excellence
Rajiv Gandhi National Quality Award-Best of All
Certifications:
ISO 9001: 2000
ISO 14001

5. BIRLA VISCOSE’s GLOBAL PRESENCE
Grasim India Total Capacity
685 TPD
Birla Cellulosic, Total Capacity
175 TPD
Spread of multi unit operations places us in a unique position to offer to our customers price competitive viscose fibre

6. OUR MARKET LEADERSHIP POSITION
Birla Cellulosic’s World Market Share = 4 %
AV Birla Group has almost 100% market share in India.

7. TEAM DETAIL Meeting Day : Tuesday , Meeting Time : 3:30 PM
Ownership Area : Spinning , DCS
Team formation date :
TEAM MEMBER
RESPONSIBILITY
Sudhansu Jain ( Leader)
To Provide Resources and Guidance
Manoj Patwari ( Dy. Leader)
Co-ordination with Process personals & Implementation of action plan
Kamal Kak
Data analysis & Use of PS Tools
Omkar Yadav
Data analysis & Use of PM Tools
Vijay Atodaria
Equipment Study and Execution of Instrument Jobs
Jitendra Adwan
Data analysis & Use of PS Tools
Deepak Patel
Equipment Study and Co-ordination during machine shutdown
Hemant Patel
Analysis of Trial implementation and Implementation of action plan

8. MEETING DATE / ATTENDANCE

9. MILESTONE CHART

10. IDENTIFICATION OF PROBLEM
Category 1
To reduce the dept book stock inventory level from 21 lacs to 15 lacs B 2
To reduce the surplus material stock at yard and wear house 3
To identify the obsolete material and arrange to selling 4
To initiate ARC of consumable items to reduce cycle time in procurement 5
To transfer the ARC instrument items at stores to release the PO from store to reduce the lead time 6
To increase the % Skill level of technician from 65% to 85% 7
Training to Instrument technician for electrical jobs 8
Training to Electrician for Instrument related jobs 9
Training to bailing press operators for alarm details A 10
To cover all team members for KIP tours at different units
“A”: To be solved by Team, “B”: Other department help required, “C”: Management decision required

11. IDENTIFICATION OF PROBLEM
Category 11
Training to technician for PDCA cycle approach B 12
Down time reduction at DRYER#1 A 13
To reduce the moisture variation at Dryer#2 due to improper logic at DCS as per viscose flow 14
Down time reduction in Spinning machine #1 due to DO card 15
Identification of critical loops for redundancy 16
To increase the % nos of Critical instruments from 42 to 65% 17
To include more nos of repeating problems in PM schedule 18
To reduce the down time of Dryer#2 control valve 19
Overload tripping of Sumpzone pumps 20
To reduce failure of DCS cards by corrosion on the tracks C
“A”: To be solved by Team, “B”: Other department help required, “C”: Management decision required

12. IDENTIFICATION OF PROBLEM
Category 21
To reduce M/c#2 freq drive card failure due to corrosion C 22
To increase the nos of Kaizen from 1.8 nos/member to 4 nos / member / year B 23
Steam leakages from the control valve galndes 24
Cable insulation failure at the line#2 PU cables 25
Magnetic flow meter card / senor testing for fluctuation in reading 26
To reduce the chronic problem of PU tube failure at cutter A 27
To modify the system for DCS data display at Forte screen 28
To remove the unwanted looping in dryer panel / MCC 29
To implement the kaizen for use of PT as level transmitter 30
To reduce the Panel view failure of bailing Press
“A”: To be solved by Team, “B”: Other department help required, “C”: Management decision required

13. IDENTIFICATION OF PROBLEM
Category 31
To reduce the high bale weight problem in bailing press B 32
Interfacing of Siemens PLC data on DCS of Prepress bale ready pressure 33
To identify the unnecessary / Obsolete items in the dept A 34
Non availability of standard labelling in the inventory room 35
Muda in Bottlenecking at DCS APM#11,13 side C 36
Muda in inventory of control valves 37
Muda in motion for Store room key 38
Muda in communication for DCS data on common LAN 39
To reduce the retrieval time form 6 min to 1 min 40
To eliminate Muda in Untidiness at DCS marshalling cabinet side multi core cabling
“A”: To be solved by Team, “B”: Other department help required, “C”: Management decision required

14. IDENTIFICATION OF PROBLEM
Category 41
To improve 5s score of ownership area form 75% to 95% B 42
Muda in untidiness at Logic manger # 17, 19 C 43
Muda in bottlenecking at LM#19 44
To create space in marshalling panel by removing unwanted signal splitter A 45
To improve file labelling level in filing cabinet 46
Higher stationery consumption in department 47
To improve the office 5s score form 78 to 85 % 48
Lack of awareness regarding safety precautions while working at CS2 line 49
Lack of awareness regarding the preventive measures while working at steam line 50
To reduce the failure of pH sensor for soft finish
“A”: To be solved by Team, “B”: Other department help required, “C”: Management decision required

15. IDENTIFICATION OF PROBLEM
Category 51
To reduce the CV for desulph bath temperature from 3.3 to 0.5 B 52
To reduce the CV for bleach bath temperature from 2.2 to 0.5 53
To reduce the CV for soft finish bath temperature from 1.7 to 0.5 54
Poor visual display about the spare channels at DCS A 55
Poor display of DO RTP details on the marshalling panel 56
To display the 24 VDC power supply looping on the marshalling cabinet 57
Poor display of MCC wise motor details in substation 58
Deletion of unwanted tags in Spinning section (APM#13) 59
To analyse top 100 consumable items to reduce its consumption. 60
To develop substitute for imported speed indicators of REXROTH machine
“A”: To be solved by Team, “B”: Other department help required, “C”: Management decision required

16. CATEGARISATION OF PROBLEM ( PIE CHART)
CATEGORY A B
Total numbers of problem Identified 60
Total numbers of problem solved 17

17. PROBLEM SELECTION IN CATEGORY ‘A’ ( By Voting )
Criteria : 16 No. for Highest priority, 1 No. for lowest priority ( Separate No for each Cause )

18. PROCESS FLOW DIAGRAM Any problem in dryer results in : VISCOSE
SPINNING
MACHINE
AFTER
TREATMENT
DRYER
BAILING
PRESS
AUXILIARY
Any problem in dryer results in :
1. Production loss due to slow run of Spinning machine
2. Adverse effect on quality of fiber

19. FIBER FLOW IN DRYER Dryer Sequence : Dryer Interlocking :
To Bailing press
From After treatment
Drum Drive#3
Drum Drive#2
Drum Drive#1
Nip roller
Doffer
Wet Feeder
Horz. Conveyer
Zero Speed switch
ExhaustFan
Motor
Dryer Sequence :
Dryer Interlocking :
Start all the fans
Start Drum Drive #3 ,2,1
Start Nip roller
Start Doffer
Start Wet feeder
Start Horizontal conveyor
If any exhaust fan stops, complete dryer will stop
If any drum drive zero speed switch senses zero speed, Dryer Sequence will stop including that drive and Horizontal conveyor will run in reverse mode

20. DEFINITION OF PROBLEM
This improvement project is related to “KAIZEN” Sub Committee to reduce the Down time.
Down time from 6-7 Hour to 0 hour/year
Tripping frequency from 18 to 0 Nos/Year
Production loss from 5.3 tons to 0 Tons/Year
Yellow Patches bale generation from 36 bales to 0 bales/Year

21. ANALYSIS OF PROBLEM / DATA
FROM APRIL-02 TO JULY-02 FROM LOG BOOK : No
Shift
Nos of occurrence
Down time
(Minute)
Average Down Time / Problem 1 G 4 80 20 2 A 17 3 B 45
22.5 C
105 35
Average down time / Problem : 24.7 minutes

22. ANALYSIS OF PROBLEM
1. Dryer#1 was stopping due to malfunctioning of zero speed switch
2. For identifying problem dryer has to restarted again and stopped to solve the problem due to which down time was increasing.
3. In B&C shift if E&I technician is busy in some remote location down time was increasing
4. For each stoppage of Dryer#1, 2 nos of SYP bales are generated which was direct loss due to yellow patches
5. For starting the dryer one fan was physically stopped to restart the sequence which was not advisable for motor
6. Attention from the main problem is diverted and main concentration is on zero speed switch
7. If there is any problem in zero speed switch and transmitter has not sensed correctly 2 to 3 hour breakdown may occur

23. BRAIN STORMING FOR CAUSE IDENTIFICATION
Team No: 44L102, 44L101, 20L104 No
CAUSES
SUGGESTED BY 1
Targets for the switch are not proper at drive shaft
J Jadav 2
Support for mounting the switches are loose
S Rajput 3
Long procedure to attend the switch problem
M Patwari 4
Zero speed switch cables damage due hot air from dryer doors
J Adwan 5
Non availability of redundant system at drum drives critical location to avoid breakdown 6
No provision to start the dryer sequence without stopping the fan
S Jain 7
No indication of zero speed switches on dryer graphics at DCS
M Patel 8
Proximity switches are not tightened with proper tool
S Garg

24. BRAIN STORMING FOR CAUSE IDENTIFICATION
Team No: 44L102, 44L101, 20L104 No
CAUSES
SUGGESTED BY 9
Use of NO contact for drum dryers at DCS RTP
M Patwari 10
Power supply to zero speed transmitter is given from lighting DB
M Dubey 11
Non availability of proper JB Schedule to reduce the down time
Nalin Parmar 12
No visual indication of switch to provision to check the healthiness of Proximity switches
Omkar Yadav 13
Loose contact of cable at the marshalling cabinet
Hemant 14
Cable glands are nor proper at the transmitter end
Omkar 15
No interlocking of dryer with after treatment low pressure to avoid jamming at drum
PN Murli 16
Fiber jamming between the drums
Deepak 17
Poor sensing of proximity switch
Vijay

25. BRAIN STORMING FOR CAUSE IDENTIFICATION
Team No: 44L102, 44L101, 20L104 No
CAUSES
SUGGESTED BY 18
Power supply is not regulated
M Patwari 19
Poor quality of zero speed switch
Kamal 20
Poor quality of zero speed transmitter 21
Corrosion at the DCS cards
Omkar 22
Corrosion at the cable terminals
J Adwan 23
While working fuse is not removed for transmitter
Vijay 24
Gap is varying between switch and target 25
Zero Speed transmitter sensitivity knob is at low side
S Garg 26
Switches are not tightened with proper tool
Hemant
Poor interlocking wrt Aftertreatment#1

26. CAUSE & EFFECT DIAGRAM FOR DRYER#1 , PROJECT
Method
Non availability of redundant zero speed switch at the drum drive end 1
Non Availability of redundant system
: Root Cause
Switches are not tightened with proper tool due its non availability
: Cause 2
Cable glands are not proper at transmitter
Check nut of switch are getting loose 3
No Bypass facility to attend the problem
No provision to start the sequence without stopping the fan
Long Procedure to attend the problem
DRYER#1, Down time increases

27. CAUSE & EFFECT DIAGRAM FOR DRYER#1 , PROJECT
Method
Transmitter sensitivity knob is at higher scale
Poor sensing of proximity switch
: Root Cause 4
No of target / rotation is less
: Cause
Gap varies between target and sensor
No interlocking at DCS with AFT#1 low Oil pressure 5
Use of NO contacts at DCS for Drum drives
Fiber jamming between drums
Zero speed switch cable covering is done for protection 6
Zero speed switch cable damage due to hot air or maintenance work
DRYER#1, Down time increases

28. CAUSE & EFFECT DIAGRAM FOR DRYER#1 , PROJECT
Material 7
LED type proximity switch is not used
: Root Cause
No Visual indication on the Switches
: Cause
Poor quality of zero speed switch
Poor quality of zero speed transmitter
Corrosion at the cable terminals
Marshaling panel is not sealed 8
Corrosion at the DCS card
DRYER#1, Down time increases

29. CAUSE & EFFECT DIAGRAM FOR DRYER#1 , PROJECT
Machine
Mounting support of switch is getting loose
: Root Cause 9
Vibration in the drum drive shaft
: Cause
Gap between switch and target varies
Power supply is given through Lighting DB 10
Power supply is not regulated
Spikes in the power supply of transmitter
DRYER#1, Down time increases
While working power supply is not switched off 11
Non Availability of JB schedule
Man

30. PRIORITIZATION OF ROOT CAUSES ( By RPN No. )
Scale for “S”: 1 to 10: Scale for “O”: 1 to 10, Scale for “D”: 1 to 10,

31. PRIORITIZATION OF ROOT CAUSES
PARETO ANALYSIS
Cumulative
Root Cause

32. FROM AUG-02 TO AUG-03 FROM LOG BOOK :
DATA COLLECTION
FROM AUG-02 TO AUG-03 FROM LOG BOOK :

33. DATA ANALYSIS Average down time / Problem : 20.5 minutes No Shift
SUMMARY OF DATA COLLECTION FROM AUG-02 TO AUG-03 : No
Shift
Nos of occurrence
Down time
(Minute)
Average Down Time / Problem 1 G 6 85 14 2 A 3 63 21 B 5
102 20 4 C
111 28
Average down time / Problem : 20.5 minutes

34. PROBLEM FACED IN IMPLEMENTING THE PROJECTNo
Problem faced
Action taken 1
Multi core cable limitation at field JB from DCS as only one spare pair was available
24 Vdc Bus made in JB and common supply given from JB instead of from DCS 2
Branch cable requirement from Junction box to transmitter for redundant switch
Spare core of existing branch cable is used 3
6 nos of redundant 2 wire proximity switch required for drum drive
Removed proximity from GCF is used ( Given by team 44L101 ) 4
Budgetary problem of Zero speed transmitter for new switches (6 Nos )
Feed back is taken to DCS and sensing of zero speed is done at DCS without transmitter

35. Average down time / Problem Average down time / Problem (Min)
TRIAL RESULT
DCS : Bypass facility at DCS to restart the Dryer #1 and finding Problem
Modification Date :
Average down time / Problem
BEFORE
DURING TRIAL
Average down time / Problem (Min)

36. Numbers of Occurrence graph at DrumDrive#1, Right side
TRIAL RESULT
Location : Drum Drive#1, Right side extra new redundant proximity switch installed
Modification Date :
Numbers of Occurrence graph at DrumDrive#1, Right side
BEFORE
DURING TRIAL
Nos of Occurrence

37. BEFORE / AFTER SKETCHES
Proximity Target
Drum drive shaft
BEFORE
Proximity Switch
Switch support
New Proximity Switch
New both side target
AFTER
Proximity Switch
Switch cable through PVC conduit

38. ACTION TAKEN / TEAM WORKING

39. ACTION TAKEN / TEAM WORKING

40. MILESTONE CHART

41. COST INVOLVED IN IMPLEMENTING THE PROJECTNo
Material required
Qty
Projected Cost
Action taken
Implemented Cost 1
Proximity switch
6 Nos
5400
Removed proximity from GCF is used 2
Multi core cable from DCS to JB ( 6 Pair X 0.75 Sqmm)
225 mtr
22500
24 Vdc Bus made in JB and Spare cable used 3
Branch cable from JB to Zero speed switch
180 mtr
9000
Spare core of 3 core cable used 4
Digital input channel
7 Nos
12000
New Digital input card installed 5
New switch support welding
1 gang
600
Support modified at work shop and welded with M/s JN associate gang 6
Zero speed transmitter
30000
TOTAL
79500
12600

42. Numbers of Occurrence / Month Nos of Occurrence/ Month
RESULTS ACHIEVED
Numbers of Occurrence / Month
BEFORE
AFTER
Project Completed
Nos of Occurrence/ Month
Root Cause

43. RISK PRIORITY NUMBER ( RPN ), After Implementation
RESULTS ACHIEVED
RISK PRIORITY NUMBER ( RPN ), After Implementation

44. RISK PRIORITY NUMBER ( RPN )
RESULTS ACHIEVED
RISK PRIORITY NUMBER ( RPN )
RPN Number
Root Cause

45. RESULTS ACHIEVED Average Down Time / Problem (Minutes)
BEFORE
DURING IMPLEMENTATION
AFTER
Project Completed
Average down time / Problem (Min)

46. RESULTS ACHIEVED No Detail Before After 1 Breakdown time 361 minute
( Aug-02 to Mar-03)
After
( Apr-03 to Aug-03) 1
Breakdown time
361 minute
0 minute 2
Frequency of occurrence
18 Nos
0 Nos 3
Numbers of Yellow patches SYP bale generation
36 Nos 4
Production loss due to slow run of machine
5.3 Tons
0 Tons 5
Proximity switch failure
3 Nos
1 Nos 6
Average Down time / Problem
20.05 Min
0 Min

47. BENEFITS Tangible benefits : Intangible benefits : No SAVING RUPEES 1
Fiber production loss due to slow run of machine ( 5.3 * )
3,44,500 2
Proximity switch consumption ( 3 * 1000 )
3,000 3
Reduction in Yellow patches bale (36*2500 )
90,000
TOTAL ( Rs/ Year)
4,37,500
Intangible benefits :
Low quality bale due to Yellow patches is reduced
Confidence on the Dryer interlocking is increased
ICSI index is increased from 75% to 95%
Inventory of the zero speed transmitter is made zero.

48. SYSTAMATISE THE PROCESS Preventive Maintenance Checklist
SUSTAINANCE OF RESULT
SYSTAMATISE THE PROCESS No
CAUSE
COUNTER MEASURE
SOURCE 1
Tightness checking of proximity switch
Switch check nut loose at support
Daily Checklist 2
Gap checking between target and zero speed switch
Gap between sensor and target should be < 10 mm
Preventive Maintenance Checklist 3
Proximity healthiness checking
LED indication on proximity switch and Green indication on graphics 4
Malfunctioning of zero speed switch
Alarms on DCS 5
Delay in attending the problem
Time in attending the problem
Training

49. SUSTAINANCE OF RESULT

50. ACKNOWLEDGEMENT
We acknowledge our sincere thanks to team of Spinning for their valuable suggestion during Brain Storming session and their support during execution of our project.
We are thankful to HOD-E&I for pondering the responsibility and support for taking up the project.
We are thankful to Vice President (Technical) for his valuable suggestions and support during execution of our project.

51. Thank you..

52. We Welcome your Suggestions & Questions