BHEL Tiruchirappalli
Quality
Powering the Growth
Gearing up for 2012…
VISION 2012 Quality
• The Quality function will be done by the
respective task performers
• Defect prevention will be given top priority
• Supported with Integrated systems and
functions towards total compliance to
specifications.
• The final task performer will certify the
outgoing product for its quality
• Quality Surveillance and audits will be the
source for improvement actions
Gearing up for 2012
Quality:
Presentation
Vision 2012:
Focus
Basis
• Larger association with suppliers and service
providers considering:
–
–
–
–
Physical Growth rate of about 10% CAGR in Shops
17% CAGR in Outsourcing/Away Centre fabrication
30% in Shops, 70% in Outsourcing
Increased Outsourcing from 1,20,000 MT to 3,20,000
MT
• Reduced in-house human resource/ talent, with
no significant inductions
• A company-wide quality culture
• Increased Automation, e-enabling
Gearing up for 2012
Quality:
Presentation
VisionFocus
2012
Defect Prevention culture to avert errors and
defects (instead of finding out defectives and
correcting the same)
The task performers own and control the
process and monitor the performance (without
the need for separate QC Personnel at Shop
floor/ Vendor Works for verification and
compliance)
The goal is to reach Zero Defects
Gearing up for 2012
Global Quality Management Approach
Gearing up for 2012
Quality:
Presentation
Vision 2012:
Focus
Strategies
1. Focus on Quality Planning rather than Inspection
2. Minimisation of human dependence with
appropriate automation
3. Increased Outsourcing of non-core activities
4. More stress on Self Inspection
5. Adequate and Reliable Supplier-base with Strong
Partnership
6. Quality Image Enhancement
7. Sustenance of Knowledge Base
8. Highly Motivated self-driven Team
Gearing up for 2012
1. Focus on Quality Planning … 1
• Effective Process Management *
• Dedicated Group to analyse data regularly,
Root Cause analysis and Mistake Proofing *
• Establishment and Monitoring of Process
Capability for all CTQ Work Centres
• Minimisation of Liaison Work through online
systems and outsourcing
• Strong internal audits and surveillance in all
functions
• Continuous Revisit and Standardisation of
Procedures and Plans *
Gearing up for 2012
1. Focus on Quality Planning … 2
• Simplifying Quality Function through
Modularisation of Products
• Enhancing Customer Confidence for
Reduction of Hold Points (CHPs)
• Augmentation and right mix of Quality
Equipments, with high utilisation
• Comprehensive documentation to task
performers on time
• Monitor and control Cost of Quality *
Gearing up for 2012
2. Minimising Human Dependence
• Automation in Inspection – *
– Automated measurements by probes in CNC System
– Laser-based linear measurements
– Portable Co-ordinate Measuring Machine (CMM)
based measurements for fabricated components
– Robots, AI based Decision Making Equipments
– Automated Equipments in Testing and NDE
• Intelligent Process Monitoring and Control of
major welding, forming and other processes
• Electronic Data Exchange of Quality Work
Instructions and Reports – IT Plan *
• Voice enabled data acquisition systems
• Increased Speed of Response *
Gearing up for 2012
3. Increased Outsourcing
The potential additional areas of
outsourcing of the Quality Activities:
• Material Quality Assessment on receipt
• Documentation work at Shop & Data Folder /
IBR certificate preparation
• Fixed Tenure Recruitment of certified NDE and
other Quality Engineers/ Supervisors for 3
shift working
• Calibration and more Routine Testing
Activities
Gearing up for 2012
4. Stress on Self Inspection / Certification
• Certification of Personnel for Specific
Assignments based on competencies
• Majority of the vendors aligned with ISO 9001
systems, with dedicated BHEL audit teams
conducting planned surveillance audits
• Robust system for monitoring effectiveness of
self inspection through interlinking of product
performance, continuous rating, feedback,
retraining etc *
Gearing up for 2012
5. Reliable Supplier-base …. 1
• Partnering with Suppliers to develop them for
manufacturing pressure parts and precision
products, through a dedicated group
– to assist in establishment of quality systems (FOT, WPS ,
Welder qualification, Speciality Tooling and Gauges,
Measurement techniques etc.) with reduced cycle time &
enhanced quality
• Wider Self Product Certification for specific jobs
• Electronic Data Interchange with Suppliers;
including online TC Verification and product
acceptance
Gearing up for 2012
5. Reliable Supplier-base …. 2
• Grooming up a team of "mobile" quality
inspector turned educators for meeting
extensive away centre/site fabrication quality
requirements
• Extensive sharing of improved "processes"
developed by BHEL with the vendors
Gearing up for 2012
6. Image Enhancement
• Creation of a Centre of Excellence for
Materials Evaluation
• Training and Support in Quality Management
(ISO 9001, TQM etc)
• Increased participation by executives as
NABL Assessors for other Testing /
Calibration Labs, CII Assessors for CII
Award, Q & HSE Audits etc
• Become a Well known Valve/ Boiler Maker
Gearing up for 2012
7. Sustenance of Knowledge-base
• Creating a robust online knowledge bank by
capturing the tacit experiences of Quality
Personnel *
– On Site Failures, Modifications, Improvement Studies,
Site Visit Tour Reports, Quality Improvement Studies,
implemented suggestions etc
• Development of On-line Query System for
clarifications in Quality Field, Online data bank
to enable task performer to take corrective
action in case of deviations
• Support to WRI to continuously assess the
impact of new materials/ new processes and
their application issues
Gearing up for 2012
8. Motivated Team
• Training and Skill Upgradation of personnel,
based on identified competency needs
• Plant wide SQC Knowledge and an SQC culture
• Training in areas like SQC, Six Sigma, FMEA and
other Quality tools to all personnel *
• Competency mapping and capability building of
personnel to enable scientific problem analysis
and solving
• System for tracking Quality Performance of Task
Performers and the linked training
• Increased team work through Quality Circles
and small group working
*
Gearing up for 2012
Quality:
Presentation
VisionFocus
2012
Quality Metrics to Monitor
Levels
Measure
From
To
Sigma Level of Processes
3.5 - 4
6
Skill Index for various Critical Operations
*
% of Activities automated
30%
75%
% of Areas adopting at least one SQC Tool
5-10%
100%
% of Areas adopting min. one Mistake Proofing Tool
<5%
100%
No. of Active Quality Circles
30
350
% of Self Certified Product Suppliers
*
 100
% Cost of Quality to Turnover
*
<1 %
Internal Non Conformance Index
2.28
<0.30%
No. of Internal & External Customer Complaints
*
0
% of Error-free and Timely Inspections
*
 100
% web-based training modules developed for
competencies
*
 100
* No Data/ System
Gearing up for 2012
Presentation
Quality: The Facets
Focus
Quality ….
- In Products
- In Services
- In Business Processes
…. Is ultimately perceived by our Customers
and Stakeholders as the Image of our
Organisation
Every facet of Quality has to meet all the
expectations of customers
Quality is every Employee’s Vision
Gearing up for 2012
Thank You
Six Sigma Projects - Welding
• Tube-to- header welding in HRSG modules – Pilot
project – Current level : 4.4σ
• Automatic welding in tubular shops - Pilot project –
Not pursued
• Manual welding (tig & arc) in tubular shops
• Panel welding in tubular products
• Long & cir seam welding in pressure parts
• Tube-to-tube sheet joints - Manual TIG
• Tube-to-tube sheet joints - Semi automatic TIG
• Fillet weld quality in drums and headers
• Leak tight one sided TIG welds in ATP area
• Body yoke welding in hancock valves
Gearing up for 2012
Six Sigma Projects - Forming
•
•
•
•
Expansion of tube-to-tube sheet joints
Surface quality in formed fittings
Dimensional control of tees
Single stage profile control in large 3D jobs of ATP
area
• Elimination of hot correction in header stubs
• Bending of large dia pipes of R/D ratio 1.5 & 2
Gearing up for 2012
Six Sigma Projects - Machining
• Hydro test performance of valves- Pilot project in
Forged conventional valves – Not pursued
• Smooth operation of coal valve gate racks
• Deep hole drilling quality in ATP area
Six Sigma Projects – Non Mfg. Processes
Contract Monitoring
Engineering
Procurement
Maintenance & Services
Production Planning
Preservation, Packing, Shipping
Documentation
Gearing up for 2012
Root Cause Analysis and Mistake Proofing
Approach
Form CFTs ( Quality, Engg, FES, OP&C, Production/ MM/ OS)
Capture all the non conformances and computerise, if not already
done/ Stratify data
Generate a software to compare non conformances and SARs
Identify repeated ones/ vital ones
Analyse and find the root cause
Identify the corrective actions and implement
Identify the fool-proofing method
Take pilot trial
Implement on regular basis
Identify the next priority
Plan for implementation during 2005-07
Gearing up for 2012
TDC Revisit Plan
Raw Material
Form
No of TDCs No of Main
TDCs
For FB
No Revisited & Finalised
Tubes & Pipes
12
3
3 (unified as 1)
Plates
4
2
Under Finalisation
By September 05
Structural Quality
Plates
5
3
Needs Re-discussion
By October 05
Forgings
6
3
Needs Re-discussion
By November 05
Piping Centre
4
4
Under Finalisation
September 2005
SSTP
13
4
4
Gearing up for 2012
New TDC Plan
Product TDCs
Undrilled Drum
Status
Ready
Finished Header
Draft under Review
Coils
To be prepared
Panels
To be prepared
Gearing up for 2012
Measurement Automation – CNC Machines
Location:
Bldg 6, Bay
4, Valves,
2 Shifts
Fossil
Boilers
Bldg 1
Drum shop
2 Shifts
M/C Detail:
SACEM
CNC HMC MSMG125C
N - 75 KW
1996
Make:
Siemens
840C
Renishaw
Probe
Use:
Products:
Edge
TOA HM
Preparation : Valve Body
d1 , d2 &
overall length
Seat Gap
Travelling
column
Drilling
machine
M/s
Strojimpot,
Czech
1995
Siemens
810GA3
Renishaw
Probe
Drum
Drums ,
Expansion
Headers
holes :
Individual
pitch ,
Cummulative
pitch & Hole
diameter
2 Machines
– existing
Probe to be
made
operational
Status:
Recondition
ing &
commissio
ning is
planned in
the current
year
Gearing up for 2012
Measurement Automation – CNC Machines
M/c, Location:
Use:
HMT CNC lathe; Edge Preparation,
4 Tool Holders; bevel angle, weld
end diameter, OD,
ID
Fossil Boilers,
Products:
Header
stubs ,
Nozzles,
fittings
Cost:
Rs. 7
lakhs
Toa Body
Rs. 8
lakhs
Bldg 1, bay-1
Toshulin, SKS25 Bore diameter ,
Vertical boring Edge preparation
m/c
15 Tool Holders
2 Machines
– Probe to
be
retrofitted
this year
Status:
Retro-fitting
planned in the
current year 0506
Valves, Bldg 6,
bay-4
Gearing up for 2012
Measurement Automation – CNC Machines
M/c, Location:
LC140 CNC lathe
Fossil Boilers,
Bldg 1, Bay-1B
4 Tool Holders
Use:
Edge Preparation :
bevel angle, weld
end diameter , OD ,
ID
Products:
Header
stubs,
Nozzles ,
fittings
Cost:
LC140 CNC lathe
Valves, Bldg 5
4 Tool Holders
Edge Preparation :
bevel angle , weld
end diameter , OD ,
ID
Valve Body
Machining
Rs. 7
lakhs
HMT HMC 800
Valves, Bldg 6,
bay-3, 40 Tool
Holders
Toa wedge : Hinge
pin Diameter ,
Location
Toa Wedge
Rs. 6.1
lakhs
Valve Body
Machining
Rs. 8
lakhs
Toshulin, SKS25
Bore diameter ,
Vertical boring m/c Edge preparation
Valves, Bldg 5, 15
Tool Holders
Rs. 7
lakhs
4 Machines –
Probe to be
retrofitted
based on
success on other
m/c
Status:
Retro-fitting
planned for 0607 base on the
success of 2
machines
identified for
05-06
Gearing up for 2012
Quality IT Plan
Expert System for Quality By June 2007
Quality Issues – Dec-2006
problem solving
Welding Knowledge – Mar-2007
Repair & rectification – Jun-2007
By June 2008
Office automation with
Digitisation of Letters – Jun-2007
emphasis on paperless
Elimination formats – Dec-2007
office
Elimination paper based queries – June 2008
By December 2007
Comprehensive Cost of
Firming up existing system in SAP Aug–2006
quality reporting
Additional Critical Elements-Jun-2007
Consolidation – Dec-2007
B2B networking with
By December 2006
vendors (for Quality
Incoming Data – July 2006
related documentation)
Outgoing data – Dec 2006
Gearing up for 2012
Quality IT Plan
Comprehensive Inspection stage
monitoring system
By December 2006
Ist Stage - June 2006
Completion - Dec 2006
Digitization of customer and IBR
documentation
By April 2008
System Development - April 2007
Non-IBR documentation-June 2007
IBR documentation with approval
electronic approval - April 2008
Quality Activity Monitoring system for
performance analysis
By June 2008
System Development - April 2008
Implementation - June 2008
Vendors Performance Monitoring
System
By December 2007
System development – Sep 2007
Implementation – December 2007
Gearing up for 2012
Speed of Response - Measures
2005-06
2012
Physical Verification
All Inspection Calls attended & Closed
(Shop & Stores)
90 % within 8 hours
100% within 2-4 hrs
All Inspection calls attended & closed
(hrs)
(Out – Sourcing )
70% within 4 hours
100% within 2-4 hrs
8 –12 hours*
Within 4 hours
Boiler – from the date of h/o final DU
Preparation
15 days*
Concurrent (On-line)
Statutory / Customer Clearance
15 days*
3-4 days*
Customer / TPI / IBR clearance
All QP stage / Final Inspection Calls
Documentation : IR / Certificates
* Average time taken
Gearing up for 2012
SPEED OF RESPONSE – How?
Physical Verification
Use of Highly Skilled Man-power
Use of Faster & accurate measuring equipments
• Laser Measurement for Linear Dimensions, Marking etc;
• portable CMM for fabricated components like Bends, fittings
• On-line report Generation facility
Customer / IBR clearance
Pursue with Customer / IBR for use of Professional TPI like
Lloyd’s, BVIS etc;
Limit the Inspection Stages to Functional / Strength / Calibration
Tests
Pursue for obtaining Well – Known Boiler / Valve Manufacturer
Documentation
On-line preparation of reports / Certificates through ERP
Pursue with Customer / TPI / IBR for On-line clearance of Reports
/ Certificates
Gearing up for 2012
Self Inspection
Self Inspected Tonnage
50000
45000
40000
35000
30000
25000
20000
15000
10000
5000
0
2005-06
2006-07
2007-08
2008-09
2009-10
2010-11
2011-12
Gearing up for 2012
Knowledge Management
Compilation of Failure Analysis Reports (2006-07)
Conversion of available Hard Data into pdf files with
keyword search (30years – 22000 pages)
Compilation of Site Repairs / Rectification (2006-07)
Collection of all Recommended Repair / Rectification
Procedures to site for the last decade
Compilation of Tour Reports of Quality Personnel to Sites
Inspection Methodology for Different Stages of
Inspection and Processes (2007-08)
Online Query System for Clarification in Quality Field
(2007-08)
Gearing up for 2012
Knowledge Management
INSPECTION TECHNIQUES TO BE DOCUMENTED (First Stage)
MARKING CYLINDERS
OPTICAL ALIGNMENT
BLUE MATCHING
SURFACE FINISH CHECKING
HELIUM LEAK TESTING
BORE DIAL USAGE
HEAT TREATMENT CHART INTERPRETATION
ALL RECOMMENDED REPAIR/RECTIFICATION
PROCEDURES TO SITE FOR THE LAST ONE DECADE.
 TOUR REPORTS OF QUALITY PERSONNEL TO SITES








Gearing up for 2012
Quality Training
Target Audience
7 Tools
Artisans, Supervisors
QC members,
Shops, Support
areas
New 7 Tools Artisans, Supervisors
and Exec- M1,M2
QC Members, CFTs
Shops, QC,
Process groups
Statistical
Techniques
Executives M1
CFTs, Imp. Project
Members
Shops, QC, QA,
Engg. OP&C
FMEA
Executives
CFTS, Imp. Project
Members.
Engg, QA,
Support groups
On class training: Qualified faculties, Training & Ref. Material.
Web based training: Monitored by Reviewer, Guided/Reviewed by
Faculty
Evaluation: By reviewer / Faculty; Identify and Plan Project
Every Training linked to hands on working on an area problem
Organised through HRDC with extensive coverage
Gearing up for 2012
Quality Circles - Revival
• Every executive a facilitator with performance weightage in
appraisal
• Mass awareness programme on Quality Circles
• Senior executives as guides to steer the QCs
• Monthly presentations in each product /function GMs
• Canteens for weekly meetings of QCs on prefixed days
• Specific tables on each day , can be earmarked for specific QCs
• Problem banks for each area to be developed by the Executives
• The Problem Bank to cover quality, productivity, customer
feedback etc., (ECPS, ICPS, EPS-FGD issues, Cust Complaints,
NCRs etc.)
• Simplified presentation template
• Simplified immediate reward system for QCs
Gearing up for 2012
Cost of Quality (BS 6143 Part 2) APPRAISAL COST
Being Captured
To be captured / How to capture
Salary of Personnel
ERP – time log against each Implementation of ininspection operation
process through ERP
Special measuring
instruments, gauges
Apportioning to be done on
Depreciation basis
Implementation of inprocess through ERP
Pre production & checks
Welder qualification tests
To be brought in ERP
Field performance tests
Details to be obtained
from FES.
Documents approvals,
fees to authorities.
--Testing on stocks of
products/ spares (shelf life)
Upgradation of materials
--To be captured in
ERP.
Gearing up for 2012
Cost of Quality (BS 6143 Part 2) PREVENTION COST
Being Captured
Salary of QA
Personnel
Calibration of
instruments / gauges
To be captured / How to capture
Quality Planning
System to be
developed
Templates, gauges (at
shop) to confirm Quality
System to be
developed
Proof tests, type tests
To be integrated in
ERP
---
---
Audits, Surveillance
-Internal / Vendor
System to be
developed
Training of Personnel
Improvement programmes
Gearing up for 2012
Cost of Quality (BS 6143 Part 2) EXTERNAL FAILURES
Being Captured
SARs, CARs, MDRs
To be captured / How to capture
---
To be integrated
Warranty
To be systemised and
integrated
Recall costs
To be integrated
Loss of sales
System to be evolved
with Commercial
Gearing up for 2012
Cost of Quality (BS 6143 Part 2) INTERNAL FAILURES
Being Captured
Butt Weld Repair,
Hydro test leaks, Reheat treatment,
Rejection
Rework due to sub
contractor error
To be captured / How to capture
Fillet Weld Repairs, Fit Up To be developed/
Reworks, Faulty Machining aligned with ERP
Failure analysis
To be captured
through ERP
Re-inspection, Re-testing
To be integrated in
ERP
---
To be integrated in
ERP
Efforts to redress NCRs
To be captured
through ERP
Down time (Job waiting
due to deviations)
System to be
developed
Gearing up for 2012
VISION 2012 Quality
Additional Back Up Slides
Gearing up for 2012
Six Sigma Programme
• Six Sigma Level – 3.4 defects per million
• Most of our manufacturing processes are at levels
between 3σ and 4σ
• Corporate target – 4.5σ level by 2007 in critical
processes
• Suggested list of processes (not exhaustive) for
implementing Six Sigma programme follows
• Examples of opportunities / sigma level calculation
presented
Gearing up for 2012
Sigma Level Calculation - Example
DEPARTME
NT
Engineering
ACTIVIT
Y
Preparati
on of
design
documen
ts
DEFECT
OPPORTUNITIES
(n)
· Design calculation
(n1)
Contract
requirements (n2)
· Code / standard /
statutory requirements
(n3)
· Manufacturing,
transportation and
erection feasibility (n4)
· Interface between
design documents (n5)
· Document
transmittal (n6)
· Drafting (n7)
NO. OF
ITEMS
PRODU
CED
(N)
NO. OF
DEFECT
S
OBSERV
ED
(d)
100
0
1
0
1
2
0
4
DPMO
(d)*106
(n)*N
8 * 106
55*100
=
1455
SIG
MA
LEVE
L
4.48
Eg:
n1 = 3
n2 = 4
n3 = 5
n4= 8
n5 = 9
n6 = 6
n7= 20
Gearing up for 2012
Sigma Level Calculation - Example
DEPARTME
NT
Contracts
ACTIVIT
Y
Contract
Manage
ment
DEFECT
OPPORTUNITIES
(n)
Work order release
CSR preparation
SDH
Delivery Monitoring
-On time
delivery
-Complete
delivery
-Sequential
delivery
• Correctness of
Despatch
• Response time to
MDRs
• Resolution time of
MDRs
• Response time to
Customer complaints
• Resolution time of
NO. OF
ITEMS
PRODU
CED
(N)
NO. OF
DEFECT
S
OBSERV
ED
(d)
DPMO
(d)*106
(n)*N
SIG
MA
LEVE
L
•
•
•
•
Gearing up for 2012
Sigma Level Calculation - Example
DEPARTME
NT
Procuremen
t
ACTIVIT
Y
Procure
ment of
materials
DEFECT
OPPORTUNITIES
(n)
• Adequacy of Indent
-TDC
-Engg. spec .
/ Drawing
-Quantity &
Size
-Delivery
date
-Method of
delivery with
destination
-Inspection
requirements
• Correctness of
Enquiry
• Approved Vendor
• Evaluation of offers
• Correctness of PO
• Material receipt
NO. OF
ITEMS
PRODU
CED
(N)
NO. OF
DEFECT
S
OBSERV
ED
(d)
DPMO
(d)*106
(n)*N
SIG
MA
LEVE
L
Gearing up for 2012
Sigma Level Calculation - Example
DEPARTME
NT
M&S
ACTIVIT
Y
DEFECT
OPPORTUNITIES
(n)
Preventi
ve
Maintena
nce
• Adherence to
Maintenance schedules
• Adequacy of
Maintenance check list
• Availability of
essential spares
• Trained Personnel
• Extent of checking
(as per check list)
• Resolution time for
user complaints
Machine
Availabili
ty
• Down time due to
break down
NO. OF
ITEMS
PRODU
CED
(N)
NO. OF
DEFECT
S
OBSERV
ED
(d)
DPMO
(d)*106
(n)*N
SIG
MA
LEVE
L
Gearing up for 2012
Sigma Level Calculation - Example
DEPARTME
NT
OP&C
ACTIVIT
Y
Preparati
on of
OPS
DEFECT
OPPORTUNITIES
(n)
NO. OF
ITEMS
PRODU
CED
(N)
NO. OF
DEFECT
S
OBSERV
ED
(d)
DPMO
(d)*106
(n)*N
SIG
MA
LEVE
L
• Work order
identification
• Sequencing of
operations
• Area / work centre
allocation
• Identification of
input documents (QWI,
WPS, Drawing etc.)
• Tooling
• Correctness of
operations
• Process allowances
• Identification of
inspection agency
• Identification of
inspn. stages
Gearing up for 2012
Sigma Level Calculation - Example
DEPARTME
NT
Production
ACTIVIT
Y
Manufact
uring
DEFECT
OPPORTUNITIES
(n)
• Material preparation
-Material
identification
-Work order
identification
-Marking
-Cutting (Method,
size)
• Forming
-Method / Technique
-Tooling
-Dimensions
• Welding
-Fit up
-Relevant WPS
-Qualified welder
-Welding parameters
-Welding
consumables
NO. OF
ITEMS
PRODU
CED
(N)
NO. OF
DEFECT
S
OBSERV
ED
(d)
DPMO
(d)*106
(n)*N
SIG
MA
LEVE
L
Gearing up for 2012
Sigma Level Calculation - Example
DEPARTME
NT
Production
ACTIVIT
Y
Manufact
uring
DEFECT
OPPORTUNITIES
(n)
• Heat treatment
-Heating
method
Temperature
-Time
-Heating /
Cooling rates
-Cooling
medium
· Testing
-Visual
inspection
-Surface
NDE (MPI/LPI)
-Volumetric
NDE (RT/UT)
-Hardness
-Mechanical
NO. OF
ITEMS
PRODU
CED
(N)
NO. OF
DEFECT
S
OBSERV
ED
(d)
DPMO
(d)*106
(n)*N
SIG
MA
LEVE
L
Gearing up for 2012
Sigma Level Calculation - Example
DEPARTME
NT
Production
ACTIVIT
Y
Manufact
uring
DEFECT
OPPORTUNITIES
(n)
NO. OF
ITEMS
PRODU
CED
(N)
NO. OF
DEFECT
S
OBSERV
ED
(d)
DPMO
(d)*106
(n)*N
SIG
MA
LEVE
L
• Final inspection
-Final
dimensions
-Surface
quality
-Inside
cleanliness
-Painting
Preservation
-Stamping
• Use of calibrated
instruments
Gearing up for 2012
Minimising Human Dependence
•
•
•
•
•
•
•
•
Wish list – automation of QC activities
(in addition to the projections of QTG)
Portable 3D Co-ordinate Measuring Machined (CMMs)
Optic line systems – photography principle
Laser Distometers
Electronic Co-ordinate Determination System (ECDS)
Data Loggers
Pneumatic Tighteners with Torque Verification
Surface Finish Testing by Optical Method
Integrating Critical Machines with Portable 3D CMM by
cabling / Remote feedback control and automatic
programme correction
Gearing up for 2012
Minimising Human Dependence
• Seam Tracker with intelligent systems for defect control in welding
• Air testing of Safety Valves in place of steam testing
• Modernisation of Hydraulic Test Benches with automatic recording
facility
• Installation of Shadowgraph to critical machines – Grinding Work
Centre
• Machines – Grinding W/C
• Mechanised Name Plate Punching
• State of the Art, handy and hand held equipment for finish
measurement, flatness measurement, visual examination, hardness
measurement etc
• TCs and Inspection Documents verification and generation of
History Cards – 100% on line
• Measurement (Service) Centre Concept for the operation of these
new equipment / facilities
Gearing up for 2012
Knowledge Management
APPROACH
–
–
–
–
–
FORMULATE A TEAM
IDENTIFY THE TOPICS TO BE LISTED
COLLECT THE INFORMATION
E ENABLE THE TOPICS
CREATE A SERACH AND HELPLINE FOR USERS
METHODOLOGY
• COLLECTION OF AVAILABLE DATA ON HARD COPY AND
CLASSIFICATION
• CONVERSION OF AVAILABLE HARD DATA INTO PDF FILES.
• INDEXING THE DATA
• E ENABLE
Gearing up for 2012
Knowledge Management
ACTION PLAN
ACTIVITY
–
–
–
–
DATE
ASSIGN TOPICS TO INDIVIDUALS
15 SEP 05
COMPILATION OF AVAILABLE MATERIALS
30 DEC 05
SCAN AND COMPILE COMPUTERISED DOC
28 FEB 06
GENERATE TEXT FOR OTHER TOPICS FOR
THOSE WHERE HARD COPY DATA ABSENCE CONTINUOUS
TARGET
10 DOCUMENTS ON INTRANET
28 FEB 06
10 DOCUMENTS
PER QUARTER
Gearing up for 2012
Training - Topics
• Seven tools for Problem solving
Data collection
Check Sheet
Histogram
• New Seven tools
1.
2.
3.
4.
Affinity diagram
Relation diagram
Tree diagram
Matrix diagram
Parato
Stratification
Scatter
Brainstorming
5. Matrix data analysis
6. Process decision
program chart
7. Arrow diagram
• Statistical Quality Control
Run Chart
Histogram Sigma
Calculation
Control Chart – Warning &
Action
Regression – Control
parameters.
• Failure Mode and Effects Analysis
Gearing up for 2012
Training - Material acquisition
• Collect Study materials
Concepts,
Techniques
Examples
Problems
• Develop Software tutorials for Web
Identify Resource
Prepare Process plan /
Specification
Develop
Software
Test
Launch
• Procure Statistical Software for online use.
Market re-search
Identification
Specification
Procurement
Installation
Training
Deployment
Gearing up for 2012
Training - Implementation
• Identify areas and work centers.
7 Tools
QC Projects
Comparison of processes
Arriving at input
parameters.
New 7 Tools
QC Projects,
Imp. Projects
Comparison of processes,
Products,
New design,
Improved method,
Statistical
Techniques
Executives
M1
Critical WC, Process capability, Status analysis.
Sampling inspection, Six
New resource
sigma projects
decisions
FMEA
Performance
evaluation
Product Failures,
•
•
•
•
•
Equipment
Failures
Identify Type of tools.
Identify trained personnel and Reviewer
Prepare Project Initiation Report.
Implement solution
Review result and Plan improvement.
Gearing up for 2012
Quality Circles - Revival
• Each executive to be a facilitator for a QC and a weightage to be
allotted in e-map for QC activities
• Mass awareness programme on QC to be conducted to cover all
employees in a short time.
• Senior executives to guide, steer the QCs for their successful
performance. Monthly presentations in each product /function GMs
• Canteens to be used for weekly meetings of QCs on prefixed days so
that regularity of meeting is ensured; Refreshments are served at
canteens during the meeting for the participants. Specific tables on
each day , can be earmarked for specific QCs
• Problem banks for each area to be developed by the Executives and
arranged for display so that QCs can choose the problems requiring
immediate attention.They will cover quality, productivity,customer
feedback etc.,(ECPS, ICPS, EPS-FGD issues, Cust Complaints, NCRs etc.)
• Simplified presentation template to be designed by Quality/BE
• Implementation of simplified immediate reward system for QCs.Say, Rs
50 once problem is taken up by QC; Rs 500 once problem is solved and
implemented; After evaluation, the balance reward
Gearing up for 2012
NTPC – Quality Add ons
Product Operation
Surface Weld
NDE
Area
Length
Drum
Nozzles
7.06 Sq M
MPI
685
4830
Gas Cut Openings
6 Sq M
UT
5270
31620
Dished Ends
14.8 Sq M
MPI
685
10206
Header
Rate Cost
(Rs)
Long. Cir seams
64 m x 2 UT
527
67456
Ring Header L Seams
185 m
MPI
68.5
12672
Ring Header L Seams
185 m
UT(Bef /
527x2
194990
aft SR
Other
Headers
Girth Welds
181 m
MPI
68.5
12938
Piping
Girthwelds
78 m
MPI
68.5
5343
Fittings
Surface
420 Sq M
MPI
750
315000
Surface
231 Sq M
UT
5800
1339800
Gearing up for 2012
50000
2008-09
258000
192000
2007-08
45000
2006-07
40000
2005-06
35000
50000
25000
100000
30000
150000
131000
200000
20000
LOAD IN TONS
250000
163000
300000
224000
350000
285000
OUTSOURCING LOAD &
SELF INSPECTION PLAN
312500
Self Inspection Plan
2010-11
2011-12
0
YEAR
2009-10
Plan for Outsourcing
Plan for Self Inspection
Gearing up for 2012
Root Cause Analysis and Mistake Proofing
Approach
Form CFTs ( Quality, Engg, FES, OP&C, Production/ MM/ OS)
Collect the Non Conformances and Stratify Data
Select the vital areas and analyse
Identify the cause
Find the solution
Implement
Monitor
Gearing up for 2012
Root Cause Analysis and Mistake Proofing
Action Plan
Form Committee September 2005
Develop Software 31 March 2006
Identify Top three items 31 July 2006
Implement Solutions 31, Mar 2007
Implement Mistake Proofing for 15 items 31, Dec 2007
Gearing up for 2012
Man Power Projections - Quality
Levels
M4- Executives (GM, AGM)
2005Jan 2007Dec 2012Dec
6
4
1
M3- Executives (E6, E6a)
10
10
7
M2- Executives (E4-E5)
24
22
14
M1- Executives (E1-E3)
77
76
59
Supervisors – Loop-line
33
30
19
Foremen
31
27
19
Asst Foremen
67
67
19
Chargemen
61
61
47
Artisans
60
57
40
Artisans – Loop-line
57
57
50
Office Staff
23
22
13
Total
449
433
287
As is levels considered for 2007, 2012
Gearing up for 2012
Man Power Projections – QA & Labs
Levels
QA
Plant Lab
2005 2007 2012
2005
2007
NDTL
2012
2005
2007
2012
M4- Executives (GM, AGM)
2
2
0
0
0
0
0
0
0
M3- Executives (E6, E6a)
3
3
2
0
0
0
1
1
1
M2- Executives (E4-E5)
7
5
3
1
0
0
2
2
1
M1- Executives (E1-E3)
4
4
4
6
6
4
11
11
4
Supervisors – Loop-line
1
1
1
0
0
0
1
1
0
Foremen
0
0
0
0
0
0
14
12
10
Asst Foremen
0
0
0
1
1
0
2
2
1
Chargemen
0
0
0
0
0
0
2
2
2
Artisans
0
0
0
8
8
7
25
23
18
Artisans – Loop-line
0
0
0
7
7
6
22
22
21
Office Staff
7
7
6
1
1
1
2
2
0
Total
24
22
16
24
23
18
82
78
58
Gearing up for 2012
Man Power Projections – Quality Control
Levels
2005Jan 2007Dec 2012Dec
M4- Executives (GM, AGM)
2
1
0
M3- Executives (E6, E6a)
4
4
2
M2- Executives (E4-E5)
12
12
8
M1- Executives (E1-E3)
52
51
43
Supervisors – Loop-line
29
26
17
Foremen
17
15
9
Asst Foremen
62
62
17
Chargemen
59
59
45
Artisans
27
26
26
Artisans – Loop-line
28
28
22
Office Staff
13
12
5
Total
305
296
194
Promotions not considered for 2007, 2012
Gearing up for 2012