1. Grasim- South D E F I N UNIT : Grasim South TEAM LEADER : Mr.S.K.Raut
TEAM MEMBERS : Mr. B.R.Sharma
: Mr. Anil Bajaj
: Mr. N.Ravikumar
: Mr. G.Suresh Kumar
TEAM CHAMPION : Mr. R.Rajagopal
WCM FACILITATOR : Mr. Anurag Seksaria D E F I N

2. IMPROVEMENT IN CEMENT MILL PRODUCTIVITY
Project Title D E F I N
IMPROVEMENT IN
CEMENT MILL
PRODUCTIVITY

3. Project Charter D E F I N

4. Grasim- South- Process Map Cement GrindingF I N

5. Grasim- South- Process Map Cement GrindingF I N

6. CEMENT MILL OUTPUT RATE
CTQ/KPOV/KPIV D E F I N
CEMENT MILL OUTPUT RATE
KPIV
KPIV
PROCESS
KPOV
CTQ
KPIV
Define Phase

7. CTQ/KPOV/KPIV
CTQ – CEMENT MILL OUTPUT RATE (TPH)
KPOV – CEMENT MILL TPH
- CEMENT MILL POWER CONSUMPTION
KPIVS – 1. ROLLER PRESS POWER
2. ROLLER PRESS HYDRAULIC PRESSURE
3. ROLLER PRESS OPERATING GAP
4. CEMENT MILL POWER
5. GYPSUM PERCENTAGE
6. ROLLER PRESS BIN LEVEL
7. FINE CLINKER BIN LEVEL
8. SEPERATOR POWER D E F I N
Define Phase

8. CTQ/KPOV/KPIV
KPIVS – 9. SEPERATOR SPEED
10. SEPERATOR FAN SPEED
11. SEPERATOR FAN POWER
12. SEPERATOR DIFFRENTIAL PRESSURE
13. CLINKER C3S
14. CLINKER GRINDABILITY
15. PETCOKE PERCENTAGE D E F I N
Define Phase

9. CTQ/KPOV/KPIV
PROJECT GOAL
TO REDUCE CEMENT MILL POWER CONSUMPTION FROM
30 KWH PER TON OF CEMENT TO
26 KWH PER TON OF CEMENT D E F I N
Define Phase

10. CTQ/KPOV/KPIV
PROJECT GOAL
CEMENT MILL PER TON POWER CONSUMPTION
IS INVERSLY PROPORTIONAL TO
CEMENT MILL PRODUCTION RATE
TO INCREASE THE CEMENT MILL PRODUCTION RATE (TPH) FROM 130 TPH TO 175 TPH. D E F I N
Define Phase

11. BASE LINE DATA
MEASURE

12. BASE LINE DATA
MEASURE

13. BASE LINE DATA
PROCESS CAPABILITY
POWER CONSUMPTION
TARGET – 26 KWH / T OF CEMENT
AVERAGE – 32 KWH / T OF CEMENT
STANDARD DEVIATION – 2
Cpk
PRODUCTION RATE - TPH
TARGET – 175 TPH
AVERAGE – 132 TPH
STANDARD DEVIATION – 9
Cpk
MEASURE

14. BASE LINE DATA
MEASURE
FACTOR
TARGET
AVERAGE SD
CAPABILITY
POWER CONSUMPTION
26 KWH / T OF CEM 32 2
- 11
TPH
175 TPH
132 TPH 9
- 14

15. MEASURMENT SYSTEM ANALYSIS
THE PRODUCTION RATE AND POWER CONSUMPTION IS MEASURED ONLINE BY WEIGH FEEDER AND POWER TRANSDUCERS
THE INSTRUMENTS ARE CAILBRATED ONCE IN A SIX MONTHS UNDER ISO 9000 CALIBRATION SCHEDULE.
THE READINGS ARE CROSSCHECKED WITH DROP TEST.
THE DATA IS AVAILABLE TO PROCESS FOR 24 HOURS ON OPERATOR SCREEN.
ONLINE DATA IS LOGGED IN TO KNOWLEDGE MANAGER, WHICH IS AVAILABLE FOR ANALYSIS.
MEASURE

16. CAUSE AND EFFECT DIAGRAM
ANALYSE
Material
Methods
GRINDABILITY
OF CLINKER
OPERATING
CONDITION
CHEMICAL
COMPOSITION
CONTROL
SYSTEM
CEMENT MILL TPH
ROLL PRESS
WEAR
IMPROPER
OPERATION
BALL CHARGE
IN MILL
FREQUENT
CHANGES
SEPERATOR
EFFICIENCY
ACCURACY
Men
Machine
Measurement

17. CAUSE AND EFFECT DIAGRAM
ANALYSE
SL NO
CAUSE
EFFECT
CORRECTIVE ACTIONS 1
MAN
IMPROPER OPERATION
PDCA CYCLE TO BE APPLIED BEFORE MAKING ANY ADJUSTMENT IN THE PROCESS
TRAINING TO BE IMPARTED

18. CAUSE AND EFFECT DIAGRAM
ANALYSE
SL NO
CAUSE
EFFECT
CORRECTIVE ACTIONS 2
MATERIAL
GRINDABILITY OF CLINKER
1. USAGE OF PETCOKE FUEL REDUCES THE GRINDABILITY OF CLINKER CAUSING UNSTABLE OPERATION OF MILL

19. CAUSE AND EFFECT DIAGRAM
ANALYSE
SL NO
CAUSE
EFFECT
CORRECTIVE ACTIONS 2
MATERIAL
2. MORE FINES IN CLINKER
USAGE OF PETCOKE FUEL MAKES UNSTABLE OPERATION IN KILN CAUSING MORE FINES GENERATION CAUSING UNSTABLE OPERATION MILL

20. CAUSE AND EFFECT DIAGRAM
ANALYSE
SL NO
CAUSE
EFFECT
CORRECTIVE ACTIONS 2
MATERIAL
2. MORE FINES IN CLINKER
3. USAGE OF PETCOKE FUEL INCREASES SO3 % IN CLINKER WHICH REDUCES GYPSUM % IN CEMENT MILL WHICH AFFETCS THE GRINDABILITY

21. CAUSE AND EFFECT DIAGRAM
ANALYSE
SL NO
CAUSE
EFFECT
CORRECTIVE ACTIONS 2
MATERIAL
3. LUMPS IN LIME STONE
LIME STONE ADDITION IN CEMENT MILL TO BE DONE WITH –50 MM SIZE ONLY.
THE REQUIRED SIZE CAN BE CRUSHED AT U-II CRUSHER

22. CAUSE AND EFFECT DIAGRAM
SL NO
CAUSE
EFFECT
CORRECTIVE ACTIONS 2
MATERIAL
3. LUMPS IN CLINKER
-50 MM SCREEN MESH TO BE PROVIDED AT CLINKER HOPPER TOP.
REGULAR INSPECTION OF CLINKER CRUSHER HAMMERS TO BE DONE AND TO BE REPLACED
ANALYSE

23. CAUSE AND EFFECT DIAGRAM
SL NO
CAUSE
EFFECT
CORRECTIVE ACTIONS 2
MATERIAL
3. LUMPS IN CLINKER
3. GRIZZELY BAR AND HAMMERS GAP TO BE OPTIMISED FOR CRUSHING THE CLINKER BELOW -50 MM
ANALYSE

24. CAUSE AND EFFECT DIAGRAM
SL NO
CAUSE
EFFECT
CORRECTIVE ACTIONS 3
MACHINE
1. WEAR OF ROLL PRESS
ROLLERS TO BE REPLACED WITH NEW ONE
ONCE ROLLERS REPLACED, ROLL PRESS SURFACE TO BE MAINTAINED IN EVERY WEEKLY SHUTDOWN
ANALYSE

25. CAUSE AND EFFECT DIAGRAM
SL NO
CAUSE
EFFECT
CORRECTIVE ACTIONS 3
MACHINE
2. GRINDING MEDIA CHARGE IN BALL MILL
GRINDING MEDIA CHARGE TO BE OPTIMISED IN BALL MILL
REGULAR WEAR MAKE UP OF MEDIA TO BE DONE
ANALYSE

26. CAUSE AND EFFECT DIAGRAM
SL NO
CAUSE
EFFECT
CORRECTIVE ACTIONS 4
METHOD
1. REGULAR VARIATION IN BLAINE BECAUSE VARIATION IN GYPSUM %
GYPSUM % TO BE VARIED ONCE IN FOUR HOURS
GYPSUM HOPPER AIR BLASTERS TO BE PROVIDED
IF GYPSUM % GOES LOW, TRIP THE CLINKER WEIGHFEEDER
ANALYSE

27. CAUSE AND EFFECT DIAGRAM
SL NO
CAUSE
EFFECT
CORRECTIVE ACTIONS 4
METHOD
2. ROLLER PRESS PRESSURE VARIATION
ROLL PRESS CONTROL SYSTEM TO BE TAKEN TO DCS FOR EASY IDENTIFICATION OF PROBLEMS AND SIMPLE OPERATION
HYDRAULIC SYSTEM TO BE SET RIGHT
ANALYSE

28. REGRESSION ANAYSIS OPERATING DATA
ANALYSE
S = R-Sq = 80.6% R-Sq(adj) = 75.7%

29. REGRESSION ANAYSIS OPERATING DATA
The regression equation is
prod rate = Pr Left Pr.right gap left
gap right power - st power - mv
mill o/l draft deg of filling mill power
SKS SEPERATOR SPEED sep INLET DRAUGHT
sep OUTLET DRAUGHT sep POWER Chlorides
- 196 SIO AL2O FE2O CAO MGO SO3
- 2.7 NA2O K2O SM AM LSF C3S
C2S C3A - 5 C4AF LIQ F.CAO
% Petcoke
ANALYSE

30. REGRESSION ANAYSIS OPERATING DATA
Source DF Seq SS
Pr Left
Pr.right
gap left
gap righ
power
power
mill o/l
deg of f
mill pow
SKS SEPE
sep INLE
sep OUTL
sep POWE
Chloride
SIO
AL2O
FE2O
CAO
MGO SO
NA2O
K2O SM AM
LSF
C3S
C2S
C3A
C4AF
LIQ
F.CAO
% Petcok
ANALYSE

31. REGRESSION ANAYSIS OPERATING DATA
ANALYSE
AFTER ROLLER REPLACEMENT

32. REGRESSION ANAYSIS OPERATING DATA
ANALYSE
S = R-Sq = 77.7% R-Sq(adj) = 75.0%

33. REGRESSION ANAYSIS OPERATING DATA
Source DF Seq SS
Pr Left
Pr.right
gap left
gap righ
power
power
deg of f
SKS SEPE
sep INLE
sep OUTL
sep POWE
SIO
AL2O SO
C3S
ANALYSE

34. REGRESSION ANAYSIS OPERATING DATA OBSERVATIONS / FINDINGS
RP PARAMETERS PRESSURE AND GAP LEFT SIDE HAS THE MAXIMUM RELATION WITH OUTPUT
PRESSURE AND GAP ARE NOT HAVING EQUAL RELATION WITH OUTPUT
SO IT IS CLEAR THAT FOLLOWING PARAMETERS ARE RESPONSIBLE
ROLLER OVALITY
FEED NOT UNIFORM
HYDRAULIC SYSTEM FAULTY
ANALYSE

35. REGRESSION ANAYSIS OPERATING DATA
AFTER HYDRAULIC SYSTEM MADE SET RIGHT
ANALYSE

36. REGRESSION ANAYSIS OPERATING DATA OBSERVATIONS / FINDINGS
THE NEXT RELATION COMES AS MOVABLE ROLLER POWER
MOVABLE ROLLER POWER IS DIRECTLY PROPORTIONAL TO OPERATING PRESSURE
PRESENT STATUS
AFTER BUILDING RP WE ARE GETTING HIGH OUTPUT FOR PERIOD OF ONE WEEK
REGRESSION SHOWS DECLINE IN OUTPUT WITH INCREASE IN PET COKE, BUT IS VERY MINIMUM ( 15%)
ANALYSE

37. REGRESSION PERCENTAGE
ANALYSE
S = R-Sq = 70.0% R-Sq(adj) = 63.3%

38. - 1.16 CM Bin Level + 0.0877 CM Power - 0.123 Sep fan il draft
REGRESSION EQUATION
ANALYSE
FEED RATE = RP Bin LV Sep fan speed Sep fan Power
CM Bin Level CM Power Sep fan il draft
Sep fan ol draft GD diff Fixed load
mov load

39. REGRESSION FINDINGS ANALYSE FEED RATE IS INVERSELY PROPORTIONAL TO
CEMENT MILL FEED BIN LEVEL ( 14.8%)
ROLLER PRESS BIN LEVEL (8.5%)
GAP DIFFERENCE ( SKEW) (12.5%)

40. WHY WHY ANALYSIS ROLLER PRESS BIN LEVEL (14.8%) WHY : ANALYSE
HIGH SKEWING OF RP
WHY:
UNUNIFORM FEED SIZE
+50 mm LIME STONE BOULDERS
SUGGESTION:
CRUSHED LIME STONE SHOULD BE RECYCLED THROUGH UNIT-II CRUSHER ENSURING MAXIMUM SIZE OF +50 mm ONLY.
ANALYSE

41. WHY WHY ANALYSIS HIGH SKEWING OF RP ANALYSE WHY: UNUNIFORM FEED SIZE
VARIATION IN CLINKER SIZE
SUGGESTION:
WORN OUT HAMMERS OF HAMMER CRUSHER TO BE REPLACED
GRIZZELY AND HAMMER GAP TO BE OPTIMISED
WEIGHFEEDER DISCHARGE GRILL TO BE INSTALLED
ANALYSE

42. WHY WHY ANALYSIS ROLLER PRESS BIN LEVEL (14.8%) WHY : ANALYSE
HIGH SKEWING OF RP
WHY:
FREQUENT VARIATION IN OPERATING PARAMETERS DUE TO BLAIN VARIATION
UN BLENDED FLY ASH OF DIFFERENT BLAINS
FREQUENT CHANGE IN GYPSUM PERCENTAGE
WEAR OF ROLLER SURFACE
ANALYSE

43. WHY WHY ANALYSIS ROLLER PRESS BIN LEVEL (14.8%)
UN BLENDED FLY ASH OF DIFFERENT BLAINS
SUGGESTION:
RECIRCULATION SYSTEM TO BE INSTALLED AND REGULAR RECIRCULATION TO BE DONE.
ANALYSE

44. WHY WHY ANALYSIS ROLLER PRESS BIN LEVEL (14.8%) ANALYSE
2. FREQUENT CHANGE IN GYPSUM PERCENTAGE
SUGGESTION:
GYPSUM PERCENTAGE MADE CONSTANT ( MADE INDEPENDENT FROM LINKMAN)
GYPSUM JAMMING TO BE AVOIDED
ANALYSE

45. WHY WHY ANALYSIS ROLLER PRESS BIN LEVEL (14.8%) ANALYSE
WEAR OF ROLLER SURFACE
SUGGESTION:
REGULAR BUILD UP OF ROLLER SURFACE
ANALYSE

46. WHY WHY ANALYSIS ROLLER PRESS BIN LEVEL (14.8%) ANALYSE
MORE RECIRCULATION
WHY:
DUE TO LOW VELOCITY ACROSS V-SEPERATOR
SUGGESTION:
TO BLOCK 2X2 NOZZLE AREA
ANALYSE

47. WHY WHY ANALYSIS ROLLER PRESS BIN LEVEL (14.8%) ANALYSE
MORE RECIRCULATION
WHY:
IMPROPER CAKE BREAKING
SUGGESTION:
TO PROVIDE IMPACT PLATE AT THE V-SEP INLET (DISCHARGE OF 531BC3)
ANALYSE

48. WHY WHY ANALYSIS ANALYSE ROLLER PRESS BIN LEVEL (14.8%)
CEMENT MILL BIN LEVEL (8.5%)
WHY :
VARIATION IN C3S
SUGGESTION:
TO MAINTAIN CONSISTENCY IN CLINKER COMPOSITION

49. WHY WHY ANALYSIS CEMENT MILL FEED BIN LEVEL (8.5%) WHY: ANALYSE
HIGH CIRCULATING LOAD ACROSS BALL MILL
SUGGESTION:
OPTIMISE GRINDING MEDIA PATTERN AND LOADING
REGULAR WEAR MAKE UP OF MEDIA
NEW PID LOOPS TO BE INSTALLED
( MILL OUTLET ELEVATOR LOAD VS MILL INLET DOSING VALVE POSITION)
MILL FEED BIN LEVEL VS DIVERTOR GATE
ANALYSE

50. WHY WHY ANALYSIS MAJOR CHANGE:
SWITCHING OVER FROM PETCOKE TO LIGNITE (OLD REGRESSION WAS SHOWING 15% RELATION FOR REDUCTION IN FEED RATE)
ANALYSE

51. ACTION PLAN
IMPROVE

52. ACTION PLAN
IMPROVE

53. ACTION PLAN
IMPROVE

54. PRESENT DATA
IMPROVE

55. PRESENT DATA
IMPROVE

56. PRESENT DATA
IMPROVE
FACTOR
TARGET
AVERAGE SD
CAPABILITY
Cpk
POWER CONSUMPTION
26 KWH / T OF CEM
25.96
1.78
0.06
TPH
175 TPH
177 TPH
4.94
-1.7

57. CONTROL – ACTION PLAN
CONTROL

58. CONTROL – ACTION PLAN
CONTROL

59. COMPARISON DATA - TPH CONTROL PROJECT START AVG – 130 TPH
PROJECT COMPLETION
AVG – 165 TPH

60. COMPARISON DATA – POWER CONSUMPTION
CONTROL
PROJECT START
AVG – 32.5 UNITS
PROJECT COMPLETION
AVG – 27.5 UNITS