Plant & System Observation

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The key takeaways from the plant observation report are issues identified across various processes like annealing, quality assurance and machine operations along with action plans to address them.

Issues observed in the annealing/furnace process include lack of process parameters recording, uneven heating, smoke generation and lack of atmosphere control.

Issues observed in the quality assurance process include infrequent instrument usage, lack of organization in the lab, improper record filling and lack of multi-skilling of quality inspectors.

PLANT & SYSTEM OBSERVATION

by Zeeshan Pathan
From 1/10/2020
Last Review 1/19/2020
Sr. No. Observation Action Plan Responsibility Target Status
Annealing/Furnace
1 Annealing production report- Temperature, hardness not mentioned Daily Monitoring of report Quality Inspector Observation Recorded

2 Actual and Written temperature differ Monitoring within specific Quality Inspector Daily reviewing
interval
3 No UCL & LCL mentioned Process Control Chart QC Completed

Regular filling of data after


4 Process report against parameter not recorded in soft- for process statics checking/job change/ before Quality Inspector To be started
shift change

5 Remark not mentioned (ok, not ok, pass, hold) Document/ report filling QC To be started
awareness to be induced

Monitoring over tag filling


6 Sr. no for treaceability not evident and QSL no. to be introduced QC Inprocess
for full proofing treaceability

7 sampling plan for annealing not displayed Sampling plan to be QC Completed


displayed
8 current running material is 441 but process control chart not evident Chart to be displayed QC Completed

Monitoring over tag filling


9 Coil no for lot A-7 20, A-15 not provided and QSL no. to be introduced QC Inprocess
for full proofing treaceability

10 Furnace:- No atmosphere control(oxygen) control, no parameter checking, Accessories to be fitted, Project & QC To be started
Checksheet to be introduced

11 Firing control (cut off, whereas it should be stepless), more unburnt gas, more smoke Accessories to be fitted. Project To be started

12 Checking of dimensional parameter not documented after annealing Checksheet to be introduced QC To be started

Safety training to be
13 PPE's awareness, adherence not evident provided, need of PPE's at HR/QC To be started
work station to be studied

14 No flame adjustment (direct firing/cutoff). Leads to non-uniform heating Accessories to be fitted. Project To be started

15 Furnace gates are completely open (More oxygen supply leads to smoke generation) Opening length to be defined Production To be started

QA
1 Pressure gauge/linear speed to be provided for amount of load is applied Supplier to be contacted QC Inprocess

Training to all Quality


2 Microscope use less frequent. inspector and testing QC Completed
frequency to be documented

3 Frequency of testing over UTM machine is less frequent Testing plan to be defined, QC Inprocess
Daily monitoring of testing

Training to be provided to
4 Multi skilling of Quality inspector every Quality inspector of QC Inprocess
every instrument

Weekly 1s & 2s Activity to be


5 Material kept in lab is unorganized like tested and non-tested samples, accessories performed apart from daily QC Inprocess
routine

Weekly 1s & 2s Activity to be


6 1s & 2s not maintained for lab (Identification and tagging) performed apart from daily QC To be started
routine

7 Vernier not calibratd (No lable if calibrated) Review List and physical tag QC To be started
over vernier calliper

Contact with Calibrating


8 4 vernier lying in miserable condition (Repair/calibrate/discard) agency for calibration/repair QC To be started
of vernier

9 Records are not filled properly Rtraining and daily All Shop floor person Inprocess
monitoring of MIS system

Training and formulation of


10 QMIS report not shared in soft to production/planning QMIS sheet for data filing QC To be started

Decentralize responsibility
11 COPQ, Sales, delivery, safety, rejection, production, pareto, customer complain not updated. and follow up for updation. QC Completed
(Now monthly)

Training to be provided to
12 Hardness testing is rarely carried every Quality inspector for QC Inprocess
handling of every instrument

Training to be provided to
13 Least number of quality inspector aware of handling quality instruments like, H.T., UTM, Microscope every Quality inspector for QC Inprocess
handling of every instrument

Multiskilling by the virtue of


14 Shop floor Quality inspector should be also be more utilized for lab report filing, testing. OJT and switch over QC To be started

Discussion with responsible


15 Raw Material inspection is not on time and not even according to sampling plan person for carrying out on QC Inprocess
regular basis

Discover instrument and start


16 Coolant fat content not checked/ nor saw refractrometer practice for checking fat QC To be started
content

Draft TC format so as to
17 TC data not standardized like TC number, unit of measurement, Customer address, grammer, values, TC according to reduce drafting error with QC Inprocess
std., SO, PO new paper for tc printing.

18 In house rejection PPM formula Correction to be made in QC Inprocess


formula

Shop Floor /Machine

Proper training along with


1 FIFO assigned for raw material but adherence is still poor, coil in R10 (A/W) (14/17), R9(14/16), R8(15/14) relevant material to be QC To be started
provided to concern person
Daily mail of disposition
2 Disposition of NC material is not on daily basis. should be provided from PPC To be started
quality to ppc

Daiy mail to ppc should be


3 Declaring of stock from QA, production not on daily basis provided for PRODUCTION & QC To be started
hold/pass/produced material

4 Cutter resharping/ reworking facility for cost saving Discussion with Maintenance MAINTENANCE To be started
person
5 Allocation of stock (Customer, QA- if hold, Planning- if excess) Format to be drafted PPC To be started

6 Excess material producing, irrespective of planning Proper work instruction to PRODUCTION To be started
production

7 Double welding torch for high thickness welding can be opted Discussion with Maintenance MAINTENANCE
person
Format number to be
8 Tube mill production log book, no format number QC To be started
provided

9 Treated (DM) water not used. Water testing to be started QC To be started

10 Water testing is not carried (PH, turbidity,TDS), whereas it is most crucial Water testing to be started QC To be started

11 PM schedule not fix Review of PM document MAINTENANCE Inprocess


Discussion with production
12 Tungsten rod should be kept one in spare for each machine.(10 min.x12 hr= 120 min= 2 hr/machine) person PRODUCTION To be started

Discussion with production


13 Operator/helper leaves machine, not always but plenty of time observed person PRODUCTION To be started

Discussion with Maintenance


14 Polishing scrubber not in operating condition (health issue) person MAINTENANCE To be started

15 Wrong material gets loaded ( 1.20 in place of 1.0 mm) Quality Tagging and PRODUCTION & QC To be started
treaceability to be done

16 Planning sheet should come with time line (time of printing template) Discussion with PPC person PPC To be started

17 Works order number should be provided on planning sheet for each order for treaceability Discussion with PPC person PPC To be started

18 Production plan on hourly basis i.e. minutes are in radian/ (1-100) not on minute format Discussion with PPC person PPC To be started

19 Machines are turned off during lunch (helper/operator can run machine alternatively) Discussion with production PRODUCTION To be started
person

20 Daily inplant rejection board not updated Responsibility of night quality QC Inprocess
incharge

Pickling

1 Water Logged Discussion with Pickling PICKLING Informed


incharge

2 Process check sheet missing Discussion with Pickling PICKLING To be started


incharge

3 Process SOP missing Discussion with Pickling PICKLING & QC Completed


incharge

4 Control chart not evident Discussion with Pickling PICKLING & QC To be started
incharge
5 PPE's not available (apart from shoe) Discussion with hr person HR To be started

6 Leakage from water line (3 days) Discussion with Pickling PICKLING Informed
incharge

7 Scrubber not in operation Discussion with Pickling PICKLING & MAINTENANCE Informed
incharge

8 Chemical testing, concentration testing not evident Discussion and formulation QC To be started

9 Ion/ fe content required/ not required Discussion and formulation QC To be started

10 Discard criteria of bath Discussion and formulation PICKLING & QC Inprocess

Discussion with Pickling


11 Loss of chemical and Process time PICKLING To be started
incharge
Formulation best on proven
12 Heater are fruitful or not QC To be formulated
practice

13 ETP not in working condition Discussion with ETP incharge ETP To be started

14 No SOP evident for ETP operation Discussion with ETP incharge ETP To be started

System/Documentation
1 No format number for quality assurance log book Document to be revised QC To be started
2 Daily review meeting to be conducted for departmental review and communication gap Discussion with Jai sir JAI SIR To be discussed
3 EHS Policy: if there not found Discussion with Jai sir JAI SIR To be started

4 No SOP for ETP operation Discussion with ETP incharge ETP To be started

5 Pickling is there i.e. chemical treatment ISO 14001 mandetory Discussion with Jai sir JAI SIR To be started

6 Daily stock taking would address issue of slow/non moving material (raw to finish) Discussion with PPC Person PPC To be started

7 No time motion study to calculate standard time for respective operation Discussion with PPC Person PPC To be started

8 MTTR & MTBF: Machine availability is calculated on 22 hr. where on the basis of 2 shift it should be 23 hr Discussion with Maintenance MAINTENANCE PERSON Discussed (Now 24 hr)
person

Review of Document along


9 In machine list: Annealing machine and furnace mentioned separately (2 Qty) MAINTENANCE PERSON Informed
with respective person

Review of Document along


10 In machine list: Weigh bridge not evident with respective person MAINTENANCE PERSON Informed

Review of Document along


11 Weight and supporting calibrating weight outsouring company list to be reviewed with respective person MAINTENANCE PERSON Informed

12 TDC having no revision date Review of All TDC QC Inprocess


13 TDC number should be easily distinguished Review of All TDC QC Inprocess
14 UBSL/TDC/18-19/aurangabad Review of All TDC QC Inprocess
15 TDC/OCI/Gtech/01 Review of All TDC QC Inprocess
Document number is not self explainatory, SYSTEM should be ISO, easily understand to all Review of All system
16 QC Inprocess
and no interpreter required. Documents
17 TDC master having no Document number Review of All TDC QC To be started

18 Document number system poor Review of Document for ease QC To be started

19 No micrometer number/ no calibrationn report for micrometer Review of list of instrument QC To be started

20 4M abnormality matrix not updated Responsibility of night quality QC Inprocess


incharge

21 Boards are not updated for due date (Dec-2019) Responsibility alocation to QC Inprocess
quality incharge
22 Rollers are not placed at allocated location Identification and dedicate PRODUCTION Completed
place for rollers
23 Safety lagging (PPE's, Policy, Mockdrill, Evacuation plan, Safety training) Discussion with hr person HR Inprocess
24 Training is not conducted according to plan (just on paper) Discussion with hr person HR Inprocess
25 Daily standing meeting to be conducted to address manpower attendance, production, quality, raw material, Discussion with Jai sir JAI SIR To be discussed
productivity, training, critical stock, spare, despatch issue
26 Crane Maintenance was in progress (No work permit for working at height) Discussion with hr person HR Discussed
27 Solar work in progress no work permit issue Discussion with hr person HR Discussed
Raw Material
Input Data Invoice Heat ID Coil Number TC Grade Dimension

Output Data Invoice Heat ID Coil Number TC Grade Dimension

Tube Mill
Input Data Heat ID Coil Number Grade Dimension

Output Data Heat ID Coil Number Dimension Lot No

CTL
Input Data Heat ID Coil Number Dimension Lot No

Output Data Heat ID Coil Number Dimension Lot No CTL Batch/Bin No

Annealing
Input Data Heat ID Coil Number Dimension Lot No CTL Batch/Bin No

Output Data Heat ID Coil Number Dimension Lot No Annealing Batch No

Straightning
Input Data Heat ID Coil Number Dimension Lot No Annealing Batch No

Output Data Heat ID Coil Number Dimension Lot No

Ct 7.5E-08
I 200
Farc=CtxI^2 0.003

V=IR 0.05 Ohm

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