Plant & System Observation
Plant & System Observation
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
5 Remark not mentioned (ok, not ok, pass, hold) Document/ report filling QC To be started
awareness to be induced
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
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
7 Vernier not calibratd (No lable if calibrated) Review List and physical tag QC To be started
over vernier calliper
9 Records are not filled properly Rtraining and daily All Shop floor person Inprocess
monitoring of MIS system
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
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.
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
10 Water testing is not carried (PH, turbidity,TDS), whereas it is most crucial Water testing to be started QC 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
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
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
19 No micrometer number/ no calibrationn report for micrometer Review of list of instrument QC To be started
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
Tube Mill
Input Data Heat ID Coil Number Grade Dimension
CTL
Input Data Heat ID Coil Number Dimension Lot No
Annealing
Input Data Heat ID Coil Number Dimension Lot No CTL Batch/Bin No
Straightning
Input Data Heat ID Coil Number Dimension Lot No Annealing Batch No
Ct 7.5E-08
I 200
Farc=CtxI^2 0.003