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7/28/2019 Gas Alarm System - Kaizen
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Farm Equipment Sector
JQM
Kaizen Presentation
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Project : Set Up time Reduction of Emission Gas Bottle System
Farm Equipment Sector
2nd November 2007
Kaizen
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Farm Equipment Sector
JQM
Organization
Products Engines & Tractors
Market Leader in Indian Tractor Industrysince last 25 years
Third position in Global Tractor Market
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Farm Equipment Sector
JQM
Organization Achievement
Mahindra is First Tractor company in the World
to achieve JQM Award
QS 9000 - 2000
ISO9001 - 1996
ISO14001 - 2003
Deming AwardNov. 2003
JQM AwardOct 2007
TS-16949-2002
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Farm Equipment Sector
JQM
Kaizen Group Information
Name :-Real Timers
Name of Members :-
Formation :- Jun07
Product unit :- Testing & Evaluation (Product Dev Group)
Facilitators :- Mr. S.K.Raut & Mr. M Raja
Mr. Yogesh Kale
Mr. Sameer Tambe
Mr. Amol Berde
Meeting Frequency:- Weekly every Monday 2.00 PM (1 hr)
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Farm Equipment Sector
JQM
Contents
Background
Old System set up
Problem Definition
Need of Kaizen
Why Why Analysis
Root Cause
Methodology
New System Set up
Result
Benefits
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Farm Equipment Sector
JQM
Background
Diesel Engine Exhaust Emission consist of major
pollutants like NOx, HC, CO, & PM
Gases with various known concentration levels
are being used in Emission analyzer
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Farm Equipment Sector
JQM
Background
1. Operating gases - XL Grade O2, XL Grade Zero Air, XL
Grade N2, H2 + HE - Continuously in use
2. Calibrating gases - Propane + N2, NO + N2, CO + N2,
Co2 +N2 - One time use
*** Each Calibrating gas has two ranges of Concentration i.e.
Low & high PPM levels
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Farm Equipment Sector
JQM
Old System
Control
room
Outside
Control room
GasBottle
Empty!
!100
80
60
40
20
0
Emission analyzer
Gasbottle
P
ress.regu
Press. Regu
panel
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Farm Equipment Sector
JQM
Background
Old System
Gas bottle with pressure
regulator
Pressure regulator
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Farm Equipment Sector
JQM
Constraints of Old System
- Consumption of operating gases are high when
compared to calibration gases
- Frequency of Replacing the gas bottle is once in
15 days or less depends on no of test/ projects
carried out
- Lead time for Gas bottle filling is high Minimum 5
Days
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Farm Equipment Sector
JQM
Problem Definition
- Location of the Gas bottles are away from the Lab
Corridor ( as per safety standard )
- Gas bottle getting emptied without any indication
surprise to Engineer
LEADING TO..Engine Emission test hold up due to
unavailability of analyzer gases
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Farm Equipment Sector
JQM
Need of Kaizen
Interruption of emission test
Unable to meet project time lines
Low utilization of test bed & Emission analyzer
Avg. 73.5 %
Emission analyzer utilization
82
68
89
70
60
72
0
10
20
30
40
50
60
70
80
90
100
Jan-07 Feb-07 Mar-07 Apr-07 May-07 Jun-07
Month
%U
tilization
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Farm Equipment Sector
JQM
Need of Kaizen
Test Bed Utilisation
OEE
73%
No man power
2%
Break down
5%
Gas bottles not
received
17%
Engine not
received
3%
No man power Engine not received Break down Gas bottles not received OEE
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Farm Equipment Sector
JQM
Need of Kaizen
Utilization Summary
Average % Utilization : 73.5 %
% Split up
- No man power : 2 %
- Engine not received : 3 %
- Break down : 5 %
- Gas bottles not available : 16.5 %
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Farm Equipment Sector
JQM
WHY WHY ANALYSIS
Test hold up
Gases Not Available
No Intimation
No Early Warning
Not Ordered
Why
Why
Why
Why
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Farm Equipment Sector
JQM
Root Cause
No Early Warning System
- Need was felt that the test engineer should have an
advance information on the status of each gas
bottle pressure in order to.
1. Place order for gas bottle in advance
2. Achieve uninterrupted test
Design a Real time pressure indicating
system for gas bottles
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Farm Equipment Sector
JQM
Methodology
Concept development
System set up
Electrical system circuit developed
Selection of components
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Farm Equipment Sector
JQM
1
Control
room
Outside
Control room
Alarm
.
1
Accept Test Reset
100
80
60
40
20
0
2 3 4
5 6 7 8
1
Emission analyzer
Gasbottle
P
ress.regu
Press. Regu
panel
Real Time Pressure
Indication System
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Farm Equipment Sector
JQM
Real Time Pressure
Indication System
Features of New Pressure Regulator :-
- Single stage pressure reduction with Contact Gauge
- Regulator is Suitable for Cyl up to 200 bar
- Safety relief valve
- Operating temp - 40C to +100C
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Farm Equipment Sector
JQM
Real Time Pressure
Indication System
Signal Box :-
- Microprocessor based alarm
- Announciator with inbuilt hooter
- Std features like Test/Accept/reset
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Farm Equipment Sector
JQM
Real Time Pressure
Indication System
New pressure regulator
connected to the gas
line
New pressure regulator
connected to Cylinder
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Farm Equipment Sector
JQM
Real Time Pressure
Indication System
- Set pressure for each gas bottle considering Lead
time, utilization & no of tests
*** New bottle pressure 120 130 bar
30H2 + HE8
30XL Grade N27
30XL Grade Zero Air6
30XL Grade O25
20Co2 +N24
20CO + N23
40NO + N22
20Propane + N21
Set
PressureBottle
Identification
no
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Farm Equipment Sector
JQM
Result
Test bed utilization improved by 11.5 %
Machine utilization
73.5
85.0
0
20
40
60
80
100
Before After
%U
tilizatio
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Farm Equipment Sector
JQM
Tangible Benefits
1. Place order for gas bottle in advance
2. Achieve uninterrupted Emission test
3. Cost saving
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Farm Equipment Sector
JQM
Intangible Benefits
1. Meet project time lines
2. Enhance test bed utilization
3. Reduce operator fatigue
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Farm Equipment Sector
JQM
P.U.: R&D ,
CELL: For all Test Beds
M/C : ETL, Loc 2
Problem / present Status: Counter Measure:
Team Members :
1.
2.
3.
Analysis : Result :1) OEE schedule adherance improved,
2) Achieve project timelines
STATUS PU M/C NO. STATUS
Completed
Benefits:
Place order for gas bottle in advance
OEE schedule adherance improved,
LOC 2R&D
M/C NO.
Achieve uninterrupted emission test
Achieve project timelinesHORIZONTAL DEPLOYMENT
PU
KAIZEN SHEET
Bench Mark
Idea : Installation of Real time
pressure indicating system
Kaizen Theme : Set up time
reduction for Gas bottle system
Kaizen No. : 35
Date : 29/06/07
25/06/07
N.A N.A
Kaizen Finish 29/06/07
Start
Yogesh Kale
5 daysTarget
Sameer Tambe
Amol Berde
Gas bottle getting emptied without any
indication
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Farm Equipment Sector
JQM