R A P

© Rapidinnovation™

N E M E (Solving ‘Wicked’ Problems & Improving

Performance) Zero Breakdown through

Minimal Design Interventions

dibyendu de

See

E M EN E M E

Nemetics

N

INNOVATION

R A P I DDesign Thinking for Serious Play

© Rapidinnovation™

“In a high-growth period, productivity can be raised by anyone. But how many can attain it during more difficult circumstances induced by low-growth rate?

This is the deciding factor in the success or failure of an enterprise.

”Taiichi Ohno – Toyota

© RMCPL All rights reserved

See

E M EN E M E

Nemetics

N

INNOVATION

R A P I DDesign Thinking for Serious Play

© Rapidinnovation™

INNOVATION

R A P I DDesign Thinking for Serious Play

© Rapidinnovation™

INNOVATION

R A P I DDesign Thinking for Serious Play

© Rapidinnovation™

R A P

© Rapidinnovation™

# Audit Parameters Previous

After1.5 y After 2.5 y

1 Production (units) 200 2000 3000

2 Production (Tons) 4500 8000 10168

3 Quality rejection 20% 7% 5%

4 Capacity < 100% = 100% >100%

Effects of Strategies– Process Plant

© RMCPL All rights reserved

Case Study on System ThinkingProblem: Frequent bearing failure of ID Fan 2 in 25

MW Power Plant The bearing fails once in 3 months…

See

E M EN E M E

Nemetics

N

Fan NDE Bearing that fails often

Fan

Motor

Example – Emergence & EssenceSee

E M E

Nemetics

N

Ask questions to explore the context

• Why ID fan 2 NDE bearing is failing & not the DE bearing?

• There are 2 identical fans close to each other but the problem is with only one of the fans and not the other.

• Why outer race bearing gets affected, why not other parts?

• Why motor bearings did not fail even once?

• The expected life of the bearing is minimum 2 years but fails once in 3 months!

Similar Symptoms: Different Problems See

E M E

Nemetics

N

Outer Race damaged bearing

Nature of the Bearing Failure. Notice the fine flute marks across the outer race of the bearing.

EmergenceSee

E M E

Nemetics

N

The surface of the rollers also show fine damages

See

E M E

Nemetics

N

Vibration Data of ID Fan2 (does not improve even after bearing replacement: so the problem is not the bearing)

POINT POINT AFTER BEARING BEFORE BEARING

ID DESCRIPTION REPLACEMENT REPLACEMENT UNITS

----- ----------------------------- ------- ----- ------- ------- ---- ---

ID FAN-02 (03-Jul-10) (03-June-10)

M1H=Motor Outboard Horizontal .390 .471 mm/Sec

M1P=Motor Outboard Horz Peakvue .289 .265 G-s

M1V=Motor Outboard Vertical .748 .151 mm/Sec

M1A=Motor Outboard Axial .365 .311 mm/Sec

M2H=Motor Inboard Horizontal .418 .531 mm/Sec

M2P=Motor Inboard Horz Peakvue .375 .352 G-s

M2V=Motor Inboard Vertical .199 .231 mm/Sec

M2A=Motor Inboard Axial .607 .579 mm/Sec

F1H=Fan Inboard Horizontal 1.353 1.049 mm/Sec

F1P=Fan Inboard Horz Peakvue .602 1.115 G-s

F1V=Fan Inboard Vertical .850 .548 mm/Sec

F1A=Fan Inboard Axial 1.883 1.294 mm/Sec

F2H=Fan Outboard Horizontal .448 .932 mm/Sec

F2P=Fan Outboard Horz Peakvue .598 1.660 G-s

F2V=Fan Outboard Vertical .234 .443 mm/Sec

F2A=Fan Outboard Axial .449 .640 mm/Sec

-------------------------------------------------------------------------

Example – Emergence & EssenceSee

E M E

Nemetics

N

Challenge the assumptions: Start with a Zen mind

Assumptions we Tried, Checked & Failed were

• Bearing failed due to misalignment of shaft.

• Lubrication condition.

• Looseness of bearing.

• Over damped System.

• Level of the shaft.

• Bearing design is the problem

Challenge the assumptionsSee

E M E

Nemetics

N

(Think by observing & Zooming Out – check the

interrelationships. From Emergence to Essence). • Fault arising in outer race of Fan NDE bearing

(emergence of the system).

• Frequent failure is only in one fan not in both fan.

• Both fans are operating at same speed, load & handling the same material.

• The gas temperature is same for the both fans.

• Electric cable passing near the ID fan 2 NDE bearing (essence of system that causes the emergence)

Observe the whole – Energy Interactions See

E M E

Nemetics

N

Cable passing near the affected bearing creates Electromagnetic flux that causes the ‘mess’

Aluminium cover provided for shielding the affected Fan NDE bearing

InteractionsSee

E M E

Nemetics

N

Create & Choose responses that eliminate the set of imperfections that create the set of

problems

• The electric cable of the 220 KW motor of the adjacent fan & passing near the NDE bearing generates electromagnetic flux.

• This is the essence of the problem that causes the bearing to often fail.

• Solution Protect the affected bearing from the electromagnetic flux (shield by aluminum sheet). Simplest solution

Interactions See

E M E

Nemetics

N

Vibration Spectrum of fan NDE Horizontal Direction (The Magic Effect – Constraint removed)

PK

Velo

city

in m

m/S

ec

Frequency in CPM

FANS - ID FAN-02ID FAN-02 -F2H Fan Outboard Horizontal

0 20000 40000 60000 80000

0

0.04

0.08

0.12

0.16

0.20

0.24

0.28

0.32

Max Amp .30

09:07:5103-Jul-10

10:26:4903-Jun-10

Before Bearing Replacement without Aluminum cover

After Bearing Replacement & providing Aluminum cover

Energy Inteactions See

E M E

Nemetics

N

Vibration Spectrum of fan NDE Axial Direction (The Magic Effect – Constraint

removed)

PK

Velo

city

in m

m/S

ec

Frequency in CPM

FANS - ID FAN-02ID FAN-02 -F2A Fan Outboard Axial

0 20000 40000 60000 80000

0

0.05

0.10

0.15

0.20

0.25

Max Amp .24

09:08:4903-Jul-10

10:28:0103-Jun-10

Before Bearing Replacement without Aluminium cover

After Bearing Replacement & providing Aluminum cover

Example – Emergence & EssenceSee

E M E

Nemetics

N

Whole picture imperfection/ Insight See

E M E

Nemetics

N

Case of Diaphragm failure

1200 failures of Diaphragms/year

See

E M E

Nemetics

N

Whole picture interactions -> Insight See

E M E

Nemetics

N

Aluminum Plant - Charging CarSee

E M E

Nemetics

N

a case studyon minimalDesign intervention

Case StudySee

E M E

Nemetics

N

• production not more than 60 packet a min• vibration between 50 to 60 microns• variation of quantity in packets – 6 to 8 ml• rat tailing – wastage of material• horizontal sealing problem• vertical sealing problem• new German machine = 1Cr• workers’ problem!

The pain ….See

E M E

Nemetics

N

• Variation in fill• Horizontal

seal• Vertical seal

The sachetSee

E M E

Nemetics

N

• Observe that the machine is like a tall column pitching effect.

• The width at the base (c to c of cushy foot) = 0.7 m. Length is 1 m

• Note the sensitive directions shown by the red arrows.

0.7 m

Principles of Sensitive Direction, Proportions & Structures See

E M E

Nemetics

N

• The paper reel unit, the stair case are attached to the main unit. (Left hand side of the red line)

• It shifts the centre of mass and induces vibration which is amplified by the low stiffness of the staircase

• The yellow line more-or-less shows the centre of mass

• Note that the machine has two regions of stiffness. One the left hand side of the red line it is the region of low stiffness and on the right is the region of high stiffness.

1 M

Low Stiff region

High Stiff region

Principles of Centre of Mass & Stiffness See

E M E

Nemetics

N

• This slider mechanism is critical for the operation.

• Here the linear bearing can’t be lubricated by any means.

• Moreover, the L/D ratio of the bearing is also not ideal. This would lead to accelerated wear & misalignment

Linear Bearings

Principle of centre of friction & proportion See

E M E

Nemetics

N

• Imperfection: the temperature of the heaters are not equal. So a steady state temperature can’t be reached.

• Solution: provide more feedback to control temperature uniformly.

Principle of Centre of Temperature See

E M E

Nemetics

N

• Imperfection: variable heat distribution.

Principle of heat distributionSee

E M E

Nemetics

N

• The shampoo feed pipe is attached to the machine. Hence pipe vibrations are easily transferred to the machine.

• Solution: Detach the pipe to isolate pipe vibration. And pipe hangers should be at unequal distance

Principle of PipesSee

E M E

Nemetics

N

• Imperfection: Heat gets trapped because of enclosure

• Solution: redesign without covers no machine there – natural convection current to take away heat.

Principle of Heat DistributionSee

E M E

Nemetics

N

• Imperfection: Heat is trapped because of the stainless steel cover. This heats up other elements in the working zone and reduces life.

• Solution: replace SS cover by Aluminum to efficiently radiate heat

Stainless Steel cover

Principle of Heat TransferSee

E M E

Nemetics

N

The new machineSee

E M E

Nemetics

N

the pains……… the gains• < 60 packets a min

• 60 microns vibration

• 6 to 8 ml per packet

• rat tailing

• horiz seal problem

• vertical seal problem

• foreign mac > 1 Cr

• workers’ problem

• 80 packets a min

• < 5 microns vibration

• 8 ml per packet

• no rat tailing

• no problem

• no problem

• new machine = 7.5L

• workers’ cooperation

Pain to GainsSee

E M E

Nemetics

N

learning to live by minimal design intervention

scaling learning – the ultimate competitive advantage!

Personal Mastery – 6th PrincipleSee

E M E

Nemetics

N

Story of the Poor PIG!See

E M E

Nemetics

N

Energy flow; Interactions; SyncSee

E M E

Nemetics

N

Pain is the starting point...

1.Yield = 92% , International Benchmark = 97%

2.Weight variation, Ideal weight 9 to 11 kg, presently 7 to 14 kgs

3.% of Poor Pigs > 30%

4.Availability < 95%

5.Tried different models and techniques for 4 years without success

See

E M E

Nemetics

N

BEAS River: Insights – POV!See

E M E

Nemetics

N

Design Intervention:

1.Change the speed and synchronize

2.Change the dimensions of the molds

3.Change the height of discharge of molten metal

4.Spray less water

See

E M E

Nemetics

N

2003-04 2004-05

88

90

92

94

96

98

100

102

92

99.9

YIELD

FY

%

International BM

Results:See

E M E

Nemetics

N

2003-04 2004-05

0

5

10

15

20

25

30

35

40

10

5

25

15

30

35

21

35

13

8

WEIGHT DISTRIBUTION

A <3

B 3.1-5.0

C 5.1-7.00

D 7.1-9

E 9.1-11

FY

%

ResultsSee

E M E

Nemetics

N

2002-03 2003-04 2004-05

0

5

10

15

20

25

30

35

40

26.3

36.3

20

24.6

34.9

15.4

PPP

Target

Achieved

FY

% PPP

ResultsSee

E M E

Nemetics

N

2003-04 2004-05

92

93

94

95

96

97

98

99

100

101

95

100

AVAILABILITY

AVAILABILITY

FY

%

ResultsSee

E M E

Nemetics

N

6%

99%+

After 1 yrAfter 1 yr

World

Class-Additional Profit2

RemarksRemarksPreviouPreviouss

Audit ParametersAudit Parameters##

6 Sigma,

Internatio

nal

Benchmar

k

92%Yield1

Effects of RAPID - Process Plants See

E M E

Nemetics

N

“We broke new grounds in achieving high yield levels…. One thing which remains

hidden…is the manner in which the opportunities for improvement are

addressed. A systematic fact-based analysis followed by out-of-the box thinking to arrive

at creative solutions lead to dramatic improvements … make positive changes

irreversible & long lasting.” Harsh K. Jha, M.D. Tata Metaliks

‘Metalogue’, Vol 4, Number 2, Feb 2005 (newsletter)

This says it allSee

E M E

Nemetics

N

Right Strategy was applied to 3 process

plants

% of equipment covered: 62 (most critical +

critical)# Audit Parameters Previous After 1 yr After 2

yrs

1 No of breakdowns/year 57 19 3

2 % of breakdown hours 25 12 5

Effects of Strategies– Process Plant

© RMCPL All rights reserved

# Audit Parameters Previous After 1 yr After 2

yrs

3Design Out maintenance cases

Nil 28 Further done

4% of increase in monitoring activities

18 42

5 Capacity < 100% > 100%

6 Cost Leadership 3 1

Effects of Strategies– Process Plant

© RMCPL All rights reserved

-- Reliability -- Cost

0

10

20

30

40

15

20

25

1 2 3 4 5 6 7 8 9 10 11 12

Reliability vs. Cost

Reliability v/s COST - Cement Plant

© RMCPL All rights reserved

Cement PlantSee

E M E

Nemetics

N

Effects of Strategies– Chemical Co.

when STRATEGY was applied to 46 critical

machines in a chemical company, the

results were impressive.

05

1015202530

1st Yr 2nd Yr 3rd Yr 4th Yr

Nu

mb

er

Years

No. of Breakdowns(Avg/month)

© RMCPL All rights reserved

# Audit Parameters Before ‘98 After May ‘01

8Annual Mean Maintenance Labour Hours in a year

4675.66 hours

3108.87 hours

9 Maintenance Budget Rs 3.4 Cr Rs 1.41 Cr

10 Production rate 1.66 T/hr 1.87 T/hr

11 Quality 3.5 6

12 Leadership Position 4th 1st (sells at premium)

Effects of Strategies– Chemical Co.

© RMCPL All rights reserved

Effects of RAPID – Aluminum PlantEffects of RAPID – Aluminum Plant

## Audit Audit ParametersParameters PreviousPrevious After 6 mAfter 6 m RemarksRemarks

1 Availability 80% 90% 10 % productivity

2 Rolls/hour 20 23 15% productivity

Effects of RAPID – Aluminum PlantEffects of RAPID – Aluminum Plant

## Audit ParametersAudit Parameters PreviousPrevious EffectEffect

3 Energy 17% reduction

4 Profits 16% increase

• Leadership

• People

Ingredients of SuccessSee

E M E

Nemetics

N

Once done the company gains permanent on-going benefits.

Prof. Tim Henry, Manchester University, U.K

BenefitSee

E M E

Nemetics

N