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


2nd November 2007

Kaizen


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JQM

Organization

Products Engines & Tractors

Market Leader in Indian Tractor Industrysince last 25 years

Third position in Global Tractor Market


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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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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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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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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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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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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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Background

Old System

Gas bottle with pressure

regulator

Pressure regulator


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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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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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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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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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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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WHY WHY ANALYSIS

Test hold up

Gases Not Available

No Intimation

No Early Warning

Not Ordered

Why

Why

Why

Why


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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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Methodology

Concept development

System set up

Electrical system circuit developed

Selection of components


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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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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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Real Time Pressure

Indication System

Signal Box :-

- Microprocessor based alarm

- Announciator with inbuilt hooter

- Std features like Test/Accept/reset


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Real Time Pressure

Indication System

New pressure regulator

connected to the gas

line

New pressure regulator

connected to Cylinder


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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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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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Tangible Benefits

1. Place order for gas bottle in advance

2. Achieve uninterrupted Emission test

3. Cost saving


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Intangible Benefits

1. Meet project time lines

2. Enhance test bed utilization

3. Reduce operator fatigue


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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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JQM

Documents

Gas Alarm System - Kaizen