Title: Reduction of Raw Mill VRM Hydraulic System Failure Due to Dusty Environment

CMS CLINKER SDN BHD

Background:

Counter Measures:

VRM hydraulic system failure/breakdown due to dusty environment at Raw

Mill Vertical Roller Mill.

No.
I

Root Cause
In appropriate
machine design

Problem Statement:
Since August 2013 until July 2014, Raw Mill VRM hydraulic system breakdown
at Raw Milling department is 266 hours.

II

Improper layout
design

VRM Hydraulic system downtime (hr)

Goal Statement:

300

To reduce raw mill VRM hydraulic system

downtime to 50% from 266 hours/year to
133 hours/year.

200
100

Contaminated
hydraulic oil in
the VRM system

Why 2

Air Filter
damage

Dust
accumulated
at air filter

0
2014

Why 3

Why 4

Why 5

Dusty
environment

Discharge from
bag filter to
reject conveyor

Original
layout
designed

Damage
hydraulic
pipe

Pipe
holder
damage

Completed

2. Cover all reject conveyor

3. Improve the dedusting system
4. Relocate the hydraulic station

Method of
fixing holder
Material of
pipe holder
easily damage

Malfunction
solenoid poppet
valve

Internal
small part
missing after
maintenance

Lack of
maintenance
skill

Insufficient/
no
training
provided

Insufficient
training include
during upgrade
2012

Lack of
troubleshooting
skill/ technical
support after
commissioning

No
experience

New
equipment

Ineffective
training

Language
problem

III

Spare part design

8. Changed the pipe holder to better

quality (adapt from other system)

IV

Lack of
workmanship

9. Checklist with visual (drawing/BOM)

10. Provide in house training.
11. Refresh training for once a while issue
12. Need training on hydraulic system

Hydraulic station
just beside the
reject conveyor
Pipe leaking
introduce dust
going into
hydraulic system

12 26
Sept. 2014

7. Blower or suction fan or super sucker

50

Root Cause Analysis:

Why 1

Status

6. Hut cover for hydraulic station

150

2013

Problem

1. Modify the discharge system to screw

conveyor type

Date

5. Modify the existing 2 discharge points

of VRM to 1 point

50%

250

Solutions Ideas

VI

Lack of
communication / in
proper setup
Unable to visualize

Maker
variance
Fix area attach
to the VRM
(always
vibrate)
Not include all
concern
person (voice
of customer)

13. Sharing session on troubleshooting by

suppliers
14. Site visit with technical knowledge
training.

Effect Confirmation:
Dust circulating in the RM VRM system has been minimized by re-routing the bag
filter product out of the system directly to the Blending silo.
Up to now, no incident of Hydraulic system breakdown.
100%
improvement
100% improvement is achieved for two months after implementation.

Before
After

Follow-up Action:
Classroom
training

Vertical Roller Mill (VRM) raw mill daily log sheet is established to detect any
abnormal fluctuation in hydraulic pressure.