Aakanksha

Welcome

Efficient Maintenance of
Siemens PLCs in RMHP

and
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MTPA
Rashtriya Ispat Nigam
Limited
Visakhapatnam Steel
Plant
2

PRODUCTS OF VIZAG
STEEL

Team
Introductio
n

K
ri
Ha

Ch
.B
sk ha
ar

Ra
ju
G
P

i
ng
iva
Sh

K V Rao

Sanjeevi

Facilitator : S Y Kondalarao
4

Quality Circle Profile

Name of the QC
QC Reg No
Leader
Rao
Facilitator

Kondala
Rao
Date of formation
2014
Date of starting

2014
Frequency of meetings
Day of meeting
Time
pm
Place of meeting
Room
Date of completion

Aakanksha
48301026
K Venkata
SY
1st August
1st August
Weekly
Saturday
4 pm to 5
RMHP-ETL
24th Jan

2015
No of projects completed

First

No of Meetings held

26

Coordinator
Sinha

Mrs Madhu

Area of working and

Responsibility
Maintenance of AC /DC
drives, PLCs ,UPS,Wireless
communication system and
repair of Electronic cards In
RMHP(Raw material
handling plant) zone
6

12steps
stepsfor
for
12
Problem
Problem
Solving
Solving

GOAL
FOLLOW UP &
REVIEW
REGULAR

IMPLEMENTATION
TRAIL IMPLEMENTATION
AND CHECK PERFORMANCE
FORESEEING PROBABLE
RESISTANCES
DEVELOPING SOLUTION

DATA ANALYSIS
ROOT CAUSE ANALYSIS
IDENTIFICATION OF CAUSES
ANALYSIS OF PROBLEM
DEFINITION OF PROBLEM
SELECTION OF PROBLEM
IDENTIFICATION OF PROBLEMS

Identificati
Identificati
on of
of
on
Problems
Problems
BrainStor mi ng (Round Robin
BrainStorming (RoundMethod)
Robin
Method)
8

Round Robin Method

Brainstormi

S.N
O
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27

PROBLEM
Communication failure of HMI with Siemens PLC
Thyristor block failure in ac drive
Conveyor operating due to jamming
Siemens plc interlocks failure
Ge fanuc micro plc failure
Communication failure of server with hmi
Abb plc i/o card failure
Drive control card failure
Igbt block failure in drive
Plc-drive communication failure
Siemens PLC IM module failure
Lc buildings roof and walls seepage
Conveyor is not starting due to wrong route no.
Selection
Dust extraction not proper
Drive incoming fuse failure
Ccr hmi & server power failure
Tippler brake not operating
Frequent siemens plc card failure
Material sticking during monsoon
Ge fanuc inputs to plc failed/not coming
Siemens cpu going to stop mode
Siemens plc networking problem
Siemens hot-standby redundancy failure
Drive tripped due to dc over voltage
Schneider plc button cell failure
Siemens plc battery failure

Improper ventilation of mcc room

28 Drive pcb failure

SUGGESTED
TYPE
BY
K.Venkata Rao
Shivangi Singh
CH.Bhaskara
Rao
P.Ganga Raju
P.Sanjeevi
K.Hari
K.Venkata Rao
Shivangi Singh
CH.Bhaskara
Rao
P.Ganga Raju
P.Sanjeevi
K.Hari
K.Venkata Rao
Shivangi Singh
CH.Bhaskara
Rao
P.Ganga Raju
P.Sanjeevi
K.Hari
K.Venkata Rao
Shivangi Singh
CH.Bhaskara
Rao
P.Ganga Raju
P.Sanjeevi
K.Hari
K.Venkata Rao
Shivangi Singh
CH.Bhaskara
Rao
P.Ganga Raju

A
A
B
A
A
A
A
A
A
A
A
C

Li
Li
st
st
of
of
Pr
Pr
ob
ob
le
le
m
m
s
s

A
B
A
A
B
A
B
A
A
A
A
A
A
A
C
A

10

S.N
O

PROBLEM

SUGGESTED
TYPE
BY

36 Non- availability of healhty siemens plc spares

K.Hari
Ambient temperature and dust levels high in operator
37
cabins
K.Venkata Rao
38 Start push button failure in operator cabin.
Shivangi Singh
CH.Bhaskara
39
Pop-up screen not opening in hmi of siemens
Rao
40 Communication failure due to bus fault om-22
P.Ganga Raju
41 Mcc cabin roofs/walls seepage
P.Sanjeevi
42 Tippler clamping failure
K.Hari
43 Operator cabin emergency push button not released K.Venkata Rao
44 Plc-plc communication failure in siemens
Shivangi Singh
CH.Bhaskara
45
Schnider plc i/p channel failure
Rao
46 Abnormal sound coming from bearing
P.Ganga Raju
47 Anntena cable got cut in scr
P.Sanjeevi
48 Communication facility at lcs /ops
K.Hari
49 Motor brake failure
K.Venkata Rao
50 Track zero magnetic limit switch failure
Shivangi Singh
CH.Bhaskara
51
Ab micrologix plc going to fault mode
Rao
52 Ethernet cable faulty in siemens
P.Ganga Raju
53 Tippler drive failure
P.Sanjeevi
54 Loose connections at ethernet port in lc-5
K.Hari
55 Siemens plc ofc cable faulty
K.Venkata Rao
56 Abb plc i/o cards faulty
Shivangi Singh
CH.Bhaskara
57
Schneider plc auto restart failure
Rao
58 Ge fanuc plc o/p channel faulty
P.Ganga Raju
59 Wrong tph value in hmi
P.Sanjeevi
60 Pusher motor failure
K.Hari
61 Fault indication on siemens olm module
K.Venkata Rao
62 Loose connection at profbus port
Shivangi Singh
CH.Bhaskara
63
Stream interlocks failure in co-44
Rao
64 Emergency push button problem
P.Ganga Raju

A
C
A
A
A
C
B
A
A
A
B
A
C
B
B

Li
Li
st
st
of
of
Pr
Pr
ob
ob
le
le
m
m
s
s

A
A
A
A
A
A
A
B
A
A
A
A
A
A

11

S.N
O
71
72
73
74
75
76
77
78
79
80
81
82
83
84
85
86
87
88

PROBLEM
Belt snapping
Wrong tag assignment to graphics in siemens server
Drive tripped due to overcurrent
Motor alignment disturbed
Modem failure
Low wireless signal strenght
Motor brushes failure
Ge fanuc plc terminating resistance problems
Apron feeder pans jamming
Pulse encoder unit failure
Hmi not working in ocr
Shuttle conveyor pull chord switch failure
Local push button station failure
Tonnage value not updating
Siemens scalence ethernet switch failure
Drive incoming isolator failure
Wrong wincc fle selection in hmi from server

Encoder allignment problem

89 Schneider plc control supply failure
90 Drive cooling fan failure

SUGGESTED
TYPE
BY
P.Sanjeevi
K.Hari
K.Venkata Rao
Shivangi Singh
CH.Bhaskara
Rao
P.Ganga Raju
P.Ganga Raju
P.Sanjeevi
K.Hari
K.Venkata Rao
Shivangi Singh
CH.Bhaskara
Rao
P.Ganga Raju
P.Sanjeevi
K.Hari
K.Venkata Rao
Shivangi Singh
CH.Bhaskara
Rao
P.Ganga Raju
P.Sanjeevi

B
B
A
A
A
A
A
A
B
B
A

Li
Li
st
st
of
of
Pr
Pr
ob
ob
le
le
m
m
s
s

A
A
A
A
A
A
B
A
A

TOTAL NO.OF PROBLEMS : 90

12

Selection of
of
Selection
Problem
Problem
ABC Analysis
ABC
ysis
StrAnal
atifi cation
Stratifidiagra
cationm
Pareto
Pareto diagram
13

Problem
Categorization
70
60

A-within the
scope of the
team

50

B-External
help is
required

40
30

20

10
0

CManagemen
t sanction is
required

IORITY GIVEN TO CATEGORY

63

21

14

Stratification of Category A Problems

Type of equipment
others

A7

2 Hrs

Field device related problems

A6

4 Hrs

Wireless system problems

A5

15 Hrs

A4

12 hrs

A3

27 Hrs

A2

22 Hrs

A1

220 Hrs

UPS related problems

AC drives related problems
DC drives related problems
PLC related problems

* Including
production and
Non production

Equipment down
time* in Hrs.
15

ParetoTable
Table
Pareto
Problems in A
category

Code

PLC Related problems

AC drives related problems

A1
A3

220
27

DC drives related problems

A2

22

Wireless system problems

A5

15

UPS related problems

A4

12

A6

A7

Field devices related

problems
Others

Delay in cumulati percent

Hrs
ve Delay
age
220
247

72.80
81.78

269

89

284

94

296

98

300

99.4

302

100

16

Pareto
Diagram
Pareto Diagram
300
250
200

Vital
Few
89

Useful many
98
94

99.4

100

90

81.78
72.8

80

220

70
60

150

50
40

100

30
20

50
0

100

27
A1

A3

10
22
A2
Delay in Hrs

15
A5

12
A4

4
A6

2
A7

Cumilative %
17

PLC
Related
problems
S.N PLC Make
o

Code

Downtime/year
in hrs

Occurran
ces

MTTR
0.57

Siemens

P1

130

54

Allen
Bradley

P2

20

35

14

27

Ge Fanuc

P3

46

60

Schneider

P4

10

20

2.4
0.52
0.76
0.5

P5
Key5 Others
Parameter
One of the KEY PERFORMANCE INDICATORS
(KPIs) for Plant maintenance is MTTR
(Mean time to Repair).
MTTR(Mean Time To Repair)=Down time in
Hours/No.of Occurrences
18

Actual MTTR
Vs
Target MTTR
3
2.5 2.4
2
1.5
0.6

1
0.57

0.5
0
Siemens

Allen Bradley

0.76
0.52
Ge fanuc

0.5
Schneider

Others

Company Target related to MTTR as per

sustainability plan for the year 2014-15
should be less than 0.6 Hours
19

Problem
Problem
Selected
Selected

High
MTTR
(Mean time to
repair)
of
Siemens PLC
problems
20

Venue
Meeting Day
Time

: ETL-RMHP OFFICE
: Saturday
: 4 5 PM.

MILESTONE CHART
TEAM ACTIVITY PLAN

#
week 4-5
s

TASK

8-9

Definition of
problem
Problem
analysis
Identification of
causes
Root Cause
Analysis

Data analysis

Developing
Solution
Foreseeing
Probable
resistance
Trial
Implementation
Regular
Implementation
Follow up and
Review

4
2

10-12

13-14

15-16

17

18 - 21

22 - 23

24 - 25

Site Conditions
Criticality of the

Equipment
Available Resources

Skill and knowledge

level of
the Team

2
22
23-Aug14

Showeet.com

6-7

Total no. of weeks

Planned

rd Jan
24rd
15

21

This work is licensed under a

Definition
Definition
of Problem
Problem
of
Fl ow chart used to under stand RMHP process
Fl ow char t used to under stand Impact
RMHP process
analysi s
Impact
analysis
Objective an d GOAL
Objective and GOAL
22

Receiving
Material
Through
wagons and
trucks
Unloading
materials at
Tippler

Sending
material to
stock yards
through
conveyors

Receiving
Material from
GPL at JH-5

RMHP/CHP process
flow
Storage in
stock yards

Stacking
through yard
conveyors
using stackers
Boiler coal sent
to crushing and
screening plant
Crushed coal
sent through
conveyors

Reclaiming
with
Reclaimers
and SCRs
Reclaimed
Coking coal
sent through
conveyors

Material sent to Material sent to

TPP
Coke Ovens

23

Receiving
Material
Through
wagons and
trucks
Unloading
materials at
Tippler

Sending
material to
stock yards
through
conveyors

RMHP/OHP process
flow
Storage in
stock yards

Stacking
through yard
conveyors
using stackers
Lump ore sent
to crushing and
screening plant
Crushed ore
sent through
conveyors

Reclaiming
with
Reclaimers
and BRCs
Reclaimed ore,
limestone and
dolomite sent
through
conveyors

Material sent to Material sent to

BF
BF, SP,

24

Functionof
ofSiemens
SiemensPLCs
PLCs
Function
inRMHP
RMHP
in
System
Commissioned 2
years back

Siemens
PLC

S7-414-4H
Processor
Control of
Control of
OHP
CHP
conveyors,
conveyors ,
Weigh
Ring
feeders,
granulators
Crushers
Dust
Etc
Etc.
Extraction
Systems

S7-313
Processor

Control of 3
SCRs in
CHP
25

Processes controlled by Siemens

PLCsTipplin
in RMHP
Tipplin
g
g

Polluti
Polluti
on
on
control
control

Crushin
Crushin
g
g&
&
Screeni
Screeni
ng
ng

Sieme
ns
PLCs

Convey
Convey
ing
ing

Stackin
Stackin
g
g

Reclaim
Reclaim
ing
ing
26

What happens when

problem occurs?
High MTTR of Siemens
PLC related problems
Less availability of
Siemens PLCs
Interruption in stacking
and reclaiming process
27

Problems
High MTTR of Siemens PLC problems
Leading to
Interruption in STACKING and
RECLAIMING process

Impact 1
Increase in rake
retention time

Impact 2
Decrease in
Productivity

Impact 3
Non
availability of
stream

Impact 4
Production
stoppage

Impact of the Problem

28

Problem definition
Interruption in Stacking
and Reclaiming process in
Raw
Material
Handling
plant due to High MTTR of
Siemens
PLC
related
problems.
29

To Increase Availability of Siemens

PLCs in RMHP.

Goal

To reduce MTTR of Siemens PLC problems

from 2.4 Hrs to less than 0 .6 Hrs by Mar15

Objective

30

Analysis of
of
Analysis
Problem
Problem
Inspection
Inspection
In for mati on from log books and History books
In for mation from log books and History
books
Del ays
data
Delays
data
Bar graph & Belt graph
Bar graph & Belt graph
31

Activities
Site inspection activities

Information from log

books and history books

Data regarding delays

32

Delays
data for 1
yearDelay not effecting production

All
values
in Hrs
Delay effecting production
13

12

13

11

10

13

10

11
9

5.5

4.5

5.5

6
4

11

6.5

7
5
3

5.5
4

6.5
5

Aug13Sep13 Oct13 Nov13Dec13 Jan14 Feb14 Mar14 Apr14May14 Jun14

Jul14

33

60

56

Delays
data Area
wise for 1
year

All
values
in Hrs

50
40
40

34

30
20
10
0

OHP S7 400

CHP S7 400

S7 300,SCR 4,5,6

34

What is the
problem?
High MTTR of
siemens PLC
problems

When is it
happening
During
?

every
Breakdown
of Siemens
Where is
PLC

the
4W-1H
How is technique problem?
In all the
the
Siemens
problem
PLC
?
Who is
Repetitiv
affected?
e
Stacking and
reclaiming
process
35

Identificati
Identificati
on
on
of causes
causes
of
Cause Enumeration
Cause Enumeration
Method
Method
Brai nstor mi ng
Braisegregati
nstor mi ng
on
segregati
on
Fi sh bone Diagr am
Fi sh bone Diagr am

36

MAIN CAUSE

SUB CAUSE
Attitude

Man

Poor maintenance

More time taken to

troubleshoot

SUB-SUB CAUSES
Reluctance in taking responsibility
Bad work culture
procrastination
Poor inspection
Negligence in maintenance
Lack of interest
Lack of expertise in SIEMENS PLC
Lack of interest
Understanding drawings
Drawings not available

Insufficient Man Power

Improper tools
ageing
Insufficient tools
Unavailability of drawings
Errors in drawings
Drawings not readable
Unhealthy spares
Non availability of spare
Procured spare not matching
Improper storage
Insufficient details
Miscommunication between shifts
Delay in communication
Wrong information
Card not inserted properly
Card placement on wrong slot
Maintenance schedule not as per
OEM
Inspection parameters
Panel glass broken
Panel door not closed
Panel not designed properly
Anti vibration pads not present
Panel not designed properly
Improper ventilation

SUGGESTED
BY
Shivangi Singh
K. Hari
Ch. Bhaskara Rao
P. Sanjeevi
K. Hari
P. Ganga Raju
Ch. Bhaskara Rao
P. Sanjeevi
Shivangi Singh
K. Hari
K.Venkata rao
K. Venkata Rao
Ch. Bhaskara Rao
Shivangi Singh
K. Hari
P. Ganga Raju
Ch. Bhaskara Rao
K. Hari
K. Venkata Rao
Ch. Bhaskara Rao
Shivangi Singh
K. Venkata Rao
K. Hari
K. Venkata Rao
Shivangi Singh
P. Sanjeevi
K. Hari

Brain storming done

Causes were listed
Tools

Material

Drawings

Spares

Communication

Method

Card fxing
Maintenance

Dust

Environment

Heavy vibration

P. Ganga Raju
Ch. Bhaskara Rao
P. Sanjeevi
P.Ganga Raju
K. Hari
K. Venkata Rao
Shivangi Singh
P. Sanjeevi

37

MATERIAL
Unhealthy
Non
spares
availabilit
y
Spares

Improper
AGEING
tools
Tools

MAN
Lack of
expertise in
Siemens PLCs

Reluctance in
taking
responsibility

Attitude

Bad workProcrastinati
culture on
Insufficie
Insufficie More time to
nt Man
Lack of
nt tools trouble shoot
power
Procured
Improper
interes
Understandi
Unavailabili
storage spares not
Lack of
Poor
ng drawings t
Errors in
ty
matching
interest
maintena
drawings
Poor
nce
Drawings not
Drawings
inspection
available
Negligen
Drawings not
ce
readable
Anti vibration
Card
pads not
Panel
placement in
present
Panel
Heavy
door
wrong slot
glass
Card
vibrati
broken open
fixing
on
Dust
Panel not
Card not
Miscommunicati
Panel not
Insufficiendesigned
inserted
on between
designed
t details properly
Maintenance
properly
shifts
Imprope
properlyPanel fan not
schedule not
r
working
as per OEM
Communica
ventilati
Maintena
Temperat
tion
on
nce
ure
Delay in
Wrong
AC not
communication
communicati
Inspection
ENVIRONMENT working
on
parameters METHOD

High
MTTR of
Siemens
PLC
problems

Fishbone diagram

38

ROOT CAUSE ANALYSIS

Brainstorming
Brainstorming
segregation
segregation
Fishbone
Fishbone
diagram
diagrams

39

Root cause identifcation

activities

Assessm
ent and
Validatio
n

Skill and
knowledge
level

Tools and
materials

Environment
al conditions

SMPs and
SOPs

40

Activities
NAME
K. VENKATA RAO & K.
HARI
SHIVANGI SINGH

CH. BHASKARA RAO

P. SANJEEVI

RESPONSIBILITY
SKILL AND KNOWLEDGE LEVEL
ASSESSMENT/VALIDATION
STANDARD OPERATING PROCEDURES
ASSESSMENT/VALIDATION
STANDARD MAINTENANCE PRACTICES
ASSESSMENT/VALIDATION
TOOLS AND MATERIAL S
ASSESSMENT/VALIDATION

P. SANJEEVI
& P. GANGA RAJU

ENVIRONMENTAL CONDITIONS
VALIDATION/ASSESSMENT

SHIVANGI SINGH

CROSS CHECKING THE RESULTS OF

ASSESSMENT AND VALIDATION
41

 Brain storming
Equipment history and log
books studied
Documents and drawings
Site audit
Assessment and validation

42

Assessment of environmental
conditions
Panels are procured as per
standards
Proper Ventilation and cooling is
provided
All the panel doors are in closed
condition
Vibration pads are present
43

MATERIAL
Unhealthy
Non
spares
availabilit
y
Spares

Improper
AGEING
tools
Tools
Insufficie More time to
nt tools trouble shoot

MAN
Lack of
expertise in
Siemens PLCs

Reluctance in
taking
responsibility
Attitude
Bad workProcrastinati
culture on
Insufficie

nt Man
Lack of
Poor
power
Understandi interesinspection
Unavailabili
Lack of
Poor
ng drawings t
Errors in
ty
interest
maintena
drawings
nce
Drawings not
Negligen
Drawings
available
ce
Drawings not
readable
Anti vibration
pads not
Card
Panel
present
Panel
placement in
Heavy
door
glass
wrong slot
vibrati
Card
broken open
on
Dust
fixing
Panel not
Miscommunicati
Card not
Panel not
Insufficiendesigned
on between
inserted
designed
t details properly
Maintenance shifts
properly
Imprope
Panel fan not
properly
schedule not
r
working
as per OEM
Communica
ventilati
Maintena
Temperat
tion
on
nce
ure
Delay in
Wrong
AC not
communication
communicati
Inspection
ENVIRONMENT working
on
parameters METHOD
Procured
Improper
storage spares not
matching

High
MTTR of
Siemens
PLC
problems

Fishbone diagram

44

Assessment of SMPs
and SOPs
PPMs and inspections are done as
per recommendations and
standards
All parameters are checked at
regular intervals
Standard Maintenance
procedures are being followed as
per OEM
Communication between Sections
and shifts is well coordinated

45

MATERIAL
Unhealthy
Non
spares
availabilit
y
Spares
Procured
Improper
storage spares not
matching

Card
fixing

MAN

Improper
AGEING
tools

Lack of
expertise in
Siemens PLCs

Tools
Insufficie More time to
nt tools trouble shoot

Reluctance in
taking
responsibility
Attitude
Bad workProcrastinati
culture on
Insufficie

nt Man
Lack of
Poor
power
Understandi interesinspection
Unavailabili
Lack of
Poor
ng drawings t
Errors in
ty
interest
maintena
drawings
nce
Drawings not
Negligen
Drawings
available
ce
Drawings not
readable

High
MTTR of
Siemens
PLC
problems

Card
placement in
wrong slot

Miscommunicati
Card not
on between
inserted
Maintenance
shifts
properly
schedule not
as per OEM
Maintena
nce
Delay in

Communica
tion

Wrong
communication
communicati
Inspection
METHOD
on
parameters

Fishbone diagram

46

Assessment of Tools and

Materials
Tools are procured as per
specifications and standards
Recommended quality spares are
being procured
As Commissioned drawing are
available
Special and standard instruments
are available
47

MATERIAL
Unhealthy
Non
spares
availabilit
y
Spares
Procured
Improper
storage spares not
matching

Improper
AGEING
tools

Lack of
expertise in
Siemens PLCs

Tools
Insufficie More time to
nt tools trouble shoot

Reluctance in
taking
responsibility
Attitude
Bad workProcrastinati
culture on
Insufficie

Lack of
Understandi interes
Lack of
ng drawings t
interest

Unavailabili
Errors in
ty
drawings
Drawings
Drawings not
readable

Card
fixing

MAN

Drawings not
available

nt Man
power

Poor
maintena
nce
Negligen
ce

High
MTTR of
Siemens
PLC
problems

Card
placement in
wrong slot

METHOD

Fishbone diagram

48

Assessment of Skill and

Knowledge level
Creative and encouraging work
culture exists
Competent persons are being
recruited
Requisite man power is being
recruited
Necessary operational and
maintenance procedures are in
place
49

MAN
Lack of
expertise in
Siemens PLCs
More time to
trouble shoot

Reluctance in
taking
responsibility
Attitude
Bad workProcrastinati
culture on
Insufficie

Lack of
Understandi interes
Lack of
ng drawings t
interest

nt Man
power

Poor
maintena
nce
Negligen
ce

High
MTTR of
Siemens
PLC
problems

Fishbone diagram

50

Root cause

Lack of Expertise in
Siemens PLC

51

Data
Analysis

Data collecti on, Si te i nspecti on

Data collection, Si te i nspecti on

52

Function of Siemens PLC in

OHP, CHP, SCR 5,6 &7 was
thoroughly studied.

Data regarding the hardware

and software used was
collected and studied based
on the drawings supplied by
OEM.
53

SIEMENS S7 414 HOTREDUNDANT PLCS

A

A
1

ES1
For
modification
ES2
and trouble
shooting
PLC
hardware
and
software

B
1

C
1

D
1
Si
e
m
en
s
PL
C
CH
O
P
HP

Programed to
Control All
equipment
excluding yard
machines
machines in
in Coal
Ore
side
SERV
SERV
ER1
ER2
For monitoring and control of process by
Control room operator
HMI1

HMI2

HMI3

54

Siemens PLCs used in

SCR
5,6 & 7
SIEMENS S7 313
SIEMENS S7 313
NON
REDUNDANT
PLC

Programed to
Control all
mechanisms in
SCR

Lap top for

programmin
g and
troubleshooti
ng

Joy sticks,
push
HMI
buttons and
Indication
lamps
Control Desk
55

Profbus
communicati
on

S7 414
redundant
PLCs

56

S7 313 non
redundant
PLC

Developing Solution

Brainstorming
Brainstorming
Plan feasibi lity
Plan feasibi lity
58

Points considered for

developing solution
Solution should be within the scope of
the team and permanent
Facility to test the spare cards

Solution should be compatible to the

present system
Process should not be affected

Solution should ensure to increase the

availability of Siemens PLC
59

plan
Brainstorming was done
to develop different
1
Plans as solution

plan
4

solutio
n

plan
2

plan
3
Feasibility study was done for selecting the most
60
suitable Plan

Plan1

Constrain
ts
Cost Intensive

Extern
al
trainin
g at
OEM
premis
es

All employees cannot

be
trained
Employees
will not be
available for the
period.sanction
training
Management
to be taken

Plan
not
feasibl
e

61

Plan 2

Familiari
zing and
getting
acquaint
ed on
the
existing
system

Constrain
ts
Faults cannot be
simulated and studied.
Can effect the system
while working online
All functionalities
cannot be tested
Permission to work on
the system may not be
available regularly

Plan
not
feasibl
e

62

Plan 3

Procure
a
Siemen
s test
jig from
OEM
and
work on
it.

Constrain
ts
High cost
Test Jigs available
with OEM are
generic
Management sanction
required

Plan
not
feasibl
e

63

Plan 4

Develop
a
Siemens
PLC Test
Jig In
House

Advanta
ges

Within
Increase in
the
familiarity while
scope of
establishing
a test
problems can
be
the
jig.
simulated and remedies
team
Plan
recorded there by team
Accept
members
can gain
Spare cards
and
ed
experience
Repaired cards can be
tested.
Training can be given to
ETL personnel and shop
electrical.

64

Foreseeing
probable Resistance
Brainstorming used to
Brainstorming
used
to
foresee the pr
oblems
foresee the pr oblems
65

Probable resistance and their remedies

S.NO

PROBABLE
RESISTANCE

REMEDIAL MEASURES TAKEN

Availability
of Requisite
spare
card
are
spare card to be available with ETL and shop
used in test jig.
Electrical

Cards used in test List of card used can be

jig may be needed distributed to all Zones and
in other Zones.
cards can be readily used from
test jig.

Cards
may
be recommendations of OEM were
damaged
during followed stringently.
implementation.

Requisite
know- Can be designed based on
how
for existing system. Drawing and
establishing
test Hardware configuration have
66
jig
to be studied.

Trial
Trial
Implementati
Implementati
on
and
check
on and check
performance
performance
(29/11/2014)
(29/11/2014)
Activity
Activity
planning
planning
Implementation
Implementation
Time schedule
Time schedule 67

30/11/20
14

Approve
d

68

Preliminary activities before Trial

Implementation
Activity 1: Thorough study of existing
system
hardware in OHP, CHP and
SCR
Activity 2: Collecting data sheets and
manuals for all the
hardware and software
needed
Activity 3: Listing out the minimum
cards and electrical
components required
Activity 4: Noting down the Physical
dimensions of the
all the items to be used in
test jig

69

Responsibility and time

schedule matrix
Activity

Time(da
ys)

Activity
1

Activity
2

Activity
3

Activity
4

RESPONSIBILITY
K.V.RA
O

S.SING
H

K.HARI

C.B.RA
O

P.G. RAJU

P.SANJEE
VI

P - Primary responsibility
S - Secondary responsibility
70

Trial
Trial implementation
implementation activities
activities

Test jig and circuit design

Develop drawings
Implement Stand alone S7 400
and S7 300 system without
redundancy and
communication
Implement Redundancy
Study PLC to PLC
communication and implement
the same between S7 400 and
S7 300 PLCs
Complete testing of the system

71

1
0
A

LEGEND

DESCRIPTION

SIMATIC S7-400H RACK

R1/R11
UR2/6ES7400-1JA11-0AA0
S7 300 DIN RAIL (480MM) /
R2
6ES7390-1AE80-0AA0
DIN RAIL FOR ET200M
R3
STATION / 6ES7195-1GF300XA0
POWER SUPPLY 10A /
PS1
6ES7407-0KA02-0AA0
POWER SUPPLY 2A / 6ES7307PS2
1BA00-0AA0
CPU1/CPU S7 414 H CPU / 6ES741411
4HM14-0AB0
S7 300 CPU / 6ES7315-2EH14CPU2
0AB0
COMMUNICATION PROCESSOR
CP1
CP443-1 / 6GK7443-1EX200XE0
COMMUNICATION PROCESSOR
CP2
CP443-5 EXTENDED /
6GK7443-5DX04-0XE0
S7 300 ETHERNET CP /
CP3
6ES7343-1CX10-0XE0
IM 153-2, ET200M INTERFACE
IM1/IM2 MODULE / 6ES7153-2BA020XB0
16 CH DIGITAL INPUT MODULE
DI1
110V/230V AC / 6ES73221BH01-0AA0
16 CHANNEL 24V DIGITAL
DI2
INPUT MODULE / 6ES73211BH02-0AA0
16 CH DIGITAL OUTPUT
DO1/DO2 MODULE 24 DC / 6ES73221BH01-0AA0
82 CH ANALOG3 INPUT
1
4

Note:
B

ACTIVE BUS MODULE

FOR IM153-2 /
6ES7195-7HD10-0XA0
C

ACTIVE BUS FOR I/O

MODULE /
6ES7195-7HB00-0XA0

Description: LEGEND
Work: Siemens Test Zig
Date:
5

Sheet No: 01
7

72
1

1
0

PLC to PLC
Communication

R2
B

R1
1

IM
1
IM11

R1

PS
11
CPU1
DP
1
RJ4 CP
5
11

PS
2
DP CPU2
RJ4 CP
5
3

Redundancy established

DP
RJ4
5

PS
1
CPU1
CP
1

DI1
DO
1
AI1
AO
1
IM
2
EMP
TY
DI2
DO
2

R3
D

PLC configuration

Description: PLC Configuration

Work: Siemens Test Zig
Date:

H
1

Sheet No: 02
7

73
1

1
0
A

220 110 24V

V
V
DC

PS
2
DP CPU2
RJ4 CP
5
3

PS1
CPU1
CP1

PS1
1
CPU11
CP1
1

DP
RJ45

DP
RJ45

IM
1
EMP
TY
DI1
DO
1
AI1
AO
1
IM
2
EMP
TY
DI2
DO
2

M
1

M M M M
2 3 4 5

M M M M
6 7 8 9

R
L
1

SMP
S1

R
L
2
F

X1
G

18

X2/1
-3

918

Layout
G

Description: Panel Front view

Work: Siemens Test Zig
Date:

H
1

Sheet No: 03
7

74
1

Regular
Regular
Implement
Implement
ation
ation
(27/12/201
(27/12/201
4)
4)

Regular
Regular
implementation
implementation
Comparati ve
Comparative
study
study 75

Regular
Regular
Implementation
Implementation
After Trail implementation was successful team
members decided to thoroughly review the
Test Jig and existing system.
Optical fiber cables along with OLM modules
were used for communicating to nodes farther
than 500 Mtrs
These OLM modules cannot be tested in
existing Test Jig setup

Test Jig was modified for testing of

OLM Modules
76

R1

OLM
1

1
0

PLC to PLC
Communication

R2
B

R1
1

IM
1
IM11

PS
11
CPU1
DP
1
RJ4 CP
5
11

PS
2
DP CPU2
RJ4 CP
5
3

Redundancy established

DP
RJ4
5

PS
1
CPU1
CP
1

OLM
2

DI1
DO
1
AI1
AO
1
IM
2
EMP
TY
DI2
DO
2

R
3

PLC configuration after

regular implementation

Description: PLC Configuration

Work: Siemens Test Zig
Date:

H
1

Sheet No: 02
7

77
1

Master

Standby

78

Comparative study From

50 January to June50
of 2014 and 5 are
Even
though
occurrences
After regular2015
implementation

OUR
OBJECTIVE AND
GOAL ACHIEVED
approximately
same,
because of
Mean
time
to
repair(MTTR)
of
40
40
4
gain
in
expertise
problems
could
Siemens PLC
be resolved
faster
leading
to
a
30
problems
is 0.530Hrs, compared
3
drastic decrease in delay time
to
2.4
Hrs
the
same
period
there
by
increasing
availability.
20
20
2
67

previous
year.
Hrs
27

10

20
10

2.4
Hrs

11
Hrs
Dela
y
201

Dela
y
201

Occurren
ces 2014

Occurren
ces
2015

0.5
Hrs
MTT
R
201

MTT
R
201

79

Follow-up
Follow-up
and Review
Review
and
Milestone char t
Milestone
t
Standardichar
zation
Standardi
zation
Data collection
Data and
collection
revi ew
and revi ew

80

Action taken to sustain the

system
All necessary drawings and datasheets are kept
near the test jig
Testing procedures were standardized and
documented
A register is being maintained for recording all
the activities for future reference
A schedule was prepared for testing all Siemens
PLC cards available at ETL stores.
Training and hands on practice is being imparted
to ETL employees and shop electrical regularly
81

Training details
ETL Employees

Shop Electrical

7
6
5

4
3
2

6
4

1
0

Feb'15 March'15April'15 May'15 Jun'15

Jul'15

Aug'15

Total No.Of Employees trained till

date 40

82

Cost Benefit Analysis

Cost
Cost to
to company
company for
for providing
providing
external
external training
training per
per Employee
Employee

Rs.50,000/Rs.50,000/-

Total
Total No.
No. Of
Of employees
employees trained
trained with
with
the
the help
help of
of test
test Jig
Jig

40
40

Cost
Cost to
to company
company If
If 30
30 employees
employees
were
were sent
sent for
for training
training

50,000*40=
50,000*40=
Rs.20,00,00
Rs.20,00,00
0/0/-

Savings because of In house training

Rs.20,00,00
0/83

SL NO

Tested Card details

CARD TYPE

QTY

DESCRIPTION

1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16

6ES7 314-6CG03-0AB0
6ES7 153-2BA02-0XB0
6ES7 323-1BL00-0AA0
6GK7 343-1EX11-0XE0
6ES7 315-2AH14-0AB0
6GK7 343-1EX30-0EX0
6GK7 343-1EX30-0EX0
6ES7 314-6CG03-0AB0
6GK7 343-1EX11-0XE0
6ES7 307-1EA00-0AA0
6ES7 315-6FF01-0AB0
6ES7 322-1BH01-0AA0
6ES7 321-1BH02-0AA0
6ES7 321-1BL00-0AA0
6ES7 322-1BL00-0AA0
6ES7 321-1FH00-0AA0

1
1
1
1
1
1
1
1
1
1
1
4
3
3
3
5

CPU
INTERFACE MODULE
DIGITAL I/O MODULE
COMMUNICATION PROCESSOR
CPU
COMMUNICATION PROCESSOR
COMMUNICATION PROCESSOR
CPU
COMMUNICATION PROCESSOR
POWER SUPPLY
CPU
SM322 DIGITAL O/P MODULE
SM321 DIGITAL I/P MODULE
DIGITAL INPUT MODULE
DIGITAL OUTPUT MODULE
16 CHANNEL DIGITAL INPUT CARD

17

6ES7 972-0AA02-0XA0

Profbus repeater

18
19
20

6ES7 953-8LL20-0AA0
6ES7 313-5BF03-0AB0
6ES7 953-8LF20-0AA0

1
1
1

25
26

6ES7414-4HM14-0AB0
6ES7343-1CX10-0XE0

2
1

28

6GK7443-5DX04-0XE0

MICRO MEMORY CARD-2MB

CPU 313C,64 KB,24DI/16DO,4AI,2AO
MICRO MEMORY CARD 64KB
MEMORY CARD FOR S7 400. FEPROM
4MB
SIMATIC S7-400H RACK UR2
POWER SUPPLY 10A
POWER SUPPLY 2A
S7 414 H CPU
S7 300 ETHERNET CP
COMMUNICATION PROCESSOR CP4431
COMMUNICATION PROCESSOR CP4435 EXTENDED
IM 153-2, ET200M INTERFACE
MODULE
OPTICAL LINK MODULE G11

STATUS
TESTED OK
TESTED OK
TESTED OK
TESTED OK
TESTED OK
TESTED OK
TESTED OK
TESTED OK
TESTED OK
TESTED OK
TESTED OK
TESTED OK
TESTED OK
TESTED OK
TESTED OK
TESTED OK
Tested NOT
OK
TESTED OK
TESTED OK
TESTED OK

During Testing found one card was faulty

6ES7 952-1KM00-0AA0
1
TESTED OK
It21
was
still
under
warranty,
so
supplier
22
6ES7400-1JA11-0AA0
2
TESTED OK
23
6ES7407-0KA02-0AA0
2
TESTED OK
replaced
card
free
of
cost.
24
6ES7307-1BA00-0AA0
1
TESTED OK
TESTED OK
TESTED OK

27
6GK7443-1EX20-0XE0
2
OK
Saving
because of timely
testing Rs TESTED
30,000

29

6ES7153-2BA02-0XB0

30

6GK1503-2CB00

TESTED OK
TESTED OK
TESTED OK

84

Benefits
of
establishing
Benefits of establishing
Expertise
TestUndersta
jig
aaonTest
jig
nd-ing of
Siemens
PLC to
team
members

Testing of
faulty
and
repaired
cards

nd-ing of
software
and
hardware
concepts

In
Hous
e
Test
JIg

Training
and
hands on
practice
to others

Testing of
spare
cards
within
warranty
Simulati
on of
faults
and
learning
85

Participation in QC and developing a

Test Jig in house has helped us in..
Improving confidence
Creating interest in
learning new things
eam
t
f
o
t
n
e
m
p
o
l
e
Dev
riytstematic
is
p
s
a
Working in
rlf belief
e
n
n
a
m
e
s
Improving

86

Venue
Meeting Day
Time

: RMHP-ASO
: Saturday
: 4 5 PM.

MILESTONE CHART
TEAM ACTIVITY PLAN

#
week 4-5
s

TASK

6-7

8-9

10-12

22 - 23

24 - 25

15-16

17

18 - 21

Definition of
problem
Problem
analysis
Identification of
causes
Root Cause
Analysis

Data analysis

Developing
Solution
Foreseeing
Probable
resistance
Trial
Implementation
Regular
Implementation
Follow up and
Review

2
22
23-Aug14

Showeet.com

13-14

Total no. of weeks

Actual

Planned

rd Jan
24rd
15

87

This work is licensed under a

TOOLS AND TECHNIQUES USED

1. BRAINSTORMING
2. DATA COLLECTION
3. FLOW DIAGRAM
4. LINE GRAPHS
5. STRATIFICATION
6. PARETO DIAGRAM
7. CAUSE AND EFFECT DIAGRAM
8. 4W & 1H TECHNIQUE
9. BAR GRAPHS

88

Achievements
Selected as best
QC in department
level.

Bagged 1st place

in Plant level QC
quiz competition
PLQC-2015

89

Next project

AC drive related
problems

90

We express our sincere

thanks to QCFI & Vizag steel
plant management for giving
us this opportunity to show
case our project
Th
a
yo nk
u
91

NY SUGGESTIONS PLEA

92

Arise! Awake! And Stop not

till the goal is reached
- Swami
Vivekananda

Thank
You

94