Kobetsu Kaizen Zero Air Leakege Presentation

TPM Club India Jishu Hozen Pillar
TAFE MOTORS AND TRACTORS

LIMITED.
ALWAR . RAJASTHAN
KOBETSU KAIZEN
( ZERO COMPRESSED AIR LEAKEGES)
TPM Club India

THEME - COMPRESSED AIR LOSSES

IDEA - NO COMPRESSED AIR LOSSES
LEAKEGES LEVEL ON 2ND. MARCH.2004 - 174 CFM
DESIRED LEVEL BY 2ND.MARCH 2005 - 30 CFM
LEVEL ACHIEVED IN MARCH.2005 - 29.0 CFM
LEVEL ACHIEVED IN MARCH 2006 - 22.2 CFM
TARGET LEVEL BY NOV’06 - 15.0 CFM
COMPRESSOR CAPACITY - 250 CFM

VALIDATED CAPACITY - 239 CFM
TPM Club India

200
174 174 Target- Industry best air losses - 30 cfm by march`05
180 Leading target - 10 cfm by mar`07
160
140 115
120
100 75
70
80 64
5353 51 25.2
60 51
43
24.7
24.5 24.5 23.5 23.2 22.3
29 29 24.5
40 29
20
24.5 23.2
0 apr`0 may`0 jun`0 sep`0 oct`0 nov`0 dec`0 jan`0 feb`0 M ar.0 M ay.0 June. Aug.0 Sep.0 Oct`0 Nov` Jan.0 Feb.0 M ar.0
jul`04 Jul.05
4 4 4 4 4 4 4 5 5 5 5 05 5 5 5 05 6 6 6
CFM 174 174 115 75 64 53 53 51 51 43 29 29 25.2 24.7 24.5 24.5 24.5 24.5 23.2 23.2 22.3
ROOT CAUSE OF AIR LOSSES .
(1) LONG LENGTH FLEXIBLE PIPE USED FOR PIPE CONNECTIONS
( 2 ) THREADED PIPE JOINTS USED IN AIR LINE
( 3 ) PIN TYPE QUICK RELEASE COUPLING USED
( 4 ) AIR BLOW GUN OF 6 MM ORIFICE SIZE USED
( 5 ) IN AUDIBLE LEAKAGES IN OVER HEAD LINE
( 6 ) USE OF AIR FOR CHIPS REMOVAL
( 7 ) MULTIPLE JOINTS / BEND IN AIR LINE

(8) NO SYSTEM OF AIR CONSUMPTION MEASUREMENT
(9) longer air circuits

EQUIPMENT PERFORMANCE VALIDATION ( COMPRESSOR GA-30)
COMPRESSOR CAPACITY -160 CFM
METHOD ADOPTED - PUMP UP TEST

TEST CARRIED OUT JOINTLY BY M/S.DEVKI-ENERGY CONSULTANTS & EICHER
COMPRESSOR MODEL - GA30 C
VOLUME OF RECEIVER / OIL SEPERATOR /MOISTURE SEPERATOR/PIPINGS - 64.54 CFT
INITIAL PRESSURE - 5KG/CM2
FINAL PRESSURE - 6 KG/CM2 Capacity ( cfm ) =(Pinitial - Pfinal ) * volume cft *

time ( seconds )
VOLUME-- 64.54 CFT
TIME TAKEN IN PRESSURE BUILDING - .42 MINUTES
CAPACITY ARRIVED - 153 CFM
SITE TESTING ERRORS +/- 5% ( AS PER DEVKI CONSULTANTS )
VALIDATED CAPACITY 160 CFM

COMPRESSOR CAPACITY -250 CFM
METHOD ADOPTED - PUMP UP TEST

TEST CARRIED OUT JOINTLY BY M/S.DEVKI-ENERGY CONSULTANTS & EICHER
COMPRESSOR MODEL - GA45W
VOLUME OF RECEIVER / OIL SEPERATOR /MOISTURE SEPERATOR/PIPINGS - 64.54 CFT
INITIAL PRESSURE - 5KG/CM2
FINAL PRESSURE - 6 KG/CM2 Capacity ( cfm ) =(Pinitial - Pfinal ) * volume cft *

time ( seconds )
VOLUME-- 64.54 CFT
TIME TAKEN IN PRESSURE BUILDING - .27 MINUTES
CAPACITY ARRIVED - 239 CFM
SITE TESTING ERRORS +/- 5% ( AS PER DEVKI CONSULTANTS )
VALIDATED CAPACITY 250 CFM

PLANT AIR LEAKAGE TESTING

DROP DOWN TEST
COMPRESSOR --GA45 DATE
Feb.2004
28 .11.04
CONDITION TIME LOAD/UNLOAD TIME
LOADING 03.43.03
134
UNLOADING 03.45.17
45
LOADING 03.46.02
136
UNLOADING 03.48.18
45
LOADING 03.49.03
136
UNLOADING 03.51.19
45
LOADING 03.52.04
TOTAL -LOADING 407

TOTAL-UNLOADING 135
TOTAL TIME 542
LOADING TIME x 239

LEAKAGE IN CFM =
TOTAL TIME
= 407 * 239 / 542 = 179 cfm

PLANT AIR LEAKAGE TESTING

DROP DOWN TEST
COMPRESSOR --GA45 DATE 15.01.2006
CONDITION TIME LOAD/UNLOAD TIME

(IN SECONDS)
UNLOADING 16.18.43
302
LOADING 16.23.45
31
UNLOADING 16.24.16
304
LOADING 16.29.20
32
UNLOADING 16.29.52
307
LOADING 16.35.59
30
UNLOADING 16.36.29
306
LOADING 16.42.35
31
UNLOADING 16.43.06
303
LOADING 16.49.09
32
UNLOADING 16.49.41
LOADING TIME x 239
LEAKAGE IN CFM =
TOTAL TIME
= 2.60X250 / 27.97
= 22.2 cfm
AIR BLOW GUN

BEFORE AFTER
LEGRIS make air blow gun PILOT make air blow gun used
used - high consumption of - low consumption of air
air
BEFORE
AIR BLOW GUN
AFTER
Air blow gun connected with Air blow gun connected with
jublee clamp - air leakages point leakproof quick fittings to .
AIR BLOW GUN Date-21.09.04

BEFORE
AFTER
Air pipe connected with jublee Air pipe connected with leakproof
clamp - air loss point quick fittings to prevent air loss.
Date-
QUICK RELEASE COUPLING 21.10.2004
BEFORE AFTER
QRC - Roller type sealing QRC - ball type sealing

ULTRASONIC AIR LEAKAGE

Date-17.08.04
DETECTOR
ULTRASONIC AIR LEAKAGE DETECTOR

USED TO DETECT INAUDIBLE LEAKAGES
ULTRASONIC AIR LEAKAGE

Date-17.08.04
DETECTOR
ULTRASONIC AIR LEAKAGE DETECTOR USED TO

DETECT INAUDIBLE LEAKAGES
AIR FLOW METER WITH TOTALIZER
AIR FLOW METER WITH TOTALIZER INSTALLED IN COMPRESSED

AIR CIRCUIT - REGULAR MONITORING OF AIR CONSUMPTION
Date-21.09.04
COMPRESSED AIR LINE
Air pipe connected with jublee clamp - Air pipe connected with thread joints -
air leakages point air leakages point
COMPRESSED AIR LINE

Date-21.09.04
Air pipe with welded leakproof quick fittings.

QUICK RELEASE COUPLING
Date-21.09.04
BEFORE AFTER
QRC - ROLLER TYPE GRIPP QRC -BALL TYPE GRIPP

QUICK RELEASE COUPLING Date-

21.05.05
QRC WITH MULTIPLE JOINTS QRC WITH SINGLE JOINT

SOURCE OF AIR LEAKAGES NO AIR LEAKAGE
COMP.AIR POWER CONS./Eq.ENGINE
9
8 38818
7
6 40111 37791
34744
5
4
3
2
1
0
June'0
023 034 045 Apr.05 May.05 July05 Aug'05 Sep.05 Oct.05 Nov.05 Dec.05 Jan.06 Feb.06
5
Series1 7.72 4.8 3.72 3.38 3.57 4.12 3.73 3.49 3.17 2.67 2.98 3.3 2.65 3
COMP.AIR COST/ Eq. ENGINE

45
40
35
30
25
20
15
10
5
0
APR.0 MAY.0 JUNE.0 JULY0 AUG'0 OCT`0 NOV`0
023 034 045 SEP`05 DEC.05 JAN'06 FEB.06
5 5 5 5 5 5 5
Series1 38.5 24 21.7 18.59 19.63 22.66 20.5 19.18 17.46 13.6 17.88 18.15 16.43 18.5
AIR CONS.IN Ft.3/Eq.ENGINE
600
500
400
300
200
100
0
APR.0 MAY0 JULY0 AUG'0 OCT`0 NOV.0
023 034 045 JUN.05 SEP`05 DEC.05 JAN.06 FEB.06
5 5 5 5 5 5
Series1 478 297 236 158 174 180 177 167 155 142 164 174 137 153
FOCUSSED IMPROVEMENT ( KOBETSU -KAIZEN )
COMPRESSED AIR LEAKEGES ELIMINATION
METHODOLOGY ADOPTED - GAMBA APPROACH
TARGET : TO BECOME INDIAN INDUSTRY BEST BY MAR.' 05 ( > 90% utilisation)

. TO BECOME WORLD CLASS IN COMPRESSOR UTILISATION ( > 92% utilisation) BY-Mar.'06
PLANT TO OPERATE WITH 160 CFM COMPRESSOR ( 250 CFM TO DISCONTINUE BY MAR.06 )
ACTIVITY INDEX ACTIVITY RESULT INDEX MANAGEMENT INDEX
Identification of air leakeges areas Reduction in mfg.var.cost(power) Saving of 182953 units (Kwh)
Esteblishment of real cause 2.92 Units /eq.eng in - 034 Saving of Rs. 10 - Lac
Real solution to leakeges 1.08 units/eq.eng in - 045
Elimination of compressed air leakeges 0.72 Units/eq.eng in - 056
Sustainance thru ultrasonic scanning

OPTIMUM UTILISATION OF AIR COMPRESSOR

487 CFM- 90 kW
250 CFM- 50 kW
160 CFM - 30 kW
Before
Before
After
STEPS FOR SUSTAINANCE
REPLACEMENT OF THREADED JOINTS WITH

WELDABLE JOINTS. ( PERMANENT MEASURE)
ULTRASONIC TEST OF AIR CIRCUITS.
STANDRADIZATION OF SPARES ( PU-PIPES /QRC/AIR
GUNS )
OPERATOR’S AUTONOMOUS CHECK POINT
TPM Club India

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TPM Club India Jishu Hozen Pillar

TAFE MOTORS AND TRACTORS

TPM Club India

THEME - COMPRESSED AIR LOSSES

COMPRESSOR CAPACITY - 250 CFM

TPM Club India

ROOT CAUSE OF AIR LOSSES .

(1) LONG LENGTH FLEXIBLE PIPE USED FOR PIPE CONNECTIONS

( 2 ) THREADED PIPE JOINTS USED IN AIR LINE

( 3 ) PIN TYPE QUICK RELEASE COUPLING USED

( 4 ) AIR BLOW GUN OF 6 MM ORIFICE SIZE USED

( 5 ) IN AUDIBLE LEAKAGES IN OVER HEAD LINE

( 6 ) USE OF AIR FOR CHIPS REMOVAL

( 7 ) MULTIPLE JOINTS / BEND IN AIR LINE

(9) longer air circuits

EQUIPMENT PERFORMANCE VALIDATION ( COMPRESSOR GA-30)

COMPRESSOR CAPACITY -160 CFM

METHOD ADOPTED - PUMP UP TEST

COMPRESSOR MODEL - GA30 C

VOLUME OF RECEIVER / OIL SEPERATOR /MOISTURE SEPERATOR/PIPINGS - 64.54 CFT

INITIAL PRESSURE - 5KG/CM2

FINAL PRESSURE - 6 KG/CM2 Capacity ( cfm ) =(Pinitial - Pfinal ) * volume cft *

TIME TAKEN IN PRESSURE BUILDING - .42 MINUTES

CAPACITY ARRIVED - 153 CFM

SITE TESTING ERRORS +/- 5% ( AS PER DEVKI CONSULTANTS )

VALIDATED CAPACITY 160 CFM

COMPRESSOR CAPACITY -250 CFM

METHOD ADOPTED - PUMP UP TEST

COMPRESSOR MODEL - GA45W

VOLUME OF RECEIVER / OIL SEPERATOR /MOISTURE SEPERATOR/PIPINGS - 64.54 CFT

INITIAL PRESSURE - 5KG/CM2

FINAL PRESSURE - 6 KG/CM2 Capacity ( cfm ) =(Pinitial - Pfinal ) * volume cft *

TIME TAKEN IN PRESSURE BUILDING - .27 MINUTES

CAPACITY ARRIVED - 239 CFM

SITE TESTING ERRORS +/- 5% ( AS PER DEVKI CONSULTANTS )

VALIDATED CAPACITY 250 CFM

PLANT AIR LEAKAGE TESTING

CONDITION TIME LOAD/UNLOAD TIME

TOTAL -LOADING 407

LOADING TIME x 239

= 407 * 239 / 542 = 179 cfm

PLANT AIR LEAKAGE TESTING

CONDITION TIME LOAD/UNLOAD TIME

AIR BLOW GUN

AIR BLOW GUN Date-21.09.04

QRC - Roller type sealing QRC - ball type sealing

ULTRASONIC AIR LEAKAGE

ULTRASONIC AIR LEAKAGE DETECTOR

ULTRASONIC AIR LEAKAGE

ULTRASONIC AIR LEAKAGE DETECTOR USED TO

AIR FLOW METER WITH TOTALIZER

AIR FLOW METER WITH TOTALIZER INSTALLED IN COMPRESSED

COMPRESSED AIR LINE

Air pipe with welded leakproof quick fittings.

QRC - ROLLER TYPE GRIPP QRC -BALL TYPE GRIPP

QUICK RELEASE COUPLING Date-

QRC WITH MULTIPLE JOINTS QRC WITH SINGLE JOINT

COMP.AIR POWER CONS./Eq.ENGINE

COMP.AIR COST/ Eq. ENGINE

AIR CONS.IN Ft.3/Eq.ENGINE

FOCUSSED IMPROVEMENT ( KOBETSU -KAIZEN )

COMPRESSED AIR LEAKEGES ELIMINATION

METHODOLOGY ADOPTED - GAMBA APPROACH