Decay: natural or forced A Culture for Prevention Adherence to Process Conditions/ Process Values Continuous Innovations in Process, Products, etc. For this: Challenge the way we Think, the way we Act Develop the Organizational Capability (MCpk) for challenging and improving on the status quo Key Objective Develop Values, Beliefs and Attitudes for rejecting Abnormalities/ Deviations from World Class Standards. And, we develop an Abnormality Free Culture that is a prerequisite for QCDIP.
And
Use Weapons, Tools and Techniques for achieving our Mission. First Step: Full use of Five Senses There is a saying: Keep your eyes, ears, nose and hand alert while working in a plant The basic mission is to ensure normal operations: Eyes: any abnormal disorder in level, flow, process parameter, metering, control, operation, etc. Ears: any abnormal sound, if installation disorder Nose: any abnormal smell of overheating, burning, leakage Hand: instant feel of temperature, vibrations, elasticity, etc. Feel: feel for irritation, etc. Unveil the Abnormalities Minor Flaws Accumulation Dust, Dirt, Powder, Oil, Grease, Rust, Paint, Coolant, Soil, Ash, Sludge, Sweep, Splash, Stain, Sogged, Leak-solified, Fumes, Debris, Fibers, Straws Bulging, Cracking, Crushing, Deformation, Chipping, Bending, Blasting, Bursting, Insulation / Coating / Lining, Corroding, Softened surface Damage Shaking, Falling out, Tilting, Eccentricity, Wear, Distortion, Misaligned, Rattling Sound, Non matching, Swaying, Locking, Back lash, Loose contacts Play Slackness Belts, Chains, Rollers / Spindles, Hangers, Hoods, Stays, Cables, Props, Fasteners Ropeways, Bearings, Hinge & Locking Unusual Noise, Overheating, Vibration, Strange smells, Discoloration, Incorrect & Improper calibration, Improper fluid flow, Pressure/Temperature Oxidation, Improper operation, Starvation, Cavitation, Water Hammer Abnormal Phenomenon Blocking, Hardening, Accumulation of Debris and of Chemicals, Peeling, Malfunctioning, Choking, Sticky / Viscous flow, Inconsistent, Scaling Adhesion Minor Flaws Lubrication/Coolant Insufficient, Unidentified & Unsuitable, Sub grade, Hot, Carbonized, Gritty & Dirty, Foaming, Choked Dirty, Damaged or Deformed lubricant Inlets, Faulty / Long / Haphazard lubricant pipes, Inadequate Pressure & Flow Lubrication Supply Dirty / Damaged / Leaking, Sight glasses, Distant location, Improper type, Incorrect scale and readings. Oil Level Gauges Unfulfilled Basic Conditions Tightening Spring & Fasteners - Slackness, Missed / Crossed / Crushed Threaded, Too long, Corroded, Wrong / Damaged Washer, Unsuitable / Over Tight, Improper Gasketing, Mis- matched seats, (Tong and Grooves) Improper MOC and Method Measuring Instruments Dirty / Damaged, Faulty; Pressure / Temperature / Volume Weight / Flow / Power / Voltage / Current Records Meters, Integrators & Recorders Unfulfilled Basic Conditions Equipment & Machines Under capacity, Mismatched, Inadequate control devices, Sluggish, Mal-routed, Wrong feeders, Inadequate Stirring / Mixing / Agitation / Decanting, Crushing / Sizing / Grading, Disruptive Material Flow and Movement, Restriction / Obstruction Defective Design Nuts and Bolts, Equipment, Belts, Chains, Bearings, etc. Lack of Maintenance No Maintenance Schedules, Improper Maintenance Planning / Resources Unfulfilled Basic Conditions Cleaning Shape, Construction, Covers, Layout, Footholds, Space around the Machine and Equipment Covers, Construction, Layout, Instrument Position, Orientation, Main Panel / Meters / Recorders, Operating Range Display, Material Level in Silo / Tankers / Wagons / Gear Boxes Checking Position of Inlet, Construction, Shape Height, Footholds, Lubricant Overflow, Drainage Lubricating Inaccessible Places Machine Layout, Position of Valves, Switches and Levers, Footholds, Starters, Breakers Operation Covers, Construction, Layout, Size, Foothold, Dusty / Fuming / Dark / Hotter Zone Tightening Position of Pressure Gauges, Thermometers, Valves, Thermo- regulators, Relays, Controllers Flow meters, Moisture gauges, Vacuum gauges, Level sensors, Limit / Time Switches Adjustments Inaccessible Places Product Leaks, Seepage, Overage, Spent, Spoiled, Spills, Spurts, Scatter, Overflow Leaks, Spills, Spurts, Scatter, Overflow, Overage Spent Spoiled Raw Materials Leaking, Spilled, and Seeping Lubricating Oils, Hydraulic Fluids, Fuel Oil, etc. Lubricants Leaking compressed air, Gasses, Steam, Vapors, Exhaust Fumes, Acid Fumes, Process Fumes Gases Contamination Source Liquid Leaking, Spilt and Spurting Cold Water / Hot Water, Half - finished Products, Cooling / Washing, Waste Water, Liquor / Oil, and Effluents etc. Flashes, Cuttings, Packaging Materials, Non conforming Product, Sand, Gritty Matters, Spent Liquor, Set / Over aged Resin, Rubber Scrap Contaminants brought by People / Fork-lift trucks, Infiltrating through cracks in Buildings, Pollutants ingress Others Contamination Source Foreign Matter Inclusion, Infiltration and Entrainment of Dirt, Rain Impurity, Rust, Chips, Wire Scraps, Insects Dropping, Jolting, Collision, Vibration, Skidding / Slipping, Sudden Stoppage, Thermal Stress, Quenching Shock Wide Variation, Absorption, Condensation Leak, Too Much, Too Little, Infiltration, Condensation Moisture Quality Defect Sources Grain Size Crystallization, Crushing, Screening, Disintegration, Separator Classifiers, Decanters, Abnormalities in Screens, Centrifugal Separators, Compressed Air Separators Concentration Inadequate Warming, Heating, Compounding, Mixing, Evaporation, Stirring Inadequate Warming, Heating, Compounding, Mixing, Evaporation Viscosity Quality Defect Sources Machinery & Equipment Pumps, Fans, Blowers, Compressor, Columns, Tanks, Agitators, Vessels, Elevators, Conveyors, Crushers, Pulverizes, Disintegrators, Ball - Mills, Heat Exchangers, Coolers, Filters, Kiln, Dryers, Transformers, Press, Cells, Reformers, Extruders, Granulators, Piping Equipment Pipes, Hoses Ducts, Valves, Dampers, Measuring Instruments Temperatures / Pressure Gauges, Voltmeters / Ammeters, Electronic Ears, Sound / Gas Emission Monitoring, Relays Switches, Regulators Unnecessary Items