Quality Circle - EM58M - AUQCC

1
EM-58M Quality Circle EM58M

Electrical Machines Division, BHEL Hyderabad
We are proud to be an Employee of 2
BHEL Hyderabad
The Founder of Quality Circle in India (1981)
Thanks To Sri S.R. Udpa,

Retd. GM Operations, BHEL Hyderabad
EM-58M Electrical Machines Division, BHEL Hyderabad
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About BHEL
A Maharatna Company, established in 1963.
Integrated power plant equipment manufacturer.
One of the largest engineering and manufacturing
companies in India in terms of turnover.
BHEL has a share of 59% in India's total installed
generating capacity contributing 69% (approx.) to the total
power generated from utility sets.

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About BHEL
BHEL have-
a. 17 manufacturing divisions
b. Two repair units
c. Four regional offices
d. Eight service centres
e. 15 regional centres

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BHEL Hyderabad
The Hyderabad unit was set up in 1965.
Started its operations with manufacturing
of Turbo-generator sets.
BHEL-Hyderabad unit has collaborations
with world renowned MNCs like M/S
General Electric, USA, M/S
Siemens,Germany, M/S Nuovo Pignone,
etc.
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Products - BHEL Hyderabad
Steam Gas Turbines Compressors Turbo- Heat

Turbines generators Exchangers
Pumps Switch Gears Gear Boxes Oil Rigs Pulverisers

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Work Area-Heavy Machine Shop

Facilities Available Heavy Machine Shop 8
CNC Centre Lathe 3 Nos.

CNC Slot Milling Machine 1 No.
CNC Horizontal Boring Machine 1 No.
CNC Vertical Turning Lathe 1 No.
Radial Drilling Machine 2 Nos.
Gun Drilling Machine 2 Nos.
Horizontal Boring Machine 2 Nos.
Team Profile EM58M 9
Pradeep Kumar Verma Jitendar Yadav E. Sivakumar N. Chetan

Leader Dy. Leader Member Member
Sridhar Reddy L Jeevan Kumar

Facilitator Area Co-ordinator

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Team Vision
To develop a productive work culture in shop through
innovation by becoming model quality circle.
Mission
Saving the Material, Time and Energy through innovation.

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Team Values
S P I R I T
Safety People Integrity Responsibility Innovation Team Work
We anticipate
Our can do
We are ethical We are change and
We Work We respect spirit delivers
and accountable respond with
Safely one another top
trustworthy for our actions creative
performance
solutions

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Performance Record - Achievements
Par-Excellence Award Gold Award 2nd Prize

NCQC-2016 CCQC-2016 AUQCC 2016
(New Circle Category)
(Raipur) (Hyderabad Chapter) BHEL Hyderabad

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Performance Record
MEETING PLANNED & CONDUCTED DURING YEAR 2017
Quality Circle Formation Date 18-05-2016
Meeting Day Monday Meeting Time 14:30 to 15:30
1 Number of Meetings Planned 27
2 Number of Meetings Conducted 27
3 Average Percentage of Attendance 98%
4 Problems Identified 61
5 Problems Solved Till Date 7
6 Work in Progress 2
7 Problems to be Solved 52

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Performance Record
Implementation Status
35
30
30
25
20 19
15
10 7
5 2 3
0 0 0 0
0
Category A Category B Category C
Completed In Progress To be started

Methodology Used Deming Wheel 15

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Table of Contents
S.No. Contents Slide No.
1 Problem Identification 17-22
2 Selection of Problem 23-26
3 Problem Description 27-34
4 Problem Analysis 35-38
5 Identifying the Causes 39-40
6 Finding the Root Causes 41-45
7 Data Analysis 46-51
8 Developing Solution 52-57
9 Foreseeing Possible Resistance 58-59
10 Trial Implementation 60-64
11 Regular Implementation 65-66
12 Follow-up & Review 67-69
13 Abstract 70-71
14 EM-58M
Future Plans
72-73
1- Problem Identification
Methodology / Tool / Technique Used-
ABC Analysis
Pie Chart
17
18
Problem Identification
Brainstorming done to identify the problems in shop and
categorized in A, B, & C category
Category Solving Method
A Within the scope of QC team
B Involvement of other department is a necessity
C Management sanction may be needed in implementing

the solution
Problem Identification 19
S. No. Problems Identified Category

1 Manufacturing of side and bottom supports of 43MW rotors for slotting on slot milling machine B
2 Manufacturing of boring bar for lesser dia jobs A
3 Operator platform manufacturing B
4 Engaging of crane during setting of jobs on horizontal boring machine A
5 Maintaining 5-S culture in shop A
6 Non availability of tooling for machining of 204- series body of sealing A
7 High vibration and more machine cycle time on CNC vertical turning lathe while retaining ring machining A
8 High ovality/runout during finish machining of rotor A
9 Journal overheating during finish machining of rotor A
10 Coolant falling over steady rest motor A
11 Clamping of 270MW TG rotor field lead core bar for parting plane machining B
12 Develpoment of tools for 270MW end shield Groove machining C
13 Developement and Manufacturing of New Key Way milling attachment for Horizontal Boring Machine (WD160) A
14 Using of screw jack for horizontal setting of rotor A
15 Utilization of rotor remaining portion in making hubs A
16 Surface finish improvement of rotor TS flange A
17 Bush manufacturing to hold the boring bar in holder B
18 Time cycle reduction during removal of armature from repair rotor A
19 Manufacturing of soft jaws for centre lathe (SRM-1250) B
20 High deviation during bearing spherical machining A

Problem Identification 20
S. No. Problems Identified Category

21 Manufacture of Tool Holder & Tool for Machining of NTPC TANDA Body Of Sealing B
22 Establishment of Exciter side coupling holes drilling on Tacchi slotting machine for 270MW Rotor. A
23 Copper Conductor Die Milling on HB WD-160 B
24 Drilling of 270MW Flange Holes A
25 Machining of Groove on End Shield A
26 Lead Hole Extension Bar Manufacture and Machining of Lead Hole of ONGC Hazira (4pole) Rotor B
27 R-40 Radius Machining for springs on Conventional Machine WD160 A
28 Cycle time reduction in marking of 150MW stator frames A
29 Cycle time reduction in Job setting of 270 MW Stator Frame on PAMA CNC Machine. A
30 Cycle Time reduction in Drilling of Turbine Side Coupling Holes on CNC Slotting Machine. B
31 Machining of 20x45 degrees chamfer on 270 MW Field lead Core Bar A
32 Inclusion of tool list in technological process for a critical operation A
33 Increasing Machinability of OIL RIG component at Electrical Machine Shop. B
34 Material Saving by re-using the damaged Studs A
35 Manufacturing of fixture for copper lead parting plane milling B
36 Extension of lead hole of 201 Tata Rotor A
37 Development and Manufacturing of New Key Way milling attachment for Horizontal Boring Machine (WD160) B
38 Safeguarding the wire harness and pneumetic hose pipes A
39 Modification in milling attachment for moon slot milling B
40 Solving of non-moving Indexable Disc milling cutter for Moon Slot operations . A

S. No.
Problem Identification Problems Identified
21
Category
41 Problem during quality inspection- run-out measurement on TG generator A
42 Problem during turning of steps while machining retaining ring for FR-VI rotor A
43 Modification of steady rest for centre lathe SUT-160 A
44 Cable trench cover to be provided on Tacchi centre lathe. B
45 Improving the process of Tapping bearing pedestal fixing holes on TG Stator frame. B
46 Standard log sheet not available for 201 series bearing A
47 Development of GO-NOGO gauge for copper bar inspection of width and thickness B
48 Standard log sheet not available for 261 series bearing A
49 Non availability of stands for Heller slotting machine cutters A
50 Non availability of stands for slings and belts for cranes A
51 Both GO-NOGO gauge entering in stator frame holes A
52 Non-availability of tools for making helical grooves on bearing C
53 Manual feeding of attendance in SAP during standard hours booking B
54 Dent-marks on steady rest diameter of rotor A
55 Poor surface finish on rotor A
56 Problem during use of "U" drill for drilling of coupling holes on rotor A
57 Frequent damage of carriage roller on tacchi slotting B
58 Frequent problem of internal coolant supply on HBM_Pama B
59 Poor surface finish on stator during machining A
60 No proper place for die-penetration test C
61 Machining of 110MW spare fan blade A

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Problem Categorization
C Category Problem Category
5%
Problem Category No. of Problems B Category
31%
A Category 39
A Category
64%
B Category 19
C Category 3 A Category B Category C Category

2- Selection of Problem
Ranking Method
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24
Problem Selection
Type A problem selected based on members priority.
Tool Used- Ranking Method
Each member have scored the problem to be selected based on scale 1-5.
1 is for lowest priority and 5 is for highest priority .

S.
Problem Selection PROBLEM
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PROBLEMS IDENTIFIED PKV JTY ESK NC Total

NO. CATOGERY
1 Manufacturing of boring bar for lesser dia jobs A 3 2 2 3 10
2 Engaging of crane during setting of jobs on horizontal boring machine A 4 3 3 2 12
3 Maintaining 5-S culture in shop A 3 3 3 3 12
4 Non availability of tooling for machining of 204- series body of sealing A 3 3 5 2 13
5 High vibration and more machine cycle time on CNC vertical turning lathe while retaining ring machining A 3 3 5 3 14
6 High ovality/runout during finish machining of rotor A 3 4 3 3 13
7 Journal overheating during finish machining of rotor A 3 4 3 3 13
8 Coolant falling over steady rest motor A 4 4 3 5 16
9 Developement and Manufacturing of New Key Way milling attachment for Horrizontal Boring Machine (WD160) A 2 2 2 2 8
10 Using of screw jack for horizontal setting of rotor A 3 2 3 2 10
11 Utilization of rotor remaining portion in making hubs A 3 3 4 4 14
12 Surface finish improvement of rotor TS flange A 3 4 3 3 13
13 Time cycle reduction during removal of armature from repair rotor A 3 3 3 4 13
14 High deviation during bearing spherical machining A 5 5 5 5 20
15 Establishment of Exciter side coupling holes drilling on Tacchi slotting machine for 270MW Rotor. A 3 3 4 3 13
16 Drilling of 270MW Flange Holes A 3 3 4 3 13
17 Machinging of Groove on End Shield A 3 2 2 3 10
18 R-40 Radius Machining for springs on Conventional Machine WD160 A 2 2 2 3 9
19 Cycle time reduction in marking of 150MW stator frames A 4 3 3 3 13
20 Cycle time reduction in Job setting of 270 MW Stator Frame on PAMA CNC Machine. A 4 3 3 3 13

MILESTONE CHART
Quality Circle Department Facilitator Team Members
EM-58-M EM Production Sridhar Reddy L Pradeep Kumar Verma Leader
Project High deviation during bearing spherical machining Jitendar Yadav Dy. Leader
Project No QCMMP/EM58M/2017/1 Start Date 13-02-2017 End Date 15-05-2017 E Sivakumar Member
Meeting Day Monday 14:30 to 15:30 No. of Projects Completed 3 N Chetan Member
S. No. Activity 1 2 3 4 5 6 7 8 9 10 11 12 Target Actual
1 Defining the Problem 27-02-2017 -
2 Analysing the Problem 20-03-2017 -
3 Identifying the Causes 27-03-2017 -
4 Finding the Root Causes 27-03-2017 -
5 Data Analysis 17-04-2017 -
6 Developing Solution 08-05-2017 -
7 Foreseeing Possible Resistance 08-05-2017 -
8 Trial Implementation 08-05-2017 -
9 Regular Implementation 15-05-2017 -

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10 Follow-up & Review 15-05-2017 -
3- Problem Description
Problem Definition
High Level Flow Diagram
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Problem Description 28
The Turbo-generator component Bearing Shell machining

operation being carried out on Horizontal Boring Machine (WD-160)
with special tool fly cutter and independent rotary table, in EM-
Heavy Machine Shop.
Bearing shell spherical dia. To be machined for various projects
varies from 220mm to 850mm
High machining cycle time
Poor surface finish of finished product due to 1.5m rotary table and
excess overhang length of RAM.
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High Level Flow Diagram
Machining of
Recieving material
Order for bearing Critical Machining of
from
manufacturing Components in Bearing Pedastal
Stores/Subcontract
Shop
Assembly of
Machining of
Finished Product Bearing
Bearing Shell
Components

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Problem Description
Turbo-Generator
Bearing Assembly TS

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Problem Description
Turbo-generator
Assembly Bearing Assembly

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Problem Description
Bearing Shell
Bearing Pedestal
Bearing Assembly

Spherical
Diameter
Surface
Roughness
Bearing
Shell
Spherical
33Diameter Bearing Shell Drawing
34
Problem Description
Bearing Shell Spherical Machining on Horizontal Boring Machine WD-160
Fly Cutter
Bearing Shell Horizontal Boring Machine

4- Problem Analysis
Data Collection
35
36
Data Collection
Deviation - Bearing Shell Spherical Dia. (2015 - 2017)
Work Order Drawing Value Max. Size Min. Size Piece Position Inspected Value
Position - 1 270.02
Pc-1 Position - 2 270.20
Position - 3 270.18
1226837708-13901001 270j6(+0.016/-0.016) 270.016 269.984
Position - 1 270.02
Position - 3 270.16
Position - 1 600.03
Position - 3 600.05
1024900800-13901001 600(-0.76/-0.146) 599.854 599.240
Position - 1 600.05
Position - 3 600.06
Position - 1 639.99
1027500300-13901001 640.1(-0.05) 640.100 640.050 Pc-1 Position - 2 639.80
Position - 3 639.98
Position - 1 634.97 Pos-2
Pos.- 3
1020220400-13901001 635.01(-0.05) 635.010 634.960 Pc-1 Position - 2 635.20
Pos.- 1
Position - 3 634.98

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Data Collection
Measurement of Surface Roughness
S. No. Project Work Order Piece Pos-1 Pos-2 Pos-3 Pos-4 Pos-5
1 TS 5.5 6.0 5.5 4.0 5.0
BRPL 1-2-268-377-08
2 ES 7.0 5.2 6.0 6.5 5.8
3 TS 6.0 5.4 5.0 6.0 5.8
Nasik 1-0-249-008-00
4 ES 4.0 3.8 4.8 5.0 5.5
5 TS 5.0 4.5 3.8 4.8 5.0 Pos-4
Pos-3
Arcelor Mittal 1-0-275-003-00
6 ES 3.5 4.4 3.6 5.2 6.8
7 TS 4.7 5.1 6.0 4.8 5.2
Maruti Suzuki 1-0-202-203-00
8 ES 5.0 4.6 5.2 4.6 3.8
9 TS 6.0 4.5 5.5 4.6 5.2
Nasik-5 1-0-249-006-00
10 ES 3.5 4.2 4.5 4.7 3.8
11 TS 5.2 5.8 4.5 5.1 6.0
Triveni-I 1-0-222-001-00
12 ES 3.8 4.6 3.8 4.2 5.0
Pos-5 Pos-2
13 TS 4.2 4.4 5.5 4.6 4.0
CPCL Chennai 1-0-260-063-00
14 ES 3.7 5.5 4.9 5.1 5.2
Pos-1
15 TS 6.5 5.6 4.8 5.2 5.0
Triveni-II 1-0-222-002-00
16 ES 3.6 4.8 4.5 4.2 5.2
17 TS 4.9 5.4 5.3 5.4 4.8
ONGC Hazira 1-0-202-212-00
18 ES 5.5 7.0 6.5 4.5 5.8
19 TS 5.2 5.8 6.1 6.5 7.2
Triveni-III 1-0-222-003-00
20 ES 7.2 4.2 3.8 5.4 5.2

38
Data Collection
MACHINING PARAMETERS
S.
Particulars Symbol Unit In Operation
No.
Speed 0.022
1 N RPM
(Table Rotation) (45min for one round)
2 Feed Rate S mm/rev 0.2 to 0.3
Depth of Cut on
3 t mm 3
dia
Machine Hourly Rs./Hrs
4 R 3,500
Rate .

5- Identification of Route Cause
Fishbone Diagram/Ishikawa Diagram
39
Fishbone (Ishikawa) Diagram
Machine Man
Hard Material Operator idleness Poor ergonomics
Machine Capability Less Utilization
Design Constraints Lengthy Process
Manual Operation
Operation Suitability Machine Capability More Cycle time
High Vibration Medical Problems
More Machining Time Frequent Absenteeism
Lack of Knowledge
Old Machine Excess RAM overhang Incompetent Trainer Personal Issues
Poor Training Ignorance Poor surface
Less Cutting Parameter Repeatness
finish, and
Frequent Damage of Tools Manual Excess RAM Repeated Cuts dimensional
overhang Process Inspection Method
Machine Capability Operation inaccuracies
Less Cutting Poor Planning
Material Wastage Measuring
Parameter
Operational Requirements Instrument
Lengthy Process
Market Demand
More Machining Allowance Manual Operation
Hard Material Customer
Requirement
Material Composition Design Constraints More Cycle Time
Design constraint
40
Material Method
6- Finding The Route Cause
Fishbone Diagram/Ishikawa Diagram
41
Finding TheCause
Route RouteAnalysis
Cause - Man 42
Man
Poor ergonomics
Operator idleness
Less Utilization
Manual Lengthy Process

Operation
Machine Capability More Cycle time
Frequent Absenteeism
Medical Problems
Lack of Knowledge
Incompetent Trainer Personal Issues Poor surface

Ignorance finish, and
Poor Training
dimensional
inaccuracies

Finding The Route Cause - Machine
Machine
Hard Material
Machine Capability
Design Constraints
Operation Suitability
High Vibration
More Machining Time
Excess RAM overhang

Old Machine Poor surface
Less Cutting Parameter Repeatness finish, and
dimensional
inaccuracies
43
Finding The Route Cause - Material
Poor surface
finish, and
dimensional
inaccuracies
Frequent Damage of Tools
Inappropriate
Machine Capability Machining
parameters
Material Wastage
Operational Requirements
More Machining Allowance

Hard Material
Material Composition
Design Constraints
44 Material
45
Finding The Route Cause - Method
Poor surface
finish, and
dimensional
inaccuracies
Repeated Cuts Process Inspection Method
Manual Operation
Poor Planning Measuring
Instrument
Lengthy Process
Market Demand
Excess RAM overhang
Less Cutting Parameter Customer

Requirement
More Cycle Time Design constraint
Method

7- Data Analysis
X Bar and R Chart
46
47
Data Analysis
Deviation - Bearing Shell Spherical Dia.
Total number of
Work Order Drawing Value Max. Size Min. Size Piece Position Inspected Value
Position - 1 270.02
Deviations
Pc-1 Position - 2 270.20 observed due to
Position - 3 270.18
1226837708-13901 270j6(+0.016/-0.016) 270.016 269.984
Position - 1 270.02
dimensional
Pc-2 Position - 2 270.14 inaccuracies for the
Position - 3 270.16
Position - 1 600.03 bearing shells
Pc-1 Position - 2 600.15 machining
Position - 3 600.05
1024900800-13901 600(-0.76/-0.146) 599.854 599.240
Position - 1 600.05 completed (2015
Pc-2 Position - 2 600.13 2017) on
Position - 3 600.06
Position - 1 639.99 Horizontal boring
1027500300-13901 640.1(-0.05) 640.100 640.050 Pc-1 Position - 2 639.80
Position - 3 639.98
machine WD-160
Position - 1 634.97 = 6 Nos.
1020220400-13901 635.01(-0.05) 635.010 634.960 Pc-1 Position - 2 635.20
Position - 3 634.98

Data Analysis X-Bar & R Chart 48
Measurement of Surface Roughness X Bar R

X Bar R
S. No. Project Work Order Piece Pos-1 Pos-2 Pos-3 Pos-4 Pos-5 UCL CL LCL UCL CL LCL
1 TS 5.5 6.0 5.5 4.0 5.0 5.20 2.0 6.04767 5.061 4.07433 3.61494 1.71 0
BRPL 1-2-268-377-08
2 ES 7.0 5.2 6.0 6.5 5.8 6.10 1.8 6.04767 5.061 4.07433 3.61494 1.71 0
3 TS 6.0 5.4 5.0 6.0 5.8 5.64 1.0 6.04767 5.061 4.07433 3.61494 1.71 0
Nasik 1-0-249-008-00
4 ES 4.0 3.8 4.8 5.0 5.5 4.62 1.7 6.04767 5.061 4.07433 3.61494 1.71 0
5 TS 5.0 4.5 3.8 4.8 5.0 4.62 1.2 6.04767 5.061 4.07433 3.61494 1.71 0
Arcelor Mittal 1-0-275-003-00
6 ES 3.5 4.4 3.6 5.2 6.8 4.70 3.3 6.04767 5.061 4.07433 3.61494 1.71 0
7 TS 4.7 5.1 6.0 4.8 5.2 5.16 1.3 6.04767 5.061 4.07433 3.61494 1.71 0
Maruti Suzuki 1-0-202-203-00
8 ES 5.0 4.6 5.2 4.6 3.8 4.64 1.4 6.04767 5.061 4.07433 3.61494 1.71 0
9 TS 6.0 4.5 5.5 4.6 5.2 5.16 1.5 6.04767 5.061 4.07433 3.61494 1.71 0
Nasik-5 1-0-249-006-00
10 ES 3.5 4.2 4.5 4.7 3.8 4.14 1.2 6.04767 5.061 4.07433 3.61494 1.71 0
11 TS 5.2 5.8 4.5 5.1 6.0 5.32 1.5 6.04767 5.061 4.07433 3.61494 1.71 0
Triveni-I 1-0-222-001-00
12 ES 3.8 4.6 3.8 4.2 5.0 4.28 1.2 6.04767 5.061 4.07433 3.61494 1.71 0
13 TS 4.2 4.4 5.5 4.6 4.0 4.54 1.5 6.04767 5.061 4.07433 3.61494 1.71 0
CPCL Chennai 1-0-260-063-00
14 ES 3.7 5.5 4.9 5.1 5.2 4.88 1.8 6.04767 5.061 4.07433 3.61494 1.71 0
15 TS 6.5 5.6 4.8 5.2 5.0 5.42 1.7 6.04767 5.061 4.07433 3.61494 1.71 0
Triveni-II 1-0-222-002-00
16 ES 3.6 4.8 4.5 4.2 5.2 4.46 1.6 6.04767 5.061 4.07433 3.61494 1.71 0
17 TS 4.9 5.4 5.3 5.4 4.8 5.16 0.6 6.04767 5.061 4.07433 3.61494 1.71 0
ONGC Hazira 1-0-202-212-00
18 ES 5.5 7.2 6.5 4.5 5.8 5.86 2.5 6.04767 5.061 4.07433 3.61494 1.71 0
19 TS 5.2 5.8 6.1 6.5 7.2 6.16 2.0 6.04767 5.061 4.07433 3.61494 1.71 0
Triveni-III 1-0-222-003-00
20 ES 7.2 4.2 3.8 5.4 5.2 5.16 3.4 6.04767 5.061 4.07433 3.61494 1.71 0
X Double Bar & R Bar 5.06 1.71
Constants: A2=0.577, D3=0, D4=2.114
UCL X Bar = X Double Bar + A2 x R Bar, LCL X Bar = X Double Bar A2 x R Bar
EM-58M
UCL R = R Bar x D4, LCL R = R Bar x D3
49
X Bar & R Chart
X Bar R Chart
7 4
UCL
UCL 3.5
6
3
5 CL
CL
2.5
4
LCL 2
3 CL
1.5
2
1
1 0.5
LCL
0 0
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20
Series1 Series2 Series3 Series4 Series1 Series2 Series3 Series4

50
Data Analysis
Particulars Unit Value
Bearing Spherical Diameter (Rough) mm 610.00
Bearing Spherical Diameter (Finsh) mm 600.00
Total Depth mm 33.14
Length of cut mm 165.00
Spindle Speed RPM 40.00
Depth of Cut (Diameter) per cut mm 2.00
Table Rotation Speed (45min per rotation) RPM 0.02
Setting Time Min 180.00
Machine Hourly Rate Rs. 3500.00
51
Data Analysis
Machining Time & Cost Calculation
No. of Cuts (Total Depth / Depth of Cut) - 16.57
Time required per cut (Table rotation time per cut) min 45.00
Total Machining Time (No. of Cuts x Time per cut) min 745.65
Set-up time min 180.00
Total Time = Total Machining Time + Set-up time min 925.65
Total Machining Time Per Piece Hrs 15.43
Machining Cost = Machine Hourly Rate x Total Time Rs. 53996.25
No. of Bearings Machined During 2016-2017 (18 Pairs) - 36.00
Machining Cost for Year 2016-2017 (18 Pairs) Approx. Rs. 1943865.00
8- Development of Solution
Brainstorming Round Robin Method
52
53
Development of Solution
Conducted Brainstorming Session to find the solution

Various ideas emanated from members were noted down
Feasibility study done for ideas emanated
Best possible solution selected

54
Name Idea Decision Remarks
Pradeep Verma Design and manufacture a fixture for Rejected Requires management
auto-rotation approval
Jitendar Yadav Use of CNC Centre Lathe Rejected Problem of holding the
Job
E. Sivakumar Use of Vertical Turning Lathe with Accepted Feasible
additional fixture plate
N Chetan Use of Horizontal Machining Centre Rejected Machine is having

bottleneck loads

55
Minimum job holding capacity of CNC
Vertical Turning Lathe is 1000mm.
Since, Job cannot be held directly in jaws as
the bearing spherical dia. Varies from 220mm
to 850mm. Fixture Plate
So, it was decided to design and manufacture

a fixture plate
Fixture plate is held between jaws and
bearing is clamped on fixture plate.
56
Bearing Shell RAM
Machining on VTL
Spherical Dia.
Fixture Plate
Jaws
Cutting Tool
Chuck

57
Before After
RAM
Fixture Plate
Job
Cutting Tool
Horizontal Boring Machine Vertical Turning Lathe

9- Foreseeing Probable Resistances
Brainstorming
58
59
Foreseeing Probable Resistances
Accepted Accepted
and
appreciated
Quality
Technology
Control
Planning &
Tool Room
Stores
Accepted Accepted

10- Trial Implementation
Cost benefit analysis
60
61
Trial Implementation
Trial Implementation done on 270MW TSGENCO-III TG
bearing shell
Found the average surface roughness within the specified
limit 1.6 (Drawing 3.2)
No dimensional inaccuracies (Average Spherical Dia
599.92 against drawing size 600-0.07/-0.14 )

Benefit Analysis Tangible 62
Data after Implementation

Bearing Spherical Diameter (Rough) mm 610.00
Bearing Spherical Diameter (Finish) mm 600.00
Total Depth mm 33.14
Length of cut mm 165.00
Speed RPM 40.00
Depth of Cut (Diameter) per cut mm 2.00
Feed Rate mm/rev 0.30
Feed Rate (Feed mm/rev X Speed-RPM) mm/min 12.00
Setting Time Min 20.00
Machine Hourly Rate Rs. 3832.00

Benefit Analysis Tangible 63

No. of Cuts (Total Depth / Depth of Cut) 16.57
Time required per cut =Total Length/Feed(mm/min) min 13.75
Total Machining Time (No. of Cuts X Time per cut) min 227.84
Set-up time min 20.00
Total Time = Total Machining Time + Set-up time min 247.84
Total Time Hrs 4.13
Machining Cost = Machine Hourly Rate X Total Time Rs. 15828.56
No. of Bearings Planned During 2017-2018 36.00
Total Machining Cost for Year 2017-2018 Rs. 569827.98
Saving Planned in year 2017-2018 (Recurring) Rs. 1374037.02

Benefit Analysis Intangible 64
S. No. Before After

1 Poor Surface finish (Ra-5.0 microns) Good Surface finish (Ra-1.8 microns)
Low cutting parameters High cutting parameters
2 (Speed =0.022RPM, Feed = 0.3mm/rev & Depth (Speed =40RPM, Feed = 0.25mm/rev & Depth of cut
of cut = 1.5mm in radius) = 2mm in radius)
High machining Cycle time (15.43Hrs per Low machining Cycle time (4.13Hrs per piece
3
piece for 270MW Bearing Shell) for 270MW Bearing Shell)
4 2-3 no. of inserts damage per bearing shell 0-1 no. of inserts damage per bearing shell
High dimensional inaccuracy approx. Dimensional accuracy within control limit
5
0.2mm 0.02mm
6 Manual Operation No Manual Operation

11- Regular Implementation
Standardization
65
66
Regular Implementation
After successful trial implementation quality and
technology department agreed to implement the same for
all upcoming projects.
Spared time (Time Saved) utilized for machining of other
critical components i.e. Rotor Flange Holes, Input Lead
operations, Stator Frames etc.

12- Follow-up and Review
67
68
Follow-up and Review
Follow-up made till complete machining of bearing for further five
projects as mentioned below-
Work Order Customer Piece Drawing Size Measured Value Surface Roughness
1024901700 TSGENCO-III Pc-1 600-0.07/-0.14 599.92 1.6
Pc-2 600-0.07/-0.14 599.91 1.8
1024901800 TSGENCO-IV Pc-1 600-0.07/-0.14 599.89 1.8
Pc-2 600-0.07/-0.14 599.91 1.7
1024901900 KPCL Pc-1 600-0.07/-0.14 599.91 1.6
Pc-2 600-0.07/-0.14 599.92 1.8
1020103300 TATA Projects Pc-1 635.1-0.05 635.07 1.6
Pc-2 635.1-0.05 635.08 1.8
Found that spherical diameter and surface roughness are within

control limit
MILESTONE CHART
Quality Circle Department Facilitator Team Members
EM-58-M EM Production Sridhar Reddy L Pradeep Kumar Verma Leader
Project High deviation during bearing spherical machining Jitendar Yadav Dy. Leader
Project No QCMMP/EM58M/2017/1 Start Date 13-02-2017 End Date 15-05-2017 E Sivakumar Member
Meeting Day Monday 14:30 to 15:30 No. of Projects Completed 2 N Chetan Member
S. No. Activity 1 2 3 4 5 6 7 8 9 10 11 12 Target Actual
1 Defining the Problem 27-02-2017 27-02-2017
2 Analysing the Problem 20-03-2017 20-03-2017
3 Identifying the Causes 27-03-2017 27-03-2017
4 Finding the Root Causes 27-03-2017 27-03-2017
5 Data Analysis 17-04-2017 17-04-2017
6 Developing Solution 08-05-2017 08-05-2017
7 Foreseeing Possible Resistance 08-05-2017 08-05-2017
8 Trial Implementation 08-05-2017 08-05-2017
9 Regular Implementation 15-05-2017 15-05-2017

69
10 Follow-up & Review 15-05-2017 15-05-2017
Documentation
New Process Old Process
70
13- Abstract
5W&1H
71
72
Abstract
What was the problem?
High deviation and poor surface finish
Where was the problem?
Bearing Shell Spherical
When did the problem arise ?
While machining of Bearing Shell
Who has noticed the problem?
Machine operator and Quality Inspector
Why did the Problem arise?
Excess overhang length of machine RAM and Excess length of rotary table
How was the problem solved?
A fixture plate manufactured

14- Future Plans
73
74
Future Plans
Target
Problems Category Status
Date
Coolant falling over steady rest motor on CNC Centre Under

A 20-10-2017
Lathe (Tacchi) Progress
Manufacturing of supports for machining of Defence

Under
Generator Rotor on CNC Slot milling machine A 10-11-2017
Progress
(TACCHI)

Thanks.
75

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1

EM-58M Quality Circle EM58M

The Founder of Quality Circle in India (1981)

Thanks To Sri S.R. Udpa,

EM-58M Electrical Machines Division, BHEL Hyderabad

EM-58M Electrical Machines Division, BHEL Hyderabad

Steam Gas Turbines Compressors Turbo- Heat

Pumps Switch Gears Gear Boxes Oil Rigs Pulverisers

EM-58M Electrical Machines Division, BHEL Hyderabad

EM-58M Electrical Machines Division, BHEL Hyderabad

CNC Centre Lathe 3 Nos.

Pradeep Kumar Verma Jitendar Yadav E. Sivakumar N. Chetan

Sridhar Reddy L Jeevan Kumar

EM-58M Electrical Machines Division, BHEL Hyderabad

Saving the Material, Time and Energy through innovation.

EM-58M Electrical Machines Division, BHEL Hyderabad

EM-58M Electrical Machines Division, BHEL Hyderabad

Par-Excellence Award Gold Award 2nd Prize

EM-58M Electrical Machines Division, BHEL Hyderabad

EM-58M Electrical Machines Division, BHEL Hyderabad

EM-58M Electrical Machines Division, BHEL Hyderabad

EM-58M Electrical Machines Division, BHEL Hyderabad

A Within the scope of QC team

B Involvement of other department is a necessity

C Management sanction may be needed in implementing

S. No. Problems Identified Category

EM-58M Electrical Machines Division, BHEL Hyderabad

S. No. Problems Identified Category

EM-58M Electrical Machines Division, BHEL Hyderabad

EM-58M Electrical Machines Division, BHEL Hyderabad

C Category 3 A Category B Category C Category

EM-58M Electrical Machines Division, BHEL Hyderabad

Tool Used- Ranking Method

1 is for lowest priority and 5 is for highest priority .

EM-58M Electrical Machines Division, BHEL Hyderabad

PROBLEMS IDENTIFIED PKV JTY ESK NC Total

EM-58M Electrical Machines Division, BHEL Hyderabad

2 Analysing the Problem 20-03-2017 -

3 Identifying the Causes 27-03-2017 -

4 Finding the Root Causes 27-03-2017 -

5 Data Analysis 17-04-2017 -

6 Developing Solution 08-05-2017 -

7 Foreseeing Possible Resistance 08-05-2017 -

8 Trial Implementation 08-05-2017 -

9 Regular Implementation 15-05-2017 -

The Turbo-generator component Bearing Shell machining

EM-58M Electrical Machines Division, BHEL Hyderabad

EM-58M Electrical Machines Division, BHEL Hyderabad

EM-58M Electrical Machines Division, BHEL Hyderabad

EM-58M Electrical Machines Division, BHEL Hyderabad

EM-58M Electrical Machines Division, BHEL Hyderabad

EM-58M Electrical Machines Division, BHEL Hyderabad

EM-58M Electrical Machines Division, BHEL Hyderabad

2 Feed Rate S mm/rev 0.2 to 0.3

EM-58M Electrical Machines Division, BHEL Hyderabad

Manual Lengthy Process

Incompetent Trainer Personal Issues Poor surface

EM-58M Electrical Machines Division, BHEL Hyderabad

Excess RAM overhang

More Machining Allowance

Less Cutting Parameter Customer

More Cycle Time Design constraint