Engineers India Limited

DAKSH –SMMS
PROJECT TOPIC:

Problems in receiving Inputs from other departments for preparation of

the corrosion control document

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STEP 1: IDENTIFICATION OF WORK RELATED
PROBLEM
Identification of work related problem

Brainstorming in each area/activity

Final list prepared based on PQCDSME

Categories

LEGENDS:
P-Productivity, Q- Quality, C- Cost, D- Delivery
S- Safety, M- Morale, E- Environment Delivering Excellence Through
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 STEP 1: FINAL LIST OF PROBLEMS

Cause Solution
Problem
Sr.
Problem Statement Classification
No. Known Unknown Known Unknown
PQCDSME

1 Accessibility of data stored in EIL systems P,Q,C, D,E Y Y

Proper logistics requirement not envisaged resulting in
2 P,Q,C,M Y Y
employee inconvenience during execution of Overseas jobs
Problems in receiving Inputs from other departments for
3 P,Q,C,D,S,M,E Y Y
preparation of the Corrosion Control Document (CCD)
4 Employee productivity affected due to long time commuting P,Q,C,D,S,M,E Y Y
5 Higher man hour rates results in loss of many potential jobs. C Y Y
Non availability of man hours for performing specialized
6 P,D Y Y
queries.
Feedback received from Clients shall be captured in structured
7 Q,C, D,M Y Y
manner.
Development of domain expertise in digital solutions for
8 P,Q, C,D Y Y
specialized jobs.
Authorized lab list not available in company for carrying out
9 P,Q,C,D,E Y Y
specialized tests.
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STEP 2 - SELECTION OF PROBLEM

A,B,C CATEGORY

RATING & RANKING

METHOD

HIGHEST RANK
PROBLEM SELECTED Delivering Excellence Through
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S. No. STEP 2: Selected problems have been classified
Problem Cat. into A, B,
and C Categories

1 Accessibility of data stored in EIL systems A

2 Proper logistics requirement not envisaged resulting in employee A

inconvenience during execution of Overseas jobs
Problems in receiving Inputs from other departments for preparation
3 of the Corrosion Control Document (CCD) A

4 Employee productivity affected due to long time commuting C

5 Higher man hour rates results in loss of many potential jobs. B

6 Non availability of man hours for performing specialized queries A

7 Feedback received from Clients shall be captured in structured A

manner.

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 STEP 2: Ranking of all members summarized &
highest rank problem was selected

TL DL M
S.
Problem Cat. Mark Total Final Rank
No. PVC SKM SG

1 Accessibility of data stored in EIL systems A 62 67 72 201 5

Proper logistics requirement not envisaged resulting in employee inconvenience during

2 A 50 55 55 160 6
execution of Overseas jobs

Problems in receiving Inputs from other departments for preparation of the Corrosion Control
3 A 75 82 73 230 3
Document (CCD)

4 Employee productivity affected due to long time commuting C 79 80 85 244 2

5 Higher man hour rates results in loss of many potential jobs. B 20 15 20 55 9

6 Non availability of man hours for performing specialized queries. A 23 25 27 75 8

7 Feedback received from Clients shall be captured in structured manner. A 40 40 45 125 7

8 Development of domain expertise in digital solutions for specialized jobs. C 69 70 70 209 4

9 Authorized lab list not available in company for carrying out specialized tests. B 80 85 90 255 1

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STEP 2: REASONS FOR SELECTING THIS PROBLEM

It is under category A . Cause is known but solution is unknown

Highest rating upon prioritization among all problems under category A

Improve efficiency during execution of such future potential jobs.

Fetch competitive edge in the market while quoting for future such jobs.

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 Milestone chart
Engineers India Limited Directorate : TECHNICAL Division : SMMS Department : METALLIC MATERIALS & Team : SMMS QUALITY CIRCLE
CORROSION

Project Theme Standardizing inputs for preparation of Corrosion control Document Improvement Methodology Quality Circle
Machine/Area Corrosion Control Team Registration No. QC ID : EILQC/GGN/22-23/017
Target Period Team
Measurement Item UOM From To From To Leader Dy. Leader Member Facilitator
23.05.2022 12.08.2022 PVC SKM SG UKV
Project No. Meeting Frequency Meeting Time Meeting Duration

Plan MAY-22 JUNE-22 JULY-22 AUG-22 SEP-22 OCT-22

S. No. Activity / Step Description
Actual W1 W2 W3 W4 W1 W2 W3 W4 W1 W2 W3 W4 W1 W2 W3 W4 W1 W2 W3 W4 W1 W2 W3 W4
Plan Y
1 Identification of Work-Related Problem
Actual
Plan
2 Selection of Problem
Actual
Plan
3 Defining the Problem (Process, Definition, Background, Impact, & Theme Setting)
Actual
Plan
4 Analyse the Problem
Actual
Plan
5 Identification of Causes ( All Possible and Most Probable Causes)
Actual
Plan Y
6 Finding the Root Causes (Cause Validation & Why-Why Analysis)
Actual
Plan Y
7 Data Analysis (Root Cause Prioritisation & Data Analysis)
Actual
Plan
8 Developing Solution
Actual
Plan
9 Foreseeing the Probable Resistance
Actual
Plan
10 Trial Implementation & Checking Performance
Actual
Plan
11 Regular implementation
Actual
Plan
12 Follow-up and Review (Standardisation, Substances, & Horizontal Deployment)
Actual

Prepared By : PVC /SKM/SG Approved By : UKV Date of Preparation : 23.05.2022 - Plan - Actual

Doc No. BEMW/WOW/02, Rev 0, 08.12.21

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STEP 3 - DEFINING THE PROBLEM

Flow diagram developed

Brief description of Corrosion

Control diagram (CCD)

Theme, Objective
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 STEP 3: Flow Diagram developed

SMMS

Metallic Materials Corrosion Refractory & Non Maintenance & Cathodic

& Corrosion Control Metallic Inspection (M&I) Protection (CP)
Protective
Materials Selection coating & Refractory,
Root cause analysis Pipeline CP
paintings Insulation ,
Welding specs & (RCA) of failures in
chart Fireproofing operating plants &
Cooling water pipeline Plant CP
treatment, chemical Direct jobs in
Specialized cleaning refractory trouble Fitness for Service
activities shooting study (FFS),
Remaining Life
Offshore CP

Assessment (RLA)
Corrosion monitoring
system Specialized
activities Assessment of fire damage

Specialized
activities
Job Specification/ Standard Specification are
Minimum involvement of other department available
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 STEP 3: Flow Diagram developed

Corrosion
Study - A detailed manual
- Huge data required
Corrosion
Control from various depts.
Document - Analysing and
Specialised Activities (CCD) compiling the provided
(Metallic Materials and Corrosion) data
Failure - Time taking, error-
Analysis prone
Welding
repair
procedure

** Outputs are in the form of recommendation/report and minimum Delivering Excellence Through
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 STEP 3: Brief description of CCD

Corrosion Control Document (CCD)

Segregate the total unit into different corrosion loops based on the applicable damage mechanism.

Define the applicable damage mechanisms in the specific corrosion loops.

Assess the severity level of the damage mechanisms.

Recommend Integrity Operating Windows

(IOWs) to set limits to the different variables that
could affect the integrity and reliability of
a process unit

Corrosion Control Document (CCD) is

the primary input for Asset Integrity/
RBI activities

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 Engineers India Limited

Click icon to add picture

SCU-HMEL
CDU-VDU-IREP

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 STEP 3 : Theme, Objective
THEME:

Standardizing inputs for preparation of Corrosion control Document

REASON FOR SELECTION:

 Huge data required from various departments.

 Data provided are in discrete manner. No formal methods to receive inputs.

 Analysing and compiling the received data is time taking and error- prone

PRIMARY OBJECTIVE:

 Reduction in man-hours consumption

Increase in accuracy

 Avoidance of repeated work

SECONDARY OBJECTIVE

Resolution of this problem can result in improving efficiency during execution of

such future potential jobs.

Efficient execution of jobs will provide us the competitive edge in the market while
quoting for future such jobs.
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 STEP 4 – ANALYSING THE PROBLEM

Tools
CCD- Preparation cycle for analysis Data Collection

Check Sheet

Data gathering from past jobs

Control Chart

Data analysis and findings

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 STEP 4: CCD preparation cycle chart for analysing the problem

Request for Data Data Preparation

Data received Data Analysis
data Extraction Compilation of CCD

Area of Concern Huge quantum of data from various

departments

Time taking and error- prone

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 STEP 4: Data collection from past jobs carried out

Period
Sr. What Data is to be Source of
Objective (Days / Tools Used Responsibility Target Date
No. collected Data
Month/ Year)

Time taken to receive Originator

Plan: 1 week
documents from various Past jobs departments
1. To analyse the data 3 weeks E-mails Actual: 3
depts from the date of experience providing the
weeks
request. documents

Plan: 1 week
Past jobs Domain
Time taken to analyse To extract relevant data Actual: 2
2. 2 weeks experience knowledge SMMS
the provided documents and compile the same weeks

Past jobs Domain Plan: 1 week

Time taken to extract
3. Input to CCD 3 weeks experience knowledge SMMS Actual: 3
and compile the data
weeks
Plan: 8
Past jobs Domain
Deliverable to Client / weeks
4. Preparation of CCD 8.5 weeks experience knowledge SMMS
Project Actual: 8.5
weeks
Note: Data like project-to-project variation, input material variation, change in supplier, etc.

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 STEP 4: Data analysis and findings

Request for Data Data Data Data Preparation

data received Analysis Extraction Compilation of CCD

PLAN 1 WEEK 1 WEEK 1 WEEK 8 WEEKS 11

WEEKS
(Total)
ACTUAL 3 WEEKS 2 WEEKS 3 WEEKS 8.5 WEEKS 16.5
WEEKS
(Total)
EXTRA 2 WEEKS 1 WEEKS 2 WEEKS 0.5 WEEKS 5.5
WEEKS
(Total)
% of extra time wrt 18% 9% 18% 4.5 % 49.5%
total planned time (total)

The objective of this project is to reduce this 27% of extra time consumed.
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 EXTRA TIME FOR ACTIVITIES DURING CCD PREPARATION

Plan Actual Extra

8.5
8
Time (Weeks)

3 3

2 2 2

1 1 1 1
0.5

Data Received Data Analyzed Data Compilation CCD Preparation

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 STEP 5 – IDENTIFICATION OF CAUSES

Tool: All Possible Causes of the problem

Brain identified
Stor
ming

Tool:
Fish
Bone
C & E Diagram used to explore root cause
Diagr
am

Tool:
Identifying the Most Probable Causes.
Brain
Stor
ming
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 Cause & Effect Diagram & Most Probable Causes
METHOD
MATERIAL
PRODUCTIVITY Huge Quantum of Data from various
department
Standard Format Not Available
Delay in receiving the data
Irrelevant data provided

Time Incurred in Interpretation of

Data Data is not in tailor made format
Inputs provided in staggered manner

27% EXTRA TIME

CONSUMED
Lack of Accountability / Ownership

Lack of clarity for the purpose

Multi tasking of concerned engineers of seeking the data

Negligence in providing Data

Human errors

Lack of CCD knowledge

ENVIRONMENT
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PERSONNEL People
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 STEP 6: Finding the root cause

Validation of Identified causes through Rating Ranking Method

Identification of Root cause

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 Rating &
Histogram
Ranking

Tools used

Data Check
Collection sheets

3M’s
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3M’s

Failure of People or Process to deliver Product

Failure due to Inconsistent, unpredictable outputs

Failure to create efficient process due to

overburden
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 CDU-VDU-IREP KOCHI

Rating Factor, Maximum Marks & Rating

S. No. Problem Total Rank Type of Waste
Time Accuracy Quality Marks

1 Huge quantum of data 9 5 4 18 4 Muda, Muri

2 Irrelevant data provided 8 7 7 22 2 Muda,Mura

3 Inputs are provided in staggered /discrete manner 9 5 5 19 3 Mura

Muda,Mura,
4 Standard format not available 10 9 9 28 1
Muri

5 Lack of Accountability/ Ownership 7 5 5 17 5 Muda,Mura

Muda,Mura
6 Multi tasking of concerned engineers 7 6 6 19 3
Muri
Muda,Mura
7 Lack of clarity for the purpose of seeking the data 6 5 5 16 6
Muri
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 BAR CHART ANALYSIS OF IREP KOCHI (CDU,VDU)

30

25

20

15 28
Rating

22
18 19 19
10 17 16

Most Probable Causes

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 STEAM CRACKER - HMEL

Rating Factor, Maximum Marks & Rating

Time Accuracy Quality Total

S. No. Problem Rank Type of Waste
Marks

1 Huge quantum of data 9 6 5 20 2 Muda, Muri

2 Irrelevant data provided 7 6 6 19 3 Muda,Mura

3 Inputs are provided in staggered /discrete manner 9 5 4 18 4 Mura

Muda,Mura,
4 Standard format not available 9 8 8 25 1
Muri

5 Lack of Accountability/ Ownership 7 5 5 17 5 Muda,Mura

Muda,Mura
6 Multi tasking of concerned engineers 7 6 6 19 3
Muri
Muda,Mura
7 Lack of clarity for the purpose of seeking the data 6 4 4 14 7
Muri
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 BAR CHART ANALYSIS OF HMEL BHATINDA (STEAM CRACKER)
25
20
15 25
20 19 18 17 19
10 14
5
0
at
a ed ne
r
bl
e ip rs ta
d iv d n ila r sh ee da
of a ne in
Rating

o va g e
m pr e
m a w en th
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a et ot O d g
a n d r t n
lit
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qu t isc a i e r
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ed fo nta co of
Hu e r d ou of e
Irr ge ar c os
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in c ko ta
s e
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id ul fo
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pr rit
a re cl a
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Most Probable Causes

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 Inputs are
provided in
staggered
/discrete
manner
Working with the root
cause will take care of
the other three most
probable causes

Standard
format not
available
Irrelevant Huge
data quantum of
provided data

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 STEP 7: Data Analysis (Prioritization)

Listing of data relevant to CCD

Prioritization of data which are required in format

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Sl. No. Inputs Required for CCD Reference Document Concerned Data Desired in Format
Department
1 Process Descriptions Design Basis Process No
2 Damage Mechanisms International Standards SMMS No
3 Inspection Techniques International Standards SMMS No
4 Corrosion Monitoring/Sampling International Standards SMMS No
techniques
5 RBI components - SMMS No
6 Material Grades for equipment Mechanical Datasheets SME, FED Yes
7 Operating/Design conditions Process Datasheets Process Yes

8 Presence of Corrosive Constituents Process Datasheets Process Yes

9 Piping Classes/ Materials Grade PMS/P&IDs Piping, Process No

10 Insulation Datasheet/P&IDs Piping, Process Yes

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STEP 8: DEVELOPING SOLUTION

Prioritized inputs

Input format prepared

Involvement of Originator department

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STEP 8: FORMAT DEVELOPED

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 FORMATS FOR ALL EQUIPMENT

Compressors DeSuperheater Ejectors Filters Fired Heaters Heat Exchangers

Mixers Plate Heat Reactors Tanks Towers

Pumps
Exchangers

Vessels and
Drums

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 STEP 9: FORSEEING THE PROBABLE RESISTANCE

Shared the solution with concerned departments through

e-mail

Resistances, suggestions, modifications in solution

Implementation of suggested changes

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 SMED RESPONSE

 Manual errors will still be there by Originator as well

 Responsibility shifts from SMMS to other department
 This can only be eliminated if the data for all process/utility
equipment & for all units (licensed or open art) is available in a
central database.
 The desired data has to be developed based on equipment MDS
issued. Hence SMMS can obtain the data from the MDS issued.
 ASTM grades, if at all required for such rotating/package
equipment items, are available only during the drawing
review/approval stages. Post approval, mechanical data sheets &
cross-sectional drawings can be shared with SMMS.

Suggestion: PDSYS system shall be utilized first by Process for all licensed/open art units so that automatic flow of data can take
place from there to SMMS's desired format.

Measure: Implementation of PDSYS for extraction of data may be feasible in future when there is regular flow of CCD jobs.

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HTD RESPONSE

Suggestion: Additional parameters

recommended to be incorporated like minimum
Arch pressure, minimum excess air in heater

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PROCESS RESPONSE

SMMS division to extract the data for

preparing the CCD of the units.

SMMS to perform this activity with care so

that errors and rework carried out in past
projects are not repeated.

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STEP-10: CHECKING PERFORMANCE

ESTIMATED MAN-HOURS FOR INCORPORATING

INPUTS IN CCD FORMAT FOR 2 CORROSION LOOPS
UNIT WITHOUT FORMAT WITH Estimated Net time
(Data analysis, FORMAT time to be saved
extraction, consumed
compilation) by other
dept

Time (Hrs) Time (Hrs) Hrs Hrs

CDU-VDU 20 4 10 6 (30%)

Steam 24 4 12 8 (33%)
Cracker

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ROOT CAUSE
Standard format not available
SOLUTION To prepare a standard format and will be utilised for future CCD
jobs

WITHOUT FORMAT WITH FORMAT

Consumption of more efforts and high probability of Consumption of efforts decreased and probability of
rework rework also lowered.

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Insert the Sub Title of Your Presentation

THANK YOU

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