Mproving Clinker Production Coal Utilization Using Six Sigma Methodology In Mugher Cement Factory

Industrial Engineering Project Topics

Get the Complete Project Materials Now! ยป

Six sigma is the process improvement tools which can be applied in various sector for defectrnminimization and better utilization of resource using DMAIC methodology. A DMAIC methodologyrnis used to identify which output parameter needs to be give more priority to get a better result.. Thus,rnin this research which focuses on improvement of clinker production coal utilization without affectingrnthe clinker quality production, an integration of six sigma with design of experiment was performed.rnThe tool integration major significance was, it provides a mechanism to narrow down the source ofrnvariation to be more explicit and for optimizing the responses. rn This research was conducted by first identifying the major response variable from quality &rnresource utilization. Therefore, from coal utilization perspective, coal consumption for the 3rn line kilnrnand from quality point of view, C3S and free lime content was selected by first conducting arnbrainstorming session with company professionals .Thus, the identified factors which affect thisrnvariables were determined by conducting brainstorming session and with considering the highest coalrnconsumption month ,which was August,2018 to study the potential causes .As a result ,from the rootrncause analysis, different factors were identified. Among them, kiln feed (proportioned raw material )rnsuch as Lime Saturation Factor(LSM), Silica Moduli(SM) and Refractory Moduli(RM) were selectedrnto observe their influence in coal consumption by considering their quality target range of each rnmaterial obtained from the quality department of the case company . rnrdrn From the analysis result ,the optimized coal consumption was found at the setting ofrnLSM=97,SM=2.4 and RM=5.5 which give a specific coal consumption of 116kg coal per ton ofrnclinker production while the company average specific coal consumption during April,2018-rnMarch,2019 was 127kg to produce a ton of clinker. In addition to these, the quality level of thernproduced clinker, particularly the C3S and free calcium content were within the preset and expectedrnquality target levels. rn Finally, based on the found improved setting, a controlling mechanism for sustaining thernmaterial proportioning target and uniformity was suggested. In addition, a guiding framework wasrnproposed for implementation of continual improvement of resource and quality improvement in MugerrnCement Factory.

Get Full Work

Report copyright infringement or plagiarism

Be the First to Share On Social



1GB data
1GB data

RELATED TOPICS

1GB data
1GB data
Mproving Clinker Production Coal Utilization Using Six Sigma Methodology In Mugher Cement Factory

281