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Saturday, 15 August 2015

ROOT CAUSE ANALYSIS CASE STUDY

We have discussed the basic of Root cause analysis and also the process of root cause analysis in our previous post i.e. 

ROOT CAUSE ANALYSIS 

Let us see one case study that i have experienced in my career 

Case Study

I was working with one steel organization; organization was working for manufacturing stainless steel. Stainless steel scraps were melted in induction furnaces and then liquid metal transported and used to pour in Argon oxygen decarburization furnace for refining the liquid metal and we maintain chemical composition over there.

We use top lance for blowing oxygen in furnace. One day we observed the top lance got punctured and damage.

I want to brief about the design and function of top lance first

Top lance was used for blowing oxygen in furnace. Top lance used to dip in liquid metal and used to blow oxygen as per operation requirement for circulating the liquid metal.

Top lance was designed with walls of hollow pipe and these hollow pipes were water cooled.

So the problem was puncture of top lance

We had carried out the root cause analysis and we have found the following feedbacks

Top lance got punctured, why?
Answer: Due to steam generation inside the hollow pipe, hollow pipe got damage

Steam generated inside hollow pipe, why?
Answer: Due to overheating of hollow pipe

Overheating of pipe, why?
Answer: cold water circulation stopped

Cold water circulation stopped, why?
Answer: Pump was failed to provide the flow

Pump failed to provide the pressure or flow, why?
Answer: Pump capture the air

Pump Capture the air, why?
Answer: Water level found low in source tank

So the route cause was low water level in source tank, hence we have concluded to fix alarm for low water level for avoiding the capturing of air by pump

This is one practical example that I have faced when I was associated with that organization and I was a member of RCA team.

Finally, we may conclude that by implementing root cause analysis and by providing the permanent solution by eliminating the route cause, we may increase the productivity of our organization.

Let us go ahead toward next precious post

Objective of total productive maintenance 

Maintenance practice and procedure 

Keep reading .....

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