YANTRA QC

NMDC DONIMALAI

WELCOMES YOU
1
 NMDC: India’s single largest Iron or produce
 Formed on 15.11.1958
 Core Competency in Iron
Ore, Diamond and Lime Stone
mining.
 ‘Navaratna’ Status in Jan 2008
 ISO 9001-2000 certification
in February 1999.
 ISO 14001 certification
Awarded in 2004.
 OHSAS 18001-2007 in Feb. 2010

2
SCIENTIFIC & ECO FRIENDLY SINGLE LARGEST PRODUCER OF
MINING IRON ORE
Mining by Mechanized means Expansion of production capacity of
Quality Control existing mines.
Mineral Beneficiation Iron Ore supply to international &
Proper Blending Domestic markets is in the ratio of 85:15.
Optimum exploitation of precious mineral

3
PRODUCTS CONTRIBUTION TO INDIAN
Doni Lump (Size : 6 mm -30 mm) ECONOMY
Doni Fines (Size : -10 mm) So far earned foreign exchange in
Baila ROM (Size :10mm - 150 mm) excess of Rs 16,000 crore.
Baila Lump (Size :6 mm - 40 mm) In recent disinvestment of NMDC
DRCLO (Size :10 mm – 40 mm) shares by Govt of India fetched around
Baila Fines (Size : -10 mm) Rs 9,930 crore.
Panna – Rough Diamonds Paying dividend since 1990-91
It has about 6000 employees.
4
 Our Valuable Customers

1. Essar Steels.
2. MMTC LTD
3.  Ispat Industries Ltd.
4. JSW Steel Ltd.
5.  Sponge Iron India Ltd.
6.  KIOCL Ltd.
7.  Lanco Industries Ltd.
8. Tata Metalliks Ltd.
9. Aparant Iron & Steel Co. Ltd.
10. Vikram Sponge Iron Ltd.
11. Visvesvaraya Iron & Steel Plant
12. Rashtriya Ispat Nigam Ltd.( VSP)
13. Kirloskar Ferrous Industries Ltd
14. Southern Iron & Steel Co. Ltd.
15. CG based Sponge Iron Units

5
 पर्यावरण-नीति ENVIRONMENT POLICY
• To adopt safe, scientific and environment friendly methods of mining and
allied activities.
• To maintain the machineries in excellent condition.
• To install, operate and monitor facilities for prevention and control of air,
water and land pollution.
• To conserve the natural resources by ensuring
minimum wastage of our products
• To promote environmental awareness amongst employees, local
communities and interested parties.
• To remain prepared and respond effectively to all foreseeable emergency
situations.
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Donimalai and Kumarswamy
Iron Ore Mine, Karnataka

Bailadila iron ore mine

(Kirandul and Bacheli Complex)
Chattisgargh

Panna Diamond Mine

Madhya Pradesh

Head Office Hyderabad

7
 QC PROFILE
 NAME : BULLDOZER QUALITY CIRCLE
 ORGANISATION : NMDC Ltd.
 UNIT : Donimalai Iron Ore Mine
 APEX COMMITTEE CHAIRMAN : Sri SAHO C G M DIOM
 STEERING COMMITTEE CHAIRMAN : Sri. RAMAYAIN . Jt G.M (Prodn.)
 DEPARTMENT : Services Mechanical Auto Garage
 HOD : Debendra Hansda.
 LEADER : ESYA NAIK
 Dy. LEADER : CHANDRASHEKAR
 MEMBERS : B KOTRESH
 : NARESH BABU
 : RAMESH

 FACILITATOR : anmol abade

 DATE OF INAUGURATION : 02/01/2018
 MEETING DAY : FRIDAY
 MEETING TIME : 12:30pm - 01:30 pm.
 AVERAGE ATTENDANCE IN MEETING : 90 %
8
 OUR VISION:LIKE YANTRA

With the quest for excellence and

the quality of innovation, we would
like to direct our sincere efforts in
making our AUTO GARAGE more
efficient in terms of productivity,
quality and safety.
 PDCA CYCLE
Identification of Work
Follow up/ Review Related Problem

Selection of Problem
Regular 12 1
A P
Implementation 2
Define the Problem
11
3
4 Analyse the Problem
10
Trial 5
Implementation C 6 Identification of Causes
9 D
8 7
Finding out Root Cause
Foreseeing Probable Data Analysis
Resistance
Developing Solution

10
 Problems Under Category A,B &C
SN Details Of Problem A B C
1. Shifting of 3rd gear is very difficulty .
2. Spring plate bending very difficulty .

3. Washing of vehicles in garage is very difficulty .

4. Oil spillage near oil drums .

5. Frequent air lock in vehicles .

6. Starter bendex worn out frequently .

7. Heavy smoke in vehicles .

8. Drilling for plate for making holes is very difficulty .

9. Charging system frequent failure .

10 Clutch plate wear out frequently .

11 Pressure plate disc wear out quickly .

11
12 .
 Problems Under Category A,B &C
SN Details Of Problem A B C
15. Hub greasing not doing in proper time .
16. Front disc wear out without operator knowledge .
17. Caliper piston jam in front brakes .
18. Steering wheel free .
19. Steering mounting box getting loose .
20. Tie rod ends and ball joints getting jam .
21. Diesel tank rust due to accumulation of fine ore .
22. Front suspension failure in jeeps .
23 Starting trouble in trucks
24 Brake jam and brake not working .
25. Engine abnormal sound .
26. Washing Water wastage .
27. Washing ramp filled with fine ore .
12
28. 
 Problems Under Category A,B &C
SN Details Of Problem A B C

30 Abnormal body sound .

31 Differential oil seal wear out .

32. Frequently double gear engage in vehicles .

33. Periodic maintenance is very difficulty .

34. Frequent Failure of Oil Seal , Bearing and Oil Spillage .

35. No timely supply of diesel in mining .

36. Poor Vehicle-maintenance .

37. Improper tools to be used by mechanics .

38. Quick stopping and starting of vehicles .

39. PTO not working properly in diesel bowsers .

13
2.1 A , B & C CLASSIFICATION AND RATING
METHODS
 CATEGORY – “A” – MINIUMUM INVOLVEMENT OF OTHER DEPARTMENTS.
 CATEGORY – “B” – INVOLVEMENT OF OTHER DEPARTMENTS IS A NECESSITY.
 CATEGORY – “C” – COMPLEX AND PRIOR MANAGEMENT SANCTION MAY BE
NEEDED.. NO. OF PROBLEMS SOLOVED

NO. OF PROBLEMS TO BE
NO. OF PROBLEMS
CATEGORY

SOLVED
SL. NO

14
14
 Other Inputs &
With in the Department’s Suggestion
Scope of the help required required from
Team Management
15
 2.1 RATING AND PRIORITISATION
The five problems selected were rated by each member individually to
decide the priority of the selected problems to be taken up first for working out a
practical solution. The problems were rated By ESYA NAIK on five factors as
depicted below:-
FACTOR MaxMarks P1 P2 P3 P4 P5
Safety 10 05 08 04 08 05
Time Saving 10 08 08 06 08 06
Equipment 10 08 08 09 09 08
Reliability
Cost Saving 10 07 09 08 09 07
Total 40 28 33 27 34 26
Priority Rating
16
 2.2 RATING AND PRIORITISATION
Name of Members
Max. Mark P1 P2 P3 P4 P5
S/Sri

ESYA NAIK 40 29 32 27 36 28

CHANDRU 40 28 33 25 34 26
KOTRESH 40 30 35 29 34 27
NARESH BABU 40 30 38 28 37 29
RAMESH 40 29 30 27 32 25
TOTAL MARKS 200 146 168 136 173 135
PRIORITY
As R3category,
the selected problem belongs to “A" R2 R4 R5
We informedR1
H.O.D. about our case-study on Date: 4/3/2022 & we have told to
develop the solution. 17
 STEP 2.3: SELECTION OF PROBLEM
SL. No. PROBLEM DESCRIPTION CODE ALLOTED
P1
1 Spring plate bending is very difficulty
3rd gear shifting very difficulty in P2
12
jeeps
P3
16 Frequent air lock in jeeps

22 P4
Front suspension failure in jeeps.

Frequent Failure of Oil Seal , Bearing P5

33
and Oil Spillage
18
 Problem Selection
Each member listed the following A related Problems
considering the safety of the equipments, Safety of the
workmen, Air Pollution, Dust Allergy, And considering the
production aspects.

1. Shifting of 3rd gear is very difficulty.

2. Tie rod ends and ball joints getting jam.
3. Abnormal body sound.
4. Differential oil seal wear out.
5. Front suspension failure in jeeps.
19
 2.2 Problem Selection By Ranking Method
The rating was given keeping in view
production aspect, reliability and
safety of the equipment and safety of
the working person.

45
40
35
30
25
20
15
10
5
0 East
Prob.1 Prob.2 Prob.3 Prob.4 Prob.5

Front suspension 7 8 8 9 8 45 I
failure in jeeps.
Scale 1 Low priority Problems 20
Scale 10 High priority
2.2
Problem Selection

21
2.3 Planning
MILESTONE CHART
Quality Circle Name Department Facilitator Leader Members
YANTRA Services Mechanical anmol ESYA NAIK Name
CHANDRA SHEKAR
Project Problem in Front suspension failure in jeeps B.KOTRESH
NARESH BABU
RAMESH
Project No. 05 Date of beginning:
Meeting Day- Friday 04-03-2022
Time – 01 to 02 PM

Sl. ACTIVITY WEEK 1 2 3 4 5 6 7 8 9 10 11 12 13 14 TARGET ACTUAL

No.

1 Define the problem 1Week

2 Analyze the problem 1Week

3 Identification of causes 2Weeks

4 Finding out the Root 2Weeks

Cause

5 Data analysis 1Week

6 Developing solution 2Weeks

7 Foreseeing probable 1Week

resistance

8 Trial implementation 2Week

9 Regular implementation 2 Week

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3.0 Define The Problem
By using High level flow diagram we detect the problem
area
PRODUCTION

PLANT MECH/SER MINING

SERVICES

SHOVELS DRILLS DUMPERS DOZERS

AUTO GARAGE 23
Problem Selection
 OUR CASE STUDY

Starting trouble in Tata

trucks

Light vehicle of model Bolero 25

 3.1समस्या की परिभाषाDefining the Problem

Suspension in vehicle is system of tires, tyre air,

springs, shock absorbers and linkages that
connects vehicle to its wheels and allows relative
motion between two means chassis and axles 26
3.1समस्या की परिभाषाDefining the Problem

Upper arm

Coil spring

Shock Absorber
Ball Joint end
Link Rod
Balancing rod
Lower arm
STEP 3.2:Defining the Problem (Using Flow-Diagram)

Suspension system failure

Check for failure of components

OK No yes

Shift the vehicle to garage

Change the failure components

related to suspension

stop
 DESCRIPTION OF THE PROBLEM
Engine TypeDI Turbo Diesel Engine Max Power63bhp@3200rpm
max Torque180Nm@1440-1500rpm No of cylinder 4 Valves Per Cylinder4

29
DESCRIPTION OF THE PROBLEM

main front glass

bonnet

Head light
bolero tyre

30
 3.3 PROBLEM DESCRIPTION
PROBLEM STATEMENT:
Frequent front suspension in jeeps of BS IV bolero
.

SLE
PROBLEM DESCRIPTION:
To move the vehicle in abnormal road condition the relative motion
between chassis and axles not direct but through some form of
springs to absorb shocks from road condition otherwise
acceleration, breaking and forces resist the vehicle to damage ie
components of the vehicle
Broadly speaking suspension system consists of spring and a
damper. The energy of road shock causes the spring to oscillate.
These oscillations are restricted to reasonable level by the damper
which is more commonly called shock absorber.
31
To reduce front suspension failure in jeeps from 100% to
30%
3.2 IMPACT OF THE PROBLEM

Loss of Availability of
Loss of Production Machine

Accident & Injury

PROBLEM Hazard

Loss of Man Power

Fatigue of the
persons

33
3.3 Objective and Goal

What is our Objective?

To reduce Front suspension failure in
% jeeps.

What is our Goal?

Light vehicle of model Bolero DI 90%.

34
34
 4.1 analyse
analyse
the problem
the problem
THROUGH “4 W & 1 H”
.What is the problem ?
.Front
. suspension failure

.Who is affected?
.Production team

.Where is the problem occurring?

.The problem occurring in mining area

.When the problem occurring?

.From June 2018 to December 2018

.How to overcome the problem? 35

.5% loss of total availability of vehicle
 4.2 analyse the problem
we collected 6 months past data from 1/03/2022 to 31/08/2022
. Date Reason for Breakdown
4/03/2022 Coil spring compressed
5/03/2022 Shock absorber failure
6/04/2022 Lower arm bend
14/04/2022 Upper arm bush worn-out
25/04/2022 Lower arm boil joint cut
19/05/2022 Shock absorber bush worn out
23/05/2022 Stud bar bend
28/05/2022 Balancing rod cut
1/06/2022 Balancing rod bushes cut
6/6/2022 Link rod of balancing rod cut
9/06/2022 Link rod bushes worn out
11/07/2022 Lower arm bend
20/07/2022 Upper arm bush worn out
6/07/2022 Coil spring compressed 36
 4.2 analyse the problem
we collected 6 months past data from 1/03/2022 to 31/08/2022
. Date Reason for Breakdown

11/07/2022 Tire worn out

1/07/2022 Steering drag on left side

5/07/2022 Link rod cut

17/08/2022 Stud bar bush worn-out

28/08/2022 Lower arm ball joint cut

6/08/2022 Lower arm bend

7/08/2022 Stud bar cut

29/08/2022 Upper arm bush worn out

37
 5.1 Identification of causes
Break Down Details Jeep of model Bolero SLE
..Frequent
. failure of suspension system following probable causes
observed. They are

Suspension coil spring compressed

Shock absorber failure
Lower arm bend
Upper arm bush worn-out
Lower arm ball joint cut
Shock absorber bush worn out
Stud bar bend
Balancing rod bushes cut
Link rod of balancing rod cut
Link rod bushes worn out. 38
STEP:5.2 IDENTIFICATION OF CAUSES
कारणों की पहचान
(Cause And Effect Diagram by Dispersion Method )
MACHINE MAN

Front suspension
failure in jeeps

METHOD MATERIAL 39
S STEP:5.3 CAUSE AND EFFECT DIAGRAM
MAN
Rash driving

e hicle c on dition Untrained driver

ng v
Not abservi d k no w ledge
o n’t ha v e goo New driver
D

Skipping good condition road

Work emergency

Front suspension
failure in jeeps

Material Method 40
 STEP:5.4CAUSE AND EFFECT DIAGRAM
MACHINE
Balancing rod cut
Frequent lower ball joint cut
Heavy load to the vehicle
Abnormal road condition
No walk around inspection Blasting Area
improper maintenance
No availability of vehicle

Operation in mining

Man

Front suspension
failure in jeeps

Material 41
Method
 STEP:5.5 CAUSE AND EFFECT DIAGRAM
Man Machine

Front suspension
failure in jeeps

Method
No proper suppliers
Many suppliers in market
Not heavy gauge material
Low cost material
Manufacture defect

MATERIAL
42
 STEP:5.6 CAUSE AND EFFECT DIAGRAM:

Front suspension
failure in jeeps

Abnormal road condition

No proper wheel alignment
Near blasting area
Rectifier unit failure Operator skip to abserve
No proper lighting
Night shift Emergency in work

METHOD 43
STEP:6 FINDING OUT THE ROOT CAUSES

44
 STEP:6.1 CAUSE AND EFFECT DIAGRAM:

Front suspension
failure in jeeps

Abnormal road condition

No proper wheel alignment
Near blasting area
Rectifier unit failure Operator skip to abserve
No proper lighting
Night shift Emergency in work

METHOD 45
6.2 Finding out the root cause
Finding the root cause by why why analysis
Front suspension failure

Mining Area

Abnormal road condition

Near Blasting Area

Ground clearance of vehicle limitation

Design limitation of the vehicle

6.3 Finding out the root cause
Finding the root cause by why why analysis
Front suspension failure

Mining Area

Abnormal road condition

Near Blasting Area

Ground clearance of vehicle limitation

In blasting area abnormal road condition

Design limitation of the vehicle

6.1
ROOT CAUSE ANALYSIS
BY CAUSE VALIDATION METHOD

Sl.No Probable Cause Validation Reason for validation

01 Front suspension failure in Valid More peoples wrong handling

jeeps

02 Operation procedures to be Valid No permanent operator

discussed with operator

03 Time to time maintains invalid Vehicle runs three shift

system

04 Wrong operation Invalid Vehicle are run by experienced

operators.

48
 ROOT CAUSE ANALYSIS
BY CAUSE VALIDATION METHOD

. Break Down Details of 10 Jeeps of model Bolero DI

Reason for Breakdown No of times
Battery discharge 15
Feed motor Failure 10
Front suspension failure in jeeps 40
Hose punctured 12
No supply for shut down valve 4
Failure starter motor 6

From the data it has been observed that Front suspension

failure in jeeps.
From the data lower arm bend due to less ground clearance of
vehicle and also abnormal road condition in mining area. 49
 7.1 Data Analysis

Break Down Details of 10 Jeeps of model Bolero DI

From the data it has been observed that Front suspension failure in
jeeps. From the data lower arm bend due to less ground clearance
of vehicle and also abnormal road condition in mining area.
50
 7.1 Data Analysis
Break Down Details of 10 Jeeps of model Bolero DI

From the data it has been observed that Front suspension failure in
jeeps.
From the data lower arm bend due to less ground clearance of
vehicle and also abnormal road condition in mining area. 51
7.4
354 Pareto Analysis 100

Break Down Details of 10 Jeeps of model Bolero DI

300 80

Vital few Useful many

% OF CUMULATIVE
B/D IN HOURS

250 60

130 40
punch hose

50 AlterN 20
Battery dis

et belt

supp
Star

No
nut
ter

ly
From the data lower arm bend due to less ground clearance of
vehicle and also abnormal road condition in mining area. 52
 7.1 Data Analysis

Reason for Breakdown No of times

.

Coil spring compressed 15

Shock absorber failure 10

Lower arm bend 40

Shock absorber bush worn out 12

Link rod bushes worn-out 4

Stud bar bend 6

53
 Brainstorming

Solution in the
scope of team

Good quality of
maintenance
SOLUTION
Long Term
Solution

Decrease spares
consumption
54
 STEP:8.2 Developing Solution (By Cause Validation Method)
Sl CAUSE PROPOSED SOLUTION EVALUATION / REMARK
No. IMPACT

1. Provide rubber mat No provision Not Feasable

2. Front Provide round bar in front of No provision Not Feasable

suspension suspension
failure in
jeeps
3. Operation procedures to be No permanent Not Feasable
discussed with operator operator
\\

4. Fix a plate with cushioning Provision to fix plate Feasable

rubber in front of suspension and
acceptable

The QC Members were convinced by the INNOVATIVE IDEA as mentioned in 4th Solution
STEP:8.3 Developing Solution (By Cause Validation Method)
Washers

6 mm
plate

Bolts
STEP:8.3 Developing Solution

Rubber Bushes
57
 STEP:8.3 Developing Solution

Video showing the Problem & the Root Cause

and solution plate
58
 STEP:8.3 Developing Solution

Plate Chassis
Frame

Pressure Switch
Rubber
bush

59
 STEP:8.3 Developing Solution

Rubber
bush

Before After

60
 STEP 9: FORESEEING PROBABLE RESISTANCE
(BY BRAIN STORMING)
S.No Agency Resistances Remedy
2. Mechanical Additional No additional maintenance
Maintenance maintenance is is required
required
3. Section In-Charge Needed more *Very Cost Effective
Investment

4. HOD, Jt.GM, More Shut Down No need of shut down

needed

61
 ESYA NAIK
Tools arrangements
RAMESH
MATERIALS ARRANGEMENT
B.Kotresh
Arrange spares
CHADRASHEKAR
Wiring
NARESH BABU
ARRANGING TOOLS
ANMOL ABADE
62
CROSS CHECK AND COORDINATION
 STEP 10: TRIAL IMPLEMENTATION
AND CHECK PERFORMANCE
Date:04/3/2022 to 31/8/2022

Sl No Reason for Breakdown No of times

1 Lower arm bend Nil

2 Upper arm bend Nil

3 Balancing rod cut Nil

4 Shock absorber 3

5 Coil spring 1

6 Balancing rod link Nil

63
 STEP 10.1: TRIAL IMPLEMENTATION
AND CHECK PERFORMANCE
Date:04/3/2022to 31/8/2022

Responsibilities Members
Checking for tyres condition ESYA NAIK

Check for any loose fittings Kotresh

Checking for balljoints RAMESH
Check for fixed plate CHANDRASHE
Check for maintanance Naresh
64
 11.1 Regular Implementation

Date:29/07/2022
Break
. Down Details Jeep of model Bolero SLE
Reason for Breakdown Before After
Lower arm bend 5 times Nil
Upper arm bush worn out 5 times 3 times
Balancing rod cut 2 times Nil
Balancing rod link cut 8 times 2 times
Lower arm bushes worn out 4 times 2 times
Shock absorber failure 2 times 1 times

65
 From the DATA

Break Down Details Jeep of model Bolero SLE

.

It has been abserved that from Data the total number of breakdown
hours reduced up to 90%

After implementation the break down time reduced to 100 hours to

30 hrs per month

From this front suspension in jeeps reduced from 100% to

30%

67
 गतिविधि चार्ट MILESTONE CHART (Target Vs Actual)
DEPARTMENT:
AUTO GARAGE HOD- DEBENDRA
HANSDAH
Quality Circle Name - facilitator-
YANTRA ANMOL

LEADER-
Esya naik
MEMBER’S NAME:S/SRI
PROJECT: B KOTRESH
Front suspension failure in jeeps REASON FOR SELECTION: RAMESH
02/ NARESH
1 CHADRASHER
DATE OF BEGINNING : 04.3.2022 DATE OF COMPLETION : 27/5/2022
9/12
1
16/
12
PROJECT No.-2
23/12

06/
01

13/
Sl 01
No Activity week 1 2 3 4 5 6 7 8 9 10 11 TARGET ACTUAL
20/
01
1 DEFINE THE PROBLEM 1 WEEK 1 WEEK
27/
01
2 ANALYSE THE PROBLEM 1 WEEK 1 WEEK
3/02
3 IDENTIFYING THE PROBLEM 1 WEEK 1 WEEK
10/
4 02 2 WEEK 2 WEEK
FINDING OUT OF THE ROOT CAUSES
We had targeted 11 weeks for this project and completed in 11 weeks. 68
5 DATA ANALYSIS 1 WEEK 1 WEEK
 ू लाभ TANGIBLE BENEFITS
अमर्त
 Tires worn-out reduced
 Lower arm failure nil
 Engine sump damage avoided
 Safe feel to the operator while driving
 All spares related to suspension like shock absorber, coilspring
bushes damage reduced to 100% to 30%
 Wheel bearing life increased
 Steering condition of the vehicle good
 While driving brake of the vehicle very effective
 Frequent wheel alignment of the vehicle reduced up to 50%

69
 ू लाभ INTANGIBLE BENEFITS
अमर्त
 KNOWLEDGE IMPROVEMENT ON PROBLEM SOLVING
TECHNIQUES (PST)
 INCREASE IN TEAM SPIRIT FOR PROBLEM SOLVING
 SELF SATISFACTION OF QC MEMBERS
 GOOD IMPRESSION FROM OTHER DEPARTMENTS
 HIGH MORAL & MOTIVATION
 HAPPINESS OF BEING RECOGNISED
 IMPROVEMENT OF ANALYTICAL ABILITY
 PUBLIC SPEAKING FEAR REDUCED
 IMPROVEMENT OF REASONING POWER
 INCREASE IN CREDIBILITY SCORE
 INCREASE OF MUTUAL TRUST BETWEEN MANAGEMENT & QC
MEMBERS 70
 SUMMARY OF THE PROJECT
What is the Problem?
Front suspension failure in jeeps

What is the root cause?

Less ground clearance of the vehicle in mining area

What is the solution developed?

Guard with cusioner(Rubber bush) provided in front of suspension system

What are the benefits of the solution?

Failure of suspension reduced from 100% to 30%(Approximately)

71
72