Quality Process Control and Preventive Maintenance Optimization of a Grinding Unit: A Case Study

Abstract

The studied process is a grinding and hydroclassification unit designed to ensure that the grain size it processes is in line with the specifications for the pipe's transport mode. Obstacles to the unit's operational process include frequent stops, plant's low reliability, product delivery with an inappropriate grain size, and a lack of control over operating parameters. These factors have a significant impact on the unit's relevance and, consequently, its performance. We created a quality culture among operators with “0 grain quality loss” through the implementation of the quality and processes control study, which was essential to improve the situation. Thus, by completing the seven project stages, we were able to enhance and optimize the grinding and hydroclassification unit's overall performance and capability to regulate the grain size quality. We noticed a notable improvement in regulating the several parameters that affect the targeted particle size after we established tools for unit quality control, such as control and monitoring charts, reaction matrices, intervention flow charts and operational standards. The unit has seen a great deal of satisfaction from the project in terms of quality, process control and resources optimization. Moreover, the incorporation of preventive maintenance into this process has shown to be crucial in guaranteeing the reliability and durability of the installation, thereby substantially improving the unit's overall efficiency.