Implementation of a New Panel for the Boiling Unit to Improve Safety, Fault Detection, and Systematic Arrangement

PROBLEM STATEMENT

The old boiling unit panel lacked systematic arrangement, made fault detection time-consuming, and was missing critical safety features like an emergency switch and a phase indicator.

PROBLEM ANALYSIS

The disorganized layout of the panel made troubleshooting challenging. The absence of key features like an emergency switch posed safety risks during operation, and the lack of a 3-phase indicator made it difficult to monitor the power supply effectively.

ROOT CAUSE

The panel’s previous design did not account for a systematic arrangement of components.
No integrated mechanism for quick power shut-off in case of emergencies.
Lack of a 3-phase indicator to ensure consistent power supply monitoring.

KAIZEN IDEA

Replace the old boiling unit panel with a new one featuring systematic arrangement, easier fault detection capabilities, an emergency switch, and a 3-phase indicator to enhance safety and efficiency.

COUNTER MEASURE

Redesign the panel for systematic arrangement, ensuring clarity and ease of access to components.
Install a clearly marked emergency switch for immediate power cutoff.
Add a 3-phase indicator to monitor power supply status.
Train operators on the new panel’s features and emphasize its safety and efficiency benefits.

BENCHMARK

Reduce fault detection time by (Insert target percentage or time reduction).
Ensure 100% compliance with safety standards, including effective use of the emergency switch.
Ensure consistent power monitoring through the 3-phase indicator, reducing unexpected power-related issues.

QUANTITATIVE

Enhanced safety: The emergency switch provides quick power shut-off, reducing risks during malfunctions.
Improved fault detection: The systematic layout allows for faster troubleshooting and reduced downtime.
Better monitoring: The 3-phase indicator ensures consistent and reliable power supply tracking.
Increased operational efficiency: The modifications streamline workflows and improve overall productivity.