QUALITY MANAGEMENT

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QUALITY MANAGEMENT IN SCCL By J. NAGAIAH,
AGM (QM)
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• SCCL's QUALITY POLICY
• SCCL, a century old Fossil fuel producer in the
  country, serving the nation's energy needs, is
  committed to a "clean energy policy" by producing
  qualitative, marketable coal, that meets
  customers' requirement, ensuring safety and
  sustainable environment, for a healthy and
  prosperous nation, with a determination for an
  all-round continuous improvement, in all related
  fields, from coal production to it's utility at
  consumer's end with satisfaction, through
  effective Quality Management System.

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Functions of the Dept.
Sampling Analysis Coal Gradation Monitoring coal
grades Coal Linkages Statutory Monitoring Coal
grades Correspondence with CCO a) Open
Permission b) Closing notices c) Provisional
grades d) Final grades e) Monitoring coal
samples
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Definitions - In this order, unless there is
anything repugnant in the subject or context
Coal includes anthracite, bituminous Coal,
Lignite, Peat and any other form of
carbonaceous matter sold or marketed as coal and
also coke Coal Controller means the person
appointed as such by the Central Government under
the provisions of the Coal Controllers
Organisation (Group A posts) recruitment Rules
1986 Colliery means any mine or open working
where winning or extraction of coal is the
principal object of the mining, quarrying or any
other operation carried on therein and includes a
plant for the production of coke or for the
washing of coal Disposal includes agreeing
or offering to dispose of, and the disposal of
ownership or any proprietary interest, the right
of possession and possession whether or not
accompanied by any disposal of ownership or of
any proprietary interest or of the right to
possession Agent Manager and Owner when
used in relation to a colliery shall have the
meanings respectively assigned to them in the
Mines Act, 1952 Size when used in relation
to coal shall have the same specification as
given from time to time, by the Bureau of Indian
Standards in their specification number IS437
1979
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DETAILS OF SOME ABBREVIATIONS CHP- Coal
Handling Plant CSP- Coal screening Plant
(Equivalent to CHP) FSA- Fuel Supply
Agreement C.C.O- Colliery Control Order,
2000 C.C- Coal Controller Sec Section
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QUALITY
Quality thus defines a high degree of men
material and thing or goodness, worth or
usefulness of the goods. In this context, let us
take high degree of the material which SCCL
produces i.e. COAL. This chapter mainly deals
about the COAL QUALITY.
ROLE
Quality play major role for industrial
development. Marketing a product is mainly based
on the quality of the product. Coal industry had
already experienced the necessity of maintaining
quality, since Sellers market has become buyers
market.
IMPLICATIONS

1. Quality of coal virtually is a key for the
   survival of the coal industry as well as other
   organizations.
2. Quality attracts the customer as build the well
   as relations.
3. Quality makes the organization financially
   viable/ sound

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Steps to Improve the Quality
At face (UG) ? By working
only rich section/ bands of the seams ? By
segregating the shale / clay ? By separately
loading and transporting of good coal ? By
picking of stones and other extraneous
material ? By commitment of face workmen and
? By Increasing inspection by officials.
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At face (OCP) ? By elimination of contamination
of OB ( over burden) with coal bench. ? By
separation of inferior coal bands and
transporting separately. ? By selective
mining. ? By working seams as per the blending
ratios. ? By arranging picking arrangements at
coal benches as well as along the quarry belts.
At CSP/CHPs Mine Elevators ? By picking
shale / stone or any other extraneous material
at crushers and from belt conveyors. ? By
arranging crushers to break huge lumps to
required size. i.e. 200mm. ? By arranging
magnetic separators. ? By regulating flow of
different grade coal as per the blending
ratios for dispatch. ? By arranging grade wise
coal stocks yards for easy blending
purposes. ? By deputing supervisors at CSP/ CHP
to check the coal being transported from the
mines.
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• Categorisation of coal -
• The Central Government may, by Notification in
  the Official Gazette, prescribe the classes,
  grades and sizes into which coal may be
  categorised and the specifications for each such
  class, grade or size of coal.
• Procedure for categorisation of coal -
• (1) On the basis of the categorisation notified
  by the Central Government under clause 3, the
  CoalController shall lay down the procedure and
  method of sampling and analysis of coal for the
  purpose of declaration and maintenance of grades
  of coal mined in a colliery.
• The owner, agent or manager of a colliery shall
  declare the classes, grades or sizes of the coal
  of any seam or section of a seam in a colliery in
  accordance with the procedure specified in
  sub-clause (1).
• The owner, agent or manager of the colliery
  shall allow the inspection of the colliery
  undertaken by the coal controller or any officer
  authorised by him in this regard so as to ensure
  the correctness of the class, grade or size
  declared. During inspection of the Coal
  Controller or the officer authorised by him
  decides to draw samples, the owner, agent or
  manager of the colliery shall provide all
  reasonable facilities and assistance for drawing
  such sample.
• If after the inspection or from the sample
  drawn, the Coal Controller is satisfied that the
  grade as declared by the owner, agent or the
  manager of the colliery does not conform to the
  grade notified under clause 3, the owner, agent
  or manager of the colliery shall be bound to
  revise the grade as per the directions issued by
  the Coal Controller.
• If any dispute arises between a consumer and a
  owner of a colliery regarding the declaration of
  grades of coal, the same may be referred to the
  Coal Controller whose decision shall be binding
  on the owner of the colliery. A memorandum of
  reference to the Coal Controller regarding such
  dispute shall be accompanied by a fee of rupees
  two thousand and five hundred and in such manner
  as may be specified by the Coal Controller, from
  time to time.

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QUALITY MONITORING Collecting samples form
mines / CSPs/ CHPs Analysing them at regular
intervells to the status of grades of coal is
called the quality monitoring system.

• SAMPLING SYSTEMGRADATION OF COAL
• There are two types of sampling systems .
• Channel sampling system For gradation of coal
  seams/ bands and to finalize the grades of seam/
  section or bands of seam.
• Statutory sampling system For regular monitoring
  of coal grades

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• Mode of channel samples
• These samples are collected form coal seams by
  cutting channels with 30cms width and 10 cm thick
  to a height of working section of the seam or of
  required to the full height of the seam.
• Before taking the channel samples, the concerned
  mine authorities should devide the areas of the
  sample spot which normally cover the working area
  of the year thus it represents the tentative
  quality of coal to be mines in that area.
• Before starting the channel cutting the side of
  the seam neatly dressed down and floor also
  should be kept clean.
• The width of the channel should be clearly marked
  by colour bands
• Each layor chipped by a chessel and collected
  separately in gunny bags marked distringctly.
  All such samples collected in gunny bags should
  be sent for analysis where layor wise analysis
  will be done and seam wise grade are thus
  declared.

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• Mode of monitoring samples These samples are
  collected from coal streams from conveyor belts
  or form moving trucks / wagons.
• Auto sampling systems
• Conventional sampling system

• Conventional sampling
• Samples from stock piles
• Samples from trucks/ tubs
• Samples from wagons
• Samples from ships
• Samples form conveyor belts

• Basis of samples
• Time basis
• Moss basis
• Mode of collection of samples.
• Samples of coal collected by increments. No. of
  increments depends up on the quality of coal to
  be sampled and quality of coal in an increment.

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All the coal thus collected through increments in
three shifts is piled and crushed to 200 mm and
taken ¼ of it by coning and quartering and
crushed to 50/ 25 mm again coning and quartering
and crushed to 3 mm. This 3 mm size powder is
made in to 3 bags each 2 Kg as below. One 2 Kg
pocket for seller One 2 Kg pocket for buyer
One 2 Kg pocket for Referee and sent it
laboratory.

• ANALYSIS At laboratory 3 mm size powder is
  again pulverized to -212 micron size.
• 3 samples each 2 to 3 grams is taken and
  analyzed for
• External moisture
• Equilibrated moisture and
• Ash content.
• All the above are calculated to percentages and
  by applying the following formulation the UHV of
  the coal is calculated. Thus arrived coal grades.

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Coal grades
HEAT VALUE RANGES - GRADE WISE ( GCV vis-a vis UHV Grading) HEAT VALUE RANGES - GRADE WISE ( GCV vis-a vis UHV Grading) HEAT VALUE RANGES - GRADE WISE ( GCV vis-a vis UHV Grading) HEAT VALUE RANGES - GRADE WISE ( GCV vis-a vis UHV Grading) HEAT VALUE RANGES - GRADE WISE ( GCV vis-a vis UHV Grading) HEAT VALUE RANGES - GRADE WISE ( GCV vis-a vis UHV Grading) HEAT VALUE RANGES - GRADE WISE ( GCV vis-a vis UHV Grading)
  G.C.V Grading G.C.V Grading   U.H.V Grading U.H.V Grading U.H.V Grading
S. (AM) GCV Grade   (AM) UHV Grade
No at M6 in K.clas/Kg       in K.clas/Kg  
1 15.30 gt6800 A1        
2 17.50 6600 - 6800 A2        
3 19.60 6400 - 6600 A3   19.50 gt6200 A
4 21.70 6200 - 6400 B1        
5 23.80 6000 - 6200 B2        
6 26.00 5800 - 6000 B3   23.90 5600 B
7 28.10 5600 - 5800 C1        
8 30.20 5400 - 5600 C2   28.60 4940 C
9 32.30 5200 -5400 D1        
10 34.50 5000 -5200 D2        
11 36.60 4800 -5000 D3   34.00 4200 D
12 38.70 4600 -4800 E1        
13 40.80 4400 - 4600 E2        
14 43.00 4200 -4400 E3   40.10 3360 E
15 45.10 4000 -4200 F1        
16 47.20 3800 -4000 F2        
17 49.30 3600 -3800 F3   47.10 2400 F
18 51.50 3400-3600 G1        
19 53.60 3200 - 3400 G2   55.10 gt1300 G
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Emperical Formulaes Emperical Formulaes
1. GCV 85.56X 100 - (1.1A) M - 60M K.cals/Kg
2. UHV 8900- 138 X (A M) K Cals/Kg 2. UHV 8900- 138 X (A M) K Cals/Kg
Where A Ash and M moiture dtermined at 60 RH and 400C. Where A Ash and M moiture dtermined at 60 RH and 400C.

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Coal beneficiation
GDK 2A, RG I 1.80 LT ROM-D UHV 4606
GDK 5A, RG I 1.00 LT ROM-D UHV 4710
GDK 6A, RG I 1.50LT ROM-D UHV 4453
GDK 7 LEP RG I 0.20 LT ROM-D UHV 4409
GDK 6B RG I 3.40 LT ROM-D UHV 4401
Linkage
GDK 8, RG 2 0.40 LT ROM-C UHV 5276

• GDK OCI CHP
• 60.28 LT
• UHV 4296 K.Cals/kg
• Cr. ROM-D

GDK 8A, RG 2 2.38 LT ROM-E UHV 3611
GDK 9, RG 2 1.10LT ROM-E UHV 3689
GDK 10, RG 2 0.40LT SLACK-D UHV 4892
GDK 10A, RG 2 0.10LT ROM-E UHV 3385
GDK. OCP2 RG-4 20.00LT ROM-D UHV 4579
GDK. OCP1 RG-4 24.00LT ROM-E UHV 4031
Med. OCP, RG-3 4.00LT ROM-D UHV 4507
Linkage summary and revenue Projections
S. No Details of admitted coal Details of admitted coal Details of admitted coal Details of admitted coal Details of admitted coal Details of dispatched coal Details of dispatched coal Details of dispatched coal Details of dispatched coal Add. Realisation Rs.Cr
S. No Type Grade Qty Qty (LT) Sale Value Type Grade Qty (LT) Sale value Add. Realisation Rs.Cr
1 ROM E 27.58 45.75 225.33 Cr ROM D 60.28 708.29 112.86
2 ROM D 32.30 53.58 364.99
3 ROM C 0.40 0.67 5.11
4 Total 60.28 100.00 595.43 60.28 708.29 112.86
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GRADE-WISE PRODUCTION FOR 2007-08
GRAD
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SCCL LINKAGE PLAN FOR 2007-08
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FINANCIAL IMPLICATIONS ON SLIPPAGE OF COAL GRADES
One grade slippage Rs. Ps B C
170.40 C D 293.90 D E 430.50 E F 13600 F
G 17800
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Quality - Responsibility

• Planning stage Selective Mining Agt/ Mgr
• Execution - Drills / Districts -
  Asst.Mgr/ U/Mgr
• Supervision - Separation of - Overman/
  Sirdar
• Shale/Stone
• Work - Picking of -
  Workmen
• Shale/Stone

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Quality Improved at GDK-3 Inc
Some of the case studies

COAL
- 2 M
Present working Section Grade D
Previous working Section Grade E
COAL
CLAY
COAL
? Instead of taking coal clay and coal with
3.4 Mts. The working height is restricted to 1.8
to 2 M along the floor/ roof to maintain quality
of coal D than E
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Quality Improved at GDK-2A Inc

COAL
Present working Section Clay Coal separately
blasted and lifted Grade D
3.6 M
Previous working Section Including Clay Grade E
CLAY
COAL
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Quality Improved at GDK- 5A Inc
Present working Section above clay leaving coal
band Grade D

COAL
- 2 M
Previous working Section with clay Grade F
COAL
CLAY
COAL
? Revenue gain Rs. 2,37,60,000-00 only 2
Mtrs. Thick coal band above clay is worked and
improved grade from F to D
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Quality Improved at GDK- 8A Inc
CLAY
0.4 Mtrs. Clay
C O A L

• Clay is first blasted and shifted
• After removing clay coal is blasted and lifted.
• Selective Mining Where top clay is present
  Thus grade improved to D form E/F.
• Revenue gain Rs. 2.6 crores

2.8 Mtrs Coal
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Quality Improved at GDK- 10A Inc

CLAY
Previous working Section 3.5 Mtrs. with clay
Grade F
COAL
CLAY
Present working Section below the clay leaving
coal band as support to clay band Grade D
COAL
COAL
A 30Cms. Coal lays below clay is left as support
against clay and only coal up to 3 Mtrs. Worked
thus improved coal grade from F to E
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Quality Improved at KTK-2A Inc

CLAY
Clay separately blasted lifted
COAL
Previous working Section with clay Grade F No
Customer
Only coal loaded separately Grade Improved F
to E
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1.

PRODUCTIVITY BEST
SAFETY FIRST
QUALITY MUST
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QUALITY IS
2.
ABILITY
CLARITY
MIGHTY
QUALITY IS
CUSTOMER
YOUR
OUR
STRENGTH
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• 3. QUALITY IS

OUR
YOUR
CUSTOMER
STRENGTH
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• 4. QUALITY IS

ABILITY
MIGHTY
CLARITY
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SLOGANS ON QUALITY

• Safety first.
• Production best.
• Quality must

• SINGARENI
• Runs for quality.
• Mines for quality and
• Wins quality

• Aim for quality
• Act for quality and
• Achieve quality.

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4. S - Strives for quality I - Inculcate
awareness for quality N - Name for
quality. G - Gives quality A - Assures
quality R - Runs for quality E - Eyes for
quality N - Never looses quality I - Inspire
for Quality
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• Q - Qualify yourself in quality
• U - Unanimously maintain quality
• A - Assure quality and achieve quality
• L - Look for quality
• I - Improve quality
• T - Thirst for quality
• Y - Yield quality all the time

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• Quality is our strength
• Qualitative quantity of coal is our priority
• Question for quantity and quality
• Introduce new technology for high quality
• Quality and quantity should go hand in
  hand.
• Aim for NO impurity and achieve quality
• 12. Quality is our motto
• 13. Quality is only the way for sellers and
  buyers

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UNDER JURISDICTION OF DIRECOTR (PP)
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UNDERJURISDICTION OF DIRECTOR (OPERATIONS)
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• QUALITY PLEDGE
• (For SCCL Employees only for its use during the
  annual quality assurance week)
• We solemnly take oath that we make our best
  efforts and strive hard to produce qualitative
  coal by segregating it from clay, stone, shale
  etc.., in a cost effective manner.
• We are happy to share our responsibility in
  qualitative coal production and dispatch to the
  best satisfaction of the customers in the
  national interest.
• We trust that this pledge is a first step in our
  quality march, which finally results in the over
  all development of us, as individuals, as a
  company and finally our motherland.

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Thank You