Development of a system to ensure execution of multiple projects of steam turbine derivative designs
Date of Issue2016-03-23
School of Mechanical and Aerospace Engineering
Bharat Heavy Electricals Limited (BHEL), a Public Sector Unit, is India’s largest manufacturer of power generation equipment. To maintain its market dominance, the company has launched a new derivative product lines in 2008 and diversified its products. However, this increase in the number of orders has disturbed the balance of standardized parts and aroused a need of a new system framework for the execution of multiple orders. The purpose of this study is to conceptualize the execution of multiple orders as a systems model, to identify the problems and suggest possible solutions System Engineering. Fault tree analysis, causal loop and system archetypes are used to identify the underlying causes of major delays in engineering, procurement, installation and commissioning. The analysis was able to pin point the emergent behavior of relatively small fastening and holding parts like screw nut, slings and welding pipes in contributing to major delays. This finding was consistent in the QFD part matrix which showed that the relative importance of a small screw was similar to that of a primary part like bearing. Since these are small items, part matrix score evaluation before designing can determine their proper standard size and hence can be rectified at the source. Further, gaps in procurement policy were identified using SSM and were compared with conceptual model. These were identified as strength of normal projects and hence emphasized the need of having a separate framework for derivative products. An overall framework is developed keeping these factors in mind and using the lesser number of part changes to its advantage. The procurement system for derivatives can be better functioning if the contracts are incentive based and based on long term benefits for vendors as well. Further, the scarcity of vendors is to be resolved using a simpler registration system proposed in the framework. Lastly, a more frequent communication mechanism between commissioning and design engineers is proposed using tools like FMEA. It will ensure that designers become aware of the risks associated with small design changes in installing parts and keep enough factor of safety while designing them. The suggested framework will be able to cater the subcritical derivative product line of various ranges.