Project: Reduction in design and quality issues in combiner box

Quality Management and Improvement is one of Mahindra’s core pillars for the mission towards “RISE” philosophy and business excellence

For Solar projects, Mahindra Susten ensures the best quality EPC services with 25 years of design life. In 2016, Mahindra Susten and other EPCs executed more than 300MW in different geographies with different environmental conditions, from the performance analysis and health monitoring of equipment in these O&M projects. But it was observed that rising temperature became a common issue for the old constructed plants and even for a few installed till date. This issue was backed by various developers and approx. 80% OEMs have been struggling for the same reason.

Our quality team recognized an area of utmost concern often not looked upon by EPCs and equipment providers in the market, i.e. “Ventilation system” for equipment, which affects the performance and life of equipment.

We took it as a challenge to come out from this situation to ensure customer satisfaction in the long term. Since causes were multiple and the solution was unknown, we adopted Six Sigma methodology (DMAIC approach). We drilled down into the design aspects and nature of failures in the components, and had detailed meetings with the respective OEMs during data collection and analyses stages. Few Six Sigma tools that were used:

Define: Brainstorming and previous year data analysis

Measure: Identify Critical Xs and Ys, Initial Sigma Level

Analysis: Pareto Analysis, Ishikawa, Cause and Effect Matrix, Data Measurement Plan

Improve: Alternative Solutions, Benchmarking, Pugh Matrix, Sigma Level

Control: Rectification, Modification and Implementation on all existing and upcoming projects

Considering the above changes required, further projects design has been standardised with our quality requirements (component ratings, BOM required etc).

“Zero Punch points” and Yearly Savings of INR 1.2 Cr. For 1 GW projects.

1. Introduction of the plant
   1. Name and location – Multiple projects In Madhya Pradesh and projects installed in Gujarat
   2. How many MW  – Approx.  200 MWp projects improvement implemented. Target implementation in upcoming 1000 MW project.
   3. How has this plant helped locals: These plants helped electricity in over 1,30,000 households.
2. Problems: 
   1. Internal and external customer dissatisfaction
   2. Stress on the reliability of plant
   3. Generation loss and downtime
   4. Component burning issues leading to risk of fire hazard
   5. Degradation in life of equipment
3. Causes for the problems
   1. The rising temperature concept was not clearly understood by EPCs and OEMs. Since the industry is fast moving, compliance to all requirements is not taken care of by OEMs.
   2. IEC Compliance and requirements were not fulfilled.
   3. Air flow requirements  were not identified and taken critically by OEMs.
4. How did the team identify and tackle the problem?
   1. Issues identified when minor component burning converted to mass scale issue. 
   2. To tackle the problem following actions were adopted:
      1. Design and testing verification
      2. Six-sigma approach of DMAIC adopted
      3. Real-time parameters monitoring at site
      4. Mock-up conducted with different design configurations and data collected & analysed
      5. Air flow calculations defined through design and test rules.
      6. Incorporation in final design and on-site implementation as pilot.
5. Conclusion
   1. OEMs to take care of all defined guidelines as per IEC – 61439 part – 1 & 2
   2. Air flow requirements to be taken as CTQ parameters during the design stage itself.
      
      Project team: 
      • Mr. Saiyam Goyal – Supply Quality
      • Mr. M Eswararao – Supply Quality
      • Mr. Prashant Thakur – Procurement

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