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Lean Six Sigma. Increasing Waste Activated Sludge. Cheryl Cronin, Waste Water Treatment Plant . Project Description. Only 50% of W.A.S is processed through the Centrifuge currently at an average Total Solids of 2.2%. Gallons wasted in 1999 – 176.15 MG

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slide1

Lean Six Sigma

Increasing Waste Activated Sludge

Cheryl Cronin, Waste Water Treatment Plant

project description
Project Description
  • Only 50% of W.A.S is processed through the Centrifuge currently at an average Total Solids of 2.2%.
  • Gallons wasted in 1999 – 176.15 MG
  • Gallons Processed at Centrifuge – 88.1 MG
  • Average TS (Thickened) – 2.2%
  • Average TS (W.A.S) – 0.7%

Problem Statement:

Increase gallons of W.A.S. processed by 40% and increase Total Solids to 4 to 5%

Objective:

benefits
Benefits
  • Savings of $28,000 per year (fuel and treatment)
  • $1.7 M for additional digester space
  • Plant able to treat 88,000,000 more gallons per year – Reduction in CSO’s
slide4

Project Team

Champion: Ted Rhinehart

Financial: Ned Byrer

Black Belt: Cheryl Cronin

Mechanic: Brian Panzer

Process Analyst: Gwen Bard

Laboratory: John Kohne

Operator: Mike Glymph

Operator: Jeff Vachon

Technical: Chris Gach

slide5

Schedule

  • Measurement: 07/17/00
  • Analyze: 08/25/00
  • Improvement: 09/29/00
  • Control: 11/03/00
  • Completion 12/30/00
slide6

Savings

  • Digester Space – Less Water, less energy for heating.
    • 33% reduction in use = $10,000.00
  • Additional Digesters
    • “Class A” sludge must have a 38% reduction in Volatile Solids and 15 day Detention time.
    • Currently there is an average 45% reduction and 7 day detention. By EPA standards, another digester is needed to achieve a 15 day detention at a cost of $1.7M.
  • Reduction of Million Gallons Treated
    • $18,000 in savings
  • Increased Capacity of Primaries Tanks
slide7

“Y”

Y =

Million gallons of W.A.S. processed through Centrifuge at 4% TS or higher per week

slide11

Revised Objective

  • After completing process mapping and the C & E matrix we were able to improve the process by moving the average thickness of the sludge to 5.2% and have kept the centrifuge running for 3months non-stop.
  • My new objective is to increase the gallons of WAS sludge processed by 40% and increase the thickness of the sludge to 6 to 8%.
slide13

Measurement Studies

  • Developed a more timely method to measure the influent W.A.S
  • Developed a method to measure the thickened sludge out of the centrifuge during production
  • Current methods are 24 hours behind actual operation
slide14

Thickened Sludge Measurement System

  • Rented a viscometer and did an initial study that told us that we should be able to correlate CPs with % solids.
  • Did a Gage R % R to confirm
slide16

Effluent Gage Stats

StdDev Study Var %Study Var %Tolerance

Source (SD) (5.15*SD) (%SV) (SV/Toler)

Total Gage R&R 1622.6 8356.3 13.90 8.36E+05

Repeatability 1037.6 5343.4 8.89 5.34E+05

Reproducibility 1247.5 6424.5 10.68 6.42E+05

C1 75.6 389.2 0.65 38923.91

C1*trials 1245.2 6412.7 10.66 6.41E+05

Part-To-Part 11563.4 59551.5 99.03 5.96E+06

Total Variation 11676.7 60134.9 100.00 6.01E+06

Number of Distinct Categories = 10

slide18

Influent Gage Stats

StdDev Study Var %Study Var

Source (SD) (5.15*SD) (%SV)

Total Gage R&R 0.040044 0.20623 19.76

Repeatability 0.035285 0.18172 17.42

Reproducibility 0.018934 0.09751 9.35

Operator 0.018934 0.09751 9.35

Part-To-Part 0.198604 1.02281 98.03

Total Variation 0.202601 1.04339 100.00

Number of Distinct Categories = 7

slide19

Multi-Vari Testing

  • Collected Data on Operators, Shift, Wet Well Height, Lab centrifuge results, Feed rate, Pinion Speed, Load, Viscometer results.
  • Length of the Test 12 days
  • Purpose to eliminate more “Xs”
slide21

Conclusions to Multi-Vari

  • We can make either thick or thin sludge but have problems making sludge in the 6 to 7 % range.
  • We see that operators still have separate methods for making sludge.
  • We have developed a reliable method for determining the thickness of influent sludge.
  • Load is significant to making thick sludge
slide22

Conclusions to Multi-Vari

  • Wet well height is not significant
  • Operators have a big impact on sludge produced
slide23

Progress Update

Centrifuge runs 44.9% of the available time

INITIAL CAPABILITY

POST-PROJECT CAPABILITY

Centrifuge runs 82% of available time

Total Improvement

Our goal was to improve processing time by 40 %. To date processing time has improved 37.3%

slide24

Centrifuge Runtime

July-December 2000

slide25

Progress Update

Initial Capability

2.2% Average Total Solids

Initial Goal

Increase to 4-5% Average Total Solids

Final Capability

5.01% Average Total Solids

slide26

Thickening Results

3.4%

4.7%

5.1%

5.8%

5.6%

5.3%

5.0%

slide27

Progress Update

  • Volatile Solids Reduction in 1999 was 44.9% and in the last 6 months of 2000 it has increased to 58.4% Goal is to be above 38%
  • Detention time in the Digesters in 1999 was 7.3 days and since this project was started the average detention time has increased to 10 days in December . Goal is to be 15days or better.
slide29

Progress Update

  • In 1999 $8,200 was spent on diesel fuel.
  • In 2000 $244. was spent on diesel fuel.
slide30

Project Tracking

Project Tracking

Project

Description

Process

Map

C & E

Matrix

Preliminary

FMEA

MSA

Measure

Analyze

Improve

Control

Initial

Capability Study

Multi-Vari

DOE (or other improvement)

ControlPlan

Hand OffTraining

Final Capability Study

OwnerSign-Off

Final ProjectReport

slide31

Next Step

  • Set up at DOE (February)
  • Develop a control Plan (March)
slide32

Hands-Off Training

In December of 2006, all equipment and programming changes were completed. The operators no longer have to make any adjustments once the process has started. They only have to set the load needed and the PLC does the rest.