Optimization of Quality Process Control and Preventive Maintenance Strategy: A Case Study

The studied process concerns a wet grinding and cycloning unit, set up to ensure that the particle size it processes complies with the requirements in terms of pipe transport mode. Frequent shutdowns, low reliability, the risk of delivering a product with inappropriate particle size, and the lack of operational parameters’ control are all obstacles for the unit, having enormous repercussions on its relevance and performance. To improve this situation, the implementation of an innovative 5-month quality and process control study has proven crucial to establish a culture of quality among operators, aiming to achieve the targeted grain size. However, the innovative aspects of our approach lie in its thoroughness and inclusiveness since it addresses the process both qualitatively and quantitatively, focusing not only on theoretically modeling and simulating the grinding circuit but also providing an integrated method to address every component of the unit. By going through the seven stages of this study, we were able to enhance the overall performance of the unit controlling the particle size at the output. After establishing a set of quality control tools, we observed a remarkable development in mastering various parameters influencing the targeted particle size. The benefits generated by the study are extremely satisfying for the unit at different levels, particularly in terms of quality, process control, and resource optimization. Furthermore, the integration of maintenance management into the process has proven essential to ensure the reliability and sustainability of the installation, thereby contributing significantly to the overall efficiency of the unit.