No.

Doc : F/KKI/K/006
Date report : Sep, 26th 2023
KAIZEN REPORT Revision :0
Date Revision :0
Page : 1 of 1

Problem Generator Forced Off Due to Limited Parameter

Generator Cummins has capacity of 500 KVA or 400 KW but few times we do load test, generator
forced off due to ampere to high, after some investigation DSE module got limitation on power and
current. The limit of power is 115% of 320 KWH and the limit of current is 100% of 500 A. In our
load test, power capacity hasn't reached limit yet but current is reached upper limit.

From that problem, we conclude a solution to remove limitation from Deepsea module in our
generator

ACTIVITY Remove Generator Limitation Parameter

① ②

Connect Deepsea module with laptop

or PC with DSE config suite app Read current configuration from module

③ ④

"Generator Current" option Change full load ampere limit

from "Generator" option from 500 A to 650 A

⑥ ⑦
⑤

Write configuration to module

Check configuration from Second check with battery on
panel
Note: Pass for our DSE4620: 2425
 No. Doc : F/KKI/K/005
Date report : 31 July 2023
KAIZEN REPORT Revision :0
Date Revision :1
Page : 1 of 2

ACTIVITY

① ② ③

Waste from MEPOXE Factory into decompose tank (cap max 420 Open valve NaOH for neutral until
RPM) pH 7
④ ⑤ ⑥

While NaOH valve is opening, sucked oil with vacuum pump Oil (mixed water) will go to
Turning on stirer form mepoxe Separation tank

⑦ ⑧ ⑨

Oil will burn to incenarator waste water transfer to bubbling tank bubbling water tank will
(Check AO and COD) bubbling upto 1 day

10 11 12

waste water into waste water sludge sedimentation will take collect sludge and waste
tank 1 manually provider will treat it
13 14 15

on afternoon, waste water from tank if OK, tank 7 will be released into
Check AO and COD for 1,4, 5,7
4 circulation ON outside
tank
Note: 1) Line rinse water mepoxe is still one with rainy line into waterwaste tank 5 . 2.) separation oil need
much time 3) Bosho separation is not optimal in bubbling tank 4) incenaration is not optimal 5) waste
water tank is not optimal
much time 3) Bosho separation is not optimal in bubbling tank 4) incenaration is not optimal 5) waste
water tank is not optimal
 No. Doc : F/KKI/K/002
Date report : 25 July 2023
KAIZEN REPORT Revision :0
Date Revision :1
Page : 2 Of 3

WASTE MAPPING AREA

 No. Doc : F/KKI/K/002
Date report : 25 July 2023
KAIZEN REPORT Revision :0
Date Revision :1
Page : 3 Of 3

KAIZEN WASTE MAPPING AREA

AEROB

OZONE

SCRUBBER
OIL SEPARATION

1. OIL SEPARATOR MACHINE

2. OIL ABSORBENT MATE

3. CARBON FILTER
 CONCENTRATOR

INDICATOR ABNORMAL

STEAM

SELENOID TIC
VALVE
BOILER

SCRUBBER
FOR EMISSION

SELENOID
VALVE
DRUM DRYER

PH-METER CONROL
 No. Doc : F/KKI/K/003
Date report : Jul, 25th 2023
KAIZEN REPORT Revision :0
Date Revision :0
Page : 1 of 1

ACTIVITY CuCl PROCESS

① ② ③

Prepared chlorine tank, check ON evaporator (note valve Open valve into reactor and check
pressure and leak auto is not function, so valve flowmeter (±175 kg Cl₂)
bypass manually)

④ ⑤ ⑥

preparation Cu (± 300 kg) and Preparation reactor and when the sample looks grey,
cut into smaller added Cu into reactor reaction is finish

⑦ ⑧ ⑨

urea

Pour CuCl into mold, and let it CuCl must be crushed before Use Urea to prevent moisture
cool and do size reduction

10
Note: while process, scrubber
must be ON.
1 Scrubber 1 is HCl,
3 2 Scrubber 2 is NaOH, and
Scrubber 3 is water.

Water NaOH HCl

product size about 400 mesh,
bigger size must be recycled
product size about 400 mesh,
bigger size must be recycled
 No. Doc : F/KKI/K/003
Date report : Jul, 25th 2023
KAIZEN REPORT Revision :0
Date Revision :0
Page : 1 of 4

ACTIVITY CHPO PASTE PROCESS

① ② ③

Preparation of DMP, EAA, Gate mixer, low speed: 15 min Move to kneader machine (3 times)
Wakker Silica, Yellow pigment, hight speed: 15 min
CHPO liquid

④ ⑤ ⑥

Measure 20,02-20,06 kg and charge in tube machine packaging in tubing form

packing in plastic bag
(double)

Inner cap
 No. Doc : F/KKI/K/003
Date report : Jul, 25th 2023
KAIZEN REPORT Revision :0
Date Revision :0
Page : 1 of 2

ACTIVITY CHPO LIQUID PROCESS

① ② ③

Prepared Prepared H₂O₂ 50%, Prepared Cyclohexanone, TEP, move on all to neutral tank (total 1)
H₂SO₄ 50%, HMPNa 5% flow into (2nd floor)
DMP enter into reactor and stir (no piping, nozzle temporary)
reactor (3rd floor) until 14⁰C 45 min

④ ⑤ ⑥

Added wet bosho (2nd floor) Added dry bosho (2nd floor) transfer to crude tank (3rd
mixed 2 hours, stop and (still manual) floor) by pump from
separated water (down phase) and cooling up to 10 ⁰C
(still manual)

⑦ ⑧ ⑨
crude tank

filter

open valve crude tank (3rd transfer to product tank and

floor) to filter tank (2nd floor) Packing Process
(filter material is paper), bosho added E-liquid (1st floor) (still manual)
will separated into wet bosho (bubling wih air vacuum)

NOTE:
⑦ filter bosho

paper filter
 paper filter

No. Doc : F/KKI/K/003

Date report : Jul, 25th 2023
KAIZEN REPORT Revision :0
Date Revision :0
Page : 2 of 2

reactor

neut tank
1
product
chamber
 No. Doc : F/KKI/K/003
Date report : Jul, 25th 2023
KAIZEN REPORT Revision :0
Date Revision :0
Page : 1 of 4

ACTIVITY MEPOXE PROCESS

① ② ③

a
1

b 2
Prepared H₂O₂ (a) and H₂SO₄(b) Prepared MEK and DMP, drop move on all to neutral tank (total 3 for
flow into reactor (3rd floor) in reactor (3rd floor) 3 shift) (2nd floor)
(still manual, H₂SO₄ Danger) (dropping still manual) (no piping, nozzle temporary)

④ ⑤ ⑥

Added wet bosho (2nd floor) Added dry bosho (2nd floor) transfer to crude tank (3rd
mixed 2 hours, stop and (still manual) floor) by pump from
separated water (down phase) and cooling up to 10 ⁰C
(still manual)

⑦ ⑧ ⑨
crude tank

filter

open valve crude tank (3rd transfer to product tank and

floor) to filter tank (2nd floor) Packing Process
(filter material is paper), bosho added E-liquid (1st floor) (still manual)
will separated into wet bosho (bubling wih air vacuum)

NOTE:
⑦ filter bosho

paper filter
 paper filter

No. Doc : F/KKI/K/003

Date report : Jul, 25th 2023
KAIZEN REPORT Revision :0
Date Revision :0
Page : 3 of 4

H₂SO₄ 50%

H₂SO₄ 50%
DANGER
CURRENT CONDITION
 No. Doc : F/KKI/K/003
Date report : Jul, 25th 2023
KAIZEN REPORT Revision :0
Date Revision :0
Page : : 1 of 2

ACTIVITY MEPOXE PROCESS

① ② ③

a
1

b 2
Prepared H₂O₂ (a) and H₂SO₄(b) Prepared MEK and DMP, drop move on all to neutral tank (total 3 for
flow into reactor (3rd floor) in reactor (3rd floor) 3 shift) (2nd floor)
(still manual, H₂SO₄ Danger) (dropping still manual) (no piping, nozzle temporary)

④ ⑤ ⑥

Added wet bosho (2nd floor) Added dry bosho (2nd floor) transfer to crude tank (3rd
mixed 2 hours, stop and (still manual) floor) by pump from
separated water (down phase) and cooling up to 10 ⁰C
(still manual)

⑦ ⑧ ⑨
crude tank

filter

open valve crude tank (3rd transfer to product tank and

floor) to filter tank (2nd floor) Packing Process
(filter material is paper), bosho added E-liquid (1st floor) (still manual)
will separated into wet bosho (bubling wih air vacuum)

⑦ filter bosho

paper filter
 paper filter

No. Doc : F/KKI/K/003

Date report : Jul, 25th 2023
KAIZEN REPORT Revision :0
Date Revision :0
Page : : 2 of 3

700 325 2450

2" 2" 2"

600 600
2" 2"
reactor
2" 1380
1350 1350
neut tank neut tank
1 2
product
chamber
1350
neut tank
piping crowded
3

net 1 net 2

net 3
 net 3
No. Doc : F/KKI/K/003
Date report : Jul, 25th 2023
KAIZEN REPORT Revision :0
Date Revision :0
Page : 3 of 3
 No. Doc : F/KKI/K/002
Date report : 25 July 2023
KAIZEN REPORT Revision :0
Date Revision :1
Page : 1 of 2

Mepoxe Old Factory CCTV Layout

Layout CCTV Old Factory 2nd Floor

Layout CCTV Old Factory 3rd Floor

3
1 2

Filter area Neut Tank Area Reactor area

 No. Doc : F/KKI/K/002
Date report : 25 July 2023
KAIZEN REPORT Revision :0
Date Revision :1
Page : 2 Of 2

Mepoxe New Factory CCTV Layout

4 6

Layout CCTV New Factory

3rd Floor

Layout CCTV Layout CCTV

New Factory New Factory
2nd Floor 3rd Floor

4 5 6

Filter area Neut Tank Area Reactor area

Engineering Note:
1. Ensure chemical vapor and dust do not distrub CCTV sight
2. Vibration from liftng machine must be considered
3. confined space for maintenance
 No. Doc : F/KKI/K/001
Date report : Jul, 21st 2023
KAIZEN REPORT Revision :0
Date Revision :1
Page : 1 of 2

ACTIVITY PACKING PROCESS

① ② ③

Empty Jerry can preparation Fill from Product Tank at same time, product is
weighed (e.g. > 5 kg)

④ ⑤ ⑥

final check, ensure insert inner cap and hit insert outter cap and rotate
product weight with tool with tools until cannot rotate

⑦ ⑧ ⑨

collect all products insert to carton packing and packing ready to keep at a
lock with finishing tape storage

Weakness Point

① Every mass product is different (actually over from standard. e.g for 5kg packing : 5,095 kg
netto. it can save quantity product when is controlled)
② Workers need 3 person to handle it (fill process, cap process, and packing process)

③ Locking and Capping is still manual, there is probability human error that cause leakage

Recommendation
Welding
① use liquid filling machine for controlling constant volume
② use conveyor for fast moving to locking and capping process
③ use lock and capping machine for ensuring finishing process
 No. Doc : F/KKI/K/001
Date report : Jul, 21st 2023
KAIZEN REPORT Revision :0
Date Revision :1
Page : 2 of 2

product
tank

filling
machine

priority

locking and
capping
 No. Doc : F/KKI/K/001
Date report : Jul, 21st 2023
KAIZEN REPORT Revision :0
Date Revision :1
Page : 2 of 2
 No. Doc : F/KKI/AR/003
Date report : Jul, 6th 2023
ABNORMALITY REPORT Revision :0
Date Revision :1
Page : :1

PROBLEM
pH-meter
deviation still
evaluated after
soaked KCl pH 4,
7 and 9
(instruction from
maker)

ANALYZE

RECOMMENDATION

Next order (export such as arab saudi) : Outter cap must be double checked when
① packing process (ensure :tight)

② Ask supplier to ensure all pins must have a hole.

③ Ask supplier to change inner cap into suitable/ fit and ensure inner cap fit in Jc one by
one.
Ask supplier to change inner cap into suitable/ fit and ensure inner cap fit in Jc one by
one.
 KCl pH=4 Deviation KCl pH=7 Deviation KCl pH=9 Deviation
PH-Meter PT KKI 4.22 7.27 9.65
PH-Meter Calibration 4.40 7.02 9.13
Litmus 4 7 9
Water (before soak KCl) Water (after soak KCl)
4.20 3.42
7.03 7.0
7 7
 No. Doc : F/KKI/AR/002
Date report : Jul, 7th 2023
ABNORMALITY REPORT Revision :0
Date Revision :1
Page : :1

PROBLEM ANALYZE

There are 1. Probably

some package is not
products got suitable with
out from chemical
packaging 2. Package
(Thailand) thickness is
2023 thinner than
standard DNT

TRIAL

① 4 cm
② 5 cm

3,5 cm
4,5 cm 13 cm
10 cm

3 cm
3,5 cm

current Package Trial Package/DNT

① 25 ② 25

20 20

15
TOTAL (DAY)

15
TOTAL DAY

10 10

5 5

0 0
CHPO OT CHPO NT CHPO TW DMP EAA CHPO OT CHPO NT DMP EAA
PRODUCT PRODUCT

thickness Current Package Thickness Trial Package/DNT

DNT CURRENT

0,59 mm

0,47 mm

RECOMMENDATION

① Change package that thicker than current package and suitable for CHPO.

② improve with alumunium sealer Alumunium Sealer

 No. Doc : F/KKI/AR/001
Date report : Jul, 6th 2023
ABNORMALITY REPORT Revision :0
Date Revision :1
Page : :1

PROBLEM

There are some leakages

on packaging 20 kg/Jc
(Korea)

ANALYZE

pin
① Outter cap is still not
fit when packing

Inner cap

② Inner cap form is

not too fit in Jc (a
little gap)

Outer cap

Jerrycan (Jc) ③ Probably, some

pin do not have a
packing 20 kg hole. It caused
vapor could not
release and made
pressure
increasing.

RECOMMENDATION

① Next order (export such as arab saudi) : Outter cap must be double checked when
packing process (ensure :tight)

② Ask supplier to change inner cap into suitable/ fit and ensure inner cap fit in Jc one by
one.
③ Ask supplier to ensure all pins must have a hole.