In the changing scenario of the power sector and ever increasing stringent environmental and regulatory norms, NTPC power plants need to operate efficiently and with high reliability. On real time basis when a unit is in operation there are number of process parameters which needs focused attention to achieve the higher level of efficiency and reliability. This project is an outcome of an innovative thought on achieving zero aberration in the process parameters. In order to achieve the target of zero aberration, project deployed DMAIC approach and used quality tools like Failure Mode Effect Analysis (FMEA), Fish Bone, Pareto, IMR Charts, Poka- Yoke etc. and embedding the same with Information Technology (IT) tools, Plant Information (PI) module for real time monitoring & solutions.