2

EXECUTIVE SUMMARYMACHINE DOWNTIME CD BAR YR 2014/2015

CD BAR YR 2013 by %FEB14

MAC14

APR14

MAY14

JUNE14

JULY14

AUG14

SEPT14

OCT14

NOV14

DEC14

JAN 15

TARGET MC D/TIME

8 8 8 8 8 8 8 8 8 8 8 8

ACTUAL % 1010 7 6 3 7 7 4 7 6 8 9 9TARGET

PM100 100 100 100 100 100 100 100 100 100 100 100

SCORE CARD PM

9595 86 77 74 72 75 73 79 87 84 79 86

SCORE SHEET TARGET 85%

MC D/TIME TARGET 8%

EXECUTIVE SUMMARYCD BAR MACHINE DOWNTIME ANALYSIS REPORT Downtime by Hours & Category

Major Downtime

Cause Action Status

Shot BlastShot Blast

- Motor don’t move as usual. ( Belt problem), Bar not shine (clogged dust collector)- Motor not balancing ( belting drop) & Concussion machine

- Change new belting, rotation motor & setting impeller 1,2,3 & 4- Change new belting & impeller

Done on 8 Jan 2015Done on 21 Jan

2015

CraneCrane - Trip ( wire pendant cable short) - Change new wireDone on 15 Jan

2015

4

MACHINEFEB ’14

MAC ’14

APR

’14

MAY

’14

JUN’14

JULY

’14

AUG

’14

SEPT

’14

OCT ’14

NOV

’14

DEC’14

JAN’15

PAY OFF STAND 2.00 9.25 0.00 0..00 10.50 4.50 0.00 0.50 0.00 0.00 0.00 0.00

PRE-STG 0.50 0.00 0.00 0.00 0.00 0.00 5.00 1.00 0.00 0.83 0.00 3.50

SHOT BLAST 0.00 0.00 3.00 0.00 0.00 0.00 0.00 0.00 0.00 2.50 11.75 7.00 DRAWING CARRIAGE

5.50 0.83 1.50 5.00 0.00 3.91 0.00 0.00 7.25 9.92 6.65 1.50

V-H ROLLER 0.00 0.00 0.00 0.00 0.00 0.00 1.50 0.00 0.00 0.00 0.00 0.00

SHEARING 3.00 0.00 0.00 0.00 0.00 0.00 0.00 1.33 0.25 2.50 0.00 0.00

PINCH ROLLER 0.00 0.00 0.00 0.00 0.00 0.00 0.50 0.00 0.50 2.00 0.00 0.25

2 ROLLER 0.00 0.00 2.75 0.00 0.00 7.00 0.50 7.50 0.00 7.00 0.00 0.00

DELIVERY TABLE 0.00 0.00 0.25 0.00 0.50 0.50 1.25 0.00 0.00 0.00 0.00 0.00

ECT 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00

KLN 0.00 0.00 0.00 0.00 0.00 1.50 8.75 0.00 0.00 0.00 1.25 0.00

SHEAR CUTTING 0.0 0.00 0.00 0.00 0.00 1.50 12.25 3.00 0.00 0.00 1.25 1.75

DUST COLLECTOR 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00

POINTING 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00

CRANE 0.00 0.00 0.00 0.00 0.00 0.25 0.00 0.00 0.00 0.00 0.00 7.99

LASTIC 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.50 0.50 0.00 0.00

COMPRESSOR 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00

Cooling Tower 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 1.50 0.00 0.00

TOTAL 11.00 10.08 7.50 5.00 11.00 19.16 29.75 13.33 8.50 26.7526.4

021.99

CD MAINTENANCE COST ANALYSIS 2014/2015(TOTAL REPAIR & MAINTENANCE + CHARGE OUT SPARE PART)

Charge out above 1 Year,

Shall be charge under depreciation

(TOTAL REPAIR & MAINTENANCE + CHARGE OUT SPARE PART BY MACHINE)

CD BAR COST DRAWING

Target RM 612

4

Major Downtime Cause (data by history card) Action Status

11 Drawing CarriageDrawing Carriage

-Machine can’t run (Bearing problem) -Arm contactor ( cant adjust jaw )- Carriage no.2 jerk ( Cylinder no.2 problem)- Machine can not clamp (arm bush uprooted), Power supply for IO card problem-Bar scratch. Valve air not opened, Machine not consistent (Jerk).-Sequence drawing table problem (setting problem), Machine can’t auto (cylinder drawing 1 current jammed) . Bar stuck at shooter pipe (have 2 bar in shooter pipe & Cylinder jammed (screw at cylinder loose)

- Alignment & bearing problem- Change arm contactor- Change solenoid valve , cylinder & encoder.- Repair arm & change new IO card - Open valve, Check wiring, troubleshoot, solder wire & change encoder- Adjust setting, Change cylinder & pull out bar from shooter pipe & checking valve , air pressure and part cylinder

Done on Feb 14Done on March

14Done on May 14Done October 14

Done on November 14

Done on December 14

22 2 Roller2 Roller

- Oil does not come out - Upper roll position do not follow the setting (ERROR) – (servo controller out alarm encoder for upper roll angel)- Alarm ( inverter fault) - Machine can’t auto ( DC controller burn), Machine can’t on ( PLC AX41C broke)

- Change belting & 1 set motor pump.- Reset PLC, Check encoder upper roll position. Call PLC contractor, setting all program, parameter upper roller position by operator.-Change new inverter, resistance breaker & dynamic breaker circuit- Change new DC Controller & PLC AX 41C)

Done on April 14Done on July 14Done on Sept14

Done on November 14

33 Pre-StraightenerPre-Straightener -Charge out spare part . -Charge out spare part .Charge out spare

part .

44 Shot BlastShot Blast

- Guide fracture . -Bar scratch (guide bar at shot blast machine - bar jammed, belting failure (pulley jammed), Quality problem (liner leak) - Bar not shine

- Alignment.-Repair/welding guide no.2 & replace new guide no.3, Change new belting, liner, adjust cylinder gate & clean up at small door - Change new belting, rotation motor & setting impeller 1,2&3

Done on April 14Done on

December 14Done on Jan 15

TOP 4 MACHINE BREAKDOWN

Sapura Machining Corp Sdn Bhd8

HIGHEST MACHINE BREAKDOWN IN JANUARY 2015LINE : CD BARMACHINE : DRAWING CARRIAGE/MEASURING ROLLERTYPE OF DAMAGE : BAR CUTTING NOT CONSISTANT/BAR SCRATCHTOTAL PRODUCTION : AVERAGE 10 TONNES PER DAY SPEED 30m/s

LineCatego

riesDepart. Issue Cause Immediately Action

Quantity/

Frequency

Part Price

Total Prod

Output

CD Bar

Machine

Measuring

Roller

Maintenance

Length bar

cutting long/short

after shear

Encoder measuring unit fault

Replace new encoder(28/01/15)

10 Times

RM 3.6 K

10 Tonnes per day speed 30m/s

CD Bar

Machine

Horizontal

vibration Roller

Maintenance

Bar scratch

after drawing

Bar stuck with

jammed roller at vibration

roller

Overhaul with SMC refurbish team,

temporary action to ensure machine can

run.(26/01/15) to fabricate new shaft & bearing

housing reverse engineering action

15 Times

Waiting

Quotation

10 Tonnes per day speed 30m/s

CD Bar

Drawing Die

Tool & Die

Bending NG for

dia. 10.84 & 10.24

Bending NG >

1.5mm

Trial run on 4/3/15Fuji Dies, Japan visit

5/3/15100%

¥ 25,00

0

60 Tonnes for 2

model

AFTER TAKE ACTION, PRODUCTION CAN RUN AN AVERAGE OF 15 TONNES PER DAY SPEED 45M/S - 50M/S.

28 JAN 2015, PRODUCTION ACHIEVED 31 TONNES SPEED 45M/S FOR SB31 DIA. 24 WITHOUT DEFECT

MACHINE Before After

MachineMeasuring

Roller

MachineHorizontal vibration

Roller

ACTION PLAN

Sapura Machining Corp Sdn Bhd10

HIGHEST MACHINE BREAKDOWN IN FEBRUARY 2015LINE : CD BARMACHINE : DRAWING CARRIAGE/MEASURING ROLLERTYPE OF DAMAGE : BAR CUTTING NOT CONSISTANT/BAR SCRATCHTOTAL PRODUCTION : AVERAGE 10 TONNES PER DAY SPEED 30m/s

LineCatego

riesDepart. Issue Cause Immediately Action

Quantity/

Frequency

Part Price

Total Prod

Output

CD Bar

Machine

Measuring

Roller

Maintenance

Length bar

cutting long/short

after shear

Encoder measuring unit fault

Replace3 new encoder(measuring, speed motor and shearing

motor)(27/02/15)

10 Times

RM 3.6 K

10 Tonnes per day speed 30m/s

CD Bar

Machine

Horizontal

vibration Roller

Maintenance

Bar scratch

after drawing

Bar stuck with

jammed roller at vibration

roller

Overhaul with SMC refurbish team,

temporary action to ensure machine can

run.(26/01/15) to fabricate new shaft & bearing

housing reverse engineering action

15 Times

Waiting

Quotation

10 Tonnes per day speed 30m/s

CD Bar

Drawing Die

Tool & Die

Bending NG for

dia. 10.84 & 10.24

Bending NG >

1.5mm

Trial run on 4/3/15Fuji Dies, Japan visit

5/3/15100%

¥ 25,00

0

60 Tonnes for 2

model

CD Bar

Shot blast

Maintenance

Uneven cd bar surface

Too many dust in steel shot

Welding shot peening internal body and to replace original dust filter

100% Rm 28.8k

3600 ton