Achieving zero breakdown

ACHIEVING ZERO BREAKDOWN

PRESENTER : B. R. DEY

A. COMPANY PROFILE

1 OUTLINE OF THE COMPANY

INCORPORATED IN 1972

TOTAL EMPLOYEES : 4818

TOTAL AREA : 26 ACRES

People Growing

Together

TURNOVER IN 2009-10 =

Rs. 7000 Million

GOVT. RECOGNISED R&D

2 MAIN COMPANY DETAILS

TOTAL AREA

105,000 SQ.M

(26 Acres)

STAFF

500

602

3716

OFFICERS

WORKMEN

TOTAL EMPLOYEES 4818

NO OF M/CS 1400

PISTONS RINGS

P I N S ENGINE VALVES

3 PRODUCTS

HFHF

RIKENRIKEN

PISTONS RINGS

ENGINE VALVESPISTONS

4 FOREIGN COLLABORATION

(1989)

RIKEN CORPN. – JAPAN

(1993)

KOLBENSCHMIDT - GERMANY

(1972)

HONDA FOUNDRY – JAPAN FUJI OOZX –JAPAN

(1978)

1.

2.

3.

4.

Passenger Cars

Two Wheelers

Commercial

Vehicles

Tractors

Industrial

Engines

HINO ENGINES

5. OUR DOMESTIC OE CUSTOMERSSPR IS

SINGLE SOURCE SINGLE SOURCE

TO 17 OEMs17 OEMs

6. OUR GLOBAL OEM CUSTOMERS

FRANCE GERMANY/AUSTRALIA/ SOUTH AFRICA

During last few years SPRL has started export business with

6 new global OEM customers

KIA MOTORS HYUNDAI

HONDA MOTORIVECO

IRAN

USA/ CHINA

KOREA

ITALY

PRODUCT BRAND NAMES

No. 1

PISTON EXPORTS No. 1

RING EXPORTS

EXPORTS TO

OVER 30 COUNTRIES

7. EXPORTS

OEM

50%

Aftermarket

23%Export

25%

Others

2%

B. APPROACH ON ZERO BREAKDOWN

SPRL

Piston Plant

Aluminium

Foundry

CI Ring

Plant

CI

Foundry

Pin

Plant

EV

Machine

EV

Forge

Steel Ring

plant

Raw Material

Machining InspectionMelting & Alloying Die Casting Packing

1. PROCESS OUTLINE

Piston Production Process

8 5

Process Flow of Aluminium Foundry

RISER CUTTING

CASTING

MELTING

HEAT TREATMENT

INSPECTION

RAW MATERIAL

ROUGH TURNING & ROUGH FACING

2. PROCESS OUTLINE OF ALUMINIUM FOUNDRY

3223 6

69

52

Total nos.of Equipments : 183

Numbers of Machines : Aluminium Foundry

Die Casting

Holding

Melting

Heat

Treat

Others

EQUIPMENT OUTLINE

• Variety of Equipment

Die Casting MachinesHolding Furnace

Metal Treatment

CNC Machines

Melting Furnace Heat Treatment

1.2 Intensification of Time based inspection and maintenance activities on all PM-A and PM-B machines.

• Review of maintenance standards

• Time based maintenance of electrical and mechanical control system

• Time based replacement of components based on their failure data from TPM Part 1 activities

S.

NO. I I I I II IV I I I I II IV I I I I I I IV I I I I I I IV I II II I IV I II II I IV I II II I IV I II I II IV I I I I II IV I I I I II IV I I I I II IV I I I I I I IV

1 OIL F IR ED FURN ACE NO.1

:ALL GEAR,WORM ,SPROCKET & CHAIN 03 M ONTH

CLEANING & GREASING TO BE DONE

:BUSH BEARINGS GREASING TO BE 06 M ONTH

DONE OF ALL SHAFTS & WHEELS OF

TILTING ASSEMBLY

:OIL IN TILTING GEAR BOX TO BE 06 M ONTH

FILLED / REPLACED

:DOOR BEARING GREASING TO BE 03 M ONTH

DONE

2 OIL F IR ED FURN ACE NO.2

:ALL GEAR,WORM ,SPROCKET & CHAIN 03 M ONTH

CLEANING & GREASING TO BE DONE

:BUSH BEARINGS GREASING TO BE 06 M ONTH

DONE OF ALL SHAFTS & WHEELS OF

TILTING ASSEMBLY

:OIL IN TILTING GEAR BOX TO BE 06 M ONTH

FILLED / REPLACED

:DOOR BEARING GREASING TO BE 03 M ONTH

DONE

:OIL TO BE FILLED IN AIR LUBRICATOR 03 M ONTH

WITH CLEANING OF AIR FILTER

3 HEA T T REATM EN T F URNA CE NO.1

:BEARING GREASING TO BE DONE 03 M ONTH













1 0 HEA T T REATM EN T F URNA CE NO.8


1 1 HEA T T REATM EN T F URNA CE NO.9


1 2 HEA T T REATM EN T F URNA CE NO.1 0


1 3 HEA T T REATM EN T F URNA CE NO.1 1


1 4 SOLUTIONISIN G FUR NACE N O.1


:TANK M OVING SPROCKET & BEARING 03 M ONTH

GREASING TO BE DONE

SHRIRAM PISTONS : GHAZIABAD

(ALUMINIUM FOUNDRY)

ANNUAL PREVENTIVE MAINTENANCE PLAN - YEAR 2003

M A CHINE / AC TIV IT IES FREQ.JAN FEB M AR A PR M AY NOV DEC

R EM A RKSJUN JUL AUG SEP OC T

Annual Maintenance Plan

2.1 Elimination of minor stoppages by Planned maintenance on different equipments.

1. 1 Focussed Planned maintenance activities were done to reduce Major and Repetitive Failures.

1.3 Condition based maintenance activities

• Bearing condition monitoring of CNC spindle bearings.

•Temperature monitoring of hydraulic power packs.

•Condition monitoring of hydraulic oil for increase in life of oil.

Hydraulic oil filtration Machine

Temperature Monitoring

69 Equipments

under CBM

SL. NO. MACHINE DETAILS1 Sol. Cum Ageing Fur.-1 Minor stoppage due to bearing cooling pipe circuit chocked

3 D.C.M/C No.- 29 Minor stoppage due to Burning of flexible pipes of mould coling

4 D.C.M/C No.- 18 Minor stoppage due to misalignment of Eye pad holder box.

5 D.C.M/C No.- 4 , 5 Minor stoppage due to steam generation in water circuit

6 Riser Cutting M/C.-7 Minor stoppage due to overheating of TCT cutters.

7 D.C.M/C No.- 49 , 50 Minor stoppage due to frequent change of cooling pipes.

LIST OF MINOR STOPPAGES : BY PLANNED MAINTENANCE

Frequency :1 Day Ref : AF/MAINT/10 Month -

Die Casting Activity : 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31

Machine no.Abnormal Noise from Motor

Abnormal Noise from Pump

Coupling mounting & Tyre condition

Hydraulic Pressure ( )

Oil level in reservior

Oil temperature ( Max.58 Degree Cent.)

Power pack Flexible pipe condition

















O.K. _/ Fitter

NOT O.K. x

Gauge Not OK O Checked By

SHRIRAM PISTONS : GHAZIABAD

( Aluminium Foundry )

DAILY CHECK CHART - DIE CASTING MACHINE

Jan-07Daily check chart

57 Components /

Assemblies

for replacement

1. Breakdown Reduction

2. Elimination of Minor Stoppages

3. APPROACH FOR ZERO BREAKDOWN

MP

Information

Deep Analysis of

Failures

Horizontal

Replication

Maintenance

Record

Observe for 3 months

Implement

Identification of potential failures

Study & Analyse

Identify Kaizen

Themes

OK

Not OK

Zero Breakdown

Approach

Observe for 3

months

Implement

OK

Not OK

Horizontal

Replication

Plan Corrective Maintenance

Analysis of daily failures with Jishu

Hozen

Review of

Maintenance standard

APPROACH FOR ZERO BREAKDOWN

Breakage of piston rods in Pin assembly

Frequent failure of quench tank

Failure of eyepad assembly

Oil leakage in center tool assembly

Failure of hydraulic power pack

Water/oil leakage in cooling/hyd ckt

Not attaining required temp of molten metal

LIST OF FAILURES IN ALUMINIUM FOUNDRY

Die Casting

Holding & Metal Treatment

Aluminium Foundry

Leakage of heat from furnace doors

38 Kaizens implemented

Heat Treat

Melting 12 Kaizens implemented

11 Kaizens

implemented

Premature failure of crucibles

Breakage of lead screw in GBF M/C

Failure due to high temp in furnace coil

Failures in pipes of cooling circuit

Failure of blower bearings

Failure due to breakage of wire ropes

Leakage of heat from furnace doors

21 Kaizens implemented

4. FAILURE ANALYSIS

17

28

34

60

1

14

12

11

17

0 20 40 60 80

Strut Load assy

Water

Vertical assy

Centre tool assy

Bottom assy

Power pack

Mould assy

Pin assy

Eyepad assy

Nos. of Breakdowns / Year

Breakdowns Frequency in Die casting Machine

Assemblywise analysis

Breakdowns Frequency Trend

Die Casting

Melting 2 %

Heat Treat 3 %

91 %

Holding 2 % Others 2 %

1

3

2

1

0 20 40 60 80

Trolley assy

Basket

carrier

Baffle plate

Blower assy


Breakdowns Frequency in Heat Treatment


1

2

1

1

0 20 40 60 80

Heating

element

Crucible

Furnace

lining

GBF


Breakdowns Frequency in Holding Furnace


1

3

2

1

0 20 40 60 80

Trolley assy

Basket

carrier

Baffle plate

Blower assy


Breakdowns Frequency in Melting Furnace


5. PROBLEM ANALYSIS

1. Elimination of Repetitive Breakdown in eyepad assembly through modification of

guide rod

Reduction of Breakdown by 10 Nos. / Annum

• Guide rods are provided in eyepad assembly to guide the eyepad holder motion

• During movement this rod gets bent due to load

• Guide rod also breaks from thread

•Guide rod was redesigned to prevent it from breakage

• Guide rod dia increased from 20 mm to 28 mm

• Size of thread also increased from M14 to M18

• No breakage of guide rods 10

0 00

4

8

12

GOOD

Nos.of

Breakdown/

Year

Problem Analysis :

Guide rod

20 O

20 O

1.5x45

14 O 14 OM14x1.5P

Eyepad assembly Guide rod

Kaizen details :1.5x45

28 O20 O

20 O

28 O

M18x1.5P

Modified Guide rod

Result :Breakdown Frequency Trend

(Guide Rod)

KAIZEN ON DIE CASTING MACHINE

6. KAIZEN

2. Breakdown reduction of frequent jamming of eyepad slide by redesigning

eyepad holder boxes in Die Casting M/C

Eyepad holder

Eyepad holder

Self lubricating strip

• To provide solution to eliminate external lubrication

• Redesigning of holder boxes by providing self

lubricating strips on all rubbing surfacesEyepad

holder box

•No need of external lubrication

•Better machine static accuracy

• Life enhancement of eyepad holders from 1 years to 3 years

Eyepad

holder box

12

0 00

5

10

15

GOOD

Nos.of

Breakdown/

Year

Problem analysis :

• Eyepad holder runs in holder box fitted on

eyepad carrier of casting machines

• The holder gets heated up due to casting

operation on machine

• Due to heat external lubrication on holders is

not effective resulting in jamming of holders in boxes

Kaizen details :

Breakdown Frequency Trend (Eyepad Holder)

Result :


3. Reduction in Breakdown of Quill pin cylinder through design improvement by

introducing guide rods to prevent breakage of piston rod in Die casting Machine

• Redesigning piston rod with support of guide rod.

• To reduce load on Piston rod & coupler due to jamming of any one pin in mould block by providing

guide rods on both sides of coupler.

• These guide rods share the load coming on

coupler & piston rod.

• No breakage of Piston rod & coupler

•Hydraulic oil saving by 50 Litres / Annuum

11

00

5

10

15

GOOD

Nos.of

Breakdown/

Year

Problem analysis :Piston rod

Coupler

Yoke

Quill pin

Cylinder• Excessive load on Piston rod & coupler due to

jamming of any one pin in mould block

• The excessive load cause breakage of Piston

rod or coupler

• This breakage causes frequent breakdown of

Die Casting Machine

Quill pin

Yoke Piston rod Guide rod

Coupler

Kaizen details :

Result : Breakdown Frequency Trend (Quill Pin Cylinder)


1. Breakdown reduction through modification of lead screw drive system in Gas

Bubbling Fixture machine

• To change the location of gear box assembly

• The gear box is relocated from top to bottom

• No breakage of guide rod of guide rod

Gear Box

Lead screw

Electrical

panel

Rotor

Gear Box

Lead screw

Electrical

panel

Rotor

2

00

1

2

3

Nos.of

Breakdown/

Year

GOOD

Problem analysis :

• Gear box is mounted on top at the height of

1.8 mtrs

• Since it is a mobile equipment, hence during

movement the lead screw is unbalanced & falls

down

Kaizen details :

Breakdown Frequency Trend (GBF) Result :

KAIZEN ON HOLDING & METAL TREATMENT


1. Elimination of minor stoppage in Solutionising & Aging Furnace due to variation

of water level

•

• Installed Water level controller and level sensor.

• To control water flow automatically by

interlocking level sensor with a solenoid valve.

• No stoppage due to water level variation6

00

4

8

Nos.of

Stoppages/

Year

GOOD

Electrical panel

Manual valve

Heater

Electrical panelLevel

Controller

Level Sensor

Solenoid valveHeater

Problem analysis :

• Manual control of water flow in quenching tank

• Stoppages due to breakdown of heaters due

to variation in water level

Kaizen details :

Minor Stoppage Trend (Soln & Aging Furnace)

Result :

KAIZEN ON MINOR STOPPAGES

Life improvement of heaters from

1month – 1 year

•

7. RESULTS

29

43

0

35

70

B.M. 2007 2010

GOODZero Breakdowns (Nos. of M/Cs)

Nos. of Machines

DIE CASTING MACHINES

54

65

0

40

80

B.M. 2007 2010


Nos. of Machines

HOLDING FURNACES

20

29

0

20

40

B.M. 2007 2010


Nos. of Machines

HEAT TREATMENT FURNACES

END OF PRESENTATION

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Achieving zero breakdown

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