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This is a proprietary document of Kirloskar Brothers Limited 1May 3, 2023
Prepared by:- Prateek Rai
This is a proprietary document of Kirloskar Brothers Limited 2May 3, 2023
Cumulative MTBF & MTTR
Apr-
16
May
-16
Jun-
16
Jul-1
6
Aug-
16
Sep-
16
Oct
-16
Nov
-16
Dec
-16
0
10
20
30
40
50
13.96
21.1028.20
34.10 34.2036.40 36.15 37.51
33.14
25
MONTHS
DAY
S
TAR-GET - 25
MTBF Trend
GOODAp
r-16
May
-16
Jun-
16
Jul-1
6
Aug-
16
Sep-
16
Oct
-16
Nov
-16
Dec
-16
02468
1012141618
4.60 3.40 3.60 3.30 3.90
7.13 7.67 8.07
14.27
1.50
MONTHS
HOURS
TARGET – 1.5MTTR Trend
GOOD
This is a proprietary document of Kirloskar Brothers Limited 3May 3, 2023
PLD Equipment – Maintenance Performance
Apr
-16
May
-16
Jun-
16
Jul-1
6
Aug
-16
Sep-
16
Oct
-16
Nov
-16
Dec
-16
10
20
30
17.85
17.82 22.76 23.7022.62
20.76
13.88
20.4521.80
25
MONTHS
DAYS
TARGET - 25 MTBF Trend
GOOD
Apr
-16
May
-16
Jun-
16
Jul-1
6
Aug
-16
Sep-
16
Oct
-16
Nov
-16
Dec
-16
0
2
4
6
8
10
12
4.803.20
2.823.24
5.676.62
11.06
4.54
9.37
1.50
MONTHS
HOURS
TARGET – 1.5
MTTR Trend
GOOD
18
19
20
21
22
23
24
2524.2
20.2
FY 2015-16FY 2016-17
Days
012345678
1.82
5.70
FY 2015-16FY 2016-17
Hours
This is a proprietary document of Kirloskar Brothers Limited 4May 3, 2023
Foundry Equipment – Maintenance Performance
Apr-
16
May
-16
Jun-
16
Jul-1
6
Aug-
16
Sep-
16
Oct
-16
Nov
-16
Dec
-16
0
5
10
15
20
25
30
17.5216.50
21.8217.87
16.69
22.82
20.17 21.85 24.0225
MONTHS
DAY
S
TARGET - 25
MTBF Trend
GOOD
Apr-
16
May
-16
Jun-
16
Jul-1
6
Aug-
16
Sep-
16
Oct
-16
Nov
-16
Dec
-16
0
2
4
6
8
10
0.81
2.40
0.80 1.23
2.781.28
6.23
3.08
9.80
1.50
MONTHS
HOURS
TARGET – 1.5MTTR Trend
GOOD
This is a proprietary document of Kirloskar Brothers Limited 5May 3, 2023
SMPD Equipment – Maintenance Performance
Apr-
16
May
-16
Jun-
16
Jul-1
6
Aug-
16
Sep-
16
Oct
-16
Nov
-16
Dec-
16
05
1015202530
25
20.25 13.73 15.87 16.08 13.4918.22 18.02 18.18
20.82
MONTHS
DAY
S
TARGET - 25
MTBF Trend
GOOD
Apr-
16
May
-16
Jun-
16
Jul-1
6
Aug-
16
Sep-
16
Oct
-16
Nov
-16
Dec-
16
02468
1012141618
10.7 5.8
4.74.6
8.9
15.5
4.73.0 1.8
1.50
MONTHS
HOURS
TAR-GET – 1.5
MTTR Trend
GOOD KVBT 65-Geometrical accuracy problemBoth ball screw repaired & bearing replaced
Miven 500(RKB)-Turret indexing problem
This is a proprietary document of Kirloskar Brothers Limited 6May 3, 2023
LPD Equipment – Maintenance Performance
Apr-
16
May
-16
Jun-
16
Jul-1
6
Aug-
16
Sep-
16
Oct
-16
Nov
-16
Dec
-16
0
10
20
30
40
50
15.78
23.2330.58 37.14
37.68
21.2416.11
21.03
21.6325
MONTHS
DAY
S
TAR-GET - 25
MTBF Trend
GOODAp
r-16
May
-16
Jun-
16
Jul-1
6
Aug-
16
Sep-
16
Oct
-16
Nov
-16
Dec
-16
0
6
12
18
24
2.93 1.44 2.973.88 5.34 3.07
21.60
5.37
15.60
1.50
MONTHS
HOURS
TARGET – 1.5MTTR Trend
GOOD SK 40- Spindle gear box gear worn out.New gear & bearing fitted
This is a proprietary document of Kirloskar Brothers Limited 7May 3, 2023
7
Preventive maintenance
Aug-
16
Sep-
16
Oct
-16
Nov
-16
Dec
-16
0102030405060
47 4840 38
4347 4843
3846
PM
Plannedachieved
MONTHS
MACHINE
Aug-16 Sep-16 Oct-16 Nov-16 Dec-160
10
20
30
40
50
60
1116
2614
9
18
7
9
8
10
Breakdown monitoring of PM m/cs
Nov-16 m/csOct-16 m/csSep-16 m/csAug-16 m/cs
This is a proprietary document of Kirloskar Brothers Limited 8May 3, 2023
8
Bar chart-MTBF
DOOSAN HMC(RKB)
HELLER 250(DB) MIVEN 500(KPD) DYNA 100(KPDS) MIVEN 500(DB)0.002.004.006.008.00
10.0012.0014.0016.0018.00
4.38 4.615.83
12.40 12.60
Top m/c With lowest MTBF(SMPD)
Days
Turret indexing problemSet indexing proxy & pressure setting
YOUJI 2000(ATPD)
KBL 120 CNC WOTON RAPID
VW 4 AXIS MACHINE
CARANAGI0.00
2.00
4.00
6.00
8.00
10.00
12.00
3.51
6.85 7.278.18 8.27
Top m/c With lowest MTBF(LPD)
Days
I/o channel probSMPS changed
GF MIXER K-LINE SAND PLANT 28CFT SUPERTUMBLAST SHOT BLAST
BMD MOULDING DRAG CIF NEW SAND PLANT0.00
1.00
2.00
3.00
4.00
5.00
6.00
7.00
8.00
1.13
3.55 3.634.15 4.21
Top m/c With lowest MTBF(Foundry)
Days
Sand accumulation prob
Main chain driving shaft damageShaft & spockit changed
427 belt damageBelt changed427 belt damage
Belt changed
Spindle speed problemReplaced speed changing coil
Machine stabilizer problemCheck stabilizer & repaired
Sliding door problemReplaced door bearing
This is a proprietary document of Kirloskar Brothers Limited 9May 3, 2023
9
Bar chart-MTTR
KBL 46” V
TL
MAZA
K MULT
IPLEX
DOOSAN HM
C(SC)
HELLE
R 250 (KPD)
MKL C
-600(DB)
1
6
11
16
21
2624.16
6.53 6.06 5.11 4.13
Top m/c With lowest MTTR(SMPD)
Days
Door jamming problemadjusted flow control valve
Hydraulic pump problemReplaced hydraulic pump
MOULDING M/C NO-1 FAME SHAKE OUT CUPOLA FURNACE NO 1 RAW MATERIAL FEEDING SYSTEM FOR CUPOLA
PLATE CONVEYOR IN CIF-30.00
20.00
70.00
120.00
170.00
220.00
270.00235.35
157.00
27.06 27.069.45
Top m/c With lowest MTTR(FOUNDRY)
Days
STANKO VBM CARANAGI VBM TITAN 3300 VBM KBL 120 CNC YOUJI 2000(ATPD)
0.00
50.00
100.00
150.00
200.00
250.00
300.00
259.24
115.16
10.50 9.17 7.01
Top m/c With lowest MTTR(LPD)
Days
I/o channel probSMPS changed
Spindle rotating problem
This is a proprietary document of Kirloskar Brothers Limited 10May 3, 2023
Oil consumption
Apr-
16
May
-16
Jun-
16
Jul-1
6
Aug-
16
Sep-
16
Oct
-16
Nov
-16
Dec
-162350
245025502650275028502950305031503250
2478
2854
2584
2893
2795
3019
2612
25402677
2800
3150
PLD
ConsumptionTARGETBench mark
LITE
RS
0
1000000
2000000
3000000
4000000 3663300
2821980
1770353
FY 14-15 FY 15-16 FY 16-17
Oil cost in Rs
10006000
110001600021000260003100036000410004600051000 45830
37800
24451
FY 14-15 FY 15-16 FY 16-17
Oil in liters
This is a proprietary document of Kirloskar Brothers Limited 11May 3, 2023
11
Coolant oil consumption
0
5000001000000150000020000002500000300000035000004000000
3354978 3351559
2075131
Coolant oil cost in Rs
FY 14-15 FY 15-16 FY 16-17
0
500010000150002000025000300003500040000
31610
22855
13694
Coolant oil in liters
FY 14-15 FY 15-16 FY 16-17
Apr-
16
May
-16
Jun-
16
Jul-1
6
Aug-
16
Sep-
16
Oct
-16
Nov
-16
Dec-
16
500
1000
1500
2000
2500
1486
801
1330
1527.1
1836
1506.716
1825.2 1881.4
150117001900
PLD
ConsumptionTargetBench mark
LITE
RS
This is a proprietary document of Kirloskar Brothers Limited 12May 3, 2023
Power consumption
Apr-1
6
May
-16
Jun-
16
Jul-1
6
Aug-
16
Sep-
16
Oct-
16
Nov-
16
Dec-
16
1000000110000012000001300000140000015000001600000170000018000001900000
1320276
15094031555571 1589122
15481731636559 1621182 1640358
1775961
1497657
1422774
PLD
Consu...
KW
H
10000003000000500000070000009000000
110000001300000015000000170000001900000021000000
17677583 18132649
14196605
Power consumption in KWH
FY 14-15 FY 15-16 FY 16-17
10000020100000401000006010000080100000
100100000120100000140100000
111788470 109096400
127476360.350817
Power consumption in Rs
FY 14-15 FY 15-16 FY 16-17
This is a proprietary document of Kirloskar Brothers Limited 13May 3, 2023
Power consumption
Apr-
16
May
-16
Jun-
16
Jul-1
6
Aug-
16
Sep-
16
Oct
-16
Nov
-16
Dec-
16
50000
100000
150000
200000
250000
168420191651184222
189609 199918
232630
153983
178104
163632
SMPD Actual consump-tionExpected consumption
KWH
Apr-
16
May
-16
Jun-
16
Jul-1
6
Aug-
16
Sep-
16
Oct
-16
Nov
-16
Dec-
16
460000510000560000610000660000710000760000810000860000910000
699824
653189
870946
721641
694737
715493
731532
795914864502
Foundries
Actual consump-tionExpected consumption
KWH
FOUNDRY
Ap
r-16
May
-16
Jun-
16
Jul-1
6
Aug-
16
Sep-
16
Oct
-16
Nov
-16
Dec-
16
100000
120000
140000
160000
180000
200000
220000
147475158655
156329159450
143485154892
114069120844
140611
LPD Actual consump-tionExpected consumption
KWH
Apr-
16
May
-16
Jun-
16
Jul-1
6
Aug-
16
Sep-
16
Oct
-16
Nov
-16
Dec-
16
20000
30000
40000
5000060000
70000
80000
90000
29832
41263 43378
2767020603
5520161089
50178 48157
MONTHS
HRC
KWH
This is a proprietary document of Kirloskar Brothers Limited 14May 3, 2023
Cont..
Apr-
16
May
-16
Jun-
16
Jul-1
6
Aug-
16
Sep-
16
Oct
-16
Nov
-16
Dec-
16
20000
25000
30000
35000
40000
45000
50000
55000
24780
3225035337
31738319513726136774
33007
47264
MONTHS
KWH
Pump testing
Apr-
16
May
-16
Jun-
16
Jul-1
6
Aug-
16
Sep-
16
Oct
-16
Nov
-16
Dec-
16
140000
160000
180000
200000
220000
240000
155475
176718161764
179422186708
202614189442
196630202869
MONTHS
Com-pres-sor
KWH
CompressorAp
r-16
May
-16
Jun-
16
Jul-1
6
Aug-
16
Sep-
16
Oct
-16
Nov
-16
Dec
-16
6000
6500
7000
7500
8000
8500
9000
9500
10000
7043 70977314 7379 7215
7673
8293
90539494
MONTHS
Street light
KWH
Apr-
16
May
-16
Jun-
16
Jul-1
6
Aug-
16
Sep-
16
Oct
-16
Nov
-16
Dec-
16
30000
80000
130000
180000
230000
280000
330000
380000
87746
248580
96281
272213263556230795
326000
256628299432
MONTHS
Com-pres-sor K
WH
Others
This is a proprietary document of Kirloskar Brothers Limited 15May 3, 2023
15
Pareto chart for power consumption
Foundrie
s
Compressor
OtherSM
PDLP
D
Res & co
m complex HRC
Pump testi
ng
Stree
t ligh
t0
100000200000300000400000500000600000700000800000900000
1000000
0.00
20.00
40.00
60.00
80.00
100.00
120.00864502
202869 171534 163632 140611 12789848157 47264
9494
Power consump-tioncummulative
This is a proprietary document of Kirloskar Brothers Limited 16May 3, 2023
16
Apr-16 May-16 Jun-16 Jul-16 Aug-16 Sep-16 Oct-16 Nov-16 Dec-160
1000
2000
3000
4000
5000 41394630
30603874
4519
3090 3350 30853628
3128
Consumption pattern per million
Units/million saleBench mark
KWH
Apr-16 May-16 Jun-16 Jul-16 Aug-16 Sep-16 Oct-16 Nov-16 Dec-160.0
100.0200.0300.0400.0500.0600.0700.0800.0900.0
1000.0
717.2636.9
486.4572.5
467.2533.9
657.4529.7 526.2
863
Consumption pattern per pump
Units/pump saleBench mark
KWH
Electricity consumption pattern
This is a proprietary document of Kirloskar Brothers Limited 17May 3, 2023
17
• Titan 2700 vertical screw nut replaced by new one & hard limit dog position corrected to seize heavy oil leakage. • Titan CNC lubrication pressure low alarm problem corrected by replacing PLC card.• Carnaghi CNC Z ball screw was jammed. Ball screw repaired & fitted in machine. • 9B Lathe new rack & pinion fitted.• Spm boring contractor replaced.• FN3 milling noise problem solved.• Kws 500 new telescopic cover fitted. • Norton grinder gear box piston was damaged, New piston was prepared in house and fitted in machine.• Woton stabilizer starting in auto mode work completed.• VBM-150(MF) spindle disc spring replaced.• New sliding rack & pinion fitted in 9B lathe• Dyna-65 x & z axis ball screw overhauled.• NFF furnace lied cover repair & refitted.• Supetumblast machine main chain driving shaft and sprocket changed.• Tata shakeout overhauled.• GF mixer gear box hollow shaft changed.• K-Line sand plant Magnet belt changed.• 426 idler pulley remove, rework & fitted.• 436 belt drive end pulley remove rework & fitted.• 427 belt replaced• 116 belt replaced• cupola no 1 CI bricks lining done• Arp BMD 1300 cope new scraper ring & guide bar bush fitted.
Major work
This is a proprietary document of Kirloskar Brothers Limited 18May 3, 2023
18
Improvement
• Stanko VBM gear box & spindle motor overhauled.• Youji 2000 motor overloading ,ATC over travelled & lubrication pressure problems are permanently solved.• Pensotti CNC lubrication made functional.• 52” VTL panel reconditioning work started.• 437 Elevator Belt replaced by light weight SS fabricated Bucket in K-line.• Omega Sand Mixer(HF) arm made motor driven for movement.• Teflon scraper inserted to minimize sand contact to Table of BMD ARPA1300 & KBMD 450 Molding Machines.• Doosan(SC) oil leakage arrested.• Emergency stop problem solved in mazak multiplex.• Miven 500(DB) oil leakage from pump arrested.• KWS-500(SC) oil leakage arrested.
This is a proprietary document of Kirloskar Brothers Limited 19May 3, 2023
Encon
• Replacement of 30 nos of 67W PL lamps with 30 nos of 30W LED lamps.• Rescheduling of heavy foundry and HRC to maximize “A” zone utilization.• Introduction of cold washing