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6-1.2 Background
We all at PM pillar are committed for retarding the natural deterioration of machines, maintaining machines with optimum cost through deployment of TBM/CBM practices, Continuous improvement & skill up gradation of maintenance personnel.
Pillar head
Members
W. Singh Utilities
SPARES MANAGEMENT
LUBRICATION MANAGEMENT
CORRECTIVE ACTIONS
1.1
Breakdown in A category equipments 1.1.2 Breakdown in B category equipments 4.2 4.2.1 Maintenance cost KAI department level Dept. Section Circle Better Unit of measure Nos
1.1.1
Nos
Nos
Liters
Nos Nos
Rs./MT
Nos
5 6
7 8
Good
FY 11
FY 13 50 5 300
FY14 0 5 270
Pillar KAI
Red tag closure PM kaizen No of failures Vs RCA done Optimize lubricant consumption Standardize spares MP sheet generation
2000 50 50 4000 NT NT FY 11
Good
Pillar KAI
Red tag closure PM kaizen No of failures Vs RCA done Optimize lubricant consumption Standardize spares
MP sheet generation
0 0 20 1056 NT NT
500 25 50 700 NT NT
1500 50 75 600 NT NT
Good
FY10 BM 389
308
FY 11 350
305
FY 12
Benchmark Targets
FY 13 250
250
FY14 230
250
Nos
Nos
250
260
4.2.1
KAI No 1
Maintenance cost
Rs./MT
1226
35.00
28.00
50.00
50
Pillar KAI
Red tag closure
Cum Nos
108
300
500
700
1100
2
3 4 5 6
PM kaizen
No of failures Vs RCA done Optimize lubricant consumption Standardize spares MP sheet generation
Cum Nos
% Liters Cum Nos Cum Nos
3
10 7776 NT NT
10
50 7500 NT 10
12
70 7300 NT 15
15
90 7100 5 25
12
100 7000 20 30
1. Support to Jishu Hozen. (Autonomous Maintenance) 2. Zero Breakdown activities (Analysis and counter measure) 3. Maintenance Information System 4. Establishing Planned Maintenance System 5. Predictive Maintenance activity 6. Lubrication Management System 7. Spare Parts management 8. Maintenance Skill enhancement
Identification of Fugais
6-4.2 JH Step 2 : Hard to access areas located by Jishu Hozen team are rectified made easy. These Areas are further classified in to following categories. a) Hard to Clean, b) Hard to inspect, c) Hard to Lubricate, d) Hard to re tight, e) Hard to operate, f) Hard to adjust. Kaizens were done to remove hard to access, Hard to clean & hard to lubricate areas. Some examples are attached below :
Theme :- To reduce the breakdown of chain in pay off basket of M/c 140.
1/10
th
BEFORE
AFTER
01 /03/13 10 /04/13
TEAM MEMBERS S ray Abhishek kumar Niranjan singh Amrendra singh Abdul sattar
Member
No tray arrangement in wire seperator stand ANALYSIS:1. Why scale scattering on floor ? WHY 2. Due to no any arrangement for collect the scale WHY 3 Design weakness .
To be shown Tray arrangement in wire seperator stand during schedule P = ( Before cleaning Time = 63min) (After cleaning Time =28 min) RESULTS:B presentation
1) Reduction in the cleaning time by 35 min
C = Rs 50000 / Year S = No any chance of incident . 2) In house Design Modifiction of the tray M = High moral ( No any wire breakage due to entanglement)
BENEFIT:-
M
Consumption of the soap is 2.85 Kg / MT Redction in consumption of the soap from 2.85 Kg / MT to 1.90 Kg/MT 26 /05/12 24/06/12 TEAM MEMBERS Abhishek Kumar Rakesh kr singh Abdul Sattar Hardeep singh Sc mahto Gopal Guha
Theme :- To Reduce the Scattering of the burnt soap from the Die Box.
BEFORE
AFTER
BENEFIT:-
No any arrangement of cover for the die box. ANALYSIS:1. Why scattering of soap in the working enviroment ? WHY 2. Due to passing of wires in the die box cause the scattering of soap WHY 3. Due to No Any arrangement of Cover in the die box WHY 4. To make arrangement of covering the die box
To be shown Arrangement of cover for the die box. during schedule RESULTS:B presentation Reduction in cleaning time.
1.Total Arresting of the scattering of soap
6-4.3 JH Step-3:
i) Preparation of Composite check sheet to clarify the JH and PM activities ii) PM to helped in preparation of tentative CLITA standards. iii) Assisting JH team on making visual inspections.
VISUAL INSPECTION
6-4.4 JH Step- 4 :
General training imparted to JH circles on following topics : Basics of pneumatics Electrical basics Basics of drives & transmission Basics of lubrication Basics of hydraulics Basics of fasteners
6 AXIS TRAINING
Lack of skill
Neglected deterioration
Design Weaknesses
After analysis the root cause was found as design weakness hence design modification was done & kaizen sheet was made for the same as shown below :
DST 10.04.11 AD AD
31.10.11
DONE
APR 2011
Roller Table # 13
APR 2011
Roller Table # 0
Hydraulic pump # 2 Violation of 2) Fitting suction 3 nos failure basic condition filters in line. 3) fitting new high capactity heat 1 nos exchanger. Gearbox jam due to coil end piece Deliberate stucked in between violation gears. Replace the Universal spindle's connecting flange and connecting flange Improper key. 1 set rotating free due to Inspection Inspection point to be key failure. included in check sheet
UP-DOWN hyd cylinder's clevis pin sheared Gearbox to motor gear coupling's key got damaged. Cobble due to tail end entered in the housing gap between roll No. 5 & 6. Design weakness Improper Maintenance Skill Inherent design weakness Replace the pin with a higher diameter pin by 1 set modifying the clevis and bracker arrangement. Training to be imparted "How to fit Keys in power transmission" Welding done of the gap.
Dropped
31.10.11
Done
7000
DST
30.06.11
dONE
AD
01.05.11
done
MAY 2011
Coil Upender
AD + DST
15.06.2011
done
JUN 2011
Roller Table # 17
AD
15.07.2011
Done
JUN 2011
Roller Table # 12
Done
With the aforesaid zero failure methodology & activities there is a marked reduction in equipment breakdowns. Following is the status of zero failure equipment in respective plants:
Total No. Of Equipments
WRM Wire Mill Jemco 136 23 Zero Breakdown Equipments 69 6
67
13
Utilities
128
102
Production (P) Effect on product Quality(Q) Cost of maintenance(C) Frequency of failure & time required for repairs(D) Effect on safety & environment(S)
Rank
A B C
Score (P+Q+C+D+S)
> 28 More than 20 less than 28 Less than 20
The above is a sample sheet of rod mill equipments criticality rating. Similarly criticality of all machines in wire & Jemco was also established. No. of Equipments No. of Equipments A -Category B -Category 116 19 29 66 Utilities 7 4 21 2 No. of Equipments C -Category 13 0 16 60
WRM
Wire Mill Jemco
Keeping Records Routine Inspection Check sheet & Maintenance Schedule (TBM)
To Prevent deterioration
To measure deterioration
Maintenance Activity Failure Analysis History Book Standard maintenance/ Operating procedure (SMP) Training Manual
Restoration
Eliminate Breakdown
From Logbook
From KPI(Key Performance Indicator) tracking system
A maintenance management information system was evolved for streamlining all the maintenance activities. It involves collection of breakdown & abnormalities data, keeping records of TBM & CBM activities, failure analysis, equipment history, SOPs ,training manuals. The management information system helps in keeping track of key performance indicators. An example of a typical maintenance calendar :
Wire Rod Mill Vibration analysis Oil analysis Illumination monitoring Ultrasonic thickness checking Bearing noise analysis Thermography Earth resistance monitoring
Wire Mill
Jemco
Inspection of equipment to find out hard to lubricate areas. Kaizens to eliminate hard to lubricate areas Lubrication schedule preparation and implementation Lubrication Visual Control Separate cans for different oils Operators trained on lubricants Recording of lubrication consumption Eliminate leakage to reduce the frequency of lubrication Improvement in lubricant type to increase lubricant life
35
26
Identified Arrested
FY13
FY14
Cost in Laks
4 3 2 1 0
Financial Year
Equipment wise listing of spares Deciding criticality of spares Analysis of consumption patterns Determination of life cycle of critical spares Raising of purchase requisitions as per lead time, spare parts life & criticality was initiated. Periodic stock review system was started. Disposal of obsolete & non usable spares was decided. Development of imported spares indigenously was started.
13,15 Guide Box RE-45 AS ( without ac cessories) Roller Holder RE-45 AS/2 Assembly Roller Holder RE-45 AS/2 Assembly Roll shaft Pivot Pin Adjusting sc rew RH (to move the roller holder) Adjusting sc rew LH (to move the roller holder) Cover ( for spring assembly) Button ( in front of Adjusting sc rew) Set sc rew M 24 X 3 X15 ( to move the roller holder UP/DOWN) Thrust Plate ( below the pivot pin)
Roller shaft spacer(in between the bearing and housing) M432819A Spacer ( to tighten the nut of roll shaft) Tapered roller bearing 32004X Tapered roller bearing 32004X DIE DIECO Spring( for roller holder) (Same as RE-115 & RE-45) spring Seal Nilos Ring Eye bolt with shoulder M 16 Soc ket head c ap screw M 6 x 25 full thread (spring cover) Soc ket set cup sc rew M16 X 25 (to tighten the insert) Hex Nyloc k nut M 16 X 2 ( for roll shaft) Assy.Adapter Plate (RE 45 FSA-2) Rollers (for stand 13) Rollers (for stand 15) Insert ( for stand 13) 5.5 mm [ 54.1 x 20.4 ] Insert ( for stand 13) 8 mm [ 54.5 x 23 ] Insert ( for stand 15) 5.5 mm [ 41.6 x 16 ] Insert ( for stand 15) 8 mm [ 45.4 x 19.8 ] Insert ( for stand 15) 5.5 mm modified [ 39.2 x 16 ] M432820AA M432805B
Import Substitution
Before
After
70
164
ROD MILL
60 50 40 30 20 10 0
59
59
WIRE MILL
84
76
26
26
Mechanical
Electircal
CLASSROOM TRAINING
Check Point/Activity
Standard
Status
Remarks
5 6 7
8 9 10
Take power cutting from the authorized person with help of power ensure cutting format, Fix suitable selling in the Cardon shaft and lift be EOT crane and Sling size 1/2" the remove all the flange bolts of the cardon shaft at roll end , and keep on the floor. loose the tension spring , lift the top roll and fix adequate packing Sling size 1/2" and hoist of 1 with frame to top roll with help of selling. ton Push the pill up bar towards qa side to remove the roll with help of bar. Open the base bolts of roll , and remove the roll from its place,with Bolt size 20 m.m. help of suitable size of slings. After removal of roll, clean the surface of the plumber block. And re fixed the new/oh roll at its place. Fixed the plumber block bolts with base frame and also fixed the check nut on the same. Check the level of the bottom roll with respect of idle roll as the roll at hot pusher tray. It must be not more then + or - 2 m.m. from the consecutive roll. Fixed the spindle bolts with help of EOT crane and proper size of selling. Fill fresh grease in to the roll Check the roll for its free movement, with help of manual movement through gear box.
Cost of Spares
Cost of Lubricant
Analysis of Data
Priortisation of Potential Svaing Area a) b) c) Spare Parts By stopping forced deterioration By increasing life span By developing Import substitute By standardisation Lubricant consumption By arresting Leakage By reducing spillage during Handling By using correct qulity of lubricant Contract Labour By developing in house repair of items
Kaizen Sheet
Good
FY10 BM
FY 11
FY 12
FY 13
FY14
Targets /Actual
1.1.1
Breakdown in A category equipments
Nos
1.1.2
4.2.1
Nos
Rs./MT
250
50
415
0 78 5 6 270 396
KAI No 1
Pillar KAI
Red tag closure
Cum Nos
436
2000 1130
PM kaizen
Cum Nos
24
50 64
25
50 50
Liters
4550
4000 4200
5 6
NT NT
NT NT NT NT
Good
FY10 BM
2935 1467
FY 11
2200 2183 1200 1310
FY 12
1500 1286 1000 965 650 518
FY 13
750 119 500 257 550 553
FY14
0 35 147 135 450 441
811
750 669
Pillar KAI
Red tag closure
1 2 3 4 5 6
500 534
PM kaizen
25 9
No of failures Vs Root Cause Analysis done Optimize lubricant consumption Standardize spares MP sheet generation
20
25 35
1056
700 634
NT NT
NT NT NT NT
Good
FY10 BM
FY 11
FY 12
FY 13
FY14
Targets /Actual
1.1.1
Breakdown in A category equipments
Nos
389
350 378
1.1.2
Nos
308
305 287
4.2.1
Maintenance cost
Rs./MT
39.05
35.00 29.88
KAI No
1
Pillar KAI
Red tag closure
Cum Nos
108
300 226
2 3 4
3 10
10 8 50 32 7500 7176
7776
5 6
NT NT
NT NT 10 8
350
300
300 250 200 150 100 50 0 10-11 11-12
136
120
84
12-13
13-14
4892
4367
3217
92% Reduction
1000
0
571
383
10-11
11-12
12-13
Numbers
13-14
GOOD
388
13-14
10-11
11-12
12-13
100
Root cause analysis of all failures.
100.00 90.00 80.00 70.00 60.00 50.00 40.00 30.00 20.00 10.00 0.00
100
80
50.00 25.00
10-11
11-12
12-13
100
85
35.00 20.00
10-11
11-12
12-13
13-14
GOOD
13-14
GOOD
90 80.00 40.00
32.00 10.00
11-12
10-11
12-13
Litres of Lub
13-14
GOOD GOOD
5000.00 4500.00 4000.00 3500.00 3000.00 2500.00 2000.00 1500.00 1000.00 500.00 0.00
3910
3800
3550
10-11
11-12
12-13
13-14
11590
2100
100
1130
11-12
10-11
3375
Increase in red tag removals
1448 534
Cum 10-11 Cum 11-12 Cum 12-13 Base Level 2009-10 Cum 13-14
GOOD
12-13
3879
13-14
GOOD
Cumulative Numbers 900 850 800 750 700 650 600 550 500 450 400 350 300 250 200 150 100 50 0
845 646
435 226
108
10-11
11-12
12-13
13-14
Commissioning of Improve work JEMCO flue exhaust environment & comply system pollution norms Automation of furnace combustion system Reduction in fuel consumption & better heating characterstics WRM ReHeat Furnace
Mechanical Deptt
Mar14
Apr14