IMPLEMENTATION OF TPM IN ROBOTIC

WELDING MACHINE
TEAM MEMBERS:
1. R.SAI PRABHU RAJ (111412114089)
2. S.SEDHU
(111412114096)
3. S.VINOTH
(111412114112)

INTERNAL
PROJECT GUIDE:
Dr. S.MAHADEVAN
Senior Professor
Mechanical Department

EXTERNAL
PROJECT GUIDE:
G.SENTHIL KUMAR
Section Manager
Caterpillar India Pvt. Ltd.

ABSTRACT

a days there is a large competition among companies. Companies are trying thei
vide the products in a innovative, exciting, cost effective way in the present globa
mpetitive market

enance department and people responsible for maintenance has the greatest
e on the company assets. Without the support of the Quality and Maintenance
possible to meet the requirements of manufacturing plants and customers.

ut effectively maintained equipment; it will not be possible to deliver the produc

ompetitive market that requires low cost products at a high quality.

PM implementation methodology is suggested for improvement in the availabilit

mance efficiency and the quality rate, results in improvement of the overall
ent effectiveness of the equipment.

im of this project is to suggest and study the implementation of the TPM program
llar India Pvt. Ltd. Located in Thiruvallur.

BRIEF ABOUT CASE COMPANY

pillar Inc., is an American corporation which designs, manufactures, markets and

ery, engines, financial products and insurance to customers

pillar is the world's leading manufacturer of construction and mining equipment,

ural gas engines, industrial gas turbines and diesel-electric locomotives.

pillar India Pvt Ltd., MATERIAL HANDLING AND UNDERGROUND EQUIPMENT DIVIS
plant is located in Mellanathur, Thiruvallur District, and Tamil Nadu.

rently employs more than 1000 employees and produces Wheel Loaders, Backho
s, and Quarry and Mining Trucks (OHT).
CPIL, Thiruvallur plant, there are totally 12 bays are present.

ays include Warehouse, Assembly line, Tool room, hex bay, axle bay, fabrication
ls bay and along with two paint shops(loader paint shop and new paint shop).

ROBOT
WELDING:

SPECIFICATIONS:
S.no
1.
2.
3.
4.
5.
6.

parameters
Welding
Metal Inert Gas Arc
type
welding
Electrode
Copper wire of gauge
diameter =1.2 mm
Flux coated Gauge diameter =1.6
mm
Shielding
Argon (90%)
gas
Carbondioxide (10%)
Robot axes
8
coolant
Water

TOTAL PRODUCTIVE MAINTENANCE

Productive Maintenance(TPM) is a system of maintaining and improving the

uction and qualitysystemsthrough the machines, equipment, processes, and
ees that addbusiness valueto an organization.

ocuses on keeping all equipment in top working condition to avoid breakdowns

ays in manufacturing processes.

LS OF TPM:

nce the volume of the production

oyee morale
atisfaction.

er for TPM to be effective, the full support of the total workforce is required.

OVERALL EQUIPMENT EFFECTIVENESS

e main objective of TPM is to increase the Overall Equipment Effectiveness

ant equipment.

OUR ACTIVITIES

ROOT CAUSE & CORRECTIVE

ACTION (RCCA)
1.1 Problem Description : Oil leak observed in isolation transformer.
Before:

After:

Machine Name & Type : Main frame robot Isolation transformer

Corrective Action : Isolation Transformer oil leak arrested and visibility

checked.

Why ? Gauge area thread loosened.

How ? Teflon added and thread tightness corrected.
Future Sustenance ? During PM isolation transformed condition will be checked. PM point
added.

1.2. Problem Description : Coil drum emptiness cannot be identified during auto welding.
Before:

After:

Machine Name & Type : Coil Drum.

Corrective Action : A new sensor has been provided to find whether coil drum coil end has been
reached or not. If reached alarm will be triggered.
Why ? Coil drum emptiness cannot be identified during auto welding.
How ? Sensor has been provided to find whether coil drum coil end has been reached or not.

1.3. Problem Description : Panel cooler filter cleaning status has not been displayed.
Before:

After:

Machine Name & Type : Main Frame robot UPS

Corrective Action : Now a check sheet has been provided for filter cleaning.
Why ? Panel cooler filter check sheet has not been provided.
How ? New check sheet has displayed.
Future Sustenance ? Check sheet activity will be carried out weekly.

Before 5S Manframe Robot Layout:

W
A
Y

G
U
I
D
E

W
A
Y

G
U
I
D
E

DUST COLLECTOR

COLUMN

MASTER FRONIUS
POWER SOURCE

SLAVE FRONIUS
POWER SOURCE

CHILLER UNIT

ROBOT CONTROL
PANEL
WS-1

COLUMN

MAIN FRAME
ROBOT 1
ELECTRICAL
CONTROL PANEL

ROBOT CONTROL
PANEL
WS-2

BALL PAC WIRE

FEEDER
(1,2)

COLUMN

BALL PAC WIRE

FEEDER
(3,4,5,6)

MANUAL WELDINGPOWER
SOURCE

CHILLER UNIT

COLUMN

MASTER FRONIUS
POWER SOURCE

SLAVE FRONIUS
POWER SOURCE

COLUMN

DUST COLLECTOR

MANUAL WELDING POWER

SOURCE

HEAD STOCK

MASTER ROBOT

SLAVEROBOT

TAIL STOCK

HEADSTOCK

MASTER ROBOT

SLAVE ROBOT

TAIL STOCK

SAFETY
LIGHT
CURTAIN

SAFETY
LIGHT
CURTAIN

WAY
IN/OUT

WAY
IN/OUT

Before 5S Manframe Robot Layout:

After 5S Mainframe Robot layout:

W
A
Y

G
U
I
D
E

W
A
Y

G
U
I
D
E

DUST COLLECTOR

COLUMN

MASTERFRONIUS
POWER SOURCE

SLAVEFRONIUS
POWERSOURCE

CHILLER UNIT

ROBOT CONTROL
PANEL
WS-1

COLUMN

MAIN FRAME
ROBOT 1
ELECTRICAL
CONTROLPANEL

ROBOT CONTROL
PANEL
WS-2

BALL PACWIRE
FEEDER
(1,2)

COLUMN

BALL PAC WIRE

FEEDER
(3,4,5,6)

MANUAL WELDINGPOWER
SOURCE

CHILLERUNIT

COLUMN

MASTERFRONIUS
POWER SOURCE

SLAVEFRONIUS
POWERSOURCE

COLUMN

DUST COLLECTOR

MANUAL WELDINGPOWER
SOURCE

HEADSTOCK

MASTER ROBOT

SLAVEROBOT

TAIL STOCK

HEADSTOCK

MASTER ROBOT

SLAVEROBOT

TAIL STOCK

TOOLSCUPBOARD

TEACH PENDENT

TEACHPENDENT

TOOLSCUPBOARD

SAFETY
LIGHT
CURTAIN

SCISSOR LIFT

SAFETY
LIGHT
CURTAIN

STEP LADDER

WAY
IN/OUT

WAY
IN/OUT

After 5S Mainframe Robot layout:

OEE CALCULATION

Overall Equipment Effectiveness (OEE)

Overall Equipment Effectiveness = Availability x Performance x Quality Yield

Availability = time available for production - downtime

time available for production

Performance = ideal cycle time x number of parts produced

operating time

Quality Yield = total number of parts produced - defect number

total number of parts produced

Table:5.1 Before TPM-Downtime losses

ITEM
Shift Length

DATA
8 hours 30 minutes (510

Break

minutes)
(2) 10 minute and (1) 30

Down Time
Standard time for welding of

minute
63 minutes 02 seconds
4 hours 30 minutes.

model:777 frame

Table:5.2. Availability data for shift-1

S.N

DOWNTIME LOSSES TIME

O
1.

Setup loss

2.

Breakdown loss

18:17

3.

Startup loss

8:42

4.

Tool change

7:38

5.

Inspection

6:57

Total

63.02

(minutes)
22:48

Planned Production Time (Total Time):

Formula: Total time = Shift Length Break
= 510 minutes 50 minutes = 460 minutes

Run Time:
Formula: Available time - losses
= 460 minutes 63 minute 02 seconds
=396 minutes 58 sec.

Performance:
Formula: (Standard Time Total Count) / Run Time
= (460 minutes 0.65) / (396 min 58 sec)
= 0.7539 (75.39%)
Quality:
Formula: Good Count / Total Count
= 2 (777 frame) / 2 (777 frame) = 1.00 (100%)
Here Quality is 100%

Availability:
Formula: Run Time / Total Time
= 396 minutes 58 sec / 460 minutes
= 0.8621 (86.21%)

OEE:
Formula: Availability Performance Quality
= 0.8621 0.7539 1.00= 0.6499~ (65%)

After TPM-Downtime losses

S.N

DOWNTIME LOSSES

TIME

O
1.

Setup loss

2.

Breakdown loss

10:22

3.

Startup loss

7:29

4.

Tool change

6:41

5.

Inspection

5:16

Total

45:15

(minutes)
16:07

Availability data for shift-1

ITEM
Shift Length

DATA
8 hours 30 minutes (510

Break

minutes)
(2) 10 minute and (1) 30

Down Time
Standard time for welding of

minute
53 minutes 02 seconds
4 hours 30 minutes.

777 frame

Planned Production Time (Total Time):

Formula: Total time = Shift Length Break
= 510 minutes 50 minutes

Performance:
Formula: (Standard Time Total Count) / Run Time
= (460 minutes 0.7) / (415 minutes)
= 0.7869 (78.69%)

= 460 minutes
Run Time:
Formula: Available time - losses

Quality:

Formula: Good Count / Total Count

= 460 minutes 45 minutes

= 415 minutes

Availability:

= 2 (777 frame) / 2 (777 frame)

= 1.00 (100%)
Here Quality is 100%

Formula: Run Time / Total Time

= 415 minutes / 460 minutes
= 0.9021 (90.21%)

OEE:

Formula: Availability Performance Quality

= 0.9021 0.7869 1.00
= 0.7098 ~ (70.98%)

Before vs After OEE

Chart Title
120

ITEMS

Before

After

Availability

86.21%

90.21%

Performance

75.39%

78.69%

Quality

100%

100%

OEE

65%

70.98%

100

80

60

40

20

Availability

Performance
Before

Quality
After

OEE