21 TTK-Pallavaram

5th TPM National Conference

Session G : Planned Maintenance

Topic :Zero Breakdown

Presentation by

Mr G VinothAsst Manager (Production)

TTK-Pallavaram

5th TPM National Conference Page 21.1

TTK-Pallavaram Zero Breakdown

SUSTAINING ZERO BREAKDOWN

AT

TTK � LIG Ltd.,

[Pallavaram Unit]

By

Mr.G. Vinoth @ Vijayan

Position of the Company within the Industy� Domestic Market : TTK- LIG is the leader with a market

share of 45%.

� Global Branded Market : SSL, our joint venture

partner, is the market leader with a market share of 26%.

The Company� TTK-LIG Ltd. is a 50:50 joint venture between

TTK Group, India and SSL International plc, UK.� Manufacturing and marketing Male Latex condoms.� Factories : Pallavaram (outskirts of Chennai),

Virudhunagar (near Madurai) and Pondicherry(160 kms south of Chennai) with Annual turnover of170 Crores.



Milestones1952 : TTK importing and selling Durapac and Durex in India.1963 : LRC (India) Ltd. established; condom manufacturing commenced.1971 : Supply of �Nirodh� condoms to Govt. of India commenced.1976 : Exports commenced � To Russia with love1979 : Launched Kohinoor � the brand leader in India, today.1987 : Vietnam Project executed � The first International turnkey project.2001 : Sales value crosses the Rs.1 billion mark2003 : TPM Excellence Award (2nd category) 2004 : TPM Excellence (2nd category) Consistency Award.

� ISO 9000 / ISO 14000 / ISO 13485� AFNOR (French certification) / DLF (German certification)� SABS (South african beuro of Standards) / HKSI ( Hong kong Safety institute)� CMDCAS (Canadian certification)

Quality Accreditations.

Production Process.

CompoundingNatural latex mixed with vulcanizingchemicals is heated, cooled & sent toDipping

DippingGlass formers are dipped in compounded

latex. A latex film (the condom) is formed on glass former surface. The formers are then dried and the condoms (dried films) are wet stripped subsequently.

PostTreatment

The condoms are washed, dried & cooled. They are then naturally aged for a minimum of 21 days to complete vulcanization by storing them in a room.

ElectronicTesting

Each and every condom is then electronically tested for holes. The good ones are sent to Foiling.

Foiling The good condoms received from ET are foiled between two layers of laminates, with a lubricant.

The foiled condoms are packed as per customer�s specifications & dispatched

Wash

Dry

Washtumbler

Centrifuge

DrytumblerCooling table



Approach - Nakona San�s Concept of Zero Breakdown

Degree of deterioration

TBM

Breakdown

Forced deterioration

Life extended 1JH

Life extended 2

Kaizen on weaknesses(CM)

Restoration

Standard

Limit line

Time

Predictive maintenance

(measurem

ent diagnosis of deterioration)

InspectionForecast

Methodology

Support Activities for Jishu Hozen

Prevention of Recurrence of breakdown

Preparation and Implementation of Time

Based Maintenance

Condition Based Maintenance

Reduction of Maintenance Cost

Activities for Elimination of Breakdown



Support To Jishu Hozen : Find all the causes of forced deterioration and restore and improve(Kaizen)

Natural deterioration

Forced Deterioration

Time




Time


Step 1 Red Tag Removal Plan and Correcting abnormalities

Implementing Counter measures against Hard to Access areas and

source of Contamination

Preparation of Tentative Standards for CLIRt.

Preparation of General Inspection training material and training the

circle leaders.

Preparation of Autonomous Inspection standards for JH

Step 2

Step 3

Step 4

Step 5

Support To Jishu Hozen � Step 1Red Tag Removal Plan and Correcting abnormalities

Sl No. Plant

Tag No.. Date Assembly Part

Physical phenomena

Founded by

Counter Measure

Target Date

Responsible Consquences Remarks

1 B 407 28/12/2004 Ist drier Blower Abnormal Noise

Operator Bearing Replaced

07/01/2005 Fitter Quality Completed.

2 C 600 10/09/2004 Main Drive Gear Box Oil Leak Operator Oil seal Replaced

15/09/2004 Fitter Break Down. Completed.

3 D 566 30/08/2004 Stripping R/C Pump Abnormal Noise

Operator Bearing Replaced

30/08/2004 Eletrician Break Down. Completed.

4 E 384 20/11/2004 I st Drier I Drier BoxPlug & Socket Loose

OperatorPlug & Socket Tightned

20/11/2004 Eletrician Quality &Safety Completed.

5 G 332 19/10/2004 Stripping R/C Pump Water Leak Operator Seal Replaced.


6 H 400 20/08/2004 Main Drive Coupling Spider Loose Fitter Seal Replaced.


Tag Register

Red Tag Status [ Cumulative ]

0

1000

2000

3000

4000

5000

6000

7000

Nos

Put -R 2597 3854 4252 5731 5980 6064 6083 6102 6313 6358Rem -R 2593 3792 4217 5774 5972 6059 6079 6098 6300 6355

2000 2001 2002 2003 H104 Q304 O 04 N04 D04 J05 F05 M05



Implementing Counter measures against Hard to Access areas and source of Contamination

Support To Jishu Hozen � Step 2

Before AfterTray provided for easy

cleaning the track chain dirtCleaning the track

chain dirt was difficult before.

Before After

Easy Cleaning of Drive End

Department Hard to

access

Source of Contamination

Compounding 8 5 Dipping 10 11 Post Treatment 5 5 Electronic Testing 13 2 Foiling 8 9

Summary of HTA / SOC

Support To Jishu Hozen � Step 3Preparation of Tentative Standards for CLIRt.

Visual for pump on / off / trip in Dipping

Visual for shaft rotation in Dipping

Visual for Low pressureDipping

Visual for Dipper Temperature Dipping



Red Tag Status [ Cumulative ]

0

1000

2000

3000

4000Nos

Put -R 872 1564 2148 2597 2714 2887 2926Rem -R 872 1564 2148 2597 2713 2884 2926

Q 1'00 Q 2'00 Q 3'00 Q 4'00 Q 1'01 Q 2'01 Q 3'01

Poor Basic Condition

Restoration [Red Tag]

Breakdown - Companywide

0

10

20

30

40

50

60

70N o s.

Nos / Mt h. 64 52 45 36 32 27 23 19

Dec'99 Q1'00 Q2'00 Q3'00 Q4'00 Q1'01 Q2'01 Q3'01

Prevention of Recurrence of Breakdown

Understand the Present Condition

Analysis � Root Cause Analysis

Classification of Causes


Lack of Periodical Inspection /

Replacement

Weak Design

Poor Knowledge / Skill


KaizenOne Point Lesson

JH Inspection Std. / TBM

Preventive Action



Under Stand the Present Condition Status As of 1999

Q1 Q2 Q3 Q4 Q1 Q2 Q3 Q41 Stripping jet blockage 2 1 2 1 1 1 0 0 02 R/C pump not running 15 16 20 22 21 6 4 1 03 Wash Brush not rotating 3 0 1 0 0 0 0 0 14 Dipper 1 Agitator not rotating 8 0 0 1 1 0 1 0 05 Dipper Agitator Blade not running 1 0 0 0 0 0 0 0 06 Drier 1 heater open / cut 6 9 10 11 12 3 0 1 07 Dipper 2 Agitator not rotating 2 0 1 0 0 0 0 0 08 Drier 2 heater open / cut 3 1 2 4 2 2 0 1 09 Beading Brush not rotating 4 8 3 0 0 0 2 2 110 Contra belt not running 3 4 6 5 6 1 0 0 011 FDE curve broken 2 0 1 0 0 0 0 0 012 Triplex chain cut off 1 1 1 0 0 0 0 0 013 Track micromaster - no output 1 0 0 1 0 0 0 0 114 Vulc heater open / cut 8 0 1 0 0 0 0 0 015 Former breakage 12 2 5 13 15 7 9 14 016 MCB / OLR - tripped / open 8 0 5 0 1 0 4 0 0

1999Physical PhenomenaSl.No

20012000

Dipping Line

No.of Glass Moulds � 2040Operating 24 hrs & 360 Days

No.of Machines - 11

Total Phenomenon - 39

Analysis

512 Why Why�s

TPM ONE �POINT LESSON No. PM 005

Date of Preparation

05.02.2000

Them

e

To Know How to tighten the bolt

with Washer Dept.

Manager Super- visor

Circle leader Prepared by

Basic Knowledge

Improvement Cases

Trouble Cases C

lass

ifi-

catio

n

N. G K. A KA K. A

Date Executed

05.02.2000

06.02.2000

05.02.2000

05.02.2000

06.02.2000

06.02.2000

05.02.2000

06.02.2000

06.02.2000

06.02.2000

Teacher KA KA KA KA KA KA KA KA KA KA

Act

ual R

esul

ts

Student BSK RS SC AK RK BK BSK KSR VSR VK

Motor Base

Foundation Base

Motor Base

Foundation Base



Classification of Causes based on Why Why Analysis




Replacement

Weak Design



KaizenOne Point Lesson

JH Inspection Std. / TBM

JH JH / PME&T KK / PM


One Point Lesson


OPL Trend

0

100200

300

400

500600

700Nos.

Nos. 42 226 302 413 531 646

D99 2000 2001 2002 2003 2004



Weak Design

Kaizen


Problem/present status : Countermeasure : By changing the pitch of Triplex Main drive - Side View Main Drive - Top View chain from 1/2 " to 3/4 ".

1/2 " Triplex Chain 3/4 " Triplex Chain

Analysis :

Root cause: Weak DesignDesign

Triplex Chain link is of 1/2 " pitch

Results :

Triplex Chain links not able to withstand the load

Triplex Chain breaks down 6 times / month Triplex Chain Breakdown

0

2

4

6

8Nos./Mth

Nos/Mth 6 0

Before After

Better

Theme 1 : Elimination of Triplex Chain Breakdown

Weak Design

Kaizen


SPRING ASSEMBLY

U - Clamp

Bush

Spindle

Brass Block

Torsional Springs

Holder

Theme 2 : To reduce stress on Torsional Spring

331Kaizens



Type of spring Torsional SpringLocation of usage Clamp Assembly in Dipping LineDia. of the wire 1.5 mmNo. of Coil 7Nominal dia. of spring 24.5 mmLocation of Mounting Hook ParallelPosition of Mounting Right AngleMaterial of Construction Stainless Steel - Spring GradeYoung Modulus nof the material 2.16 x 105 N / mm²Ultimate bending stress of Spring 935 N / mm²

Initial Stress on the Spring 494.49 N / mm²( When Loading with Clamp )Working Stress on the Spring 989 N / mm²Swinging 0 to 90° ( i.e. 180° - Total twisting angle of spring )

Stress Analysis of Torsional Spring - Before

OLD SPRING - LOADED

OLD SPRING - UNLOADED

Initial Stress494.5 N/mm²

Swing Angle -0°

Swing Angle -90°

Theme: To reduce the initial Load on torsional spring

Results :Initial Stress reduced due to hook

modification

494.49

330

300

350

400

450

500

550

600

Be for e After

N / mm ²

Bet ter

30°

B efore Counte rme asure : By changing the spring hook angle Torsional springs are used in clamp assembly with Afterinitial twisting of 90° from normal condition. Initial twisting angle reduced to 60°

B e n e f i t s :

P r o d u c t io n in c r e a s e d= 1 3 8 0 0 p c s . / m c . /

m o n th

Analysis :

Root Cause : Higher working stress Design

Clamp replacement high

Spring life less

Spring gets over stressed

Working stress on the spring is higher than allowable stress

33 %

Results :Initial Stress reduced due to hook

modification

494.49

330

300

350

400

450

500

550

600

Be for e After

N / mm ²

Bet ter

30°30°

B efore Counte rme asure : By changing the spring hook angle Torsional springs are used in clamp assembly with Afterinitial twisting of 90° from normal condition. Initial twisting angle reduced to 60°

B e n e f i t s :

P r o d u c t io n in c r e a s e d= 1 3 8 0 0 p c s . / m c . /

m o n th

Analysis :

Root Cause : Higher working stress Design

Clamp replacement high

Spring life less

Spring gets over stressed

Working stress on the spring is higher than allowable stress

33 %



Theme: To reduce the Working Load on torsional spring

Before Countermeasure : By changing the curve angleTorsional springs are used in clamp assembly to Afterswing the former from 0° to 90° and hold in 0° Reducing the Swinging angle by 40° ( i.e.from 0° toin dipper and leach tank 50° of swinging angle ) and hold the former in 0° in

dipper and leach tank by altering the former travellingguide.

Analysis : Benefits :

= 6900 pcs. / mc. /month

Spring swings the formers from 0° to 90° and vice versa

Root Cause : Higher swinging angleDesign

Theme: To reduce the Working stress on the torsional spring

No. of clamp replacement high

Springs get Over stressed

Production increased

Results :Working Stress reduced due to curve

modification494.49

275

200250300350400450500550

Before After

N / mm²

Better

Angle change from 0 ° - 90 ° - 0°Angle change smoothen from 0° - 50 ° - 0°

42 %

90°50°

Before Countermeasure : By changing the curve angleTorsional springs are used in clamp assembly to Afterswing the former from 0° to 90° and hold in 0° Reducing the Swinging angle by 40° ( i.e.from 0° toin dipper and leach tank 50° of swinging angle ) and hold the former in 0° in

dipper and leach tank by altering the former travellingguide.

Analysis : Benefits :

= 6900 pcs. / mc. /month

Spring swings the formers from 0° to 90° and vice versa

Root Cause : Higher swinging angleDesign

Theme: To reduce the Working stress on the torsional spring

No. of clamp replacement high

Springs get Over stressed

Production increased

Results :Working Stress reduced due to curve

modification494.49

275

200250300350400450500550

Before After

N / mm²

Better

Angle change from 0 ° - 90 ° - 0°Angle change smoothen from 0° - 50 ° - 0°

42 %

90°90°50°

Type of spring Before AfterLocation of usageDia. of the wireNo. of CoilNominal dia. of springLocation of Mounting HookPosition of Mounting 90° 60°Material of ConstructionYoung's Modulus of the material 2.16 x 105 N / mm ² 2.16 x 105 N / mm ²Allowable bending stress of Spring 935 N / mm ² 935 N / mm ²

Initial Stress on the Spring( When Loading with Clamp )Working Stress on the SpringSwinging 0 to 50° ( i.e. 110° - total twist of spring )

1.5 mmClamp Assembly in Dipping Line

330 N / mm ²

Parallel24.5 mm7

605 N / mm ²

494.49 N / mm ²

989 N / mm ²

Stainless Steel - Spring Grade

Stress Analysis of Torsional Spring - After

NEW SPRING - LOADED

NEW SPRING - UNLOADED

Initial Stress330 N/mm²

Swing Angle -0°

Swing Angle -60°



TBM

TBM

ForcedDeterioration

Time


Natural DeteriorationParts replaced though still useful

Severe wear but change before breakdown

Parts Not replaced before failure

Change parts on schedule Limit Line

* Tendency to replace at greater frequency is expensive

TBM

TBM

ForcedDeterioration

Time








Replacement

Time Based Maintenance


TBM Calendar

TBM Checklist

Inspection Standard - JH

Physical Phenomenon Analysis - Status As of 2002

Dipping Line

Q1 Q2 Q3 Q4 Q1 Q2 Q3 Q4 Q1 Q2 Q3 Q41 Stripping jet blockage 2 1 2 1 1 1 0 0 0 0 0 0 02 R/C pump not running 15 16 20 22 21 6 4 1 0 1 1 0 03 Wash Brush not rotating 3 0 1 0 0 0 0 0 1 0 0 1 04 Dipper 1 Agitator not rotating 8 0 0 1 1 0 1 0 0 1 0 0 05 Dipper Agitator Blade not running 1 0 0 0 0 0 0 0 0 0 0 1 06 Drier 1 heater open / cut 6 9 10 11 12 3 0 1 0 1 2 0 07 Dipper 2 Agitator not rotating 2 0 1 0 0 0 0 0 0 0 0 0 08 Drier 2 heater open / cut 3 1 2 4 2 2 0 1 0 0 0 1 09 Beading Brush not rotating 4 8 3 0 0 0 2 2 1 1 0 0 010 Contra belt not running 3 4 6 5 6 1 0 0 0 0 2 0 011 FDE curve broken 2 0 1 0 0 0 0 0 0 0 0 0 012 Triplex chain cut off 1 1 1 0 0 0 0 0 0 2 2 0 013 Track micromaster - no output 1 0 0 1 0 0 0 0 1 0 0 0 014 Vulc heater open / cut 8 0 1 0 0 0 0 0 0 1 0 0 015 Former breakage 12 2 5 13 15 7 9 14 0 0 1 0 016 MCB / OLR - tripped / open 8 0 5 0 1 0 4 0 0 1 0 0 0

1999Physical PhenomenaSl.No

200220012000

Total Phenomenon - 39Phenomenon Eliminated - 39



Breakdown - Dipping

0

10

20

30

40

50N o s.

N o s / M t h. 3 9 3 0 2 6 2 2 2 0 19 16 13 11 10 6 2 0 0 0

D ec'9

Q1'0 0

Q2 '0 0

Q3 '0 0

Q4 '0 0

Q1'0 1

Q2 '0 1

Q3 '0 1

Q4 '0 1

Q1'0 2

Q2 '0 2

Q3 '0 2

Q4 '0 2

Q1'0 3

Q2 '0 3

B etter

T arget - Z ero

Achieved Zero

BreakdownIn Q2�2003

Breakdown - Electronic Testing

0

2

4

6

8N o s.

N o s / M t h. 6 6 5 5 5 4 4 4 4 3 3 2 1 1 0 0

D ec' 9

Q1'0 0

Q2' 0

Q3' 0

Q4' 0

Q1'0 1

Q2' 0 1

Q3' 0 1

Q4' 0 1

Q1'0 2

Q2' 0

Q3' 0

Q4' 0

Q1'0 3

Q2' 0

Q3' 0

B et ter

T arget - Z ero

Breakdown - Foiling

0

5

10

15

20N o s.

N os / M t h. 19 16 14 9 7 4 3 2 0 0 0

D ec'9 9

Q1'00

Q2 '00

Q3 '00

Q4 '00

Q1'01

Q2 '01

Q3 '01

Q4 '01

Q10 2 Q2 02

B etter

T arge t - Z ero

Breakdown Vs Kaizens - Companywide

0

10

20

30

40

50

60

70N o s.

0

50

100

150

200

250

300

350N o s.

Nos / Mth. 64 52 45 36 32 27 23 19 15 13 9 4 1 0 0 0

Kaizens 24 56 84 115 124 142 164 194 209 231 249 271 292 317 324 331

Dec'99 Q1'00 Q2'00 Q3'00 Q4'00 Q1'01 Q2'01 Q3'01 Q4'01 Q1'02 Q2'02 Q3'02 Q4'02 Q1'03 Q2'03 Q2'04

Preventive ActionM/c. /LineNo.

1 F Agitator - 1 Agitator not rotating Latex entered Bearing Agitator bearing blockinto the bearing replaced height elevated by 20

mm and included shaftcleaning during dipperstaining - JH

2 H Beading brush - 1 Beading brush Motor terminal Retightened Included in thenot rotating block wire loose Inspection Schedule - PM

3 X & Arms Arms lifted Hylum guide found Hylum guide Hylum guidespringY broken and positioning replaced replaced included in

spring lost its tension TBMschedule-Yearly - PM4 Y Carousel Tank Tank not rotating Inside of drum Steel balls Included in

steel balls struck replaced TBM Schedule - PM5 C Dehumidifier Dehumidifer not Desicant bed Screw replaced Screw replaced instead of

working rivet broken rivetand Limitswitch position altered toavoid rubbing on the rivet /screw - PM

6 G U - Clamp Track not moving Clamp loosened Washer replaced Training given to the fittersdue to spring washer and tightened on the importance of themissed spring washers in theU -

Clamp assembly - E&T

Sl No

Component Physical Phenomena Root Cause Corrective Action

Preventive Action / Inspection



SUSTENANCE

OF

ZERO BREAKDOWN

Sustenance of Zero BreakdownAchieve Zero

Breakdown by thorough analysis

of Breakdown

Proactive measures to prevent recurrence of breakdown

Breakdown

Analysis

Counter measure / Kaizen

Check the result

Horizontal deployment

Identify critical components

Identify Potential causes &

Conditions

Inspect & take Counter measure

Check the result

Practising TBM

Collection of replaced Parts

Analyse & identify weakness

Implement Kaizen / Countermeasure

Preventive measures � Revise Inspection & TBM standards

Support to Jishu Hozen in making

the operator -Equipment competent

CBM



Support To Jishu Hozen



Time




Time


Step 1 Red Tag Removal Plan and Correcting abnormalities

Implementing Counter measures against Hard to Access areas and

source of Contamination

Preparation of Tentative Standards for CLIRt.

Preparation of General Inspection training material and training the

circle leaders.

Preparation of Autonomous Inspection standards for JH

Step 2

Step 3

Step 4

Step 5

Support To Jishu Hozen � Step 4Preparation of General Inspection training material and training the circle

leaders.

Training to Circle Leaders

Beading Unit

Training to Circle members



Support To Jishu Hozen � Step 5Preparation of Autonomous Inspection standards

Potential Cause Analysis

Physical Phenomena

Critical Parts

Potential Cause

How to check

What to do -if not okay Preventive Action

1 Main DriveWorn outCrack on JointsBlow holes

Alignment Misalignment Check Parallality

Align the Sprockets

Skewness Misalignment Check Faceout

Align the Sprockets

Micromaster - no output

Electronic Components

Life unpredictable

Check the Electrical connection

Replace by new one

Replace once in 5 Years.

Sprocket dislocation

Locking Screw

Screw tip damaged

Check the locking tip

Replace the screw

Replace the Screw whenever removed

2 Former Assy.

Former breakage Clamp Spring Sticky of Clamp

Visually check the Spring

Replace the clamp with new spring

Clamp assembly to be modified

Drive chain cut

a. Aligned the Sprocket b. Match the fixing bolts with tight mark c. Trained the fitters on alignment

Chain & Sprockets

Sl.No

FDE curve broken

Welded Joint Check Joints Visually

Grind and Reweld

a. Before welding, ends to be chamfered. b. Trained the welder

Main Drive of Dipping Line



Revision of PM Standard

Actions to overcome the inherent weaknesses.

Before AfterDepartment : Dipping

Contra Rotation Gear Box

Contra drive needs 1 Amps. i.e., 0.5 HP Drive and A - 112 Gear box not withstand the Drive Load

Change from A -112 Model to A - 162 Model 45 Days One year

Stripping Area

Recycling Pump

Operating at higher voltage ( 240 - 250 V ) and starting current also high

Converted to Three phase from Single phase

3 Months One year

Main Drive Triplex Chain

Drive needs to be strengthened alongwith other modifications in the dipping line

Converted to 3/4" Pitch from 1/2" Pitch 3 Months Two years

Contra Rotation

Drive and Driven pulley shaft

Shaft material is softConverted the Shaft material to EN - 8 from Stainless Steel

Monthly Six Months

Contra Rotation Belt Guide

Teflon guide wearsout causing belt slippage

Changed from Teflon to Cast Nylon 3 Months Two years

Contra Rotation Flat belt 2mm Belt looses its tension

Changed from 2 mm thick to 3.2 mm thick belt 45 Days Six Months

Contra Rotation

Driven Shaft Supporting Bearing

More Alignment time due to the shaft supported by Individual Bearings

Replaced the Pillow block bearings to bearing housing with double bearing

20 Mins. to adjust / align

5 Mins. to adjust / align

Station Component Weakness control measures Identified the weakness control

Life

Beading Station of Dipping Lines



Failure Mode and Effect analysis

Sub System Component Function Functional

Failure Failure mode Occurance A

Impact B

RestorationC

Detection Degree D

Scoring Criteria

AxBxCxDEffect of Failure Proposed Task

Beading System

Winding open, Drawing high current, Single Phasing

Condition Monitoring through Tong Tester - for working current - Every month

Hamming noise, Tripped off

Inspect the OLR setting before restart after any shutdown

Over Heat Inspect the fan blade during shutdown, Clean the motor body finns

Over bearing noise Following Time based maintenance - once in three years

Oil Seal Damaged, Noise

Following Time based maintenance - once in three years

Worn out of hylum Gears Following Time based maintenance - once in six months.

Misalignment Inspect the alignement during shutdown

Slippage of key & locking screw, wornout of bore and teeth,

Visual check during any shutdown, Alignment to be checked whenever Sprocket, Chain, Gear box & Driven shaft replaced / serviced

Misalignment Training of technicians on mounting and dismounting on opportunity

Key To integrate Sprocket with shaft

Unable to integrate

Looseness, Shear, Crush 1 5 1 2 10

Refitting - 15 mins. hrs down time, replacement & alignment. Production Loss of 3750 Pcs & Product scrap 1000 Pcs.

Check the key, keyway and Fitness whenever refitted

101 5 1 2

1 4 60

Servicing and replacement of Geared Motor time - 120

Mins. i.e., 1000 Pcs. Product scrap & 27000 Pcs.

Production loss

5 3

Failure Mode & Effect Analysis - Automatic Plant ( Sub System - Beading System )

Replacement & alignment time - 15 Mins. i.e., 1000

Pcs. Product scrap & 3750 Pcs. Production loss

Unable to transmit

To ensure the transmission of drive

Drive Sprocket

Unable to drive the beading brush

To ensure the drive the beading brush

Geared Motor

Theme: To Increase the Mean time between TouchCounter Measure; By Changing the Hylum gear drive to metal gear drive

Before After

ResultsAnalysis:Production Loss is high.

Time for replacement of Gears is high.

Wear out of Gears

Gear are made of hylum ( soft material ).

Design.Root Cause: Hylum Gears.

Geared Motor is used to drive beadingbrushes to form beads on the Product. The Gears are made of both Metal & Hylum sheets.

Gears in the Geared motor is changed with Metal Gears.

L ife of G ear - Increased in M TB T

0

5

1 0

1 5

2 0

2 5

3 0M o nths

M o nth 6 2 4

B e fo re E xpe cte d L ife

B e tte r

D ri ve S h a ft

D ri ve n S h a ft

H yl u m G e a rs

M e ta ll ic G e a rs

D r i v e S h a f t

D r i v e n S h a f t

M e ta l l i c G e a r s

Theme: To Increase the Mean time between TouchCounter Measure; By Changing the Hylum gear drive to metal gear drive

Before After

ResultsAnalysis:Production Loss is high.

Time for replacement of Gears is high.

Wear out of Gears

Gear are made of hylum ( soft material ).

Design.Root Cause: Hylum Gears.

Geared Motor is used to drive beadingbrushes to form beads on the Product. The Gears are made of both Metal & Hylum sheets.

Gears in the Geared motor is changed with Metal Gears.

L ife of G ear - Increased in M TB T

0

5

1 0

1 5

2 0

2 5

3 0M o nths

M o nth 6 2 4

B e fo re E xpe cte d L ife

B e tte r

D ri ve S h a ft

D ri ve n S h a ft

H yl u m G e a rs

M e ta ll ic G e a rs

D r i v e S h a f t

D r i v e n S h a f t

M e ta l l i c G e a r s



PM Matrix

Component Categorisation

System Sub Assembly Platinum Gold Silver Bronze Component Platinum Gold Silver BronzeDrive System 10 3 3 4 40 22 6 8 4Beading 38 8 15 5 10 105 45 20 22 18Drier 8 2 4 2 32 7 12 5 8Dipper 12 3 1 5 3 44 2 8 24 10Dry Brush 18 8 1 3 6 48 18 9 18 3Product Stripping 8 1 3 4 20 9 3 4 4Track Chain 6 2 4 24 12 4 6 2

Total 100 20 25 22 33 313 115 62 87 49

MTTR - Sub Assembly MTBF - ComponentCatagorisation of PM Components - Before

System Sub Assembly Platinum Gold Silver Bronze Component Platinum Gold Silver BronzeDrive System 10 6 4 40 29 5 6 0Beading 38 10 28 105 62 28 7 8Drier 8 8 32 13 14 3 2Dipper 12 6 6 44 15 19 4 6Dry Brush 18 9 9 48 24 13 11 0Product Stripping 8 2 5 1 20 11 6 1 2Track Chain 6 2 4 24 18 5 1 0

Total 100 27 62 7 4 313 172 90 33 18

Catagorisation of PM Components - AfterMTBF - ComponentMTTR - Sub Assembly

Period CategoryMore than 1 Year PlatinumMore than 6 Months GoldMore than 3 Months SilverMonthly or Less Bronze

Period CategoryLess than 10 min PlatinumLess than 90 min GoldLess than 240 min SilverMore than 240 min Bronze

MTBF - Componentwise

MTTR - Subassemblywise

26 % Increase in

MTTR Platinum

33 % Increase in

MTBF Platinum



Condition Based MonitoringTBM

TBM

ForcedDeterioration

Time







TBM

TBM

ForcedDeterioration

Time







CBM

Time

Limit Line

ForcedDeterioration

Kaizen onweaknesses(CM)

NaturalDeterioration

Prediction

Standard

Inspection

Standard Values can be set near the limitlime if the diagnosis is reliable

To check the workingcondition

To check theCondition of

Bearing

To check the Voltagedrop

To Scan the surfacetemp. of Former

To check the LengthVariation

Condition Based Maintenance - Mapping in Dipping Lines



Results

Breakdown Downtime vs Production Loss - Dipping

0

10

20

30

40

Numbers

Nos . 39 34 27 4 0 0 0 0 0 0 0

Mins. 11040 7445 6605.5 481.2 0 0 0 0 0 0 0

Pcs. 1E+06 804060 713394 519 70 0 0 0 0 0 0 0

Target 30 20 10 0 0 0 0 0 0 0 0 0 0 0 0

1999 2000 2001 2002 200 3 H104 Q304 O'04 N'04 D'04 J'05 F'05 M'05 A'05-S'05

O'05-M'06

Better

Breakdown Downtime vs Production Loss - Electronic Testing

0

1

2

3

4

5

Numbers

No s . 2 3 1 1 1 0 0 0 0 0 0

Mins . 1275 1885 240 220 30 0 0 0 0 0 0

P cs . 45900 67860 8640 7920 1080 0 0 0 0 0 0

Target 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0

1999 2000 2001 2002 2003 H104 Q304 O'04 N'04 D'04 J '05 F '05 M'05 A'05-S'05

O'05-M'06

Better

Breakdown Downtime vs Production Loss - Foiling

0

5

10

15

20

Numbers

No s . 19 12 8 0 0 0 0 0 0 0 0

Mins . 3410 2694 713 0 0 0 0 0 0 0 0

P cs . 163680 129312 34224 0 0 0 0 0 0 0 0

Target 15 10 0 0 0 0 0 0 0 0 0 0 0 0 0

1999 2000 2001 2002 2003 H104 Q304 O'04 N'04 D'04 J '05 F'05 M'05A'05-S '05

O'05-M'06

Better

Breakdown Trend

Sustaining Zero Breakdown for 22

Months

Breakdown - Company WIde

0

10

20

30

40

50

60

70

80

Num bers

No s . 60 49 36 5 1 0 0 0 0 0 0

Ta rge t 45 30 10 0 0 0 0 0 0 0 0 0 0 0 0

1999 2000 2001 2002 2003 H104 Q304 O'04 N'04 D'04 J '05 F '05 M '05 A'05-S '05

O'05-M '06

Better

126 Equipments

Documents

21 TTK-Pallavaram