A Presentation on Practical Training at
EICHER ENGINES, ITARANA ROAD,ALWAR (RAJ.)
(A unit of tafe motors & tractors ltd .Alwar)
Department of Mechanical Engineering,Laxmi Devi Institute of Engineering & Technology, Chikani, Alwar
Session: 2010-2011
Products
• Automotive Engine
• Stationary Engine
• Cooling technology based: • Cooling technology based:
a) Air cooled
b) Water cooled
Products
• Cylinder technology based:
a) Single cylinder - air cooled,
b) Double cylinder - air cooled,b) Double cylinder - air cooled,
c) Triple cylinder - air cooled,
d)Triple cylinder - water cooled.
In-House Machining Component
• Single Cylinder
1. Carter
2. Control housing
3. Cylinder head3. Cylinder head
4. Cooling jacket
5. Integra liner
6. Crank shaft
7. Fly wheel balancing
8. Blower fan balancing
In-House Machining Component
• Multi Cylinder
1. Crank housing 298
2. Crank case 398
3. Cylinder head
4. Cylinder liner
5. Blower assembly 298
6. Blower assembly 398
In-House Machining Component
• Valtra Water Cooled
1. Cylinder block
2. Cylinder head
3. Front cover3. Front cover
4. Gear housing
5. Fly wheel casing
6. Fly wheel housing
7. Cylinder liner
AFFECT CHECK QUESTIONNAIRE -1
Q1.Pick the correct in-house-machining
component for single cylinder:
(a) Gear housing (b) Crank case 398
(c) Cooling jacket(c) Cooling jacket
Q2.Give the name of type of engine produced in
this division.
Q3.Which award is for technical specification?
(a) ISO-9001 (b) TS-16949 (c) ISO-14001
TPM Means
Total Profit Management
Total Product ManufacturingTotal Product Manufacturing
Total Productive Maintenance
Total People Management
OBJECTIVES OF TPM• Achieve Zero Defects, Zero Breakdown and
Zero accidents in all functional areas of the
organization.
• Involve people in all levels of organization.• Involve people in all levels of organization.
• Form different teams to reduce defects and
Self Maintenance
Direct Benefits Of TPM
• Increase productivity and OPE (Overall Plant Efficiency) by 1.5 or 2 times.
• Rectify customer complaints.
• Reduce the manufacturing cost by 30%.• Reduce the manufacturing cost by 30%.
• Satisfy the customer’s needs by 100 % (Delivering the right quantity at the right time, in the required quality)
• Reduce accidents.
• Follow pollution control measures.
Indirect Benefits of TPM
• Higher confidence level among the employees.
• Keep the work place clean, neat and attractive.
• Favorable change in the attitude of the
operators.operators.
• Achieve goals by working as team.
• Horizontal deployment of a new concept in all
areas of the organization.
• Share knowledge and experience.
• The workers get a feeling of owning the
machine
AUTONOMOUS MAINTENANCE (JH)
• Concept of people who operate a
machine should also maintain the
machine. machine.
• Starts with basic lubrication,
cleaning, inspection & then turns to
repairs.
Reasons Why Autonomous Maintenance is RequiredNo satisfactory increase in the performance
record can be seen …
Activities to prevent
equipment degradation
Activities to keep record
on equipment
degradation• Confirmation of
working conditions
• Daily inspection
• Periodical inspection
• Keep cleaning
• Inspection
• Additional
tightening
• Frequent servicing
• Solution of abnormality
• Good communication
Activities to restore
the machine
conditions
Production
MaintenanceTPM
Japanese
style of PM
Maintenance
Department’s
sole
responsibility
U.S style of PM
Preventive
Maintenance
1. MINOR FLAWS
2. UNFULFILLED BASIC CONDITIONS
3. INACCESSABLE PLACES
7. UNSAFE PLACES
4. CONTAMINATION SOURCES
5. QUALITY DEFECT SOURCES
6. UNNECCERY AND NON-URGENT ITEMS
1. MINOR FLAWS :
Contamination Dust, Dirt, powder, oil, grease, rust, paint
Damage Cracking, crushing, deformation, chipping,
bending,
Play Shaking, falling out, tilting, eccentricity,
wear, distortion, corrosion,wear, distortion, corrosion,
Slackness Belts, Chains
Abnormal
Phenomenon
Unusual noise, overheating, Vibration,
strange smells, discoloration, incorrect
pressure or current
Adhesion Blocking, hardening, accumulation of
debris, peeling, malfunction
2. UNFULFILLED BASIC CONDITIONS
Lubrication Insufficient, Dirty, Unidentified,
unsuitable, Leaking
Lubrication
Supply
Dirty, damaged or deformed lubricant
inlets, faulty lubricant pipes
Oil level gauges Dirty, Damaged, leaking, No indication of
correct level
Tightening Nuts and Bolts slackness, Missing,
Cross-threaded, Too long, Crushed,
Corroded, Unsuitable washers, wing
nuts on backward.
Cleaning Machine construction, Covers, Layout,
footholds, Space
Checking Construction, Covers, Layout, footholds,
Instrument position and Orientation, Operating –
Range display
Lubricating Position of lubricant inlet, construction, height,
3. INACCESSABLE PLACES
Lubricating Position of lubricant inlet, construction, height,
footholds, lubricant outlets, space
Tightening Covers, Construction, Layout size, Space
Operation Machine layout, Position of valves, Switches
and leavers, Footholds
Adjustment Position of pressure gauges, thermometers,
flow meters, moisture gauges, vacuum gauges,
etc.
Product Leaks, Spills, Spurts, Scattering, Overflow
Raw materials Leaks, Spills, Spurts, Scattering, Overflow
Lubricants Leaking, Spills, Seeping oils, Hydraulic fluids,
Fuel oils, etc.
Gases Leaking compressed air, gases, steam,
vapors, exhaust fumes, etc.
4. CONTEMINATION SOURCES
vapors, exhaust fumes, etc.
Liquids Leaking water, Hot, Cold, half finished
products, Waste water, Leaking supply lines
etc.
Scrap Flashes, cuttings, packaging materials, and
non conforming products.
Others Contaminants by people & Forklifts,
Infiltration through cracked walls, broken
windows etc.
Foreign
Matter
Dust, Rust, powder, chips, moisture, wire
scraps, wood pieces, paper pieces, stones
etc.
Shock Dropping, Jolting, collision, Vibration etc.
Moisture Too little or Too much, infiltration
5. QUALITY DEFECT SOURCES
Gain Size Abnormalities in screens, Compressed air
separators, centrifugal separators,
Concentration Inadequate warming, heating,
compounding, mixing, evaporation, stirring
etc.
Viscosity Inadequate warming, heating,
compounding, mixing, evaporation, stirring
etc.
Machinery Pumps, fans, compressors, columns, tanks
etc.
Piping
equipment
Pipes, hoses, ducts, valves, dampers etc.
Measuring
instruments
Temperatures, pressure gauges, vacuum
gauges, ammeters etc.
6. UNNECCERY AND NON-URGENT ITEMS
Electrical
equipment
Wiring, piping, power leads, switches, plugs
etc.
Jigs & Tools General tools, cutting tools, jigs, molds,
dies, frames etc.
Spare parts Standby equipment, spares, permanent
stocks, auxiliary materials, etc.
Makeshift
repairs
Tape. String, wire, metal plates etc.
Floors Unevenness, cracked, holes, projections,
peeling, wear of steel chucker plates, slipping.
Steps Too steep, irregular, slipping, missing handrails,
etc.
Lights Dim, out of position, dirty or broken covers, no
explosion proofing, etc.
7. UNSAFE PLACES
explosion proofing, etc.
Rotating
machinery
Displaced, fallen oil or broken covers, not safe
for emergency, missing emergency stop devices
Lifting
Devices
Wires, hooks, brakes and other parts of cranes
and hoists etc.
Others Special substances, solvents, toxic gases,
insulating materials, danger signs, protective
clothing etc.
Equipment Name ………………
Control No……………………..
Date of detection……………….
Detected by……………………..
Red Tags to be attended by Maint.
Equipment Name ………………
Control No……………………..
Date of detection……………….
Detected by……………………..
White tags for operators
Detected by……………………..
Description of Minor defects
………………………………….
…………………………………..
………………………………….
Description of Minor defects
………………………………….
…………………………………..
………………………………….
KAIZEN
• Japanese word kaizen means improvement.
• Kai means change or ‘the action to correct’.correct’.
• Zen means good.
• Therefore, kaizen = change for improvement/good.
Loss Category
1. Failure losses - Breakdown loss
2. Setup / adjustment losses
3. Cutting blade loss
4. Start up loss
5. Minor stoppage / idling loss.
6. Speed loss - operating at low speeds.
7. Defect / rework loss
Losses that impede
equipment efficiency
CHECK FOR 16 MAJOR LOSSES IN ORGANISATION
7. Defect / rework loss
8. Scheduled downtime loss
9. Management loss
10.Operating motion loss
11.Line organization loss
12.Logistic loss
13.Measurement and adjustment loss
Loses that impede
human work efficiency
14.Energy loss
15.Die, jig and tool breakage loss
16.Yield loss.
Loses that impede
effective use of
production resources
PLANNED MAINTENANCE
• Aimed to have trouble free machines and
equipments producing defect free products for
total customer satisfaction
• Unplanned maintenance create problems like • Unplanned maintenance create problems like
a) huge inefficiencies in maintenance labor.
b) confusion and disturbance in scheduling,
production and other areas.
c) Morale problems
Planned maintenance aims at:
• Achieve and sustain availability of
machines
• Optimum maintenance cost.
• Reduces spares inventory.
• Improve reliability and maintainability
of machines
AFFECT CHECK QUESTIONNAIRE-2
Q1. What is the main objective of TPM ?
Q2. What is the concept of ‘autonomous
maintenance’?
Q3. List the abnormalities to be checked for JH.
Q4. How & when to use the red & white tags?
Meaning in Japanese context:Throw away all rubbish & unrelated material in workplace.
Industrial definition:
Seiri= Sort
Industrial definition:To distinguish between necessary thingsand unnecessary things.
Meaning in Japanese context:
Set everything in proper place for quick
retrieval & storage.
Seiton = stabilize/organize
retrieval & storage.
Industrial definition:
It is a way of eliminating
search.
Seiso = Shine/Clean
Definition:
Eliminating trash, filth, and foreign Eliminating trash, filth, and foreign
matters for a cleaner workplace.
Cleaning as a form of inspection.
•Quick 5S drill
•Sparkling clean campaign
•Everybody is a janitor
Typical SEISO Activities
Broom
Mop
Dust pan
INDUSTRIAL DEFINITION
Keeping things organized, neat
and clean; in personal and
environmental aspects.
SeitonSeiri
environmental aspects.
Seiso
• Make quality manual• Directional markings•Color-coded pipes
Typical Seiketsu Activities
Before After
Meaning in Japanese context:
Practice ‘5s’ daily- make it a way of
Shitsuke = Self-discipline
Practice ‘5s’ daily- make it a way of
life; this also means ‘commitment’.
AFFECT CHECK QUESTIONNAIRE-3
Q1. Name the value system followed in the
organization:
Q2. 1s stands for:
(a) Shine (b) Sort (c) Standardize(a) Shine (b) Sort (c) Standardize
Q3. 2s stands for:
(a) Stabilize (b) self-discipline (c) Sustain
Q4.What is a ‘30 second rule’?
Safety Rules
• Wear shoes, tight & clean clothes (trouser and shirt) at work
• It is required from everyone to use spectacles for the protection of eyes.spectacles for the protection of eyes.
• Proper use of ‘safety equipments’ is a must.
• Use mouth mask and safety shoes while painting.
Continue….
Safety Rules
• Use specs while working at grinder &
washing machine.
• On finding some unusual noise, smoke • On finding some unusual noise, smoke
or condition immediately switch off
machine & inform the supervisor.
• In case of fire inform ‘main gate’
(tel.ph.200 or 206) and shout FIRE &
come out at emergency collecting point.
Rules For Production
• Work according to rules & regulations
and instructions written in OS/AOS.
• Use critical instruments like vernier, • Use critical instruments like vernier,
TPG etc. and check CMM.
• Use special instruments according to
OS.
• Change or mend the hammer before its
surface gets round or damaged. Continue…
Rules For Production• During the shift ensure that adjuster on
the tork rinch should not be below tape marking.
• Don’t try to tighten further once tightened • Don’t try to tighten further once tightened by the oil pulse tool.
• Avoid and stop defects. If you have any suggestions regarding it give it to the supervisor.
• Learn from mistakes, don’t repeat them
Continue…
Rules For Production• While punching number take a note to
put stamp first in which 12 digits should be punched & punching should not be light.light.
• Clean the punch once a month and
change it after every 3 months.
• Give suggestion regarding increase of ‘Production Output’.
ISO-14001 Instructions
• Switch off fans, cooler, lights of your
work place while going for tea,
lunch/dinner and at the end of shift.
• Close taps after usage.
• Stop the leakage of air, coolant and oil
during work.
ISO-14001 Instructions
• Avoid spilling of oil, chips, paper,etc.
Throw the wastage like paper, cloth,
plastic in specified dustbins i.e. RED,
BLUE and GREEN. BLUE and GREEN.
Autonomous Check Sheet
• Take complete information about check sheet.
• Operators have to fill the autonomous check sheet while taking of the following check sheet while taking of the following points:
1) Operator has to fill the pre-control chart and data sheet.
2) Is there any problem with fixtures?
Continue…
Autonomous Check Sheet
3) Is the level of hydraulic oil, lubricant oil and coolant level correct?
4) Is air pressure, hydraulic system pressure correct?pressure correct?
5) Is sound from machine normal?
6) Has reliever removed chips and dust from machine?
7) Is there any kind of leakage in machine?
Continue…
Autonomous Check Sheet
8) Are the meters on the machine working properly?
9) Has the condition of cutting tools been checked?checked?
10)Are all the push buttons, switches, indication lamp working properly?
11) Is component’s all documents attached to the machine?
Continue…
Autonomous Check Sheet
12)Are all the tools, gauges, fixtures and rotate parts cleaned and placed at their fixed place?
Note: In case of negligence of any of the Note: In case of negligence of any of the above points inform the supervisor without the further delay
Complete work on time while maintaining discipline.
TS & 5s Instructions
• Decide what is needed and what is not
needed at the work place. Remove the
things which are not needed and put a 1s
tag on them and keep them at specified tag on them and keep them at specified
place.
• Don’t overload the trolley and after using
it keep it at the right place.
Continue…
TS & 5s Instructions
• Gang way should be absolutely clear and
nothing should be laid there.
• Place the component only on the
conveyor, trolley or machine. And not on
the floor/platform.
• Don’t put anything (finish/scrap/tools etc)
on the floor.
Continue…
TS & 5s Instructions• Don’t throw duster or gloves near
machine or inside tank or on the floor.
• Have to clean the resting face of fixture after every piece.after every piece.
• At the end of shift clean the side ways, glide ways.
• Follow the standards designed for the workplace.
Continue…
TS & 5s Instructions• Keep the rejection/rework products aside,
do know the reason of rejection/rework and mark it. Mark the component with the marker, keep it at the specified place the marker, keep it at the specified place at the end of shift before leaving the workplace.
• Take care of cleanliness of the work place.
AFFECT CHECK QUESTIONNAIRE-4
Q1.What would you do in case of an emergency?
Q2.When should punch be cleaned & changed?
Q3.What kind of waste will you dispose off in
RED, BLUE & GREEN dustbins?RED, BLUE & GREEN dustbins?
Q4.What is to be done to utilize ‘ideal time’?
Q5. What will you do if any component is
rejected?
AFFECT CHECK QUESTIONNAIRE-4
Q6.How will you check oil & coolant level?
Q7.Where to use (a) ear plugs (b) safety goggles
(c) gloves?
Q8.How to check tool condition?Q8.How to check tool condition?
Q9.How will you check drill/tap sizes?
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