Preventive Maintenance and Breakdown Reduction of Critical Machines

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1 Iteratioal Research Joural of Egieerig ad Techology (IRJET) e-issn: Volume: 03 Issue: 06 Jue p-issn: Prevetive Maiteace ad Breakdow Reductio of Critical Machies Sathish Kumar.N 1, Dr.H.Yogish 2, 1 PG studet, M.Tech (Maiteace Egieerig) SJCE, Mysuru Karataka, Idia 2 Associate Professor Dept. of Mechaical Egieerig, SJCE, Mysuru Karataka, Idia *** Abstract - Maufacturig idustries are facig a greater competitio i the market because of various factors like techology, stadardizatio, quality, etc. to ame a few. This drives compaies to work hard o systems of the compay to improve ad icrease both quality ad productivity cotiuously. Oe of the ways to icrease the productivity is to icrease the availa of existig machies. More the machie availa more is the scope for icrease i productivity keepig other fuctioal aspects of maagemet is rest assured. Total productive maiteace (TPM) aims to icrease the availa of existig equipmet.tpm ca be defied i terms of overall equipmet effectiveess (OEE). of machies ca be icreased by reducig the dowtime or breakdows of the machies. Mai objective is to improve the machie performace by fidig out the major breakdows causig productio losses to the compay ad arrivig & executig the couter measures by which these problems ca be reduced. I this project, prevetive maiteace ad a breakdow reductio methodology is adopted to improve the machie performace. Root cause aalysis is coducted to fid the root cause of breakdows ad some parallel improvemet opportuities were also idetified for so as to reduce the dowtime. The project thus aims to miimize dowtime, maximize availa, miimize maiteace cost ad maximize profit. The project work cocludes that this will help the maiteace departmet to icrease equipmet availa. Fially suggestio was give for future work. Key Words: Prevetive Maiteace, Total Productive Maiteace, Overall Equipmet Effectiveess, Breakdow Reductio Methodology, Root Cause Aalysis, Dowtime. 1. INTRODUCTION [1]Machie maiteace is gaiig importace i idustry because of the eed to icrease relia ad to decrease the possi of productio loss due to machie breakdow. Schedule prevetive maiteace reduces the regular breakdows ad icreases the availa of machie. [2]Maiteace is a activity to esure that equipmet is i a satisfactory coditio ad reliable. The goal of maiteace is to esure that equipmet is satisfactory. [4]There is a itese eed for maufacturig idustries to reduce uexpected breakdows ad remai competitive, ad motivatig maiteace operatios should be itegrated ito productio schedulig models. Dew (1991) ad Sproull (2001) state that idetifyig ad elimiatig root causes of ay problem is of utmost importace.root cause aalysis is the process of idetifyig causal factors usig a structured approach with techiques desiged to provide a focus for idetifyig ad resolvig problems.tools that assist groups ad idividuals i idetifyig aalysis tools (3). Maiteace literature is rich with studies cocerig the developmet ad of mathematical models for maiteace plaig i deterioratig systems. Surveys coducted by authors (4), ad a i-depth mathematical aalysis by (5), comprehesively documet the various approaches to modellig maiteace. May researchers have developed models to address systems that operate cotiuously, as well as system that operates itermittetly. The latter case assumes the system to age or deteriorate oly durig the operatig periods (6). This project deals with the idetifyig the critical machies of a automotive plat based o productio, quality, eviromet ad safety criteria. Troubleshootig o critical machies which has the highest breakdow hours ad breakdow occurrece, I this project, prevetive maiteace ad breakdow reductio methodology is adopted to improve the machie performace. Root cause aalysis is coducted to fid the root cause of breakdows ad some parallel improvemet opportuities were also idetified for so as to reduce the dowtime. Few poits were added i the prevetive maiteace checklist. The availa is icreased cosiderably followig the breakdow reductio & prevetive maiteace methodology. The mai objective of the project is to miimize dowtime ad maximize availa of the machies. 1.1 Methodology of Work 2016, IRJET Impact Factor value: 4.45 ISO 9001:2008 Certified Joural Page 2632 The iitial data collectio of the breakdow details of the machie i.e. The data s such as breakdow hours,

Iteratioal Research Joural of Egieerig ad Techology (IRJET) e-issn: 2395-0056 Volume: 03 Issue: 06 Jue-2016 www.irjet.et p-issn: 2395-0072 breakdow occurrece,, are collected & studied.

Performig root cause aalysis to reduce the recurrece of failures. Performig WHY-WHY aalysis. Replace the defective parts of the machie. Implemetig the corrective steps.

Break dow Descriptio Compoet is ot movig Root cause Rollers gettig jammed Physical pheomeo Roller Ed support bearig jammed Root Cause from Why-Why Aalysis Plumber block cover plate is loose Now the

2 Iteratioal Research Joural of Egieerig ad Techology (IRJET) e-issn: Volume: 03 Issue: 06 Jue p-issn: breakdow occurrece,, are collected & studied. Selectig the critical machie i.e., Shot Blast & Cold Swage for the aalysis. Studyig the type of failures occurred & frequetly repeatig failures. Followig the breakdow reductio methodology. Performig root cause aalysis to reduce the recurrece of failures. Performig WHY-WHY aalysis. Replace the defective parts of the machie. Implemetig the corrective steps. Moitorig ad verifyig the results 2. ROOT CAUSE ANALYSIS & IMPLEMENTATION 1. Break dow Descriptio Compoet is ot movig Root cause Rollers gettig jammed Physical pheomeo Roller Ed support bearig jammed Root Cause from Why-Why Aalysis Plumber block cover plate is loose Now the cover plate is tighteed, greased & plumber block is replaced Beefits/Results - Roller ed support bearig are free from gettig jammed; ow the roller is rotatig & compoets are movig. Problem Compoet is ot movig Roller gettig jammed Roller ed support bearig jammed Bearig wor out due to deterioratio Bearig ot replaced periodically 2. Break dow Descriptio Table tiltig is ot workig Root cause Limit switches ot workig Physical pheomeo Limit switch cable got cut Root Cause from Why-Why Aalysis Problem Table tiltig is ot workig Table tiltig Limit switches all o s ot workig Corrective couter measure Roller bearig is greased durig prevetive maiteace Roller bearig plate is tighteed Limit switch cable got cut Cable to be checked & rejoied Cable to be replaced o Time Based Maiteace Plumber block bearig is replaced Corrective couter measure Table tiltig Limit switches all o s ot workig Cable to be checked & replaced. Roller ed support bearig is jammed 2016, IRJET Impact Factor value: 4.45 ISO 9001:2008 Certified Joural Page 2633

Iteratioal Research Joural of Egieerig ad Techology (IRJET) e-issn: 2395-0056 Volume: 03 Issue: 06 Jue-2016 www.irjet.et p-issn: 2395-0072 3.

04% = Cable is replaced, Limit switches all o s ow workig = = = 55.12

3 Iteratioal Research Joural of Egieerig ad Techology (IRJET) e-issn: Volume: 03 Issue: 06 Jue p-issn: Total umber of breakdows i the period Oct-2015 to Ja-2016= 39 = Table tiltig is ot workig, cable got cut = = = 93.96% Loss of availa = = = 6.04% = Cable is replaced, Limit switches all o s ow workig = = = = hours = 138 = = 3.53 hours Process Parameters of Disa Shot Blast Machie the Implem of Couter Measures Table tiltig is ow workig Beefits/Results - After cable replacemet, limit switches all o s ow workig hece the table tiltig problem is elimiated, & cold swage operatio is further proceeded. 1. Total dowtime of Disa Shot blast machie i the period Feb-2016 to Apr-2016 = 48 hours 2. Total available time for Disa Shot blast machie i the period Feb-2016 to Apr-2016 = 1716 hours (22hours 26 Days, 26Days 3Moths = 572 3=1716) Excludig Sudays, holidays, & luch time. 3. Total umber of breakdows i the period Feb-2016 to Apr-2016= RESULTS AND DISCUSSION 3.1 Process Parameters of Disa Shot Blast Machie the Implem of Couter Measures 1. Total dowtime of Disa Shot blast machie i the period Oct-2015 to Ja-2016 = 138 hours 2. Total available time for Disa Shot blast machie i the period Oct-2015 to Ja-2016 = 2288 hours (22hours 26 Days, 26Days 4Moths = 572 4=2288) Excludig Sudays, holidays, & luch time. = = = = 97.20% 2016, IRJET Impact Factor value: 4.45 ISO 9001:2008 Certified Joural Page 2634

Iteratioal Research Joural of Egieerig ad Techology (IRJET) e-issn: 2395-0056 Volume: 03 Issue: 06 Jue-2016 www.irjet.et p-issn: 2395-0072 Loss of availa = 1-0.9720 = 0.028 = = = 18 = 92.

8% Table 1: Compariso of results ad of couter measures of a Disa Shot Blast Machie 100 90 80 70 60 50 40 30 20 10 0 BEFORE AND AFTER IMPLEMETATION OF COUNTER MEASURES 55.12 92.

3 Graph Showig Compariso of ad of couter measures 3.2 Process Parameters of BFW Cold Swage Machie the Implem of Couter Measures 1.

4 Iteratioal Research Joural of Egieerig ad Techology (IRJET) e-issn: Volume: 03 Issue: 06 Jue p-issn: Loss of availa = = = = = 18 = hours = = 2.66 hours = 2.8% Table 1: Compariso of results ad of couter measures of a Disa Shot Blast Machie BEFORE AND AFTER IMPLEMETATION OF COUNTER MEASURES BEFORE AFTER IMPLEMENTATION IN () IMPLEMENTATION IN () Fig.2 Graph Showig Compariso of ad of couter measures metat io meta tio Fig.3 Graph Showig Compariso of ad of couter measures 3.2 Process Parameters of BFW Cold Swage Machie the Implem of Couter Measures 1. Total dowtime of BFW Cold Swage machie i the period Oct-2015 to Ja-2016 = 134 hours Fig.1 Graph Showig Compariso of ad of couter measures 2. Total available time for BFW Cold Swage machie i the period Oct-2015 to Ja-2016 = 2288 hours (22hours 26 Days, 26Days 4Moths = 572 4=2288) Excludig Sudays, holidays, & luch time. 3. Total umber of breakdows i the period Oct-2015 to Ja-2016= , IRJET Impact Factor value: 4.45 ISO 9001:2008 Certified Joural Page 2635

5 Iteratioal Research Joural of Egieerig ad Techology (IRJET) e-issn: Volume: 03 Issue: 06 Jue p-issn: = = = = 94.14% metat io meta tio Loss of availa = = = 5.86% = = = = = hours = 17 = hours = = 134 = = 3.94 hours Process Parameters of BFW Cold Swage Machie the Implem of Couter Measures 1. Total dowtime of BFW Cold Swage machie i the period Feb-2016 to Apr-2016 = 46 hours 2. Total available time for BFW Cold Swage machie i the period Feb-2016 to Apr-2016 = 1716 hours (22hours 26 Days, 26Days 3Moths = 572 3=1716) Excludig Sudays, holidays, & luch time. 3. Total umber of breakdows i the period Feb-2016 to Apr-2016= 17 = = = = 2.70 hours Table 2: Compariso of results ad of couter measures of BFW Cold Swage Machie AVAILABILTY BEFORE AND AFTER IMPLEMENTATION OF COUNTER MEASURES 97.31% = = % = 97.31% AVAILABILITY BEFORE COUNTER MEASURE IN AVAILABILITY AFTER COUNTER MEASURE IN Loss of availa = = Fig.4 Graph Showig Compariso of ad of couter measures = 2.69% 2016, IRJET Impact Factor value: 4.45 ISO 9001:2008 Certified Joural Page 2636

6 Iteratioal Research Joural of Egieerig ad Techology (IRJET) e-issn: Volume: 03 Issue: 06 Jue p-issn: BEFORE AND AFTER IMPLEMETATION OF COUNTER MEASURES BEFORE IMPLEMENTATION IN () AFTER IMPLEMENTATION IN () Fig.5 Graph Showig Compariso of ad of couter measures Fig.6 Graph Showig Compariso of ad of couter measures 4. CONCLUSION BEFORE AND AFTER IMPLEMETATION OF COUNTER MEASURES 3.94 BEFORE IMPLEMENTATION IN () 2.70 AFTER IMPLEMENTATION IN () The use of root cause aalysis helped to idetify the correct causes of failures by which the suitable coutermeasures are developed ad eted. The process measurable such as,, ad are calculated ad the of couter measures. Cotiuous moitorig of processes is doe the of couter measures ad followig coclusios are draw: The Breakdows such as Rollers problem, Spout uit problem, Impeller problem i Disa Shot Blast Machie is completely elimiated. The availa of Disa Shot Blast Machie is icreased from 93.96% to 97.20%. The of Disa Shot Blast machie is icreased from hours to hours. The of Disa Shot Blast machie is decreased from 3.53 hours to 2.66 hours. The Effectiveess of prevetive maiteace of Disa Shot Blast machie is improved. The Breakdows such as Table tiltig problem, Deep Pressmark o job, Proximity Sesors problem i BFW Cold Swage Machie is completely elimiated. The availa of BFW Cold Swage Machie is icreased from 94.14% to 97.31%. The of BFW Cold Swage Machie is icreased from hours to hours. The of BFW Cold Swage Machie is decreased from 3.94 hours to 2.70 hours. The Effectiveess of prevetive maiteace of BFW Cold Swage Machie is improved. ACKNOWLEDGEMENT I exted sicere thaks to Dr. H. Yogish, Associate Professor, Departmet of Mechaical Egieerig, SJCE, Mysuru, for ledig his esteemed guidace ad his idefatigable kowledge i the field of productive systems which helped a lot i completig this project work. I sicerely thak Mr. Jayaramegowda K H, Deputy Maager Geeral maiteace, plat egieerig departmet, of automotive axle limited, Mysuru, for his extremely valuable time, guidace, Support ad helpig us i familiarizig with the plat ad completig the project work. I exted sicere thaks to Mr. Dhaashekar, Maager Traiig, Automotive Axles Limited, Mysuru, for Givig Me Project Placemet i the Orgaizatio. REFERENCE [1]. "Maagemet of idustrial maiteace" - Athoy Kelly ad M.J. Harris. Butterworth ad Co. Ltd., [2]. "Maiteace plaig ad cotrol" - Athoy Kelly. East west press Pvt. Ltd., 1984 [3]. "Root cause aalysis i aircraft fial assembly" - Brow J I. Master abstract iteratioal.1994 [4]. Egieerig maiteace by B.S Dhillo, Ph.D. [5]. Zero Breakdow Strategies by Terry Wirema- Haser Garder Publicatios. 2016, IRJET Impact Factor value: 4.45 ISO 9001:2008 Certified Joural Page 2637

Iteratioal Research Joural of Egieerig ad Techology (IRJET) e-issn: 2395-0056 Volume: 03 Issue: 06 Jue-2016 www.irjet.et p-issn: 2395-0072 Articles (1) Sergio Rossi [ lea maufacturig ].

Quality progress,24(3),pp97-107, (3) Sproull, B (2001).Process Problem Solvig: A guide for maiteace ad Operatios. Teams. Portlad: Productivity Press (4) Gits, C.W.

7 Iteratioal Research Joural of Egieerig ad Techology (IRJET) e-issn: Volume: 03 Issue: 06 Jue p-issn: Articles (1) Sergio Rossi [ lea maufacturig ].i early s, Treds i Mechaical Egieerig at AIT, Chikkamagaluru. http; // (2) Dew, J. R. (1991) i search of the Root Cause. Quality progress,24(3),pp97-107, (3) Sproull, B (2001).Process Problem Solvig: A guide for maiteace ad Operatios. Teams. Portlad: Productivity Press (4) Gits, C.W., O the Maiteace Cocept for a Techical System: A Framework for Desig, Ph.D. Thesis, Eidhove Uiversity of Techology, (5) Sherif, Y.S., ad Smith, M.L, Optimal Maiteace Models for Systems Subject to Failure: A Review, Naval Research logistics quarterly, volume 28, pp.47-74, (6) Flores, ad Feldma, RM., A Survey of Prevetive Maiteace Models for Stochastically Deterioratig Sigle- Uit Systems, Naval Research logistics quarterly, volume 36, No. 4 pp , Dr.H.Yogish 2, 2 Associate Professor Dept. of Mechaical Egieerig, SJCE, Mysuru Karataka, Idia He has 16 years teachig experiece i the same istitutio, with specializatio i Thermal. (7) Y. Sherif, M.L. Smith, - Optimal maiteace models for systems subject to failure-a review, Naval Research logistics quarterly, volume 28, March 1988, pp (8) Li, C. H., & Chag, S. C. (2002). Model for prevetive maiteace operatios ad forecast method for iterval triggers. Semicoductor Maufacturig Techology workshop 2002, 10-11Dec.2002, pp., (9) ACMP , Egieerig Desig Hadbook: Maiteace Egieerig Techiques, Departmet of Defece, Washigto DC, (1975). BIOGRAPHIES Sathish Kumar.N 1, 1 PG studet, M.Tech (Maiteace Egieerig) SJCE, Mysuru Karataka, Idia He also preseted this paper i Natioal Coferece o Emergig 2016, IRJET Impact Factor value: 4.45 ISO 9001:2008 Certified Joural Page 2638

Identifying poor performers while the process is running

Identifying poor performers while the process is running Idetifyig poor performers while the process is ruig KEYWORDS Michel Ruel P.E. Presidet, TOP Cotrol Ic 4734 Soseeahray Drive 49, Bel-Air St, #103 Hubertus, WI 53033 Levis Qc G6W 6K9 USA Caada mruel@topcotrol.com