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5th TPM National Conference

Session G : Planned Maintenance

Topic :
Zero Breakdown

Presentation by

Mr G Vinoth Asst Manager (Production) TTK-Pallavaram

TTK-Pallavaram

Zero Breakdown

SUSTAINING ZERO BREAKDOWN AT TTK LIG Ltd., [Pallavaram Unit] By Mr.G. Vinoth @ Vijayan

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 of 170 Crores.

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%.

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Zero Breakdown

Milestones
1952 : 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 love 1979 : 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 mark 2003 : TPM Excellence Award (2nd category) 2004 : TPM Excellence (2nd category) Consistency Award.

Quality Accreditations.
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)

Production Process
.

Compounding

Natural latex mixed with vulcanizing chemicals is heated, cooled & sent to Dipping Glass 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.
Wash Wash tumbler Cooling table Centrifuge Dry Dry tumbler

Dipping

Post Treatment

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. Each and every condom is then electronically tested for holes. The good ones are sent to Foiling. The good condoms received from ET are foiled between two layers of laminates, with a lubricant.

Electronic Testing Foiling

The foiled condoms are packed as per customers specifications & dispatched

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Zero Breakdown

Approach - Nakona Sans Concept of Zero Breakdown


Time Kaizen on weaknesses (CM) Degree of deterioration

Predictive maintenance (measurement diagnosis of deterioration)

Restoration

Life extended 2 Inspection

Forced deterioration Life extended 1 JH Breakdown TBM

Standard

Forecast Limit line

Methodology
Activities for Elimination of Breakdown Support Activities for Jishu Hozen Preparation and Implementation of Time Based Maintenance Prevention of Recurrence of breakdown

Condition Based Maintenance

Reduction of Maintenance Cost

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

5th TPM National Conference

Degree of deterioration
1 2 3 4 5 6

Step 2

Step 3

Step 4

Step 5

Support To Jishu Hozen Step 1


Red Tag Removal Plan and Correcting abnormalities Tag Register
Sl Tag Plant No. No.. B C D E G H 407 600 566 384 332 400 Date Assembly Part Blower Physical phenomena Abnormal Noise Oil Leak Founded by Operator Operator Operator Operator Operator Counter Measure Bearing Replaced Oil seal Replaced Bearing Replaced Plug & Socket Tightned Seal Replaced. Seal Replaced. Target Date Responsi ble Consquences Quality Break Down. Remarks Completed. Completed. Completed. 28/12/2004 Ist drier 07/01/2005 Fitter 15/09/2004 Fitter

10/09/2004 Main Drive Gear Box 30/08/2004 Stripping 20/11/2004 I st Drier 19/10/2004 Stripping R/C Pump

Abnormal Noise Plug & I Drier Box Socket Loose R/C Pump Water Leak

30/08/2004 Eletrician Break Down.

20/11/2004 Eletrician Quality &Safety Completed. 20/10/2004 Fitter 20/08/2004 Fitter Break Down. Break Down. Completed. Completed.

20/08/2004 Main Drive Coupling

Spider Loose Fitter

Nos 7000 6000 5000 4000 3000 2000 1000 0


Put -R Rem -R 2000 2597 2593 2001 3854 3792

Red Tag Status [ Cumulative ]

2002 4252 4217

2003 5731 5774

H104 5980 5972

Q 304 6064 6059

O 04 6083 6079

N04 6102 6098

D04 6313 6300

J05 6358 6355

F05

M05

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Support To Jishu Hozen Step 2


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

Summary of HTA / SOC


Department Compounding Dipping Post Treatment Electronic Testing Foiling Hard to access 8 10 5 13 8 Source of Contamination 5 11 5 2 9

Before Cleaning the track chain dirt was difficult before.

After Tray provided for easy cleaning the track chain dirt

Easy Cleaning of Drive End

Before

After

Support To Jishu Hozen Step 3


Preparation of Tentative Standards for CLIRt.

Visual for pump on / off / trip in Dipping

Visual for shaft rotation in Dipping

Visual for Low pressure Dipping

Visual for Dipper Temperature Dipping

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Poor Basic Condition


Nos 4000 3000

Red Tag Status [ Cumulative ]

Restoration [Red Tag]

2000 1000 0
Put -R Rem -R

Q 1'00 872 872

Q 2'00 1564 1564

Q 3'00 2148 2148

Q 4'00 2597 2597

Q 1'01 2714 2713

Q 2'01 2887 2884

Q 3'01 2926 2926

N o s.

70 60 50 40 30 20 10 0
Nos / Mt h. Dec ' 99 64 Q1' 00 52

Breakdown - Companywide

Q2' 00 45

Q3' 00 36

Q4' 00 32

Q1' 01 27

Q2' 01 23

Q3' 01 19

Prevention of Recurrence of Breakdown


Understand the Present Condition Analysis Root Cause Analysis Classification of Causes

Poor Basic Condition

Poor Knowledge / Skill

Weak Design

Lack of Periodical Inspection / Replacement JH Inspection Std. / TBM

Restoration [Red Tag]

One Point Lesson

Kaizen

Preventive Action

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Under Stand the Present Condition Status As of 1999

No.of Glass Moulds 2040 Operating 24 hrs & 360 Days No.of Machines - 11

Sl. No 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16

Physical Phenomena Stripping jet blockage R/C pump not running Wash Brush not rotating Dipper 1 Agitator not rotating Dipper Agitator Blade not running Drier 1 heater open / cut Dipper 2 Agitator not rotating Drier 2 heater open / cut Beading Brush not rotating Contra belt not running FDE curve broken Triplex chain cut off Track micromaster - no output Vulc heater open / cut Former breakage MCB / OLR - tripped / open

1999 2 15 3 8 1 6 2 3 4 3 2 1 1 8 12 8

2000 2001 Q1 Q2 Q3 Q4 Q1 Q2 Q3 Q4 1 2 1 1 1 0 0 0 16 20 22 21 6 4 1 0 0 1 0 0 0 0 0 1 0 0 1 1 0 1 0 0 0 0 0 0 0 0 0 0 9 10 11 12 3 0 1 0 0 1 0 0 0 0 0 0 1 2 4 2 2 0 1 0 8 3 0 0 0 2 2 1 4 6 5 6 1 0 0 0 0 1 0 0 0 0 0 0 1 1 0 0 0 0 0 0 0 0 1 0 0 0 0 1 0 1 0 0 0 0 0 0 2 5 13 15 7 9 14 0 0 5 0 1 0 4 0 0

Dipping Line

Total Phenomenon - 39

Theme

Analysis

TPM ONE POINT LESSON


To Know How to tighten the bolt with Washer
No. Date of Preparation
Dept. Manager Supervisor K. A N. G Basic Knowledge Improvement Cases Trouble Cases PM 005 05.02.2000 Circle leader KA Prepared by K. A

Classification

Motor Base

Foundation Base

Motor Base

Foundation Base

Actual Results

Date Executed Teacher Student

05.02. 2000 KA BSK

06.02. 2000 KA RS

05.02. 2000 KA SC

05.02. 2000 KA AK

06.02. 2000 KA RK

06.02. 2000 KA BK

05.02. 2000 KA BSK

06.02. 2000 KA KSR

06.02. 2000 KA VSR

06.02.2000 KA VK

512 Why Whys

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Classification of Causes based on Why Why Analysis


Classification of Causes

Poor Basic Condition

Poor Knowledge / Skill

Weak Design

Lack of Periodical Inspection / Replacement JH Inspection Std. / TBM

Restoration [Red Tag]

One Point Lesson

Kaizen

JH

E&T

KK / PM

JH / PM

Classification of Causes

Nos. 700 600 500 400 300 200 100 0 Nos. D99 42 2000 226

OPL Trend

2001 302

2002 413

2003 531

2004 646

Poor Knowledge / Skill

One Point Lesson

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Classification of Causes

Theme 1 : Elimination of Triplex Chain Breakdown


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

Weak Design

Kaizen

1/2 " Triplex Chain

3/4 " Triplex Chain

Analysis : Triplex Chain breaks down 6 times / month

Results :
Nos./Mth 8 6 4 Triplex Chain Breakdown

Triplex Chain links not able to withstand the load Triplex Chain link is of 1/2 " pitch

2 0 Before 6

Better

After 0

Design Root cause: Weak Design

Nos/Mth

Classification of Causes

331 Kaizens

Theme 2 : To reduce stress on Torsional Spring


SPRING ASSEMBLY
U - Clamp

Weak Design
Spindle

Bush

Brass Block

Kaizen
Holder

Torsional Springs

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OLD SPRING - UNLOADED

Stress Analysis of Torsional Spring - Before


Type of spring Location of usage Dia. of the wire No. of Coil Nominal dia. of spring Location of Mounting Hook Position of Mounting Material of Construction Young Modulus nof the material Ultimate bending stress of Spring Initial Stress on the Spring ( When Loading with Clamp ) Working Stress on the Spring Swinging 0 to 90 ( i.e. 180 - Total twisting angle of spring ) Torsional Spring Clamp Assembly in Dipping Line 1.5 mm 7 24.5 mm Parallel Right Angle Stainless Steel - Spring Grade 2.16 x 105 N / mm 935 N / mm 494.49 N / mm 989 N / mm

Swing Angle -0

OLD SPRING - LOADED


Initial Stress 494.5 N/mm

Swing Angle -90

Theme: To reduce the initial Load on torsional spring


B efo re
Torsional springs are used in clamp assembly with initial twisting of 90 from normal condition. Counte rme as ure : B y changing the s pring hook angle

After
Initial twisting angle reduced to 60

30
Analysis :
Clamp replacement high Spring life less Spring gets over stressed Working stress on the spring is higher than allowable stress Design Root Cause : Higher working stress

Results :
N / mm 600 550 500 450 400 350 300 Be f or e Af t er

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

Initial Stress reduced due to hook modification


494.49 Bet t er

33 %

330

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Theme: To reduce the Working Load on torsional spring


Theme: To reduce the Working stress on the torsional spring Countermeasure : By changing the curve angle Before Torsional springs are used in clamp assembly to After
swing the former from 0 to 90 and hold in 0 in dipper and leach tank
Angle change from 0 - 90 - 0

Reducing the Swinging angle by 40 ( i.e.from 0 to 50 of swinging angle ) and hold the former in 0 in dipper and leach tank by altering the former travelling Angle change smoothen from 0 - 50 - 0 guide.

90

50
Results :
N / mm 550 500 450 400 350 300 250 200 Before After

Analysis :
No. of clamp replacement high Springs get Over stressed Spring swings the formers from 0 to 90 and vice versa Design Root Cause : Higher swinging angle

Benefits :
Working Stress reduced due to curve modification

494.49

Production increased = 6900 pcs. / mc. / month

42 %

Better 275

NEW SPRING - UNLOADED

Stress Analysis of Torsional Spring - After


Type of spring Location of usage Dia. of the wire No. of Coil Nominal dia. of spring Location of Mounting Hook Position of Mounting Material of Construction Young's Modulus of the material Allowable bending stress of Spring Before Clamp Assembly in Dipping Line 1.5 mm 7 24.5 mm Parallel 90 60 Stainless Steel - Spring Grade 2.16 x 10 N / mm 935 N / mm
5 5

After
Swing Angle -0

NEW SPRING - LOADED


Initial Stress 330 N/mm

2.16 x 10 N / mm 935 N / mm 330 N / mm 605 N / mm

Swing Angle -60

Initial Stress on the Spring 494.49 N / mm ( When Loading with Clamp ) Working Stress on the Spring Swinging 0 to 50 ( i.e. 110 - 989 N / mm total twist of spring )

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Classification of Causes

Lack of Periodical Inspection / Replacement Inspection Standard - JH

Time Based Maintenance

TBM Calendar

TBM
Time
Kaizen on weaknesses (CM)

TBM Checklist
* Tendency to replace at greater frequency is expensive

Natural Deterioration Forced Deterioration

Parts replaced though still useful Severe wear but change before breakdown Parts Not replaced before failure

Change parts on schedule TBM

Limit Line

Physical Phenomenon Analysis - Status As of 2002

Dipping Line

Sl. No 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16

Physical Phenomena Stripping jet blockage R/C pump not running Wash Brush not rotating Dipper 1 Agitator not rotating Dipper Agitator Blade not running Drier 1 heater open / cut Dipper 2 Agitator not rotating Drier 2 heater open / cut Beading Brush not rotating Contra belt not running FDE curve broken Triplex chain cut off Track micromaster - no output Vulc heater open / cut Former breakage MCB / OLR - tripped / open

1999 2 15 3 8 1 6 2 3 4 3 2 1 1 8 12 8

2000 2001 2002 Q1 Q2 Q3 Q4 Q1 Q2 Q3 Q4 Q1 Q2 Q3 Q4 1 2 1 1 1 0 0 0 0 0 0 0 16 20 22 21 6 4 1 0 1 1 0 0 0 1 0 0 0 0 0 1 0 0 1 0 0 0 1 1 0 1 0 0 1 0 0 0 0 0 0 0 0 0 0 0 0 0 1 0 9 10 11 12 3 0 1 0 1 2 0 0 0 1 0 0 0 0 0 0 0 0 0 0 1 2 4 2 2 0 1 0 0 0 1 0 8 3 0 0 0 2 2 1 1 0 0 0 4 6 5 6 1 0 0 0 0 2 0 0 0 1 0 0 0 0 0 0 0 0 0 0 1 1 0 0 0 0 0 0 2 2 0 0 0 0 1 0 0 0 0 1 0 0 0 0 0 1 0 0 0 0 0 0 1 0 0 0 2 5 13 15 7 9 14 0 0 1 0 0 0 5 0 1 0 4 0 0 1 0 0 0

Total Phenomenon - 39 Phenomenon Eliminated - 39

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N o s.

70 60 50 40 30 20 10 0
No s / Mth . Kaizen s Dec'9 9 64 24 Q1 '0 0 52 56 Q 2 '0 0 45 84

Breakdown Vs Kaizens - Companywide

N o s.

350 300 250 200 15 0 10 0 50

Q 3 '0 0 36 115

Q4 '0 0 32 124

Q1 '0 1 27 142

Q 2 '0 1 23 164

Q 3 '0 1 19 194

Q4 '0 1 15 209

Q 1 '0 2 13 231

Q 2 '0 2 9 249

Q3 '0 2 4 27 1

Q4 '0 2 1 292

Q 1 '0 3 0 317

Q 2 '0 3 0 324

Q2 '0 4 0 331

N o s.

50 40 30 20 10 0
De c' 9 39 Q 1' 00 30

Breakdown - Dipping
T a rge t - Z e ro

N o s.

8 6 4

Breakdown - Electronic Testing


T arge t - Z e ro

B et ter

B etter

2
Q2 ' Q 3 ' Q4 ' 00 00 00 26 22 20 Q 1' 01 19 Q2 ' Q3 ' Q4 ' 01 01 01 16 13 11 Q 1' 02 10 Q2 ' Q3 ' Q4 ' 02 02 02 6 2 0 Q 1' 03 0 Q2 ' 03 0

0
N o s / M t h.

De c' 9 6

Q 1' Q2 0 0 '0 6 5

Q3 '0 5

Q4 '0 5

Q 1' 01 4

Q 2 Q3 Q4 Q1' '0 1 '0 1 '0 1 02 4 4 4 3

Q2 '0 3

Q3 '0 2

Q4 '0 1

Q1' Q 2 03 '0 1 0

Q3 '0 0

N o s / M t h.

N o s.

20 15 10 5 0
D ec ' 99 19 Q 1' 0 0 16 Q2 ' 0 0 14

Breakdown - Foiling
T a rge t - Z e ro

B etter

Achieved Zero Breakdown In Q22003

Q3 ' 0 0 9

Q4 ' 0 0 7

Q 1' 0 1 4

Q2 ' 0 1 3

Q3 ' 0 1 2

Q4 ' 0 1 0

Q 10 2 0

Q2 0 2 0

N o s / M t h.

Preventive Action
M/c. / Sl Component Line No No. 1 F Agitator - 1 Physical Phenomena Agitator not rotating Root Cause Latex entered into the bearing Corrective Action Bearing replaced Preventive Action / Inspection Agitator bearing block height elevated by 20 mm and included shaft cleaning during dipper staining - JH Included in the Inspection Schedule - PM Hylum guidespring replaced included in TBMschedule-Yearly - PM Included in TBM Schedule - PM Screw replaced instead of rivetand Limit switch position altered to avoid rubbing on the rivet / screw - PM Training given to the fitters on the importance of the spring washers in theU Clamp assembly - E&T

Beading brush - 1 Beading brush not rotating 3 X & Arms Arms lifted Y 4 5 Y C Carousel Tank Dehumidifier Tank not rotating Dehumidifer not working

Motor terminal block wire loose Hylum guide found broken and positioning spring lost its tension Inside of drum steel balls struck Desicant bed rivet broken

Retightened Hylum guide replaced Steel balls replaced Screw replaced

U - Clamp

Track not moving

Clamp loosened due to spring washer missed

Washer replaced and tightened

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Zero Breakdown

SUSTENANCE OF ZERO BREAKDOWN

Sustenance of Zero Breakdown


Achieve Zero Breakdown by thorough analysis of Breakdown Breakdown Analysis Counter measure / Kaizen Check the result Proactive measures to prevent recurrence of breakdown

Support to Jishu Hozen in making the operator Equipment competent

Identify critical components Identify Potential causes & Conditions Inspect & take Counter measure Check the result

Practising TBM CBM Collection of replaced Parts Analyse & identify weakness Implement Kaizen / Countermeasure

Horizontal deployment Preventive measures Revise Inspection & TBM standards

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Support To Jishu Hozen


Degree of deterioration Natural deterioration Forced Deterioration 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 4


Preparation of General Inspection training material and training the circle leaders.

Beading Unit

Training to Circle Leaders

Training to Circle members

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Support To Jishu Hozen Step 5


Preparation of Autonomous Inspection standards

Potential Cause Analysis Main Drive of Dipping Line

Sl. Physical No Phenomena


1 Main Drive

Critical Parts

Potential Cause

How to check

What to do Preventive Action if not okay


a. Before welding, ends to be chamfered. b. Trained the welder a. Aligned the Sprocket b. Match the fixing bolts with tight mark c. Trained the fitters on alignment

Worn out Check Joints Welded Joint Crack on Joints Visually Blow holes Chain & Sprockets Check Alignment Misalignment Drive chain cut Parallality Check Skewness Misalignment Faceout Check the Micromaster - no Electronic Life Electrical output Components unpredictable connection Sprocket Locking Screw tip Check the dislocation Screw damaged locking tip 2 Former Assy. FDE curve broken Former breakage Clamp Spring Sticky of Clamp

Grind and Reweld Align the Sprockets Align the Sprockets

Replace by new Replace once in 5 one Years. Replace the screw Replace the Screw whenever removed

Replace the Clamp assembly to be Visually check clamp with new modified the Spring spring

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Zero Breakdown

Revision of PM Standard

Actions to overcome the inherent weaknesses.


Station Component Weakness control measures Contra drive needs 1 Amps. i.e., 0.5 HP Drive and A - 112 Gear box not withstand the Drive Load Operating at higher voltage ( 240 - 250 V ) and starting current also high Drive needs to be strengthened alongwith other modifications in the dipping line Identified the weakness control Life Before After

Beading Station of Dipping Lines

Department : Dipping Contra Rotation Stripping Area Gear Box Change from A -112 Model 45 Days to A - 162 Model Converted to Three phase 3 Months from Single phase Converted to 3/4" Pitch from 1/2" Pitch Converted the Shaft material to EN - 8 from Stainless Steel Changed from Teflon to Cast Nylon Changed from 2 mm thick to 3.2 mm thick belt Replaced the Pillow block bearings to bearing housing with double bearing One year

Recycling Pump

One year

Main Drive Triplex Chain

3 Months

Two years

Contra Rotation Contra Rotation Contra Rotation Contra Rotation

Drive and Driven pulley Shaft material is soft shaft Teflon guide wearsout Belt Guide causing belt slippage Flat belt Driven Shaft Supporting Bearing 2mm Belt looses its tension More Alignment time due to the shaft supported by Individual Bearings

Monthly 3 Months 45 Days 20 Mins. to adjust / align

Six Months Two years Six Months 5 Mins. to adjust / align

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Failure Mode and Effect analysis


Failure Mode & Effect Analysis - Automatic Plant ( Sub System - Beading System )
Sub System Beading System Component Geared Motor Function Functional Failure Failure mode Winding open, Drawing high current, Single Phasing Hamming noise, Tripped off Over Heat 1 5 3 4 60 Occurance Impact Restoration Detection A B C Degree D Scoring Criteria AxBxCxD Effect of Failure Servicing and replacement of Geared Motor time - 120 Mins. i.e., 1000 Pcs. Product scrap & 27000 Pcs. Production loss Proposed Task

To ensure the Unable to drive the drive the beading beading brush brush

Over bearing noise Oil Seal Damaged, Noise Worn out of hylum Gears Misalignment Drive Sprocket To ensure the Unable to Slippage of key & locking transmission transmit screw, wornout of bore and of drive teeth,

1 Misalignment

10

Condition Monitoring through Tong Tester - for working current - Every month Inspect the OLR setting before restart after any shutdown Inspect the fan blade during shutdown, Clean the motor body finns Following Time based maintenance once in three years Following Time based maintenance once in three years Following Time based maintenance once in six months. Inspect the alignement during shutdown Replacement & alignment Visual check during any shutdown, time - 15 Mins. i.e., 1000 Alignment to be checked whenever Pcs. Product scrap & 3750 Sprocket, Chain, Gear box & Driven Pcs. Production loss shaft replaced / serviced Training of technicians on mounting and dismounting on opportunity

Key

To integrate Unable to Sprocket integrate with shaft

Looseness, Shear, Crush

10

Refitting - 15 mins. hrs down Check the key, keyway and Fitness time, replacement & whenever refitted alignment. Production Loss of 3750 Pcs & Product scrap 1000 Pcs.

Theme: To Increase the Mean time between Touch


Counter Measure; By Changing the Hylum gear drive to metal gear drive

Before

After

Geared Motor is used to drive beading brushes to form beads on the Product. The Gears are made of both Metal & Hylum sheets.
H ylum G e a rs M e ta l l i c G e a rs

Gears in the Geared motor is changed with Metal Gears.


M e ta l l i c G e a rs

D ri v e S h a ft

D ri v e n S h a ft

D riv e S h a ft

D rive n S h a ft

Analysis: 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.

Results
M o nths 30 25 20 15 10 5 0 M o nth B e fo re 6 E xpe c te d L ife 24 B e tte r

L ife of G ear - In creased in M TB T

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Zero Breakdown

PM Matrix

Component Categorisation
Catagorisation of PM Components - Before
MTTR - Sub Assembly MTBF - Component System Sub Assembly Platinum Gold Silver Bronze Component Platinum Gold Silver Bronze Drive System 10 3 3 4 40 22 6 8 4 38 8 15 5 10 105 45 20 22 18 Beading Drier 8 2 4 2 32 7 12 5 8 12 3 1 5 3 44 2 8 24 10 Dipper Dry Brush 18 8 1 3 6 48 18 9 18 3 8 1 3 4 20 9 3 4 4 Product Stripping Track Chain 6 2 4 24 12 4 6 2 100 20 25 22 33 313 115 62 87 49 Total

MTBF - Componentwise Period Category More than 1 Year Platinum More than 6 Months Gold More than 3 Months Silver Monthly or Less Bronze MTTR - Subassemblywise Period Category Less than 10 min Platinum Less than 90 min Gold Less than 240 min Silver More than 240 min Bronze

Catagorisation of PM Components - After


MTTR - Sub Assembly MTBF - Component System Sub Assembly Platinum Gold Silver Bronze Component Platinum Gold Silver Bronze Drive System 10 6 4 40 29 5 6 0 38 10 28 105 62 28 7 8 Beading Drier 8 8 32 13 14 3 2 12 6 6 44 15 19 4 6 Dipper Dry Brush 18 9 9 48 24 13 11 0 8 2 5 1 20 11 6 1 2 Product Stripping Track Chain 6 2 4 24 18 5 1 0 100 27 62 7 4 313 172 90 33 18 Total

26 % Increase in MTTR Platinum

33 % Increase in MTBF Platinum

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Condition Based Monitoring


TBM
Time
Kaizen on weaknesses (CM)

Natural Deterioration Forced Deterioration

* Tendency to replace at greater frequency is expensive

Parts replaced though still useful Severe wear but change before breakdown Parts Not replaced before failure

Change parts on schedule TBM

Limit Line

CBM
Time
Kaizen on weaknesses (CM) Inspection Standard Forced Deterioration

Natural Deterioration

Prediction

Standard Values can be set near the limit lime if the diagnosis is reliable

Limit Line

Condition Based Maintenance - Mapping in Dipping Lines

To check the Voltage drop

To Scan the surface temp. of Former

To check the Length Variation

To check the working condition

To check the Condition of Bearing

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Results Breakdown Trend 126 Equipments


Nu m be rs 80 70 60 50 40 30 20 10 0
199 9 No s . Ta rge t 60 45 2 00 0 49 30 20 01 36 10 20 02 5 0 20 03 1 0 H 104 0 0 Q 30 4 0 0 O '04 0 0 N '04 0 0 D '0 4 0 0 J '05 0 0 0 0 0 0 F '05 M '05 A '05 S '0 5 O '05M '06

Numbers 40 30 20 10 0
19 9 9 No s . Mins. Pcs. Targ et 39 110 4 0 1E+0 6 30 2000 34 74 4 5 20 2001 27 6 6 0 5.5 10

Breakdown Downtime vs Production Loss - Dipping

Better

2002 4 4 8 1.2 519 70 0

200 3 0 0 0 0

H10 4 0 0 0 0

Q3 0 4 0 0 0 0

O'0 4 0 0 0 0

N'0 4 0 0 0 0

D'0 4 0 0 0 0

J'0 5 0 0 0 0

F'0 5

M'0 5

A'0 5S'0 5

O'0 5M'0 6

8 0 4 0 6 0 713 3 9 4

Breakdown - Company WIde


Num be rs 5 4 3

Breakdown Downtime vs Production Loss - Electronic Testing

Better

2 1 0
199 9 No s . M ins . P cs . Ta rge t 2 1275 45900 0 2000 3 1885 67860 0 2001 1 240 8640 0 2002 1 22 0 7 920 0 2003 1 30 1080 0 H104 0 0 0 0 Q304 0 0 0 0 O'0 4 0 0 0 0 N'04 0 0 0 0 D'04 0 0 0 0 J '0 5 0 0 0 0 0 0 F '0 5 M '0 5

Better

A'05S'05

O'05M '06

Numbe rs 20 15 10 5 0
1999 No s . M ins . P cs . Ta rge t 19 3410 15 2000 12 2694 10 2001 8 713 0

Breakdown Downtime vs Production Loss - Foiling

Sustaining Zero Breakdown for 22 Months

Better

2002 0 0 0 0

2003 0 0 0 0

H104 0 0 0 0

Q304 0 0 0 0

O'04 0 0 0 0

N'04 0 0 0 0

D'04 0 0 0 0

J '05 0 0 0 0

F'05

M '05

A'05S '05

O'05M '06

163680 129312 34224

5th TPM National Conference

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