Bharati Vidyapeeth College Of Engineering

UNIVERSITY OF MUMBAI
A PROJECT REPORT ON IMPROVING OVERALL EFFICIENCY OF THE CUTTING MACHINES BY IMPLETATION OF PILLARS OF TPM

SUBMITTED BY
YASHRAJ V. RANE HARSHAD V. SURYAWANSHI KALPESH D. KHOCHARE AMOL P. SHETKE DHIRAJ B. WAGHMARE

GUIDED BY PROF L. R. SURYAWANSHI

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Bharati Vidyapeeth College Of Engineering `

(INTERNAL GUIDE)
DEPARTMENT OF MECHANICAL ENGINEERING BHARATI VIDYAPEETH’S COLLEGE OF ENGINEERING SECTOR -7,CBD BELAPUR,NAVI MUMBAI-400614 2009-2010

Bharati Vidyapeeth’s College of Engineering
(Affiliated to the University of Mumbai) Sector 7,CBD,Navi Mumbai-400614

A PROJECT REPORT ON IMPROVING OVERALL EFFICIENCY OF THE CUTTING MACHINES BY IMPLETATION OF PILLARS OF TPM SUBMITTED BY
YASHRAJ V. RANE

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Bharati Vidyapeeth College Of Engineering ` HARSHAD V. SURYAWANSHI KALPESH D. KHOCHARE AMOL P. SHETKE DHIRAJ B. WAGHMARE

GUIDED BY PROF L. R. SURYAWANSHI (INTERNAL GUIDE) DEPARTMENT OF MECHANICAL ENGINEERING APRIL-2010

Bharati Vidyapeeth’s College of Engineering
(Affiliated to the University of Mumbai) Sector 7,CBD,Navi Mumbai-400614
CERTIFICATE DATE : This is to certify that the project titled

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IMPROVING OVERALL EFFICIENCY OF THE CUTTING MACHINES BY IMPLETATION OF PILLARS OF TPM

Is
Submitted By
KALPESH.D.KHOCHARE YASHRAJ.V.RANE HARSHAD.V.SURYAWANSHI AMOL.P.SHETKE DHIRAJ.B.WAGHMARE (4759) (4760) (4761) (4762) (4766)

B.E.(Mechanical engineering) class of Bharati Vidyapeeth’s College of Engineering, Navi Mumbai in the year 2009-2010 towards the fulfillment of the requirements for the award of the Degree of Bachelor of Engineering under the University of Mumbai.

Prof L. R. Suryawanshi Prof.S.D. Jadhav (Internal Guide) (H.O.D)

Prof R.K.Agrawal (Project Co-ordinator)

Bharati Vidyapeeth’s College of Engineering

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Bharati Vidyapeeth College Of Engineering `

(Affiliated to the University of Mumbai) Sector 7,CBD,Navi Mumbai-400614

DEPARTMENT OF MECHANICAL ENGINEERING A PROJECT REPORT ON IMPROVING OVERALL EFFICIENCY OF THE CUTTING MACHINES BY IMPLETATION OF PILLARS OF TPM

Is
Submitted By
KALPESH.D.KHOCHARE YASHRAJ.V.RANE HARSHAD.V.SURYAWANSHI AMOL.P.SHETKE DHIRAJ.B.WAGHMARE (4759) (4760) (4761) (4762) (4766)

Has been examined and approved as per the fulfillment of the requirements for the award of the Degree of Bachelor of Engineering (Mechanical) of the University of Mumbai in the academic year 2009-2010.

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Signature Name : (External examiner) examiner)

Signature Name: (Internal

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ACKNOWLEDGEMENT

At the very onset of this project, we would like to take this opportunity to express our heartfelt gratitude to the people whose unstinting help and co-operation has made this study a success. We would like to express our appreciation to Mr. Neel Shrivastava (Department Head) & Mr. F. R. Bava-Adam (Divisional Personnel) for granting us permission to complete our project in their prestigious organization We express our sincere gratitude to our external guide Mr. T. A. Pooniwala (Maintainance Head) for providing us all the necessary information, training and valuable guidance during the project We are thankful to Prof. Mr. L. K. Suryawanshi, our project guide who co-operated every now and then and took every effort to make this project a grand success. Humble thanks to our teachers and project co-coordinator Prof. Mr. R.K. Agrawal for their keen guidance. We would like expressing our indebtedness to our eminence to Respected principal, Prof. Mr. D.P. Mishra and Prof. Mrs. S.N. Jadhav madam, our head of Mechanical Department for their constant inspiration, guidance and encouragement. Finally we thank all people, our colleagues who offered their valuable time, guidance, suggestions and assistance directly to us to carry out this educative report

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Abstract
Total Productive Maintenance (TPM) is a process that maximizes the productivity of equipment for its entire life. It fosters an environment where improvement efforts in safety, quality, cost, delivery, and creativity are encouraged through the participation of all employees. TPM is not simply a preventive maintenance program. Rather, it is a strategic management initiative to increase capacity and end the vicious cycle of ‘breakdown’ or reactive repairs through the use of autonomous and predictive maintenance, as well as equipment modifications to facilitate optimum machine availability, quality, and performance. The TPM presentation focuses on a results oriented implementation methodology designed to minimize the 6 major equipment losses. Overall Equipment Effectiveness (OEE), an equipment performance assessment or measurement, is introduced. By understanding and implementing TPM, companies can use it as a foundation and fundamental discipline to facilitate Condition Based Maintenance (CBM) effectively.

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Table Of Contents

Sr. No
01 02 03 04 05

Particulars
Chapter 1: INTRODUCTION TO COMPANY Chapter 2: INTRODUCTION TO PROJECT Chapter 3: LITERATURE REVIEW Chapter 4: METHODOLOGY Chapter 5: ANALYSIS

Pg. No.
1-9 10-20 21-25 26-29 30-38

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Bharati Vidyapeeth College Of Engineering ` 06 07 08 09 10 11 Chapter 6: SUGGESTION Chapter 7: DESIGN Chapter 8: SCOPE Chapter 9: RESULTS AFTER IMPLEMENTATION CONCLUSION BIBLIOGRAPHY 39-42 43-47 48-49 50-54 55-55 56-56

FIGURES

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Bharati Vidyapeeth College Of Engineering ` FIGURE NO. FIGURE 1 FIGURE 2 FIGURE 3 FIGURE 4 FIGURE5 FIGURE 6 FIGURE 7 FIGURE 8 FIGURE 9 FIGURE 10 FIGURE 11 FIGURE 12 FIGURE 13 FIGURE 14 FIGURE 15 FIGURE 16 FIGURE 17 FIGURE 18 NAME OF THE FIGURES Company Photo Heat Exchanger Heavy walled Reactor High Pressure Vessel BEHRINGER BANDSAW CNC GAS CUTTING MACHINE – SUAG BEHRINGER BANDSAW Band-saw Cutting Blade CNC GAS CUTTING MACHINE - SUAG Cutting Torch for CNC Gas Cutting Machine Pillars of TPM Fishbone Diagram Flow Chart OEE Chart for BEHRINGER BANDSAW Bar Chart for set up time and measurement Pie Chart BEHRINGER BANDSAW OEE Chart CNC GAS CUTTING MACHINE - SUAG Bar Chart for CNC GAS CUTTING MACHINE - SUAG FIGURE 19 Pie Chart for CNC GAS CUTTING MACHINE - SUAG
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PAGE NO. 02 05 06 06 11 11 12 14 16 17 22 25 29 33 34 35 37 37

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TABLES
TABLE NO. TABLE NO 01 TABLE NAME SPECIFICATION OF BEHRINGER BANDSAW TABLE NO 02 TABLE NO 03 SPECIFICATION OF CNC GAS CUTTING MACHINE - SUAG Time study on Behringer Band Saw Cutting M/C TABLE NO 04 TABLE NO 05 TIME STUDY ON BEHRINGER BAND SAW CUTTING M/C LOSSES Time study on CNC Gas cutting M/C SUAG TABLE NO 06 TABLE NO 07 TIME STUDY ON CNC SUAG CUTTING M/C LOSSES Data recorded before Implementation on Behringer Bandsaw TABLE NO 08 Data recorded after Implementation on Behringer Bandsaw 51 51 38 36 35 32 19 PAGE NO. 15

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Bharati Vidyapeeth College Of Engineering ` TABLE NO 09 Improved OEE of Behringer Bandsaw after implementing Scale TABLE NO 10 TABLE NO 11 Result of Improved OEE of Behringer Bandsaw after implementing Scale Data recorded before Implementation on CNC Gas cutting M/C - SUAG TABLE NO 12 TABLE NO 13 Data recorded after Implementation on CNC Gas cutting M/C - SUAG Improved OEE of CNC GAS CUTTING M/C-SUAG TABLE NO 14 Result of Improved OEE of CNC GAS CUTTING M/C-SUAG 54 54 53 53 52 52

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CHAPTER -1
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INTRODUCTION TO COMPANY

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Fig.no-1: Company Photo
In the year 1997, Godrej & Boyce celebrated their centenary year. This dynamic organization has progressed tremendously since its inception and has been gaining strength consistently. Quality is the hallmark of all the Godrej products and any product with the 'Godrej' mark represent quality, dependability & satisfaction to its customers. What now is a gainful industrial organization was a brainchild of Mr. Ardeshir GODREJ, which through the help dedicated men with tremendous foresight and finely honed engineering and marketing skills, has become one of the biggest houses in India. Godrej also made a significant contribution to self-reliance of the century by building the engine for the PSLRU locker launched by India. In the year 1978 Godrej diversified in to the field of chemicals by starting the manufacturing of soaps and further diversified into production of chemicals for various industries like textile mills, pharmacies, confectioneries, etc.

The most recent achievement by Godrej was made when it acquired the ISO 9000, ISO 9001 and ISO 14000 certificate, which former reinforced the rest of not only the Indian market but also the global market in the product of Godrej Today Godrej employee over 15,000 people and has grown in to a multi-core professionally managed group with far reaching service and distribution network. "Economy and Services” are being the main motto of Godrej they have already diversified in to field of Indian industry thus helping in the economic growth of the country. Century old brand name, 'Godrej', it now also provides electronic security systems products and is angered with the supply and installation of the electronics safes, electronics

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Bharati Vidyapeeth College Of Engineering ` security alarm systems, access control systems, closed circuit television systems and very highly sophisticated advanced electronic surveillance systems.

VARIOUS PLANTS IN GODREJ

GODREJ & BOYCE MFG. CO LTD.:-

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Bharati Vidyapeeth College Of Engineering ` It is truly a mullet-faceted company. This is the major collaboration of Godrej with Boyce Company. The maximum of the business of Godrej is known by this name. At present all the divisions mentioned below come under this company.

 OFFICE EQUIPMENT (O.E.) DIVISION: The manufacturing activities in this division are distributed in the following plants:
➢ ➢ ➢ ➢ ➢

Plant 1: Steel processing plant Plant 4 & 14: Furniture systems plant Plant 13: Industrial storage system Plant 17: Security equipment LOCKS DIVISION: -Plant 18 A

TYPEWRITER DIVISION: – Plant 18 B

➢ ➢ ➢ ➢ ➢

MATERIAL HANDLING DIVISION: -Plant 16 MACHINE TOOL DIVISION: -Plant 9 & 19 TOOL ROOM DIVISION: -Plant 7 OFFICE AUTOMATION DIVISION: -Plant 19 A PROCESS EQUIPMENT DIVISION: -Plant 15

This division is located in Plant 15 and it designs and fabricates a large range of custom-made sophisticated equipment for chemicals, petrochemicals and fertiliser industries

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Bharati Vidyapeeth College Of Engineering ` such as heat exchangers, boiler shells, tower internals, etc., as well as equipment for nuclear and aerospace applications such as parts of atomic reactor, cryogenic engines and projects of ISRO (Indian Space Research Organisation).

Fig.no-2: Heat Exchanger The process equipment division consists of five main production departments as follows:
♦ ♦ ♦ ♦ ♦ Columns. Heat exchanger. Reactors & Vessels. Aerospace Division. Trays & tower internals.

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Product range –
• • •

Heavy Walled Reactors Equipment Internals Fractionating / Distillation Columns High Pressure Shell & Tube Heat Exchangers Custom built Equipment

Fig.no-4:-High Pressure Vessels Fig.no-3:-Heavy Walled Reactor

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INTRODUCTION TO MACHINE SHOP DEPARTMENT

Machine shop department is one of the vital departments in the ‘Process Equipment Division’. It possesses machines that are required for machining the various components of the pressure vessel assembly. The department produces components that are related to the heat exchanger of the pressure vessel assembly. The machine shop department is a service department and works in tandem with other departments of the plant.The components produced in machine shop department can be given as follows: ♦ ♦ ♦ ♦ ♦ Tube sheets Baffles Tie rods Spacers Flanges

The various machines used in the machine shop department can be given as follows:

➢ CNC DRILLING MACHINES: ♦ ♦ ARBOGA 1 ARBOGA 2

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♦ ♦ ♦ ♦

HARTFORD 1 HARTFORD 2 BATLIBOI KOLB

DRILLING MACHINES:- The Drilling machine is in tends fro drilling

medium to large and heavy work pieces. The machine consists of a heavy round, vertical column mounted on a large base. The column supports a radial arm which can be raised and lowered to accommodate work pieces to different heights.
♦ ➢

RADIAL 1,2,3,4,5,6,7 CNC LATHE MACHINE:HMT LATHE HORIZONTAL LATHE MACHINES:- The Lathe has got all the basic


parts e.g. Bed, Headstock and Tailstock. The Headstock contains mechanisms for driving a spindle at multiple speeds. Lathe can feed the tool both in cross and longitudinal direction with reference to lathe axis. A lathe receives its power from an individual motor known as motor driven lathe. ♦ BOMBAY LATHE ♦ THREE JAW LATHE ♦ MODULAR LATHE

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Bharati Vidyapeeth College Of Engineering ` ♦ BECO LATHE ♦ NEW LATHE

VERTICAL LATHE MACHINES:- This type of boring machine

combines the advantages of vertical boring machine and turret lathe. It has an indexable turret lathe mounted the cross rail above the table for multiple tooling. A four station square turret side head which enables facing, turning under cutting and many other operations. ♦ VTL1 SINGLE ARM (CNC) ♦ VTL5 DOUBLE ARM (CNC) ♦ VTL6 (FARREL)

HORIZONTAL BORING MACHINE:- In a Horizontal Boring machine,
the work is supported on a table which is stationary and the tool revolves in a horizontal axis. A Horizontal machine can perform boring, reaming, turning, threading, facing, milling, milling, grooving, recessing and any other operation with suitable tools.

VERTICAL MILLING MACHINES:- A Milling machine is a machine

tool that removes metal as the work is fed against a rotating multipoint cutter. In a vertical milling machine position of the spindle is vertical or perpendicular to the work

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table. The spindle head can be swivelled at an angle. This machine is adapted for machining grooves, slots and flat surfaces.

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CHAPTER-2

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INTRODUCTION TO PROJECT

“IMPROVING OVERALL EFFICIENCY OF THE CUTTING MACHINES BY IMPLEMENTATION OF PILLARS OF TPM”

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Fig 5: MACHINE 1: BEHRINGER BANDSAW

Fig 6:

MACHINE 2: CNC GAS CUTTING MACHINE – SUAG MACHINE DETAILS: (BEHRINGER BANDSAW)

Fig 7

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Bharati Vidyapeeth College Of Engineering ` Morgantown, PA (April 7, 2010) – A new line of bandsaws engineered to accommodate and cut large diameter tubing quickly and efficiently is available from Behringer Saws, Inc. HBP-800AXL Automatic and HBP-800XL Semi-Automatic Series Bandsaws allow companies to save on upfront capital expenditures and avoid buying more expensive bandsaws for everyday cutting while expanding their capability to specifically cut large tubes when needed. The HBP-800AXL Automatic and HBP-800XL Semi-Automatic Bandsaws deliver all the performance and capabilities of “standard” HBP-800 Series Bandsaws cutting solid bars and structurals up to 31.5”. In addition, these new bandsaws allow for the cutting of tubes up to 39" in diameter. Companies can now purchase a lower cost bandsaw to handle day-to-day production cutting needs at the standard size range while utilizing this additional feature to accept new projects requiring the cutting of large diameter tubing.All HBP-800 Bandsaws are built with strong cast iron frame construction and a twin column parallel down feed design for proper saw blade tensioning to deliver quick, efficient and forceful low vibration cutting for smooth cuts. These bandsaws also come with a heavy-duty roller conveyor for quick and efficient handling of heavy materials pre- and post-cut. HBP-800 Bandsaws feature a frequency controlled 14.7 horsepower main drive motor with a variable speed range of between 55-393 Surface Feet Per Minute (SFM) which is easily selected at the operator’s control panel. Hydraulic and hardened clamping jaws on the bandsaw ensures steady and precise cuts at all speeds. This bandsaw is available in both automatic and semi-automatic versions and requires minimal operator intervention as it is controlled by a programmable logic controller (PLC). It features an easy-to-use operator’s terminal with diagnostic display,

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Bharati Vidyapeeth College Of Engineering ` data entry and program storage. The speed is easily set, controlled and monitored before and during the cutting process. Behringer Saws, Inc. provides a full range of sawing and turnkey pre- and post-cut material handling productivity-enhancing products. Behringer supplies world-class quality automatic bandsaws to corporations, service centers, job shops and manufacturers throughout the world. The company also offers the Behringer Eisele brand of manual, semi-automatic and automatic miter circular cold saws, high performance circular cold saws utilizing bi-metal or carbide saw blades and CNC miter circular sawing systems. Also, the Vernet Behringer line of structural fabricating equipment includes high performance drilling, punching, shearing, notching and marking machines along with beam coping and drilling and sawing lines. For more information on the HBP-800AXL and HBP-800XL Bandsaws, contact Behringer Saws, Inc., 721 Hemlock Road, Morgantown, PA 19543. Call toll-free at 888234-7464.

Description of machine: Stainless steel and tool steel. Tempered steel, special alloys and aluminum. In different thicknesses, shapes and diameters. Singly, in bundles of fixed lengths. Whatever you aim to saw, our HBP, HBV and HBM high-performance and automatic bandsaw series offer the solution you are looking for. In every cutting range. Despite their outstanding performance, our machines are all designed to offer maximum operating simplicity and space savings. And like everything from BEHRINGER, they are unbeatable in terms of speed, precision and quality.

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BAND-SAW CUTTING BLADE:

Fig 8: Band-saw Cutting Blade
The typical metal cutting bandsaw machine is used for simple cutting of solid steel, tubing, and odd shaped material. The material to be cut is mounted in a vise attached to the bed of the machine. An electric motor drives the bandsaw blade through a belt and pulley arrangement from which three speeds may be obtained. The sawing machine frame, upon which the drive wheel, idler wheel, bandsaw blade, and motor are mounted, pivots from one corner of the sawing machine bed. The frame is counterbalanced by a tension spring between the frame and the bed. Feed is controlled by positioning a sliding weight along a bar fixed to the top side of the sawing machine frame. A dashpot is positioned between the frame and bed to stabilize the feed movement and prevent any quick movement of the frame that could cause damage to the bandsaw blade.

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Bharati Vidyapeeth College Of Engineering ` The vise used to hold the material being cut is a quick-positioning type and can be adjusted easily to any angle. An adjustable work piece stop is provided for rapid positioning of production work pieces.

SPECIFICATION OF BEHRINGER BANDSAW:-

Model Cutting range 90° round (inch) 90° flat (W x H) (inch) 90° square (W x H) (inch) 75° meter left dia. / flat (W x H) (inch) 60° meter left dia. / flat (W x H) (inch) 45° meter left dia. / flat (W x H) (inch) Working height (inch) Single stroke of the feeding gripper (inch) Drive motor (H.P.) – frequency controlled Cutting speed (FPM) Cutting capacities

HBP 413A 16.1 19.7x15.7 15.7x15.7 31.5 15.7 5.4 65-459 47.2" x 31.5"

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Saw blade dimensions Weight (lbs) Space requirement (inch) Large dual column - parallel down-feed design Solid cast bow frame Cast Meehanite band wheels

19’0”x1-1/2”x .050” 5,170 116x77

Fully automatic hydraulic blade tensioning & carbide blade guides

Table No: 01

MACHINE DETAILS: (CNC GAS CUTTING MACHINE - SUAG)

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Fig 9
The RUM is the latest generation of CNC profile cutting machine that combines the quality of construction of the MAXI machine with the advantages of the price/output ratio of RUR machine. Standard equipment of the RUM includes all available automation facilities.  Basic equipment  fully welded beam without bolted joints  linear bearing in cross axis  AC servomotors  digital synchronization in longitudinal axis  BURNY 10 LCD Plus control system with touch screen  membrane keyboard  floating cutting heads  electric ignition  capacitive height control of oxy-fuel torch  automatic gas console  torch selection from control panel

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Bharati Vidyapeeth College Of Engineering `  automatic initial height sensing of plasma torch  arc voltage height sensing of plasma torch  parking facility for heads out of cutting area  limit switch in each axis  Optional equipment  plasma system by customer request  pneumatic anti-collision system  pneumatic, plasma or inkjet marker  air cooling of portal frame  control system heating (for winter operation)

CUTTING TORCH:
A cutting torch head is used to cut metal. It is similar to a welding torch, but can be identified by having three pipes that go to a 90 degree nozzle and by the oxygen-blast trigger. Only iron and steel can be cut using this method. The metal is first heated by the flame until it is cherry red. Once this temperature is attained, oxygen is supplied to the heated parts by pressing the "oxygen-blast trigger". This oxygen reacts with the metal, forming iron oxide and producing heat. It is this heat which continues the cutting process. The cutting torch only heats the metal to start the process; further heat is provided by the burning metal.

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Fig 10: Cutting Torch for CNC Gas Cutting Machine Acetylene is the primary fuel for oxy-fuel welding and is the fuel of choice for repair work and general cutting and welding. Acetylene gas is shipped in special cylinders designed to keep the gas dissolved. Oxygen is not the fuel: It is what chemically combines with the fuel to produce the heat for welding. This is called 'oxidation', but the more general and more commonly used term is 'combustion'.

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SPECIFICATION OF CNC GAS CUTTING MACHINE - SUAG:RUM max. number of torches rail span cutting width * - 1 torch cutting width * - 2 torches cutting width * - 3 torches cutting width * - 4 torches cutting width * - 5 torches cutting width * - 6 torches cutting length min. parallel cut cutting speed standard cutting thickness machine width machine length machine height incl. rails cutting table height plasma system supply voltage 3500 6 3500 mm 3100 mm 3100 mm 3100 mm 3080 mm 2945 mm 2810 mm by customer request 90 mm 0 - 20000 mm/min. 200 mm 4100 mm 1200 mm 1700 mm 700 mm by customer request 230V/50Hz 4600 mm 5100 mm 4000 mm 3600 mm 3600 mm 3600 mm 3580 mm 3445 mm 3310 mm 4500 mm 4100 mm 4100 mm 4100 mm 4080 mm 3945 mm 3810 mm 4000 4500

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Bharati Vidyapeeth College Of Engineering ` Plate widths 1,000 to 2,000mm Speed 0 to 8,000mm/min Track 2,000mm (standard) 1,000mm (optional) Drives: Longitudinal Rack and pinion Transverse Rack and pinion Plasma: Upto 200amp plasma system. Full height sense and heavy duty head Gas and heads: Hi Lo preheat (standard) 2 stage pierce (optional) Cutters: 2 Maximum Controller: C.N.C. controller mounted on a pedestal

Table No: 02

Key features:
 Burny 1250 control system includes a fully-integrated Burny 2.5 CNC Shape Cutting Control, Plasma process controls and a servopak 120 watt pulse with modulated drive  CNC Width 2000mm  Track length to be advised  Maximum Cutting Speed 6000mm/min  Maximum Cutting Thickness with gas 300mm  Single sided drive  Combined gas and plasma post with ESAB Cool jet Cutting Post  Operational Manuals  Mains input would require 240 volts single phase  Photographs taken on site PRIOR to any work commencing.

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CHAPTER-3

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LITERATURE REVIEW

Literature Review: AN INTRODUCTION TO TOTAL PRODUCTIVE MAINTENANCE (TPM):
In today’s industrial scenario huge losses/wastage occur in the manufacturing shop floor. This waste is due to operators, maintenance personal, process, tooling problems and non-availability of components in time etc. Other forms of waste includes idle machines, idle manpower, break down machine, rejected parts etc are all examples of waste. The quality related waste are of significant importance as they matter the company in terms of time, material and the hard earned reputation of the company. There are also other invisible wastes like operating the machines below the rated speed, start up loss, break down of the machines and bottle necks in process. Zero oriented concepts such as zero tolerance for waste, defects, break down and zero accidents are becoming a pre-requisite in the manufacturing and assembly industry. In this situation, a revolutionary concept of TPM has been adopted in many industries across the world to address the above said problems. chapter deals in length about this TPM.

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Pillars of TPM

Fig TPM Pillars To Implement PILLAR 1 - JISHU HOZEN (Autonomous maintenance):

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This pillar is geared towards developing operators to be able to take care of small maintenance tasks, thus freeing up the skilled maintenance people to spend time on more value added activity and technical repairs. The operators are responsible for upkeep of their equipment to prevent it from deteriorating.

PILLAR 2 – KOBETSU KAIZEN:
"Kai" means change, and "Zen" means good (for the better). Basically kaizen is for small improvements, but carried out on a continual basis and involve all people in the organization. Kaizen is opposite to big spectacular innovations. Kaizen requires no or little investment. The principle behind is that "a very large number of small

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Bharati Vidyapeeth College Of Engineering ` improvements are move effective in an organizational environment than a few improvements of large value. This pillar is aimed at reducing losses in the workplace that affect our efficiencies. By using a detailed and thorough procedure we eliminate losses in a systematic method using various Kaizen tools. These activities are not limited to production areas and can be implemented in administrative areas as well. 1. METHODS:  Time to process Raw-material.  Lack of proper understanding. 1. PEOPLE:  Lack of availability of designers.  Conflicting mindsets of designers.  Inadequate skill-mapping.  Lack of motivation & understanding. 1. MANPOWER:  Dedicated personnel for planning.  Lesser no. of designers involved.  Dynamics of self-help groups.
1. POLICIES:

 Government oriented(Time-consuming) paper work.  Lack of finance to create larger SHG’s.  Investment. 1. PLACE:  Time & cost incurred.

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Bharati Vidyapeeth College Of Engineering `  Proximity to large markets slightly less. 1. SURROUNDING:  Traditional barriers & mind-sets.  Linguistic barriers(biggest issues). 1. PROCEDURES:  Material constraints.  Requires fine tuning of mind towards market.  Requires deeper market understandings by designers. 1. SKILLS:  Newer skills not impaired.
 Imbalance in skills.

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Fig 12: Fishbone Diagram

CHAPTER-4

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METHODOLOGY

Application of critical examination results into number of alternatives since all points are not practicable, only few of them are to be developed. Following are the key points for the development of new methods: Elimination of all unnecessary operation.  Sensors for measurement of jobs.  Designing the process wherever required. We will be developing new methodology in the following stages.
1. Recognition of problems:

Every development process starts with recognition or identification of need. Recognition of need is to outcome of either the requirement of the discontent of the existing system. 2. Definition of problem: The difference the statements of need the identification of the problem lies in the fact of the problem is more specific. Definition of problem must include all inputs , parameters, functional requirement and constraints of the system. 3. Evaluation and Synthesis:

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Bharati Vidyapeeth College Of Engineering ` After detail study of TPM tools, we have obtained number of alternatives and by evaluation we shortlisted the number alternatives and decided whether all alternatives should be accepted or not. By pillars of TPM, we selected process, manpower and machinery as an area of development. Synthesis is a process of selecting the mechanism so as to get desired output by given input. It involves number of iterations. By synthesis we decided to synchronize the first three operations.

4. Investigation: Once the number of alternatives are shortlisted in the evaluation step it becomes necessary to convert these alternatives in to practical needs. Investigation does this. It usually involves preparation of making prototype, considering trial run etc. Initially we are trying to synchronize cutting operations. The following operations we are going to perform to increase production and efficiency of machines.  Elimination of all unnecessary operations.  Sensors of measurement of jobs.  Designing the process wherever required. 1. Final Design: On successful synchronization of all processes, we will make final design and decide parameters for smooth functioning of developed process with increased productivity. The design will be based on following parameters.

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Bharati Vidyapeeth College Of Engineering `  Investment needed.  Rate of production.  Production cost per unit.  Return of investment.

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Fig 13: Flow Chart

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CHAPTER-5

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ANALYSIS

Today, with competition in industry at an all time high, TPM may be the only thing that stands between success and total failure for some companies. It has been proven to be a program that works. It can be adapted to work not only in industrial plants, but also in construction, building maintenance, transportation, and in a variety of other situations. Employees must be educated and convinced that TPM is not just another "Program of the month" and that management is totally committed to the program and the extended time frame necessary for full implementation. If everyone involved in a TPM program does his or her part, an unusually high rate of return compared to resources invested may be expected. As shown below we have shown the information with the help of Time Study charts with proper description of whatever the losses affecting the production. On the basis of Time Study charts we have drawn the pie-charts. We have developed an OEE chart (Overall Equipment Efficiency) and collected all the Time Study data and implemented it on OEE chart. From these OEE charts we have listed following major losses:

BEHRINGER BAND SAW CUTTING M/C
 M/C down time

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 Setting of JOB

 Measurement

CNC GAS CUTTING M/C- SUAG
 Scheduled/Planned Stoppages  Non Availability of Material  Non Availability of EOT Crane

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Time study on Behringer Band Saw Cutting M/C Table No: 03

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Fig 14: OEE Chart

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Fig 15: Bar Chart for set up time and measurement

TIME STUDY ON BEHRINGER BAND SAW CUTTING M/C LOSSES
SR.NO. 1. 2. 3. 4. 5. 6. TOTAL ACTIVITY Setting of JOB Measurement Operator non availability Crane waiting time M/C down time Tool changing time TIME in min 115 83 35 15 313 30 581 % 19.79 14.28 4.30 2.58 53.87 5.16 100

Table No: 04

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Fig 16: Pie Chart TIME STUDY ON CNC GAS CUTTING M/C - SUAG

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No:

Table 05

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Fig 17: OEE Chart for CNC GAS CUTTING MACHINE - SUAG

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Fig 18: Bar Chart for CNC GAS CUTTING MACHINE - SUAG CNC SUAG CUTTING M/C LOSSES
SR.NO. 1. 2. 3. 4. 5. 6. TOTAL ACTIVITY Scheduled/Planned Stoppages Setting Time Start-up Losses[mock-up] Minor Stoppage[Time Loss] Non Availability of Material Non Availability of Operator TIME in min 698 17 288 20 340 40 1403 % 49.75 1.22 20.52 1.42 24.24 2.85 100

Table No: 06 Fig 19: Pie Chart for CNC GAS CUTTING MACHINE - SUAG

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CHAPTER -6

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SUGGESTION

SUGGESTIONS BEHRINGER BAND SAW CUTTING M/C:Three Major Losses in Behringer:1. 2. 3. M/C Down Time. Setting Time. Measurement.

1. M/C Down Time REASON
Break-down maintenance

SOLUTION
Preventive Maintenance of M/C to be done on time to avoid maintenance while M/C is in production.

2. Setting time REASON

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Fatigue to Operator in Setting the Job.

SOLUTION
Sensors are to be employ on machine.

3. Measurement REASON
1. Presently measurement is done manually by operator. 2. New measurement type equipment must be procured to minimize measurement time.

SOLUTION
Sensors assembly has to be done near to the machine blade so measurement time will be minimum.

SUGGESTIONS CNC SUAG CUTTING M/C:Three Major Losses in CNC Suag:1. 2. 3. Scheduled/Planned Stoppages. Non Availability of Material. Start up Loss[mock-up].

1. Scheduled/Planned Stoppages REASON

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Bharati Vidyapeeth College Of Engineering ` 1. Loading Time Of Plate Is Too High. 2. Time consumed for Setting the Job Plate.

SOLUTIONS
1. Loading Time Should Be Minimized By Offline Setting Of Plate. 2. Special fixture to be Designed for Quick Setting of Job Plate.

2. Non Availability of Material REASON
Improper & Unplanned Stacking of Plates.

SOLUTIONS
1. Proper stacking of plates as per priority. 2. Proper proactive planning to feed the m/c as per plan.

2. Start up Loss[mock-up] REASON
1. No cleaning before Operator reports the machine. 2. Major time consumed in Test Run.

SOLUTIONS

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Bharati Vidyapeeth College Of Engineering ` 1. Special Cleaning staff to be provided for cleaning of the m/c before operator reports on the m/c during each shift. 2. Special Fixture to be made to avoid Test Run.

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CHAPTER -7

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DESIGN

Introduction to Rack Design
Introduction

A rack is a device for locating, holding and supporting a workpiece or plates during a manufacturing operation. Rack are essential part of production processes as they are required for material handling of a particular materials. There are many standard material handling devices such as belt conveyor,trolley etc. which are widely used in workshops and industries and are usually kept in stock for general applications. Rack are normally designed for a definite operation to process a specific workpiece and are designed and manufactured individually.

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Fig 20-a: Design given for Behringer Bandsaw Scale used for measurement

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Fig 20-b: Design given for Behringer Bandsaw Scale used for measurement

Fig 20-c: Design given for Behringer Bandsaw Scale used for measurement

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Fig 21 Design given for CNC GAS CUTTING MACHINE – SUAG

Stacking of plates

The cross section of the fillet weld consists of a right angled triangle having two equal

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Bharati Vidyapeeth College Of Engineering ` sides. The length of each of the two equal sides id called leg. As a rule, the leg length h is equal to the plate thickness.

Fig 22: Welded Joint
The throat is the minimum cross section of the weld located at 45o to the leg dimension. Therefore, t = h cos 45o or t = 0.707 h Failure of the fillet weld occurs due to shear along the minimum cross section at the throat. It will be provided at a later stage in the above given section, that for parallel fillet weld, the inclination of the plane where maximum shear stress is induced is 45o to the leg dimension. The cross sectional area at the throat is (tl) or (0.707 hl). The shear stress in the fillet weld is given by,
τ=P0.707 hl

Rearranging the term of the above equation, the strength equation of the parallel fillet weld is written in the following form, P = 0.707 hlτ where, P = tensile force on plates (N) h = leg of weld (mm) l = length of weld (mm) τ = permissible shear stress for the weld (N/mm2) Usually there are two welds of equal length on two sides of vertical plate. In that case P = 2 (0.707 hlτ)

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Bharati Vidyapeeth College Of Engineering ` or P = 1.414 hlτ

CHAPTER -8

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SCOPE

Due to following advantages, our project is having a greater future scope: ADVANTAGES: 1. Reduction in manufacturing time. 2. High accuracy. 3. Smooth operation. 4. Better transmission motion. But it has also disadvantages;

DISADVANTAGES:

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Bharati Vidyapeeth College Of Engineering ` 1. Operation cost is more.
2. Maintenance cost is more.

CHAPTER -9
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DATE OF PERFORMANCE 4/9/2009 11/9/2010

MEASUREMENT TIME 20 30

RESULTS AFTER IMPLEMENTATION

BEFORE Table No: 07

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Fig No: 23 AFTER
DATE OF PERFORMANCE 22/04/2010 23/04/2010 MEASUREMENT TIME 15 24

Table No: 08

Fig No: 24

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Improved OEE of Behringer Bandsaw after implementing Scale

Table
DATE 04/09/2009 22/04/2010 11/9/2010

No: 09
23/04/2010

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BEFORE OEE AFTER OEE

90.34 92.3

48.86 60.87

Table No: 10 BEFORE
DATE OF PERFORMANCE 11/9/2009 25/09/2009 AVAILABILITY OF MATERIAL 30 20

Table No: 11

Fig No: 25

AFTER
DATE OF PERFORMANCE 22/04/2010 AVAILABILITY OF MATERIAL 12

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23/04/2010

15

Table No: 12

Fig No: 26 Improved OEE of CNC GAS CUTTING M/C-SUAG

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Table No: 13

Table No: 14 CONCLUSION

As defined in this paper, Total Productive Manufacturing (TPM) is a structured equipment-centric continuous improvement process that strives to optimize production effectiveness by identifying and eliminating equipment and production efficiency losses throughout the production system life cycle through active teambased participation of employees across all levels of the operational hierarchy. Although TPM is historically equipment-focused, effective implementation offers a continuous improvement methodology to increase overall manufacturing productivity. TPM methodology provides enterprises with the tools required to explore, increase, document, and proliferate organizational learning.improved machine performance is the result of improved behaviors from people
DATE BEFORE OEE AFTER OEE 11/09/2009 84.1 91.3 22/04/2010 25/09/2009 78.3 83 23/04/2010

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Bharati Vidyapeeth College Of Engineering ` involved in the machine’s life cycle. Improved behavior comes from new learning. Continuous improvement is born of continuous learning.” Research and case studies indicate that TPM implementation can have significant positive impact on manufacturing performance. After the implementation of TPM, it can be seen that from above Results that O.E.E. of the machines improved by 3% to 7%.

BIBLIOGRAPHY:

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COMPANY GUIDE: Trivesh pooniwala.(Dy.Managermaintenance)P.E.D.pooni@godrej .com, www.godrej.com REFERENCES: 1. Ames, V. A. (1996). Implementing the Complete TPM Process. SEMATECH TPM/OEE Case Study 2. Workshop, Tempe, AZ, SEMATECH. Ames, V. A. (2003). TPM Interview. T. Pomorski. Austin, Tx. 3. Asaka, T. and K. Ozeki (1990). Handbook of Quality Tools, The Japanese Approach. Cambridge, MA,Productivity Press.Bahrani, A. (1995). 4. TPM Management. SEMATECH TPM/OEE Case Study Workshop, Austin, TX, SEMATECH. Bamber, C. J., J. M. Sharp, et al. (1999). “Factors Affecting Successful Implementation of Total
5. Productive Maintenance: A UK Manufacturing Case Study Perspective.” Journal of

Quality in Maintenance Engineering 5(3): 162-181. WEBSITE:
1. www.wekipedia.com 2. www.google.com 3. www.scribd.com 4. www.3brooks.com/tmp/2110.pdf

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