WORK INTEGRATED LEARNING

PROGRAMME
Subject: Maintenance And Safety (Semester1_2023_ENGGZC242)
Assignment: Project Based Assignment
Project: Failure Data Analysis Dynamic Dashboard
Student Name: VORA MEHUL JAWAHAR
Student ID: 202218BT203

Project Topic: This project aims to create a dynamic dashboard of “Failure Data Analysis”
using key parameters of “MTBF” (Mean Time Between Failure) & “MTTR” (Mean Time To
Repair).

About MTBF and MTTR:

MTBF and MTTR are two of the most important Key Performance Indicators for
managers and business leaders to look at when trying to improve the reliability of a product,
service, or piece of machinery. They can be used independently but are even more useful when
put together. MTBF stands for Mean Time Between Failures and is the average length of time
before a piece of machinery or a product breaks. MTTR is Mean Time to Repair, or the average
length of time it takes to get a piece of machinery back up and running or repaired when it does
break down.

MTBF (Mean Time Between Failures) is a metric that can help measure issues with products,
services, or machines that don’t break down or cause issues very frequently. Trying to increase
the MTBF means reducing defects, downtime, and errors that cause failure.

The formula to calculate MTTR is: MTBF = Length of time / Number of failures during that
period of time.

MTTR (Mean Time to Repair) is a valuable metric for measuring the average amount of time it
takes to bring a system back online after it has broken down. This calculation can be used by
business leaders across various industries, although the metrics and ways of measuring MTTR
may change.

The formula to calculate MTTR is: MTTR = Total downtime / Number of repairs.
Below is the list of Group-S Students involved in this project work.

S.No Name of The Student Student ID

1 BENDULURI SAIVENKATAMANIKANTA 202218bt627
2 DALE SUREKHA SAMBHAJI 202218bt230
3 DEEPAK KUMAR BHATT 202218bt160
4 DIVAKAR SATISH KAMALAKAR 202218bt564
5 HARISH S 202218bt805
6 HEMANTH KUMAR G 202218bt279
7 LAKSHMI MARDI 202218bt527
8 MANIKANDAN K 202218bt753
9 MOHAMED FAYASUDEEN A 202218bt207
10 MOHANRAJ A 202218bt846
11 PARTHIBAN S 202218bt122
12 PAYAL MUKHERJEE 202218bt664
13 PHALKE SURAJ MANOHAR 202218bt076
14 RAJ KUMAR 202218bt460
15 RAKESH JHA 202218bt736
16 RAMAR A 202218bt715
17 RAMKUMAR G 202218bt506
18 RAUT SHIVAM SANTOSH 202218bt011
19 RAVIKANTH.P. 202218bt063
20 SAYYAD ASIKABBAS SHAEKALLI 202218bt789
21 SHASHI KUMAR T 202218bt318
22 SHIVARAM K 202218bt170
23 SHREEDHAR K S 202218bt728
24 SHUBHOJIT POLLEY 202218bt293
25 SUDARSHAN ANIL BHAT 202218bt034
26 TIRMARE JAYASHRI BHALACHANDRA 202218bt598
27 TRIVEDI PRAGNESH BHUPENDRABHAI 202218bt361
28 V S H R SUDHEER KAIGALA 202218bt053
29 VAGEESH T V 202218bt519
30 VIGNESH E 202218bt688
31 VIJAY KRISHNAN C 202218bt710
32 VINU BALAKRISHNAN 202218bt143
33 VISHWANATH .K.N 202218bt810
34 VIVEK JADHAV 202218bt792
35 VORA MEHUL JAWAHAR 202218bt203
 EXCEL DASHBOARD PICTURE

OPEN EXCEL FOR ACTIVE DASHBOARD CONTROL AND MONITORING

About Master Data:

In this Failure Data Analysis study, we dig into the province of theoretical
reliability analysis by opting for a unique approach employing imaginary data (For the year
2022). Instead of relying on real-world figures, we explore the consequences of failures in a
system using complex numbers, specifically imaginary numbers. This unconventional choice
allows us to conduct a more abstract and theoretical examination of system reliability.

We acknowledge the theoretical nature of our chosen approach and reflect on the
advantages and limitations of employing imaginary numbers in the context of reliability
engineering. This deviation from conventional methodologies serves as a reminder of the
flexibility and creative potential within the realm of theoretical analyses.

In conclusion, our exploration into reliability through imaginary data using MTBF and
MTTR provides a unique perspective on failure scenarios. By embracing abstraction, we aim to
contribute to the theoretical understanding of system reliability.

Equipment Covered In Failure Data Analysis are as follows:

 Plastic Feeder
 Extrusion
 Chilling Tower
 Spot Welding-1
 Compressor
 Lathe Machine
 Winder
 Slitting
 STP Pump
 CNC Milling

Below tabulated master data we have developed for Failure Data Analysis:
 Date Return
Breakdown Time
Machine Downtime Time after Time to
Time between
Name Reason Repair Repair
(Clock) failure
(Clock)
Chilling Motor
11-Jan-2022 03:20 PM 05:40 PM 02:20:00 0.00
Tower Failure
Chilling Sensor
17-Feb-2022 03:30 PM 05:45 PM 02:15:00 37.00
Tower Failed
Chilling Motor
31-Mar-2022 10:50 AM 01:15 PM 02:25:00 42.00
Tower Failure
Chilling Maintenance
22-Apr-2022 03:30 PM 05:45 PM 02:15:00 22.00
Tower Gear Box
Chilling
24-May-2022 Bearing fail 09:15 AM 01:30 PM 04:15:00 32.00
Tower
Chilling Operator
3-Jun-2022 11:30 AM 01:45 PM 02:15:00 10.00
Tower Error
Chilling Motor
15-Jul-2022 03:10 PM 05:25 PM 02:15:00 42.00
Tower Failure
Chilling Sensor
19-Aug-2022 10:25 AM 10:55 AM 00:30:00 35.00
Tower Failed
Chilling Motor
13-Sep-2022 03:05 PM 03:35 PM 00:30:00 25.00
Tower Failure
Chilling Operator
29-Nov-2022 01:20 PM 03:45 PM 02:25:00 77.00
Tower Error
Seal
9-Feb-2022 CNC Milling 10:15 AM 12:30 PM 02:15:00 0.00
Damage
14-Apr-2022 CNC Milling Bearing fail 02:10 PM 04:35 PM 02:25:00 64.00
14-Jun-2022 CNC Milling Bearing fail 01:20 PM 03:45 PM 02:25:00 61.00
Seal
2-Aug-2022 CNC Milling 10:55 AM 11:25 AM 00:30:00 49.00
Damage
2-Sep-2022 CNC Milling Bearing fail 08:00 AM 10:30 AM 02:30:00 31.00
Lubricant
22-Sep-2022 CNC Milling 02:15 PM 02:45 PM 00:30:00 20.00
Leak
Sensor
28-Oct-2022 CNC Milling 02:15 PM 02:45 PM 00:30:00 36.00
Failed
Lubricant
18-Nov-2022 CNC Milling 09:30 AM 12:45 PM 03:15:00 21.00
Leak
Maintenance
29-Dec-2022 CNC Milling 09:30 AM 12:45 PM 03:15:00 41.00
Gear Box
Motor
2-Jan-2022 Compressor 08:15 AM 02:30 PM 06:15:00 0.00
Heated
Seal
14-Feb-2022 Compressor 12:50 PM 03:20 PM 02:30:00 43.00
Damage
Operator
6-Mar-2022 Compressor 04:05 PM 04:35 PM 00:30:00 20.00
Error
Seal
10-Apr-2022 Compressor 10:00 AM 12:30 PM 02:30:00 35.00
Damage
Operator
19-May-2022 Compressor 02:40 PM 04:55 PM 02:15:00 39.00
Error
Maintenance
7-Jun-2022 Compressor 08:10 AM 01:20 PM 05:10:00 19.00
Gear Box
Alignment
18-Jul-2022 Compressor 03:10 PM 05:25 PM 02:15:00 41.00
Disturbed
Lubricant
4-Aug-2022 Compressor 10:25 AM 10:55 AM 00:30:00 17.00
Leak
31-Aug-2022 Seal
Compressor 09:00 AM 11:30 AM 02:30:00 27.00
Damage
Motor
8-Sep-2022 Compressor 02:20 PM 04:45 PM 02:25:00 8.00
Failure
Alignment
13-Oct-2022 Compressor 03:15 PM 03:45 PM 00:30:00 35.00
Disturbed
Seal
18-Nov-2022 Compressor 03:30 PM 06:00 PM 02:30:00 36.00
Damage
29-Dec-2022 Compressor Bearing fail 11:10 AM 01:40 PM 02:30:00 41.00
Motor
26-Jan-2022 Extrusion 08:45 AM 10:15 AM 01:30:00 0.00
Maintenance
Operator
18-Mar-2022 Extrusion 12:50 PM 03:20 PM 02:30:00 51.00
Error
Sensor
12-May-2022 Extrusion 09:30 AM 11:45 AM 02:15:00 55.00
Failed
21-Jul-2022 Extrusion Bearing fail 11:15 AM 01:40 PM 02:25:00 70.00
Sensor
20-Oct-2022 Extrusion 09:45 AM 10:15 AM 00:30:00 91.00
Failed
Lathe Seal
15-Jan-2022 07:45 AM 10:15 AM 02:30:00 0.00
Machine Damage
Lathe Motor
29-Jan-2022 12:50 PM 03:20 PM 02:30:00 14.00
Machine Failure
Lathe Sensor
22-Feb-2022 08:30 AM 01:00 PM 04:30:00 24.00
Machine Failed
Lathe
6-Mar-2022 Bearing fail 02:40 PM 04:55 PM 02:15:00 12.00
Machine
Lathe Sensor
8-May-2022 09:15 AM 01:30 PM 04:15:00 63.00
Machine Failed
Lathe Seal
2-Jul-2022 08:45 AM 09:15 AM 00:30:00 55.00
Machine Damage
Break
Lathe
7-Aug-2022 Assembly 02:20 PM 03:50 PM 01:30:00 36.00
Machine
failed
Plastic Lubricant
2-Jan-2022 08:15 AM 02:30 PM 06:15:00 0.00
Feeder Leak
Break
Plastic
19-Feb-2022 Assembly 07:45 AM 10:15 AM 02:30:00 48.00
Feeder
failed
Plastic Motor
10-Apr-2022 10:00 AM 12:30 PM 02:30:00 50.00
Feeder Maintenance
Plastic Motor
15-May-2022 02:50 PM 05:05 PM 02:15:00 35.00
Feeder Maintenance
Plastic Operator
27-Jul-2022 02:20 PM 04:45 PM 02:25:00 73.00
Feeder Error
Plastic Operator
3-Sep-2022 08:00 AM 10:30 AM 02:30:00 38.00
Feeder Error
Plastic Motor
3-Nov-2022 11:10 AM 01:40 PM 02:30:00 61.00
Feeder Failure
Cutter Chip
19-Jan-2022 Slitting 08:30 AM 11:00 AM 02:30:00 0.00
off
5-Feb-2022 Slitting Bearing fail 08:45 AM 09:15 AM 00:30:00 17.00
Seal
17-Mar-2022 Slitting 09:25 AM 01:40 PM 04:15:00 40.00
Damage
Motor
15-Apr-2022 Slitting 08:30 AM 01:00 PM 04:30:00 29.00
Failure
2-May-2022 Slitting Cutter Chip 09:00 AM 11:30 AM 02:30:00 17.00
 off
Maintenance
12-May-2022 Slitting 01:10 PM 02:40 PM 01:30:00 10.00
Gear Box
Lubricant
20-Jun-2022 Slitting 10:45 AM 11:15 AM 00:30:00 39.00
Leak
26-Jul-2022 Slitting Bearing fail 11:30 AM 03:45 PM 04:15:00 36.00
9-Aug-2022 Slitting Fuse Failure 02:15 PM 04:45 PM 02:30:00 14.00
Cutter Chip
6-Sep-2022 Slitting 01:55 PM 03:20 PM 01:25:00 28.00
off
Break
9-Oct-2022 Slitting Assembly 03:15 PM 03:45 PM 00:30:00 33.00
failed
Cutter Chip
8-Nov-2022 Slitting 09:25 AM 01:40 PM 04:15:00 30.00
off
Spot Alignment
9-Jan-2022 08:15 AM 02:30 PM 06:15:00 0.00
Welding-1 Disturbed
Spot Alignment
22-Feb-2022 01:55 PM 03:20 PM 01:25:00 44.00
Welding-1 Disturbed
Spot Alignment
7-Mar-2022 04:05 PM 04:35 PM 00:30:00 13.00
Welding-1 Disturbed
Spot Sensor
19-Apr-2022 10:00 AM 12:30 PM 02:30:00 43.00
Welding-1 Failed
Spot Alignment
15-May-2022 02:40 PM 04:55 PM 02:15:00 26.00
Welding-1 Disturbed
Spot Alignment
1-Jun-2022 11:30 AM 01:45 PM 02:15:00 17.00
Welding-1 Disturbed
Spot Sensor
8-Jul-2022 11:30 AM 01:45 PM 02:15:00 37.00
Welding-1 Failed
Spot
23-Sep-2022 Fuse Failure 03:10 PM 05:25 PM 02:15:00 77.00
Welding-1
Spot Sensor
6-Oct-2022 10:25 AM 10:55 AM 00:30:00 13.00
Welding-1 Failed
Spot Seal
25-Oct-2022 02:20 PM 04:45 PM 02:25:00 19.00
Welding-1 Damage
Spot Sensor
25-Dec-2022 10:45 AM 11:15 AM 00:30:00 61.00
Welding-1 Failed
Maintenance
27-Jan-2022 STP Pump 07:45 AM 10:15 AM 02:30:00 0.00
Gear Box
Maintenance
13-Feb-2022 STP Pump 11:10 AM 11:40 AM 00:30:00 17.00
Gear Box
Lubricant
9-Mar-2022 STP Pump 08:30 AM 01:00 PM 04:30:00 24.00
Leak
23-Apr-2022 STP Pump Bearing fail 09:00 AM 11:30 AM 02:30:00 45.00
Lubricant
18-May-2022 STP Pump 01:20 PM 03:45 PM 02:25:00 25.00
Leak
Motor
5-Jun-2022 STP Pump 03:30 PM 06:00 PM 02:30:00 18.00
Maintenance
Motor
28-Jun-2022 STP Pump 03:30 PM 06:00 PM 02:30:00 23.00
Heated
30-Jul-2022 STP Pump Bearing fail 08:00 AM 10:30 AM 02:30:00 32.00
Seal
9-Sep-2022 STP Pump 09:40 AM 11:05 AM 01:25:00 41.00
Damage
Operator
27-Sep-2022 STP Pump 02:15 PM 02:45 PM 00:30:00 18.00
Error
6-Oct-2022 STP Pump Motor 10:20 AM 12:50 PM 02:30:00 9.00
 Failure
6-Jan-2022 Winder Bearing fail 10:50 AM 01:15 PM 02:25:00 0.00
3-Mar-2022 Winder Bearing fail 04:05 PM 04:35 PM 00:30:00 56.00
Motor
5-Apr-2022 Winder 02:20 PM 03:50 PM 01:30:00 33.00
Failure
19-Apr-2022 Winder Bearing fail 11:15 AM 01:40 PM 02:25:00 14.00
Alignment
12-May-2022 Winder 03:05 PM 03:35 PM 00:30:00 23.00
Disturbed
Motor
7-Jun-2022 Winder 09:15 AM 01:30 PM 04:15:00 26.00
Failure
Motor
25-Jun-2022 Winder 09:30 AM 11:45 AM 02:15:00 18.00
Failure
12-Jul-2022 Winder Fuse Failure 08:45 AM 10:15 AM 01:30:00 17.00
Lubricant
8-Aug-2022 Winder 09:40 AM 11:05 AM 01:25:00 27.00
Leak
Motor
22-Sep-2022 Winder 10:45 AM 11:15 AM 00:30:00 45.00
Failure
9-Oct-2022 Winder Bearing fail 10:20 AM 12:50 PM 02:30:00 17.00
10-Oct-2022 Winder Bearing fail 08:30 AM 11:00 AM 02:30:00 1.00
Sensor
10-Nov-2022 Winder 11:10 AM 01:40 PM 02:30:00 31.00
Failed
Maintenance
13-Nov-2022 Winder 11:10 AM 11:40 AM 00:30:00 3.00
Gear Box
Alignment
17-Dec-2022 Winder 09:30 AM 12:45 PM 03:15:00 34.00
Disturbed