SUVI I

MACHINE BREAK DO

ACTUAL DOWN TIME

S NO. MACHINE NAME B/D SLIP NO. MACHINE PROBLEM
DATE/TIME

10
10

11

12

13

14

15

16

17

18

19

20

21
22
 SUVI INDUSTRIES
MACHINE BREAK DOWN RECORD (MONTH & YEAR)

ROOT CAUSE SPARE REPLACED DETAILS IF

CORRECTIVE & PREVENTIVE ACTION
ANALYSIS ANY
 FROMAT NO. SUVI/MN/FT/01
ISSUE REVISION 1.0
DATE 25.12.2023

TOTAL BREAKDOWN
COMPLETION
CARRIED OUT BY TIME
DATE/TIME HOURS (HH.MM)
 TOTAL

SIGN.
 MAC

ACTUAL DOWN TIME

S NO. MACHINE NAME B/D SLIP NO.
DATE/TIME

02.01.24
1 Screw Press 2000T 01 316
10.40 am

05.01.24
2 Screw Press 2000T 01 317
06.25 pm

08.01.24
3 IBH 750 KW 01 319
08.25 am

08.01.24
4 Circular Saw CS 100 01 320
06.38 pm

09.01.24
5 Screw Press 2000T 01 321
07.00 pm

11.01.24
Trimming Press 250T
6 322
01
01.50 pm

12.01.24
7 IBH 750 KW 01 323
02.15 pm

15.01.24
8 EOT Crane 01 324
09.30 am

16.01.24
9 IBH 750 KW 01 325
01.15 am

18.01.24
Heat Treatment
10 326
Furnace
 Heat Treatment
10 326
Furnace
03.00 pm

21.01.24
11 Screw Press 2000T 01 327
12.00 am

24.01.24
12 Screw Press 2000T 01 328
03.50 am

24.01.24
13 IBH 750 KW 01 329
12.00 pm

25.01.24
14 IBH 750 KW 01 331
09.00 am

27.01.24
15 Circular Saw CS 100 01 332
01.59 pm

28.01.24
16 Lathe Machine 01 333
06.20 am
 SUVI INDUSTRIES
MACHINE BREAK DOWN RECORD JAN 2024

MACHINE PROBLEM ROOT CAUSE ANALYSIS

Bottom Ejector not working Sensor Broken

Oil Level low alarm Hose pipe damaged

IBH trip again and again Sensor faulty

Back side clamp broken Bolt broken

Bottom Ejector not working Plug has faulty

Stopper pin broken Pin Broken

IBH Coil spark Coil Punchered

Crane not working Brake looses

Sparking in Scada Panel Switch Switch has faulty

Return Trolley Conveyor not

Motor Brakes faulty
working
Return Trolley Conveyor not
Motor Brakes faulty
working

Bottom Ejector not working Hose pipe leakage

Bottom Ejector not working Hose pipe damaged

Conveyor not working Bearing has faulty

IBH not working Malfuctioning of PLC

Shuttle vice clamp bolt broken Bolt broken

Single and Double cycle not Lever faulty

working
INDUSTRIES
K DOWN RECORD JAN 2024

SPARE REPLACED DETAILS IF

CORRECTIVE & PREVENTIVE ACTION
ANY

Checked and found that Ejector sensor rod has broken so

Nil
we repaired the rod and fixed it then working ok

Checked and found that Lubrication oil level has low as

oil is leaking from hose pipe So we opened the pipe and Nil
repaired it from outsource then fixed it.

Checked and found that Pusher cylinder back proximity Proximity Sensor PNP NO 01
has faulty So we replaced it with new one. Nos

Checked and found that Main vice clamp has broken So

Nil
we repaired the clamp and then fixed it.

Checked and found that Ejector Valve coil's plug has

Coil Plug 24V 01 Nos
faulty so we replaced it with new one.

We replaced the broken pin with new one. Stopper Pin 01 Nos

Checked and found that coil has punchered So we remove

the coil from heater and fixed other coil for continue our
production and send the faulty coil to OEM for repairing White Cement 250 kg
it.

Checked and found that crane brakes has looses so we

tight the brakes by adjusting their nut bolt then working Nil
ok

Checked and found that Rotary switch has faulty so we Rotary Switch 32 amp - 01
replaced the switch with new one. Nos

Checked and Found that Conveyor Motor Brakes has

Motor Winding wire - 8 kg
faulty So we Repaired it then fixed it.
 Checked and Found that Conveyor Motor Brakes has
Motor Winding wire - 8 kg
faulty So we Repaired it then fixed it.

Checked and found that Oil is leaking from Ejector Hose

Nil
pipe So we repaired the pipe and fixed it then working ok

Checked and found that Ejector hose pipe damaged So we

arranged the pipe from outsource and fixed it then Nil
working ok

Checked and found that Conveyor Bearing has jammed So

Nil
we repaired the bearing then working ok

Checked and found that IBH shows cooling alarm So we

Nil
reset it then working ok

We Replaced the broken bolts with new one then working Allen Bolt M12*30mm 4 Nos
ok

Checked and found that single and double changing lever Nil
broken so we repaired it then working ok
 FROMAT NO. SUVI/MN/FT/01
ISSUE REVISION 1.0
DATE 25.12.2023

TOTAL BREAKDOWN
COMPLETION TIME
CARRIED OUT BY
DATE/TIME HOURS (HH.MM)

02.01.24
Vinod 1.50
12.10 pm

05.01.24 DONE
Vinod 6.00
12.25 am

08.01.24
Rajiv 0.58
09.00 am

08.01.24
Vinod 1.16
07.48 pm

10.01.24
Vinod 7.5
02.30 am

11.01.24
Satnam 1.86
03.42 pm

12.01.24
Rajiv 1.75
04.00 pm

15.01.24
Sonu 0.75
10.15 am

16.01.24
Sonu 0.5
01.45 am

18.01.24 DONE
Rajiv/Satnam 7
Rajiv/Satnam 7
10.00 am

21.01.24
Sonu/Rajiv 1.66
01.40 am

24.01.24 DONE
Sonu 5.66
09.30 am

24.01.24
Vinod/Sonu 2.5
02.30 pm

25.01.24
Rajiv 0.16
09.10 am

27.01.24
Vinod 0.91
02.54 pm

28.01.24
Vinod/Satnam 0.58
06.55 am

TOTAL 40.07

SIGN.
 M

ACTUAL DOWN TIME

S NO. MACHINE NAME B/D SLIP NO. MACHINE PROBLEM
DATE/TIME

01.02.24
1 Compressor 01 334 Compressor not working
09.30 am

01.02.24
2 Transfer Conveyor 01 335 Transfer Conveyor not working
10.00 am

01.02.24
3 Compressor 01 336 Compressor not working
11.10 am

01.02.24
4 Screw Press 2000T 01 337 Top Ejector not working
04.25 pm

06.02.24
5 Shot Blast 01 338 Machine not working
03.15 pm

13.02.24
Trimming Press 250T
6 339 Spring Broken
01
09.35 am
 SUVI INDUSTRIES
MACHINE BREAK DOWN RECORD FEB 2024

ROOT CAUSE ANALYSIS CORRECTIVE & PREVENTIVE ACTION

Checked and found that Compressor has tripped due to

Malfuctioning of Voltage voltage fluctuation So we reset the compressor and adjust
the voltage from transformer.

Bearing has faulty Checked and found that Conveyor Bearing has jammed So
we repaired the bearing then working ok

MCB has faulty Checked and found that compressor Main supply MCB
has faulty So we replaced the MCB with new one.

Coil has faulty Checked and found that Ejector valve coil has faulty So we
replaced the coil with new one.

Timer faulty Checked and found that Machine Combination timer has
faulty So we replaced it with new one.

Spring broken We replaced the broken spring with new one.

 FROMAT NO.

ISSUE REVISION
DATE

COMPLETION
SPARE REPLACED DETAILS IF ANY CARRIED OUT BY
DATE/TIME

01.02.24
Nil Satnam/Varinder
10.30 am

01.02.24
Nil Vinod
11.00 am

01.02.24
MCB 3 Pole 63 Amp - 01 Nos Satnam/Varinder
11.50 am

01.02.24
Valve Coil 24V 01 Nos Vinod/Varinder
05.00 pm

06.02.24
Combination Timer 01 Nos Varinder
04.45 pm

13.02.24
Spring 12 inch - 1 Nos Vinod
10.00 am

TOTAL

SIGN.
SUVI/MN/FT/01
1.0
25.12.2023

TOTAL BREAKDOWN
TIME
HOURS (HH.MM)

0.66

0.58

1.5

0.41

5.15
 MACH

ACTUAL DOWN TIME

S NO. MACHINE NAME B/D SLIP NO.
DATE/TIME

02.03.24
1 Weighing Scale 50kg 01 340
06.34 pm

07.03.24
2 Screw Press 2000T 01 341
10.20 pm

09.03.24
3 IBH 350 KW 02 342
09.25 am

09.03.24
4 IBH 750 KW 01 343
10.00 am

12.03.24
Trimming Press 150T
5 345
02
02.45 am

12.03.24
6 Screw Press 1000T 02 346
03.50 am

12.03.24
7 IBH 350 KW 02 347
04.05 am

18.03.24
8 Screw Press 2000T 01 348
07.00 am

18.03.24
9 Screw Press 2000T 01 350
11.40 pm

19.03.24
Trimming Press 250T
10 351
01
 Trimming Press 250T
10 351
01
07.40 am

19.03.24
11 Screw Press 2000T 01 352
02.30 pm

20.03.24
12 Circular Saw CS 100 01 353
05.00 pm

22.03.24
Trimming Press 250T
13 354
01
12.55 pm

23.03.24
Trimming Press 150T
14 355
02
04.00 pm
 SUVI INDUSTRIES
MACHINE BREAK DOWN RECORD MARCH 2024

MACHINE PROBLEM ROOT CAUSE ANALYSIS

Not working bolt looses

Bottom Ejector not working Sensor has faulty

IBH not working Alignment out

IBH not working Sensor has faulty

Wire burn out Wire burnet

Controller Alarm and Noise Thimble and wire melted

issue

Water leakage from coil Pipe Looses

Motor not working Pump has faulty

Top Ejector not working Pin Broken

Double Stroke Problem Alignment out

 Double Stroke Problem Alignment out

Top Ejector not working Valve has faulty

Cutter broken and jammed Cutter broken

Stopper pin broken Pin Broken

Slide up down not working Chain broken

NDUSTRIES
DOWN RECORD MARCH 2024

SPARE REPLACED DETAILS IF

CORRECTIVE & PREVENTIVE ACTION
ANY

Checked and found that scale table adjusting bolt has

Nil
loose so we tighted it then working ok

Checked and found that Ejector up position proximity Proximity Sensor PNP NO
sensor has faulty So we replaced it with new one. 01 Nos

Checked and found that Infeed conveyor alignment

Nil
disturbed So we fixed it then working ok

Checked and found that Pusher cylinder back proximity is

Nil
not working So we adjust it as required then working ok

Checked and Found that wire of foot padle has burn due
to hot flash fallen on it So we reapired the wire then Nil
working ok

Checked and found that abnormal sound occurred from

Copper thimble 50 sq mm
main motor as its terminal thimble has melted So we
01 Nos
replaced the thimble and tighted it properly

Checked and found that water is leaking from joint of

hose pipe so we tight the juble clamp the working ok Nil

Checked and found that Lubrication motor is working but

pump not making pressure so we cleaned the pump and Nil
their suction filter then working ok

Checked and found that Ejector Cam Mechanism pin has

broken So we dismental the cam shaft and replaced the Pin 12mm 01 Nos
pin then working ok

Checked and found that Stopper shaft alignment out so

Nil
we aligned it then working ok
 Checked and found that Stopper shaft alignment out so
Nil
we aligned it then working ok

Checked and found that Ejector Hyd. Valve has faulty so

Nil
we repaired the valve then working ok

Checked and found that cutter broken and stuck with

billet rod so we remove the cutter from rod by force then Nil
ok

Checked and found that stopper pin has broken So we

Stopper Pin 01 Nos
replaced the pin with new one.

Checked and found that Slide up down motor's chain has

Nil
broken So we repaired the chain then working ok
 FROMAT NO. SUVI/MN/FT/01
ISSUE REVISION 1.0
DATE 25.12.2023

TOTAL BREAKDOWN
COMPLETION
CARRIED OUT BY TIME
DATE/TIME HOURS (HH.MM)

02.03.24
Varinder 0.26
06.50 pm

07.03.24
Vinod 2
12.20 pm

09.03.24
Varinder 0.33
09.45 am

09.03.24
Satnam 3.5
01.30 am

12.03.24
Sonu 0.66
03.25 am

12.03.24
Sonu 0.75
04.35 am

12.03.24
Sonu 0.25
04.20 am

18.03.24
Varinder 1.16
08.10 am

18.03.24 DONE
Vinod 6.33
06.00 am

19.03.24
Satnam 0.58
 Satnam 0.58
08.20 am

19.03.24
Satnam 1.66
04.10 pm

20.03.24
Satnam 0.5
05.30 pm

22.03.24
Sonu/Satnam 1.76
02.41 pm

23.03.24
Sonu 1.33
05.20 pm

TOTAL 21.07

SIGN.
 M

ACTUAL DOWN TIME

S NO. MACHINE NAME B/D SLIP NO.
DATE/TIME

01.04.24
1 IBH 350 KW 02 357
11.00 pm

08.04.24
2 IBH 350 KW 02 358
11.00 PM

13.04.24
Trimming Press 250T
3 360
02
04.35 am

16.04.24
4 Screw Press 2000T 01 361
12.10 am

17.04.24
5 Screw Press 2000T 01 362
07.00 am

25.04.24
6 Lathe Machine 02 363
10.00 am

26.04.24
7 IBH 350 KW 02 364
10.30 pm

29.04.24
Trimming Press 250T
8 01 365
12.15 am
 SUVI INDUSTRIES
MACHINE BREAK DOWN RECORD APRIL 2024

MACHINE PROBLEM ROOT CAUSE ANALYSIS

Cooling Alarm, Water Pressure

Motor has faulty
low

IBH not start due to DM water Prersure Switch Faulty

Trimming Press not working

Hyd Fitting Damaged
and oil leakage

Top Ejector not working Bush pin opened

Bottom Ejector Not working Cylinder Seal Damaged

Jaw tharel Problem Screw wear out

Water Leakage from IBH Coil Clamp of hose pipe has looses

Trimming Press Bolt open Bolt looses

VI INDUSTRIES
EAK DOWN RECORD APRIL 2024

SPARE REPLACED DETAILS IF

CORRECTIVE & PREVENTIVE ACTION
ANY

Checked and found that Cooling tower Pump's motor has

faulty So we Run the Machine on stand by pump and Nil
remove the faulty motor from tank to repair it

Checked and found that DM water Pressure signal has

malfuctioning as pressure switch has faulty So we Pressure Switch 01 Nos
replaced it with new one.

Checked and found that Oil is leaking from Hyd pipe

Hyd Fitting 01
fitting So we opened the fitting and replaced it.

Checked and found that Ejector Internal Mechanism has

faulty So we removed the mechanism and found that Nil
Bush pin has open So we fixed it then working ok

Checked and found that Bottom Ejector Hyd Cylinder Has

faulty So we Dismental the cylinder and replaced their Bottom Ejector Seal Kit
seal kit set then fixed it

Checked and found that Chuck's Job clamp screw wear

Chuck's Clamp Screw
out So we replaced it with new one.

Checked and found that water is leaking from hose pipe

So we replaced the clamp of hose pipe then leakage Juble Clamp 0.5" 1 Nos
plugged.

Checked and found that Stopper pin bolt looses so we

tighted it then working ok Nil
 FROMAT NO. SUVI/MN/FT/01
ISSUE REVISION 1.0
DATE 25.12.2023

TOTAL BREAKDOWN
COMPLETION
CARRIED OUT BY TIME
DATE/TIME HOURS (HH.MM)

01.04.24 DONE
Sonu/Varinder/Vinod 10.5
09.30 am

08.04.24
Sonu 1.0
12.00 AM

13.04.24
Vinod 1.5
06.05 am

17.04.24
Sonu 3
03.10 am

17.04.24
Vinod 3.5
10.30 am

24.04.24
Vinod 1
11.00 am

26.04.24
Sonu 1
11.30 pm

29.04.24
Satnam 0.58
12.50 am

TOTAL 22.08

SIGN.
 FROMAT NO. SUVI/MN/FT/01

SUVI INDUSTRIES ISSUE REVISION 1.0

DATE 25.12.2023

MACHINE BREAK DOWN RECORD MAY 2024

TOTAL BREAKDOWN
ACTUAL DOWN TIME SPARE REPLACED DETAILS IF COMPLETION
S NO. MACHINE NAME B/D SLIP NO. MACHINE PROBLEM ROOT CAUSE ANALYSIS CORRECTIVE & PREVENTIVE ACTION CARRIED OUT BY TIME
ANY
DATE/TIME DATE/TIME HOURS (HH.MM)

1.05.24 1.05.24
Checked and found that Lubrication Tank oil level low So Lubrication Oil 150 No. - 50
1 Screw Press 2000T 01 366 Lubrication Alarm on Machine Oil Level low Satnam 0.83
we filled oil in it then working ok Ltr
01.10 am 02.00 am

03.05.24 03.05.24
Checked and found that Control Panel Rotary switch has
2 IBH 750 KW 01 367 Control Panel Fault Rotary switch faulty Rotary Switch 32 Amp 01 Nos Sachin/Varinder 1.41
faulty So we replaced the switch with new one.
08.45 am 10.10 am

04.05.24 04.05.24
Checked and found that Feed Gear Bush has wear out So
3 Lathe Machine 02 368 Gear Box Feed not working Bush wear out Bush 01 Nos Sonu 0.83
we replaced the bush with new one.
09.30 am 10.20 am

08.05.24 08.05.24
Inching Cylinder Welding Checked and found that Balancing Cylinder shaft has
4 Trimming Press 02 370 Shaft Broken Nil Vinod/Sonu 2.00
Broken broken So we repaired the shaft then working ok
07.30 am 09.30 am

08.05.24 Checked and found that Drive shows alarm of E005 and 08.05.24
5 Screw Press 2000T 01 371 Drive Alarm Position Card Faulty then we replaced the position card of Front Motor then Position Card 01 Nos Varinder/Sachin 3.50
04.00 pm Machine working ok 07.30 pm

12.05.24 12.05.24
Checked and found that Ejector Up Sensor setting
6 Screw Press 2000T 01 372 Top Ejector not working Sensor Setting Disturbed Nil Vinod/Sachin 0.58
disturbed So we fixed it then working ok
08.35 am 09.05 am

14.05.24 14.05.24
Checked and found that Top Ejector Cam Mechanism Pin
7 Screw Press 2000T 01 373 Top Ejector not working Lock Pin Opened Circulip Lock of Pin Vinod 3.00
lock open So we fixed it
12.30 pm 03.30 pm

17.05.24 Checked and Found that Sensor 24V Supply is 17.05.24

malfuctioning So then we checked all control and then
8 Screw Press 2000T 01 374 Bottom Ejector not working Power Supply has Faulty SMPS 24V 14 Amps 01 Nos Sachin 4.00
found that 24V SMPS has faulty So we replaced it with
07.23 am new one. 11.23 am

23.05.24 23.05.24
Checked and found that Machine Gear Box Bearings has
9 Circular Saw CS 100 01 375 CS 100 Bearing Broken Bearing Damaged Bearing 7308 B 02 Nos Vinod/Sonu 1.83
Damaged So we replaced the bearings with new one.
02.00 pm 03.50 pm

28.05.24 Checked and found that Proximity Sensor has faulty and 28.05.24
Proximity Sensor PNP NO
10 IBH 350 KW 02 377 Sensor Shot Sensor Faulty their wire also Damaged So we replaced the sensor and Sachin 4.00
with wire 01 Nos
02.56 pm wire with new one. 06.56 pm

29.05.24 29.05.24
Checked and found that Conveyor Chain's lock has
11 IBH 750 KW 01 378 Conveyor not working Chain lock open Nil Satnam 0.25
opened So we fixed it then working ok
11.46 am 12.11 pm

30.05.24 30.05.24
Checked and found that Ejector Cylinder Seals has
12 Screw Press 2000T 01 379 Seals Damaged Bottom Ejector not working Cylinder Seal kit Set 01 Nos Sonu 4.00
damaged So we replaced the seals with new one.
12.00 am 04.00 am

TOTAL 26.23

SIGN.
 FROMAT NO. SUVI/MN/FT/01

SUVI INDUSTRIES ISSUE REVISION 1.0

DATE 25.12.2023

MACHINE BREAK DOWN RECORD APRIL 2024

TOTAL BREAKDOWN
ACTUAL DOWN TIME SPARE REPLACED DETAILS IF COMPLETION
S NO. MACHINE NAME B/D SLIP NO. MACHINE PROBLEM ROOT CAUSE ANALYSIS CORRECTIVE & PREVENTIVE ACTION CARRIED OUT BY TIME
ANY
DATE/TIME DATE/TIME HOURS (HH.MM)

10

11

12

TOTAL

SIGN.