Progressive Maintenance
Presentation No 13 PM Pillar Activities
PM Analysis – Frame Numbering m/c
Presenter name :
Duration of presentation
Presentation : 10 Min
Q&A : 05 Min
Slide Number: 1 TVS Motor company – P2
Business Expectation & Progressive Maintenance
PM Pillar Activities
Objective
PM Analysis – Frame Numbering m/c
Eliminating line stoppers and reducing maintenance cost were the business
expectations from PM pillar.
The objective of PM pillar is to
Improve availability of machines by achieving Zero Breakdown
Reduce Maintenance cost & Energy Cost
Slide Number: 2 TVS Motor company – P2
Targets Progressive Maintenance
PM Pillar Activities
PM Analysis – Frame Numbering m/c
02-'03 Target %
Area of focus Category Measure UOM 03-'04 04-'05 05-'06 06-'07 07-'08
BM From BM
Line stopper Numbers 1344
Line stopper 0 0 0 0 0 100%
(Vehicles) /month
Break down Numbers 809
D 590 450 250 97 37 95%
frequency /month
Break down
Break down Hours 910 650 510 330 114 33 96%
hours /month
Manufacturing Maintenance Rupees 360
C 260 240 220 196 243 32%
cost cost /vehicles
Targets for PM
Slide Number: 3 TVS Motor company – P2
Progressive Maintenance
Layout of Plant 2 PM Pillar Activities
PM Analysis – Frame Numbering m/c
Process flow of Plant 2
N
Painting Unit
Engine
Vehicle Assembly Fabrication Unit
Assembly
Machining Machining
To Stores Unit Stores
Unit
vehicle
ware house
Vehicle MIW Parts Supplier parts
Slide Number: 4 TVS Motor company – P2
Progressive Maintenance
Introduction PM Pillar Activities
PM Analysis – Frame Numbering m/c
PC
NUMBERING HEAD
COMPONENT
CLAMPING
PRINTER
Slide Number: 5 TVS Motor company – P2
Machine Ranking Progressive Maintenance
PM Pillar Activities
Vehicle Assy PM Analysis – Frame Numbering m/c
Location Machine Name Machine No Rank
STAR VEHICLE ASSY CONVEYOR 204004300 A
STAR VEHICLE ASSY PETROL TANK LEAK TESTING M/C 506048000 A
STAR VEHICLE ASSY PETROL TANK LEAK TESTING M/C 506060700 A
STAR VEHICLE ASSY PRECITEC NUMBERING M/C 203000400 A
STAR VEHICLE ASSY CHASIS - I 506103400 B
STAR VEHICLE ASSY CHASIS - II 506103500 B
STAR VEHICLE ASSY CHASIS - III 506103600 B
STAR VEHICLE ASSY CHASIS - IV 506103700 B
STAR VEHICLE ASSY CHASIS - V 600012600 B
STAR VEHICLE ASSY CONE BOTTOM PRESSING 204020800 B
STAR VEHICLE ASSY FORK OIL FILLING M/C 506128000 B
STAR VEHICLE ASSY FRONT FORK SUB ASSY 202039900 B
STAR VEHICLE ASSY FRONT PANEL SPEEDOMETER ASSY 204020000 B
STAR VEHICLE ASSY PILLION FOOT REST RUBBER PRESSING 620008100 B
STAR VEHICLE ASSY SWING ARM BUSH PRESSING M/C 302014700 B
STAR VEHICLE ASSY SWING ARM BUSH PRESSING M/C 620138800 B
12 Equipment Failure details (06-07) UOM : Nos
8
9
5
FREQ
6 4
2
3
NUMB M/C LEAK TEST M/C 1 LEAK TEST M/C 2 CONVEYOR
Slide Number: 6 TVS Motor company – P2
Vehicle Assy layout Progressive Maintenance
PM Pillar Activities
PM Analysis – Frame Numbering m/c
Warehouse
Booking
Chassis dynamometer
Frame
numbering
m/c
Conveyor Main line
* Frame numbering m/c stoppage affects the conveyor.
Slide Number: 7 TVS Motor company – P2
Progressive Maintenance
PM Pillar Activities
PM Analysis – Frame Numbering m/c
•NUMBERING HEAD
•FRAME
NUMBERING IMPRESSION
Slide Number: 8 TVS Motor company – P2
Progressive Maintenance
PM Pillar Activities
PM Analysis – Frame Numbering m/c
Specify Phenomenon
NUMBERING NOT IN STRAIGHT LINE IN HORIZONTAL DIRECTION
Frame
MD6256F5271E63962
NOT OK NUMBERING
Understand Phenomenon
Slide Number: 9 TVS Motor company – P2
Progressive Maintenance
Numbering Path PM Pillar Activities
PM Analysis – Frame Numbering m/c
MD6256F5
271E63962
Stylus Marking path Stylus Movement path
Conclusion : The stylus takes the shortest path from the end point of a number to
starting point of the subsequent number.
Slide Number: 10 TVS Motor company – P2
Number shift pattern Progressive Maintenance
PM Pillar Activities
PM Analysis – Frame Numbering m/c
Type 1 Type 2 Type 3 Type 4
5 H 6 1 2 7 5 8
Only X axis moves Both X & Y axis moves
50 % 50 %
Movement path
Slide Number: 11 TVS Motor company – P2
STEP 1 : CLARIFY THE Progressive Maintenance
PM Pillar Activities
PHENOMENA WITH 5W 1H
PM Analysis – Frame Numbering m/c
Slide Number: 12 TVS Motor company – P2
Progressive Maintenance
PM Pillar Activities
DEFINE PHENOMENA :
PM Analysis – Frame Numbering m/c
Numbering Shifting from Center line on upper side
MD6256F5271E63962
OK FRAME
Shift
MD6256F5271E63962
NOT OK FRAME
Slide Number: 13 TVS Motor company – P2
STEP 2 : CONDUCT PHYSICAL Progressive Maintenance
PM Pillar Activities
ANALYSIS
Understand Machine functioning PM Analysis – Frame Numbering m/c
Power Signals Drive commands
PC DRIVE UNIT
NUMBERING HEAD
HYDRAULIC Frame
POWER PACK Clamping
Stylus
X Axis
Numbering Geometry
Y Axis
Slide Number: 14 TVS Motor company – P2
STEP 2 : CONDUCT PHYSICAL Progressive Maintenance
PM Pillar Activities
ANALYSIS
Understand M/c functioning PM Analysis – Frame Numbering m/c
Drive belt
Drive motor
Carriage Bush
Guide rods
Driven pulley
Carriage with guide rods
Driven pulley
Slide Number: 15 TVS Motor company – P2
STEP 2 : CONDUCT PHYSICAL Progressive Maintenance
PM Pillar Activities
ANALYSIS
A : Identify Operating Principle PM Analysis – Frame Numbering m/c
AXIS MOVEMENT
• The Stepper motors through
the timer belt move X & Y axes.
BLOCK DIAGRAM FOR AMPLIFIER UNIT ( NUMBERING M/C )
MMI KEYPAD & STEP DOWN
INDICATION LED'S TRANSFORMER
2. The amount of movement is decided by the
SMPS
OPTIONAL REGULATED POWER
CONNECTORS FOR SUPPLY SECTION
ADDON CARDS
pulses supplied to stepper motor by drive unit. CPU
LINE SURGE
SUPPOSER
OPERATING
VOLTAGE
SELECTION
UNIT 110V/220V
MEMORY SOL RELAY AXIS MOTOR SUPPLY
BATTERY CONTROL SECTION
X
Y
RS232 TO REMOTE POWER
PC INTERNET START/STOP NUMBERING
SUPPLY 230V AC 50 Hz
SIGNALS HEAD INPUT
3. The supply of pulses by the drive unit is controlled
by the processor with respect to the program fed by
the operator
Slide Number: 16 TVS Motor company – P2
STEP 2 : CONDUCT PHYSICAL Progressive Maintenance
PM Pillar Activities
ANALYSIS
A : Identify Operating Principle PM Analysis – Frame Numbering m/c
NUMBERING IMPRESSION
1. The numbering impression is created by hammering effect of the stylus.. The down
movement is controlled by the pneumatic pressure & up movement by a spring.
1c 1a STYLUS PARTS
1e 1a. Outer body
1d 1b. Stem Guide bush (brass)
1c. O ring
1d. Stem
1e. Spring
Stylus Assy
1. Stylus
2. The hammering effect is generated by
sequential operation of solenoid valves 18
18. Pneumatic solenoid
8a valves
in pneumatic circuit. 1
18a 18a. Solenoid control
3. This is controlled by the main processor cable
making 12 V supply ON & OFF to the
valves. 19a. Air inlet hose
22
19a 22.Air Outlet
Slide Number: 17 TVS Motor company – P2
STEP 2 : CONDUCT PHYSICAL Progressive Maintenance
PM Pillar Activities
ANALYSIS
B : Identify Operating Standards PM Analysis – Frame Numbering m/c
AXIS MOVEMENT
1. The reference point (home position) of the stylus should not go out of memory
3. The Co ordinate setting for the numbering should not be disturbed.
5. Y axis should be parallel to frame axis
B : Identify Operating Standards
NUMBERING IMPRESSION
1. The stylus needle point should be sharp
2. No welding spatter or beads should be present on frame surface
3. Air pressure should be maintained at 4~6 Kg / cm2
4. Hydraulic clamping pressure should be 40 ~ 50 kg / cm2
5. Voltage supply for solenoid valves should be 12V
Slide Number: 18 TVS Motor company – P2
STEP 2 : CONDUCT PHYSICAL Progressive Maintenance
PM Pillar Activities
ANALYSIS
PM Analysis – Frame Numbering m/c
PHENOMENA
Numbering Shifting from Center line on upper side
DEFINE RELATED CONDITIONS
Y AXIS A Y axis “A” &
Numbering axis “B”
NUMBERING 54864163E03220 B
MAD2
AXIS
QUANTIFY THE REALTIONSHIP BETWEEN INTERACTING ELEMENTS
Y AXIS A
C Distance “C” between Y axis “A”
NUMBERING 54864163E03220 B
AXIS
MAD2 & Numbering axis “B”
DEFINE QUANTITATIVE PHYSICAL CHANGE
Y AXIS A The distance [C]
r t C
between the Y axis [A] &
NUMBERING
AXIS
MAD2
54864163E03220 B
Numbering Axis [B]
varies [D]
D(r≠t) TVS Motor company – P2
Slide Number: 19
STEP 3 : IDENTIFY CONSTITUENT CONDITIONS Progressive Maintenance
STEP 4 : STUDY 4Ms FOR CAUSAL FACTORS
PM Pillar Activities
PM Analysis – Frame Numbering m/c
CONSTITUENT CONDITION PRIMARY 4 M ANALYSIS
1. Frame rotates/ moves while
1.1 Clamp force is less than the weight of
numbering.
frame.
1.2 Clamping stroke is not enough to hold
frame
9. The stylus slips
2.1 Play in needle / bush
2.2 Play between Stylus body & main housing
Slide Number: 20 TVS Motor company – P2
STEP 3 : IDENTIFY CONSTITUENT CONDITIONS Progressive Maintenance
STEP 4 : STUDY 4Ms FOR CAUSAL FACTORS
PM Pillar Activities
PM Analysis – Frame Numbering m/c
CONSTITUENT CONDITION PRIMARY 4 M ANALYSIS
3. Drive does not reach desired 31 Drive belt slips
position 3.2 Motor does not rotate by desired angle.
3.3 Slides Jam.
3.4 Not restarting from home position
A
Home for Y axis
r t
C
Shift Numbering axis
D(r≠t)
Slide Number: 21 TVS Motor company – P2
STEP 3 : IDENTIFY CONSTITUENT CONDITIONS Progressive Maintenance
STEP 4 : STUDY 4Ms FOR CAUSAL FACTORS
PM Pillar Activities
PM Analysis – Frame Numbering m/c
PRIMARY 4 M ANALYSIS SECONDARY 4 M ANALYSIS
1.1.1 Clamping fixture seating wear out.
1.1 Clamp force is less than the weight of 1.1.2 Hydraulic pressure is low
frame.
1.1.3 Frame seating surface damage
Frame Clamping cylinder
1.2 Clamping stroke is not enough to hold 1.2.1 Frame cone length less than spec
frame
Play 1.2.2 Clamping cylinder stroke is less.
Stroke not
enough
Slide Number: 22 TVS Motor company – P2
STEP 3 : IDENTIFY CONSTITUENT CONDITIONS Progressive Maintenance
STEP 4 : STUDY 4Ms FOR CAUSAL FACTORS
PM Pillar Activities
PM Analysis – Frame Numbering m/c
PRIMARY 4 M ANALYSIS SECONDARY 4 M ANALYSIS
2.1 Play in needle / bush 2.1.1 Punching needle wear out
2.1.2 Brass bush wear out.
Guide Bush
Needle
Needle slipping
Due to play
2.2 Play between Stylus body & main 2.2.1 Mounting thread wash out.
housing 2.2.2 Stylus not tightened properly.
Guide Bush
Needle
Body is loose
Due to play
Slide Number: 23 TVS Motor company – P2
STEP 3 : IDENTIFY CONSTITUENT CONDITIONS Progressive Maintenance
STEP 4 : STUDY 4Ms FOR CAUSAL FACTORS
PM Pillar Activities
PM Analysis – Frame Numbering m/c
PRIMARY 4 M ANALYSIS SECONDARY 4 M ANALYSIS
1 Drive belt slips 3.1.1 Belt teeth wear out.
3.1.2 Idler pulley mounting loose.
3.1.3 Drive gear teeth wear out
3.2.1 Faster sequencing
3.2 Motor does not rotate by desired angle.
3.2.2 More load
3.3.1 Guide bush misalignment
3.3 Slides Jam.
3.3.2 Lack of lubrication
3.3.3 Foreign material entry ( Burr )
3.4 Not starting from home position 3.4.1 No feedback of home positioning.
Slide Number: 24 TVS Motor company – P2
Kaizens implemented Progressive Maintenance
PM Pillar Activities
PM Analysis – Frame Numbering m/c
Abnormality Improvement
• Dust accumulation on guide rods •Provide bellow cover to avoid dust entry
• Stylus thread damaged •Introduce adapter piece between stylus &
housing bore.
Slide Number: 25 TVS Motor company – P2
Progressive Maintenance
Kaizens implemented PM Pillar Activities
PM Analysis – Frame Numbering m/c
Abnormality Improvement
• Dust entry in guide ways bush •Provide bellow cover between bush
• Home position not reached •Interlock home position sensing with
cycle start .
No
feedback
for home
positioning
Slide Number: 26 TVS Motor company – P2
Progressive Maintenance
Kaizens implemented PM Pillar Activities
PM Analysis – Frame Numbering m/c
Abnormality Improvement
• Clamp with low hydraulic pressure • Introduce Pressure switch & interlock
with cycle start
Only Hydraulic
pressure indicating
gauge available
• Correct stroke length as per spec in system &
• Stroke length of stylus more
lock with password.
Incorrect entry
Slide Number: 27 TVS Motor company – P2
Progressive Maintenance
Kaizens implemented PM Pillar Activities
PM Analysis – Frame Numbering m/c
Abnormality Improvement
• High air pressure than recommended •Provide regulated pressure with gauge
indication
Only pressure
indicating gauge
available
•Belt mounting loose Mounting •Provide double belt locking.
Bolt Additional
Body
backing
belt
Belt
Slide Number: 28 TVS Motor company – P2
STEP 2 : CONDUCT PHYSICAL Progressive Maintenance
PM Pillar Activities
ANALYSIS
Understand Machine functioning PM Analysis – Frame Numbering m/c
Direction
Stator coils of rotation
Rotor
Operating principle
A stepper motor converts electrical energy into discrete motions or steps.
It consists of rotor which has projecting teeth which align with the magnetic fields of the
windings. When the coils are energized in sequence by direct current, the teeth follow the
sequence and rotate a discrete distance necessary to re-align with the magnetic field.
The number of coil and the number of teeth determines the number of steps (resolution) of
the motor. For eg , a 200 step per rev (spr) motor has 50 rotor teeth times 4 coil combinations
to equal 200 spr.
Slide Number: 29 TVS Motor company – P2
STEP 2 : CONDUCT PHYSICAL Progressive Maintenance
PM Pillar Activities
ANALYSIS
Understand Machine functioning PM Analysis – Frame Numbering m/c
Direction
Stator coils of rotation
Rotor
Operating principle
If 1 > 2, the rotor will slip.** Sequencing of pulses = 1
Rotor movement =2
If the rotor slips (step loss), it will align with the next available magnetic pulse.
** This results in pulse missing for drive to move & stylus doesn't travel as desired.
Slide Number: 30 TVS Motor company – P2
Manufacturer recommendation Progressive Maintenance
PM Pillar Activities
PM Analysis – Frame Numbering m/c
Rated Actual
Number Marking Speed : 15 mm /sec 20 mm/sec **
Axis movement speed : 110 mm /sec 200 mm /sec
** This results in pulse missing for drive to move & stylus doesn't travel as desired.
** The numbering starts well above the reference line & results in NOT OK
Component.
Slide Number: 31 TVS Motor company – P2
Results Progressive Maintenance
PM Pillar Activities
PM Analysis – Frame Numbering m/c
10 EQUIPEMENT FAILURE – Frame numbering machine
9 Better
8
UOM : Frequency
7
3
2 2
2
1 1 1 1
1
0 0 0 0 0 0 0 0 0 0 0 0 0
0
Jan,07
Wk 10
Wk 8
Wk 9
Feb
Jun
Jun
Oct
Oct
Jul
Jul
May
May
Mar
Nov
Nov
Dec
Dec
Sep
Sep
Aug
Aug
Apr
Apr
Plan Actual Limit
Slide Number: 32 TVS Motor company – P2
Intangible benefits Progressive Maintenance
PM Pillar Activities
PM Analysis – Frame Numbering m/c
•Problem solving approach improved by understanding
machine functioning.
Slide Number: 33 TVS Motor company – P2
Progressive Maintenance
PM Pillar Activities
PM Analysis – Frame Numbering m/c
End of presentation
Slide Number: 34 TVS Motor company – P2
