MOULDING ISSUE TREE AND CA i.

Power not
available (6500KW
instead of
a. Metal not avlbl a. Speed losses 10000KW)

a. More Cycle
b. Quality (waiting for time(77min instead
1. Pouring Delay
chemical comp) of 60min/heat)

c. Job Change over a. Using of low

density raw matl
b. Time lost for slag
removing
2. Mould line B/D c. Time to adjust
chemistry for high
alloy items,
d. More slag build up
on furnace linings
Availability
decreases furnace
3. Others
effi

4. No Power

5. CCC B/D

6. Sand not avlbl

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 MOULDING ISSUE TREE AND CA

1. Pouring Delay Transfer cars (VW1 / VW 2 /VW

3 / VW4/TZ /ZL /Z6) / KEV2

Pattern change delays

2. Mould line B/D
Shakeout/ Manipulator /
Flowtex problem

FM stop

Oil Temp High / Oil leakage /

Hydraulic motor

Availability

3. Others

4. No Power

5. CCC B/D

6. Sand not avlbl

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 MOULDING ISSUE TREE AND CA

1. Pouring Delay
Bolster / filling unit /hopper/
shake out cleaning
2. Mould line B/D

CATF Correction
3. Others
Pattern correction work

4. No Power

Return casting from Fettling

Availability

CCC stop due to Fettling Prod

5. CCC B/D
CCC stop due to Maint.

Sand belt /OBMS / BE /MIXER /

COOLER stop due to Maint.
6. Sand not avlbl
Sand delay

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 MOULDING ISSUE TREE AND CA

Speed losses

S.
LOSS REASON POTENTIAL ROOT CAUSES IDEAS / LEVERS
NO

i. Ensure the availability of 10000KW power for

Power not available (6500KW melting
1 Speed losses
instead of 10000KW) ii. Ensure Cupola furnace to be operated on regular
basis
High Density steel scrap should be procured.
Use of low density raw matl Eg: Bundle steel & rolling Mill end cuttings instead of tar
steel
More Cycle
time(77min
1.a Time lost for slag removing Runner & riser can be Shot blasted / Tumblasted
instead of
60min/heat)
Time to adjust chemistry for high Planning of high alloy items/ same grade group items
alloy items continuously will reduce the time

Quality (waiting for chemical

Reduce the number of batches will reduce the time loss
comp)
3 Pouring Delay
Job change over should be max 3 times/ shift will
Job Change over
reduce this time by 15min max/Shift

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 MOULDING ISSUE TREE AND CA
Mould line B/D
S. LOSS
POTENTIAL ROOT CAUSES IDEAS / LEVERS
NO REASON
1. Due to failure in the proportional card the 1. Additional Protection circuit provided to prevent the failure
replacement of cards and downloading of Proportion cards
the program to the proportional cards. 2. The pallet plate broken is the main reason for the box
2. Box derailment in the transfer car and also derailment and hence the all broken pallet plates are
welding in support cylinder replaced and welding done in support cylinder
Transfer cars
(VW1 / VW 2 1. The cable connecting to VW1 transfer car 1. Identified the faulty cable and the same has been insulated
1. /VW 3 / got grounded properly. Rerouting of cable done to avoid the recurrence
VW4/TZ /ZL 2. Oil leak in cushioning cylinder of DZ1-6 2. Replaced the piston rod with hard chrome plating to avoid
/Z6) / KEV2 cylinder the leak
1. Magnet guide got bend due to metal
piece struck 1. Removed the metal piece and adjusted the bend.
2. JVH 19 hydraulic lock piston rod got 2. Broken area welded and made ready
broken
1. Replaced the drive with motor and PLC program modified.
Pattern 1. The Drives in AR1 and AR5 failed and
Drastic Reduction in time observed however the drive
2. change hence the delay also on occasion pattern
needs to be obtained to eliminate the delay. P.O for drive
delays changing done manually
raised and material expected by II week of Aug12
1.Manipulator Hydraulic hose damaged Replaced the hydraulic hose and fittings
1. The potentiometer value got disturbed and hence the value
1. Manipulator horizontal movement
Shakeout/ adjusted as per the instruction provided in the manual
problem.
Manipulator / 2. The seals of the pitch cylinder in the roll shaft arrangement
3. 2. Pitch cylinder not working
Flowtex replaced
problem Hydraulic hose got cut New hydraulic hoses are replaced
Shakeout motor failure due to failure in
New motor replaced.
bearings
 MOULDING ISSUE TREE AND CA

Mould line B/D

S. LOSS
POTENTIAL ROOT CAUSES IDEAS / LEVERS
NO REASON
Due to Oil contamination in the FM squeezing
The hydraulic valves replaced and oil filtration decided to be
zone hydraulic valve pressure did not develop
done once in 2 months.
leading to breakdown

FM hopper gate cable got grounded Faulty cable replaced

4. FM stop Fm multi-piston squeezing cylinder and turn

Replaced the oil seal for both the multi-piston and turntable
table oil seal failure due to aging factor

FM multi-piston hydraulic cylinder seal failure Replaced the oil seal

Oil got bypassed in FM squeezing station and

Operated the valve manually and valve replaced
hence pressure did not develop
Oil Temp
1. Replaced the cable with armored type to eliminate the root
High / Oil 1. Cable short in Cooling tower fan
5. cause
leakage/Hydr 2. Multi-piston hydraulic cylinder seal failure
2. Replaced the oil sea
aulic motor
 MOULDING ISSUE TREE AND CA

Others
S. LOSS
POTENTIAL ROOT CAUSES IDEAS / LEVERS
NO REASON
Bolster /
filling unit
Sand accumulation in the shake out an Perforated platforms can be provided, that avoids sand
1 /hopper/
shake out
that to cleaned accumulation.
cleaning
CATF
2 Valve/sensor problem occurs Valve/sensor replaced
Correction

CCC B/D
S. LOSS
POTENTIAL ROOT CAUSES IDEAS / LEVERS
NO REASON
Return casting from Fettling

Due to man power shortage in fettling.

CCC stop due to Fettling Prod
CCC B/D
1.
CCC stop due to Maint.
1. DUE TO SHEAR PIN CUT
1. Shear pin replaced with new one.
2. Due to motor failure
2. Motor replaced

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 MOULDING ISSUE TREE AND CA

Sand not available

S.
LOSS REASON POTENTIAL ROOT CAUSES IDEAS / LEVERS
NO
206 belt got cut due to falling of Replaced the distributor with
distributor (got broken) from 134 OHMW polymer and also Belt
Hopper replaced .
Suitable control provided for
236 bucket elevator buckets got
feeding with replacement of New
broken
buckets and started the production .
Cooler moisture probe got bend Collar wear plate welded and probe
due to strucking for collar wear bend corrected . Ordered for new
Plate moisture probe.
Sand belt /OBMS
/ BE /MIXER / BE 134 problem, 206 belt problem The fixing bolts in the ploughs of the
1. COOLER stop and cable short in pullchord of arm replaced to achieve better
due to Maint BE124 and BC 120. rotation and efficiency .
Sand temperature form the cooler Flow meter serviced and problem
found high. Solved.
The spring in the isolator got
Water Flow meter problem. damaged and hence the problem.
Replaced the spring
Sand plant dust collector isolator Due to aging factor the belt got cut .
problem New belt replaced.
BC120 belt got cut due to
New belt replaced
falling of material from shake out .

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