VFM ASSEMBLY

• MACHINE BREAKDOWN REPORT

• SUB ASSY ENGINE AND BACKUP HOIST NOT FUNCTION – DT 32.4

MIN
 UNDERSTANDING BREAKDOWN SITUATION

4W
WHAT HOIST BACKUP NOT FUNCTION , THE MAIN BREAKER (MCB)WAS
TRIPPED.

WHEN 19/3/21 , FRIDAY , DAY SHIFT AT 11:40 AM

WHERE SUB ASSY ENGINE ,CHASIS LINE , ASSEMBLY SHOP

WHO USER = TEAM MEMBER SUB ASSY ENGINE .

TROUBLESHOOTER = VFM ASSEMBLY TEAM
LAY OUT
 BASIC FUNCTION
1) THE STANDBY / BACKUP
HOIST WILL BE USED IF
THERE ARE ANY ISSUES /
PROBLEM RELATED WITH
HOIST ENGINE OR REAR
SUSPENSION HOIST .

2) THE STANDBY / BACKUP

HOIST USED DIFFERENT
ENGINE STANDBY / SPECIFICATION AND
HOIST BACKUP REAR SUSPENSION HOIST
HOIST MODEL COMPARE TO
BOTH ENGINE AND REAR
HOIST MAKER AND SPEC.
BEAM HOIST.
ENGINE HOIST –(DEMAG – DC PRO)

REAR SUSPENSION – (DEMAG –DC PRO)

BACKUP HOIST – (DEMAG – DKUN 5)

 PROBLEM TIMELINE / CHRONOLOGY
• At 4:00 am. The Engine Hoist had issue, cannot lifting up / down (intermittence).
• Arrangement to used BACKUP HOIST.
• Running backup hoist
• Troubleshoot engine hoist.
18/3/21 SHIFT A • UNTIL 7:00am. Still not OK
(NIGHT SHIT

• 8:00am continue troubleshoot ENGINE HOIST.

• CONTINUE RUNNING BACK UP HOIST.
19/3/21 SHIFT B
(DAY SHIFT) 8:00AM
~11:39AM

• PRODUCTION CALL BACK UP HOIST NOT FUNCTION

• FM ASSY TECHNICIAN check the problem found MAIN BREAKER (MCB) for BACKUP HOIST TRIPPED.
• FM ASSY TEAM troubleshoot BACKUP HOIST.
19/3/21 – (11:40AM
-12:00 PM)

• AFTER DISCUSS with production Assembly consider to used the ENGINE HOIST back due to long STOP TIME
• THE ENGINE HOIST still can USED due to the problem is minor ( LIFTING ISSUE SOMETIME OK , SOMETIME N/G. INTERMITTENCE.)

1:00 PM -1:45PM
 FLOW OF T. SHOOTING(ENGINE HOIST)

CHANGE 1 SET
CHANGE CABLE
ENGINE HOIST MOTOR FOR
PENDANT –
DISPLAY ERROR LIFTING. – RESULT
RESULT NG.
OK
 FLOW OF T. SHOOTING(BACKUP HOIST)

RUNNING HOIST
BACKUP HOIST ONN MCB AND
LONG TRAVEL
TRIPPED RUNNING
FWD REV.

FOUND FIRE
CHECK AT AREA
FOUND SOME SPARKING AT
SPARKING
WIRE WAS AREA MOTOR
( MOTOR CABLE
INJURED. TRAVEL AND MCB
TERMINAL BOX)
TRIPPED

CUT AREA
INJURED AND
BACKUP HOIST
MAKE NEW
RUNNING OK
TERMINATION
WIRE
 MAJOR BREAKDOWN REPORT Ref No. W/O 2 M

MA JOR BREA K DOWN REPORT Shop: ASSEMBLY Date 21/2/2021

Reason 1. Report prepared due to follow reporting standard 2. Report prepared due to management instruction SV / Ex ec A.M / Manager
1. Prompt / fast report MACHINE STOP TIME
ENGINE HOIST

Definition
8 9 10 11 12 1 2 3 4 5 6 7 8
2. Definite report

Report i tem Cause of the problem （ Estimate　・　Firmed ）

Date Occurred / Start Time 19/3/2021
Shop /Li ne name Assy / A2 li ne
AFFECTED AREA
Equipment Code / Name ART-0019 ENGINE HOIST
Li ne stop From 11.40 AM 32min stop(CUMM)
LOSS d ue to this breakd ow n

Fi nal line stop 32min stop

Ti me of machinery stop From 11:40 PM 32min stop
Ti me of Back up From min stop HOIST NO.1(MAIN)

Fai lu re, Parts repair HANGER EMPTY AT TRANSFER LIFTER 1

HANGER CANNOT T RANSFER T O T L-1
Over time cut 、 etc
HOIST NO 2 (BACKUP)
Restoration time T ime to find root cause 15min WIRE CUT AND SPARK
T otal repair time 17min AREA(TOUCHING WITH
HOIST BODY)
Claim downtime 32min
№ Chronology : start 　～ 　 end ( Situation of Process)
1 11:40 AM HOIST PICKUP ENGINE FROM PALLET TO TROLLEY STOP,CANNOT FUNTION
2 11:42AM FOUND ELCB FOR HOIST NO.2 TRIPPED
3 11.43AM ON ELCB FOR HOIST NO 2 & TRY OPERATE HOIST,ELCB TRIP ONCE AGAIN
4 11:45AM CHECK HOIST SUB BOX AT OVERHEAD,NO ABNORMAL FOUND
5 11:47AM TEST HOIST FUNCTION 0NE BY ONE & FOUND LONG TRAVEL FUNCTION
CAUSED THE ELCB TRIP.
6 11:50AM TRY TO PUT DOWN THE ENGINE HANGING ON THE HOIST ON TROLLEY-OK
7 12:00PM TRY TO MOVE HOIST TO STANBY AREA STILL NG BACAUSE LONG TRAVEL
CANNOT FUNCTION & CAUSED THE ELCB TRIP Find root cause with why-why analysis (5 why) № Contents of countermeasure PIC Date Result
8 12:02PM DECIDE TO LOOSEN FRICTION WHEEL NG HOIST & FORCE PUSH USING 1 HOIST NO.3 CANNOT FUNCTION 1 ARMI 28/2/2021
ARMI 28/2/2021 DONE

How to improv e
ANOTHER HOIST TO STANBY AREA - OK 2

repair time
9 12:04PM USE HOIST NO 2 THAT EARLIER NIGHT SHIFT(A) HAVE ISSUE WITH 2 ELCB FOR HOIST NO.2 TRIPPED
UP/DOWN FUNTION INTERMITTEN
10 12:06PM PRODUCTION BUILT UP BUFFER AT ENGINE SUB ASSY 3 WIRE FOR LONG TRAVEL CUT & TOUCHING WITH BODY
& ENGINE LIFTER BUFFER
11 12:12PM PRODUCTION CONTINUE TO RUN LINE AS USUAL 4 WIRE HARNESS PULL OUT FIR TERMINAL BOX 1 ARMI 21/2/2021 DONE

2 ARMI 22-24/2/21 DONE

02:45PM - CHANGE NEW UNIT HOIST FOR UP/DOWN FUNCTION SPEC DC PRO5-500.
06:00PM CHECEK HOIST NO.2(BACKUP)CONDITON THAT CAUSED ELCB TRIP FOR LONG

How to prev ent

re-oc c uranc e
(PDT) TRAVEL FUNCTION & FOUND POWER CABLE AT MOTOR TERMINAL BOX
HAVE CUT OFF A LITTLE BIT & HAVE SPARKING MARK ON CABLE.

This machinery 　1: 1st　　2: 2～5 years ago　　3: 3 month～2 years ago　　4: Less than three months Repair time analysis 1: Need to prepared.　2: Need to re-analyzed.　3: Re-analyzed is unnecessary 　4: Unnecessary to prepared
Failure frequency
Similar machinery 　1: 1st　　2: 2～5 years ago　　3: 3 month～2 years ago　　4: Less than three months Yokoten 1: Required (My shop, Others) 2: Required (Only to my shop) 3: Requied (Only to other shop) 4: Not requried
Resp. section 1: FMU 2: Production 3: Production Engineering (PE) 4: Property 5: ME 6: Machine maker 7: Others Request to production line 1: Required　 　　2: Not required　 PPC 1: Required 2: Not required
Item check

Classificat io n
o f ro ot cause

1: Repair mistake 2: Bad inspection, service, oiling (PM) 3: Late inspection, service, oiling (PM) 4: Miss plan of PM 5: Miss handling 6: Operation mistake 7: Interlocking NG 8: Unsuitable/Bad Adjustment
Root cause
10: Material not suitable 11: Structure not suitable 　　12: Specification not suitable.　　13: Late restoration　　20: Unknown cause
Long downtime (OK to choose >
1: Command mistake 2: Lack of machinery knowledge 3: Lack of basic knowledge 4: Lack of machine skill 5: Lack of electric skill 6: Bad working environment 7: Shortage of tool 8: No spare parts 10 Others
2)
Possibility to prevent throug h inspection 1: NG (OK)　2: Item not included as inspection point 3: Inspection frequency is long 4: Method/jdugement not suitable 5: Lack of skill 6: Cant stop machinery 7: Lack of manpower 8: Cannot go near/touch machine 10: Others
FMD1002-A
ENGINE HOIST – change new motor for lifting
BACKUP HOIST – Cover and insulate wire due to wire injured.

NO COVER COUPLING / GROMMET

MCB TRIPPED wire friction with motor terminal box

WIRE INJURED

WIRE INJURED
PUT WIRE COVER
AND INSULATED
 ACTION PLAN
# ITEM COUNTER MEASURE & ACTION PIC TARGET STATUS
PLAN

1 WIRE INJURED Put wire grommet or copling Shahril johar 19/3/21 done
DUE FRICTION cable to prevent friction at
WITH MOTOR motor terminal box
TERMINAL BOX
2 NO GROMMET / Issued PPC to PSD . And to Armi Fairuz 22/3/21 pending
COUPLING WIRE ensure and confirm every new Sidang
DURING machine are provide with wire
INSTALLATION grommet or coupling at terminal
box motor
3