POWER QUALITY CIRCLE OF T.S.R.T.

C WELCOMES
YOU ALL TO CCQC-2019.
Slide No.1
 T.S.R.T.C ZONAL WORKSHOP
UPPAL
We are public service oriented
corporation serving more than 3000
buses, i.e 59 Depots with Major
Aggregates like Engines, Gearbox,
FIP and Rear Axles for the smooth
transportation of the public in the
busses.
Our Moto is to safe, clean,
comfortable, punctual at an
economical fair to public.
Slide No.2
 From Nizam State Road
Transport Corporation

TO

Telangana State Road

Transport Corporation
Slide No.3
 CASE STUDY PRESENTATION ON

“ACCUMULATION OF TATA 1618 CRANKS DUE TO OIL

SEAL AREA WORN OUT CAUSING HUGE REVENUE
LOSS”

Slide No.4
 Q.C NO : 002
 Q.C NAME : POWER
 DAY OF MEETING : THURSDAY
 TIME OF MEETING : 15.30 – 16.30 HRS.
 CIRCLE ESTABLISHED : 1989
 PROBLEMS IDENTIFIED : 70
 PROBLEMS SOLVED : 52
 PRESENTED PROJECTS : 18
 NO OF MEETINGS HELD FOR
THIS CASE STUDY : 12
 PERCENTAGE OF
ATTENDENCE : 96%

Slide No.5
 LEADER Dy. LEADER
R.DHARAMRAJ P N K.YADAV

MEMBER MEMBER MEMBER

A.SHEKHAR R.LAXMAN B.SRINIVAS
Slide No.6
 Mrs J.KAVITHA
(WORKS MANAGER)
CO-ORDINATOR

Mr .R.LAXMA REDDY Mrs. B.SARITHA

ASST. WORKS MANAGER SUPDT(MECH.) TEAM GUIDE
FACILITATOR
Slide No.7
 CC QC NCQC
SECURED 1ST PLACE IN CCQC 1991, SECURED DISTINGUISHED Award's
1993, 1994, 1995, 1996. IN THE YEARS 1992, 2004, 2006, 2007,
2008,
SECURED EXCELLENT PLACE IN SECURED EXCELLENT PLACE IN
CCQC – 2009. NCQC 2009.

WE HAVE ALSO SECURED SILVER IN NCQC 2011 WE HAVE SECURED

PRIZE IN C.C.Q.C. IN THE YEAR 2011 & DISTINGUISHED PRIZE..
CCQC-2012 - GOLD PRIZE.
•WE HAVE SECURED GOLD AWARDS WE HAVE SECURED EXCELLENT
IN CCQC’2013 , 2014 & 2015, SILVER AWARD IN NCQC’2013 ,2014,2015
AWARD IN 2016 & GOLD IN 2017 & AND DISTINGUSHED PRIZE 2018.
Slide No.8
 WORK AREA AND NATURE OF WORK

WORK AREA NATURE OF WORK

 OVERHAULING OF TATA & A/L
ENGINES.
 CYLINDER HEADS.

ENGINE SECTION  AIR COMPRESSORS.

 CASE OIL COOLER PLATES.
 WATER PUMPS.
 TURBO CHARGERS & TESTING OF
VARIOUS TYPES OF ENGINES.
Slide No.9
 P.D.C.A. CYCLE
AFTER SETTING THE OBJECTIVES, WE CAN ACHIEVE
IT, BY FOLLOWING THE P.D.C.A. CYCLE OF DEMING`S
PRINCPLE TO SOLVE THE PROBLEM.

ACT PLAN

CHECK DO
NOTE:- We have followed PDCA Cycle methodology to solve the problem in 12steps.
Slide No.10
 12 STEPS FOR PROBLEM SOLVING
12
11
10
9
8
7
6
5
4
3
2
1
Slide No.11
 DEMING WHEEL

PLAN

Dr. EDWARDS
DEMING

IDENTIFICATION OF
PROBLEMS
Slide No.12
 PROBLEMS ON HAND

CATEGORY

1. HOUSE KEEPING. A
2. NO PROPER TOOL FOR REMOVING DAMPER PULLY. B
3. ADJUSTING OF MAIN CAPS. A
4.ACCUMULATION OF TATA 1618 CRANKS DUE TO OIL SEAL AREA WORN OUT
CAUSING HUGE REVENUE LOSS. B

5.HIGH ACCUMULATION OF CYLINDER HEAD CAUSING REVENUE LOSS . B

6. DEEP PITTINGS FOUND ON ROCKER FINGERS. A
7. DAMAGES TO AIR CLEANER HOUSINGS. B
8. TURBO CHARGER INLET BODYGETTING W/OUT. B
9. NO PROPER TOOL TO REMOVE OIL PUMP GEAR. B
10. FLY WHEEL PRESSURE PLATE MOUNTING HOLES OBLONG. B
11.CAMSHAFT CAMS ARE GETTING WORNOUT. B
12.ENGINE BLOCK BORE FOUND PITTING. B
13.NO PROPER TOOL TO REMOVE PISTONS FROM CYLINDER BLOCKS. A
14.PROVISION OF PNEUMATIC TOOLS. C
15. PROVISION OF LATEST HYDRAULIC MACHINE. C
16. PROVISION OF CONVEYOR BELT. C
17. PROVISION OF LOAD TEST BENCH. C
18. PROVISION OF AIR TANK TEST BENCH. A
19. TEST BENCH LIGHTING PROBLEM. Alide No.13
S
S.NO. PROBLEM CATEGORY
20. REMOVING OF DAMPER PULLY. C
21. PROVISION OF AIR POINTS . C
22. FLYWHEEL HOUSINGS CRACKS. B
23. UNEVEN SUMP SEATING. A
24. PROVISION OF ENGINE STANDS. C
25. UNEVEN CYLINDER BLOCK SURFACE. B
26 .UNEVEV CYLINDER HEAD SURFACE. B
27. ENGINE BLOCK BORE OBLONG. B
28. CRISS CROSS HOLES OBLONG. B
29. PITTING ON VALVE STEM TIP. B
30. PITTING ON VALVE FINGERS. A
31. PITTING ON TAPPET. A
32. HINO ENGINE BLOCK BORE SCORING. B
33. SEIZURE OF CRANK SHAFT MAIN JOURNALS. B
34. SEIZURE OF CRANK PINS. B
35. BREAKAGES OF FLY WHEEL BOLTS AT CRANK B
SHAFT REAR END.
36. CRANK SHAFT FRONT THREADS DAMAGE. B
37. DAMPER PULLEY BREAKAGES. B
38. PITTING/WEAR ON GEAR TEETH. B
39. WORNOUT OIL PUMP SHAFTS. C
Contd….
Slide No.14
S.NO. PROBLEM CATEGORY
40. WORNOUT OIL PUMP BUSHES. B
41. PITTING ON IDLER GEAR TEETH. C
42. WORNOUT SPINDLE. B
43. SURFACE CRACKS ON FLYWHEEL FACING. B
44. UNEVEN FLYWHEEL FACING. B
45. DOUBLE GROOVE FORMATION ON CRANK SHAFT B
REAR END.
46. SCORING ON AIR COMPRESSOR BORE. B
47. TAPPER/OVALITY A.C CYLINDER BORE. B
48. SCORING ON A.C CRANK JOURNALS. B
49. TAPPER/OVALITY ON A.C CRANK SHAFT JOURNALS. B
50. WORNOUT A.C CRANK THREADS. B
51. LEAKAGE OF A.C HEAD REED VALVES. A
52. BREAKAGES OF AIR CLEANER HOUSING BOTTOM B
PLUNGER.
53. WORNOUT WING NUT SEATING OF AIR CLEANER HOUSING. B
54. CLOSED AIR CLEANER ELEMENT. C
55. DAMAGE OF BROKEN (MESH) ELEMENT. C
56. WORNOUT CONNECTING ROD SMALL END BORE. B
57. REMOVAL OF OIL PUMP BUSHES. B
58. REMOVAL OF OIL PUMP DRIVE GEAR. B
59. HIGH ACCUMULATION OF ORDINARY AIR COMPROSSER BLOCK. B

Category Problems
A 10
B 38
C 11 Slide No.15
 DEMING WHEEL

PLAN

Dr. EDWARDS
DEMING

SELECTION OF PROBLEM
Slide No.16
CATEGORISATION OF PROBLEMS

A : SOLVING OF PROBLEMS BY SELF.

B : SOLVING OF PROBLEMS WITH THE
HELP OF OTHER DEPARTMENTS.
C : SOLVING OF PROBLEMS BY INTERVENTION
OF MANAGEMENT.

Slide No.17
Having a detailed study on failure and demand of Engines
at Depots, we have decided to take up TATA Engine failure
as Vital Problem among the, on hand problems for the
reasons given below:-

1. High Cost involved in procuring New TATA Crank

shaft.

2. Demand of Tata Engines are very high at depots and

production line.

3. To Increase the Production of Tata 1618 Engines .

Slide No.18
 SHORT LISTED FROM ON HAND PROBLEMS

1. TURBO CHARGER INLET BODY WORN OUT. (C)

2. AIR COMPRESSOR BLOCK BORE SCORING

& WORN OUT. (C)

3. HIGH ACCUMULATION OF TATA CRANK SHAFT

OIL SEAL AREA WORN OUT. (B)

Slide No.19
 ANALYSIS ON ACCUMULATION AND COST

Sl. Description Accumulation Unit Value (Rs.) Total Value

No.
1. Turbo Charger 20 2,215/- 44,300/-
2. Air Compressor 25 2,500/- 75,000/-
Block
3. TATA Crank shaft 30 29,228/- 8,76,840/-

Slide No.20
 PRIORITY CHART

TURBO CHARGERINLET
1 5 3 4 5 5 22
BODYWORNOUT. (C)
AIR COMPRESSOR
2 CYLINDERBLOCK BORE
3 6 5 6 4 24
SCORING &WORN OUT.
(C)

3 HIGH ACCUMULATION OF
4 5 8 8 7 32
TATACRANKSHAFT

• HIGH ACCUMULATION OF TATA CRANK SHAFT. (B) SELECTED”

RAKING METHOD 1 - 10

Slide No.21
 Leader : R. DHARAM RAJ
MlLESTONE CHART Dy. Leader : P.N.K. YADAV
Members : A.SHEKHAR
: R.LAXMAN
Quality circle name : POWER : B.SRINIVAS
Department : T.S.R.T.C
Project Name : HIGH ACCUMULATION OF TATA CRANK SHAFT CAUSING HUGE REVENUE LOSS

Starting Date: 03 JAN 2019 Ending Date : 28 MARCH 2019

PDCA Activity  \ Week  2 3 4 5 6 7 8 9 10 11 12 WEEKS

PLAN 3 Defining the Problem 1

  4 Analyzing the Problem 1

5 Identification of causes
  6 Find out the root cause 1
 DO 7 Data Analysis 1
8 Developing Solution 1

Foreseeing probable
 CHECK 9 Resistance 1

Trial, implementation and

checking performance
10 2
ACT 11 Regular implementation 1
  12 Follow up and review   3

Slide No.22
 DEMING WHEEL

PLAN

Dr. EDWARDS
DEMING

DEFINE THE PROBLEM

Slide No.23
 TATA Engines is giving trouble of oil Leakages, Low Oil
pressure, Vehicle Break Down and is New Model.
 Due to the above problems depots are sending the TATA
Engines to workshop

Worn out crank front oil seal area Slide No.24

 To supply Complete overhauled TATA Engines in
adequate numbers to depots.

 To educate Depot Maintenance Staff on Preventive

Measures & Maintenance to be taken to minimize the
Failures.

GOAL
 Complete Elimination of Accumulation of TATA Crank
shaft on Shop Floor.
Slide No.25
 FLOW DIAGRAM
START

TATA
ENGINES

STRIPPING

DEGREASING &
CLEANING

TATA ENGINES TAKING

SCRAP INSPECTION OK FOR
NO
PRODUCTION LINE
OK

ASSY OF TATA
NO ENGINES
FOR RETRIEVAL IF FOUND SUITABLE
N
O
NO TESTING OF
ENGINE
DISPATCH TO FOUND OK
DISPATCH DEPOTS
Slide No.26
 DEMING WHEEL

DO
Dr. EDWARDS
DEMING

ANALYZING THE PROBLEM

Slide No.27
 Initially M/s TATA Manufactured cummins Engines are fitted to vehicles
and supplied.

 TATA cummins Engines are fitted with crank shaft, Fip, water pump,
Cooler Plate, Air compressor & Pistion for Starting of Engines &
controlling Fuel Supply.

 TATA Engines are giving trouble’s like Oil leakage from Damper pulley
area
Low oil pressure & heavy engine oil consumption, hence they are being sent
to workshop.

 After dismantling the TATA Engines, while inspection we found that the
crankshaft front oil seating area worn out.

 Hence Tata Crank shaft are accumulated in our work shop floor .

Slide No.28
 DATA ANALYSIS

 ANALYSIS OF CRANK SHAFTS AVAILABILITY ON SHOP FLOOR.

A) TOTAL CRANK SHAFTS - 50

B) TATA CRANK SHAFTS - 30

C) A/L CRANK SHAFTS - 10

D) A/L MINI CRANK SHAFTS - 10

Slide No.29
 DEMING WHEEL

DO

Dr. EDWARDS
DEMING

IDENTIFICATION OF CAUSES BY BRAIN

STORMING

Slide No.30
 CAUSE & EFFECT DIAGRAM
HIGH COST OF
NEW CRANK SHAFT UNABLE TO SOLVE THE
PROBLEM AT DEPOT LEVEL

NEW MODEL
MATERIAL MEN LACK OF KNOWLEDGE AT
DEPOT LEVEL
SHORT
SUPPLY OF
NEW CRANK SHAFT

ACCUMULATION OF
TATA 1618 CRANK
SHAFT CAUSING
REVENUE LOSSES
ASSEMBLING AS
PER O.E MANUAL

MAINTENACE AS PER
O.E .
TATA 1618 NEW
MODEL ENGINE

METHOD MAINTENANCE
DUST ENTRY ON OIL
SEAL AREA

Slide No.31
ANALYSIS OF PROBLEM
BRAIN STORMING LACK OF
KNOWLEDGE
AT DEPOT
LEVEL

SHORT
SUPPLY OF
NEW CRANK
SHAFT

TECHNOLOGY
CHANGES

INCREASED
DEMAND FOR
TATA ENGINES
Slide No.32
 DEMING WHEEL

Step # 6
DO

Dr. EDWARDS
DEMING

FINDING OUT THE ROOT CAUSES

Slide No.33
 ROOT CAUSES

 AFTER BRAIN STORMING ON DEFECT AND CAUSES, IT HAS BEEN

FOUND THAT TATA 1618 C.O ENGINES ARE FAILING AT DEPOTS
CAUSING HUGE REVENUE LOSSES.

WHY OIL LEAKAGES IN ENGINES

WHY OIL LEAKAGE AT TIMING COVER AREA

WHY CRANK SHAFT FRONT OIL SEAL AREA

WORNOUT
WHY DUST ENTRY ON OIL SEAL AREA OF CRANK
SHAFT
HOW BY ANALYZING THE CAUSES & DEVELOPING
SOLUTION

Slide No.34
 DEMING WHEEL

DO
Dr. EDWARDS
DEMING

DEVELOP SOLUTION
Slide No.35
 BRAIN STORMING AND PROPOSED SOLUTIONS
During brain storming session following views were given by
our members.

R.LAXMAN TO TAKE SUGGESTION WILL NO

SUGGESTIONS NOT BE GIVEN BY
FROM O.E.M O.E.M
R.DHARAMRAJ TO PURCHASE HIGH COST INVOLVED NO
NEW TATA
CRANK SHAFT
P.N.K.YADAV REPLAC E WITH SLEEVES NOT NO
NEW SLEEVE ON AVAILABLE IN
WORN OUT AREA MARKET
A.SHEKHAR TO WELD WORN YES POSSIBLE YES
& OUT AREA OF OIL
B. SRINIVAS SEAL &
MACHINING

All The Circle Members Unanimously Agreed To Take Up

Suggestion No.4, On Trial Basis Duly Taking Management Approval.

Slide No.36
 DEVLOPMENT OF SOLUTION
We have selected one front Oil seal seating area worn out TATA
1618 Crank shaft for repair. The worn out area is welded with LH106
Electrode then machined the Welded area on L17 Lathe machine for
finishing to the STD size 63.5mm. After completion of repair crank is
loaded in the TATA block and completed the assembly of engine at
various stages from Timing stage to final stage and tested on test bench
and found ok with out any leakage.

Welded & Finshing the worn out oil seal Machining the welded area to
seating area STD size 63.5 mm Slide No.37
ASSEMBILING OF RECONDTIONED TATA CRANK
SHAFT OIL SEAL SEATING AREA AND FITMENT
OF DAMPER PULLY

Slide No.38
 TESTING OF TATA ENGINE

TEST BENCH FABRICATED BY QC TEAM INSPECTION OF ENGINE FOUND OK

Slide No.39
 DEMING WHEEL

CHECK

Dr. EDWARDS
DEMING

FORESEENG PROBABLE RESISTANCE

Slide No.40
 RESISTANCES APPREHENDED
BY MACHINIST

RESISTANCE REASON SOLUTION

WHILE MACHINING 6013 MS LH 106 LH
THE CRANK ELECTRODE USED ALLOYELECTRODE
FINISHING WAS NOT FOR WELDING . USED AND FINISHING
GOOD. ACHIVED .

Slide No.41
 DEMING WHEEL

CHECK

Dr. EDWARDS
DEMING

TRIAL IMPLEMENTATION AND

CHECKING PERFORMANCE
Slide No.42
 TELENGANA STATE ROAD TRANSPORT CORPORATION
o/o THE ASST. WORKS MANAGER
ZWS: UPL, DT: 27.02.2019

To,
THE POWER QUALITY CIRCLE,
ENGINE SECTION,
ZONALWORKSHOP, UPPAL,
T.S.R.T.C, HYDERABAD.

SUB: Approval for elimination of accumulation of TATA 1618 Cranks on shop floor –

Reg.

******

It is observed that the quality circle POWER has submitted data to eliminate accumulation of
TATA Cranks on shop floor after seeing the relevant data, it is felt to recondition the TATA Cranks
duly eliminating the accumulated TATA Engines. That the accumulation of TATA Engines will be
cleared and to supply the reconditioned TATA Engines to Depots to avoid loss of revenue to the
corporation.

Copy to: WM/ZWS/UPL for favor of information.

Slide No.43
Three nos. of Reconditioned Cranks Assembled to TATA 1618 C.O
Engines Tested and Issued To Three Different Depots And They Are
Running In Good Condition.
Feed Back From Depots
SL. MONTH
DEPOT REMARKS
NO. ISSUED

RUNNING IN GOOD
MIYAPUR- II March – 19
1 CONDITION TILL DATE

RUNNING IN GOOD
BHEL March – 19
2 CONDITION TILL DATE

RUNNING IN GOOD
3 MUSHEERABAD-II March – 19 CONDITION TILL DATE

Slide No.44
Cost of One New TATA Crank shaft - Rs. 29,228/-

Cost of Reconditioning Material & Man power - Rs.1800/-

Total cost saved on 30 No’s of TATA Cranks - Rs.8,22,840/-

(30 TATA Cranks are reconditioned till May ’2019)

SAVINGS ARE RECURRING IN NATURE

Slide No.45
 DEMING WHEEL

ACT

Dr. EDWARDS
DEMING

REGULAR
IMPLEMENTATION Slide No.46
 TELENGANA STATE ROAD TRANSPORT CORPORATION
OFFICE OF THE WORKS MANAGER, ZONAL WORKSHOP, UPPAL, DT 02.03.2019

To,
THE POWER QUALITY CIRCLE,
ENGINE SECTION,
ZONALWORKSHOP, UPPAL,
T.S.R.T.C, HYDERABAD.

SUB: Approval for elimination of accumulation of TATA Crank shaft on shop floor – Reg.

******

It is approved to take up the works of elimination of TATA Crank shaft on shop floor by
reconditioning TATA Cranks E3 No. on trail basis to TATA Depots i.e. Miyapur , BHEL and
Mufheerabad which operate long distance services in the month of March 2019 and there have still
running in good condition.

Copy to: AWM- I / ZWS/ UPL for follow up.

Having Taken The Approval Of Management, Q.C. Decision

Was Implemented From May-2019 onwards.
Slide No.47
 TELENGANA STATE ROAD TRANSPORT CORPORATION
OFFICE OF THE WORKS MANAGER, ZONAL WORKSHOP, UPPAL, DT 14.06.16

CERTIFICATE
After seeing the performance of TATA ENGINES Fitted with Recondition crank were sent
on Trail basis in the month of March’19 and the performance of the TATA Engines was found
Satisfactory and which are still running in good condition at the Depots.

It is appreciated that the POWER Quality Circle Members have done reconditioning of TATA
Crank and their working condition is satisfactory. Hence it is ordered to implement regularly from
May – 2019 onwards and review and followup the performance of reconditioned TATA Cranks every
month.

To,
THE POWER QUALITY CIRCLE,
ENGINE SECTION,
ZONALWORKSHOP, UPPAL,
T.S.R.T.C, HYDERABAD.

Slide No.48
 BEFORE
1.Production Holdup.
2. Short supply of TATA Cranks.
3.Vehicle Break down on
Roads due to Oil leakage.
4.Oil consumption more .
5.We could not meet demand of
depots.
6. Low oil pressure.
7. Vehicle’s off road for want of
TATA Engines (02).
AFTER
1. Production achieved.
2. Reconditioned (30) TATA Cranks
used.
3. No Break down .
4. No more oil consumption.
5. Demand full filled .
6. Oil pressure achieved.
7. No off road of vehicles (0).
Slide No.49
 DEMING WHEEL

ACT

Dr. EDWARDS
DEMING

FOLLOW UP & REVIEW

Slide No.50
 FOLLOW UP & REVIEW
Every Month we receive reports on performance of TATA
1618 Engines Fitted with Recondition Crank from depots. No
Failures are Reported till now.

Sl. Issued
Depot KMs
No. Date
1 MYP -II 12.05.19 40105
2 BHEL 25.05.19 39185
3 MSRD-II 30.05.19 38101
4 HYT- I 05.06.19 38110
5 RNG -II 12.06.19 38205
6 DSNR 22.06.19 33145

Slide No.51
 Since TATA Cranks are being reconditioned
in house and therefore accumulation of TATA
are totally eliminated.

 Preventive check list is sent to depots to carry out

proper maintenance.

Slide No.52
PREVENTIVE CHECK LIST TO DEPOTS.

Slide No.53
 Leader : R.DHARAM RAJ
MILESTONE CHART Dy. Leader : P.N.K.YADAV
Members : A.SHEKHAR
:R. LAXMAN
: B.SRINIVAS
Quality circle name : POWER
Department : T.S.R.T.C
Project Name : HIGH ACCUMULATION OF TATA 1618 CRANKS CAUSING REVENUE LOSS
Starting Date: 03 JAN 2019 Ending Date : 28 MARCH 2019

PDCA Activity  \ Week  2 3 4 5 6 7 8 9 10 11 12 WEEKS

PLAN 3 Defining the Problem 1

  4 Analyzing the Problem 1

5 Identification of causes
  6 Find out the root cause 1
 DO 7 Data Analysis 1
8 Developing Solution 1

Foreseeing probable
 CHECK 9 Resistance 1

Trial, implementation and

checking performance
10 2
ACT 11 Regular implementation 1
  12 Follow up and review   3

Slide No.54
• TATA Engines Fitted with Recondition Cranks are being given
on
counter exchange to Depots. (Before 5 per month now 15 per
month).
• 2 buses daily going Off road for want of TATA Engines were
eliminated.
• Purchasing of new TATA Cranks is minimized from 10 to
2 Nos.
• Amount saved on 30 TATA Cranks is Rs:8,76,840/-.
• Supply position of TATA Engines are improved up to
Expectations of depot’s. (Per month 15).

Slide No.55
1. Skill improved among team members.

2. Team sprit improved.

3. Communicating skills developed.

4. Confidence level boosted.

5. We could also improve morale among Non Q.C. members

on Shop floor.

Slide No.56
 FUTURE PLAN

TO AVOID TATA CYLINDER BLOCK

CRACKS Slide No.57
WE THANK
The Chief Guest.

The Dignitaries.

The Steering Committee.

The Machine shop for there

support.

The Distinguished
gathering at “CCQC - 2019”.

Slide No.58
 ANY
QUESTION
PLEASE

Slide No.62