A Presentation on Practical Training at

EICHER ENGINES, ITARANA ROAD,ALWAR (RAJ.)

(A unit of tafe motors & tractors ltd .Alwar)

Department of Mechanical Engineering,Laxmi Devi Institute of Engineering & Technology, Chikani, Alwar

Session: 2010-2011

Products

• Automotive Engine

• Stationary Engine

• Cooling technology based: • Cooling technology based:

a) Air cooled

b) Water cooled

Products

• Cylinder technology based:

a) Single cylinder - air cooled,

b) Double cylinder - air cooled,b) Double cylinder - air cooled,

c) Triple cylinder - air cooled,

d)Triple cylinder - water cooled.

In-House Machining Component

• Single Cylinder

1. Carter

2. Control housing

3. Cylinder head3. Cylinder head

4. Cooling jacket

5. Integra liner

6. Crank shaft

7. Fly wheel balancing

8. Blower fan balancing

In-House Machining Component

• Multi Cylinder

1. Crank housing 298

2. Crank case 398

3. Cylinder head

4. Cylinder liner

5. Blower assembly 298

6. Blower assembly 398

In-House Machining Component

• Valtra Water Cooled

1. Cylinder block

2. Cylinder head

3. Front cover3. Front cover

4. Gear housing

5. Fly wheel casing

6. Fly wheel housing

7. Cylinder liner

AFFECT CHECK QUESTIONNAIRE -1

Q1.Pick the correct in-house-machining

component for single cylinder:

(a) Gear housing (b) Crank case 398

(c) Cooling jacket(c) Cooling jacket

Q2.Give the name of type of engine produced in

this division.

Q3.Which award is for technical specification?

(a) ISO-9001 (b) TS-16949 (c) ISO-14001

Value System

• Total Productivity Maintenance

(TPM)

• 5s• 5s

• Process Improvement

What is TPMTPM

TPM Means

Total Profit Management

Total Product ManufacturingTotal Product Manufacturing

Total Productive Maintenance

Total People Management

ProductionProductivity =

Productivity - Definition

CostProductivity =

Simultaneously

OBJECTIVES OF TPM• Achieve Zero Defects, Zero Breakdown and

Zero accidents in all functional areas of the

organization.

• Involve people in all levels of organization.• Involve people in all levels of organization.

• Form different teams to reduce defects and

Self Maintenance

Direct Benefits Of TPM

• Increase productivity and OPE (Overall Plant Efficiency) by 1.5 or 2 times.

• Rectify customer complaints.

• Reduce the manufacturing cost by 30%.• Reduce the manufacturing cost by 30%.

• Satisfy the customer’s needs by 100 % (Delivering the right quantity at the right time, in the required quality)

• Reduce accidents.

• Follow pollution control measures.

Indirect Benefits of TPM

• Higher confidence level among the employees.

• Keep the work place clean, neat and attractive.

• Favorable change in the attitude of the

operators.operators.

• Achieve goals by working as team.

• Horizontal deployment of a new concept in all

areas of the organization.

• Share knowledge and experience.

• The workers get a feeling of owning the

machine

AUTONOMOUS MAINTENANCE (JH)

• Concept of people who operate a

machine should also maintain the

machine. machine.

• Starts with basic lubrication,

cleaning, inspection & then turns to

repairs.

Reasons Why Autonomous Maintenance is RequiredNo satisfactory increase in the performance

record can be seen …

Activities to prevent

equipment degradation

Activities to keep record

on equipment

degradation• Confirmation of

working conditions

• Daily inspection

• Periodical inspection

• Keep cleaning

• Inspection

• Additional

tightening

• Frequent servicing

• Solution of abnormality

• Good communication

Activities to restore

the machine

conditions

Production

MaintenanceTPM

Japanese

style of PM

Maintenance

Department’s

sole

responsibility

U.S style of PM

Preventive

Maintenance

1. MINOR FLAWS

2. UNFULFILLED BASIC CONDITIONS

3. INACCESSABLE PLACES

7. UNSAFE PLACES

4. CONTAMINATION SOURCES

5. QUALITY DEFECT SOURCES

6. UNNECCERY AND NON-URGENT ITEMS

1. MINOR FLAWS :

Contamination Dust, Dirt, powder, oil, grease, rust, paint

Damage Cracking, crushing, deformation, chipping,

bending,

Play Shaking, falling out, tilting, eccentricity,

wear, distortion, corrosion,wear, distortion, corrosion,

Slackness Belts, Chains

Abnormal

Phenomenon

Unusual noise, overheating, Vibration,

strange smells, discoloration, incorrect

pressure or current

Adhesion Blocking, hardening, accumulation of

debris, peeling, malfunction

2. UNFULFILLED BASIC CONDITIONS

Lubrication Insufficient, Dirty, Unidentified,

unsuitable, Leaking

Lubrication

Supply

Dirty, damaged or deformed lubricant

inlets, faulty lubricant pipes

Oil level gauges Dirty, Damaged, leaking, No indication of

correct level

Tightening Nuts and Bolts slackness, Missing,

Cross-threaded, Too long, Crushed,

Corroded, Unsuitable washers, wing

nuts on backward.

Cleaning Machine construction, Covers, Layout,

footholds, Space

Checking Construction, Covers, Layout, footholds,

Instrument position and Orientation, Operating –

Range display

Lubricating Position of lubricant inlet, construction, height,

3. INACCESSABLE PLACES

Lubricating Position of lubricant inlet, construction, height,

footholds, lubricant outlets, space

Tightening Covers, Construction, Layout size, Space

Operation Machine layout, Position of valves, Switches

and leavers, Footholds

Adjustment Position of pressure gauges, thermometers,

flow meters, moisture gauges, vacuum gauges,

etc.

Product Leaks, Spills, Spurts, Scattering, Overflow

Raw materials Leaks, Spills, Spurts, Scattering, Overflow

Lubricants Leaking, Spills, Seeping oils, Hydraulic fluids,

Fuel oils, etc.

Gases Leaking compressed air, gases, steam,

vapors, exhaust fumes, etc.

4. CONTEMINATION SOURCES

vapors, exhaust fumes, etc.

Liquids Leaking water, Hot, Cold, half finished

products, Waste water, Leaking supply lines

etc.

Scrap Flashes, cuttings, packaging materials, and

non conforming products.

Others Contaminants by people & Forklifts,

Infiltration through cracked walls, broken

windows etc.

Foreign

Matter

Dust, Rust, powder, chips, moisture, wire

scraps, wood pieces, paper pieces, stones

etc.

Shock Dropping, Jolting, collision, Vibration etc.

Moisture Too little or Too much, infiltration

5. QUALITY DEFECT SOURCES

Gain Size Abnormalities in screens, Compressed air

separators, centrifugal separators,

Concentration Inadequate warming, heating,

compounding, mixing, evaporation, stirring

etc.

Viscosity Inadequate warming, heating,

compounding, mixing, evaporation, stirring

etc.

Machinery Pumps, fans, compressors, columns, tanks

etc.

Piping

equipment

Pipes, hoses, ducts, valves, dampers etc.

Measuring

instruments

Temperatures, pressure gauges, vacuum

gauges, ammeters etc.

6. UNNECCERY AND NON-URGENT ITEMS

Electrical

equipment

Wiring, piping, power leads, switches, plugs

etc.

Jigs & Tools General tools, cutting tools, jigs, molds,

dies, frames etc.

Spare parts Standby equipment, spares, permanent

stocks, auxiliary materials, etc.

Makeshift

repairs

Tape. String, wire, metal plates etc.

Floors Unevenness, cracked, holes, projections,

peeling, wear of steel chucker plates, slipping.

Steps Too steep, irregular, slipping, missing handrails,

etc.

Lights Dim, out of position, dirty or broken covers, no

explosion proofing, etc.

7. UNSAFE PLACES

explosion proofing, etc.

Rotating

machinery

Displaced, fallen oil or broken covers, not safe

for emergency, missing emergency stop devices

Lifting

Devices

Wires, hooks, brakes and other parts of cranes

and hoists etc.

Others Special substances, solvents, toxic gases,

insulating materials, danger signs, protective

clothing etc.

EXAMPLE OF ABNORMALITY

( LOOSE FITTINGS )

EXAMPLE OF ABNORMALITY

( LEAKAGES )

Equipment Name ………………

Control No……………………..

Date of detection……………….

Detected by……………………..

Red Tags to be attended by Maint.

Equipment Name ………………

Control No……………………..

Date of detection……………….

Detected by……………………..

White tags for operators

Detected by……………………..

Description of Minor defects

………………………………….

…………………………………..

………………………………….

Description of Minor defects

………………………………….

…………………………………..

………………………………….

KAIZEN

• Japanese word kaizen means improvement.

• Kai means change or ‘the action to correct’.correct’.

• Zen means good.

• Therefore, kaizen = change for improvement/good.

Loss Category

1. Failure losses - Breakdown loss

2. Setup / adjustment losses

3. Cutting blade loss

4. Start up loss

5. Minor stoppage / idling loss.

6. Speed loss - operating at low speeds.

7. Defect / rework loss

Losses that impede

equipment efficiency

CHECK FOR 16 MAJOR LOSSES IN ORGANISATION

7. Defect / rework loss

8. Scheduled downtime loss

9. Management loss

10.Operating motion loss

11.Line organization loss

12.Logistic loss

13.Measurement and adjustment loss

Loses that impede

human work efficiency

14.Energy loss

15.Die, jig and tool breakage loss

16.Yield loss.

Loses that impede

effective use of

production resources

The PDCA cycle

PLANNED MAINTENANCE

• Aimed to have trouble free machines and

equipments producing defect free products for

total customer satisfaction

• Unplanned maintenance create problems like • Unplanned maintenance create problems like

a) huge inefficiencies in maintenance labor.

b) confusion and disturbance in scheduling,

production and other areas.

c) Morale problems

Planned maintenance aims at:

• Achieve and sustain availability of

machines

• Optimum maintenance cost.

• Reduces spares inventory.

• Improve reliability and maintainability

of machines

Comparison of Planned Maintenance with and without TPM

AFFECT CHECK QUESTIONNAIRE-2

Q1. What is the main objective of TPM ?

Q2. What is the concept of ‘autonomous

maintenance’?

Q3. List the abnormalities to be checked for JH.

Q4. How & when to use the red & white tags?

5sWhat is

Sei-riSei-ri

整理整理整理整理

Meaning in Japanese context:Throw away all rubbish & unrelated material in workplace.

Industrial definition:

Seiri= Sort

Industrial definition:To distinguish between necessary thingsand unnecessary things.

Typical Seiri Activities

•Eliminate defects and breakage

•Organize the warehouse

BEFORE AFTER

整頓整頓整頓整頓

Meaning in Japanese context:

Set everything in proper place for quick

retrieval & storage.

Seiton = stabilize/organize

retrieval & storage.

Industrial definition:

It is a way of eliminating

search.

30 Second Rule

30 Second Rule

Fig 1: condition of tools before Seiton

Fig 2: tools after implementing Seiton,30 second rule

清掃清掃清掃清掃

Seiso = Shine/Clean

Definition:

Eliminating trash, filth, and foreign Eliminating trash, filth, and foreign

matters for a cleaner workplace.

Cleaning as a form of inspection.

•Clean the workplace;

•Everyone should be a janitor

Key Points:

Keep things clean

+ Inspection

Key Words:

(Caring attitude)

+ Inspection

•Quick 5S drill

•Sparkling clean campaign

•Everybody is a janitor

Typical SEISO Activities

Broom

Mop

Dust pan

清潔清潔清潔清潔

Seiketsu = Standardize

Meaning in Japanese context

Standardize the way of maintaining cleanliness

INDUSTRIAL DEFINITION

Keeping things organized, neat

and clean; in personal and

environmental aspects.

SeitonSeiri

environmental aspects.

Seiso

• Make quality manual• Directional markings•Color-coded pipes

Typical Seiketsu Activities

Before After

DIRECTIONAL MARKINGS

Indication marks for nuts & bolts

Indication for valve controls

躾躾躾躾

Meaning in Japanese context:

Practice ‘5s’ daily- make it a way of

Shitsuke = Self-discipline

Practice ‘5s’ daily- make it a way of

life; this also means ‘commitment’.

AFFECT CHECK QUESTIONNAIRE-3

Q1. Name the value system followed in the

organization:

Q2. 1s stands for:

(a) Shine (b) Sort (c) Standardize(a) Shine (b) Sort (c) Standardize

Q3. 2s stands for:

(a) Stabilize (b) self-discipline (c) Sustain

Q4.What is a ‘30 second rule’?

Safety Rules

• Wear shoes, tight & clean clothes (trouser and shirt) at work

• It is required from everyone to use spectacles for the protection of eyes.spectacles for the protection of eyes.

• Proper use of ‘safety equipments’ is a must.

• Use mouth mask and safety shoes while painting.

Continue….

Safety Rules

• Use specs while working at grinder &

washing machine.

• On finding some unusual noise, smoke • On finding some unusual noise, smoke

or condition immediately switch off

machine & inform the supervisor.

• In case of fire inform ‘main gate’

(tel.ph.200 or 206) and shout FIRE &

come out at emergency collecting point.

Rules For Production

• Work according to rules & regulations

and instructions written in OS/AOS.

• Use critical instruments like vernier, • Use critical instruments like vernier,

TPG etc. and check CMM.

• Use special instruments according to

OS.

• Change or mend the hammer before its

surface gets round or damaged. Continue…

Rules For Production• During the shift ensure that adjuster on

the tork rinch should not be below tape marking.

• Don’t try to tighten further once tightened • Don’t try to tighten further once tightened by the oil pulse tool.

• Avoid and stop defects. If you have any suggestions regarding it give it to the supervisor.

• Learn from mistakes, don’t repeat them

Continue…

Rules For Production• While punching number take a note to

put stamp first in which 12 digits should be punched & punching should not be light.light.

• Clean the punch once a month and

change it after every 3 months.

• Give suggestion regarding increase of ‘Production Output’.

ISO-14001 Instructions

• Switch off fans, cooler, lights of your

work place while going for tea,

lunch/dinner and at the end of shift.

• Close taps after usage.

• Stop the leakage of air, coolant and oil

during work.

ISO-14001 Instructions

• Avoid spilling of oil, chips, paper,etc.

Throw the wastage like paper, cloth,

plastic in specified dustbins i.e. RED,

BLUE and GREEN. BLUE and GREEN.

Autonomous Check Sheet

• Take complete information about check sheet.

• Operators have to fill the autonomous check sheet while taking of the following check sheet while taking of the following points:

1) Operator has to fill the pre-control chart and data sheet.

2) Is there any problem with fixtures?

Continue…

Autonomous Check Sheet

3) Is the level of hydraulic oil, lubricant oil and coolant level correct?

4) Is air pressure, hydraulic system pressure correct?pressure correct?

5) Is sound from machine normal?

6) Has reliever removed chips and dust from machine?

7) Is there any kind of leakage in machine?

Continue…

Autonomous Check Sheet

8) Are the meters on the machine working properly?

9) Has the condition of cutting tools been checked?checked?

10)Are all the push buttons, switches, indication lamp working properly?

11) Is component’s all documents attached to the machine?

Continue…

Autonomous Check Sheet

12)Are all the tools, gauges, fixtures and rotate parts cleaned and placed at their fixed place?

Note: In case of negligence of any of the Note: In case of negligence of any of the above points inform the supervisor without the further delay

Complete work on time while maintaining discipline.

TS & 5s Instructions

• Decide what is needed and what is not

needed at the work place. Remove the

things which are not needed and put a 1s

tag on them and keep them at specified tag on them and keep them at specified

place.

• Don’t overload the trolley and after using

it keep it at the right place.

Continue…

TS & 5s Instructions

• Gang way should be absolutely clear and

nothing should be laid there.

• Place the component only on the

conveyor, trolley or machine. And not on

the floor/platform.

• Don’t put anything (finish/scrap/tools etc)

on the floor.

Continue…

TS & 5s Instructions• Don’t throw duster or gloves near

machine or inside tank or on the floor.

• Have to clean the resting face of fixture after every piece.after every piece.

• At the end of shift clean the side ways, glide ways.

• Follow the standards designed for the workplace.

Continue…

TS & 5s Instructions• Keep the rejection/rework products aside,

do know the reason of rejection/rework and mark it. Mark the component with the marker, keep it at the specified place the marker, keep it at the specified place at the end of shift before leaving the workplace.

• Take care of cleanliness of the work place.

AFFECT CHECK QUESTIONNAIRE-4

Q1.What would you do in case of an emergency?

Q2.When should punch be cleaned & changed?

Q3.What kind of waste will you dispose off in

RED, BLUE & GREEN dustbins?RED, BLUE & GREEN dustbins?

Q4.What is to be done to utilize ‘ideal time’?

Q5. What will you do if any component is

rejected?

AFFECT CHECK QUESTIONNAIRE-4

Q6.How will you check oil & coolant level?

Q7.Where to use (a) ear plugs (b) safety goggles

(c) gloves?

Q8.How to check tool condition?Q8.How to check tool condition?

Q9.How will you check drill/tap sizes?