start pages of report fot tpm tracking

TPM Tracking Device for Machine Shop

PROJECT REPORT

ON

“TPM Tracking Device For Machine Shop (H/W)”

SUBMITTED BY

Mr. KADAM GANESH R

Mr. KUMBHAR AMOL R

Mr. JADHAV RAHUL R

Under Guidance of

Dr. Mrs. S.B.PATIL

Dr.J.J.Magdum College of Engineering, Jaysingpur

DEPARTMENT OF ELECTRONICS ENGINEERING

Academic Year

2014-2015

Dr.J.J.M.C.O.E


Dr.J.J.Magdum College of Engineering, Jaysingpur.


CERTIFICATEThis is to certify that the project entitled,


Is being submitted in partial fulfilment of the requirement for the degree of Bachelor of

Electronics Engineering under Shivaji University during the academic year 2014-2015. This is

the result of original work completed by,

Mr. KADAM GANESH R.(Roll No.-74)

Mr. KUMBHAR AMOL R. (Roll No.-75)

Mr.JADHAV RAHUL R. (Roll No.-73)

And that, I have instructed and guided them for the said work from time to time and found them

to be satisfactory and progressive.

Dr. Mrs.S.B. Patil Prof. DR. Mrs. V. V. Patil

Guide H.O.D. (ELECTRONICS)

Prof. Dr. A. K. Gupta

Dr.J.J.M.C.O.E


Principal I/C

Dr.J.J.Magdum College of Engineering, Jaysingpur.


Academic Year

2015-2016

CERTIFICATE

This is to certify that, the project titled


Is presented before Department Research Committee (DRC) by

Sr. No. Name Roll No.

1. KADAM GANESH R 74

2. KUMBHAR AMOL R 75

3. JADHAV RAHUL R 73

Under Guidance of Dr. Mrs.S.B. Patil for the academic year 2014-2015.

The DRC has consented to give approval for the said project.

Head,

Department of Research Committee (DRC)

Department of Electronics Engineering

Dr.J.J.M.C.O.E


Index

Sr. No. Topic Page no.

1. Acknowledgement v

2. Synopsis viii

3. List of tables xix

4. List of figures xx

5. List of Abbreviations xxi

6. Introduction 1

7. Literature Review and Relevance 2

8. Hardware Implementation 6

9. Software Implementation 34

10. Discussions and Future Scope 44

11. References 47

Dr.J.J.M.C.O.E


ACKNOWLEDGEMENT

Gratitude is the hardest emotion to express often one does not find adequate words to

convey that entire one feels.

We are very thankful to Dr.Mrs. Patil S.B. our project guide who played defining role in

shaping this report. Without her constant support, guidance and assistance this report would not

have been completed. We are very much glad to express our gratitude towards her guidance.

Every help and friendly support which has been given by our guide.

We would also like to thank Prof.Dr.Mrs. V.V.Patil, H.O.D. Electronics Department who

with such derlying interest reviewed and endorsed this project report.

Mr. KADAM GANESH R

Mr. KUMBHAR AMOL R

Mr. JADHAV RAHUL R

B.E. (Electronics)

Dr. J. J. Magdum College of Engineering, Jaysingpur.

Date - __/__/2015

Place - Jaysingpur

Dr.J.J.M.C.O.E


CONTENTS

I. Index……………………………………………………………………………………iv

II. Acknowledgement………………………………………………………………….....v

III. Abstract………………………………………………………………………….....viii

IV. List of tables…………………………………………………………………………ix

V. List of figures…………………………………………………………………………x

VI. List of Abbreviations………………………………………………………………xiChapter 1: Introduction ………………………………………………………………..1

Chapter 2: Literature review…………………………………………………………..2

2.1 Literature review……………………………………………………………..2

2.2. Present theory and practices………………………………………………..4

Chapter 3: Relevance of work…………………………………………………………5

3.1 AVR based decision device……………………………………………………5

3.2 Ethernet protocol ……………………………………………………………..5

3.3 GUI system built in pc………………………………………………………...5

Chapter4: Hardware implementation………………………………………………...6

4.1 Block diagram…………………………………………………………………...64.2 Proteus based figure…………………………………………………………….7

4.3 circuit layout…………………………………………………………………..…8

4.4 list of component……………………………………………………………….10

4.5 power supply component………………………………………………...……12

4.6AVR ICATMEGA32………………………………………………...………...14

4.6.1 Features……………………………………………………...……………14

4.6.2 pin diagram………………………………………………………………..16

Dr.J.J.M.C.O.E


4.6.3 pin description…………………………………………………………….16

4.6.4 connections of ATMEGA35 IC………………………………………..…20

4.7 opamp IC LM358 21

4.7.1features……………………………………………………………..……...21

4.7.2 Connections of LM358………………………………………..………….22

4.8 LCD………………………………………………………………...………………23

4.8.1 pin description…………………………………………………………….24

4.9 temperature sensor IC LM35……………………………...……………………...25

4.9.1 features………………………………………...………………………….26

4.9.2 pin description……………………………...……………………………..27

4.9.3 electrical characteristics of LM35……...…………………………………27

4.10 voltage regulator IC 78xx series…………...…………………………………….28

4.10.1 features…………………………………………………………………..28

4.11MAX 232…………………………………………………………………………..30

4.11.1 features…………………….…………………………………………….30

4.11.2 pin out and pin description………………………………………………30

4.12 Relay……………………………………………………………………………….31

4.12.1 Advantages………………………………………………………….…...33

Chapter 5 :software implementation………………………………………………….34

5.1 software used…………………..…………………………………………...34

5.1.1 about VB.net……...……………………………………………….34

5.1.2 about SQL…………………………………………………………35

5.1.2.1 SQL server 2005…………………………………………………35

5.2 flow chart for software implementation…………………………………...37

5.2.1 operation……………………………………………………………38

Dr.J.J.M.C.O.E


5.3 flow chart for fill list view…………………………………………………..39

5.3.1 operation…………………………………….……………………...40

5.4 flow chart for report……………………………….………………………..42

5.4.1 Operation……………………………….…………………………...42

Chapter 6 :discussion and future scope………………….……………………………..44

6.1 discussion………………………………………………………………..…….44

6.2 advantages…………………………………………………………….………44

6.3 disadvantages………………………………………………………………....45

6.4 application……………………………………………………………………..45

6.5 future scopes…………………………………………………………………..46

References…………………………………………………………………………………47

Synopsis

Dr.J.J.M.C.O.E


DEPARTMENT OF ELECTRONICS ENGINEERINGDr.J.J.Magdum College of Engineering, Jaysingpur.

A

PROJECT SYNOPSISON

“TPM TRACKING DEVICE FOR MACHINE SHOP (H/W)”

.

SubmittedBy

1. Mr.KADAM GANESH R 482. Mr.KUMBHAR AMOL R 493. Mr. JADHAV RAHUL R 50

Under the GuidanceOf

Prof. Dr.Mrs.S.B.PATIL

Academic Year

Dr.J.J.M.C.O.E


2014 – 2015

Dr.J.J.M.C.O.E


Introduction:

TPM is a maintenance management program with the objective of eliminating equipment downtime. It focuses on overall equipment effectiveness, covering areas such as breakdowns, setups, an ability to maintain cutting tolerances, capacity and more.TPM which stands for “Total Productive Maintenance”. Maintenance is one of the areas in modern management to increase machine productivity and to produce quality products. This obviously improves equipment efficiency rates and reduces costs. So, our project consists of a well-conceived TPM implementation program not only improves the equipment efficiency and effectiveness but also brings appreciable improvements in other areas of the manufacturing enterprise. The circuit that we are going to design will control the operation of VMC machines used in industries. The records will vary by company, but at a minimum, they should include:

Date of problem Description of problem Time the machine was inoperable Problem resolution steps Final solution Permanent corrective action plans

CNC/VMC machines are used for atomizing purpose in industries to get accurate and fast product within less time. Our circuit will control the machines start cycle, stop cycle and if breakdown occurs at any time, it will ask for a reason.

Dr.J.J.M.C.O.E


Literature review:

1] Mr.Melesse Workneh Wakjira, Mr.Ajit Pal Singh evaluated the contributions of total productive maintenance(TPM) in the paper “TOTAL PRODUCTIVE MAINTENANCE: A CASE STUDY IN MANUFACTURING INDUSTRY”Global Journal of researches in engineeringIndustrial engineering (February 2012)

The purpose of this paper is to evaluate the contributions of total productive maintenance(TPM) initiatives towards improving manufacturing performance in Ethiopian malt manufacturing industry. The correlations between various TPM implementation dimensions and manufacturing performance improvements have been evaluated and validated by employing overall equipment effectiveness (OEE) in boiler plant. The research focuses upon the significant contributions of TPM implementation success factors like top management leadership and involvement, traditional maintenance practices and holisticTPM implementation initiatives, towards affecting improvements in manufacturing performance in the Ethiopian industry. The study establishes that focused TPM implementation over a reasonable time period can strategically contribute towards realization of significant manufacturing performance enhancements. The study highlights the strong potential of TPM implementation initiatives in affecting organizational performance improvements. The achievements of Ethiopian manufacturing organizations through proactive TPM initiatives have been evaluated and critical TPM success factors identified for enhancing the effectiveness of TPM implementation programs in the Ethiopian context.[1,2]

2] Mr. Sharma Kumar Rajiv& Mrs. Sharma Pooja explained the system reliability analysts/managers/engineers/ practitioners to conduct RAM analysis of the system in the paper “COMPUTING RAM INDICES FOR RELIABLE OPERATION OF PRODUCTION SYSTEMS” on 7th April 2012

The purpose of this paper is to permit the system reliability engineers/ practitioners to conduct RAM analysis of the system which may helps them to model, analyze and predict the behavior of industrial systems in a more realistic and consistent manner. Design/methodology/approach: Markova approach is used to model the system behavior. For carrying out study, Root Cause Analysis (RCA) of the subsystems is carried out and transition diagrams for various subsystems are drawn and differential equations associated with them are formulated. After obtaining the steady state solution the corresponding values of reliability and maintainability are estimated at different mission times.

Dr.J.J.M.C.O.E


Research limitations/implications: Based on the RAM analysis, possible maintenance strategies can be investigated which might help the plant personnel to improve the system effectiveness. Practical Implications: Without exercising much effort in developing complex system models, the proposed method for analyzing system performance may prove helpful to the reliability analysts/ engineers/practitioners to model analyze and predict the behavior of system more efficiently and resolve the RAM requirements of the system in unison. Originality/value: The simultaneous adoption of both qualitative (RCA) and quantitative (Markov approach) approach to analyze and obtain RAM indices for measuring the system performance helps the maintenance engineers to improve RAM aspects after understanding the failure behavior of component(s) in the system.[3]

3] P.Prakash, S.Kumar, T.Sakthieswaran they are explained or analysis the Total Productive maintenance (TPM) is an innovative approach which holds the potential for enhancing efficiency of production facilities. in the paper ” IMPLEMENTATION OF TOTAL PRODUCTIVE MAINTENANCE IN INDUSTRY – A CASE STUDY” International Journal of Engineering Trends and Technology (IJETT) - Volume4Issue4- April 2013

Total Productive maintenance (TPM) is an innovative approach which holds the potential for enhancing Efficiency of production facilities. TPM is a process that maximizes the productivity of equipment for its entire life. It demands significant change of work culture and radical restructuring of work. It eliminates breakdowns and promotes autonomous operator maintenance through day-to-day activities, which involve the total workforce. It fosters an environment where improvement efforts in safety, quality, cost, delivery and creativity are encouraged through the participation of all employees. It is a strategic management initiative to increase capacity and end the vicious cycle of breakdown or reactive repairs through the use of autonomous and predictive maintenance, as well as equipment modifications to facilitate optimum machine availability, quality and performance. TPM will drive the operational efficiency of a manufacturing environment and profitability of the organization. In our project we focus on studying the existing methods for rescheduling Section Layout, implementing 5S Principles in the shop floor, manufacturing systems management, and maintenance management and to improve the efficiency of process with TPM implementation. 5s is an integral step in TPM. It focuses on developing stability and standardization in the organization. It can provide benefits in areas from safety to quality.[4]

Dr.J.J.M.C.O.E


Relevance of work:

The AVR controller is the heart of system. It consist of segments, each designed for a specific purpose. They are;

1. AVR based decision device.2. Ethernet protocol to send data.3. GUI system built in P.C. to visualize the data as per company requirement.

1. AVR based decision device-

The circuit having AVR controller in it will take data from VMC machine. It will compare and sense the taken data with standard data which is already given to AVR controller through programming. The output of AVR processor is stored in EEPROM memory.

2. Ethernet protocol –

To send machine data to maintenance department the proper channel is required which is capable to visualize data received in company required manner. Ethernet is the most popular LAN technology in the world. It is an easy, relatively inexpensive way to provide high-performance networking to all different types of computer equipment.

3. GUI system built in P.C.

Graphical user interface that allows users to interact with electronic devices through graphical icons and visual indicators such as secondary notation, as opposed to text-based interfaces, typed command labels or text navigation. GUIs were introduced in reaction to the perceived steep learning curve of command-line interfaces which require commands to be typed on the keyboard.

Dr.J.J.M.C.O.E

http://en.wikipedia.org/wiki/Computer_keyboard

http://en.wikipedia.org/wiki/Command-line_interface

http://en.wikipedia.org/wiki/Learning_curve

http://en.wikipedia.org/wiki/Text-based_user_interface

http://en.wikipedia.org/wiki/Text-based_user_interface

http://en.wikipedia.org/wiki/Secondary_notation

http://en.wikipedia.org/wiki/Icon_(computing)

http://en.wikipedia.org/wiki/Human%E2%80%93computer_interaction

http://en.wikipedia.org/wiki/User_(computing)

http://en.wikipedia.org/wiki/User_interface


Proposed Work:

BLOCK DIAGRAM

<Fig.> Block schematic of TPM tracking system for machine

The above block schematic shows the block representation of TPM tracking system for machine shop. System will take data from VMC machine. Parameters of VMC machine will act as an input to our system. AVR controller has some standard values which are given already to it through programming as per requirement of maintenance department. The EEPROM memory is interface with controller in order to expand memory capacity and keep record of data. The system also consists of prototype simulator [1]. The simulator is nothing but one of the software. The reason behind using the simulator is to get the machine data directly near machine place. In most of industries they favor to send their data through wired medias. But in our system we are using the rules of Ethernet protocol to send data from AVR controller to maintenance department. Ethernet is the collective name for a variety of closely related network standards. As a network standard, each version of Ethernet includes specifications for the physical network layer: how the signals will be sent and received. Protocols like IP or NetWare, in contrast, define communications without reference to the physical transport medium. It treats the various

Dr.J.J.M.C.O.E

VMC

Machine

AVR

Controller

Ethernet

Protocol

Prototype

Simulator

EEPROM P.C.

GUI


Ethernet standards as if they were protocols, discriminating among them based on the unique form each one gives to packet headers.

The data receive by manufacturing department should follow their standard format. In order to convert the information coming from machine into standard manner we have designed one software which takes data and merge it into their standard format. The GUI system is connected with P.C A graphical user interface (GUI) is a human-computer interface that uses windows, icons and menus and which can be manipulated by a mouse . GUIs stand in sharp contrast to command line interfaces, which use only text and are accessed solely by a keyboard[2]. A window is a rectangular portion of the monitor screen that can display its contents program independently of the rest of the display screen. A major feature is the ability for multiple windows to be open simultaneously. Each window can display a different application, or each can display different files that have been opened or created with a single application.

Dr.J.J.M.C.O.E

http://www.linfo.org/icon.html

http://www.linfo.org/window.html


Proposed Methodology:

The method employed for the development of “TPM Tracking Divider for Machine Shop” is divided into two parts: Software and Hardware sections.

1. Software Section-

Industries preferres to get data in simplified manner there are certain rules and their fixed units in which data can be viewed. In case if any obstacle occurs while production, it should be observed quickly. This project software will be developed which helps to get machine data transmitted by the system can be easily viewed on maintenance department computer and into their required format.

To prepare software in order to display data in standard manner “.net” software will be used.

2. Hardware Section –

In hardware part we are going to sense the data from VMC machine through RS232 cable. The data taken from machine is compared with standard value of machine data which is already fixed in AVR through programming. The system which will be designed will control the start cycle and stop cycle. In start cycle system will take data as serial code, machine input, job/component I.D., operation I.D. The system will also take time and date of shift code. In stop cycle, system will ask for what is reason to stop machine and up to what time the machine will remain in off state. Also to expand memory capacity in order to store data permanently EEPROM memory is interface with AVR. To send data proper system is designed which is compatible with Ethernet protocol. There are following tasks;

1) Developing PCB with AVR controller.2) Memory interfacing circuit.3) Data transmitting circuit of Ethernet protocol.

Dr.J.J.M.C.O.E


Facility required:

1) AVR development board.2) PCB designing Lab.3) AVR IC burner.4) Regulated power supply.5) Ethernet channel6) Software tool for data displaying.

Dr.J.J.M.C.O.E


Signature:

Dr. Mrs. S.B. Patil Mrs. M.U.Phutane

Project guide Project Co-ordinator

Signature of students:-

Name of students signature

Mr. Sagare Avdhoot A.

Mr. Hirave Vishal T.

Mr. Sawant Rohan R.

Dr.J.J.M.C.O.E


REFERENCES:

1. Mr.Melesse Workneh Wakjira, Mr.Ajit Pal Singh “TOTAL PRODUCTIVE MAINTENANCE: A CASE STUDY IN MANUFACTURING INDUSTRY” Global Journal of researches in engineering. Industrial engineering (February 2012) Volume 12 Issue 1 Version 1.0 February 2012

2. Ahuja, I.P.S. & Khamba, J.S. (2007). “An evaluation of TPM implementation initiatives in an Indian manufacturing enterprise”. Journal of Quality in Maintenance Engineering 13(4), 338-52.

3. Mr. Sharma Kumar Rajiv& Mrs. Sharma Pooja “COMPUTING RAM INDICES FOR RELIABLE OPERATION OF PRODUCTION SYSTEMS” on 7th April 2012 Advances in Production Engineering & Management 7 (2012) 4, 245-254 ISSN 1854-6250 Scientific paper

4. P.Prakash, S.Kumar, T.Sakthieswaran “Implementation of total productive maintenance in industry – a case study” P.A.College of Engineering and Technology,International Journal of Engineering Trends and Technology (IJETT) - Volume4Issue4- April 2013

Dr.J.J.M.C.O.E


List of Tables

Sr. No.

Table Name Page No.

4.1 List of Components 11

4.2 Pin Description of 7805 13

4.3 Pin Description of ATMEGA32 19

4.4 Pin Functions of LCD 24

4.5 function of pins of LM35 26

4.6 Electrical characteristics LM-35 27

4.7 pin functions of MAX 232 30

Dr.J.J.M.C.O.E


List of Figures

SR.NO. Figure Name Page No.

4.1 Block diagram for project 6

4.2 AVR controller circuit 7

4.3 Three phase sensing and temperature control 7

4.4 AVR controller circuit 8

4.5 Three phase sensing and temperature control 9

4.6 Power Supply 12

4.7 Regulator 12

4.8 Pinout of IC ATMEGA 32 16

4.9 Physical IC Photograph 19

4.10 Physical IC Photograph in SMD package 19

4.11 pin out of LM 358 OP-amp 21

4.12Opamp IC LM 358 22

4.13 LCD Display 23

4.14 Temperature sensor IC LM35 25

4.15 Pin Description of LM35 26

4.16 IC 7805 Pin diagram 28

4.17 IC 7805 Block Diagram 29

4.18 pin out of MAX 232 30

4.19 Relay 32

5.1 Starting window of VB 345.2 window of SQL server 2005 36

5.3 flow chart for form 1 37

5.4 window of frame 1 38

Dr.J.J.M.C.O.E


5.5 FLOW CHART FOR FILL LIST VIEW 39

5.6 window of creation of table 40

5.7 window of table filled with data 41

5.8 FLOW CHART FOR REPORT 42

5.9 window of graphical representation Fig 43

List of Abbreviations

Dr.J.J.M.C.O.E


No Name1 CNC – Computer Numeric Machine2 VMC -Vertical machine control3 PCB – Printed Circuit Board4 ADC – Analog to Digital Converter5 LCD – Liquid Crystal Display6 LED – Light Emitting Diode 7 IC – Integrated Circuit 8 VB-visual basic9 SQL- Structured query language

Dr.J.J.M.C.O.E


Dr.J.J.M.C.O.E

start pages of report fot tpm tracking

Engineering

machine shop dr

patil dr

electronics department

machine shop hw

kumbhar amol r

jadhav rahul r

kadam ganesh r

magdum college of engineering