tpm progress by kandakure engineering pvt ltd-i plot no-105 midc shendra aurangabad oct-nov - 2012...

TPM Progress By Kandakure

Engineering pvt Ltd-I Plot No-105 MIDC shendra AURANGABAD

Oct-Nov - 2012

“Achieve Excellence Through TPM”

“The Prime Mover towards excellence”

TPM Award Targets & Status

ParametersBenchmarkAvg.

AwardCriteria

TargetsJune-

12July-12

Aug-12

Sep-12

Oct-12

Nov-12

Status

1S/ 2S

1S/2S self assessment score

--- 100% 100% 81% 84% 85% 89% 88% 85% Work in progress

MH

Material Handling-As per agreed norms in visually countable container

--- All Parts All Parts All

PartsAll

Parts

All Parts

All Parts

All Parts

All Parts Achieved

E & T

Awareness of QM,JH & KK pillar activities

-- 100% 80% 78% 80% 83% 85% 83.4 Not Achieved

Q

Customer Complaints (Occurrence) (Nos.)

---Zero 0 04 05 12 10 02 3 Not Achieved

Customer complaint (PPM)

---Bronze award criteria

0 850 834 933 604 31 1290 Not Achieved

In-house Rejection (PPM)

60% Down

50 870 850 1456 1990 980 2096 Not Achieved

C Cost of Manufacturing (Rs)

----20%

Down-- - - - - - - --

D Delivery Adherence (%) 100% 100% 95% 95% 95% 95% 98% 92% Not Achieved

S Accidents - Major (Nos. / Month) 0 0 01 00 0 0 0 0 Not Achieved

M Nos. of Kaizen / Employee / Month (Nos.)

1 1 0.31 0.7 0.78 0.8 0.85 0.83 (Not Achieved )

TPM Organization Structure

TPM Coordinator Mr. Shaikh F R

JH KK QMPM E&T DM SHE OT

Pillar HeadMr. Kapate S. S Core team1-Mr.Shelake 2-Mr.Kapate S3-Mr.Pawar V.4-Mr.Garad V.5-Mr.Hade 6-Mr.Gade

Pillar HeadMr.Gawali A.

Core team1-Mr.Shaikh.2-Mr.Kande3-Mr.Pawar V.4-Mr.Garad V.5-Mr.Jadhav S.

Pillar HeadMr. ShelakeCore team1-Mr.Tupe P. B.2-Mr.Shingade 3-Mr.Pawar V.4-Mr.Garad V.5-Mr. Shaikh F.6-Mr. Shyam

Pillar Head Mr. Hade

Core team1-Mr.Sonawane2-Mr.Bhusare R3-Mr.kapate S.4-Mr.Lohar 5-Mr.Garad V.6. Jadhav S. J.

Pillar Head Mr. Jadhav S.

Core team1-Mr.Kande2-Mr.Kapate 3-Mr.Garad V.4-Mr.Pathan H5-Mr.Lohar

Pillar Head Mr. Lolewar S.

Core team1-Mr.Vikas 2-Mr.Shaikh F.3-Mr.Bhusare R 4-Mr.Mohsin5-Mr.Kapate S.6-Mr.Wanarse

Pillar HeadMr. Deepak

Core team1-Mr.Sheikh F.2-Mr.Dapke 3-Mr.Gande G.4-Mr.Bhusare R5-Mr.Dutta6-Mr. saudagar

Pillar HeadMr. Bhusare.

Core team1-Mr.Shaikh F. 2-Mr.Kapate S3-Mr.Pawar V.4-Mr.Garad V.5-Mr.Shyam6-Mr. Sonawan

Mr. Salunke R. U. TPM Chairman

1S, 2S Zone Wise Organization Structure

TPM CoordinatorMr. Shaikh F. R.

ZONE-1LEADER-Mr. Deepak

Zone memberMr. DuttaMr. SaudagarMr. RameshMr. Dadarao.

Zone- 5LEADERMr. Garad V.N.

Zone memberMr. Jadhav S.Mr .Namdev.Mr. Pathan H.Mr. Paswan

ZONE-9LEADERMr. Gorakh.

Zone memberMr. Kapate S.Mr. Dapke.Mr. Garad V. Mr. Shelke K.

ZONE-8LEADERMr. Pawara

Zone memberMr. Pawara V. Mr. Shaikh HamidMr. Tathe ManojMr. matlakute B.Mr. Bhalerao M.

ZONE-2LEADERMr. Lolewar S.

Zone memberMr. GawaliMr.tupe P. B.Mr. Jadhav V.Mr. shaikh m.Mr. Pathade

ZONE-6LeaderMr. Tribhuvan.

Zone memberMr. ShingadeMr. RockeyMr. Alex aoMr. Hapse

Zone-7LEADERMr. Kapate

Zone memberMr. Shaikh F.Mr. Gande G.Mr. Dapake M.Mr. Gore B. L.

ZONE-4LEADERMr. .Pathan H

Zone member

Mr. Sonu GuptaMr. Pintukumar Mr. YadavMr. Rajrakhan.

Mr. Salunke R. U. ( V. P.)Mr. Gunjal V. (Development )

ZONE-3LEADERMr. Shingade.

Zone member

Mr. Shyam Mr. Ramesh Mr. Paswan M.

ZONE-10LEADERMr. Bhusare.

Zone member

Mr. ShyamMr. Ramesh Mr. Shaikh

Sr. No. Training Subject No. of People coveredNo of people

balanceRemark

1 1S~2S All Employees Nil Training Freq. after every 3 months

2Customer

Complaints

All Supervisors, Inspectors

and operators Nil Training freq.

every 2 month

3 A B C Defects All operators Nil Training freq. –every 3 month

4 Inspection Final Inspectors Nil Training freq. –every 3 month

5 Material HandlingAll zone members

Nil Training freq. –

every 3 month .

6 Safety All Employees Nil Training freq. –every 3 month

7 Kaizen TrainingSupervisors, inspectorsand operators

Operators Training freq. –

every 3 month

Education Training

Workman & casuals - 59 Staff - 32 Total Employees - 81

Sr.No Training Programme Why Training needed? No. of People BatchesTraining

Hours

1 1S~2S To update Knowledge All Employees 1/zone 5 min /day

2 Customer ComplaintsZero customer

complaintsAll zone

members2

1 hours / month

3 A B C DefectsTo control in house

RejectionsAll operators 1/zone

15 min / weak

4 InspectionTo minimize rejection in

house and at customer end.

Final Inspection 1/zone 5 min/ day

5 Material Handling To update KnowledgeAll zone

members1/zone 5min/ day

6 SafetyBetter working

conditionAll zone

members2

1 hours/ month

7 Kaizen TrainingTo minimise rej&cust

compSupervisors and

operators.2

1 hours/ month

8 5S Activities To update KnowledgeAll zone

members2

1 hours/ month

Education & Training plan

1S Activities

1S-2S Zone Mapping

SR.NO. ZONE ZONAL HEAD PHOTO

1 Store & main gate Mr. Koltame D.

2 Wirecut & office Mr. Gorakh Gande

3 Tool Room Mr. Pawara V.

4 Quality Mr. Lolewar S.

5 core pack Mr. Pathan H.

6 Plate Clutch Mr. Garad V.

7 Assembly Mr. Shingade

8 Rieter Mr. Tribhuvan D.

9 SPM & fine blanking Mr. Wanarse U.

10 Maiintainance Mr. Kapate

11 Campus Mr. Dada mali

8

2

3

8

109

5

6

7

11

41

S. No

Activities Responsibility July2012 Aug-12 Sep-12 Oct-12 Nov-12 Dec-12 Jan-12 Feb-12

1Division of factory premises into various zones

Mr. Sheikh F.

2Formation of Zonal Team with Zone Leader

Mr. F. R. Shaikh

31S ~ 2S Awareness Programme

Mr.:V.S.Gunjal

4 Preparation of Master Plan

Mr.:V.S.Gunjal

5 Go to LOCATIONS

Zone Leaders & Members

6Asses items available in the location


7Decision on Requirement and actions


8Allocation of space for items


09Marking of the space with label


10Keeping items in respective location


11

Arrive at simple Visual Arrangements to know Quantity.


Plan Actual

1S~2S Master Plan

Improvement sheets

AFTERBEFORE

Zone name/no :- Press Shop 24.10.2012

Benefits :- :- Air pressure maintained & prevent low air pressure working …….By Mr.Hade & Mr.Gade

Problem Status: No Pressure switch Counter measure: - Pressure switch add

Improvement Sheet.

Pressure Switch

AFTERBEFORE


Benefits :- Oil collected in chamber & No wastage of oil & save oil ………By Garad

Problem Status: No chamber Counter measure: Oil protective chamber provided to Ram

Improvement Sheet.

Chamber for oil protection

AFTERBEFORE


Benefits :- Save rejection & tool life……………..By Mr.Gade

Problem Status: No sensor Counter measure: : Sensor add to stop the miss feed operation

Improvement Sheet.

No Snap

Sensor

AFTERBEFORE


Benefits :- :-Save operator time & no chances to accidents & missing of oil dripping in machine…………By Gade & Hade

Problem Status: No lubricant Unit Counter measure: :Add automatic Lubricant unit

Improvement Sheet.

No Snap

AFTERBEFORE

Zone name/no :- Maintenance Department 09.10.2012

Benefits :- :-1s & 2s done & time save for searching the tools & maintain the safety……….By Mr.Shelke & Jadhav …………By Mr.Bhusare & Kapate & Team

Problem Status: No stand to store the tools Counter measure: : Stand provided to store the tools & instruments

Improvement Sheet.

No Snap

AFTERBEFORE

Zone name/no :- Press Shop

Benefits :- :- To prevent the heavy shocks directly on machine bed & Safety …..By Mr.Bhusare & Kapate Team

Problem Status: No bed on 160Ton to support the die Counter measure: : Bed Provided on

160Ton to protect the base of machine

Improvement Sheet.

No Snap

AFTERBEFORE

Zone name/no :- Press Shop Date:-8/10/12

Benefits :- :-Proper oiling To srtip & safety By Mr.Kapate & Team

Problem Status: No oiling system availableCounter measure: :Auto Oiling system provided to 160 Ton Manzoni press

Improvement Sheet.

No Snap

AFTERBEFORE


Benefits :- :- Manual oiling replace to Auto oiling …By Jadhav & Team

Problem Status: No oil Tank available to machine Counter measure: : Oil Tank Provided to

Manzoni press

Improvement Sheet.

No Snap

AFTERBEFORE


Benefits :- :- Safety & smooth feeding………………By Jadhav & Team

Problem Status: No stand to protect the coil on 160Ton Counter measure: : Stand provided for

proper protection to coil.

Improvement Sheet.

AFTERBEFORE


Benefits :- :-Addition of 100Ton machine in press shop for shoe web blank………..By Kapate & Team

Problem Status: No Auto feeder on 100Ton machine Counter measure: : Auto feeder add-on

100Ton machine

Improvement Sheet.

No Snap

AFTERBEFORE


Benefits :- :- Oil Saving & operator time saving & No chances to accident. By Garad & Gade

Problem Status: No Auto OilingCounter measure: : Auto oiling provided

Improvement Sheet.

Auto Oiling Unit

AFTERBEFORE

Zone name/no :- Tool Room 30.10.2012

Benefits :- To prevent the surface oily & safty

Problem Status: No Stand for Hydraulic Unit Counter measure: : Stand Provided for Hydraulic Unit in tool Room

Improvement Sheet.

Stand for Hydraulic Unit

AFTERBEFORE


Benefits :- :- Power Saving & prevent to transformer heating….By Mr.Gade

Problem Status: No Contactor Counter measure: : Contactor add on 100 Ton Machine

Improvement Sheet.

No Snap

AFTERBEFORE


Benefits :- If stroke interval delay for 05 mints then Machine automatically shout down after 05 mints .power save & safety……Mr.Gade

Problem Status: No Timer added Counter measure: : Timer Added on 25 Ton Hydraulic Machine

Improvement Sheet.

No Snap

Timer

AFTERBEFORE


Benefits :- :- Web cylinder run very smoothly ,No detection in working…..Mr.Gade

Problem Status: No Auto Drain Valve Counter measure: : Auto Drain valve provided

Improvement Sheet.

No Snap

AFTERBEFORE

Zone name/no :- Weld shop 28.10.2012

Benefits :- :- Safety & increases the plunger life due to continues jerk & vibration….Mr.Hade

Problem Status: No side support to plunger Counter measure: : Inclined support provided to plunger

Improvement Sheet.

No Snap

Support to Plunger

Apr,12 May'12 Jun'12 Jul'12 Aug'12 Sep'12 Oct'12 Nov'1210000

100000

1000000

10000000 1,827,636.00

1,729,957.00

1,810,842.00

2,061,379.00

1,699,402.00

1,755,170.00

2,200,142.00

1,988,750.00

26556 30294 3050048286

39185 43030 44110 36670

ProdMSEB UNIT

MSEB READING vs PRODUCTION QUANTITY

Details for Power Cost R

S

Month0

50000

100000

150000

200000

250000

300000

350000

40000024

360

2792

0

2655

6

3092

4

3150

0

4828

6

3918

5

4303

0

4411

0

3667

0

153,

057.

00

172,

219.

00

166,

392.

00

187,

597.

00

339,

890.

00

377,

297.

00

264,

170.

00

370,

650.

00

332,

030.

00

230,

890.

00

UnitsAmount

Details of month wise sale R

S

Month0

5000000

10000000

15000000

20000000

25000000

30000000

1467

3438

.2

1430

7763

1496

6447

.23

1462

5822

1414

3179

.1

1424

8784

.97

2451

1700

.28

1689

2805

.92

Raw Material Sale

Scrap Sale

Tool Sale

Item Sale

Total Sale

Planned Maintenance Activities - PM

Zero breakdown sustenance

Zero defects sustenance

Zero Accident

Maintenance at lower cost

Aim

PM Structure

PILLAR CHAIRMANMr Hade

Mr. Gade Mr. Sonawane Mr. Kapate Mr. Garad V Mr. Shelake Mr. Jadhav S.

A – Bottleneck & critical machines for production & Quality.

B – Machines affecting Production

C – Alternate arrangement

Sr.No. Area/Shop

Total no of

Machine s

Machine Classification

A B C

1 Press Shop 29 4 4 21

2 Tool Room 10 0 0 10

3 Welding SPM 3 0 3 0

Total 42 4 10 31

Classification of Machines

Happened Breakdown recording & Analysis

Break down (Occurrence) - Plant

5

0

22

3

4

0

1

2

3

4

5

6

BM ( July'11 toOct'11)

Aug'12 Sep'12 Oct,12 Nov,12 Target

Nos

.

Down Time Occurrence - Plant

Benchmark Target

Month Target Month Actual

Break down (Time) (machine) - Plant

50

10

23.120.5

31.5

39.5

0

10

20

30

40

50

60

BM ( July'11 to Oct'11)

Aug'12 Sep'12 Oct'12 Nov,12 Target

Hou

rs

Breakdown (Time in Hours ) - PlantBenchmark Target

Month Target Month Actual

PM checklist for K3 core pack

Die Name k-3core pack stacking Date: / /

Sr No. Description ActivityStand. Condition

Frequency Attened By Root Cost Remark

1 k-3core pack stacking Checking die plate For wear no wear2 blanking punch Checking blanking punch For wear no wear3 noching punch Checking noching punch For wear no wear4 2.2 punch Checking 2.2 punch For wear no wear5 i.d. punch Checking i.d. punch For wear no wear6 2.7 punch Checking 2.7 punch For wear no wear7 4.1 punch Checking 4.1 punch For wear no wear8 5.7 punch Checking 5.7 punch For wear no wear9 spring Checking spring For wear no wear

10 paylat punch Checking paylat punch For wear no wear11 kushan pin Checking kushan pin For wear no wear12 2.28 button Checking 2.28 button For wear no wear13 2.78 button Checking 2.78 button For wear no wear14 5.78 button Checking 5.78 button For wear no wear15 noching ensart Checking noching ensart For wear no wear16 kushan pin spring Checking kushan pin spring For broken No Brocken17 4.1 button Checking 4.1 button For wear no wear18 stiper bolt Checking stiper bolt For wear no wear19 blanking punch bolt Checking blanking punch bolt For wear no wear20 die plate bolt Checking die plate bolt Loosenes no Loose

Production Head: Mantanance head:

PM Check Sheet

PM checklist for welding SPM

Machine Name :

Cell Name:

AUG SEP. NOV DEC JAN FEB

1 Cleaneing the surfcae of machine weekly

2 Trueing slide attrition confirmation weekly

3 Various lows are glid must hit the butter weekly

4 Zero point examintion block position weekly

5 locates the sensor position comfirmation weekly

6 Voltage & current checking weekly

7 greasing chain and gear weekly

8 main motor faundation bolt tight weekly

9 stoper and chain tension cheaking weekly

10 Gear box oil fill monthly

11 main electric breaker cheaking monthly

12 all electric conection tight monthly

SIGNATURE OF MECHANIC

M/C No. :

Date :

Name of Mechanic :

SR. NO. CHECK POINTS FREQUENCY2012-2013

REMARK

Preventive Maintenance checklist

PM checklist for press machine

Machine Name Mach. Press Date: / / M/C No.

Sr No. Description ActivityStand.

ConditionFrequency Attened By Root Cost Remark

1 Motor belt Checking belt for looseness No loose Monthly 2 Motor bearing Check bearing for cleaning No dust Monthly 3 Balancing cylinder Check cylender for aire leackages No leackege Monthly 4 Brake liner Inspect for brake liner No wear out Monthly 5 Lubrication tank Check oil supply for cleaning No dust Monthly 6 Receiver tank Inspect for receiver tank No water Monthly 7 Clutch plate Inspect clutch plate for looseness No loose Monthly 8 Cam box chain Checking chain for looseness No loose Monthly 9 Power contactor Check connection for looseness No loose Monthly

10 Control contactor Inspect for corbone depostion No depostion Monthly 11 Solenoid valve Inspect solenoid valve for lubrecting No dust Monthly 12 Roto seal Inspect roto seal for leackages No leackage Monthly 13 Hose pipe Inspect roto seal for leackages No leackage Monthly 14 Pressure gauge Inspect pressure gauge for proper pressure No leackage Monthly 15 FRL unit Inspect FRL unit for aire pressure leackages No leackage Monthly 16 Ammeter Inspect ammeter for Monthly 17 Control transformer Inspect for corbone depostion No depostion Monthly 18 Motor foundation bolt Checking foundation bolt for looseness No loose Monthly 19 Motor megger testing Monthly 20 Motor Resistance testing Monthly 21 M/C foundation pad Checking foundation pad for looseness No loose Monthly 22 Foot switch contact block Inspect for corbone depostion No depostion Monthly 23 Cam box sensor Inspect sensor conaction for looseness No loose Monthly 24 Oring Check oring for leackages No leackage Monthly 25 Stroke locking cap Checking loking cap for looseness No loose Monthly 26 Slide Cover Bolt Checking loking cap for looseness No loose Monthly

27 Main Gear Check Theeth For weare No wear Monthly

28 Pinion Gear Check Theeth For weare No wear Monthly 29 Pinion Gear Oil Level Check Oil Level No Low Oil Level Monthly 30 Clutch Check Air leackage No leackage Monthly 31 Pitman Scrow Check Up & Down NO Tite Monthly 32 Booster Plate Check Bolt For looseness No loose Monthly 33 Air Perssore Switch Check air Perssore Cutup No Direct Monthly 34 Over Lode Check Oil leackages No leackages Monthly 35 Photo Gard Check For Any Candaction m/c Stop No Contunew Monthly 36 Cranck Shaft Housing Check Bush For Tear & Wear No Tear & Wear Monthly 37 Fly Wheel Check bearing for Condication No Sound & Vabraction Monthly 38 clutch Linner Plate Check Bush & Pin For Wear No wear Monthly 39 Break Linner Plate Check Bush & Pin For Wear No wear Monthly

Prod.Supervisor Sing.

PM Check Sheet

Maint.Head Sing.

Happened Breakdown Analysis

JH Activities

JH STEP - 0

Machine Mapping & allocation of members

Area Name

1 Electrical

Mr. Gade SandipMr. Garad VMr. Jadhav S. J

2 Mechanical

Mr. Kapate S. S.Mr. Jadhav S. JMr. Shelke

1

2

Contents

• Aim

• JH Pillar Organization Structure

• JH Pillar Targets

• Master Plan for JH Activities

• Selection criteria

• JH Steps studies

• Machine map

• Audit reports

• Abnormality Trend over all plant

46

Aim

To Improve Machine efficiency by systematic monitoring and control of Break down time losses resulting into higher effective utilization of machines and men.

“My Machine I Operate I Maintain”

To stabilized various production processes for producing consistent quality with lower cost and in time delivery

47

Master Plan – Critical Machine

Sr. No.

Activity

Month

Jun’12 Jul'12 Aug'12 Sep'12 Oct'12 Nov'12 Dec‘12

W1 W2 W3 W4 W1 W2 W3 W4 W1 W2 W3 W4 W1 W2 W3 W4 W1 W2 W3 W4 W1 W2 W3 W4 W1 W2 W3 W4

7.2Identify Kaizen Themes and implement kaizen

8.1Arrival of Optimal Condition and its Check sheet

8.2Breakdown analysis (Why-Why Analysis) and kaizen/c’measure

9.1Customer complaint elimination by improvement in Inspection

9.2Defect analysis and Kaizen/Countermeasures

9.3 Quality Maintenance Matrix

10Weekly review of the Progress and achieving target

JH PILLAR Structure

Mr.Hade

PILLAR CHAIRMANMr Gawali

Mr.Tribhuvan D

Mr. Jadhav S.

Mr. Pathan H.

Mr. GaradMr. Shielake

Mr. GadeMr. Kapate.

Present JH Status

Sr. No. Parameter BM (Oct’11 to ’12 Target Status

Oct’12

1.1 Total no. of Machines 29 29

1.2 No of machines in JH step 3 0 3 3



1.5 No of tags put/removed 902/826 104 62

1.6 No of Kaizens for CLIRT reduction

1.7 No of improvement for visual management

1.9 No of Kaizens for defect elimination due to poor JH

Abnormality Trend

JH Step - 1

3864 62 63 71 64 78 69 56

171

104

62

3857 60 63 66 57

98

5725

111 118

76

0

50

100

150

200

Numb

ers

Tags Attached Tags Removed

JH STEP – 1 Analysis of Abnormality Removed & Removal Plan

52

Tag No.Date of

detectionMPR00069(SHINOHARA

150T) Abnormality

Why it is "Abnormality"?(What will happen if it is

left as it is)

Why did it become so?

(What is cause?)

Contents of the

countermeasures

Abnormality tag

classificationExecutor Planned

Date of completio

n

1 20/10/2012 Oil leakage to sliding Ram Break down Continuous useReplace new

onewhite

Mr. Shailkh

Comp Comp

2 20/10/2012 Knockout plate bolt bend Break down Continuous useReplaced New

OneRed

Mr. Shailkh

Comp Comp

3 20/10/2012 Front sliding cover open Break down Continuous useReplaced New

OneWhite Mr.hade Comp Comp

4 20/10/2012 Excess wire at topside Hard to clean Not needed Removed Red Mr Tupe Comp Comp

5 20/10/2012 Oil pipe broken at top Accident Continuous useReplaced New

OneWhite Mr.Adikari Comp Comp

6 20/10/2012 operating pannel cable Damage Accident Continuous useReplaced New

OneRed Mr Tupe Comp Comp

7 20/10/2012 motor V-belt loose Break down Continuous useReplaced New

OneWhite Mr Tupe Comp Comp

8 20/10/2012 No FRL for oiling Break down Attach. Removed Retightening RedMr.

ShailkhComp Comp

9 20/10/2012 cock Not availble for GI air pipe Break down Continuous useReplaced New

OneWhite

Mr. Shailkh

Comp Comp

10 20/10/2012Safety photo sensor Not available

Accident Attach. RemovedReplaced New

OneWhite Mr Tupe 20/10/12 20/10/12

11 20/10/2012 Pressure switch Not available Break down Attach. RemovedReplaced New

Onewhite Mr Tupe 20/10/12

12 20/10/2012 Operating panel not fix Hard to clean Excess oil Give oil

collection boxRed

Mr. Shailkh

Comp Comp

13 20/10/201Lubrication unit fitting bolt loose

Break down Continuous use Retightening White Mr. Jadhav Comp Comp

14 20/10/2012 No arrow for flywheel direction Hard to count Attach. Removed change location White Mr.gawali Comp Comp

15 20/10/2012 No arrow for motor direction Break down Attach. Removed Retightening WhiteMr.

ShailkhComp Comp

16 20/10/2012 Excess air pipe to cushion Break down Not needed Retightening White Mr.hade Comp Comp

17 20/10/2012 Cock missing for GI air pipe-2 Break down Continuous use Retightening WhiteMr.

ShailkhComp Comp

18 20/10/2012 Machine lamp not availble Accident Attach. RemovedReplaced New

OneWhite Mr.Jadhav Comp Comp

19 20/10/2012 No marking to all bolt Break down Continuous use Set in proper White Mr.Jadhav Comp Comp

20 20/10/2012 No proper table to strip guide Accident Not neededReplaced New

OneWhite Mr.hade 20/10/2012

21 20/10/2012 No proper packing to clamp Accident Not needed Removed WhiteMr.

Shailkh30/11/12 Comp

JH STEP – 1 Analysis of Abnormality Removed & Removal Plan

53

Tag No.Date of


150T) Abnormality


left as it is)


(What is cause?)

Contents of the

countermeasures

Abnormality tag

classificationExecutor

Planned

Date of completio

ndate

21 20/10/201 Loose switch due to no washer Hard to get HandelingReplaced New

Onewhite

Mr. Shailkh

Comp.Comp.

22 20/10/201 No stand for transformer Hard to clean Continuous use closed WhiteMr.

SonawaneComp.

23 20/10/201 No guard to backside flywheel Accident Attach. RemovedReplaced New

OneWhite

Mr. Sonawane

Comp. Comp.

24 20/10/201Nut missing top cover of transformer

Break down Continuous useResharp & Chafered

WhiteMr.Dayara

mComp. Comp.

25 20/10/201 Loose airline Break down No proper locationReplaced New

OneRed

Mr. Shailkh

20/12/12

26 20/10/201 No safety valve to air tank Break down Continuous useReplaced New

OneRed

Mr. Shailkh

Comp. Comp.

27 20/10/201 No balancer air pressure gauge Break down Attach. Removed Retightening WhiteMr.

SonawaneComp. Comp.

28 20/10/201 Degree mover damage Break down Continuous useReplaced New

OneWhite Mr.Adikari Comp. Comp.

29 20/10/201 Excess air support plate to front Hard to tightening Continuous useReplaced New

OneWhite

Mr. Sonawane

Comp. Comp.

30 20/10/201 Front support pipe bend Break down Continuous use Retightening White Mr.Adikari Comp. Comp.

31 20/10/201pressure switch electric connection

Break down Continuous useReplaced New

OneRed

Mr.Dayaram

Comp. Comp.

32 20/10/201 pannel cabin door loose Accident M/C Vibration Retightening White Mr.Makode Comp. Comp.

33 20/10/201 Foundation Bolt loose Break down Continuous use Retightening White Mr.Adikari Comp. Comp.

34 20/10/201 Panel cable gland missing Break down M/C VibrationReplaced New

OneRed Mr.hade Comp. Comp.

35 20/10/201 Chain guard loose Break down Continuous use Retightening White Mr.hade Comp. Comp.

36 20/10/201 Balencing cylender loose Break down Continuous use Retightening White Mr.hade Comp. Comp.

37 20/10/201 Stroke lub. Oil pipe missing Break down Continuous useReplaced New

OneWhite Mr.hade Comp. Comp.

38 20/10/201Excess cable on machine topside

Break down Not neededReplaced New

OneWhite Mr.Adikari Comp. Comp.

39 20/10/201 PU connector air leakage Break down M/C VibrationReplaced New

OneRed

Mr.Makode Comp. Comp.

40 20/10/201 pipe clamp by cotton Break down Continuous use Retightening White Mr.Adikari Comp. Comp.

Analysis of Abnormality and Removal Plan JH Step – 1

54

Tag No.Date of


150T) Abnormality


left as it is)


(What is cause?)

Contents of the

countermeasures

Abnormality tag

classificationExecutor

Planned

Date of completio

ndate

41 12/09/2012 connector oil leakage Break down M/C Vibration Retightening White Mr.Adikari 20/10/12 20/10/12

42 12/09/2012 Earthing cable loose Break down M/C Vibration Retightening WhiteMr.

Shailkh20/10/12 20/10/12

43 12/09/2012 open air line Break down To Be closeReplaced New

OneWhite

Mr. Shailkh

20/10/12 20/11/12

44 12/09/2012 Machine pad crack Break down M/C VibrationReplaced New

OneWhite

Mr. Sonawane

20/10/12 14/12/12

45 12/09/2012 open cable near transformer Accident M/C VibrationReplaced New

OneWhite Mr.hade 20/10/12 14/12/12

46 12/09/2012 main gear bolt loose Break down Continuous useReplaced New

OneWhite

Mr. Sonawane

20/10/12 20/10/12

47 12/09/2012 slider bolt loose Break down Continuous use Removed WhiteMr.

Sonawane20/10/12 20/10/12

48 12/09/2012 Machine Ram taper chek Break down Continuous useReplaced New


49 12/09/2012 stopper bolt missing Hard to indication Continuous useReplaced New

OneWhite

Mr. Sonawane

20/10/12 20/10/12

50 12/09/2012 Guard bolt missing Hard to indication Continuous useReplaced New

OneWhite Mr. Jadhav 20/10/12 20/10/12

51 12/09/2012 Reciever tank air leakage Break down Continuous useReplaced New


52 12/09/2012 Clutch spring bolt loose Break down Continuous use Set in proper White Mr.hade 20/10/12 20/10/12

53 12/09/2012 Motor foundation bolt loose Break down Continuous useReplaced New

OneWhite

Mr. Sonawane

20/10/12 20/10/12

54 12/09/2012 Booster plate bolt loose Break down Continuous use Reclamped White Mr.Iliyash 20/10/12 20/10/12

55 12/09/2012 main gear bolt missing Break down Continuous useReplaced New

OneWhite Mr.Adikari 20/10/12 20/10/12

56 12/09/2012 Control pannel Nut missing Break down Continuous useReplaced New


57 12/09/2012 Gear box bolt loose Break down Continuous use Retightening WhiteMr.

Sonawane20/10/12 20/10/12

58 12/09/2012 No rack for clamp & bolt Hard to search No Attachment Retightening White Mr.hade 20/10/12

59 12/09/2012 Air line union leakage Break down Continuous useReplaced New


60 12/09/2012 Main gear gressing not proper Break down Continuous useReplaced New

OneWhite Mr. Jadhav 20/10/12 20/10/12

Analysis of Abnormality and Removal Plan JH Step – 1

55

Tag No.Date of

detectionCVT DE/MPR/03

Abnormality

Why it is "Abnormality"?(What will happen if it is left

as it is)


(What is cause?)

Contents of the

countermeasures

Abnormality tag

classification

Executor

Planned Date of

completion

ate

61 20/10/201 Indication lamp not working Accident Continuous useReplaced New


62 20/10/201No cover Gear guard at right side

Break down Attach. RemovedReplaced New

OneWhite Mr.Adikari 20/10/12

0

10

20

30

40

50

60

70

80

90

100

Total Tag White Tag put & remove

Red Tag put & remove

6252

10

52

32

710 103

Total tag put

Total White Tag

Total Red Tag

No

of T

ag Abnormality Trend – Model M/C

56

tpm progress by kandakure engineering pvt ltd-i plot no-105 midc shendra aurangabad oct-nov - 2012...

Documents

gawali mr

gade pillar head mr

kapate zone member

paswan zone

deepak zone member

pawara zone member

hapse zone

pathade zone