02 TVS Motor Co. Ltd

TVS M t CTVS Motor Company

TVS Motor Company – P2Slide Number: 1

A case study presentation by Progressive (Planned) Maintenance

TPM approach towards

P d h & M f C Production achievement & Manufacturing Cost

reductionreduction


TVS Motor CompanyTVS Motor Company Location of plants

Company Introduction

NEW DELHI

p

INDIA

CHENNAI

MUMBAI

KOLKATTA

• Nalagarh (HP)

BANGALORE CHENNAI

Hosur - 2 WheelerMysore (Karnataka)Jakarta (Indonesia) Mysore (Karnataka)

Mysore plant view

Production started : Total Area :

Jakarta (Indonesia)

Hosur - 3 Wheeler


TPM Policy


TPM Model

TPM in Plant2

D 100% V lQ R d PDI l i t

Customer satisfaction in quality, cost & delivery

Improve OEE by minimising losses Cheerful & safe work place

P: 30% increase in productivity

D: 100% - Volume achievement by reducing

line stopper thro’ OEE improvement

Q: Reduce PDI complaints C: Reduce manufacturing cost

Reduce inventory

M&S: Increase suggestion per employee

Sustain ‘Zero’ accidents

Improve PQCDMS

izen nten

ance

gem

ent

zen

Trai

ning

M nviro

nmen

t

nage

men

t

Kob

etsu

Ka

gres

sive

Mai

ualit

y M

anag

Jish

u H

oz

ucat

ion

and

T

Offi

ce T

PM

Hea

lth &

En

opm

ent m

an

5 S activities by all employees

Prog Q

u

Edu

Safe

ty,

Dev

el


Total Employee Involvement

y p y

Background

Production Achievement Line stopper

97

100

96

98

100

Better7.58

68

10 Better

9292.5

92

94

96

3

024

90

00-01' 01-02' 02-03 BM

Manufacturing cost

00-01' 01-02' 02-03 BM

100

93

96

95

100

gBetter

Numbers are

80

85

90 indexed


00-01' 01-02' 02-03 BM

Plant Loss Analysis

Loss Percentage Plant focus area

1 Shut down Loss 1.56

2 Equipment failure Loss 2.423 Set up & adjustment Loss 1.944 Cutting tool & Jig change Loss 1.515 Startup Loss 0.15 Line stoppers6 Minor stoppage 30.517 Reduced speed Loss 0.007 Idle running Loss 0.008 Management Loss 1.10

39%

g9 Measurement & adjustment Loss 0.05

10 Rejection Loss 10.9010 Rework Loss 13.8611 Operating motion Loss 0.27

PDI 24%

p g12 Line organisation Loss 6.7213 Logistic Loss 6.8414 Energy Loss 1.2615 Die tool & Jig Loss 20.90

Manufacturing Cost36%


g16 Yield loss Material Cost

Plant Targets

Production Achievement 100%

Improve OEE 85%

Reduce Line stoppers to Zero

R d M f i b 30%Reduce Manufacturing cost by 30%


Deployment –Pillar wiseTPM Policy & Target

Area of Focus KK PM QM JH OTPM E&T DMArea of Focus KK PM QM JH OTPM E&T DMArea of Focus KK PM QM JH OTPM E&T DM

PDI - ComplaintsLow capability of operators to identify abnormality Machines with variations leads to defect & scrap

Area of Focus KK PM QM JH OTPM E&T DM

PDI - ComplaintsLow capability of operators to identify abnormality Machines with variations leads to defect & scrap Off quality of supplier partsLine stoppers Low efficiency of machines Low efficiency of operator

Off quality of supplier partsLine stoppers Low efficiency of machines Low efficiency of operatorLow efficiency of operator Weak Suppliers creating quality and delivery problems Capacity constraintsBreakdowns

Low efficiency of operator Weak Suppliers creating quality and delivery problems Capacity constraintsBreakdowns Machine basic condition not maintained Low skill level of maintenance staff Maintenance systems not robust Cost

Machine basic condition not maintained Low skill level of maintenance staff Maintenance systems not robust CostCost Cost deployment not clear High process scrap High Maintenance cost

Cost Cost deployment not clear High process scrap High Maintenance cost


Under utilisation of men Under utilisation of men

160114

120

Background Vehicle line stoppage due to Break down Breakdown frequency

142135

130

145

100

114

106

102

108

114

y

Better Better

100100

115

00 01' 01 02' 02 03 BM

100

90

96

102

00 01' 01 02' 02 03 BM

108110160

00-01' 01-02' 02-03 BM00-01' 01-02' 02-03 BM

Breakdown hours Maintenance CostBetter Better

100102

100

105

128120130

145Better

90

95

00-01' 01-02' 02-03 BM

100100

115

00-01' 01-02' 02-03 BM


Numbers are indexed

Objectives & Targets of PM

Reduce Line Stoppers due toReduce Line Stoppers due to Equipment Breakdown to Zero

Reduce Maintenance cost by 30%Reduce Maintenance cost by 30%


PM Sub committee

Pillar Chairman

D Rajendra Babu

Machining Unit PED Training Assembly

Unit

P Baburaj Vijay Kumar Pandurangan P Arun Kumar

Machining Unit

Painting Unit FabricationEnergy

Management


N RaviG SridharD Rajesh P Saravanan

Methodology

Evaluate the effectiveness

S

Step 7

Budget control / Stock control

Maintenance Prevention

Step 5

Step 6

Scheduled Planning Periodic (TBM ) /

Build maintenance information systemStep 4

Breakdown elimination / Corrective maintenanceStep 2

Scheduled Planning – Periodic (TBM ) / Predictive (CBM) Maintenance

Step 3

Support to Jishu Hozen

Breakdown elimination / Corrective maintenance

Step 1

Step 2


Support to Jishu HozenSupport to Jishu Hozen


In Phase 1 Support to JH was to identify and correct abnormalities.

Support to JH

PM Pillar supports JH in

Removal of Red Tags.

Reduce Cleaning timeReduce Cleaning time

Reduce Inspection time.

Create accessibility to reduce CLI time.

Before After

Kaizen – Easy to inspect:


Fully covered guard – Not easy to inspect Visual cover provided - Easy to inspect

Support to JH

Operators are trained on Machine sub systems like Hydraulics & Pneumatics

HYDRAULIC TRAINER KIT

Operators are trained on Machine sub systems like Hydraulics & Pneumatics.

Significant parts are explained in detail with illustrations.

Procured a Hydraulic Trainer kit and

HYDRAULIC TRAINER KIT

Procured a Hydraulic Trainer kit and

displayed for Operator and Team Leader

training.

Elements are transparent. So, easy to

understand.

Demonstrate the functions of hydraulic

elements and its internal construction.


Support to JH

In Phase 2 Support to JH is to enhance operator’s knowledge level about theIn Phase 2 Support to JH is to enhance operator s knowledge level about the

machine and its functions.

Methodology to improve operator knowledge:

Overview about the machine & its capability

Methodology to improve operator knowledge:

Working mechanism of the machine

Machine parameters related to quality

Significant parts and its Working principle

Probable Failure modes in each sub assembly


Immediate corrective actions required

Support to JHRed Tag removal trend

122793131133

160000UOM: Nos

77004

106481120000

rem

oved

18628

45462

40000

80000

o of

Tag

s

18628

0

40000N

2003-04 2004-05 2006-07 2007-08 2008-09 2009-10

131133 Red Tags has been cleared in order to support JH


131133 Red Tags has been cleared in order to support JH

Awareness training to Operators & Team LeadersSupport to JH


Support to JH

Example: Spindle motor Z axis Servo motor

Overview about Fanuc ROBODRILL machine

a p e Spindle motor Z- axis Servo motor

machine

Home position marking

Turret

Clamping system

Y- axis Servo motorSpindle

X- axis

Fixture

Operators are educated about the machine subassemblies and its functions


Operators are educated about the machine subassemblies and its functions.

Significant parts are explained in detail with illustrations.

11 Step approachEquipment failure Elimination

1 Equipment grouping and Ranking

2 Analysis of Datay

3 Eliminate Forced Deterioration

4 Identify root cause and implement counter measure

5 Identify breakdown reoccurrence / understand phenomenon

6 Investigate design weakness and improve it

7 Investigate natural deterioration

8 Set deterioration pattern

9 Select and evaluate maintenance point

10 Decide PM/TBM/CBM


11 Build best maintenance procedure

JH Step 4 Working demonstrationSupport to JH

Lubrication System Hydraulic Elements


Bolts & Nuts Pneumatic Elements

100

120

100

120

Breakdown frequency

Better

Breakdown Hours

Better

74

5449

60

80

100

42

60

90

24

49

20

40

'04-05 '05-06 '06-07 Apr May Jun Jul Aug Sep Oct Nov Dec Jan Feb Mar

19

6

19

0

30

'04-05 '05-06 '06-07 Apr May Jun Jul Aug Sep Oct Nov Dec Jan Feb Mar

Vehicle line stoppage due to Equipment failure 640

262

300

Better

219 219

150

200

250

Numbers are

55

50

100indexed


0'04-05 '05-06 '06-07 Apr May Jun Jul Aug Sep Oct Nov Dec Jan Feb Mar

Equipment Ranking – Machine Shop

Step 1 : Equipment Ranking

Rank A Rank B Rank C

47

Business Impact

No Alternate machines 14

195

88

Alternate machines available 60

26

Values are indexed

AOpn 10 No Alternate

An example of Ranking in a Cell

88Simple machines 26

AC

BB

Opn 10

Opn 20

No Alternate

Can be shifted to Other machine

Two Machines doing same operationBB

AC

Opn 30

Opn 40 No AlternateNo Alternate


COpn 50 Can be shifted to Other machine

Step 2

Break down Elimination


Production Non Achievement

Background

Production Non-Achievement

OEE 85 %

B/O parts shortage

(OTPM ill )

Inhouse Losses

OEE < 85 % (OTPM pillar)

Tool change loss

Equipment Failure loss

Rework loss Start up loss

Minor Stoppage

loss

(PM pillar)

C t d

(KK pillar) (QM pillar) (KK pillar)

loss

(JH pillar)


Case study

Equipment details

Step 2 : Analyze the Present status

1. BFW VMC – 2 machines

2. NTC VMC – 1 machine

3. FANUC VMC – 2 machines

4. SPM – 3 machines

Stratification of slips - Equipment wise

4577 100

9540

50

80

100p q p

22

16

52

20

30

40

60

4

0

10

BFW Fanuc Robo SPM NTC0

20


BFW Fanuc Robo SPM NTC


PROCESS

Breakdown History

PROCESS

AbnormalitiesMachine

Technicians & JH members

SAP

Analysis

Sub systems (Causing breakdowns)

OUTCOME

Action plan (For identified abnormalities)


Action plan (For identified abnormalities)


93100

15 100

Phenomena stratification in BFW machine ( subsystem wise)

9

12

64

78

87

9

12

ena

60

80

P

6

4

8

27

47

6

9

No. o

f Phe

nom

e

40

60

Percentage

3 3

0

3

0

20

ATC ToolMagazine

Guarding Axes Coolant Pneumatic Hydraulic


COVER CLUTCH CELL LAYOUT


BFW FANUC OPN 40OPN 50

SPM FANUC OPN 30OPN 60 SPM FANUC OPN 30OPN 60

NTCSPM OPN 20OPN 70

BFW OPN 10SPMOPN 80


Equipment details


1. BFW VMC – 2 machines

2. NTC VMC – 1 machine

3. FANUC VMC – 2 machines

4. SPM – 3 machines

Phenomena identified from past occurrence


Step 2 : Analyze the Present statusStep 3 : Elimination of Forced deterioration

Hydraulic system

Problematic Subsystems

Machine

SpindleHydraulic system

3 – Axes (X,Y,Z)

ZAutomatic Tool Changer Coolant system

X

YZ


Tool Magazine

Action plan for abnormality correction


p y


F il d P t iPROCESS


Failure mode – Part wise PROCESS

Analysis

Forced deteriorationOUTCOME

Design weakness

Natural deteriorationdeterioration

ElementsOUTCOME weakness

Elementsdeterioration Parts


Action plan

Subsystem / Part wise – Failure mode Analysis:



A ti f F d d t i ti

Step 3 : Elimination of Forced deterioration

Action for Forced deterioration : BFW - VMC

SpindleSpindleTool Magazine

Automatic Tool Changer

Phenomena due to Forced deterioration:


1. Tool falling down from ATC gripper.

Action for Forced deterioration:

Step 3 : Elimination of Forced deterioration

Example: Tool Falling down

Automatic Tool Changer

d


Plunger movement reduced from 27mm to 15mm

Example: Tool Falling downStep 4 : Identify root cause & Implement countermeasure

dATC Gripper

Variation in Plunger movementVariation in Plunger movement

Plunger Struck up

Tool Positioning Wrong

Restriction in spring Movement

Spindle Orientation errorStruck up Wrongspring Movement Orientation error

Plunger Bend

Guide Screw Loose

Spring Broken Arm

DamageTennon loose

Spring CorrodedLoose Damage loose

Coolant Entry

S l F il

Less Corrosion resistance

S

Coolant PH & concentration


Seal Failure Spring steel used

CM 1 : Replace seal in TBM CM 2 : Change to SS coated material

Actions arising after why why analysis:

Step 5 : Identify breakdown recurrence & understand phenomena

1. Replace Arm plunger seal once in a year ( Add in TBM calendar )

2. Check arm tennon for any looseness in Weekly JH check

3. Refill grease in arm plunger spring once in three monthsg p g p g

Before After

Springs with no rust prevention coating Springs with SS coatingSprings with no rust prevention coating Springs with SS coating


Action for Design Weakness:

Step 6 : Investigate design weakness

ATC

Home position


Tool pot ATC Spindle

Action for Design Weakness:



Example: Spindle orientation position changing

Actions for Design Weakness:Step 6 : Investigate design weakness

Interacting Elements

Physical Quantifiable change

Phenomenon Contact Diagram

Physical Analysis

Example: Spindle orientation position changing

Spindle Orientation not

in position

1.Encoder 2.Coupling 3.Belt4.Pulley

Variation in Encoder Pulley Position

4.Pulley

Spindle pulley

Encoder pulley


θReference pulse

Variation in encoder pulley position


Drive slippage in encoder Spindle drive

Encoder PulleyEncoder Belt

Pulley Shaft play

Pulley Teeth worn out

Pulley shaft play

Pulley Teeth worn outSlackness Teeth worn

out

Center distance between pulley not

constant

Assembly error

Misalignment

Play between Pulley and bearings

P ll h ft t


Pulley shaft worn out

4M Analysis


Pulley Shaft Worn OutFailure Mode

MAN MACHINE MATERIAL METHOD

• Pulley diameter variation

• Support bearing condition

• Belt tension setting

• Alignment

• Interference Fit between bearing & Shaft

• High spindle speed • Bearing assembly error


4M Condition Investigation


Failure mode: Pulley Shaft worn-out

S.No 4 M Condition Specification Genba

ObservationRelationshipNo Observation nship

1 Man Belt Tension setting Permissible slackness = 2mm for 100mm length

1.5mm (within spec)

R f l2 Man Belt alignment Assembly should be

done as per drawing

Reference plane is given for easy assembly

High operating Running at max3 Machin

e

g p gspeed of the spindle ( Process parameter)

Max Speed : 8000 RPMRunning at max. speed (within spec)

4 Material Pulley shaft diameter variation

Diameter, D = 20.01 mm

Diameter, D = 19.68 mm

Strong relationship M di l ti hi Weak relationship


Strong relationship Medium relationship Weak relationship


Opn No. Operating speed Operation Pulley Failure

Comparision between BFW Machines

4M Condition Investigation

Opn No. Operating speed Operation Pulley Failure

10 8000 RPM max Milling

50 3500 RPM max Drilling,reaming & boringg, g g

10 8000 RPM max Milling

20 4000 RPM max Drilling reaming & boring20 4000 RPM max Drilling,reaming & boring

30 3500 RPM max Drilling,reaming & boring

Problem occurs only in machines operated at high speeds


While spindle stops for orientation, speed


Encoder

While spindle stops for orientation, speed

reduces from 8000rpm to 0rpm within 2 sec.

During spindle stoppage, 10Nm inertial force

t dditi ll th d ll h ft

Coupling

BearingShaft

acts additionally on the encoder pulley shaft.

Shaft material couldn’t withstand the excess

load since hardness is low (9 HRC - Aluminium).Bearing

R

F

Inertial Force

Encoder pulley Spindle pulleyEncoder belt Spindle


Inertial Force, F = m x (N x 3.14 x D) / (60 x 2)

Actions arising after analysis:


1. Change shaft material from aluminium to steel

2. Surface hardness is maintained at 40HRC

3. Check belt slackness & pulley teeth profile in monthly PM checkp y p y

Before After

Shaft made of steel (40 HRC)Shaft made of aluminium (9 HRC) Shaft made of steel (40 HRC)Shaft made of aluminium (9 HRC)

Spigot & 5mm dowel for easy alignment

M6x25 screws 3nos for


M6x25 screws – 3nos for torque transmission

Actions for Natural deterioration:

Step 7 : Investigate natural deteriorationExample for Natural deteriorationActions for Natural deterioration:

Parts that doesn’t have any influence such as forced deterioration and design flaw, will

follow natural deterioration pattern.

Parts that follow natural deterioration pattern, are covered under preventive maintenance

(PM).

ce

Deterioration pattern

Rate of deterioration

erfo

rman

c changes over period

Rate of deterioration C t t

CBM

Pe

Probability of FailureLife

Constant TBM


Age

Scheduled planning

TBM & CBM


Methodology:

Step 10 : Decide PM / TBM / CBM

11. Is service life guaranteed between the time of overhaul to next overhaul ?

Select part to be monitored

1

2

next overhaul ?NO

2. Is there accelerated deterioration?YES

NO

3

2

2. Is thereaccelerateddeterioration? Restore &

Improve

YES 3. Is service life of the component reasonable?

4. Is service life stable?

YES

NO

4

5

2

Restore &

YES

NOYES

NO

5. Do we understand deterioration process ? 6. Do we have YES

6Improve

PM CORRECTIVE CBM

Deterioration indicator ?NO

YES

NO

Research onDeterioration

process

Elimination of Design defects


INSPECTION MAINTENANCE TBM CBM

Identification of Maintenance method:

Step 10 : Decide PM / TBM / CBM

# Part Accelerated Deteroriation

Service life Guaranteded

Service life resonable

Service life stable

Deterioration Indicator

Maintenance Method

1 Spindle bearing CBM

2 Labyrinth seal TBM

3 Drawbar Spring CBM

4 Steel ball CBM

5 Bearing Spacer CBM

6 Timer Pulley TBM

7 Ti B lt TBM7 Timer Belt TBM

8 Encoder Pulley TBM

9 Encoder Belt TBM

10 Tennon CBM

11 Cylinder seal kit TBM

12 Spindle motor CBM


12 Spindle motor CBM

Not Ok Ok

TBM Parts:

Step 11 : Build best maintenance standard


CBM techniques being followed:

Instrument


Identification of inspection item for CBM:


SpindleS.No Component Inspection item

1 Vibration

SPINDLE ASSEMBLY

2 Run out

3 Axial play

4 Drawbar spring Clamping pressure

Spindle bearing

5 Steel ball Diameter

6 Bearing spacer Length

7 Timer Pulley Profile

8 Timer Belt Profile / Crack

9 Encoder Pulley Profile

10 Encoder Belt Profile / Crack

11 Tennon Width

12 Tool declamp cylinder Pressure

13 CurrentMotor


14 Temperature

Breakdown frequency V/s Kaizens implementedResult

7681

86150 100

100

8063

45100

frequ

ency

60

80

plem

ente

d

3512

3250

eakd

own

f

40

izen

s im

p

4 3 112

0

Bre

0

20 Ka

'02-03 BM '03-04 '04-05 '05-06 '06-07 '07-08 '08-09

Breakdown frequency Kaizens


Numbers are indexed

5260

No of check points covered under TBM

2330

45

114

10

0

15

Machining Painting Fabrication Assembly Utilitiesg g y

No of check points covered under CBM 7680

40

60

Numbers are9 5 4 3

0

20

Machining Painting Fabrication Assembly Utilities

Numbers are indexed


Machining Painting Fabrication Assembly Utilities

100120

Breakdown frequency

UOM: % Better

80

6360

90

97%

2412

4 20

30

02-03' BM 03-04' 04-05 05-06' 06-07' 07-08' 08-09'

100120

Breakdown hours

UOM: % Better

7460

25

60

90

95%

258 5 4

0

30

02-03' BM 03-04' 04-05 05-06' 06-07' 07-08' 08-09'


100100

UOM: % Better100%

Vehicle line stoppage due to Equipment failure

7363

4850

75

6 5 00

25

02 03 03 04 04 05 05 06 06 07 '07 08 '08 09

100100

02-03BM

03-04 04-05 05-06 06-07 07-08 08-09

UOM: %Better100%

Engine line stoppage due to Equipment failure

5250

75

Better100%

2920

11 80

0

25


02-03BM

03-04 04-05 05-06 06-07 '07-08 '08-09

Reduce Manufacturing Cost

through TPM Methodology


Manufacturing Cost

Manufacturing cost – Stratification

Manufacturing Cost

Energy Cost Repair & Maintenance Cost

Tool Cost Consumable Cost

(KK pillar)

Fuel Cost Spares Cost Labour CostPower Cost

(PM pillar)C t d


(PM pillar)Case study

110

Manufacturing cost UOM : % Better

100

90

100

80 7976

70

80

2004-05 2005-06 2006-07 2007-08

7%

Manufacturing cost – Stratification

UOM : % Better

57%

16%

7%

Power & fuel cost contributes 57 % of the 57%

20%

P&F R&M St T l

contributes 57 % of the total Manufacturing cost


P&F R&M Stores Tool

Overall approach towards the Energy cost reduction

Four types of Losses

Ideal loss

Th ti l

Condition of zero losses

Theoreticallosses

Opportunity

Theoretically inherent loss & can not be eliminated

This is the loss which can not be recovered as benefitsOpportunitylosses

Recoverable losses

This is the loss which can not be recovered as benefits even after elimination immediately.

This is the loss which we normally attack & removelosses & remove

GuidelinesTake actions straight away for recoverable loss

Do kaizens to capture & reduce opportunity loss though it will not give immediate benefits

Look at the physical view & try to convert theoretical loss in to opportunity loss


Look at the physical view & try to convert theoretical loss in to opportunity loss

Total Power consumption – Plant 2 Period : Apr 08 – Sep 08

16%

7%

57%20%

P&F R&M Stores Tool

1255700

UOM: KWH

units per

month ( Avg )


Total Power consumption – Plant 2

Period : Apr 08 – Sep 08UOM: KWH p p

36%30% Paint shop36%30%

3% 4%6%

Machine shopFabricationEngine assyVehicle assy

21%6%Utilities

Utilities

Lighting24%

Compressor76%


Compressed air pconservationconservation


Pneumatic cylindersUsage of compressed air

Air hoist

Gauges

Part seat sensingApplication of

compressed airComponent Cleaning

Pneumatic tools

p

Pneumatic tools

Numbering


Paint mixing and painting guns

Methodology

Step 7Explore alternate source

Step 5Identify opportunity losses

Step 6Action for elimination

Action for reduction and elimination Step 4

y pp y

Identify the recoverable losses Step 3

Measure actual air consumption

Step 1

Step 2


Calculate theoretical air consumption Step 1

Step 1 Calculate theoretical air consumptionKey Points

Data collection on Compressors capacity

Pneumatic mappingpp g

Summarise air consumption points

C l l ti f th ti l i tiCalculation of theoretical air consumption

Cylinders

GaugesGauges

Blow guns

Part seat sensing

Air hoist

Rotary fixtures

D b i


Deburring gun

Step 1 Calculate theoretical air consumptionCompressor capacity

Lub Compressors Non Lub Compressors

i

I0

F1

F2

F3

ELEKTRONIKON

Atlas

copco

GA75

i

I0

F1

F2

F3

ELEKTRONIKON

Atlas

copco

GA75

i

I0

F1

F2

F3

ELEKTRONIKON

Atlas

copco

GA75

i

I0

F1

F2

F3

ELEKTRONIKON

Atlas

copco

GA75

i

I

0F1

F2

F3

ELEKTRON

i

I

0F1

F2

F3

ELEKTRONo o o o

IKON

Atlas

copco

GA75

IKON

Atlas

copco

GA75

Non Lub Air Ring mains

580 CFM 570 CFM 200 CFM 200 CFM 535 CFM 535 CFM 535 CFM 625 CFM 570 CFM

Machining MachiningMachining Taikisha

Lub Air Ring mains Paint shops

g

Fabrication Eng Assy

gg

Veh assy

CED

Prism

Powder coat


Powder coat

Estimate leakages

Method for leak quantification

Shut off compressed air operated equipments

Run the compressor to charge the system to set pressure of operationRun the compressor to charge the system to set pressure of operation

Note the time taken for ‘loading cycle

Note the time taken for ‘Unloading cycleNote the time taken for Unloading cycle

The system leakage is calculated as:

% leakage = T × 100 / (T + t)

(or) System leakage (m3/minute) = Q × T / (T + t)

Q = Actual free air being supplied during trial in M3per minute (cmm)Q = Actual free air being supplied during trial, in M per minute (cmm)

T = Time on load in minutes

t = Time on unload in minutes


Estimate leakages

Compressor capacity (m3/minute) = 45

Cut in pressure kg/cm2 = 6 5Cut in pressure, kg/cm2 = 6.5

Cut out pressure, kg/cm2 = 7

Load kW drawn = 279 kW

Unload kW drawn = 140 kW

Average ‘Load’ time = 17 minutes

Average ‘Unload’ time = 21 minutes g

a) Leakage quantity (m3/minute) = 45*17/(17+21) = 20.7 m3/min

= 730 CFMb) 5 CFM = 1 KWb) 5 CFM = 1 KW

c) 730 CFM = 146 KW

Total energy loss per day = 3212 units per dayTotal energy loss per day 3212 units per day

Total energy cost loss per day = Rs. 24090 per day

Total energy cost loss per annum = Rs. 72.3 lakhs / annum


Step 1 Total Air ConsumptionUOM : CFM

12001200

1400

Total air

850800

1000

Total air consumption

2770 CFM

350400

600

800

350

180 190

0

200

400

0

Machine shop

Paint shop Fabrication Veh Assy Eng Assy


Step 1Pneumatic mapping Cell 1

100 110 120 130 140 1504 4 1 3 3 1

OPNCylinder 4 4 1 3 3 1

0 0 0 0 0 00 0 1 1 1 0

CylinderGaugesP Seat 0 0 1 1 1 0

Cell 2

P.Seat.

10 20 30 50 60 80 90 100OPN2 2 1 4 1 1 4 10 0 1 1 0 1 1 1

CylinderGauges


1 1 0 1 1 1 1 1P.Seat.

Step 1Summarize air consumption points

Pneumatic cylinders

32 nos

Gauges

Air consumption

5 nos

Part seat sensing

Air consumption

points 10 nos

Component Cleaning

5 nos

Pneumatic tools

5 nos


Calculation of Theoretical air consumptionStep 1Opn no. Cyl. Dia.

( in mm)

Stroke length

(in mm)Qty Volume

(in litres)No. of cycles

No. of strokes

Actual consump. (in l/min)

Actual consump.

(in cfm)

Q(in l/min.) = π * d2 * L * (P + A)

4 *106 * A *t

100 30 50 3 0.79 800 1600 6.29 0.22100 20 400 1 0.93 800 1600 7.46 0.26110 30 50 3 0.79 800 1600 6.29 0.22110 20 400 1 0.93 800 1600 7.46 0.26120 40 400 1 3.73 800 1600 29.83 1.05130 30 50 3 0.79 800 1600 6.29 0.22

Where

L = Stroke length

4 10 A t130 16 500 1 0.75 800 1600 5.97 0.21140 30 50 3 0.79 800 1600 6.29 0.22140 20 500 1 1.17 800 1600 9.32 0.33150 40 400 1 3.73 800 1600 29.83 1.0510 16 200 1 0.30 800 1600 2.39 0.0810 16 300 1 0.45 800 1600 3.58 0.1320 16 200 1 0 30 800 1600 2 39 0 08

d = Cylinder dia.

P = Working pressure=6.5bar

A = Atm Pressure= 1 013 bar

20 16 200 1 0.30 800 1600 2.39 0.0820 16 300 1 0.45 800 1600 3.58 0.1330 30 300 1 1.57 800 1600 12.58 0.4440 40 400 1 3.73 800 1600 29.83 1.0550 20 400 3 2.80 800 1600 22.37 0.7960 40 400 1 3.73 800 1600 29.83 1.0570 16 500 1 0.75 800 1600 5.97 0.21 A = Atm. Pressure= 1.013 bar

t= actuation time80 16 500 1 0.75 800 1600 5.97 0.2190 16 400 1 0.60 800 1600 4.77 0.17100 20 400 1 0.93 800 1600 7.46 0.26

8.41


Calculation of Theoretical air consumption

T i f h l

ReferenceStep 1

True size of hole dia.

(in mm)

Air leakage at 6 bar (in cfm)

1 22 8

For 1mm dia. Hole, CFM = 2

For inspection gauge with hole dia.. d,2 83 214 345 576 72

CFM = (2 cfm)* d2

Hole dia. (in mm) CFM Qty.

10 220(in mm)

1 2 5

Total CFM 10Total CFM 10


Calculation of Theoretical air consumptionStep 1

Air blow gunsFor 2mm dia. nozzle, CFM = 8

F i bl & hi / l ith l di dCFM dFor air blow gun & washing m/c nozzles with nozzle dia. dCFMand washing = (2 cfm)* d2

Air blow gun and washing nozzle

Nozzle dia CFM Qty TotalNozzle dia CFM Qty Total

2 8 5 402 8 5 40

1 2 12 24



Part seat sensing

F 1 di l CFM 2For 1mm dia. nozzle, CFM = 2

For Part seat sensing dia. d,For Part seat sensing dia. d,

Nozzle dia CFM Qty Total

1 2 10 20


For Cylinders, Cfm = 8.4


o Cy de s, C 8

For air blow guns, Cfm= 40

For gauges, Cfm = 10

For Part seat , Cfm = 20

For Washing, Cfm = 24

Total theoretical CFM = 102.4


Measure the actual consumptionStep 2

Measuring actual Value of air consumption by flow g p y

meter

1. Install flow meter in the line1. Install flow meter in the line

2. Take Readings at Interval

3. Average out

Total CFM measured by the Flow meter = 136.8 cfmy

GAP = 34.4 cfm


Step 3 Identify Recoverable Loss

Tree Diagram for Pipe lines

Leakage from

PipesDamaged

Pipe

Rubbing to moving

Part

Not removed/ Blocked

Properly Excessive bend

Wrong selection

Of pipe

Selection ofSelection of

Wrong connectors

Loose Connectors

Loose End caps



T Di f Bl

Leakage from Damaged Rubbing to

Tree Diagram for Blow guns

Blow guns Pipe Moving Part

Excessive bend

Continues exposure

To oil/ coolant

Plunger stuck upWrong part

Used as plunger

Faulty adaptor

Spring failure

Rear Nut Loose


Faulty adaptor

T Di f C li d


Air loss from Damaged

Tree Diagram for Cylinders

Cylinders seals

Worn out

Piston rod

Across Piston

Leakage

Selection of

Wrong connectors

Loose Connectors


Loose End caps

Step 4 Action for reduction and elimination

Arresting leakagesArresting leakages

Hose replacement

Hose re-routing

Fitting replacedFitting replaced

Seal replaced

Gasket corrected

Total no of leak points identified - 1747 points


Total no of leak points identified 1747 points

Total no of leak points corrected - 1326 points


Air leaks through Air supplied through foot switch

Ideal loss

Theoreticalthe gauges during inspection onlylosses

Opportunityllosses

Recoverable losses

No. of gauge points applicable : 117 nos.


g g p pp

No. of gauge points completed : 75 nos.

Step 4Air supply stopped when not in use

Action for reduction and elimination

Ideal loss

TheoreticalSolenoid

Coillosses

Opportunityl

Exhaust

losses

Recoverable losses

Start R1R1

Stop

+ 24 V

Start R1R1

Stop

+ 24 V

Relay Timer Solenoid

T1

Stop

R

Ti t

Relay Timer Solenoid

T1

Stop

R

Ti t


Timer set for 2 min.Timer set for 2 min.

Step 4Cycle start Part seat Air supply ON

Input OutputAction for reduction and elimination

Part seat OK Clamping ON

Ideal loss

TheoreticalClamping OK Cycle ONlosses

Opportunityl

Not OKAir supply

Cycle not runninglosses

Recoverable losses

Solenoid

Coil

E h t

Coil

OK

Cycle not running

Air supply


Exhauststopped

Step 5 Identify opportunity losses

Opportunity losses in compressed air

Optimising the air pressurep g p

Eliminating pneumatic operation

E l i th li ti f it ti l fExploring the application of gravitational force

Pressurised air drying to air blowing


Before After

Air hose from control unit


Cylinder Air hose from control unit

Air point removed

Door Door


Air consumed while door close Door closed in gravity Applicable : 16 nos

Alternate technology for air savingStep 7


Result Air ConsumptionUOM : CFM

12001200

1400

520 CFM saved1 Compressor

switched off

850900

750800

1000

Total air

350400

600

Total air consumption

2250 CFM

350

180 190260

160 180200

400

0

Machine shop

Paint shop Fabrication Veh Assy Eng Assy


p

ResultCompressor capacity

Lub Compressors Non Lub Compressors

i

I0

F1

F2

F3

ELEKTRONIKON

Atlas

copco

GA75

i

I0

F1

F2

F3

ELEKTRONIKON

Atlas

copco

GA75

i

I0

F1

F2

F3

ELEKTRONIKON

Atlas

copco

GA75

i

I0

F1

F2

F3

ELEKTRONIKON

Atlas

copco

GA75

i

I

0F1

F2

F3

ELEKTRON

i

I

0F1

F2

F3

ELEKTRONo o o o

IKON

Atlas

copco

GA75

IKON

Atlas

copco

GA75

Non Lub Air Ring mains

580 CFM 570 CFM 200 CFM 200 CFM 535 CFM 535 CFM 535 CFM 625 CFM 570 CFM

Machining MachiningMachining TaikishaLub Air Ring mains

Paint shops

g

Fabrication Eng Assy

gg

Veh assy

CED

Prism

Powder coat


Powder coat

Lighting Energy conservation

Lighting24%

Utilities

24%

Compressor76%


76%

LightingsTypes of Lightings

Shop floor lighting Office lighting Task lighting Street lightingp g g g g g g g g

High bay lighting Low bay lighting

94000

95000

Lighting energy consumption

3724

60291000

92000

93000

93 93

9079

4

8927

6

87000

88000

89000

90000


Apr '08 May '08 Jun '08 Jul '08

Lowering the High bay MV lamps

E1

αd2

E- Illumination

d – distance between plane to source of light

7.5

m

m6.

0

Illumination

220 luxIllumination

220 lux360 lux


5 m 3 m

Lux mapping

LUX LEVEL MONITORING IN MACHINE SHOP

SSl.No. AREA

Spec

(lux) Day Night Day Night

1 BAY 02 200-300 260 243 253 240

2 BAY 03 200-300 250 238 245 233

3 BAY 04 200-300 229 220 230 218

4 BAY 05 200-300 234 219 229 214

5 BAY 06 200-300 257 229 249 232

6 BAY 07 200-300 241 233 236 228

7 BAY 08 200-300 220 217 228 215

8 BAY 09 200-300 243 228 240 221

9 BAY 10 200-300 236 224 249 230


10 BAY 11 200-300 259 239 251 242

Time office

LUX LEVEL MAPPING – Zonal

StoresMachine shop

Machine shop StoresVehicle

assembly

Fabrication shop Engine assembly Vehicle Assembly

Taikisha

Paint plant

Jost

Paint

P.coating

Paint

CED

PaintHaden Jost

Paint plant

Prism

Paint Thermax

Paint plantPaint plantplant Plant Plant

Paint plantplant

Paint plant

Transhipment area Substation PMD & CU Stores


Transhipment area Substation PMD & CU Stores

Standard illumination IS 3646


Actions

Optimising the illumination Standard 100-150 luxlevel in the Gangways

Standard 100-150 lux

220 l 150 lux220 lux 150 lux

Switch off High bay lights

wherever low bay lighting provided


Actions

Optimizing the Energy consumption by introducing low bay

lights in the gang ways

250 W tt 150 W tt250 Watts 150 Watts

Introducing T5 tube lights in the machining unit energy

consumption reduced from 150 to 84 Watts


150 Watts 84 Watts

Actions

Optimizing the Energy consumption of street lights from

250 watts to 150watts

250 W tt 150 W tt250 Watts 150 Watts

Introducing LED lamps for the street lightings through which

energy consumption has reduced from 150 to 90 Watts.


150 Watts 90 Watts

Actions

Auto timers for lighting LDB

LDB Timer

Timer


Results

50000 units saved

Moff

10000 units saved


Energy conservation at M hi hMachine shop

36%30% Paint shop

Machine shop

Fabrication

3%

21%4%

6%

Fabrication

Engine assy

Vehicle assy

Utilities


Methodology

Step 5Check the results

Action for reduction and elimination Step 4

Identify the losses Step 3

Measure actual energy consumption

Step 1

Step 2


Calculate theoretical energy consumption Step 1

Step 1 Calculate theoretical energy consumptionKey points

Collect the Volume based operating hours –IED recommendations

Calculate the energy consumptions - Operation wisegy p p

Summarize the energy consumption / component

A i th th ti l ti / tArrive the theoretical energy consumption /component


Step 1 Calculate theoretical energy consumption

Collect the Volume based operating hours –IED recommendationsCollect the Volume based operating hours IED recommendations

Cell name SMM

(M

PO

)

Dep

loym

ent

Tim

e (G

roup

ing

) Cap

acity

/D

ay

OE

Volu

me

Spar

es

Vol

Cal

cula

ted

valu

e

No

of

Shift

s

Line 2

Line 3 8.36

600 7.91 25.83 954

4.93 954

5.16

4.67

600 8.36 25.77 6.17 954Line 1

LH & RH 1 (Cooper

LH 1

RH 1

950

600 7.3 2

600 5.87 24.33 1150

5.42 1150

3.77

4.43

(Cooper mill)

LH & RH 2 (Cooper

mill) 850

950

CELL 1 & 2

RH 3

LH 3

8.36 26.17 954 600

8.36 2

6.17 954 600 8.36 2

6.17 954 600

14.77

12.77

13.77


6.17 954 600 8.36 215.77

Step 1Energy measuring tool used

Calculate theoretical energy consumption

Portable power analyser

Cost : Rs. 2.5 lakhs

In house made Power analyser

Expense : Rs. 0.1 lakhs

No. of parameters measured : 30 No. of parameters measured : 8


Step 1Measure the energy consumptions - Operationwisegy p p

Star Crankcase –Feeder BBT 38 A and 51E

Opns 10 20 30 40 60 80 90 100 110 120 130 140 150 160 170 180

Qty 10 10 10 10 10 10 10 10 10 10 10 10 10 10 10 10y

Units 0.2 0.4 0.1 0.5 0.4 0.6 0.7 0.3 0.4 0.4 0.4 0.3 0.5 0.4 0.4 0.1


Step 1Summarise the energy consumption / componentgy p p

MACHINEWISE LOAD DETAILS OPNS NO. OPERATION KWH

(START)KWH (END)

NO. OF CYCLES

TOTAL TIME TAKEN

TOTAL KWH CONSUMED

KWH CONSUMED /

CYCLE10 Spot facing & Drilling 138.2 138.6 5 6 min 0.4 0.4/5=0.08

20 Joint face milling 2 dowelling 138.7 138.9 5 6 min 0.2 0.2/5=0.04

30 Exhaust Boring 138.9 139.3 5 7 min 0.4 0.4/5=0.08

40 Oil hole drimming & Reaming 139.4 139.7 5 6 min 0.3 0.3/5=0.06

50 Cam chain spot facing & drilling 139.7 140 5 6 min 0.3 0.3/5=0.06

60 Spark plug hole 140.1 140.6 5 7 min 0.5 0.5/5=0.1

70 140.7 141.1 5 6 min 0.4 0.4/5=0.08

90 141.1 141.5 5 7 min 0.4 0.4/5=0.0890 5 5 0 0 /5 0 08

STAR CRANK CASE90 Joint face Boring 141.6 142.2 5 15 0.6 0.6/5=0.012

100 Joint face fine boring 142.4 143 3 0.6 0.6/3=0.2

110 Cover face fine boring 143 143 3 5 6 min 0 3 0 3/5=0 06110 Cover face fine boring 143 143.3 5 6 min 0.3 0.3/5 0.06

120 Joint face boring 143.4 143.6 5 4 min 0.2 0.2/5=0.1

130 143.6 143.9 5 6 min 0.3 0.3/6=0.05


Step 1Calculate the theoretical energy consumptiongy p

Opns 10 20 30 40 60 80 90 100 110 120 130 140 150 160 170 180

Qty 10 10 10 10 10 10 10 10 10 10 10 10 10 10 10 10

Units 0.2 0.4 0.1 0.5 0.4 0.6 0.7 0.3 0.4 0.4 0.4 0.3 0.5 0.4 0.4 0.1

Total energy consumed - 6.1 unitsgy

Total components produced – 10 nos

Theoretical Energy consumption per component – 0.61 units / component


Step 2Online Energy management system

Measure actual energy consumption


Step 2 Measure actual energy consumption

Total components produced- 695 nos

Theoretical energy ( calculated ) – 695 x 0.61 = 424 units

Actual energy consumption – 229 + 340 = 569 units Area for OEE improvement

-Supported by KK,JH,Office,DM

700

800

Opportunity to reduce

424

569

500

600

700 pp y

424300

400

500

200

300

Theoretical energy Actual


Step 3 Identify the lossesTrials

700

800

Break down

Changeover delay

424

424

569

300

400

500

600

Availability

Startup loss200


yWaiting for trolley

Want of man

Want of material

Want of powerWant of power

Meetings


Planned stoppage

Step 3 Identify the losses

700

800

424

424

569

300

400

500

600

Loading delay

200


Performance Unloading delay

Defect & correction

Rejection lossQuality


Step 3 Identify the lossesBBT

H d li t

UITPower Distribution

in machinesHydraulic motor

Spindle motor

Hydraulic motorNoise cut-off transformer

yd au c oto

Spindle motorCoolant motor

Coolant motor

Axis motors

Opportunity loss569600

700

800

Slide

motor

424

424

569

300

400

500

600


200


T Di f O t it l i hi

Step 3 Identify the losses

Energy loss in the Hydraulic motor

Tree Diagram for Opportunity loss in a machine

Idle running

machine

Coolant motor Idle running

Spindle motorIdle running during

non cutting

Axis motor

Panel lightsg

Noise cut off

transformerNo load losses



Idle time off in the machines

Input Output

Idle time off in the machines

No input flag Idle timer

Idle timer On Hyd ckt OffHydraulic motor

Spindle motor

Hyd ckt ON Auto Cycle enable

motor

Coolant motorCoolant motor


Slide

motor

Power factor correction


Grid Bus

DG Bus

Cable

Auto PF

correct


OHBBT 64Step 4 Action for reduction and elimination

BEFORE AFTER

P.F.

CURRENTCURRENT


Step 4 Action for reduction and eliminationEliminate no load losses of Noise cut off transformers

3 phase supply

Control relay

Machine offTransformer off


Machine off

Result

Energy Consumption

Step 5Period : Nov ‘08

85 80 75

90 95 95 95100UOM : %

80 7575 Rs. 4.5 lakhs

per moth saved

25

50

0

25

0Painting unit Machining

unitFabrication Veh Assy


120

Summary of Results

AvailabilityUOM : % B tt

Breakdown FrequencyUOM %

Better

Numbers are indexed

100

80

6360

90

120

89

92

95

90

95

100UOM : % Better UOM : %

2412

4 20

30

60

8587

89

80

85

90

02-03' BM 03-04' 04-05 05-06' 06-07' 07-08' 08-09'

10090

8004-05 05-06' 06-07' 07-08' 08-09'

OEEBetter UOM : % Better

Production Achievement

8890

93

97

90

95

100

8082

85

80

85

90UOM : %

Better UOM : %

8688

80

85

7677

70

75


04-05 05-06' 06-07' 07-08' 08-09'04-05 05-06' 06-07' 07-08' 08-09'

3134

40130

Power cost

UOM : % Better

Power consumption

UOM : units / veh Better

Summary of Results

29 31 30

23

20

30

110

121

111110

120

0

10

2004-05 2005-06 2006-07 2007-08 2008-09

100102

90

100

2004-05 2005-06 2006-07 2007-08 2008-09

110

Manufacturing cost

UOM : % Better

100

90

100

UOM : % Better

80 79 7876

70

80


2004-05 2005-06 2006-07 2007-08 2008-09

02 TVS Motor Co. Ltd

Documents

Transcript of 02 TVS Motor Co. Ltd