FINAL REPORT

Classified - Internal use

Project on

To eliminate the Minor stops in

overhead conveyor

UNDER GUIDANCE OF

T. Rajya.ShesuPabitra pradhan

Submitted By : Naba Kishore Sarkar

Institute of Technical Education & Research (ITER)

Bhubaneswar Certificate

This is to certify that the report entitled “To eliminate the Minor stops in overhead conveyor ” submitted by Mr. Naba Kishore sarkar in partial fulfillment of the requirements for the summer training of the degree of Bachelor of Technology in Mechanical

Engineering at Institute of Technical Education & Research, Bhubaneswar is an authentic work carried out by him under our

supervision and guidance. To the best of our knowledge, the matter embodied in the thesis has not been submitted to any other university/institute for the

award of any degree or diploma.

Date: Place: Bhubaneswar

Professor and Head Planning Manager Dr. D.N.Thatoi Arul Ram Department of Mechanical Engineering Bhubaneswar ITER, Bhubaneswar

I would like to express my gratitude to all those who helped me during my report work. First and foremost, I wish to thank my supervisor Dr. D.N.Thatoi , Prof. and Head Mechanical Engineering Department, ITER Bhubaneswar and my co-supervisor Mr. Arul Ram ,Planning Manager, HCCBPL Khurda with generosity those who have provided me an opportunity to work in such a novel and exciting research area under their great supervision.

I am sincerely thankful to Dr. H.C.Das, Prof. Mechanical Engineering Department, ITER Bhubaneswar for his valuable and kind suggestions.

I am extremely grateful to Mr. T.Rajya.Sheshu, Production Manager , HCCBPL Khurda for his persistent support and advice during the project work. I am also thankful to Mr. Pabitra Pradhan, Team Leader Production(RGB Line), HCCBPL Khurda for his help during project work.

Special thanks to my family members, without their blessings and support, I could not have reached this destination. Last but not the least, I wish to place my deep sense of thanks to my friends especially to Mr. Debashis, Line Executive(RGB) and Mr. Amar pahi for their cooperation and critical suggestion during my project work and studies.

Place: Bhubaneswar Naba Kishore sarkar

Acknowledgement

Declaration

We do hereby declare that this project entitled,” To eliminate the minor stops in Overhead conveyor” has been carried out by us in coordination with our project supervisor Mr.T.Rajya Sheshu for the fulfillment of our summer training. Any other institution for financial rewards or any other purpose has not submitted this work. We do further declare that the fact of data and figures presented in the project are to the best of our knowledge & belief.

Place: HCCBPL KhurdaDate:

Arul Ram(Planning Manager)

Pabitra Pradhan(Team leader Production Dept)

Contents

1. Project charter2. Introduction3. Process mapping4. Downtimes check list5. Downtimes chart6. Problems7. Fish bone analysis8. Causes 9. Facts10. Improvement a. Sensor b. Initial loading bay flush11. Dry floor12. Fork lift analysis chart

Project Name: Project #: Project Start/End Dates:

To eliminate the Minor stops in overhead conveyor

30 May 2013 Project Lead: Naba kishore sarkar Executive Sponsor: Arul RamUnder Guidence of: Project Costs: (include required capital, expenses)

T. Rajya . SheshuPabitra Pradhan

- /- - Expenses:

Mission/Project Overview:

To find out the main problems behind the downtimes of over head conveyor

Objectives: (include beginning & ending KPI's) Net Benefits:

To improve SLE of RGB from current level Reduce downtimes

In Scope: OE Tools to be used: Out of Scope:

RGB overhead conveyor

Assumptions: Risks & Constraints:

Number of product changes will remain same or less than current ratio.

Project Milestones: Dependencies:

Define : 30 June 2013

Measure : 15 July 2013Analyze: Causes of downtimes

Improve : Reduce the downtimes

Control : Break down

Project Lead Time: (Total time required to implement) 2Months Other Key Stakeholders & Areas Affected:

Approvals:

Project Lead: Naba Kishore Sarkar Date: Area Lead: Date: Finance: Date: Executive Sponsor/Steering Committee:

Date:

PROJECT CHARTERList of downtimes of overhead conveyor

A conveyor system is a common piece of mechanical & electrical handling equipment that moves materials from one location to another. Conveyors are especially useful in applications involving the transportation of heavy or bulky materials.

Overhead conveyor which is used in HCCBPL RGB line is stainless steel flat top chain.

Introduction :

Process mapping

Empty yard( Loading Bay)

Slope conveyor(upward)

Slope conveyor(downward)

Horizontal

Spiral conveyor

Horizontal

Uncaser

SL. No DATE SHIFT PROBLEM ACTION TAKEN ROOT CAUSE DOWNTIME(mins)

1 30-May C chain link bend 4 Link cutted over age & lack of lubrication 4

2 31-May A chain out Chain shortened wear & tear 2

3 31-May B broken crate problem

crate released and conveyor restarted

broken crate stucking 4

4 1-Jun A chain out sporcket changed sprocket damage 14

5 1-Jun A spiral conveyor strip damage strip was replaced more chain

slackness 4

6 1-Jun chain out (slope conveyor) Chain shortened Worn out due to

lack of lubrication 10

7 2-Jun B chain out sprocket changed Sprocket damage 8

8 2-Jun spiral conveyor strip damage new strip fitted Due to life span 4

9 3-Jun A chain out cutted and fitted wear & tear 12

10 4-Jun B chain out Chain shortened Worn out due to lack of lubrication 14

11 5-Jun A chain out from idler new modified collar was fitted heavy dirt particles 8

12 5-Jun B chain out sprocket changed Sprocket damage 24

13 7-Jun C chainout Chain shortened wear & tear 12

14 8-Jun C chain out Chain shortened lack of lubrication 6

15 11-Jun B OHC stops sensor was cleaned sensor problem due to heavy rain 4

16 11-Jun C OHC trip reset and restarted Frequent start and stop 3

17 12-Jun B OHC chain slip sprocket changed Sprocket damage 4

18 12-Jun A chain out repaired Wear striped damaged 24

19 13-Jun B chain out repaired Wear striped damaged 6

20 13-Jun C sensor problem sensor was cleaned sensor problem due to heavy rain 4

21 14-Jun A sensor problem sensor was cleaned sensor problem due to heavy rain 20

Downtimes check list

1) Chain out from sprocket2) Motor trip3) Chain link bend4) Cable short5) Channel break6) Collar roller damage7) Bearing damage8) Strip damage (spiral

conveyor)9) Sensor malfunction10)Broken crate

Problems faced in overhead conveyor (Top ten)


Overhead

conveyor stops

Overhead

conveyor stops

Technical skill

Training

Broken crate Sensor malfunction

Cable short

Chain link bend

Strip damage in spiral

conveyor

Channel break

Chain out from sprocket

MATERIAL

METHOD

MACHINE

MAN

Heavy dirt particles & heavy rain

Motor tripped

Fishbone analysis for Overhead conveyor failure

Lack of lubrication

Lack of awareness

Fluctuation of voltage

supplyOver load &

bearing failure

Lack of lubrication & life

span of strip

Frequent use & lack of

lubrication

Bearing damage

Lack of lubrication Wear and tearOver load ( sensor malfunction)Sprocket worn outHeavy dirt particlesFrequent start & stop ( Fluctuation

of power)Broken crate stuck Life span

Causes of chain out


* Stainless steel flat chains slides over plastic plates to get less friction and obtain better slide.

Improvement to reduce downtimes

Before After

No protection from rain New SS cover for sensor to avoid heavy rain

Improvement to reduce downtimes

By this modification heavy dirt particles coming with crate will get flushed & SS cover will avoid water contact with motor.

Pictures captured during breakdown

Strip broken on spiral conveyor SS flat chain link broken

BEFORE AFTER


Day 2 Fork Lift No : 14 (Double capacity , battery operated )

Date : 25 May 2013

Driver Name : Mr Kesar Gajendra

Shift: A

Sl. No. Time Workdone1 Workdone2 Workdone3 Workdone4 Remarks

Total Total

Palates

cases

1 6:00-7:00

Was there in ware house till 6:30am

Engine starts at 6:30am

Shifting of palates till 7am NA NA NA NA

2 7:00-8:00

At 7:00 started working in ware

house7:55-8:00 No work NA NA

Only shifted few palates which were not fully

loaded11 581

3 8:00-9:00

Switched off engine at8:15 Went for breakfast NA NA Lifted few fully loaded

palates 3 146

4 9:00-10:00 Engine starts at 9:00 Went to maintenance

yard at 9:15Engine switched off for battery change NA Did sourcing work 14 856

5 10:00-11:00

At 10:02 engine starts after battery

changed.10:08- 10:10 took rest 10:30-10:35 roamed

without any work10:35-10:55 again

took rest

Here he worked in production, sourcing,

dustbin shifting etc19 976

6 11:00-12:00

Worked in sourcing of empty RGB

11:40-11:50 mango pulp drums shifting

Worked for production This 1hr he worked at a

good speed 74 ####

7 12:00-13:00 NA NA NA NA NA NA NA

8 13:00-14:00

NA NA NA NA NANA NA

Initial running hour= 10107 Total no. palates =121

Final running hour =10111.5 Total no. cases=6079Total running hour= 4.5hr BY- Naba Kishore Sarkar

Participated in taking the observation for determining forklift efficiency.

THANK YOU

FINAL REPORT

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