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Typ Notifctn Notif.date EquipmentBD

typeDescription MalfStrt Malf.end

Downti

meCause Wor

M2 10135873 01.08.2013 8STN-403 E motor not run 13:30:00 15:30:00 2Motor fan not working, so motor

heated up

Changed

down th

M2 10135869 01.08.2013 8STN-403 E motor power short 10:30:00 12:00:00 1.5 Motor heated up so MCB trippedReset M

shorting

M2 10135441 01.08.2013 H-402 M spindle sound prob. 13:30:00 14:00:00 0.5 wedge got stuckremove

done

M2 10135872 01.08.2013 SRG-403 E single phase alarm 11:10:00 12:40:00 1.5one phase missing for A axis servo

motor for roatry from amplifier

Checkedcontinui

motor si

M2 10135867 01.08.2013 SVM-402 E x axes, y axes & z axes alarm 11:10:00 12:00:00 0.83VRDY alarm repeated , Z axis

motor heated up

Checked

coupling

cable wi

M2 10135874 02.08.2013 8STN-403 Eback chamfer motor trip

prob.13:45:00 14:00:00 0.25

Motor heated up and found play in

spindle shaft

Remove

checked

motor sh

M2 10135829 04.08.2013 SHD-403 M air pressure high & low 20:20:00 20:30:00 0.17Air pressure low as Nitrogen plant

runStarted

M2 10135824 05.08.2013 H-402 M sound prob. 10:20:00 10:30:00 0.17 y-clamp bolt loose y-clamp

M2 10135823 05.08.2013 H-403 E spindle not run 16:30:00 17:20:00 0.83 belt damaged Belt cha

M2 10135875 05.08.2013 SVM-402 M

hydraulic pressure gauge

offset/ rotary switch for

h draulic ressure aua e

15:30:00 17:15:00 1.75

Roatry switch for hydraulic

pressure gauge not working due to

one o-rin found dama ed

changed

disment

M2 10135825 07.08.2013 H-403 M break shoo broken 7:50:00 8:50:00 1 clutch liner loose changed

M2 10135831 07.08.2013 H-404 Eboth m/c power connection

on panel7:40:00 9:20:00 1.67

Motor connection loose so motor

heated uprepaired

M2 10135830 07.08.2013 H-405 E motor not working 7:40:00 9:20:00 1.67Motor connection loose so motor

heated uprepaired

M2 10135879 07.08.2013 SRG-401 E rotary over heat alarm 21:45:00 23:00:00 1.25

coolant entered inside rotary

motor due to parralism upset and

coolant leaka e from there

Remoev

and dry

cover on

M2 10135878 07.08.2013 SVM-402 E indexing prob. 8:00:00 9:10:00 1.17Limit switch signal not coming due

to element stucked inside

Changed

damage

M2 10135826 08.08.2013 8STN-404 M back chamfer spindle prob. 0:20:00 0:45:00 0.42 belt wear out due to wet condition change t

M2 10135828 08.08.2013 8STN-404 E power trip prob. 12:03:00 12:23:00 0.33NC tripping problem due to lamp

connection choke shorted

Remove

changed

M2 10135832 08.08.2013 H-405 bush not ok 8:30:00 9:00:00 0.5 cylinder fittment space problem sheet gr

M2 10136372 08.08.2013 M-401 running time spindle stop 4:00:00 22:30:00 18.5 Spindle rotation gears bolt broken Remove

M2 10135833 08.08.2013 SHD-403 M air pressure low 12:30:00 12:40:00 0.17 vary from FRL FRL set

M2 10135891 08.08.2013 SVM-401 M Spindle belt broken 16:30:00 17:20:00 0.83 belt ribs cut belt cha

M2 10135827 09.08.2013 8STN-404 M belt slip prob. 0:30:00 1:00:00 0.5Belt wear out of 6th head

backchamferChanged

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M2 10135902 09.08.2013 CLTAP-401 M spindle offset 12:50:00 13:00:00 0.17 footpaddle problem repaired

M2 10135895 09.08.2013 SRG-401 M rotary prob. 10:20:00 10:40:00 0.33Variation in component due to

rotary axis coupling slip down

Changed

ETP-22 a

M2 10135892 09.08.2013 SVM-402 E enter down reason alarm 7:30:00 9:30:00 2Ethernet adopter was creating

problem and hanged

Remoev

line TPM

Etherne

M2 10135905 10.08.2013 SHH-401 M home position forget prob. 10:10:00 10:30:00 0.33 Encoder cable loose Tightene

M2 10136373 10.08.2013 SVM-403 E air sensor not on 10:45:00 11:10:00 0.42 air sensor faulty changed

M2 10136396 11.08.2013 SRG-404 E x.y.a. delete alarm 7:00:00 7:40:00 0.67

Softkeys not working due to oil

and so wrong data feeded in

machine

Cleaned

checked

LCD scre

M2 10136397 13.08.2013 SHH-401Cycle start push button not

working13:40:00 13:50:00 0.17 NC element creating problem Changed

M2 10136380 14.08.2013 H-403 M spindle prob. 7:30:00 8:50:00 1.33Spindle not taking load due to

push rod moutning loosetightene

M2 10136395 16.08.2013 8STN-404 M spindle jam prob. 19:30:00 20:00:00 0.5

Found spindle moving very tight

and with sound as its face cover

one bolt was not sittin ro erl in

Lossene

changed

M2 10136394 16.08.2013 H-403 M spindle not stop prob. 12:45:00 13:30:00 0.75Wedge not coming outside due toone cylinder mounting was

creatin roblem and not workin

Repaired

and set t

M2 10136405 16.08.2013 SHD-403 M air pressure low 16:30:00 16:40:00 0.17Air pressure low as Nitrogen plant

runStarted a

M2 10136398 16.08.2013 SVM-401 M clamping prob. 12:10:00 12:25:00 0.25 coil connection loose connect

M2 10136950 17.08.2013 8STN-405 M belt slip prob. In 2nd head 7:20:00 11:40:00 4.33

Found belt in ok condition, but

RPM slow down during running

cycle

Changed

remain s

side ( mo

M2 10136951 17.08.2013 H-403 M spindle not stop 0:10:00 1:00:00 0.83 brake shoe bolt setting disturbed bolt sett

M2 10136957 17.08.2013 H-404 E both m/c power connectionconnect

7:00:00 7:40:00 0.67 mpcb faulty of h-405 as both m/cconnected with same mcb

changed

M2 10136956 17.08.2013 H-405 M spindle not run 7:00:00 10:30:00 3.5

Spindle motor heated up due to

single phasing from MCB pole

fault and heav sound

Changed

and cha

M2 10136959 17.08.2013 SFB-401 Mslide cover broken(Aprin

cover for ball screw)22:15:00 22:30:00 0.25

Aprin cover for ball screw

protection damaged as during tool

chan e force on a rin cover is

Repaired

prod pe

M2 10136958 17.08.2013 SHD-403 M chamfer more prob. 14:30:00 15:00:00 0.5 Air pressure vary during operationSet the a

regulato

M2 10136952 18.08.2013 H-403 spindle not stop 9:00:00 9:10:00 0.17 brake shoe bolt setting disturbed bolt sett

M2 10136966 19.08.2013 SHH-401 y axis home position forget 14:05:00 14:30:00 0.42Checked and found that encoder

connector loosetightene

M2 10136954 23.08.2013 H-403 M load prob. 13:30:00 15:00:00 1.5 Cluthc liner not working changed

M2 10136953 23.08.2013 SHH-403 M pulls miss alarm 12:00:00 12:10:00 0.17 Load on spindle released

M2 10136962 23.08.2013 SVH-401 M abnormal sound prob. 11:00:00 11:10:00 0.17Sound came from Hydraulic pump

unit

Checked

level , m

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M2 10138708 25.08.2013 8STN-404 M spindle not run 18:50:00 19:30:00 0.67spindle pulley bolt open and stuck

in belt and pulley

remove t

properly

M2 10138766 26.08.2013 8STN-404 M coolant bud broken 16:30:00 17:00:00 0.5

one spiral coolant bud broken due

to frequent motion on toll for

coolant setting

Repaired

for new o

M2 10138767 26.08.2013 8STN-405 E power trip prob, 17:10:00 17:30:00 0.33 relay malfunctioning relay cha

M2 10138952 26.08.2013 DDG-401 Evoltage stabilizer

modification8:10:00 8:30:00 0.33

steplizer not working in auto mode

due to card problemso setting

M2 10138768 26.08.2013 H-403 M spindle jam prob. 21:50:00 22:15:00 0.42spindle coupling got shift due to

bolt loose

so tightne

properly

M2 10138951 26.08.2013 SHD-403 M air pressure low 7:30:00 7:40:00 0.17 vary from FRL set the F

M2 10138939 27.08.2013 SRG-401 Erotary prob.(jerking in

rotary)18:00:00 18:40:00 0.67 Checked and found belt may sl ip

Checked

under ob

M2 10138765 27.08.2013 SVM-401 M run out prob. 7:50:00 8:15:00 0.42Bellow coupling may cause the

problem

Changed

19x20

M2 10138941 29.08.2013 8STN-403 E a axis o.v.c. alarm 17:15:00 18:10:00 0.92tap head play due to spindle pulley

key wear outchange th

M2 10138935 29.08.2013 H-402 m belt broken 21:45:00 0:00:00 0 belt broken belt chna

M2 10138934 29.08.2013 SVM-403 M hydraulic pressure low 17:15:00 18:00:00 0.75Hydraulic pressure reduced in

pumpSet the p

M2 10138938 30.08.2013 DAM-407 E clamp declamp prob. 3:30:00 3:50:00 0.33 NO-elemnt malfunctioning change th

M2 10138943 31.08.2013 SRG-403 M foot pedal not working 13:40:00 13:50:00 0.17Foot padel wiring loose from

insideTightene

M2 10138945 31.08.2013 SVM-402 Epower not available in panel

/LCD17:15:00 18:40:00 1.42

Electrical Shorting of 24 V DC

electrical panel due to one wire

cut and touched with bod

Cut nd re

58

92

50600

63.21

1.089827586

872.4137931

Frequency

Total m/c

total available

hrs.

Total Break

down Hrs.

MTTR

MTBF

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M/C code BD hrs.

SM-401 18.5

SVM-402 7.17

H-403

H-405

8STN-403 168STN-405 4.66

8STN-404 2.92

H-404

SRG-401 2.25

SRG-403 1.67

SVM-401 1.5

SHD-403 1.18

SVM-403 1.17

SHH-401 0.92

H-402 0.67SRG-404 0.67

DAM-407 0.33

DDG-401 0.33

SFB-401 0.25

CLTAP-401 0.17

SHH-403 0.17

SVH-401 0.17

60.7

M/C code OccurancesH-403 8

8STN-404 6

SVM-402 5

SHD-403 5

8STN-403 4

H-405 3

SRG-401 3

SVM-401 3

SHH-401 3

8STN-405 2H-404 2

SRG-403 2

SVM-403 2

H-402 2

SM-401 1

SRG-404 1

DAM-407 1

DDG-401 1

18.5

7.17

16

4.6

0

2

4

6

8

10

12

14

16

18

20

8

6

5 5

4

3

1

2

3

4

5

6

7

8

9

Nos.

1. 18.5 Hrs. - Gear unitbolts broken- changedbolt

Hrs.

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SFB-401 1

CLTAP-401 1

SHH-403 1

SVH-401 1

58

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6

2.922.25

1.67 1.5 1.18 1.17 0.92 0.67 0.67 0.33 0.33 0.25 0.17 0.17 0.17

BD hrs.- Aug-13 BD hrs.

1. Clutch liner not working due tofaceplate damaged/rubbed- rpetaed

problem- will take in reconditioningafter installation of Ingish machine

1. 2 hrs. -Enterdown reason came for OnlineTPM - ethernet adopter was creating problem-

removed at time and changed.

2. 1.75 Hrs. - Hydraulic gauge rotaryswitch not working- found o-ringdamaged inside-changed3. 1.42 Hrs. - Shorting in electrical 24v DC -one cable foun cut in operator panel

3 3 3

2 2 2 2 2

1 1 1 1 1 1 1 1

Occurances- Aug-13 Occurances

Machine name

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Machine name

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Repeated BD elimination

S.No. M/C code Problem Cause

1 SVM-403 HSRA line

Hydraulic pressure in SVM-

403 machine going down

from 30kg to 20 kg

Vane pump setting disturbed

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Action Done date Effectiveness

Dismentelled thepump and set the

ring and spring as

per drawing of

Pump

28.08.2013Pressure set is on 35 kg still

maintained and not coming down

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Preventive action

Training manual to be made to set the pump if

there is any variation in pressure due to pump

setting distrubed

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1 Belt Inspection weekly

2 Pulley Inspection weekly

3 Operator panel inspection weekly

4 Lub oil leakage inspection fortnightly

5 Hydraulic oil leakage inspection fortnightly

6 Coolant leakage from machine inspection fortnightly

7 Mist collector cleaning monthly

8 SRG- rotary runout on Shunk weekly

9 Coolant entry in SRG rotary weekly

10 Parralalism bolt length in roatry plate weekly

11 Stabilser maintenance monthly

12 Thru coolant rotary coupling inspection monthly

13 Compressor service monthly

14 R.O. service monthly

15 Softner working / service monthly

16

17

18

19

20

Monthly Inspection Schedule

Sr.No. Activity Planned Schedule

Date

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Line SHIFT Month Date M/c Description

Intake A August 1-Aug-13 8STN-403 Back chamfer motor power short

Intake A August 1-Aug-13 8STN-403 Back chamfer motor not run.

Intake A August 2-Aug-13 8STN-403 Back chamfer motor trip

Intake A August 29-Aug-13 8STN-403 SOUND PROB,

Intake B August 29-Aug-13 8STN-403 A AXIS O.V.C. ALARM

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Dept. Type Duration start time end time Duration

107 M2 90 10:30 12:00 90

107 M2 120 13:30 15:30 120

107 M2 15 13:45 14:00 15

107 M2 10:30 14:10 220

107 M2 55 17:15 18:10 55