Low Voltage StartabilityNew Code & Sticker

A S A 51 RRated Voltage & Frequency

A : 220 – 240V/ 50Hz

B : 220 – 240V/ 60Hz

C :127V/ 60Hz

Cooling Type

S : Static Cooling

Revision No.

A

B

C

Displacement

51 : 5.11cc/rev

Motor Type

R : Run Capacitor S : Start Capacitor N : Induction Run

LVS

IMPROVEMENTS OVER OLD COMPRESSOR

Compressor Improvements

Failure Reason Root Cause Old PracticeBest Prctice Implementation

High Amps

CRA Jam due to contamination

Graphite based Lubricant Water based lubricant used

Air Gap Shift Manual Rotor SkewingAuto Skew Rotor & stators to be started

Rotor concentricity more

 electronic gauge inplemented at supplier's end

stator squareness not ok

 squareness checking gauge implemented

No start at low voltageMotor Starting torque less

Starting Voltage ≤170V Starting Voltage ≤150V

Motor BurnMotor Overheating due

to oil starvationBlind oil hole in C/shaft

Hole Depth/ Dia verification with High Pressure cleaning

High NoiseDMA Assy bending improper

DMA Assy Manual Bending Bending Jig Implemented

checking procedure `  development of new gauges in process

IMPROVEMENTS

BEFORE AFTER

GRAPHITE BASED LUBRICANT WATER BASED LUBRICANT

EARLIER USED GAUGE FOR CHECKING

NEW GAUGE FOR CHECKING

INTRODUCTION OF WATER BASE D LUBRICANTS

INTRODUCTION OF NEW GAUGE & 100% CHECKING AT VENDOR'S END.

HEIGHT NOT OK

SPRING

ProblemComponent Action Plan

STAMPING OF UNIQUE CODE ON TOP LAMINATION STARTED

MIXING MODELS

STATOR

IMPURITIES DUE TO USE OF GRAPHITE BASED LUBRICANT

UPPER BEARING

NO STAMPING DONE STAMPING STARTED MODEL/DATE

IMPROVEMENTS

BEFORE AFTER

EARLIER USED GAUGE FOR CHECKING

NEW GAUGE FOR CHECKING

SEPARATE BINS & TRAYS

INTRODUCTION OF NEW GAUGE & 100% CHECKING

SQUARENESS NOT OKSTATORS

ProblemComponent Action Plan

DESIGN CHANGED & 100% IMPLEMENTATION

PUNCTURERUBBERCAPS

NO IDENTIFICATION & HENCE MIXINGROTORS

OLD DESIGN NEW DESIGN

NO IDENTIFICATION

IMPROVEMENTS

BEFORE AFTER

ONLY ID VERIFICATION ID + DEPTH VERIFICATION

EARLIER USED BINS

NEW BINS FOR STORAGE

BOTH ID & DEPHIS BEING VERIFIED

INTRODUCTION OF NEW BINS AT VENDOR'S END.

DENTS &DAMAGE

SHAFTS

ProblemComponent Action Plan

GUIDES PROVIDED FOR SAME.

BENDINGNOT PROPER

DMA

ONLY ID WAS BEING CHECKEDEARLIER

SHAFTS

BENDING DONE WITHOUT GUIDES

BENDING DONE WITH GUIDES

COMPONENT ACTION PLAN TARGET RESP. RESULTUPPER

BEARINGon & off timings to be changed from 20 min to 10 min. 9/9/2009 jayant

blow holes found <3 % & contamination increased >80%

temp from 470 changed to 650 9/9/2009 jayant special lot in front of mr joshi will be made & sent to VG 9/9/2009 jayant injection speed to be reduced 17/09/09 jayant done

to use ejector rods in place of bumper rods which are presently in use 17/09/09 jayant no improvement

water based die coat to be used instead of graphite based die coat 20/09/09 khotkar done raw material to be procured from new vendor 2/10/2009 Nimade done

ROTOR run out of machine mandrel to be checked after every hour. 9/9/2009 Khotkar done new gauge for checking of counter wt lamination to be received 9/9/2009 jayant done amps to be increased to 41amps for bluing at impulse 9/9/2009 jayant done Frequency of changing Plunger to 15 Days from 20 Days 19/09/09 Rahul done Online training for New operators 25.09.09 Rahul done

O D Turning in 1 Pass instead of 2 Pass. Production up by 50 % 26/09/09 Rahul done

New 200 Nos Pins will be available 10.10.09 Rahul done new fixture for done

Auto Temperature controller to be installed (at die casting process) 10.10.09 Rahul done

One spare Air Gauge set ( Electronics Column, AECM Unit, Adaptor & Ring Gauges ) 15.10.09 Khotkar done

SHELLS pdi check to be started/shift wise monitoring 10/9/2009 sandeep done to revisit the supplier to verify the process. 20/09/09 jayant done

SEAL PRESS. FAIL

all filtearation systems to be made ok with increased freequency of filteration.

15/09/09 Rahul done done

introduction of new rubbing process 3/10/2009 jayant doneLUG TAP. NOT OK

pieces with through drill/half to be given on line for tapping 25/08/09 drill breaking highpieces with through drill to be given on line for tapping

16/09/09 jayant100% ok tapping still problem of burr exists

drill length to be reduced before final tapping 3/10/2009 jayant AIR GAP without rib mufflers trial to be taken on line 28/08/09 jayant air gap improved

without rib mufflers trial to be taken on line 19/09/09 jayant air gap improved revised drawing without rib to be released 30/09/09 Dattu kr. done shuffling of operations 15/10/09 amol done

REF LINE REJECTION

high pressure cleaning of shaft to be started 30/08/09 venu donecounter on upper bearing to be started. 30/08/10 venu done

100% segregation of upper bearing to be started 20/09/09 rahul done

Action Plan & Results

IMPROVEMENTS TO REDUCE RUST/CONTAMINATION

BEFORE AFTERProblemComponent Action Plan

The Laminations were bound with binding wire by twisting the joints with the help of cutting pliers.

Refer hereunder the photograph in the Ref :Before section.

Now the two ends of the binding wire is being bent (By hand) in the side profile of the laminations as shown in the photograph Ref : After section A separate area is identified for keeping the segregated good lamination cores

Excess twisting was the reason which could cause the bend in the laminations

New binding method is introduced in the side profile of laminations which will eliminate the bend in the top & bottom lamination

Existing Packing method

1.Initially wooden box was covered with polythene stretch film.

2.Each & every layer was covered with vci paper .

3.Before closing ,the box was covered with the vci paper then it was covered with polythene stretch film.

4. Put the top wooden plate on box and belt strapped.

New packing method

1.Instead of using wooden box new carton box is introduced for packing the laminations

.

2.The carton box inside is covered with blue color & VCI coated polythene bag .

3. VCI paper is used in between the layers.

4.A top cover is used to close the box .Then box will be belt strapped

After completion of Annealing process, immediately the laminations are packed as per the new packing method.

A new packing method is introduced. It will be standardized based on the customer approval.

TopLaminationsBeing scraped

Laminationsreceived rusty