Project on List of downtimes of overhead conveyor & closure of the same by PM check or by visual...
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Transcript of Project on List of downtimes of overhead conveyor & closure of the same by PM check or by visual...
Classified - Internal use
Project on
List of downtimes of overhead conveyor & closure of the same by PM check or by visual methodology
Project Name: Project #: Project Start/End Dates:
List of downtimes of overhead conveyor & closure of the same by PM check & visual methodology 30 May 2013 Project Lead: Naba kishore sarkar Executive Sponsor:
Arul Ram
Under 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 is stainless steel flat top chain.
Introduction :
Process mapping
Empty yard( Loading Bay)
Slope conveyor(upward)
Slope conveyor(downward)
Horizontal
Spiral conveyor
Horizontal
Uncaser
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
Types of problems occurs in overhead conveyor (Top ten)
Classified - Internal use
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
MACHINE
METHOD
MAN
Heavy dirt particles & heavy rain
Motor tripped
Fishbone analysis for Overhead conveyor failure
Lack of lubrication
Lack of awareness
Fluctuation of voltage supply
Over 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)Heavy dirt particlesBroken crate stuck Frequent start & stop ( Fluctuation of power)Life spanSprocket worn out
Causes of chain out
Classified - Internal use
* 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
Classified - Internal use
BEFORE AFTER
Classified - Internal use
BEFORE AFTER
Classified - Internal use
Classified - Internal use
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 house 7:55-8:00 No work NA NA Only shifted few palates which were not fully
loaded 11 581
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 9:15 Engine 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
work 10:35-10:55 again took rest Here he worked in production, sourcing, dustbin shifting etc 19 976
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 13:00-14:00NA NA NA NA NA
NA NA
Initial running hour= 10107 Total no. palates =121
Final running hour =10111.5 Total no. cases=6079
Total running hour= 4.5hr BY- Naba Kishore Sarkar
Participated in taking the observation for determining forklift efficiency.
THANK YOU