Gear Monthly Report,Sep'10

8/8/2019 Gear Monthly Report,Sep'10

1/24


2/24

16/9/2010 B Atsunyu gear grindi AGG301 lub motor trip & pressure not build up 6:20 8

6/9/10 B Final gear FGH202 4:30

11/9/10 B Sleeve line SNH404 Auto door problem 17:20

18/9/2010 A Hira gear HGH704 Part carrier Raise problem 7:15

20/9/2010 A Sleeve line SNH504 Auto door not working 1;30

28/9/2010 A Input shaft ISH408 Lubrication oil leakage problem 8:00

28/9/2010 B Hira gear HGH601 Auto door Obstacle detection alarm 16:00 1

18/9/2010 A Input shaft ISH311 Door open close problem 9:10

20/9/2010 C Sleeve line SNH604 Broach cutting coolant not coming 11:30

16/9/2010 C Hira gear grinding HGG501 Motor over load alarm 2:20

1/9/10 C Sleeve line SNH101 Broaching m/c hyd pipe have leakage 12;30 0

3/9/10 B Input shaft ISH201 LH slide down 16:00

7/9/10 B Sleeve line SGH201 Pull head open close both LS faulty 11:55

9/9/10 A Sleeve line SGH106 Cycle not complete 7:30

16/9/2010 C Input shaft ISH209 Component present senser not working 5:00 0

20/9/2010 B Input shaft ISH205 Area senser continuously high 4:00

27/9/2010 B Counter shaft CSH208 Deburing motor not ok 10:45

8/9/10 B Counter shaft grindi CSG104 Foot stock advance alarm 7:00

15/9/2010 C Sleeve line SNH302 Pusher not working 4:45

3/9/10 A Counter shaft CSH404 Out chute not working 7:20

18/9/2010 B Counter shaft CSH207 M/C master not On 3:45

Auto cycle not run & cutter slide continuouslyrotate


3/24

Sum of Effective Time(In MIN) Count of Effective Time(In MIN)Machine No Total Machine No TotalIGH603 5760 SNH404 4ISH110 2040 ISH201 3

ISH319 930 FGH202 2ISH108 600 HGG501 2CSH301 480 IGH203 2ISH201 465 ISH110 2ISH210 460 ISH210 2MGH107 420 MGH105 2SNH404 395 SGH201 2MSH105 330 SNH504 2HGH302 320 AGG203 1AGG203 270 AGG301 1IGH203 270 AGG704 1MSH106 250 AGG705 1

AGH606 240 AGH202 1FGH202 230 AGH503 1CSG105 210 AGH601 1IGH404 180 AGH604 1SNH504 180 AGH606 1AGG705 170 AGH704 1CSG405 150 CSG104 1HGG501 150 CSG105 1ISH302 150 CSG201 1SGH107 150 CSG403 1ISH213 140 CSG405 1SNH503 140 CSH105 1

SGH201 135 CSH108 1AGG301 130 CSH207 1HGH601 120 CSH208 1HGH704 120 CSH209 1ISH408 120 CSH301 1ISH311 110 CSH404 1SNH604 105 FGG302 1IGG403 90 HGG401 1IGH303 90 HGH302 1IGH402 90 HGH601 1ISH205 90 HGH701 1ISH209 90 HGH704 1

SGH106 90 HGH804 1SNH101 90 HGH903 1CSH208 80 IGG403 1MGH105 80 IGH303 1CSG104 75 IGH402 1CSH105 75 IGH404 1SNH302 75 IGH501 1CSH207 60 IGH603 1


4/24

CSH404 60 IGH801 1SGH205 60 IGH901 1SNH406 60 ISG203 1AGH202 55 ISG204 1AGH604 55 ISG405 1CSG403 55 ISH108 1

FGG302 55 ISH205 1IGH801 55 ISH209 1MGH106 55 ISH213 1AGG704 50 ISH302 1AGH601 50 ISH310 1CSH108 50 ISH311 1CSH209 50 ISH319 1ISG405 50 ISH402 1MSH104 50 ISH408 1SNH506 50 MGH106 1HGH804 45 MGH107 1ISH310 45 MSH104 1

AGH503 40 MSH105 1IGH901 40 MSH106 1ISG204 40 SGH101 1AGH704 30 SGH106 1CSG201 30 SGH107 1HGG401 30 SGH205 1HGH903 30 SNH101 1ISH402 30 SNH302 1ISG203 25 SNH406 1SGH101 25 SNH503 1HGH701 20 SNH506 1IGH501 20 SNH604 1

(blank) (blank)Grand Total 18305 Grand Total 89


5/24

IGH603 5760 5760ISH110 2000 7760ISH319 930 8690

ISH108 600 9290CSH301 480 9770MGH107 420 10190ISH210 420 10610MSH105 330 10940HGH302 320 11260AGG203 270 11530MSH106 250 11780AGH606 240 12020IGH203 240 12260 SNH404 4 4ISH201 240 12500 ISH201 3 7CSG105 210 12710 FGH202 2 9

IGH404 180 12890 HGG501 2 11AGG705 170 13060 IGH203 2 13CSG405 150 13210 ISH110 2 15ISH302 150 13360SGH107 150 13510SNH503 140 13650ISH213 140 13790ISH201 135 13925AGG301 130 14055FGH202 120 14175SNH404 120 14295HGH704 120 14415

SNH504 120 14535ISH408 120 14655HGH601 120 14775ISH311 110 14885SNH604 105 14990HGG501 100 15090SNH101 90 15180ISH201 90 15270SGH201 90 15360SGH106 90 15450ISH209 90 15540ISH205 90 15630

IGG403 90 15720CSH208 80 15800CSG104 75 15875CSH105 75 15950SNH302 75 16025SNH404 70 16095CSH404 60 16155CSH207 60 16215


6/24

SGH205 60 16275SNH504 60 16335SNH406 60 16395


7/24

Date Shift Line Machine No From Up To Effective Ti

22/9/2010 B Ittai gear IGH603 7:00 5760

1/9/10 A Input shaft ISH110 8:30 16:00 2000

30/9/2010 B Input shaft ISH319 5:00 8:30 930

7/9/10 B Input shaft ISH108 7:00 17:00 600

08/09/10 C Counter shaft CSH301 3:00 11:30 480

08/09/10 A Two wheeler MGH107 7:00 14:00 420

14/9/2010 B Input shaft ISH210 16:00 19:05 420

13/9/2010 A Two wheeler MSH105 7:00 12:30 330

14/9/2010 B Hira gear HGH302 16:30 23:30 320

20/9/2010 B Atsunyu gear grindinAGG203 8:15 12:30 270

18/9/2010 A Two wheeler MSH106 7:00 12:00 250

14/9/2010 B Atsunyu gear AGH606 16:30 20:00 240

16/9/2010 C Ittai gear IGH203 3:00 7:00 240

29/9/201011:50PM


8/24

22/9/2010 C Input shaft ISH201 12;30 4:30 240

27/9/2010 A Counter shaft grindinCSG105 8:00 11:30 210

10/09/10 A Ittai gear IGH404 8:00 3:30 180


20/9/2010 B Sleeve line SNH404 3:45 7:30 160


7/9/10 B Input shaft ISH301 18:00 20:30 150

7/9/10 B Sleeve line SGH107 14:00 18;30 150

08/09/10 B Sleeve line SNH503 6:20 8:40 140

24/9/2010 A Input shaft ISH213 8;40 11:15 140

3/9/10 A Input shaft ISH201 13:30 15;45 135


6/9/10 B Final gear FGH202 4:30 6:30 120

11/09/10 B Sleeve line SNH404 17:20 19:30 120

18/9/2010 A Hira gear HGH704 7:15 9:20 120


9/24

20/9/2010 A Sleeve line SNH504 1;30 3:30 120

28/9/2010 A Input shaft ISH408 8:00 10:00 120

28/9/2010 B Hira gear HGH601 16:00 20:00 120

7/9/10 A Final gear FGH202 7:40 9:30 110

18/9/2010 A Input shaft ISH311 9:10 11:00 110

20/9/2010 C Sleeve line SNH604 11:30 1:45 105

16/9/2010 C Hira gear grinding HGG501 2:20 4:00 100

1/9/10 C Sleeve line SNH101 12;30 2:00 90

3/9/10 B Input shaft ISH201 16:00 17;30 90

7/9/10 B Sleeve line SGH201 11:55 1:30 90

09/09/10 A Sleeve line SGH106 7:30 9:00 90

16/9/2010 C Input shaft ISH209 5:00 6:30 90

20/9/2010 B Input shaft ISH205 4:00 5:30 90

23/9/2010 B Ittai gear IGH303 17:30 19; 90

23/9/2010 B Ittai gear grinding IGG403 6:30 8:00 90

28/9/2010 C Ittai gear IGH402 4:36 6:20 90

27/9/2010 B Counter shaft CSH208 10:45 12:05 80

08/09/10 B Counter shaft grindinCSG104 7:00 8:15 75

11/09/10 C Counter shaft CSH105 12:45 2:00 75

15/9/2010 C Sleeve line SNH302 4:45 6:00 75

09/09/10 A Sleeve line SNH404 1:00 2:10 70


10/24

3/9/10 A Counter shaft CSH404 7:20 8:20 60


22/9/2010 C Sleeve line SGH205 2:00 3:00 60

24/9/2010 C Sleeve line SNH504 2:00 3:00 60

25/9/2010 C Sleeve line SNH406 3:00 4:00 60

1/9/10 A Two wheeler MGH106 10:30 11:30 55

4/9/10 B Final gear grinding FGG302 19:00 19:55 55

6/9/10 A Atsunyu gear AGH604 7:40 9:00 55


16/9/2010 C Ittai gear IGH801 1:55 3:00 55


11/24

22/9/2010 C Atsunyu gear AGH202 5:00 6:00 55

3/9/10 B Atsunyu gear grindinAGG704 10:00 111;30 50

4/9/10 B Sleeve line SNH506 7:40 8;30 50

20/9/2010 A Two wheeler MSH104 7:10 8:15 50


28/9/2010 B Hira gear grinding HGG501 7:00 7:50 50


29/9/2010 A Input shaft grinding ISG405 2:10 3:00 50

30/9/2010 C Atsunyu gear AGH601 12:30 1:20 50

4/9/10 B Input shaft ISH310 3:45 4:30 45

7/9/10 B Sleeve line SNH404 3;30 4:15 45

18/9/2010 C Sleeve line SGH201 1:15 2:00 45

27/9/2010 A Hira gear HGH804 1:30 2:15 45

18/9/2010 C Ittai gear IGH901 12:20 1:00 40


12/24

25/9/2010 A Two wheeler MGH105 7:50 8;30 40

25/9/2010 C Input shaft ISH110 1:00 1:40 40

27/9/2010 A Two wheeler MGH105 7:00 8;40 40

28/9/2010 B Input shaft grinding ISG204 9:00 9:40 40

29/9/2010 A Input shaft ISH210 11:45 12:25 40

30/9/2010 B Atsunyu gear AGH503 5:00 5:40 40

6/9/10 C Input shaft ISH402 12:45 1:15 30

7/9/10 B Counter shaft grindinCSG201 6:00 6:30 30

21/9/2010 A Atsunyu gear AGH704 12:00 12:30 30

27/9/2010 C Hira gear HGH903 4:45 5:15 30

27/9/2010 C Hira gear grinding HGG401 3:00 3:30 30

29/9/2010 B Ittai gear IGh203 10;30 11:00 30

7/9/10 B Input shaft grinding ISG203 7:15 7:40 25

09/09/10 B Sleeve line SGH101 8:20 8:45 25

09/09/10 B Ittai gear IGH501 11:00 11:20 20

10/09/10 A Hira gear HGH701 10:40 11:00 20


13/24

Breakdown

Change the Bearing now ok

ATC falling tool Unknown

Change the new bearing now ok

Change the wire now ok

Unknown Bolt changed

Pending from A shift Change the rotary s/w

M/C control not On Change the soleniod valve now ok welding done

Repair the wire by resoldering change the belt

Lub pump not ok

alarm no. 300 & 307 M/C Refrencing done So put new wire now ok

Welding done connect wire

Unknown change the push button

Component profile NGproblem

Hob spindle Bearingfaulty

oun s s e ac ngpulley spindle ring phaseopen or break so to becheck in Sunday now m/crunning

Check the ATC arm spring & camfollower bearing & tight it andchange the pin also but problemnot solve

Check & filled gas inchiller unit & restart nowok

Spindle motor over load alarm

Tail stock spindlebearing faulty

445 X axis softdisconnect

X axis motor coupling broken

Change the coupling & donereferencing now ok

Proper meshing done &push button repair

Programme not select& RH spindle REV notrun

Programmeselsector s/w faulty& Rev contactor burn

Programme s/w bypass in hardwiring & contactor change

Part carrier cylinder up/down mountingbolt broken

Change another motor now ok

M/c tool fallingproblem

Change its ATC cam follower bearing

Due to clamp /declamp soi. Foundshort

Turret Indexing abortalarm

Turret indexingmotor encoder wirebroken

Pump not build uppressure

Pump O ring found damage sochanged the O ring

Change the relay nowm/c ok

Z axis home positionnot ok

M/c door open closeproblem

Door broken fromone side

Component not clampand declamp

Check by manually operate but notok so pending


14/24

Hyd. Oil level low Filled the hyd. Oil now ok Set the senser now ok

Soleniod valve jam

Unloader not working Replaced the photo senser now ok So set it now ok

Front door problem Change the seal

Auto door fault Welding done

Change the bolt Weld the block

Due to vibration Change the hyd. Pipe

Change the bolt

LS change

LH slide down Tight the cylinder chuck nut

Pump jam Checked & clean the pump now ok

Change the hose pipe

Auto door problem Welding done

Unknown Set the read s/w

LH slide not in homeposition

LH slide chuck nutopen & fall down

Took axis to position & chuck nuttight

When check & foundfixture clamp reads/w malfunction thenset it properly

Foot stocknotadvance

Part stand notworking

Check & change the soleniod valvenow ok

key pad changed nowok

Part present photosenser faulty

Cylinder sealdamage

Due to dog bolt broken somodifythe dog now ok

due to mounting

broken

relief valve, motor but stillnoise coming.Thenchange the sucktion pipe

fitting,M/C OK

Z axis 0VC softthermal alarm

Rh slide centeringpully belt tensionmounting boltbroken

Part carrier up downhyd pipe broken

Componentclamp/unclamp fault

May be programmefault

Check & found clamp unclampworking ok in Manual but problem

coming in auto applied M61, M62code with MDI working ok insteadof M12 & M13

Loading arm alignmentdone

Chuck centre notworking

Because its air regulator spring &pressure s/w faulty

Change the spring & pressure s/wnow ok

cylinder chuck notopen

Gripper cylinder interchange with CSH110

lub motor trip &pressure not build up

Set the lifter locking pinthen ok

Auto cycle not run &cutter slidecontinuously rotate

Vertical slide senser not working

Change the vertical slide senser &set horizental slode home senser

Its mounting platedamage

change the senser faulty

Part carrier Raiseproblem

Check Hyd. Pr. & cylinder found okclean soleniod now ok


15/24

Auto door not working Weld the plate

O ring damage Reset the power now ok

Repair safety s/w now ok

Change the Soleniod valve now ok

Motor over load alarm Input conveyor jam

New pipe fitted

LH slide down Pending from A shift

Clean the cylinder

Cycle not complete Replaced the pressure s/w Alignment done now ok

senser faulty change the senser

Area senser faulty Bypass area senser

clean the valve now ok

Auto cycle not run Clean the cylinder change the pipe now ok

Remove AC connection

Deburing motor not ok Its belt broken Chanege the belt & pulley refitted Tight it

change the bolt Piston rod again fitted

Auto cycle not start By pass the senser

Gripper not working Welding done

Auto door not working Mounting plate bend Straight the plate now ok Welding done

Due to cylinder seal jam

So open the cylinder and changedcylinder seal

Lubrication oilleakage problem

change the wheel head assemblyO ring

Auto door Obstacledetection alarm

Auto door rubber shielding not ok

Check & auto door Rubber shielding clean & tight connection

So check & clean nowok

Chamfering L slidemotor not stop after auto cycle complete

Because its motor pulley not set withchange pulley andlocking plate open

So fitted & proper set the lockingplate

So done teaching of loader arm but not okthen Loader armalignment done

Door open closeproblem

Found its Safety s/wfaulty

Connect PB wire nowok

Broach cutting coolantnot coming

Coolant line SOIvalve faulty

So change the senser now ok

Adjust the conveyor Tension nowok

Alignment done &up/down flow adjust

Broaching m/c hydpipe have leakage

Table down pipebroken

Arm alignment doneMany times then ok

Remove the broken bolt then fittednew bolt now ok

MPCB top handle remove& unloader dog settingdone

Pull head open closeboth LS faulty

Limit s/w plunger stucked

Fitted one LS from SNH101 &bypass another LS

Chuck clamppressure s/w faulty

Component presentsenser not working

So clean the senser &adjust now ok

Area senser continuously high

Change the senser nowok

Drill broken again &again

Spindle coolant notcoming

Check valve faulty so bypass thevalve now ok

Conveyor inputsepretaor cylinder not working

Turret not clampalarm

Found chipsconveyor stuck andmay be its air catchsenser faulty

Clean the chips & bypass air catchsenser then reset alarm

Foot stock advancealarm

Shutter mountingbolt broken

Due to part presentsenser not working

Change the stooper now ok

Gripper cylinder mounting broken

Manually operate theturret now ok


16/24

Out chute not working clean the guide way

M/C master not On

Welding done

Soleniod valve changed bypass the door s/w

Gripper jam

Cylinder jam

Done referencing So replace the new pump

Auto door not working

change the senser

due to guide way rod jam

Change the cylinder seal but its pusher notreturn because X2binput high so dogsetting done

Due to controlsupply shorting

Shorting in Component presentsenser so by pass it

Open motor & sendfor rewinding

Auto door open closeproblem

Auto door cylinder mounting platbroken

open the cover thenclean limit s/w nowok

Auto cycle startingover time

Auto door soleniodfaulty

Unloader gripper open close problem

So open the gripper cylinder andclean now ok

so check & forward limits/w bypass

Part unload photosenser faulty

Due to oil in junctionbox

clean its junction box & replacedthe amplifier

Check & change ServoAMP. But problem notsolve then change motor but motor heat up thendone its meshing properlybut after this m/c controltrip again & again soclean motor all connector now ok

Seprator No-2 solabnormal alarm

clean the cylinder and change flowcontrol

Change power supplybut not ok then changethe shorted senser

Ring loader servoAmp malfunction

Ring loader motor referencing lost

LM bush mountingopen, Railing wear out, Cyl. Air inputfitting broken

So check and fitted the bush andrail falling and change the air fittingnow m/c ok

Took out thermo

couplel clean it &refitted now ok

Part carrier notworking

Gripper settingdisturb & part carrier cylinder piston rodopen

Setting done & Piston rodreconnect


17/24

Auto door not working Welding done

Welding done

NC alarm Referencing lost Referencing done

Soleniod valve faulty Inter changed the soleniod valve welding done

Photo senser faulty change the photo senser

New bolt fitted Setting done

change the senser setting done

Alarm bypass

cycle stop during Auto Change the read s/w

Door not working New bolt fitted

Tight the piston rod change the pipe

Unknown A axis drive clean & refitted now ok gap s/w bypass

Strip found broken so welding done Change the senser

Part clampingunclamping fault

Part clamp unclampboth senser high

part unclamp senser dog miss sobolt provided

Hose pipe alignmentdone

Auto door connectedstrip broken

Check & change pumpbut not ok then modifythe logic now under observation

Auto door open closefault

door cylinder guideplate broken

Interchange the coolantvalve & flow s/w & modifylogic now under observationclean the guide bush &lubrication done now ok

Unloader not ejectingcomponent in autoSeprator 2 open closealarm

clean the pull head nowok

Deburing unit notworking

Deburing unit boltbroken

Component overlapproblem

3rd stationcomponent presentsenser faulty

Part catcher detectalarm

Read s/w continuoushighPusher read s/wsignal fluctuation

Repair the wire thenrefitted now ok

Door mounting boltbroken

Bypass the shutter opensenser now ok

Tool lifter Sol.Abnormal

Pull head cylinder piston rod open

A axis INV. CurrentexcessMSTB air single off alarm

Auto door not openclose


18/24

Ram up down not ok Change th fuse now ok

Unloader soi. Faulty clean the soleniod now ok

NC alarm So Refrencing done Change the senser

Foot stock adv. Alarm So bypass it Bypass the signal

Motor fitted now ok cleaned the fan

Auto cycle not start

Cycle not start Set the photo senser

Auto door not working Door stuck with track Alignment done S/w selsection made ok

change the flow control Clean the senser now ok

Robot not working read s/w setting done

Auto cycle not start Clamp signal miss Senser adjust So clean the slide now ok

Bypass the senser

Hydraulic oil leakage

Overload trip Same

Its relay fuse foundblown

Dog ram down pressures/w set

Unloader up/downproblem

So Auto locator cylinder nut tight now ok

M/c forget homeposition

Foot stock linear scale fault

Deburing motor to befitted

Motor to be fittedafter rewinding

part loader up downproblem

Componentunloader senser notsense in dog setting

So component unloading senser dog proper set

componentunloading limit s/wwire faulty

So check & cut the wire and jointthe wire

Clean the pressure s/wnow ok

NG componentsignal not coming

Change the Air catchsenser

Part ejector notworking

Found its flowcontrol faultyFound unloader notin position

Took unloader to home positionnow ok

Shutter open closefault

Shutter close signalnot come

Change the Soft Key Padfrom Sleeve line

Table up-down cyl.Pipe fitting wasloose

So tight the pipe fitting of check theoil leakage ok

So changed its soleniodvalve but not ok so needto change the cylinder

Spindle motor over weak

Spindle motor fannot work

Alarm resent hand over C shiftmotor fan clear

change the new cylinder now ok

componentfomd incomponent and OLRreset

Fitted its original J comunit after interchangedthe touch screen


19/24

and PushButtoncover tobeprovided


20/24

size pipefitting tobe kept in

spare

door cylinder mountingandProximity


21/24


22/24

Rajamane120LPMpump tobe kept inspare andold pumpImpeller tobe madenew


23/24

All shigiyamachineShutter door cylinder mountingandProximitysensors tobechecked


24/24

AllOperator Panles tobecoveredby plastic

Gear Monthly Report,Sep'10

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