Importance of Maintenance Importance of Maintenance HPDC FoundryHPDC Foundry

Definition of MaintenanceDefinition of Maintenance

Activity to ensure uninterrupted ProductionActivity to ensure uninterrupted ProductionStipulation of each activityStipulation of each activityMaintenance of records of each activityMaintenance of records of each activityStipulation of frequency of activityStipulation of frequency of activityAdherence to Implementation of stipulationAdherence to Implementation of stipulationAudit of implementationAudit of implementationMaintenance as a means of Quality Maintenance as a means of Quality AssuranceAssurance

Equipment MaintenanceEquipment Maintenance

Machines (Casting, Pneumatic, Trimming)Machines (Casting, Pneumatic, Trimming)Furnace & BurnerFurnace & BurnerTools (Dies & Molds)Tools (Dies & Molds)Metal Handling Tools and EquipmentMetal Handling Tools and EquipmentInstrumentsInstrumentsSafety EquipmentSafety EquipmentAdministrative EquipmentAdministrative EquipmentEnvironmentEnvironmentRecordsRecords

Machine Maintenance PlanMachine Maintenance Plan

Salient FeaturesSalient Features

Areas of Attention:Areas of Attention:1.1. Control Panel Control Panel 2.2. Oil PumpOil Pump3.3. Water Cooling CircuitWater Cooling Circuit4.4. Tie BarsTie Bars5.5. PlatensPlatens6.6. HydraulicsHydraulics7.7. Control ValvesControl Valves8.8. Accumulator CircuitAccumulator Circuit9.9. Pressure GaugesPressure Gauges10.10. Cleanliness (Leakages, seepages, oil stains)Cleanliness (Leakages, seepages, oil stains)

Tool Maintenance PlanTool Maintenance Plan

Casting Dies and MoldsCasting Dies and Molds

Auxiliary Mold Equipment (Sleeve, Bush, Auxiliary Mold Equipment (Sleeve, Bush, Plunger)Plunger)

Trimming tools and equipmentTrimming tools and equipment

Maintenance of Metal Handling Maintenance of Metal Handling EquipmentEquipment

Fuel Storage EquipmentFuel Storage EquipmentFuel Dosing EquipmentFuel Dosing EquipmentFuel Supply Civil WorksFuel Supply Civil WorksFuel PumpsFuel PumpsHeating Equipment (burners, heating elements, etc.)Heating Equipment (burners, heating elements, etc.)Furnaces (lining and insulation)Furnaces (lining and insulation)Temperature Control InstrumentsTemperature Control InstrumentsCruciblesCruciblesMetal Storage and identification of alloysMetal Storage and identification of alloysFlue Gas discharge EquipmentFlue Gas discharge Equipment

Measuring InstrumentsMeasuring Instruments

Importance of InstrumentsImportance of Instruments

Tools and GaugesTools and Gauges

Importance of Calibration of Instruments Importance of Calibration of Instruments and Gaugesand Gauges

Frequency stipulationFrequency stipulation

Adherence to implementationAdherence to implementation

Record MaintenanceRecord Maintenance

Maintenance of Safety EquipmentMaintenance of Safety Equipment

Minimum Equipment RequiredMinimum Equipment Required

Importance of Safety EquipmentImportance of Safety Equipment

Testing of Safety EquipmentTesting of Safety Equipment

Record KeepingRecord Keeping

Safety AuditSafety Audit

Maintenance of Administrative Maintenance of Administrative EquipmentEquipment

ComputersComputers

Files and FoldersFiles and Folders

Importance of “Hard Copy” Importance of “Hard Copy”

Accounting System MaintenanceAccounting System Maintenance

AuditAudit

Environment MaintenanceEnvironment Maintenance

Pollution ControlPollution Control

Health Records of Human ResourceHealth Records of Human Resource

Environment as a means of Cost ControlEnvironment as a means of Cost Control

RecordsRecords

Record keeping as a means of controlRecord keeping as a means of control

Importance of AuditImportance of Audit

Model RecordsModel Records

Model Records (Machine Model Records (Machine Maintenance)Maintenance)

Data to highlightData to highlight Oil Pump ConditionOil Pump Condition Oil Level RecordOil Level Record Oil Condition TestOil Condition Test Oil Consumption RecordOil Consumption Record Response to Pressure SettingResponse to Pressure Setting Motor Temperature monitoringMotor Temperature monitoring Condition of Electric ConnectionsCondition of Electric Connections Pump Cooler ConditionPump Cooler Condition Water DischargeWater Discharge Water pipe Decal kingWater pipe Decal king Cooling Water levels in Tank/Reservoir Cooling Water levels in Tank/Reservoir

Model Records (Machine Model Records (Machine Maintenance)Maintenance)

2. Machine Panel2. Machine PanelData to highlightData to highlight

Cleanliness Cleanliness Condition of Circuit Data CardsCondition of Circuit Data CardsCondition of indicator bulbsCondition of indicator bulbsCondition of connectorsCondition of connectorsCondition of fusesCondition of fusesVoltage and current readingsVoltage and current readingsResponse of the machine parameters to Response of the machine parameters to microprocessor settingmicroprocessor setting

Model Records (Machine Model Records (Machine Maintenance)Maintenance)

3. Condition of Machine Elements 3. Condition of Machine Elements Data to highlightData to highlight

Condition of Tie BarsCondition of Tie BarsDie Height SettingDie Height SettingTie Bar Lubrication ReportTie Bar Lubrication ReportCondition of PlatensCondition of PlatensWater Cooling of PlatensWater Cooling of PlatensCondition of T-slots for Die ClampingCondition of T-slots for Die ClampingCondition of Hydraulic cylindersCondition of Hydraulic cylindersReportage of oil leakage observation and repair instructionReportage of oil leakage observation and repair instructionCondition of Pressure Gauges (incl. Response to differential pressure Condition of Pressure Gauges (incl. Response to differential pressure setting)setting)Accumulator Gas pressure check and replenishmentAccumulator Gas pressure check and replenishmentCondition of electromagnetic valvesCondition of electromagnetic valvesCondition of limit switches/ sensorsCondition of limit switches/ sensorsCleanliness (oils, lubricants, metal flashes, etc.)Cleanliness (oils, lubricants, metal flashes, etc.)

Model Records (Die Maintenance)Model Records (Die Maintenance)

Features to highlightFeatures to highlight

Daily Check-listDaily Check-list

Weekly check-listWeekly check-list

Die Hardware ChecksDie Hardware Checks

Reportage of inspection to concerned Reportage of inspection to concerned authorityauthority

Implementation report of repairs Implementation report of repairs undertaken undertaken

Model Records (Maintenance of Model Records (Maintenance of Hardware for Fuel Equipment)Hardware for Fuel Equipment)Features to highlightFeatures to highlightFuel tank Fuel tank

1.1. Fuel level checkFuel level check2.2. Fuel leakage checkFuel leakage check3.3. Fuel sediment inspectionFuel sediment inspection4.4. Fuel -flow inspectionFuel -flow inspection5.5. Burner inspection for fuel flowBurner inspection for fuel flow6.6. Burner nozzle inspection and reportageBurner nozzle inspection and reportage7.7. Burner Setting of correct Fuel/Air RatioBurner Setting of correct Fuel/Air Ratio8.8. Record of Daily Fuel ConsumptionRecord of Daily Fuel Consumption

Model Records (Maintenance of Model Records (Maintenance of Furnace)Furnace)

Features to highlightFeatures to highlight

1.1. Crucible conditionCrucible condition

2.2. Reportage of weekly Crucible rotationReportage of weekly Crucible rotation

3.3. Brick Lining ConditionBrick Lining Condition

4.4. Record of Heat insulation condition by Record of Heat insulation condition by checking the shell temperaturechecking the shell temperature

5.5. Checking and calibrating ThermocouplesChecking and calibrating Thermocouples

6.6. Check of condition of insulating sheathing of Check of condition of insulating sheathing of Thermocouples that are dipped in liquid metalThermocouples that are dipped in liquid metal

Model Records (Instrument Model Records (Instrument Calibration)Calibration)

Features to highlightFeatures to highlight1.1. Record of stipulation of tests and testing Record of stipulation of tests and testing

frequency recommended by original frequency recommended by original manufacturermanufacturer

2.2. Instruction sheet of calibration procedure for Instruction sheet of calibration procedure for each instrument each instrument

3.3. Record of calibration performance of each Record of calibration performance of each instrumentinstrument

4.4. Instruction of next calibration dateInstruction of next calibration date5.5. Audit report of calibration of each instrumentAudit report of calibration of each instrument

Model Records (Die Loading)Model Records (Die Loading)

Table of this data sheet is separately Table of this data sheet is separately available for studyavailable for study

Model Records of Safety Model Records of Safety StandardsStandards

Features to highlightFeatures to highlight1.1. List of Safety EquipmentList of Safety Equipment2.2. Record of stipulation of tests and testing Record of stipulation of tests and testing

frequency recommended by original frequency recommended by original manufacturermanufacturer

3.3. Instruction sheet of test procedure for each Instruction sheet of test procedure for each equipmentequipment

4.4. Record of performance of test of each Record of performance of test of each equipmentequipment

5.5. Instruction of next testing dateInstruction of next testing date6.6. Audit report of calibration of each equipmentAudit report of calibration of each equipment

EpilogueEpilogueEnvironmental ResponsibilityEnvironmental ResponsibilityFoundry, in its total functioning, is a pollution prone industry. The work force Foundry, in its total functioning, is a pollution prone industry. The work force involved in production activity is vulnerable to tough physical activity and health involved in production activity is vulnerable to tough physical activity and health hazards. But, it doesn’t mean that it cannot be improved. A good working condition hazards. But, it doesn’t mean that it cannot be improved. A good working condition can always be created with the strong managerial will and inclination. Any cost can always be created with the strong managerial will and inclination. Any cost involved in creating involved in creating clean working ambience is an investment and not a costclean working ambience is an investment and not a cost. . An improved quality of output and productivity is an undisputed outcome in a clean An improved quality of output and productivity is an undisputed outcome in a clean and well-lit foundry.and well-lit foundry.Maximum use of natural light, proper exhaust system for flue gases and lawful Maximum use of natural light, proper exhaust system for flue gases and lawful disposal of waste, aeration are a few examples of the cheapest methods of disposal of waste, aeration are a few examples of the cheapest methods of achieving the goal. Mechanization in foundries must be well aimed and targeted to achieving the goal. Mechanization in foundries must be well aimed and targeted to reduce physical effort that can be utilized to maximize per capita output with least reduce physical effort that can be utilized to maximize per capita output with least effort. This is best done by understanding the problems involving the workforce by effort. This is best done by understanding the problems involving the workforce by constant tête-à-tête. This, in modern parlance, is called rationalization. Though, this constant tête-à-tête. This, in modern parlance, is called rationalization. Though, this term is often misinterpreted as replacement of manpower by automation. Due to the term is often misinterpreted as replacement of manpower by automation. Due to the very nature of work it is a bad practice to ignore safety. Clothing and equipment of very nature of work it is a bad practice to ignore safety. Clothing and equipment of safety are bare essentials. safety are bare essentials. Clean and well lit die casting shop (observe light and cleanliness)Clean and well lit die casting shop (observe light and cleanliness)

Thank You!Thank You!