TPM Progress By Kandakure Engineering pvt Ltd-I Plot No-105 MIDC shendra AURANGABAD Oct-Nov - 2012...
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Transcript of TPM Progress By Kandakure Engineering pvt Ltd-I Plot No-105 MIDC shendra AURANGABAD Oct-Nov - 2012...
TPM Progress By Kandakure
Engineering pvt Ltd-I Plot No-105 MIDC shendra AURANGABAD
Oct-Nov - 2012
“Achieve Excellence Through TPM”
“The Prime Mover towards excellence”
TPM Award Targets & Status
ParametersBenchmarkAvg.
AwardCriteria
TargetsJune-
12July-12
Aug-12
Sep-12
Oct-12
Nov-12
Status
1S/ 2S
1S/2S self assessment score
--- 100% 100% 81% 84% 85% 89% 88% 85% Work in progress
MH
Material Handling-As per agreed norms in visually countable container
--- All Parts All Parts All
PartsAll
Parts
All Parts
All Parts
All Parts
All Parts Achieved
E & T
Awareness of QM,JH & KK pillar activities
-- 100% 80% 78% 80% 83% 85% 83.4 Not Achieved
Q
Customer Complaints (Occurrence) (Nos.)
---Zero 0 04 05 12 10 02 3 Not Achieved
Customer complaint (PPM)
---Bronze award criteria
0 850 834 933 604 31 1290 Not Achieved
In-house Rejection (PPM)
60% Down
50 870 850 1456 1990 980 2096 Not Achieved
C Cost of Manufacturing (Rs)
----20%
Down-- - - - - - - --
D Delivery Adherence (%) 100% 100% 95% 95% 95% 95% 98% 92% Not Achieved
S Accidents - Major (Nos. / Month) 0 0 01 00 0 0 0 0 Not Achieved
M Nos. of Kaizen / Employee / Month (Nos.)
1 1 0.31 0.7 0.78 0.8 0.85 0.83 (Not Achieved )
TPM Organization Structure
TPM Coordinator Mr. Shaikh F R
JH KK QMPM E&T DM SHE OT
Pillar HeadMr. Kapate S. S Core team1-Mr.Shelake 2-Mr.Kapate S3-Mr.Pawar V.4-Mr.Garad V.5-Mr.Hade 6-Mr.Gade
Pillar HeadMr.Gawali A.
Core team1-Mr.Shaikh.2-Mr.Kande3-Mr.Pawar V.4-Mr.Garad V.5-Mr.Jadhav S.
Pillar HeadMr. ShelakeCore team1-Mr.Tupe P. B.2-Mr.Shingade 3-Mr.Pawar V.4-Mr.Garad V.5-Mr. Shaikh F.6-Mr. Shyam
Pillar Head Mr. Hade
Core team1-Mr.Sonawane2-Mr.Bhusare R3-Mr.kapate S.4-Mr.Lohar 5-Mr.Garad V.6. Jadhav S. J.
Pillar Head Mr. Jadhav S.
Core team1-Mr.Kande2-Mr.Kapate 3-Mr.Garad V.4-Mr.Pathan H5-Mr.Lohar
Pillar Head Mr. Lolewar S.
Core team1-Mr.Vikas 2-Mr.Shaikh F.3-Mr.Bhusare R 4-Mr.Mohsin5-Mr.Kapate S.6-Mr.Wanarse
Pillar HeadMr. Deepak
Core team1-Mr.Sheikh F.2-Mr.Dapke 3-Mr.Gande G.4-Mr.Bhusare R5-Mr.Dutta6-Mr. saudagar
Pillar HeadMr. Bhusare.
Core team1-Mr.Shaikh F. 2-Mr.Kapate S3-Mr.Pawar V.4-Mr.Garad V.5-Mr.Shyam6-Mr. Sonawan
Mr. Salunke R. U. TPM Chairman
1S, 2S Zone Wise Organization Structure
TPM CoordinatorMr. Shaikh F. R.
ZONE-1LEADER-Mr. Deepak
Zone memberMr. DuttaMr. SaudagarMr. RameshMr. Dadarao.
Zone- 5LEADERMr. Garad V.N.
Zone memberMr. Jadhav S.Mr .Namdev.Mr. Pathan H.Mr. Paswan
ZONE-9LEADERMr. Gorakh.
Zone memberMr. Kapate S.Mr. Dapke.Mr. Garad V. Mr. Shelke K.
ZONE-8LEADERMr. Pawara
Zone memberMr. Pawara V. Mr. Shaikh HamidMr. Tathe ManojMr. matlakute B.Mr. Bhalerao M.
ZONE-2LEADERMr. Lolewar S.
Zone memberMr. GawaliMr.tupe P. B.Mr. Jadhav V.Mr. shaikh m.Mr. Pathade
ZONE-6LeaderMr. Tribhuvan.
Zone memberMr. ShingadeMr. RockeyMr. Alex aoMr. Hapse
Zone-7LEADERMr. Kapate
Zone memberMr. Shaikh F.Mr. Gande G.Mr. Dapake M.Mr. Gore B. L.
ZONE-4LEADERMr. .Pathan H
Zone member
Mr. Sonu GuptaMr. Pintukumar Mr. YadavMr. Rajrakhan.
Mr. Salunke R. U. ( V. P.)Mr. Gunjal V. (Development )
ZONE-3LEADERMr. Shingade.
Zone member
Mr. Shyam Mr. Ramesh Mr. Paswan M.
ZONE-10LEADERMr. Bhusare.
Zone member
Mr. ShyamMr. Ramesh Mr. Shaikh
Sr. No. Training Subject No. of People coveredNo of people
balanceRemark
1 1S~2S All Employees Nil Training Freq. after every 3 months
2Customer
Complaints
All Supervisors, Inspectors
and operators Nil Training freq.
every 2 month
3 A B C Defects All operators Nil Training freq. –every 3 month
4 Inspection Final Inspectors Nil Training freq. –every 3 month
5 Material HandlingAll zone members
Nil Training freq. –
every 3 month .
6 Safety All Employees Nil Training freq. –every 3 month
7 Kaizen TrainingSupervisors, inspectorsand operators
Operators Training freq. –
every 3 month
Education Training
Workman & casuals - 59 Staff - 32 Total Employees - 81
Sr.No Training Programme Why Training needed? No. of People BatchesTraining
Hours
1 1S~2S To update Knowledge All Employees 1/zone 5 min /day
2 Customer ComplaintsZero customer
complaintsAll zone
members2
1 hours / month
3 A B C DefectsTo control in house
RejectionsAll operators 1/zone
15 min / weak
4 InspectionTo minimize rejection in
house and at customer end.
Final Inspection 1/zone 5 min/ day
5 Material Handling To update KnowledgeAll zone
members1/zone 5min/ day
6 SafetyBetter working
conditionAll zone
members2
1 hours/ month
7 Kaizen TrainingTo minimise rej&cust
compSupervisors and
operators.2
1 hours/ month
8 5S Activities To update KnowledgeAll zone
members2
1 hours/ month
Education & Training plan
1S Activities
1S-2S Zone Mapping
SR.NO. ZONE ZONAL HEAD PHOTO
1 Store & main gate Mr. Koltame D.
2 Wirecut & office Mr. Gorakh Gande
3 Tool Room Mr. Pawara V.
4 Quality Mr. Lolewar S.
5 core pack Mr. Pathan H.
6 Plate Clutch Mr. Garad V.
7 Assembly Mr. Shingade
8 Rieter Mr. Tribhuvan D.
9 SPM & fine blanking Mr. Wanarse U.
10 Maiintainance Mr. Kapate
11 Campus Mr. Dada mali
8
2
3
8
109
5
6
7
11
41
S. No
Activities Responsibility July2012 Aug-12 Sep-12 Oct-12 Nov-12 Dec-12 Jan-12 Feb-12
1Division of factory premises into various zones
Mr. Sheikh F.
2Formation of Zonal Team with Zone Leader
Mr. F. R. Shaikh
31S ~ 2S Awareness Programme
Mr.:V.S.Gunjal
4 Preparation of Master Plan
Mr.:V.S.Gunjal
5 Go to LOCATIONS
Zone Leaders & Members
6Asses items available in the location
Zone Leaders & Members
7Decision on Requirement and actions
Zone Leaders & Members
8Allocation of space for items
Zone Leaders & Members
09Marking of the space with label
Zone Leaders & Members
10Keeping items in respective location
Zone Leaders & Members
11
Arrive at simple Visual Arrangements to know Quantity.
Zone Leaders & Members
Plan Actual
1S~2S Master Plan
Improvement sheets
AFTERBEFORE
Zone name/no :- Press Shop 24.10.2012
Benefits :- :- Air pressure maintained & prevent low air pressure working …….By Mr.Hade & Mr.Gade
Problem Status: No Pressure switch Counter measure: - Pressure switch add
Improvement Sheet.
Pressure Switch
AFTERBEFORE
Zone name/no :- Press Shop 10.10.2012
Benefits :- Oil collected in chamber & No wastage of oil & save oil ………By Garad
Problem Status: No chamber Counter measure: Oil protective chamber provided to Ram
Improvement Sheet.
Chamber for oil protection
AFTERBEFORE
Zone name/no :- Press Shop 15.10.2012
Benefits :- Save rejection & tool life……………..By Mr.Gade
Problem Status: No sensor Counter measure: : Sensor add to stop the miss feed operation
Improvement Sheet.
No Snap
Sensor
AFTERBEFORE
Zone name/no :- Press Shop 02.10.2012
Benefits :- :-Save operator time & no chances to accidents & missing of oil dripping in machine…………By Gade & Hade
Problem Status: No lubricant Unit Counter measure: :Add automatic Lubricant unit
Improvement Sheet.
No Snap
AFTERBEFORE
Zone name/no :- Maintenance Department 09.10.2012
Benefits :- :-1s & 2s done & time save for searching the tools & maintain the safety……….By Mr.Shelke & Jadhav …………By Mr.Bhusare & Kapate & Team
Problem Status: No stand to store the tools Counter measure: : Stand provided to store the tools & instruments
Improvement Sheet.
No Snap
AFTERBEFORE
Zone name/no :- Press Shop
Benefits :- :- To prevent the heavy shocks directly on machine bed & Safety …..By Mr.Bhusare & Kapate Team
Problem Status: No bed on 160Ton to support the die Counter measure: : Bed Provided on
160Ton to protect the base of machine
Improvement Sheet.
No Snap
AFTERBEFORE
Zone name/no :- Press Shop Date:-8/10/12
Benefits :- :-Proper oiling To srtip & safety By Mr.Kapate & Team
Problem Status: No oiling system availableCounter measure: :Auto Oiling system provided to 160 Ton Manzoni press
Improvement Sheet.
No Snap
AFTERBEFORE
Zone name/no :- Press Shop
Benefits :- :- Manual oiling replace to Auto oiling …By Jadhav & Team
Problem Status: No oil Tank available to machine Counter measure: : Oil Tank Provided to
Manzoni press
Improvement Sheet.
No Snap
AFTERBEFORE
Zone name/no :- Press Shop
Benefits :- :- Safety & smooth feeding………………By Jadhav & Team
Problem Status: No stand to protect the coil on 160Ton Counter measure: : Stand provided for
proper protection to coil.
Improvement Sheet.
AFTERBEFORE
Zone name/no :- Press Shop 31.10.2012
Benefits :- :-Addition of 100Ton machine in press shop for shoe web blank………..By Kapate & Team
Problem Status: No Auto feeder on 100Ton machine Counter measure: : Auto feeder add-on
100Ton machine
Improvement Sheet.
No Snap
AFTERBEFORE
Zone name/no :- Press Shop 31.10.2012
Benefits :- :- Oil Saving & operator time saving & No chances to accident. By Garad & Gade
Problem Status: No Auto OilingCounter measure: : Auto oiling provided
Improvement Sheet.
Auto Oiling Unit
AFTERBEFORE
Zone name/no :- Tool Room 30.10.2012
Benefits :- To prevent the surface oily & safty
Problem Status: No Stand for Hydraulic Unit Counter measure: : Stand Provided for Hydraulic Unit in tool Room
Improvement Sheet.
Stand for Hydraulic Unit
AFTERBEFORE
Zone name/no :- Press Shop 17.10.2012
Benefits :- :- Power Saving & prevent to transformer heating….By Mr.Gade
Problem Status: No Contactor Counter measure: : Contactor add on 100 Ton Machine
Improvement Sheet.
No Snap
AFTERBEFORE
Zone name/no :- Press Shop 28.10.2012
Benefits :- If stroke interval delay for 05 mints then Machine automatically shout down after 05 mints .power save & safety……Mr.Gade
Problem Status: No Timer added Counter measure: : Timer Added on 25 Ton Hydraulic Machine
Improvement Sheet.
No Snap
Timer
AFTERBEFORE
Zone name/no :- Press Shop 27.10.2012
Benefits :- :- Web cylinder run very smoothly ,No detection in working…..Mr.Gade
Problem Status: No Auto Drain Valve Counter measure: : Auto Drain valve provided
Improvement Sheet.
No Snap
AFTERBEFORE
Zone name/no :- Weld shop 28.10.2012
Benefits :- :- Safety & increases the plunger life due to continues jerk & vibration….Mr.Hade
Problem Status: No side support to plunger Counter measure: : Inclined support provided to plunger
Improvement Sheet.
No Snap
Support to Plunger
Apr,12 May'12 Jun'12 Jul'12 Aug'12 Sep'12 Oct'12 Nov'1210000
100000
1000000
10000000 1,827,636.00
1,729,957.00
1,810,842.00
2,061,379.00
1,699,402.00
1,755,170.00
2,200,142.00
1,988,750.00
26556 30294 3050048286
39185 43030 44110 36670
ProdMSEB UNIT
MSEB READING vs PRODUCTION QUANTITY
Details for Power Cost R
S
Month0
50000
100000
150000
200000
250000
300000
350000
40000024
360
2792
0
2655
6
3092
4
3150
0
4828
6
3918
5
4303
0
4411
0
3667
0
153,
057.
00
172,
219.
00
166,
392.
00
187,
597.
00
339,
890.
00
377,
297.
00
264,
170.
00
370,
650.
00
332,
030.
00
230,
890.
00
UnitsAmount
Details of month wise sale R
S
Month0
5000000
10000000
15000000
20000000
25000000
30000000
1467
3438
.2
1430
7763
1496
6447
.23
1462
5822
1414
3179
.1
1424
8784
.97
2451
1700
.28
1689
2805
.92
Raw Material Sale
Scrap Sale
Tool Sale
Item Sale
Total Sale
Planned Maintenance Activities - PM
Zero breakdown sustenance
Zero defects sustenance
Zero Accident
Maintenance at lower cost
Aim
PM Structure
PILLAR CHAIRMANMr Hade
Mr. Gade Mr. Sonawane Mr. Kapate Mr. Garad V Mr. Shelake Mr. Jadhav S.
A – Bottleneck & critical machines for production & Quality.
B – Machines affecting Production
C – Alternate arrangement
Sr.No. Area/Shop
Total no of
Machine s
Machine Classification
A B C
1 Press Shop 29 4 4 21
2 Tool Room 10 0 0 10
3 Welding SPM 3 0 3 0
Total 42 4 10 31
Classification of Machines
Happened Breakdown recording & Analysis
Break down (Occurrence) - Plant
5
0
22
3
4
0
1
2
3
4
5
6
BM ( July'11 toOct'11)
Aug'12 Sep'12 Oct,12 Nov,12 Target
Nos
.
Down Time Occurrence - Plant
Benchmark Target
Month Target Month Actual
Break down (Time) (machine) - Plant
50
10
23.120.5
31.5
39.5
0
10
20
30
40
50
60
BM ( July'11 to Oct'11)
Aug'12 Sep'12 Oct'12 Nov,12 Target
Hou
rs
Breakdown (Time in Hours ) - PlantBenchmark Target
Month Target Month Actual
PM checklist for K3 core pack
Die Name k-3core pack stacking Date: / /
Sr No. Description ActivityStand. Condition
Frequency Attened By Root Cost Remark
1 k-3core pack stacking Checking die plate For wear no wear2 blanking punch Checking blanking punch For wear no wear3 noching punch Checking noching punch For wear no wear4 2.2 punch Checking 2.2 punch For wear no wear5 i.d. punch Checking i.d. punch For wear no wear6 2.7 punch Checking 2.7 punch For wear no wear7 4.1 punch Checking 4.1 punch For wear no wear8 5.7 punch Checking 5.7 punch For wear no wear9 spring Checking spring For wear no wear
10 paylat punch Checking paylat punch For wear no wear11 kushan pin Checking kushan pin For wear no wear12 2.28 button Checking 2.28 button For wear no wear13 2.78 button Checking 2.78 button For wear no wear14 5.78 button Checking 5.78 button For wear no wear15 noching ensart Checking noching ensart For wear no wear16 kushan pin spring Checking kushan pin spring For broken No Brocken17 4.1 button Checking 4.1 button For wear no wear18 stiper bolt Checking stiper bolt For wear no wear19 blanking punch bolt Checking blanking punch bolt For wear no wear20 die plate bolt Checking die plate bolt Loosenes no Loose
Production Head: Mantanance head:
PM Check Sheet
PM checklist for welding SPM
Machine Name :
Cell Name:
AUG SEP. NOV DEC JAN FEB
1 Cleaneing the surfcae of machine weekly
2 Trueing slide attrition confirmation weekly
3 Various lows are glid must hit the butter weekly
4 Zero point examintion block position weekly
5 locates the sensor position comfirmation weekly
6 Voltage & current checking weekly
7 greasing chain and gear weekly
8 main motor faundation bolt tight weekly
9 stoper and chain tension cheaking weekly
10 Gear box oil fill monthly
11 main electric breaker cheaking monthly
12 all electric conection tight monthly
SIGNATURE OF MECHANIC
M/C No. :
Date :
Name of Mechanic :
SR. NO. CHECK POINTS FREQUENCY2012-2013
REMARK
Preventive Maintenance checklist
PM checklist for press machine
Machine Name Mach. Press Date: / / M/C No.
Sr No. Description ActivityStand.
ConditionFrequency Attened By Root Cost Remark
1 Motor belt Checking belt for looseness No loose Monthly 2 Motor bearing Check bearing for cleaning No dust Monthly 3 Balancing cylinder Check cylender for aire leackages No leackege Monthly 4 Brake liner Inspect for brake liner No wear out Monthly 5 Lubrication tank Check oil supply for cleaning No dust Monthly 6 Receiver tank Inspect for receiver tank No water Monthly 7 Clutch plate Inspect clutch plate for looseness No loose Monthly 8 Cam box chain Checking chain for looseness No loose Monthly 9 Power contactor Check connection for looseness No loose Monthly
10 Control contactor Inspect for corbone depostion No depostion Monthly 11 Solenoid valve Inspect solenoid valve for lubrecting No dust Monthly 12 Roto seal Inspect roto seal for leackages No leackage Monthly 13 Hose pipe Inspect roto seal for leackages No leackage Monthly 14 Pressure gauge Inspect pressure gauge for proper pressure No leackage Monthly 15 FRL unit Inspect FRL unit for aire pressure leackages No leackage Monthly 16 Ammeter Inspect ammeter for Monthly 17 Control transformer Inspect for corbone depostion No depostion Monthly 18 Motor foundation bolt Checking foundation bolt for looseness No loose Monthly 19 Motor megger testing Monthly 20 Motor Resistance testing Monthly 21 M/C foundation pad Checking foundation pad for looseness No loose Monthly 22 Foot switch contact block Inspect for corbone depostion No depostion Monthly 23 Cam box sensor Inspect sensor conaction for looseness No loose Monthly 24 Oring Check oring for leackages No leackage Monthly 25 Stroke locking cap Checking loking cap for looseness No loose Monthly 26 Slide Cover Bolt Checking loking cap for looseness No loose Monthly
27 Main Gear Check Theeth For weare No wear Monthly
28 Pinion Gear Check Theeth For weare No wear Monthly 29 Pinion Gear Oil Level Check Oil Level No Low Oil Level Monthly 30 Clutch Check Air leackage No leackage Monthly 31 Pitman Scrow Check Up & Down NO Tite Monthly 32 Booster Plate Check Bolt For looseness No loose Monthly 33 Air Perssore Switch Check air Perssore Cutup No Direct Monthly 34 Over Lode Check Oil leackages No leackages Monthly 35 Photo Gard Check For Any Candaction m/c Stop No Contunew Monthly 36 Cranck Shaft Housing Check Bush For Tear & Wear No Tear & Wear Monthly 37 Fly Wheel Check bearing for Condication No Sound & Vabraction Monthly 38 clutch Linner Plate Check Bush & Pin For Wear No wear Monthly 39 Break Linner Plate Check Bush & Pin For Wear No wear Monthly
Prod.Supervisor Sing.
PM Check Sheet
Maint.Head Sing.
Happened Breakdown Analysis
Happened Breakdown Analysis
Happened Breakdown Analysis
Happened Breakdown Analysis
JH Activities
JH STEP - 0
Machine Mapping & allocation of members
Area Name
1 Electrical
Mr. Gade SandipMr. Garad VMr. Jadhav S. J
2 Mechanical
Mr. Kapate S. S.Mr. Jadhav S. JMr. Shelke
1
2
Contents
• Aim
• JH Pillar Organization Structure
• JH Pillar Targets
• Master Plan for JH Activities
• Selection criteria
• JH Steps studies
• Machine map
• Audit reports
• Abnormality Trend over all plant
46
Aim
To Improve Machine efficiency by systematic monitoring and control of Break down time losses resulting into higher effective utilization of machines and men.
“My Machine I Operate I Maintain”
To stabilized various production processes for producing consistent quality with lower cost and in time delivery
47
Master Plan – Critical Machine
Sr. No.
Activity
Month
Jun’12 Jul'12 Aug'12 Sep'12 Oct'12 Nov'12 Dec‘12
W1 W2 W3 W4 W1 W2 W3 W4 W1 W2 W3 W4 W1 W2 W3 W4 W1 W2 W3 W4 W1 W2 W3 W4 W1 W2 W3 W4
7.2Identify Kaizen Themes and implement kaizen
8.1Arrival of Optimal Condition and its Check sheet
8.2Breakdown analysis (Why-Why Analysis) and kaizen/c’measure
9.1Customer complaint elimination by improvement in Inspection
9.2Defect analysis and Kaizen/Countermeasures
9.3 Quality Maintenance Matrix
10Weekly review of the Progress and achieving target
JH PILLAR Structure
Mr.Hade
PILLAR CHAIRMANMr Gawali
Mr.Tribhuvan D
Mr. Jadhav S.
Mr. Pathan H.
Mr. GaradMr. Shielake
Mr. GadeMr. Kapate.
Present JH Status
Sr. No. Parameter BM (Oct’11 to ’12 Target Status
Oct’12
1.1 Total no. of Machines 29 29
1.2 No of machines in JH step 3 0 3 3
1.3 No of machines in JH step 2 3 8 7
1.4 No of machines in JH step 1 26 18 18
1.5 No of tags put/removed 902/826 104 62
1.6 No of Kaizens for CLIRT reduction
1.7 No of improvement for visual management
1.9 No of Kaizens for defect elimination due to poor JH
Abnormality Trend
JH Step - 1
3864 62 63 71 64 78 69 56
171
104
62
3857 60 63 66 57
98
5725
111 118
76
0
50
100
150
200
Numb
ers
Tags Attached Tags Removed
JH STEP – 1 Analysis of Abnormality Removed & Removal Plan
52
Tag No.Date of
detectionMPR00069(SHINOHARA
150T) Abnormality
Why it is "Abnormality"?(What will happen if it is
left as it is)
Why did it become so?
(What is cause?)
Contents of the
countermeasures
Abnormality tag
classificationExecutor Planned
Date of completio
n
1 20/10/2012 Oil leakage to sliding Ram Break down Continuous useReplace new
onewhite
Mr. Shailkh
Comp Comp
2 20/10/2012 Knockout plate bolt bend Break down Continuous useReplaced New
OneRed
Mr. Shailkh
Comp Comp
3 20/10/2012 Front sliding cover open Break down Continuous useReplaced New
OneWhite Mr.hade Comp Comp
4 20/10/2012 Excess wire at topside Hard to clean Not needed Removed Red Mr Tupe Comp Comp
5 20/10/2012 Oil pipe broken at top Accident Continuous useReplaced New
OneWhite Mr.Adikari Comp Comp
6 20/10/2012 operating pannel cable Damage Accident Continuous useReplaced New
OneRed Mr Tupe Comp Comp
7 20/10/2012 motor V-belt loose Break down Continuous useReplaced New
OneWhite Mr Tupe Comp Comp
8 20/10/2012 No FRL for oiling Break down Attach. Removed Retightening RedMr.
ShailkhComp Comp
9 20/10/2012 cock Not availble for GI air pipe Break down Continuous useReplaced New
OneWhite
Mr. Shailkh
Comp Comp
10 20/10/2012Safety photo sensor Not available
Accident Attach. RemovedReplaced New
OneWhite Mr Tupe 20/10/12 20/10/12
11 20/10/2012 Pressure switch Not available Break down Attach. RemovedReplaced New
Onewhite Mr Tupe 20/10/12
12 20/10/2012 Operating panel not fix Hard to clean Excess oil Give oil
collection boxRed
Mr. Shailkh
Comp Comp
13 20/10/201Lubrication unit fitting bolt loose
Break down Continuous use Retightening White Mr. Jadhav Comp Comp
14 20/10/2012 No arrow for flywheel direction Hard to count Attach. Removed change location White Mr.gawali Comp Comp
15 20/10/2012 No arrow for motor direction Break down Attach. Removed Retightening WhiteMr.
ShailkhComp Comp
16 20/10/2012 Excess air pipe to cushion Break down Not needed Retightening White Mr.hade Comp Comp
17 20/10/2012 Cock missing for GI air pipe-2 Break down Continuous use Retightening WhiteMr.
ShailkhComp Comp
18 20/10/2012 Machine lamp not availble Accident Attach. RemovedReplaced New
OneWhite Mr.Jadhav Comp Comp
19 20/10/2012 No marking to all bolt Break down Continuous use Set in proper White Mr.Jadhav Comp Comp
20 20/10/2012 No proper table to strip guide Accident Not neededReplaced New
OneWhite Mr.hade 20/10/2012
21 20/10/2012 No proper packing to clamp Accident Not needed Removed WhiteMr.
Shailkh30/11/12 Comp
JH STEP – 1 Analysis of Abnormality Removed & Removal Plan
53
Tag No.Date of
detectionMPR00069(SHINOHARA
150T) Abnormality
Why it is "Abnormality"?(What will happen if it is
left as it is)
Why did it become so?
(What is cause?)
Contents of the
countermeasures
Abnormality tag
classificationExecutor
Planned
Date of completio
ndate
21 20/10/201 Loose switch due to no washer Hard to get HandelingReplaced New
Onewhite
Mr. Shailkh
Comp.Comp.
22 20/10/201 No stand for transformer Hard to clean Continuous use closed WhiteMr.
SonawaneComp.
23 20/10/201 No guard to backside flywheel Accident Attach. RemovedReplaced New
OneWhite
Mr. Sonawane
Comp. Comp.
24 20/10/201Nut missing top cover of transformer
Break down Continuous useResharp & Chafered
WhiteMr.Dayara
mComp. Comp.
25 20/10/201 Loose airline Break down No proper locationReplaced New
OneRed
Mr. Shailkh
20/12/12
26 20/10/201 No safety valve to air tank Break down Continuous useReplaced New
OneRed
Mr. Shailkh
Comp. Comp.
27 20/10/201 No balancer air pressure gauge Break down Attach. Removed Retightening WhiteMr.
SonawaneComp. Comp.
28 20/10/201 Degree mover damage Break down Continuous useReplaced New
OneWhite Mr.Adikari Comp. Comp.
29 20/10/201 Excess air support plate to front Hard to tightening Continuous useReplaced New
OneWhite
Mr. Sonawane
Comp. Comp.
30 20/10/201 Front support pipe bend Break down Continuous use Retightening White Mr.Adikari Comp. Comp.
31 20/10/201pressure switch electric connection
Break down Continuous useReplaced New
OneRed
Mr.Dayaram
Comp. Comp.
32 20/10/201 pannel cabin door loose Accident M/C Vibration Retightening White Mr.Makode Comp. Comp.
33 20/10/201 Foundation Bolt loose Break down Continuous use Retightening White Mr.Adikari Comp. Comp.
34 20/10/201 Panel cable gland missing Break down M/C VibrationReplaced New
OneRed Mr.hade Comp. Comp.
35 20/10/201 Chain guard loose Break down Continuous use Retightening White Mr.hade Comp. Comp.
36 20/10/201 Balencing cylender loose Break down Continuous use Retightening White Mr.hade Comp. Comp.
37 20/10/201 Stroke lub. Oil pipe missing Break down Continuous useReplaced New
OneWhite Mr.hade Comp. Comp.
38 20/10/201Excess cable on machine topside
Break down Not neededReplaced New
OneWhite Mr.Adikari Comp. Comp.
39 20/10/201 PU connector air leakage Break down M/C VibrationReplaced New
OneRed
Mr.Makode Comp. Comp.
40 20/10/201 pipe clamp by cotton Break down Continuous use Retightening White Mr.Adikari Comp. Comp.
Analysis of Abnormality and Removal Plan JH Step – 1
54
Tag No.Date of
detectionMPR00069(SHINOHARA
150T) Abnormality
Why it is "Abnormality"?(What will happen if it is
left as it is)
Why did it become so?
(What is cause?)
Contents of the
countermeasures
Abnormality tag
classificationExecutor
Planned
Date of completio
ndate
41 12/09/2012 connector oil leakage Break down M/C Vibration Retightening White Mr.Adikari 20/10/12 20/10/12
42 12/09/2012 Earthing cable loose Break down M/C Vibration Retightening WhiteMr.
Shailkh20/10/12 20/10/12
43 12/09/2012 open air line Break down To Be closeReplaced New
OneWhite
Mr. Shailkh
20/10/12 20/11/12
44 12/09/2012 Machine pad crack Break down M/C VibrationReplaced New
OneWhite
Mr. Sonawane
20/10/12 14/12/12
45 12/09/2012 open cable near transformer Accident M/C VibrationReplaced New
OneWhite Mr.hade 20/10/12 14/12/12
46 12/09/2012 main gear bolt loose Break down Continuous useReplaced New
OneWhite
Mr. Sonawane
20/10/12 20/10/12
47 12/09/2012 slider bolt loose Break down Continuous use Removed WhiteMr.
Sonawane20/10/12 20/10/12
48 12/09/2012 Machine Ram taper chek Break down Continuous useReplaced New
OneWhite Mr.hade 20/10/12 20/10/12
49 12/09/2012 stopper bolt missing Hard to indication Continuous useReplaced New
OneWhite
Mr. Sonawane
20/10/12 20/10/12
50 12/09/2012 Guard bolt missing Hard to indication Continuous useReplaced New
OneWhite Mr. Jadhav 20/10/12 20/10/12
51 12/09/2012 Reciever tank air leakage Break down Continuous useReplaced New
OneWhite Mr.hade 20/10/12 20/10/12
52 12/09/2012 Clutch spring bolt loose Break down Continuous use Set in proper White Mr.hade 20/10/12 20/10/12
53 12/09/2012 Motor foundation bolt loose Break down Continuous useReplaced New
OneWhite
Mr. Sonawane
20/10/12 20/10/12
54 12/09/2012 Booster plate bolt loose Break down Continuous use Reclamped White Mr.Iliyash 20/10/12 20/10/12
55 12/09/2012 main gear bolt missing Break down Continuous useReplaced New
OneWhite Mr.Adikari 20/10/12 20/10/12
56 12/09/2012 Control pannel Nut missing Break down Continuous useReplaced New
OneWhite Mr.Adikari 20/10/12 20/10/12
57 12/09/2012 Gear box bolt loose Break down Continuous use Retightening WhiteMr.
Sonawane20/10/12 20/10/12
58 12/09/2012 No rack for clamp & bolt Hard to search No Attachment Retightening White Mr.hade 20/10/12
59 12/09/2012 Air line union leakage Break down Continuous useReplaced New
OneWhite Mr.hade 20/10/12 20/10/12
60 12/09/2012 Main gear gressing not proper Break down Continuous useReplaced New
OneWhite Mr. Jadhav 20/10/12 20/10/12
Analysis of Abnormality and Removal Plan JH Step – 1
55
Tag No.Date of
detectionCVT DE/MPR/03
Abnormality
Why it is "Abnormality"?(What will happen if it is left
as it is)
Why did it become so?
(What is cause?)
Contents of the
countermeasures
Abnormality tag
classification
Executor
Planned Date of
completion
ate
61 20/10/201 Indication lamp not working Accident Continuous useReplaced New
OneWhite Mr.Adikari 20/10/12 25/11/12
62 20/10/201No cover Gear guard at right side
Break down Attach. RemovedReplaced New
OneWhite Mr.Adikari 20/10/12
0
10
20
30
40
50
60
70
80
90
100
Total Tag White Tag put & remove
Red Tag put & remove
6252
10
52
32
710 103
Total tag put
Total White Tag
Total Red Tag
No
of T
ag Abnormality Trend – Model M/C
56