02 TVS Motor Co. LTD

TVS M Motor t C Company
A case study presentation by Progressive

Slide Number: 1
(Planned) Maintenance TVS Motor Company P2
TPM approach towards P d Production achievement h &M Manufacturing f C Cost reduction
Slide Number: 2
TVS Motor Company P2
Company Introduction
TVS Motor Company
Location of p plants
NEW DELHI
INDIA MUMBAI
KOLKATTA
Nalagarh (HP)
CHENNAI
BANGALORE
Jakarta (Indonesia)
Mysore (Karnataka)
Production started : Total Area :
Hosur - 2 Wheeler
Mysore plant view
Hosur - 3 Wheeler
Slide Number: 3
TPM Policy
Slide Number: 4
TPM Model
TPM in Plant2
Customer satisfaction in quality, cost & delivery Q Reduce Q: R d PDI complaints l i t
D 100% - Volume D: V l achievement by reducing line stopper thro OEE improvement
Improve OEE by minimising losses
Cheerful & safe work place
C: Reduce manufacturing cost Reduce inventory
P: 30% increase in productivity
M&S: Increase suggestion per employee Sustain Zero accidents
Improve PQCDMS Safety, Health & En nvironment Development man nagement Prog gressive Maintenance
Edu ucation and T Training
Qu uality Manag gement
Kobetsu Kaizen
Jishu Hoz zen
5 S activities by y all employees p y Total Employee Involvement

Slide Number: 5
Office TPM M
Background
Production Achievement
100 100 98
Line stopper
Better
10 8 6 4
8 3
Better
7.5
97
96
94
92.5 92
92
2 0
90
00-01'
00-01' 01-02' 02-03 BM
01-02'
02-03 BM
Manufacturing g cost
100 95 90 85 80 00-01' 01-02' 02-03 BM 100 96 93
Better
Numbers are indexed
Slide Number: 6
Plant Loss Analysis
Loss 1 2 3 4 5 6 7 7 8 9 Shut down Loss Equipment failure Loss Set up & adjustment Loss Cutting tool & Jig change Loss Startup Loss Minor stoppage Reduced speed Loss Idle running Loss Management g Loss Measurement & adjustment Loss
Percentage Plant focus area 1.56 2.42 1.94 1.51 0.15 30.51 0.00 0.00 1.10 0.05 10.90 13.86 0.27 6.72 6.84 1.26 20.90 Material Cost Manufacturing Cost 36% PDI 24% Line stoppers 39%
10 Rejection Loss 10 Rework Loss 11 Operating p g motion Loss 12 Line organisation Loss 13 Logistic Loss 14 Energy Loss 15 Die tool & Jig g Loss 16 Yield loss
Slide Number: 7
Plant Targets Production Achievement 100% Improve OEE 85% Reduce Line stoppers to Zero Reduce R d M Manufacturing f i cost b by 30%
Slide Number: 8
TPM Policy & Target
Deployment Pillar wise

Area of Focus PDI - Complaints Low capability of operators to identify abnormality Machines with variations leads to defect & scrap Off quality of supplier parts Line stoppers Low efficiency of machines Low efficiency of operator Weak Suppliers creating quality and delivery problems Capacity constraints Breakdowns Machine basic condition not maintained Low skill level of maintenance staff Maintenance systems not robust Cost Cost deployment not clear High process scrap High Maintenance cost Under utilisation of men
KK PM QM JH
OTPM
E&T
DM
Slide Number: 9
Background
120 114 108 102 96 90 00 01' 00-01' 01 02' 01-02' 02 03 BM 02-03 100
Vehicle line stoppage due to Break down

114
160 145
y Breakdown frequency
Better
142 135
Better
106
130 115 100 100 00 01' 00-01' 01 02' 01-02' 02 03 BM 02-03
160 145 130 115 100 100 00-01'
Breakdown hours
Better
110 105
Better
Maintenance Cost
102
108
128 120
100 100 95 90
01-02'
02-03 BM
00-01'
01-02'
02-03 BM
Numbers are indexed

Slide Number: 10
Objectives & Targets of PM
Reduce Line Stoppers due to Equipment Breakdown to Zero Reduce Maintenance cost by 30%
Slide Number: 11
PM Sub committee
Pillar Chairman
D Rajendra Babu
Machining Unit
PED
Training
Assembly Unit
P Baburaj
Vijay Kumar
Pandurangan
P Arun Kumar
Energy Management
Painting Unit
Machining Unit
Fabrication
D Rajesh
G Sridhar
P Saravanan
Slide Number: 12
N Ravi TVS Motor Company P2
Methodology
Step 7 S Step 6 Step 5 Step 4 Step 3 Step 2 Step 1 Evaluate the effectiveness
Maintenance Prevention Budget control / Stock control
Build maintenance information system
Scheduled Planning Periodic (TBM ) / Predictive (CBM) Maintenance Breakdown elimination / Corrective maintenance
Support to Jishu Hozen
Slide Number: 13
Support to Jishu Hozen
Slide Number: 14
Support to JH
In Phase 1 Support to JH was to identify and correct abnormalities.
PM Pillar supports JH in Removal of Red Tags. Reduce Cleaning time Reduce Inspection time. Create accessibility to reduce CLI time.
Kaizen Easy to inspect: Before After
Fully covered guard Not easy to inspect
Visual cover provided - Easy to inspect TVS Motor Company P2
Slide Number: 15
Support to JH
Operators are trained on Machine sub systems like Hydraulics & Pneumatics Pneumatics. Significant parts are explained in detail with illustrations.
HYDRAULIC TRAINER KIT
Procured a Hydraulic Trainer kit and displayed for Operator and Team Leader training. Elements are transparent. So, easy to understand. Demonstrate the functions of hydraulic elements and its internal construction.
Slide Number: 16
Support to JH
In Phase 2 Support to JH is to enhance operator operators s knowledge level about the machine and its functions.
Methodology to improve operator knowledge:
Overview about the machine & its capability
Working mechanism of the machine
Machine parameters related to quality
Significant parts and its Working principle
Probable Failure modes in each sub assembly
Immediate corrective actions required
Slide Number: 17
Support to JH
Red Tag removal trend
UOM: Nos
160000 122793 N o of T ags rem ov ed 120000 77004 80000 45462 40000 18628 106481
131133
0 2003-04 2004-05 2006-07 2007-08 2008-09 2009-10
131133 Red Tags has been cleared in order to support JH

Slide Number: 18
Support to JH
Awareness training to Operators & Team Leaders
Slide Number: 19
Support to JH a pe Example:
Overview about Fanuc ROBODRILL machine
Home position marking Turret Clamping system Spindle motor Z axis Servo motor Z-
Fixture X- axis
Spindle
Y- axis Servo motor
Operators are educated about the machine subassemblies and its functions functions. Significant parts are explained in detail with illustrations.
Slide Number: 20
Equipment failure Elimination
11 Step approach
1 Equipment grouping and Ranking 2 Analysis y of Data 3 Eliminate Forced Deterioration 4 Identify root cause and implement counter measure 5 Identify breakdown reoccurrence / understand phenomenon 6 Investigate design weakness and improve it 7 Investigate natural deterioration 8 Set deterioration pattern 9 Select and evaluate maintenance point 10 Decide PM/TBM/CBM 11 Build best maintenance procedure
Slide Number: 21
Support to JH
JH Step 4 Working demonstration
Lubrication System
Hydraulic Elements
Bolts & Nuts

Slide Number: 22
Pneumatic Elements
Breakdown frequency
120
Breakdown Hours
120
Better
100
Better
100
90
80
74
60
60 54
42
49
30
40
19
19 6
24
20
'04-05 '05-06 '06-07 Apr May Jun Jul Aug Sep Oct Nov Dec Jan Feb Mar
0
Vehicle line stoppage due to Equipment failure

300 262 250 219 200 219 640
Better
150
100 55 50
Numbers are indexed
0
Slide Number: 23
Step 1 : Equipment Ranking

Equipment Ranking Machine Shop
Business Impact
Rank A Rank B Rank C
No Alternate machines Alternate machines available Simple machines
47 14
Values are indexed

195 60 88 26
An example of Ranking in a Cell

Opn 10 Opn 20 Opn 30 Opn 40 Opn 50
A C B A C B
No Alternate Can be shifted to Other machine
Two Machines doing same operation No Alternate Alternate
Can be shifted to Other machine
Slide Number: 24
Step 2 Break down Elimination
Slide Number: 25
Background
Production Non-Achievement Non Achievement
Inhouse Losses
B/O parts shortage
OEE < 85 %
(OTPM pillar) ill )
Equipment Failure loss

(PM pillar)
Tool change loss

(KK pillar)
Rework loss
Start up loss
(KK pillar)
Minor Stoppage loss

(JH pillar)
(QM pillar)
C Case study t d
Slide Number: 26
Step 2 : Analyze the Present status Equipment details

1. 2. 3. 4. BFW VMC NTC VMC FANUC VMC SPM 2 machines 1 machine 2 machines 3 machines
Stratification of slips p - Equipment q p wise

50 40 30 20 10 0 BFW Fanuc Robo SPM NTC
52 22 16 45
100
77 95 100
80 60 40
4
20 0
Slide Number: 27
Step 2 : Analyze the Present status
PROCESS
Machine
SAP Breakdown History Abnormalities Technicians & JH members
Analysis
Sub systems
OUTCOME
(Causing breakdowns)
Action plan
(For identified abnormalities)
Slide Number: 28
Phenomena stratification in BFW machine ( subsystem wise)

15
87 12 64 9 Percentage P 78 93 100
100
12
No. of Phenome ena
80
9
47
8 6
60
6
27 4 3 3
40
20
0 ATC Tool Magazine Guarding Axes Coolant Pneumatic Hydraulic
Slide Number: 29
Step 2 : Analyze the Present status COVER CLUTCH CELL LAYOUT
OPN 50
BFW
FANUC
OPN 40
OPN 60
SPM
FANUC
OPN 30
OPN 70
SPM
NTC
OPN 20
OPN 80
SPM
BFW
OPN 10
Slide Number: 30
Step 2 : Analyze the Present status COVER CLUTCH CELL LAYOUT
OPN 50
BFW
FANUC
OPN 40
OPN 60
SPM
FANUC
OPN 30
OPN 70
SPM
NTC
OPN 20
OPN 80
SPM
BFW
OPN 10
Slide Number: 31
Step 2 : Analyze the Present status Equipment details

1. 2. 3. 4. BFW VMC NTC VMC FANUC VMC SPM 2 machines 1 machine 2 machines 3 machines
Phenomena identified from past occurrence
Slide Number: 32
Step 3 : Elimination of Forced deterioration Step 2 : Analyze the Present status
Problematic Subsystems
Hydraulic system Spindle
Machine
3 Axes (X,Y,Z)
Automatic Tool Changer
Z Y X Coolant system
Tool Magazine TVS Motor Company P2
Slide Number: 33
Step 2 : Analyze the Present status Action p plan for abnormality y correction
Slide Number: 34
PROCESS
F il Failure mode d Part P t wise i
Analysis
OUTCOME
Forced deterioration Elements
Design weakness Elements
Natural deterioration Parts
Action plan
Slide Number: 35

Subsystem / Part wise Failure mode Analysis:
Slide Number: 36
Step 3 : Elimination of Forced deterioration
A ti f Action for F Forced dd deterioration t i ti :
BFW - VMC
Spindle Tool Magazine
Phenomena due to Forced deterioration: 1. Tool falling down from ATC gripper.
Slide Number: 37
Step 3 : Elimination of Forced deterioration
Action for Forced deterioration: Example: Tool Falling down
d Plunger movement reduced from 27mm to 15mm

Slide Number: 38
Step 4 : Identify root cause & Implement countermeasure
Example: Tool Falling down
ATC Gripper
Variation in Plunger movement
Plunger Struck up
Restriction in spring Movement
Spindle Orientation error
Tool Positioning Wrong
Plunger Bend
Guide Screw Loose
Spring Broken Coolant Entry S l Failure Seal F il
Spring Corroded Less Corrosion resistance Spring steel S used Coolant PH & concentration
Arm Damage
Tennon loose
CM 1 : Replace seal in TBM

Slide Number: 39
CM 2 : Change to SS coated material TVS Motor Company P2
Step 5 : Identify breakdown recurrence & understand phenomena Actions arising after why why analysis: 1. 2. 3. Replace Arm plunger seal once in a year ( Add in TBM calendar ) Check arm tennon for any looseness in Weekly JH check grease in arm p plunger g spring p g once in three months Refill g Before
Springs with no rust prevention coating
After
Springs with SS coating
Slide Number: 40
Step 6 : Investigate design weakness
Action for Design Weakness:
Home position
Tool pot
ATC
Slide Number: 41
Spindle
Action for Design Weakness:
Slide Number: 42
Actions for Design Weakness:

Example: Spindle orientation position changing
Physical Analysis Phenomenon Contact Diagram Interacting Elements Physical Quantifiable change
Spindle Orientation not in position
1.Encoder 2.Coupling 3.Belt 4.Pulley
Variation in Encoder Pulley Position
Spindle pulley
Encoder pulley Reference pulse

Slide Number: 43

Variation in encoder pulley position
Drive slippage in encoder
Spindle drive
Encoder Belt
Encoder Pulley
Slackness
Teeth worn out
Pulley Teeth worn out
Pulley Shaft play
Pulley Teeth worn out
Pulley shaft play
Assembly error
Misalignment
Center distance between pulley not constant
Play between Pulley and bearings
P ll shaft Pulley h ft worn out t
Slide Number: 44
Step 6 : Investigate design weakness 4M Analysis
Failure Mode
Pulley Shaft Worn Out
MAN
MACHINE
MATERIAL
METHOD
Belt tension setting Alignment
Support bearing condition High spindle speed
Pulley diameter variation
Interference Fit between bearing & Shaft Bearing assembly error
Slide Number: 45
Step 6 : Investigate design weakness 4M Condition Investigation Failure mode: Pulley Shaft worn-out S. No 1 4M Man Condition Belt Tension setting Specification Genba Observation Relatio nship
Permissible slackness = 1.5mm (within 2mm for 100mm length spec) Assembly should be done as per drawing Reference R f plane l is given for easy assembly Running at max max. speed (within spec) Diameter, D = 19.68 mm Weak relationship
Man
Belt alignment High g operating p g speed of the spindle ( Process parameter) Pulley shaft diameter variation
Machin e
Max Speed : 8000 RPM
Material
Diameter, D = 20.01 mm M di Medium relationship l ti hi
Strong relationship
Slide Number: 46
4M Condition Investigation
Comparision between BFW Machines

Opn No. 10 50 10 20 30 Operating speed 8000 RPM max 3500 RPM max 8000 RPM max 4000 RPM max 3500 RPM max Operation Milling g, g & boring g Drilling,reaming Milling Drilling reaming & boring Drilling,reaming Drilling,reaming & boring Pulley Failure
Problem occurs only in machines operated at high speeds
Slide Number: 47

While spindle stops for orientation, speed Encoder reduces from 8000rpm to 0rpm within 2 sec. During spindle stoppage, 10Nm inertial force acts t additionally dditi ll on the th encoder d pulley ll shaft. h ft Coupling Shaft Bearing Shaft material couldnt withstand the excess load since hardness is low (9 HRC - Aluminium).
R F
Inertial Force Encoder pulley Encoder belt Spindle pulley Spindle
Inertial Force, F = m x (N x 3.14 x D) / (60 x 2)

Slide Number: 48
Step 6 : Investigate design weakness Actions arising after analysis: 1. 2. 3. Change shaft material from aluminium to steel Surface hardness is maintained at 40HRC pulley y teeth p profile in monthly y PM check Check belt slackness & p Before
Shaft made of aluminium (9 HRC)
After
Shaft made of steel (40 HRC) Spigot & 5mm dowel for easy alignment
M6x25 screws 3nos for torque transmission TVS Motor Company P2
Slide Number: 49
Step 7 : Investigate natural deterioration Example for Natural deterioration
Actions for Natural deterioration:

Parts that doesnt have any influence such as forced deterioration and design flaw, will follow natural deterioration pattern. Parts that follow natural deterioration pattern, are covered under preventive maintenance (PM).
Deterioration pattern Pe erformanc ce

Rate of deterioration changes over period
Rate of deterioration C Constant t t
CBM
TBM
Life Probability of Failure
Age
Slide Number: 50
Scheduled planning
TBM & CBM
Slide Number: 51
Step 10 : Decide PM / TBM / CBM
Methodology:
Select part to be monitored
1
YES
1. Is service life guaranteed between the time of overhaul to next overhaul ?

NO
2. Is there accelerated deterioration?
2
2. Is there accelerated deterioration?
YES
NO
3. Is service life of the component reasonable?
Restore & Improve
3
NO
YES
2
NO
4. Is service life stable?
YES
4
YES
NO
Restore & Improve
5
NO
5. Do we understand deterioration process YES ? 6. Do we have Deterioration indicator ?
Elimination of Design defects
PM INSPECTION
CORRECTIVE MAINTENANCE
Research on Deterioration process
6
NO
YES
TBM
CBM
Slide Number: 52
Step 10 : Decide PM / TBM / CBM
Identification of Maintenance method:

# Part Accelerated Deteroriation Service life Guaranteded Service life resonable Service life stable Deterioration Indicator Maintenance Method CBM TBM CBM CBM CBM TBM TBM TBM TBM CBM TBM CBM
Spindle bearing Labyrinth seal Drawbar Spring Steel ball Bearing Spacer Timer Pulley Ti Timer Belt B lt Encoder Pulley Encoder Belt Tennon Cylinder seal kit Spindle motor
2 3 4 5 6 7 8 9 10 11 12
8 8 8 8 8 8 8 8 8 8 8
9 9
9 9 9 9 9 9 9
8 8
9 9 9 9 9 9 9
8
9
8 8 8 8 8 8
9 9
8
9 9 9 9 9 9 9 9
8 8
9 9 9
Not Ok
9 9 9 9
8
9
8
Ok
Slide Number: 53
Step 11 : Build best maintenance standard TBM Parts:
Slide Number: 54
CBM techniques being followed:

Instrument
Slide Number: 55
Step 11 : Build best maintenance standard
Identification of inspection item for CBM:

Spindle
S.No 1 2 3 4 5 6 7 8 9 10 11 12 13 Motor 14 Temperature Drawbar spring Steel ball Bearing spacer Timer Pulley Timer Belt Encoder Pulley Encoder Belt Tennon Tool declamp cylinder Spindle bearing
SPINDLE ASSEMBLY
Component Inspection item Vibration Run out Axial play Clamping pressure Diameter Length Profile Profile / Crack Profile Profile / Crack Width Pressure Current
Slide Number: 56
Step 11 : Build best maintenance standard
Slide Number: 57
Result
Breakdown frequency V/s Kaizens implemented
150 100
Bre eakdown f frequency
100
100
80
63 80 32 45 35
60
40
50
12 4
0
20
3
'07-08 Kaizens
1
0
'02-03 BM '03-04
'04-05
'05-06
'06-07
'08-09
Breakdown frequency
Numbers are indexed

Slide Number: 58
Ka izens im p plem ented
76
81
86
No of check points covered under TBM

60 45 30 15 0 Machining g Painting g Fabrication Assembly y Utilities 23 11 4 10 52
No of check points covered under CBM

80 60 40 20 0 Machining Painting Fabrication Assembly Utilities 9 76
Numbers are indexed
Slide Number: 59
Breakdown frequency
120 100 90 80 63 60 24 12 0 02-03' BM 03-04' 04-05 05-06' 06-07' 07-08' 08-09' 4 2
UOM: % Better
97%
30
Breakdown hours
120 90 60 30 0 02-03' BM 03-04' 04-05 05-06' 06-07' 07-08' 08-09'
100
UOM: %
Better
74 60 25 8 5 4
95%
Slide Number: 60
Vehicle line stoppage due to Equipment failure

100
100
UOM: %
100%
63 48
Better
75
73
50
25
6
0 02-03 02 03 BM 03 04 03-04 04 05 04-05 05 06 05-06 06 07 06-07
5
'07 07-08 08
0
'08 08-09 09
Engine line stoppage due to Equipment failure

100
100
UOM: %
100%
75
Better
52
50
29
25
20 11 8 0
'07-08 '08-09
0 02-03 BM 03-04 04-05 05-06 06-07
Slide Number: 61
Reduce Manufacturing Cost through TPM Methodology
Slide Number: 62
Manufacturing cost Stratification

Manufacturing Cost
Energy Cost
Tool Cost
Consumable Cost
Repair & Maintenance Cost
(KK pillar)
Power Cost
Fuel Cost
Spares Cost
Labour Cost
C Case study t d
(PM pillar)
Slide Number: 63
Manufacturing cost
110
UOM : %
100
Better
100
90
80
80
79 76
70
2004-05
2005-06
2006-07
2007-08
Manufacturing cost Stratification

UOM : %
7% 16%
Better
Power & fuel cost contributes 57 % of the total Manufacturing cost
57% 20%
P&F
R&M
St Stores
T l Tool
Slide Number: 64
Overall approach towards the Energy cost reduction Four types of Losses
Ideal loss Theoretical Th ti l losses Opportunity losses Recoverable losses
Condition of zero losses
Theoretically inherent loss & can not be eliminated This is the loss which can not be recovered as benefits even after elimination immediately. This is the loss which we normally attack & remove
Guidelines
Take actions straight away for recoverable loss Do kaizens to capture & reduce opportunity loss though it will not give immediate benefits Look at the physical view & try to convert theoretical loss in to opportunity loss
Slide Number: 65
65
Total Power consumption Plant 2

7% 16%
Period : Apr 08 Sep 08

57%
20%
P&F
R&M
Stores
Tool
UOM: KWH
1255700 units per month ( Avg )
Slide Number: 66
Total Power consumption Plant 2

UOM: KWH Period : Apr p 08 Sep p 08
30%
36%
Paint shop Machine shop Fabrication Engine assy
3%
4% 6% 21%
Vehicle assy Utilities
Utilities
Lighting 24%
Compressor 76%
Slide Number: 67
Compressed p air conservation

Slide Number: 68
Usage of compressed air Pneumatic cylinders Air hoist
Gauges
Application of compressed p air
Part seat sensing Component Cleaning Pneumatic tools Numbering Paint mixing and painting guns
Slide Number: 69
Methodology
Step 7
Explore alternate source
Action for elimination Identify y opportunity pp y losses
Step 6
Step 5
Action for reduction and elimination
Step 4
Identify the recoverable losses
Step 3
Measure actual air consumption
Step 2
Calculate theoretical air consumption
Step 1
Slide Number: 70
Step 1

Data collection on Compressors capacity Pneumatic mapping pp g Summarise air consumption points C l l ti of Calculation f theoretical th ti l air i consumption ti Cylinders Gauges Blow guns Part seat sensing Air hoist Rotary fixtures D b i gun Deburring
Key Points
Slide Number: 71
Step 1

Compressor capacity
Non Lub Compressors
i i
Lub Compressors
i E L EF F F K1 2 3 T R O N I K O N I 0 A t l a s G A c 7 o 5 p c o E L EF F F K1 2 3 T R O N I K O N I 0 A t l a s G A c 7 o 5 p c o i
E L E K TF F R1 2 O N I K O N
I F 3 0
A t l a s c G o A p 7 c 5 o
580 CFM
570 CFM
200 CFM
200 CFM
535 CFM
535 CFM
535 CFM
625 CFM
570 CFM
Non Lub Air Ring mains Lub Air Ring mains Paint shops
Taikisha CED
Machining g Fabrication
Machining g Eng Assy
Machining g Veh assy
Prism Powder coat
Slide Number: 72
E L EF F F K1 2 3 T R O N I K O N
I 0
A t l a s G A c 7 o 5 p c o
I 0
E L E K TF F F R1 2 3 O N I K O N
I 0
Estimate leakages
Method for leak quantification

Shut off compressed air operated equipments Run the compressor to charge the system to set pressure of operation Note the time taken for loading cycle Note the time taken for Unloading Unloading cycle
The system leakage is calculated as: % leakage = T 100 / (T + t) (or) System leakage (m3/minute) = Q T / (T + t) Q = Actual free air being supplied during trial, trial in M3per minute (cmm) T = Time on load in minutes t = Time on unload in minutes
Slide Number: 73
Estimate leakages
Compressor capacity (m3/minute) = 45 Cut in pressure pressure, kg/cm2 = 6.5 65 Cut out pressure, kg/cm2 = 7 Load kW drawn = 279 kW Unload kW drawn = 140 kW Average Load time = 17 minutes g Unload time = 21 minutes Average a) Leakage quantity (m3/minute) = 45*17/(17+21) = 20.7 m3/min = 730 CFM
b) 5 CFM = 1 KW c) 730 CFM = 146 KW
Total energy loss per day = 3212 units per day Total energy cost loss per day = Rs. 24090 per day Total energy cost loss per annum = Rs. 72.3 lakhs / annum
Slide Number: 74
Step 1
Total Air Consumption

UOM : CFM
1400 1200 1000 800 600 400 200 0 Machine shop Paintshop Fabrication VehAssy EngAssy 350 180 190 1200
Total air consumption 2770 CFM
850
Slide Number: 75
Step 1
Pneumatic mapping
Cell1
OPN Cylinder Gauges P Seat P.Seat.
100 4 0 0
110 4 0 0
120 1 0 1
130 3 0 1
Cell2
140 3 0 1
150 1 0 0
OPN Cylinder Gauges P.Seat.
10 2 0 1
20 2 0 1
30 1 1 0
50 4 1 1
60 1 0 1
80 1 1 1
90 4 1 1
100 1 1 1
Slide Number: 76
Step 1
Summarize air consumption points
Pneumatic cylinders Gauges 32 nos
5 nos
Air consumption points

Part seat sensing 10 nos
Component Cleaning
5 nos
Pneumatic tools
5 nos
Slide Number: 77
Step 1 Calculation of Theoretical air consumption

Opn no. 100 100 110 110 120 130 130 140 140 150 10 10 20 20 30 40 50 60 70 80 90 100 Cyl. Dia. ( in mm) 30 20 30 20 40 30 16 30 20 40 16 16 16 16 30 40 20 40 16 16 16 20 Stroke length (in mm) 50 400 50 400 400 50 500 50 500 400 200 300 200 300 300 400 400 400 500 500 400 400 Qty 3 1 3 1 1 3 1 3 1 1 1 1 1 1 1 1 3 1 1 1 1 1 Volume (in litres) 0.79 0.93 0.79 0.93 3.73 0.79 0.75 0.79 1.17 3.73 0.30 0.45 0 30 0.30 0.45 1.57 3.73 2.80 3.73 0.75 0.75 0.60 0.93 No. of cycles 800 800 800 800 800 800 800 800 800 800 800 800 800 800 800 800 800 800 800 800 800 800 Actual Actual No. of consump. consump. strokes (in l/min) (in cfm) 1600 1600 1600 1600 1600 1600 1600 1600 1600 1600 1600 1600 1600 1600 1600 1600 1600 1600 1600 1600 1600 1600 6.29 7.46 6.29 7.46 29.83 6.29 5.97 6.29 9.32 29.83 2.39 3.58 2 39 2.39 3.58 12.58 29.83 22.37 29.83 5.97 5.97 4.77 7.46 0.22 0.26 0.22 0.26 1.05 0.22 0.21 0.22 0.33 1.05 0.08 0.13 0 08 0.08 0.13 0.44 1.05 0.79 1.05 0.21 0.21 0.17 0.26
Q(in l/min.) = * d2 * L * (P + A) 4 *10 106 * A *t t Where L = Stroke length d = Cylinder dia. P = Working pressure=6.5bar A = Atm Atm. Pressure= 1 1.013 013 bar t= actuation time
8.41
Slide Number: 78

Reference
For 1mm dia. Hole, CFM = 2 For inspection gauge with CFM = (2 cfm)*
T True size i of f hole h l dia. (in mm) 1 Air leakage at 6 bar (in cfm) 2
hole dia.. d,
Qty. 5
2
3 4 5 6 10
8
21 34 57 72 220
d2
Hole dia. (in mm) 1 Total CFM
CFM 2
10
Slide Number: 79
Step 1 Calculation of Theoretical air consumption Air blow guns

For 2mm dia. nozzle, CFM = 8 For air F i blow bl gun & washing hi m/c / nozzles l with ith nozzle l dia. di dCFMand dCFM d washing = (2 cfm)* d2 Air blow gun and washing nozzle
Nozzle dia CFM Qty Total
40
12
24
Slide Number: 80
Step 1 Calculation of Theoretical air consumption Part seat sensing

F 1mm For 1 dia. di nozzle, l CFM = 2 For Part seat sensing dia. d,
Nozzle dia
CFM
Qty
Total
10
20
Slide Number: 81

For o Cylinders, Cy de s, C Cfm = 8.4 8 40 10 20 24
For air blow guns, Cfm= For gauges, Cfm For Part seat , Cfm For Washing, Cfm = = =
Total theoretical CFM = 102.4
Slide Number: 82
Step 2 Measure the actual consumption
Measuring g actual Value of air consumption p by y flow meter 1. 2. 3. Install flow meter in the line Take Readings at Interval Average out
Total CFM measured by y the Flow meter = 136.8 cfm GAP = 34.4 cfm
Slide Number: 83
Step 3
Identify Recoverable Loss
TreeDiagramforPipelines
Leakage from Pipes
Damaged Pipe Not removed/ Blocked Properly Excessive bend Rubbing to moving Part
Wrong selection Of pipe
Selection of Wrong connectors
Loose Connectors
Loose End caps
Slide Number: 84
84
Step 3
T Di Tree Diagramf forBl Blowguns

Leakage from Blow guns Damaged Pipe Rubbing to Moving Part
Excessive bend Continues exposure To oil/ coolant Plunger stuck up Wrong part Used as plunger
Spring failure
Faulty adaptor
Rear Nut Loose
Slide Number: 85
85
Step 3
T Di Tree Diagramf forC Cylinders li d

Air loss from Cylinders Damaged seals Worn out Piston rod Across Piston Leakage Selection of Wrong connectors Loose Connectors
Loose End caps
Slide Number: 86
86
Step 4
Arresting leakages
Hose replacement Hose re-routing Fitting replaced Seal replaced Gasket corrected
Total no of leak points identified Total no of leak points corrected -
1747 points 1326 points

Slide Number: 87
Step 4
Ideal loss Theoretical losses Opportunity losses Recoverable losses
Air leaks through the gauges
Air supplied through foot switch during inspection only
No. of g gauge g points p applicable pp : 117 nos. No. of gauge points completed : 75 nos.
Slide Number: 88
Step 4
Action for reduction and elimination Air supply stopped when not in use
Ideal loss Theoretical losses Opportunity l losses Recoverable losses

+ 24 V
R1 Start Stop T1 R R1
Solenoid Coil
Exhaust
Relay
Timer Ti Timer set t for 2 min.
Solenoid
Slide Number: 89
Step 4
Input Cycle start
Output Part seat Air supply ON
Ideal loss
Part seat OK Clamping ON
Theoretical losses Opportunity l losses Cycle not running Recoverable losses

Air supply
Clamping OK
Cycle ON
Not OK
Solenoid
Cycle not running
Coil
Air supply
E h Exhaust t
OK
stopped
Slide Number: 90
Step 5
Identify opportunity losses
Opportunity losses in compressed air Optimising p g the air pressure p Eliminating pneumatic operation E l i the Exploring th application li ti of f gravitational it ti l force f Pressurised air drying to air blowing
Slide Number: 91
Step 6 Action for reduction and elimination Before

Air hose from control unit
After
Air point removed
Cylinder
Door
Door
Air consumed while door close
Applicable : 16 Door nos closed in gravity

Slide Number: 92
Step 7 Alternate technology for air saving
Slide Number: 93
Result
1400 1200 1000 800 600 400 200 0 Machine p shop 1200 900
Air Consumption
UOM : CFM 1 Compressor 520 CFM saved switched off
850 750
Total air consumption 2250 CFM
350 260
180160
190180
Paintshop Fabrication
VehAssy
EngAssy
Slide Number: 94
Result
Compressor capacity
Lub Compressors
i i i i
Non Lub Compressors
E L E K TF F R1 2 O N I K O N
I F 3 0
580 CFM
570 CFM
200 CFM
200 CFM
535 CFM
535 CFM
535 CFM
625 CFM
570 CFM
Non Lub Air Ring mains Paint shops Lub Air Ring mains
Taikisha CED
Machining g Fabrication
Machining g Eng Assy
Machining g Veh assy
Prism Powder coat
Slide Number: 95
I 0
I 0
I 0
I 0
E L E K TF F F R1 2 3 O N I K O N
I 0
Lighting Energy conservation

Utilities
Lighting 24%
Compressor 76%
Slide Number: 96
Lightings Types of Lightings
Shop p floor lighting g g
Office lighting g g
Task lighting g g
Street lighting g g
High bay lighting
Low bay lighting

95000 94000 93000 92000
93 3724
Lightingenergyconsumption
90000 89000 88000 87000
93 602
91000
90794
Apr '08
May'08
Jun'08
Jul'08
Slide Number: 97
89276
Lowering the High bay MV lamps

E 1
d2 E- Illumination d distance between plane to source of light
7.5 m
Illumination 220 lux
Illumination 360 lux
5m
Slide Number: 98
3m
6.0 m
Lux mapping LUX LEVEL MONITORING IN MACHINE SHOP

S Spec Sl.No. 1 2 3 4 5 6 7 8 9 10 AREA (lux) BAY 02 BAY 03 BAY 04 BAY 05 BAY 06 BAY 07 BAY 08 BAY 09 BAY 10 BAY 11 200-300 200-300 200-300 200-300 200-300 200-300 200-300 200-300 200-300 200-300 Day 260 250 229 234 257 241 220 243 236 259 Night 243 238 220 219 229 233 217 228 224 239 Day 253 245 230 229 249 236 228 240 249 251 Night 240 233 218 214 232 228 215 221 230 242
Slide Number: 99
LUX LEVEL MAPPING Zonal

Time office Stores Machine shop Machine shop Stores Vehicle assembly
Fabrication shop
Engine assembly
Vehicle Assembly
Taikisha Paint plant
Jost Paint plant
P.coating Paint Plant
CED Paint Plant
Haden Jost Paint plant
Prism Paint plant
Thermax Paint plant
Transhipment area
Substation
PMD & CU
Stores
Slide Number: 100
Standard illumination
IS 3646
Slide Number: 101
Actions
Optimising the illumination level in the Gangways
Standard
100-150 lux
220 l lux
150 lux
Switch off High bay lights wherever low bay lighting provided
Slide Number: 102
Actions
Optimizing the Energy consumption by introducing low bay lights in the gang ways
250 W Watts tt
150 W Watts tt
Introducing T5 tube lights in the machining unit energy consumption reduced from 150 to 84 Watts
150 Watts
Slide Number: 103
84 Watts
Actions
Optimizing the Energy consumption of street lights from 250 watts to 150watts
250 W Watts tt
150 W Watts tt
Introducing LED lamps for the street lightings through which energy consumption has reduced from 150 to 90 Watts.
150 Watts
Slide Number: 104
90 Watts
Actions LDB
Auto timers for lighting

LDB Timer
Timer
Slide Number: 105
Results
50000 units saved Moff
10000 units saved
Slide Number: 106
Energy conservation at M hi shop Machine h

30% 36%
Paint shop Machine shop Fabrication Engine assy
3%
4% 6% 21%
Vehicle assy Utilities
Slide Number: 107
Methodology
Check the results
Step 5
Step 4
Identify the losses
Step 3
Measure actual energy consumption
Step 2
Calculate theoretical energy consumption
Step 1
Slide Number: 108
Step 1

Key points
Collect the Volume based operating hours IED recommendations Calculate the energy gy consumptions p - Operation p wise Summarize the energy consumption / component A i the Arrive th theoretical th ti l energy consumption ti /component / t
Slide Number: 109
Step 1

Deployme nt Time (Grouping )
Collect the Volume based operating hours IED IED recommendations

Calculate d value Capacity /Day OE Volume Spares Vol SMM (MPO) No of Shifts 2 2 2 2 2 2 2 2
Cell name Line 1 Line 2 Line 3 LH 1 RH 1 LH & RH 1 (Cooper mill) LH & RH 2 (Cooper mill) RH 3 LH 3 CELL 1 & 2
5.77 5.16 4.67 3.77 4.43
6.17 5.83 4.93 4.33 5.42
954 954 954 1150 1150 950
600 600
8.36 7.91 8.36
600 600
5.87 7.3
850 12.77 13.77 14.77 15.77 6.17 6.17 6.17 6.17 954 954 954 954 600 600 600 600 8.36 8.36 8.36 8.36
Slide Number: 110
Step 1
Energy measuring tool used
Portable power analyser Cost : Rs. 2.5 lakhs No. of parameters measured : 30
In house made Power analyser Expense : Rs. 0.1 lakhs No. of parameters measured : 8
Slide Number: 111
Step 1
Measure the energy gy consumptions p - Operationwise p
Star Crankcase Feeder BBT 38 A and 51E
Opns Qty y Units
10 10 0.2
20 10 0.4
30 10 0.1
40 10 0.5
60 10 0.4
80 10 0.6
90 10 0.7
100 10 0.3
110 10 0.4
120 10 0.4
130 10 0.4
140 10 0.3
150 10 0.5
160 10 0.4
170 10 0.4
180 10 0.1
Slide Number: 112
Step 1
Summarise the energy gy consumption p / component p MACHINEWISE LOAD DETAILS
OPNS NO. 10 20 30 40 50 60 70 90 OPERATION Spot facing & Drilling Joint face milling 2 dowelling Exhaust Boring Oil hole drimming & Reaming Cam chain spot facing & drilling Spark plug hole KWH KWH (START) (END) 138.2 138.7 138.9 139.4 139.7 140.1 140.7 141.1 138.6 138.9 139.3 139.7 140 140.6 141.1 141.5 5 KWH NO. OF TOTAL TIME TOTAL KWH CONSUMED / CYCLES TAKEN CONSUMED CYCLE 5 6 min 0.4 0.4/5=0.08 5 5 5 5 5 5 5 6 min 7 min 6 min 6 min 7 min 6 min 7 min 0.2 0.4 0.3 0.3 0.5 0.4 0.4 0 0.2/5=0.04 0.4/5=0.08 0.3/5=0.06 0.3/5=0.06 0.5/5=0.1 0.4/5=0.08 0.4/5=0.08 0 /5 0 08
STAR CRANK CASE

90 100 110 120 130 Joint face Boring Joint face fine boring Cover face fine boring Joint face boring 141.6 142.4 143 143.4 143.6 142.2 143 143 3 143.3 143.6 143.9 5 3 5 5 5 6 min 4 min 6 min 15 0.6 0.6 03 0.3 0.2 0.3 0.6/5=0.012 0.6/3=0.2 0 3/5=0 0.3/5 0.06 06 0.2/5=0.1 0.3/6=0.05
Slide Number: 113
Step 1
Calculate the theoretical energy gy consumption p
Opns Qty Units
10 10 0.2 20 10 0.4 30 10 0.1 40 10 0.5 60 10 0.4 80 10 0.6 90 10 0.7 100 10 0.3 110 10 0.4 120 10 0.4 130 10 0.4 140 10 0.3 150 10 0.5 160 10 0.4 170 10 0.4 180 10 0.1
Total energy gy consumed - 6.1 units Total components produced 10 nos
Theoretical Energy consumption per component 0.61 units / component
Slide Number: 114
Step 2
Online Energy management system
Slide Number: 115
Step 2
Total components produced- 695 nos Theoretical energy ( calculated ) 695 x 0.61 = 424 units Actual energy consumption 229 + 340 = 569 units Area for OEE improvement -Supported by KK,JH,Office,DM
800 700 600 500 400 300 200 Theoreticalenergy Actual 424 424
Opportunity pp y to reduce
569
Slide Number: 116
Step 3
800 700 600 500 400 300 200 Theoreticalenergy 424
Identify the losses

Trials
569
Break down Changeover delay Startup loss Availability y Waiting for trolley Want of man Want of material Want of power Meetings Planned stoppage 117
424
Actual
Slide Number: 117
Step 3
800 700 600 500 400 300 200 Theoreticalenergy 424
Identify the losses

569
424
Actual
Loading delay Performance Unloading delay Defect & correction Quality Rejection loss
Slide Number: 118
118
Step 3
Identify the losses
BBT UIT
H d Hydraulic li motor t
Power Distribution in machines

Noise cut-off transformer Hydraulic yd au c motor oto Spindle motor Coolant motor Axis motors
800 700 600 500 400 300 200 Theoreticalenergy Actual 424 424 569
Spindle motor
Coolant motor
Opportunity loss
Slide motor
Slide Number: 119
Step 3
Identify the losses
T Di Tree Diagramfor f Opportunity O t it loss l i inamachine hi

Energy loss in the machine Coolant motor Idle running Idle running during non cutting Hydraulic motor Idle running
Spindle motor
Axis motor
Panel lights g Noise cut off transformer
No load losses
Slide Number: 120
120
Step 4
Idle time off in the machines
Input No input flag
Output Idle timer
Hydraulic motor
Idle timer On Hyd ckt Off
Spindle motor
Hyd ckt ON
Auto Cycle enable
Coolant motor
Slide motor
Slide Number: 121
121
Step 4
Power factor correction
Grid Bus
DG Bus
Cable
Auto PF correct
Slide Number: 122
12 2
Step 4
OHBBT 64
BEFORE AFTER
P.F.
CURRENT
Slide Number: 123
12 3
Step 4

Eliminate no load losses of Noise cut off transformers
3 phase supply
Control relay
Transformer off Machine off

Slide Number: 124
124
Step 5
Result Energy Consumption

Period : Nov 08
UOM : %
100 75 50 25 0
85
90 80 75
95
95
Rs. 4.5 lakhs per moth saved
95
Painting unit
Machining unit
Fabrication
Veh Assy
Slide Number: 125
Summary of Results Breakdown Frequency

120
UOM : % B tt Better
100
Numbers are indexed Availability

UOM : % Better
95
100 90 80 63 60 24 12 0 02-03' BM 03-04' 04-05 05-06' 06-07' 07-08' 08-09' 4 2

80 04-05 05-06' 06-07' 07-08' 08-09' 90 87 85 85 89 95 92
30
OEE
90
Production Achievement
Better
85
UOM : %
100
UOM : %
Better
97
85 82 80 80 76 75 77
95 90 90 86 85 88
93
70 04-05 05-06' 06-07' 07-08' 08-09'
80 04-05 05-06' 06-07' 07-08' 08-09'
Slide Number: 126
Summary of Results
Power consumption
130
Power cost
Better UOM : %
121
120
40
UOM : units / veh
Better
34 31 30
29
30
23
110
20
110
111
102
10
100
100
0 2004-05 2005-06 2006-07 2007-08 2008-09
90
2004-05
2005-06
2006-07
2007-08
2008-09
Manufacturing cost
110
UOM : %
Better
100
100
90
80
80
79
78 76
70
2004-05
2005-06
2006-07
2007-08
2008-09
Slide Number: 127

02 TVS Motor Co. LTD

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02 TVS Motor Co. LTD

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TVS M Motor t C Company

A case study presentation by Progressive

(Planned) Maintenance TVS Motor Company P2

TPM approach towards P d Production achievement h &M Manufacturing f C Cost reduction

TVS Motor Company P2

Mysore plant view

TVS Motor Company P2

TVS Motor Company P2

Improve OEE by minimising losses

Cheerful & safe work place

C: Reduce manufacturing cost Reduce inventory

P: 30% increase in productivity

M&S: Increase suggestion per employee Sustain Zero accidents

Edu ucation and T Training

Qu uality Manag gement

Jishu Hoz zen

5 S activities by y all employees p y Total Employee Involvement

TVS Motor Company P2

Numbers are indexed

TVS Motor Company P2

Plant Loss Analysis

TVS Motor Company P2

TVS Motor Company P2

TPM Policy & Target

Deployment Pillar wise

TVS Motor Company P2

Vehicle line stoppage due to Break down

130 115 100 100 00 01' 00-01' 01 02' 01-02' 02 03 BM 02-03

160 145 130 115 100 100 00-01'

Numbers are indexed

TVS Motor Company P2

Objectives & Targets of PM

TVS Motor Company P2

N Ravi TVS Motor Company P2

Maintenance Prevention Budget control / Stock control

Build maintenance information system

Support to Jishu Hozen

TVS Motor Company P2

Support to Jishu Hozen

TVS Motor Company P2

Kaizen Easy to inspect: Before After

Fully covered guard Not easy to inspect

Visual cover provided - Easy to inspect TVS Motor Company P2

TVS Motor Company P2

Working mechanism of the machine

Machine parameters related to quality

Significant parts and its Working principle

Probable Failure modes in each sub assembly

Immediate corrective actions required

TVS Motor Company P2

0 2003-04 2004-05 2006-07 2007-08 2008-09 2009-10

131133 Red Tags has been cleared in order to support JH

TVS Motor Company P2

TVS Motor Company P2

Y- axis Servo motor

TVS Motor Company P2

Equipment failure Elimination

TVS Motor Company P2

JH Step 4 Working demonstration

Bolts & Nuts

Vehicle line stoppage due to Equipment failure

Numbers are indexed

TVS Motor Company P2