ACHIEVING ZERO BREAKDOWN

PRESENTER

: B. R. DEY

A. COMPANY PROFILE

1 OUTLINE OF THE COMPANY

INCORPORATED IN 1972 TURNOVER IN 2009-10 = Rs. 7000 Million TOTAL EMPLOYEES : 4818 TOTAL AREA : 26 ACRES GOVT. RECOGNISED R&D

People Growing Together

2 MAIN COMPANY DETAILS

TOTAL EMPLOYEES 4818

OFFICERS STAFF WORKMEN

500 602 3716

TOTAL AREA NO OF M/CS

105,000 SQ.M (26 Acres) 1400

3 PRODUCTS
PISTONS RINGS

PINS

ENGINE VALVES

FOREIGN COLLABORATION

PISTONS
1. 3.

RINGS RIKEN RIKEN

RIKEN CORPN. JAPAN

KOLBENSCHMIDT - GERMANY

(1972)

(1978)

PISTONS
2.

ENGINE VALVES
4.
FUJI OOZX JAPAN

HF
HONDA FOUNDRY JAPAN

(1989)

(1993)

SPR IS SINGLE SOURCE TO 17 OEMs

Two Wheelers

5.

OUR DOMESTIC OE CUSTOMERS

Passenger Cars

Commercial Vehicles

HINO ENGINES

Tractors

Industrial Engines

6.

OUR GLOBAL OEM CUSTOMERS

During last few years SPRL has started export business with 6 new global OEM customers

FRANCE

GERMANY/AUSTRALIA/ SOUTH AFRICA

KIA MOTORS
IRAN

HYUNDAI
KOREA

IVECO
ITALY

HONDA MOTOR
USA/ CHINA

7.

EXPORTS
OEM 50%

Export 25%

Aftermarket

23%

EXPORTS TO OVER 30 COUNTRIES

Others 2%

No. 1 PISTON EXPORTS

No. 1 RING EXPORTS

PRODUCT BRAND NAMES

B. APPROACH ON ZERO BREAKDOWN

1. PROCESS OUTLINE
SPRL

CI Foundry Aluminium Foundry Piston Plant

CI Ring Plant

Steel Ring plant

Pin Plant

EV Machine

EV Forge

Piston Production Process

Raw Material

Melting & Alloying

Die Casting

Machining

Inspection

Packing

2. PROCESS OUTLINE OF ALUMINIUM FOUNDRY

Process Flow of Aluminium Foundry

RISER CUTTING

HEAT TREATMENT

CASTING
85

INSPECTION

MELTING

ROUGH TURNING & ROUGH FACING

RAW MATERIAL

EQUIPMENT OUTLINE
Numbers of Machines : Aluminium Foundry
Others Heat Treat
23 32 52 6 69

Melting Holding

Die Casting Total nos.of Equipments : 183

Variety of Equipment

Melting Furnace

Metal Treatment

Heat Treatment

CNC Machines

Holding Furnace

Die Casting Machines

3. APPROACH FOR ZERO BREAKDOWN

1. Breakdown Reduction
1. 1 Focussed Planned maintenance activities were done to reduce Major and Repetitive Failures. 1.2 Intensification of Time based inspection and maintenance activities on all PM-A and PM-B machines.
ANNUAL PREVENTIVE MAINTENANCE PLAN - YEAR 2003

Annual Maintenance Plan

(ALUMINIUM FOUNDRY)
M AR I II III IV I A PR II I I I IV I M AY II II I IV I JU N II II I IV I JU L II II I IV I AUG II I II I V I SEP II I II I V I OC T II I II I V I NOV II I II I V I DEC II III IV R E M A R KS

SHR IR AM PISTONS : GH AZIAB AD

Review of maintenance standards Time based maintenance of electrical and mechanical control system Time based replacement of components based on their failure data from TPM Part 1 activities

S. NO. 1

M A C HI N E OI L F IR ED

A C T IV IT IES N O .1

F R E Q.

JA N I II I II I V I

F EB II I II I V

FURN ACE

:A L L GEA R,W ORM ,SPROCKET & CH A IN CL EA N ING & GREA SING TO B E DONE :B USH B EA RINGS GREA SING TO B E D ONE OF A LL SH A FTS & W H EEL S OF TILTING A SSEM B LY :OIL IN TILTIN G GEA R B OX TO B E FILL ED / REPLA CED :D OOR B E A RING GREA SING TO B E D ONE F IR ED FURN ACE N O .2

0 3 M ONTH 0 6 M ONTH

0 6 M ONTH 0 3 M ONTH

DAILY CHECK CHART - DIE CASTING MACHINE Month - Ja n-07 9 10 11 1 2 3 4 5 6 7 8 12 13 14 15 16

Fre que ncy :1 Da y

Re f : AF/MAINT/10

Daily check chart

( Aluminium Foundry ) 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31

SHRIRAM PISTONS : GHAZIABAD

2 Die Cas ting Activity :OI L

:A L L GEA R,W ORM ,SPROCKET & CH A IN

0 3 M ONTH 0 6 M ONTH

Machine no. Abn orm al fr om M ot or C Nois L EA N e ING & GREA SING Abn orm al Nois e fr om Pum p

TO B E DONE

:B USH B EA RINGS GREA SING TO B E D ONE OF A LL SH A FTS & W H EEL S OF

A SSEM B LY Cou pling TILTING m o unting & T yre cond it ion

Hydrau licFILL Pre s s ure ( ED / REPLA CED

:D OOR B E A RING Oil le ve l in re s e rvior D ONE

:OIL IN TILTIN G GEA R B OX TO B E

0 6 M ONTH 0 3 M ONTH 0 3 M ONTH

GREA SING TO B E

Oil t e m p e rat ure ( FILLED M ax.58 De g re e RICA Ce nt .) :OIL TO BE IN A IR LUB TOR Po w e r p ack Fle xible pipe condit ion
3 4 HE A T HE A T T R EA T M EN T T R EA T M EN T W ITH CLE A NING OF A IR FIL TER F URNA CE F URNA CE B E DON E URNA CE

N O .1 03 2 M ONTH

Die Cas ting Activity : :B EA RING

GREA SING TO B E DON E

10

11

12

13

14

15

16

17

18

19

20

21

22

23

24

25

26

27

28

29

30

31

Machine no. Abn orm al e fr om M ot or :B Nois EA RING GREA SING TO

5 HE A T T R E A T M E N T F Abn orm al Nois e fr om Pum p

N O .2 0 3 M ONTH N O .3 0 3 M ONTH N O .4 0 3 M ONTH N O .5 0 3 M ONTH N O .6 0 3 M ONTH 0 3 M ONTH N O .7

:B EA RING GREA SING TO B E DON E :B EA RING GREA SING TO B E DON E T R EA T M EN T T R EA T M EN T F URNA CE F URNA CE CE

Cou pling mA oT unting & T yre cond it ion 6 HE T R EA TM EN T F UR N A CE Hydrau lic Pre s s ure (
7 8 HE A T HE A T

:B EA GREA SING Oil le ve l in reRING s e rvior

TO B E DON E

Oil t e m p e rat ure ( GREA M ax.58 De g re e DON Ce nt :B EA RING SING TO BE E .)

9 HE A T T R E A T M E N T F U R N A Po w e r p ack Fle xible pipe condit ion :B EA RING GREA SING TO B E DON E T T R EA T M EN T F URNA CE URNA CE B E DON E :B EA RING GREA SING TO B E DON E

Die Cas ting Activity 1 0 : HE A

1 N O .2 8
N O .9

10

11

12

13

14

15

16

17

18

19

20

21

22

23

24

25

26

27

28

29

30

31

Machine no. Abn1 orm al Nois e fr om M ot or 1 HE A T T R E A T M E N T F

1 2 HE A T T R EA T M EN T EN T G

0 3 M ONTH 0 3 M ONTH N O .1 0 0 3 M ONTH N O .1 1 0 3 M ONTH 0 3 M ONTH 0 3 M ONTH

:B Nois EA RING GREA SING p TO Abn orm al e fr om Pum

F URNA CE F URNA CE

Cou pling m o RING unting & T yre TO cond it ion E :B EA GREA SING BE DON
1 3 HE A T T R E A T M Hydrau lic Pre s s ure ( :B EA RING GREA SING TO B E DON E FUR NACE N O.1 :B EA RING GREA SING TO B E DON E

Oil le 1 ve 4 l in SO re LU sT eIrvior ON I SIN

Oil t e m p e rat ure ( M ax.58 De g re e Ce nt .) :TA NK M OV ING SPROCKET & B EA RIN G

GREA SING TO B E DONE Po w e r p ack Fle xible pipe condit ion

O.K. NOT O.K. Ga uge Not OK

_/ x

57 Components / Assemblies for replacement

Fitte r Che cke d By

1.3

Condition based maintenance activities

Bearing condition monitoring of CNC spindle bearings. Temperature monitoring of hydraulic power packs. Condition monitoring of hydraulic oil for increase in life of oil. 69 Equipments under CBM
Temperature Monitoring

2. Elimination of Minor Stoppages

2.1 Elimination of minor stoppages by Planned maintenance on different equipments.
SL. NO.
1 3 4 5 6 7

Hydraulic oil filtration Machine

LIST OF MINOR STOPPAGES : BY PLANNED MAINTENANCE
MACHINE
Sol. Cum Ageing Fur.-1 D.C.M/C No.- 29 D.C.M/C No.- 18 D.C.M/C No.- 4 , 5 Riser Cutting M/C.-7 D.C.M/C No.- 49 , 50

DETAILS
Minor stoppage due to bearing cooling pipe circuit chocked Minor stoppage due to Burning of flexible pipes of mould coling Minor stoppage due to misalignment of Eye pad holder box. Minor stoppage due to steam generation in water circuit Minor stoppage due to overheating of TCT cutters. Minor stoppage due to frequent change of cooling pipes.

APPROACH FOR ZERO BREAKDOWN

Zero Breakdown Approach

Analysis of daily failures with Jishu Hozen

Deep Analysis of Failures Identification of potential failures

Plan Corrective Maintenance

Study & Analyse

Implement

Identify Kaizen Themes

Implement

Not OK

Observe for 3 months

OK

Not OK

Observe for 3 months

OK

Horizontal Replication

Maintenance Record

Horizontal Replication

MP Information

Review of Maintenance standard

4. FAILURE ANALYSIS
LIST OF FAILURES IN ALUMINIUM FOUNDRY
Failure of eyepad assembly Breakage of piston rods in Pin assembly Failure of hydraulic power pack

38 Kaizens
implemented

Die Casting

Oil leakage in center tool assembly Frequent failure of quench tank Water/oil leakage in cooling/hyd ckt Not attaining required temp of molten metal

Breakage of lead screw in GBF M/C

21 Kaizens
implemented

Aluminium Foundry

Holding & Metal Treatment

Premature failure of crucibles Leakage of heat from furnace doors

Melting

Failure due to high temp in furnace coil Failures in pipes of cooling circuit

12 Kaizens implemented

Failure of blower bearings

Heat Treat

Failure due to breakage of wire ropes Leakage of heat from furnace doors

11 Kaizens implemented

5. PROBLEM ANALYSIS
Breakdowns Frequency Trend
91 %

Heat Treat 3 % Die Casting Holding 2 % Others 2 % Melting 2 % Breakdowns Frequency in Heat Treatment Assemblywise analysis
Blower assy Baffle plate Basket carrier Trolley assy
40 60 80 0

Breakdowns Frequency in Die casting Machine Assemblywise analysis

Eyepad assy Pin assy Mould assy Power pack Bottom assy Centre tool assy Vertical assy Water Strut Load assy
0

60 34 28 17 17 14 12 11 1
20

3 2 1 1
20 40 60 80

Nos. of Breakdowns / Year Breakdowns Frequency in Holding Furnace Assemblywise analysis

GBF Furnace lining Crucible Heating element
0

Nos. of Breakdowns / Year Breakdowns Frequency in Melting Furnace Assemblywise analysis

Blower assy Baffle plate Basket carrier Trolley assy
20 40 60 80 0

2 1 1 1

3 2 1 1
20 40 60 80

Nos. of Breakdowns / Year

Nos. of Breakdowns / Year

6. KAIZEN
KAIZEN ON DIE CASTING MACHINE
1. Elimination of Repetitive Breakdown in eyepad assembly through modification of guide rod
Problem Analysis :
Guide rod
1.5x45 20 O

20 O

14 O

14 O

M14x1.5P Guide rod

Eyepad assembly

Guide rods are provided in eyepad assembly to guide the eyepad holder motion During movement this rod gets bent due to load Guide rod also breaks from thread

Kaizen details :
Guide rod was redesigned to prevent it from breakage Guide rod dia increased from 20 mm to 28 mm Size of thread also increased from M14 to M18
28 O

1.5x45 20 O 20 O 28 O

M18x1.5P

Modified Guide rod

Result :
Nos.of Breakdown/ Year

Breakdown Frequency Trend

(Guide Rod)
12 8 4 0 0 0 10

No breakage of guide rods

GOOD

Reduction of Breakdown by 10 Nos. / Annum

2. Breakdown reduction of frequent jamming of eyepad slide by redesigning eyepad holder boxes in Die Casting M/C
Problem analysis :
Eyepad holder runs in holder box fitted on eyepad carrier of casting machines The holder gets heated up due to casting operation on machine Due to heat external lubrication on holders is not effective resulting in jamming of holders in boxes
Eyepad holder box Eyepad holder

Kaizen details :
To provide solution to eliminate external lubrication Redesigning of holder boxes by providing self lubricating strips on all rubbing surfaces

Eyepad holder

Eyepad holder box Self lubricating strip

Result :
Nos.of Breakdown/ Year

Breakdown Frequency Trend

(Eyepad Holder)
15 12 10 5 0 0 0

No need of external lubrication Better machine static accuracy Life enhancement of eyepad holders from 1 years to 3 years Reduction of Breakdown by 12 Nos. / Annum

GOOD

3. Reduction in Breakdown of Quill pin cylinder through design improvement by introducing guide rods to prevent breakage of piston rod in Die casting Machine
Problem analysis :
Excessive Yoke Piston rod

Cylinder

load on Piston rod & coupler due to jamming of any one pin in mould block

Quill pin

The excessive load cause breakage of Piston rod or coupler This breakage causes frequent breakdown of Die Casting Machine

Coupler

Kaizen details :
Redesigning piston rod with support of guide rod. To reduce load on Piston rod & coupler due to jamming of any one pin in mould block by providing guide rods on both sides of coupler. These guide rods share the load coming on coupler & piston rod.
Quill pin

Yoke

Piston rod

Guide rod

Coupler

Result :
Nos.of Breakdown/ Year

Breakdown Frequency Trend

(Quill Pin Cylinder)
15 11 10 5 0 0

No breakage of Piston rod & coupler Hydraulic oil saving by 50 Litres / Annuum

GOOD

Reduction of Breakdown by 11 Nos. / Annum

KAIZEN ON HOLDING & METAL TREATMENT

1. Breakdown reduction through modification of lead screw drive system in Gas Bubbling Fixture machine
Gear Box

Problem analysis :
Gear box is mounted on top at the height of 1.8 mtrs Since it is a mobile equipment, hence during movement the lead screw is unbalanced & falls down
Lead screw Rotor

Electrical panel

Kaizen details :
To change the location of gear box assembly The gear box is relocated from top to bottom
Lead screw Rotor

Electrical panel

Gear Box

Breakdown Frequency Trend

Result :
Nos.of Breakdown/ Year

(GBF)
3 2 1 0 0 2

No breakage of guide rod of guide rod

GOOD

Reduction of Breakdown by 3 Nos. / Annum

KAIZEN ON MINOR STOPPAGES

1. Elimination of minor stoppage in Solutionising & Aging Furnace due to variation of water level
Problem analysis :
Manual control of water flow in quenching tank Stoppages due to breakdown of heaters due to variation in water level
Heater Electrical panel

Manual valve

Electrical panel

Kaizen details :
Installed Water level controller and level sensor. To control water flow automatically by interlocking level sensor with a solenoid valve.
Heater

Level Controller Level Sensor

Solenoid valve

Result :
8

Minor Stoppage Trend

(Soln & Aging Furnace)
6 4

No stoppage due to water level variation Life improvement of heaters from 1month 1 year

Nos.of Stoppages/ Year

GOOD
0

7. RESULTS
DIE CASTING MACHINES
Zero Breakdowns (Nos. of M/Cs)
70

HOLDING FURNACES
GOOD
80

Zero Breakdowns (Nos. of M/Cs)

GOOD
65

Nos. of Machines

Nos. of Machines

54
40

43
35

29

B.M. 2007

2010

B.M. 2007

2010

HEAT TREATMENT FURNACES

Zero Breakdowns (Nos. of M/Cs)
40

GOOD

Nos. of Machines

29 20
20

B.M. 2007

2010

END OF PRESENTATION