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Topic :
Zero Breakdown
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TTK-Pallavaram
Zero Breakdown
SUSTAINING ZERO BREAKDOWN AT TTK LIG Ltd., [Pallavaram Unit] By Mr.G. Vinoth @ Vijayan
The Company
TTK-LIG Ltd. is a 50:50 joint venture between TTK Group, India and SSL International plc, UK.
Manufacturing and marketing Male Latex condoms. Factories : Pallavaram (outskirts of Chennai),
Virudhunagar (near Madurai) and Pondicherry (160 kms south of Chennai) with Annual turnover of 170 Crores.
Page 21.1
TTK-Pallavaram
Zero Breakdown
Milestones
1952 : TTK importing and selling Durapac and Durex in India. 1963 : LRC (India) Ltd. established; condom manufacturing commenced. 1971 : Supply of Nirodh condoms to Govt. of India commenced. 1976 : Exports commenced To Russia with love 1979 : Launched Kohinoor the brand leader in India, today. 1987 : Vietnam Project executed The first International turnkey project. 2001 : Sales value crosses the Rs.1 billion mark 2003 : TPM Excellence Award (2nd category) 2004 : TPM Excellence (2nd category) Consistency Award.
Quality Accreditations.
ISO 9000 / ISO 14000 / ISO 13485 AFNOR (French certification) / DLF (German certification) SABS (South african beuro of Standards) / HKSI ( Hong kong Safety institute) CMDCAS (Canadian certification)
Production Process
.
Compounding
Natural latex mixed with vulcanizing chemicals is heated, cooled & sent to Dipping Glass formers are dipped in compounded latex. A latex film (the condom) is formed on glass former surface. The formers are then dried and the condoms (dried films) are wet stripped subsequently.
Wash Wash tumbler Cooling table Centrifuge Dry Dry tumbler
Dipping
Post Treatment
The condoms are washed, dried & cooled. They are then naturally aged for a minimum of 21 days to complete vulcanization by storing them in a room. Each and every condom is then electronically tested for holes. The good ones are sent to Foiling. The good condoms received from ET are foiled between two layers of laminates, with a lubricant.
The foiled condoms are packed as per customers specifications & dispatched
Page 21.2
TTK-Pallavaram
Zero Breakdown
Restoration
Standard
Methodology
Activities for Elimination of Breakdown Support Activities for Jishu Hozen Preparation and Implementation of Time Based Maintenance Prevention of Recurrence of breakdown
Page 21.3
TTK-Pallavaram
Zero Breakdown
Support To Jishu Hozen : Find all the causes of forced deterioration and restore and improve(Kaizen)
Natural deterioration Forced Deterioration Time
Step 1
Red Tag Removal Plan and Correcting abnormalities Implementing Counter measures against Hard to Access areas and source of Contamination Preparation of Tentative Standards for CLIRt. Preparation of General Inspection training material and training the circle leaders. Preparation of Autonomous Inspection standards for JH
Degree of deterioration
1 2 3 4 5 6
Step 2
Step 3
Step 4
Step 5
10/09/2004 Main Drive Gear Box 30/08/2004 Stripping 20/11/2004 I st Drier 19/10/2004 Stripping R/C Pump
Abnormal Noise Plug & I Drier Box Socket Loose R/C Pump Water Leak
20/11/2004 Eletrician Quality &Safety Completed. 20/10/2004 Fitter 20/08/2004 Fitter Break Down. Break Down. Completed. Completed.
O 04 6083 6079
F05
M05
Page 21.4
TTK-Pallavaram
Zero Breakdown
After Tray provided for easy cleaning the track chain dirt
Before
After
Page 21.5
TTK-Pallavaram
Zero Breakdown
2000 1000 0
Put -R Rem -R
N o s.
70 60 50 40 30 20 10 0
Nos / Mt h. Dec ' 99 64 Q1' 00 52
Breakdown - Companywide
Q2' 00 45
Q3' 00 36
Q4' 00 32
Q1' 01 27
Q2' 01 23
Q3' 01 19
Weak Design
Kaizen
Preventive Action
Page 21.6
TTK-Pallavaram
Zero Breakdown
No.of Glass Moulds 2040 Operating 24 hrs & 360 Days No.of Machines - 11
Sl. No 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
Physical Phenomena Stripping jet blockage R/C pump not running Wash Brush not rotating Dipper 1 Agitator not rotating Dipper Agitator Blade not running Drier 1 heater open / cut Dipper 2 Agitator not rotating Drier 2 heater open / cut Beading Brush not rotating Contra belt not running FDE curve broken Triplex chain cut off Track micromaster - no output Vulc heater open / cut Former breakage MCB / OLR - tripped / open
1999 2 15 3 8 1 6 2 3 4 3 2 1 1 8 12 8
2000 2001 Q1 Q2 Q3 Q4 Q1 Q2 Q3 Q4 1 2 1 1 1 0 0 0 16 20 22 21 6 4 1 0 0 1 0 0 0 0 0 1 0 0 1 1 0 1 0 0 0 0 0 0 0 0 0 0 9 10 11 12 3 0 1 0 0 1 0 0 0 0 0 0 1 2 4 2 2 0 1 0 8 3 0 0 0 2 2 1 4 6 5 6 1 0 0 0 0 1 0 0 0 0 0 0 1 1 0 0 0 0 0 0 0 0 1 0 0 0 0 1 0 1 0 0 0 0 0 0 2 5 13 15 7 9 14 0 0 5 0 1 0 4 0 0
Dipping Line
Total Phenomenon - 39
Theme
Analysis
Classification
Motor Base
Foundation Base
Motor Base
Foundation Base
Actual Results
06.02. 2000 KA RS
05.02. 2000 KA SC
05.02. 2000 KA AK
06.02. 2000 KA RK
06.02. 2000 KA BK
06.02.2000 KA VK
Page 21.7
TTK-Pallavaram
Zero Breakdown
Weak Design
Kaizen
JH
E&T
KK / PM
JH / PM
Classification of Causes
Nos. 700 600 500 400 300 200 100 0 Nos. D99 42 2000 226
OPL Trend
2001 302
2002 413
2003 531
2004 646
Page 21.8
TTK-Pallavaram
Zero Breakdown
Classification of Causes
Weak Design
Kaizen
Results :
Nos./Mth 8 6 4 Triplex Chain Breakdown
Triplex Chain links not able to withstand the load Triplex Chain link is of 1/2 " pitch
2 0 Before 6
Better
After 0
Nos/Mth
Classification of Causes
331 Kaizens
Weak Design
Spindle
Bush
Brass Block
Kaizen
Holder
Torsional Springs
Page 21.9
TTK-Pallavaram
Zero Breakdown
Swing Angle -0
After
Initial twisting angle reduced to 60
30
Analysis :
Clamp replacement high Spring life less Spring gets over stressed Working stress on the spring is higher than allowable stress Design Root Cause : Higher working stress
Results :
N / mm 600 550 500 450 400 350 300 Be f or e Af t er
B e n e fits :
P r o d u c t io n in c r e a s e d = 1 3 8 0 0 p cs. / m c. / m o n th
33 %
330
Page 21.10
TTK-Pallavaram
Zero Breakdown
Reducing the Swinging angle by 40 ( i.e.from 0 to 50 of swinging angle ) and hold the former in 0 in dipper and leach tank by altering the former travelling Angle change smoothen from 0 - 50 - 0 guide.
90
50
Results :
N / mm 550 500 450 400 350 300 250 200 Before After
Analysis :
No. of clamp replacement high Springs get Over stressed Spring swings the formers from 0 to 90 and vice versa Design Root Cause : Higher swinging angle
Benefits :
Working Stress reduced due to curve modification
494.49
42 %
Better 275
After
Swing Angle -0
Initial Stress on the Spring 494.49 N / mm ( When Loading with Clamp ) Working Stress on the Spring Swinging 0 to 50 ( i.e. 110 - 989 N / mm total twist of spring )
Page 21.11
TTK-Pallavaram
Zero Breakdown
Classification of Causes
TBM Calendar
TBM
Time
Kaizen on weaknesses (CM)
TBM Checklist
* Tendency to replace at greater frequency is expensive
Parts replaced though still useful Severe wear but change before breakdown Parts Not replaced before failure
Limit Line
Dipping Line
Sl. No 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
Physical Phenomena Stripping jet blockage R/C pump not running Wash Brush not rotating Dipper 1 Agitator not rotating Dipper Agitator Blade not running Drier 1 heater open / cut Dipper 2 Agitator not rotating Drier 2 heater open / cut Beading Brush not rotating Contra belt not running FDE curve broken Triplex chain cut off Track micromaster - no output Vulc heater open / cut Former breakage MCB / OLR - tripped / open
1999 2 15 3 8 1 6 2 3 4 3 2 1 1 8 12 8
Page 21.12
TTK-Pallavaram
Zero Breakdown
N o s.
70 60 50 40 30 20 10 0
No s / Mth . Kaizen s Dec'9 9 64 24 Q1 '0 0 52 56 Q 2 '0 0 45 84
N o s.
Q 3 '0 0 36 115
Q4 '0 0 32 124
Q1 '0 1 27 142
Q 2 '0 1 23 164
Q 3 '0 1 19 194
Q4 '0 1 15 209
Q 1 '0 2 13 231
Q 2 '0 2 9 249
Q3 '0 2 4 27 1
Q4 '0 2 1 292
Q 1 '0 3 0 317
Q 2 '0 3 0 324
Q2 '0 4 0 331
N o s.
50 40 30 20 10 0
De c' 9 39 Q 1' 00 30
Breakdown - Dipping
T a rge t - Z e ro
N o s.
8 6 4
B et ter
B etter
2
Q2 ' Q 3 ' Q4 ' 00 00 00 26 22 20 Q 1' 01 19 Q2 ' Q3 ' Q4 ' 01 01 01 16 13 11 Q 1' 02 10 Q2 ' Q3 ' Q4 ' 02 02 02 6 2 0 Q 1' 03 0 Q2 ' 03 0
0
N o s / M t h.
De c' 9 6
Q 1' Q2 0 0 '0 6 5
Q3 '0 5
Q4 '0 5
Q 1' 01 4
Q2 '0 3
Q3 '0 2
Q4 '0 1
Q1' Q 2 03 '0 1 0
Q3 '0 0
N o s / M t h.
N o s.
20 15 10 5 0
D ec ' 99 19 Q 1' 0 0 16 Q2 ' 0 0 14
Breakdown - Foiling
T a rge t - Z e ro
B etter
Q3 ' 0 0 9
Q4 ' 0 0 7
Q 1' 0 1 4
Q2 ' 0 1 3
Q3 ' 0 1 2
Q4 ' 0 1 0
Q 10 2 0
Q2 0 2 0
N o s / M t h.
Preventive Action
M/c. / Sl Component Line No No. 1 F Agitator - 1 Physical Phenomena Agitator not rotating Root Cause Latex entered into the bearing Corrective Action Bearing replaced Preventive Action / Inspection Agitator bearing block height elevated by 20 mm and included shaft cleaning during dipper staining - JH Included in the Inspection Schedule - PM Hylum guidespring replaced included in TBMschedule-Yearly - PM Included in TBM Schedule - PM Screw replaced instead of rivetand Limit switch position altered to avoid rubbing on the rivet / screw - PM Training given to the fitters on the importance of the spring washers in theU Clamp assembly - E&T
Beading brush - 1 Beading brush not rotating 3 X & Arms Arms lifted Y 4 5 Y C Carousel Tank Dehumidifier Tank not rotating Dehumidifer not working
Motor terminal block wire loose Hylum guide found broken and positioning spring lost its tension Inside of drum steel balls struck Desicant bed rivet broken
U - Clamp
Page 21.13
TTK-Pallavaram
Zero Breakdown
Identify critical components Identify Potential causes & Conditions Inspect & take Counter measure Check the result
Practising TBM CBM Collection of replaced Parts Analyse & identify weakness Implement Kaizen / Countermeasure
Page 21.14
TTK-Pallavaram
Zero Breakdown
Step 1
Red Tag Removal Plan and Correcting abnormalities Implementing Counter measures against Hard to Access areas and source of Contamination Preparation of Tentative Standards for CLIRt. Preparation of General Inspection training material and training the circle leaders. Preparation of Autonomous Inspection standards for JH
Step 2
Step 3
Step 4 Step 5
Beading Unit
Page 21.15
TTK-Pallavaram
Zero Breakdown
Critical Parts
Potential Cause
How to check
Worn out Check Joints Welded Joint Crack on Joints Visually Blow holes Chain & Sprockets Check Alignment Misalignment Drive chain cut Parallality Check Skewness Misalignment Faceout Check the Micromaster - no Electronic Life Electrical output Components unpredictable connection Sprocket Locking Screw tip Check the dislocation Screw damaged locking tip 2 Former Assy. FDE curve broken Former breakage Clamp Spring Sticky of Clamp
Replace by new Replace once in 5 one Years. Replace the screw Replace the Screw whenever removed
Replace the Clamp assembly to be Visually check clamp with new modified the Spring spring
Page 21.16
TTK-Pallavaram
Zero Breakdown
Revision of PM Standard
Department : Dipping Contra Rotation Stripping Area Gear Box Change from A -112 Model 45 Days to A - 162 Model Converted to Three phase 3 Months from Single phase Converted to 3/4" Pitch from 1/2" Pitch Converted the Shaft material to EN - 8 from Stainless Steel Changed from Teflon to Cast Nylon Changed from 2 mm thick to 3.2 mm thick belt Replaced the Pillow block bearings to bearing housing with double bearing One year
Recycling Pump
One year
3 Months
Two years
Drive and Driven pulley Shaft material is soft shaft Teflon guide wearsout Belt Guide causing belt slippage Flat belt Driven Shaft Supporting Bearing 2mm Belt looses its tension More Alignment time due to the shaft supported by Individual Bearings
Page 21.17
TTK-Pallavaram
Zero Breakdown
To ensure the Unable to drive the drive the beading beading brush brush
Over bearing noise Oil Seal Damaged, Noise Worn out of hylum Gears Misalignment Drive Sprocket To ensure the Unable to Slippage of key & locking transmission transmit screw, wornout of bore and of drive teeth,
1 Misalignment
10
Condition Monitoring through Tong Tester - for working current - Every month Inspect the OLR setting before restart after any shutdown Inspect the fan blade during shutdown, Clean the motor body finns Following Time based maintenance once in three years Following Time based maintenance once in three years Following Time based maintenance once in six months. Inspect the alignement during shutdown Replacement & alignment Visual check during any shutdown, time - 15 Mins. i.e., 1000 Alignment to be checked whenever Pcs. Product scrap & 3750 Sprocket, Chain, Gear box & Driven Pcs. Production loss shaft replaced / serviced Training of technicians on mounting and dismounting on opportunity
Key
10
Refitting - 15 mins. hrs down Check the key, keyway and Fitness time, replacement & whenever refitted alignment. Production Loss of 3750 Pcs & Product scrap 1000 Pcs.
Before
After
Geared Motor is used to drive beading brushes to form beads on the Product. The Gears are made of both Metal & Hylum sheets.
H ylum G e a rs M e ta l l i c G e a rs
D ri v e S h a ft
D ri v e n S h a ft
D riv e S h a ft
D rive n S h a ft
Analysis: Production Loss is high. Time for replacement of Gears is high. Wear out of Gears Gear are made of hylum ( soft material ). Design. Root Cause: Hylum Gears.
Results
M o nths 30 25 20 15 10 5 0 M o nth B e fo re 6 E xpe c te d L ife 24 B e tte r
Page 21.18
TTK-Pallavaram
Zero Breakdown
PM Matrix
Component Categorisation
Catagorisation of PM Components - Before
MTTR - Sub Assembly MTBF - Component System Sub Assembly Platinum Gold Silver Bronze Component Platinum Gold Silver Bronze Drive System 10 3 3 4 40 22 6 8 4 38 8 15 5 10 105 45 20 22 18 Beading Drier 8 2 4 2 32 7 12 5 8 12 3 1 5 3 44 2 8 24 10 Dipper Dry Brush 18 8 1 3 6 48 18 9 18 3 8 1 3 4 20 9 3 4 4 Product Stripping Track Chain 6 2 4 24 12 4 6 2 100 20 25 22 33 313 115 62 87 49 Total
MTBF - Componentwise Period Category More than 1 Year Platinum More than 6 Months Gold More than 3 Months Silver Monthly or Less Bronze MTTR - Subassemblywise Period Category Less than 10 min Platinum Less than 90 min Gold Less than 240 min Silver More than 240 min Bronze
Page 21.19
TTK-Pallavaram
Zero Breakdown
Parts replaced though still useful Severe wear but change before breakdown Parts Not replaced before failure
Limit Line
CBM
Time
Kaizen on weaknesses (CM) Inspection Standard Forced Deterioration
Natural Deterioration
Prediction
Standard Values can be set near the limit lime if the diagnosis is reliable
Limit Line
Page 21.20
TTK-Pallavaram
Zero Breakdown
Numbers 40 30 20 10 0
19 9 9 No s . Mins. Pcs. Targ et 39 110 4 0 1E+0 6 30 2000 34 74 4 5 20 2001 27 6 6 0 5.5 10
Better
200 3 0 0 0 0
H10 4 0 0 0 0
Q3 0 4 0 0 0 0
O'0 4 0 0 0 0
N'0 4 0 0 0 0
D'0 4 0 0 0 0
J'0 5 0 0 0 0
F'0 5
M'0 5
A'0 5S'0 5
O'0 5M'0 6
8 0 4 0 6 0 713 3 9 4
Better
2 1 0
199 9 No s . M ins . P cs . Ta rge t 2 1275 45900 0 2000 3 1885 67860 0 2001 1 240 8640 0 2002 1 22 0 7 920 0 2003 1 30 1080 0 H104 0 0 0 0 Q304 0 0 0 0 O'0 4 0 0 0 0 N'04 0 0 0 0 D'04 0 0 0 0 J '0 5 0 0 0 0 0 0 F '0 5 M '0 5
Better
A'05S'05
O'05M '06
Numbe rs 20 15 10 5 0
1999 No s . M ins . P cs . Ta rge t 19 3410 15 2000 12 2694 10 2001 8 713 0
Better
2002 0 0 0 0
2003 0 0 0 0
H104 0 0 0 0
Q304 0 0 0 0
O'04 0 0 0 0
N'04 0 0 0 0
D'04 0 0 0 0
J '05 0 0 0 0
F'05
M '05
A'05S '05
O'05M '06
Page 21.21