A Presentation on Practical Training

at
EICHER ENGINES, ITARANA ROAD,
ALWAR (RAJ.)
(A unit of tafe motors & tractors ltd .Alwar)

Department of Mechanical Engineering,

Laxmi Devi Institute of Engineering & Technology, Chikani, Alwar
Session: 2010-2011
 Products
• Automotive Engine
• Stationary Engine
• Cooling technology based:
a) Air cooled
b) Water cooled
 Products
• Cylinder technology based:
a) Single cylinder - air cooled,
b) Double cylinder - air cooled,
c) Triple cylinder - air cooled,
d)Triple cylinder - water cooled.
 In-House Machining
Component
• Single Cylinder
1. Carter
2. Control housing
3. Cylinder head
4. Cooling jacket
5. Integra liner
6. Crank shaft
7. Fly wheel balancing
8. Blower fan balancing
 In-House Machining
Component
• Multi Cylinder
1. Crank housing 298
2. Crank case 398
3. Cylinder head
4. Cylinder liner
5. Blower assembly 298
6. Blower assembly 398
 In-House Machining
Component
• Valtra Water Cooled
1. Cylinder block
2. Cylinder head
3. Front cover
4. Gear housing
5. Fly wheel casing
6. Fly wheel housing
7. Cylinder liner
 AFFECT CHECK
QUESTIONNAIRE -1
Q1.Pick the correct in-house-machining
component for single cylinder:
(a) Gear housing (b) Crank case 398
(c) Cooling jacket
Q2.Give the name of type of engine produced in
this division.
Q3.Which award is for technical specification?
(a) ISO-9001 (b) TS-16949 (c) ISO-14001
 Value System
• Total Productivity Maintenance
(TPM)
• 5s
• Process Improvement
What is TPM
 TPM Means
Total Profit Management

Total Product Manufacturing

Total Productive Maintenance

Total People Management

Productivity - Definition

Production
Productivity =
Cost

Simultaneously
 OBJECTIVES OF TPM
• Achieve Zero Defects, Zero Breakdown and
Zero accidents in all functional areas of the
organization.
• Involve people in all levels of organization.
• Form different teams to reduce defects and
Self Maintenance
 Direct Benefits Of TPM
• Increase productivity and OPE (Overall Plant
Efficiency) by 1.5 or 2 times.
• Rectify customer complaints.
• Reduce the manufacturing cost by 30%.
• Satisfy the customer’s needs by 100 %
(Delivering the right quantity at the right
time, in the required quality)
• Reduce accidents.
• Follow pollution control measures.
 Indirect Benefits of TPM
• Higher confidence level among the employees.
• Keep the work place clean, neat and attractive.
• Favorable change in the attitude of the
operators.
• Achieve goals by working as team.
• Horizontal deployment of a new concept in all
areas of the organization.
• Share knowledge and experience.
• The workers get a feeling of owning the
machine
AUTONOMOUS MAINTENANCE
(JH)
• Concept of people who operate a
machine should also maintain the
machine.
• Starts with basic lubrication,
cleaning, inspection & then turns to
repairs.
 Reasons Why Autonomous Maintenance is Required
No satisfactory increase in the performance
record can be seen …
Activities to keep record
on equipment
• Confirmation of degradation
working conditions
• Daily inspection
• Periodical inspection

Activities to prevent
equipment degradation

• Keep cleaning
• Inspection
• Additional
tightening

Activities to restore
Preventive Production the machine
Maintenance Maintenance TPM
conditions

Japanese
U.S style of PM
style of PM

Maintenance
Department’s
sole
responsibility • Frequent servicing
• Solution of abnormality
• Good communication
1. MINOR FLAWS
2. UNFULFILLED BASIC CONDITIONS
3. INACCESSABLE PLACES
4. CONTAMINATION SOURCES
5. QUALITY DEFECT SOURCES
6. UNNECCERY AND NON-URGENT ITEMS
7. UNSAFE PLACES
1. MINOR FLAWS :

Contamination Dust, Dirt, powder, oil, grease, rust, paint

Damage Cracking, crushing, deformation, chipping,
bending,
Play Shaking, falling out, tilting, eccentricity,
wear, distortion, corrosion,
Slackness Belts, Chains
Abnormal Unusual noise, overheating, Vibration,
Phenomenon strange smells, discoloration, incorrect
pressure or current
Adhesion Blocking, hardening, accumulation of
debris, peeling, malfunction
2. UNFULFILLED BASIC CONDITIONS

Lubrication Insufficient, Dirty, Unidentified,

unsuitable, Leaking

Lubrication Dirty, damaged or deformed lubricant

Supply inlets, faulty lubricant pipes
Oil level gauges Dirty, Damaged, leaking, No indication of
correct level
Tightening Nuts and Bolts slackness, Missing,
Cross-threaded, Too long, Crushed,
Corroded, Unsuitable washers, wing
nuts on backward.
3. INACCESSABLE PLACES
Cleaning Machine construction, Covers, Layout,
footholds, Space
Checking Construction, Covers, Layout, footholds,
Instrument position and Orientation, Operating –
Range display
Lubricating Position of lubricant inlet, construction, height,
footholds, lubricant outlets, space
Tightening Covers, Construction, Layout size, Space
Operation Machine layout, Position of valves, Switches
and leavers, Footholds
Adjustment Position of pressure gauges, thermometers,
flow meters, moisture gauges, vacuum gauges,
etc.
4. CONTEMINATION SOURCES
Product Leaks, Spills, Spurts, Scattering, Overflow
Raw materials Leaks, Spills, Spurts, Scattering, Overflow
Lubricants Leaking, Spills, Seeping oils, Hydraulic fluids,
Fuel oils, etc.
Gases Leaking compressed air, gases, steam,
vapors, exhaust fumes, etc.
Liquids Leaking water, Hot, Cold, half finished
products, Waste water, Leaking supply lines
etc.
Scrap Flashes, cuttings, packaging materials, and
non conforming products.
Others Contaminants by people & Forklifts,
Infiltration through cracked walls, broken
windows etc.
5. QUALITY DEFECT SOURCES

Foreign Dust, Rust, powder, chips, moisture, wire

Matter scraps, wood pieces, paper pieces, stones
etc.
Shock Dropping, Jolting, collision, Vibration etc.
Moisture Too little or Too much, infiltration
Gain Size Abnormalities in screens, Compressed air
separators, centrifugal separators,
Concentration Inadequate warming, heating,
compounding, mixing, evaporation, stirring
etc.
Viscosity Inadequate warming, heating,
compounding, mixing, evaporation, stirring
etc.
6. UNNECCERY AND NON-URGENT ITEMS
Machinery Pumps, fans, compressors, columns, tanks
etc.
Piping Pipes, hoses, ducts, valves, dampers etc.
equipment
Measuring Temperatures, pressure gauges, vacuum
instruments gauges, ammeters etc.
Electrical Wiring, piping, power leads, switches, plugs
equipment etc.
Jigs & Tools General tools, cutting tools, jigs, molds,
dies, frames etc.
Spare parts Standby equipment, spares, permanent
stocks, auxiliary materials, etc.
Makeshift Tape. String, wire, metal plates etc.
repairs
7. UNSAFE PLACES

Floors Unevenness, cracked, holes, projections,

peeling, wear of steel chucker plates, slipping.
Steps Too steep, irregular, slipping, missing handrails,
etc.
Lights Dim, out of position, dirty or broken covers, no
explosion proofing, etc.
Rotating Displaced, fallen oil or broken covers, not safe
machinery for emergency, missing emergency stop devices
Lifting Wires, hooks, brakes and other parts of cranes
Devices and hoists etc.
Others Special substances, solvents, toxic gases,
insulating materials, danger signs, protective
clothing etc.
EXAMPLE OF ABNORMALITY
( LOOSE FITTINGS )
EXAMPLE OF ABNORMALITY
( LEAKAGES )
White tags for operators
Red Tags to be attended by Maint.
Equipment Name ………………
Control No……………………..
Date of detection……………….
Detected by……………………..
Description of Minor defects
………………………………….
…………………………………..
………………………………….
Equipment Name ………………
Control No……………………..
Date of detection……………….
Detected by……………………..
Description of Minor defects
………………………………….
…………………………………..
………………………………….
 KAIZEN
• Japanese word kaizen means
improvement.
• Kai means change or ‘the action to
correct’.
• Zen means good.
• Therefore, kaizen = change for
improvement/good.
CHECK FOR 16 MAJOR LOSSES IN ORGANISATION
Loss Category
1. Failure losses - Breakdown loss
2. Setup / adjustment losses
3. Cutting blade loss
4. Start up loss Losses that impede
5. Minor stoppage / idling loss. equipment efficiency
6. Speed loss - operating at low speeds.
7. Defect / rework loss
8. Scheduled downtime loss
9. Management loss
10.Operating motion loss
Loses that impede
11.Line organization loss
human work efficiency
12.Logistic loss
13.Measurement and adjustment loss
14.Energy loss Loses that impede
15.Die, jig and tool breakage loss effective use of
16.Yield loss. production resources
The PDCA cycle
PLANNED MAINTENANCE
• Aimed to have trouble free machines and
equipments producing defect free products for
total customer satisfaction
• Unplanned maintenance create problems like
a) huge inefficiencies in maintenance labor.
b) confusion and disturbance in scheduling,
production and other areas.
c) Morale problems
 Planned maintenance aims at:

• Achieve and sustain availability of

machines
• Optimum maintenance cost.
• Reduces spares inventory.
• Improve reliability and maintainability
of machines
Comparison of Planned
Maintenance with and without
TPM
 AFFECT CHECK
QUESTIONNAIRE-2
Q1. What is the main objective of TPM ?
Q2. What is the concept of ‘autonomous
maintenance’?
Q3. List the abnormalities to be checked for JH.
Q4. How & when to use the red & white tags?
What is 5s
 Sei-ri

整理
 Seiri= Sort
Meaning in Japanese context:
Throw away all rubbish & unrelated
material in workplace.
Industrial definition:
To distinguish between necessary things
and unnecessary things.
Typical Seiri Activities
•Eliminate defects and breakage
•Organize the warehouse

BEFORE AFTER
整頓
Seiton = stabilize/organize
Meaning in Japanese context:
Set everything in proper place for quick
retrieval & storage.

Industrial definition:
It is a way of eliminating
search.
30 Second Rule
30 Second Rule
 Fig 1: condition of tools
before Seiton

Fig 2: tools after implementing

Seiton,30 second rule
清掃
 Seiso = Shine/Clean

Definition:
Eliminating trash, filth, and foreign
matters for a cleaner workplace.
Cleaning as a form of inspection.
Key Points:

•Clean the workplace;

•Everyone should be a janitor
Key Words:
Keep things clean
+ Inspection
(Caring attitude)
Typical SEISO Activities
•Quick 5S drill
•Sparkling clean campaign
•Everybody is a janitor

Broom

Dust pan
Mop
清潔
 Seiketsu = Standardize
Meaning in Japanese context
Standardize the way of maintaining
cleanliness
INDUSTRIAL DEFINITION
Seiri Seiton
Keeping things organized, neat
and clean; in personal and
environmental aspects.
Seiso
Typical Seiketsu Activities
• Make quality manual
• Directional markings
•Color-coded pipes

Before After
DIRECTIONAL MARKINGS

Indication marks
Indication for
for nuts & bolts
valve controls
躾
Shitsuke = Self-discipline

Meaning in Japanese context:

Practice ‘5s’ daily- make it a way of
life; this also means ‘commitment’.
 AFFECT CHECK
QUESTIONNAIRE-3
Q1. Name the value system followed in the
organization:
Q2. 1s stands for:
(a) Shine (b) Sort (c) Standardize
Q3. 2s stands for:
(a) Stabilize (b) self-discipline (c) Sustain
Q4.What is a ‘30 second rule’?
 Safety Rules
• Wear shoes, tight & clean clothes
(trouser and shirt) at work
• It is required from everyone to use
spectacles for the protection of eyes.
• Proper use of ‘safety equipments’ is a
must.
• Use mouth mask and safety shoes
while painting.
Continue….
 Safety Rules
• Use specs while working at grinder &
washing machine.
• On finding some unusual noise, smoke
or condition immediately switch off
machine & inform the supervisor.
• In case of fire inform ‘main gate’
(tel.ph.200 or 206) and shout FIRE &
come out at emergency collecting point.
 Rules For Production
• Work according to rules & regulations
and instructions written in OS/AOS.
• Use critical instruments like vernier,
TPG etc. and check CMM.
• Use special instruments according to
OS.
• Change or mend the hammer before its
surface gets round or damaged. Continue…
 Rules For Production
• During the shift ensure that adjuster on
the tork rinch should not be below tape
marking.
• Don’t try to tighten further once tightened
by the oil pulse tool.
• Avoid and stop defects. If you have any
suggestions regarding it give it to the
supervisor.
• Learn from mistakes, don’t repeat them
Continue…
 Rules For Production
• While punching number take a note to
put stamp first in which 12 digits should
be punched & punching should not be
light.
• Clean the punch once a month and
change it after every 3 months.
• Give suggestion regarding increase of
‘Production Output’.
ISO-14001 Instructions
• Switch off fans, cooler, lights of your
work place while going for tea,
lunch/dinner and at the end of shift.
• Close taps after usage.
• Stop the leakage of air, coolant and oil
during work.
ISO-14001 Instructions
• Avoid spilling of oil, chips, paper,etc.
Throw the wastage like paper, cloth,
plastic in specified dustbins i.e. RED,
BLUE and GREEN.
 Autonomous Check Sheet
• Take complete information about check
sheet.
• Operators have to fill the autonomous
check sheet while taking of the following
points:
1) Operator has to fill the pre-control
chart and data sheet.
2) Is there any problem with fixtures?
Continue…
 Autonomous Check Sheet
3) Is the level of hydraulic oil, lubricant oil
and coolant level correct?
4) Is air pressure, hydraulic system
pressure correct?
5) Is sound from machine normal?
6) Has reliever removed chips and dust
from machine?
7) Is there any kind of leakage in machine?
Continue…
 Autonomous Check Sheet
8) Are the meters on the machine working
properly?
9) Has the condition of cutting tools been
checked?
10)Are all the push buttons, switches,
indication lamp working properly?
11) Is component’s all documents attached
to the machine?
Continue…
 Autonomous Check Sheet
12)Are all the tools, gauges, fixtures and
rotate parts cleaned and placed at their
fixed place?
Note: In case of negligence of any of the
above points inform the supervisor
without the further delay
Complete work on time while maintaining
discipline.
 TS & 5s Instructions
• Decide what is needed and what is not
needed at the work place. Remove the
things which are not needed and put a 1s
tag on them and keep them at specified
place.
• Don’t overload the trolley and after using
it keep it at the right place.

Continue…
 TS & 5s Instructions
• Gang way should be absolutely clear and
nothing should be laid there.
• Place the component only on the
conveyor, trolley or machine. And not on
the floor/platform.
• Don’t put anything (finish/scrap/tools etc)
on the floor.

Continue…
 TS & 5s Instructions
• Don’t throw duster or gloves near
machine or inside tank or on the floor.
• Have to clean the resting face of fixture
after every piece.
• At the end of shift clean the side ways,
glide ways.
• Follow the standards designed for the
workplace.
Continue…
 TS & 5s Instructions
• Keep the rejection/rework products aside,
do know the reason of rejection/rework
and mark it. Mark the component with
the marker, keep it at the specified place
at the end of shift before leaving the
workplace.
• Take care of cleanliness of the work
place.
 AFFECT CHECK
QUESTIONNAIRE-4
Q1.What would you do in case of an emergency?
Q2.When should punch be cleaned & changed?
Q3.What kind of waste will you dispose off in
RED, BLUE & GREEN dustbins?
Q4.What is to be done to utilize ‘ideal time’?
Q5. What will you do if any component is
rejected?
 AFFECT CHECK
QUESTIONNAIRE-4
Q6.How will you check oil & coolant level?
Q7.Where to use (a) ear plugs (b) safety goggles
(c) gloves?
Q8.How to check tool condition?
Q9.How will you check drill/tap sizes?