Successfully reported this slideshow.
We use your LinkedIn profile and activity data to personalize ads and to show you more relevant ads. You can change your ad preferences anytime.

Maintenance Improvement 15-16

140 views

Published on

  • Be the first to comment

Maintenance Improvement 15-16

  1. 1. Maintenance : Improvements list for 15-16 Amber Pune Unit Process owner : Amrit Raj Jaiswal & Team
  2. 2. Best Practice : Water cooling arrangement for Bending & TPP  Result Details Issue Details  Process  Provision for heat exchangers with cooling tower arrangement for Armstrong bending m/c & TPP m/c.  M/c tripping problem due to heating reduced to zero.  Oil cooling proper now  M/c tripping due to heat up  O-ring damage problem.  Bending & TPP Initial Status Breakthrough Idea Initial Status Leadership Through Innovation NOT EXIST EARLIER
  3. 3. Best Practice : R.O plant re-conditioning  Result Details Issue Details  Process  Cover boxes provided for all motors  Painting activity done  Safety Improvement & 2’s Improvement  Poor 5 ‘S’ & no equipment safety during rainy & dust  R.O Plant Initial Status Breakthrough Idea Initial Status Leadership Through Innovation
  4. 4. Best Practice : Re-conditioning of main fire hydrant  Result Details Issue Details  Process  Cover boxes provided for all motors  Painting activity done  Safety Improvement & 2’s Improvement  Poor 5 ‘S’ & no equipment safety during rainy & dust  Main fire hydrant Initial Status Breakthrough Idea Initial Status Leadership Through Innovation
  5. 5. Best Practice : Press brake Safety improvement  Result Details Issue Details  Process  Hand operated switch with protected cover  Safety Improvement Unsafe working condition due to Foot operated switch , major cause of accident  Press brake operating Initial Status Breakthrough Idea Initial Status Leadership Through Innovation
  6. 6. Best Practice : Cost saving by In-house installation of new ITW Gama gun  Result Details Issue Details  Process  Proposed cost - Rs. 74000 (quote)  Actual In-house cost - Rs. 24000  CI - Rs. 50000 New gun Installation cost higher  Auto Gun booth Initial Status Breakthrough Idea Initial Status Leadership Through Innovation Before After 74 K 24 K Installation cost In Rs.  CI Benefit: Rs. 50 k  CI Approved By : Accounts GM (O) Plant Head
  7. 7. Best Practice : Installation of New compressor with capacity enhancement  Result Details Issue Details  Process  New compressor installation In- house with added capacity  Capacity enhancement Lesser capacity of compressor with added business volumes  Compressor Initial Status Breakthrough Idea Initial Status Leadership Through Innovation NOT EXIST EARLIER
  8. 8. Best Practice : Rack provision for PU sheet storage ( Trolley cover)  Result Details Issue Details  Process  Rack designed & mfg. , stored near trolley rectification area  5 ‘S’ improvement Plastic corrugated sheets keeping on floor, poor 5 ‘S’  PU Sheet Storege Initial Status Breakthrough Idea Initial Status Leadership Through Innovation
  9. 9. Best Practice : VM on Motor for lubrication & rotation point.  Result Details Issue Details  Process  VM done by using vinyl sticker on motors & m/c  VM improvement No identification mark for motor rotation & lubrication point  Motor preventive measures Initial Status Breakthrough Idea Initial Status Leadership Through Innovation
  10. 10. Best Practice : Cutter m/c mobile trolley with safety  Result Details Issue Details  Process  Mobile trolley in-house made for operator’s safety & mobility  Safety improvement Unsafe working condition for operator’ during pipe cutting  Fabrication work Initial Status Breakthrough Idea Initial Status Leadership Through Innovation
  11. 11. Best Practice : Re-conditioning of dispatch ramp hyd. powerpack  Result Details Issue Details  Process  Dispatch Ramp motor cover to avoid water entry during rainy season & dust prevention & 2’s  Safety improvement & 2’s No motor safety provision for hyd. Motor power pack , also poor 2 ‘S’  Dispatch Ramp Initial Status Breakthrough Idea Initial Status Leadership Through Innovation
  12. 12. Best Practice : Material rack provision & VM For fabrication material  Result Details Issue Details  Process  New material rack made in-house with VM sticker on the rack  VM & 2’s improvement No proper identification & space for fabrication material , poor 5 ‘S’  Fabrication area Initial Status Breakthrough Idea Initial Status Leadership Through Innovation NOT EXIST EARLIER
  13. 13. Best Practice : Transformer area re-conditioning  Result Details Issue Details  Process  Cleanliness & painting activity with VM display  Utility Initial Status Breakthrough Idea Initial Status Leadership Through Innovation NOT EXIST EARLIER  Safety & 5 ‘S’ improvement Unsafe working condition & poor 5 ‘S’ at transformer area
  14. 14. Best Practice : CI in localization in purchase of Vibration motor  Result Details Issue Details  Process  More efficient vibration motor purchasing  Local vendor developed for vibration motor  CI – By Rs. 92 K  Supplier localization leads to easy for spare mgt.  Powder Choking Problem due to vibration motor life ends  Imported motor ( ITW Gama) cost too high Powder recovery unit Initial Status Breakthrough Idea Initial Status Leadership Through Innovation Before After Purchase cost In Rs. 1.04 L 0.12 L  CI Benefit: Rs. 92 k  CI Approved By : Accounts GM (O) Plant Head
  15. 15. Best Practice : Installation of a new Desiccant dryer for capacity enhancement  Result Details Issue Details  Process  New desiccant dryer installation with double capacity  Dew point with in (-40 )  Dry Air capacity increase  Quality improvement  Lesser capacity of dry air in paint shop dept.  Continuous quality issues related to higher dew point ,reqd. (-40) actual (-30) Powder coating utility Initial Status Breakthrough Idea Initial Status Leadership Through Innovation Before After Dry Air capacity 90 cfm 200cfm
  16. 16. Best Practice : Air set up time reduction during power cut  Result Details Issue Details  Process  Installed an accumulator in series with input of a desiccant dryer for air storage  During power cut air change over time reduced  During power cut , air pressure lower due to no air accumulation , loss of air  Powder coating utility Initial Status Breakthrough Idea Initial Status Leadership Through Innovation Before After Air change over time 10 min Zero NOT EXIST EARLIER
  17. 17. Best Practice : Welding line re-layout with Jogging track creation  Result Details Issue Details  Process  All water , Air & Electrical lines installed from roof side , line re-layout done  Safety & VM improvement Jogging track creation from wall side  Welding area water line /air line & cabling not as per industrial norms , All line are on floor , unsafe  Weld shop layout Initial Status Breakthrough Idea Initial Status Leadership Through Innovation
  18. 18. Best Practice : Fabrication Shed re-conditioning  Result Details Issue Details  Process  Re-conditioning done by wall painting, providing display board & switch covers  5’S & VM improvement Poor 5’S in fabrication shed  Fabrication shed Initial Status Breakthrough Idea Initial Status Leadership Through Innovation
  19. 19. Best Practice : Dispatch ramp Elect panel safety improvement  Result Details Issue Details  Process  Emergency s/w provided  Switch board re-conditioning  Safety improvement Elect switches in broken condition , unsafe  Dispatch ramp working panel Initial Status Breakthrough Idea Initial Status Leadership Through Innovation
  20. 20. Best Practice : Re-conditioning of shop floor fans  Result Details Issue Details  Process  Fan guards cleanliness and powder coating  Equipment efficiency improved Shop floor wall-mounted fans condition poor , dust , color fade  Shop floor Infra Initial Status Breakthrough Idea Initial Status Leadership Through Innovation
  21. 21. Best Practice : Transfer Pipes standardization – Color coding  Result Details Issue Details  Process  Pipe line color coding as per Industry standardization  VM & safety improvement  As per Std. coding : Air – Blue Water – Green Gas – Yellow Fire – Red  All transfer pipelines no standardization / identification for water, air & gas pipes  Shop floor Infra Initial Status Breakthrough Idea Initial Status Leadership Through Innovation
  22. 22. Best Practice : LT cable duct Fabricated covers provision  Result Details Issue Details  Process Duct covering with fabricated structure  Safety & VM improvement LT cable duct in open condition , unsafe  LT cable routing at outside area Initial Status Breakthrough Idea Initial Status Leadership Through Innovation
  23. 23. Best Practice : PCO & WDO ducts Re-conditioning  Result Details Issue Details  Process  Internal duct and Damper broken and worn out need to be repaired  Productivity & Quality improvement  Improper temperature variation observed at PCO & WDO due to duct open & damper broken  Paint shop Area Initial Status Breakthrough Idea Initial Status Leadership Through Innovation
  24. 24. Best Practice : Paint shop motors autonomous maintenance  Result Details Issue Details  Process Complete overhauling with varnish ,bearing check ,fan check & coloring  Autonomous Maintenance Motor Preventive Maint. Not as per TPM std.  Motor PM Initial Status Breakthrough Idea Initial Status Leadership Through Innovation
  25. 25. Best Practice : Elect wiring /cables dressing in tray  Result Details Issue Details  Process  All open cable routed by providing cable tray  Elect cables in paint shop are in open condition , Unsafe working  Paint shop Infra Initial Status Breakthrough Idea Initial Status Leadership Through Innovation  Safety/ VM improvement
  26. 26. Best Practice : Removal of excess cables & proper dressing  Result Details Issue Details  Process  All excess cable removed and proper dressing done Unwanted open cables in paint shop area causes unsafe working  Paint shop Infra Initial Status Breakthrough Idea Initial Status Leadership Through Innovation  VM Improvement
  27. 27. Best Practice : Safety guard on blower shaft  Result Details Issue Details  Process  Safety cover provided for safe operation  Unsafe working condition at PT line blower  Paint shop Infra Initial Status Breakthrough Idea Initial Status Leadership Through Innovation  Safety improvement
  28. 28. Best Practice : Water level indication for low/high level  Result Details Issue Details  Process  Installation of Level indicator panel to sense water level & avoid water wastage  No level indicator t for identification of low/high level of water in the tank  Paint shop Infra Initial Status Breakthrough Idea Initial Status Leadership Through Innovation  VM improvement
  29. 29. Best Practice : Cable dressing at Conference hall  Result Details Issue Details  Process  All excess cable removed properly dressed & covered  Unwanted open cables in Conference room  Conference room Initial Status Breakthrough Idea Initial Status Leadership Through Innovation  Safety & Equipment Efficiency
  30. 30. TPM PT line – Cleaning with meaning v v vv v v
  31. 31. Best Practice : Repairing of Solar street light  Result Details Issue Details  Process  Repairing activity carried out & 6 nos. of lights repaired  Solar street light not in working condition  Plant Initial Status Breakthrough Idea Initial Status Leadership Through Innovation Energy efficiency Before After Power cost redn.  CI Benefit: Rs. 09 k  CI Approved By : Accounts GM (O) Plant Head
  32. 32. Best Practice : Closed area for DM & ETP line  Result Details Issue Details  Process  Fabricated shed installation , which protect instruments  ETP line is open condition , no infra safety  Paint shop Infra Initial Status Breakthrough Idea Initial Status Leadership Through Innovation  Basic infrastructure safety
  33. 33. Best Practice : Re-conditioning of STP  Result Details Issue Details  Process  Re-conditioning with added capacity of STP plant  Capacity less as per current requirement , STP water not 100 % usages  General Infra Initial Status Breakthrough Idea Initial Status Leadership Through Innovation  Basic infrastructure improvement Capacity added by 30 %
  34. 34. Best Practice : Elect power conservation activity  Result Details Issue Details  Process  Removal of all CFL cubes by LED cubes of 30 W /Pc.  High power consumption of typical CFL cubes (72W/Pc.)  Office Area Initial Status Breakthrough Idea Initial Status Leadership Through Innovation Energy efficiency – Total 15 no. of cubes changed. Before After Power cost reduction  CI Benefit: Avg. Rs. 34 k /Year  CI Approved By : Accounts GM (O) Plant Head
  35. 35. Best Practice : Elect power conservation activity  Result Details Issue Details  Process  Removal of all CFL cubes by LED cubes of 30 W /Pc.  Total 15 no. of cubes changed.  High power consumption of typical CFL cubes (72W/Pc.)  Office Area Initial Status Breakthrough Idea Initial Status Leadership Through Innovation Energy efficiency Before After Cost Saving Before After LUX level 600 1000  CI Benefit: Avg. Rs. 32 k /Year  CI Approved By : Accounts GM (O) Plant Head
  36. 36. Best Practice : Elect power conservation activity  Result Details Issue Details  Process  Removal of all CFL cubes by LED cubes of 30 W /Pc. – Total 15 no. of cubes changed.  High power consumption of typical CFL cubes (72W/Pc.)  Office Area Initial Status Breakthrough Idea Initial Status Leadership Through Innovation Energy efficiency Before After Cost Saving LUX level  CI Benefit: Avg. Rs. 32 k /Year  CI Approved By : Accounts GM (O) Plant Head Before After 600 1000
  37. 37. Best Practice : Maint office renovation  Result Details Issue Details  Process  Removal of Red Tag components Re-conditioning  Maint dept poor 5 ‘S’  Office Area Initial Status Breakthrough Idea Initial Status Leadership Through Innovation Basic infrastructure improvement
  38. 38. Best Practice : TPM activity board  Result Details Issue Details  Process  Design & display board on shop floor  No TPM monitoring board display at shop floor  Shop floor Initial Status Breakthrough Idea Initial Status Leadership Through Innovation TPM activity NOT EXIST EARLIER
  39. 39. Best Practice : Greece & Oil storage room provision  Result Details Issue Details  Process  New location at Compressor room, No storage area for Grease & Oil storage  Maint stores Initial Status Breakthrough Idea Initial Status Leadership Through Innovation Basic infrastructure. NOT EXIST EARLIER
  40. 40. Best Practice : All utility equipment board display board  Result Details Issue Details  Process  Design of board & implementation Utility board display not available  Office Area Initial Status Breakthrough Idea Initial Status Leadership Through Innovation  FI 05 activity  VM improvement NOT EXIST EARLIER
  41. 41. Best Practice : Facility provision for Nano coating booth  Result Details Issue Details Design & in-house fabrication activity  No provision for fumes extraction in Nano coating area Operator unsafe activity Initial Status Breakthrough Idea Initial Status Leadership Through Innovation  Cost saving by In-house red tag material using Operator safety ensured NOT EXIST EARLIER
  42. 42. Best Practice : Design of Enclosure in PC panel  Result Details Issue Details  Design of enclosure & implementation with Air conditioner working Reduction in maint time  All wiring & panels are in open condition, unsafe activity  Dust & temp. affects on panel working, higher down time Initial Status Breakthrough Idea Initial Status Leadership Through Innovation  Equipment safety  Lower maint B/down time
  43. 43. Best Practice : Facility provision at ETP plant  Result Details Issue Details  In-house fabricated ladder installation with safe working in inspection at ETP plant  No ladder in ETP plant, unsafe to operator while working Initial Status Breakthrough Idea Initial Status Leadership Through Innovation  Equipment Efficiency  Safety Improvement NOT EXIST EARLIER
  44. 44. Best Practice : Re-design in sheet feeding process Extra roller provided to hold the sheet Issue Improvement Result  Extra Roller provided which hold the sheet during feeding  In perforation Mc higher rejection due to folding of sheet in working Leadership Through Innovation Mc down time reduction due to wrong sheet feeding Before After 90 Avg. Mc BD time in min/day Zero
  45. 45. Best Practice : Safety activity at HT area Entrance gate reconditioning Issue Improvement Result  Repairing of gate with in-house facility HT area unsafe due to entrance gate not working  Safety Improvement Leadership Through Innovation
  46. 46. Best Practice : 110 T hydra. press BD time reduction Issue Improvement Result  Re-design entire system with new hardware locally available  Continuous BD of mc due to relay design not suites in mass production , also spares not locally available Old system replaced with New hardware system Leadership Through Innovation  BD time reduction Before After 18 Avg. Mc BD hrs/month Zero
  47. 47. Best Practice : Energy conservation in press shop Replacement of MHSV lamp by LED for power cost saving Issue Improvement Result Power cost per Year [Unit : INR ]  Installation of LED lights to replace the conventional 250W MHSV lamp , replacing 08 nos. MHSV lamp to 4 nos. of LED lamps with LUX level as per std. Before After 49920 8986 LUX Level [Unit : Lumen ] Before After 210 300  Higher power cost with low LUX level Leadership Through Innovation
  48. 48. Best Practices : Exhaust system design at Nano coating line Issue Improvement Result  Design of exhaust system as per process std. & safety measures  No provision of exhaust Chimney in Nano coating line , unsafe to operator Leadership Through Innovation  Safety improvement NOT EXIST EARLIER Design of Exhaust system with safety measures
  49. 49. Best Practices : Energy conservation at Street light working Issue Improvement Result  Timer fitted which automatically OFF the street light s & avoid power misusages  Street light getting ON during day if person forgotten to OFF Leadership Through Innovation  Power saving Design of Exhaust system with safety measures
  50. 50. Best Practices : Water wastages reduction Issue Improvement Result  Hand spray pump installation to avoid water spillage  During water dispensing , spillage & wastages Leadership Through Innovation  Water wastage reduction Hand spray pump for drinking water dispensing
  51. 51. Best Practices : Dummy designing with cost reduction Issue Improvement Result  In-house Fabrication ,Designing & hardware implementation of dummy  Designing & Preparation of in-house dummy Leadership Through Innovation  Cost Saving – INR 200000 In-house modification of Dummy for ODU checking NOT EXIST EARLIER Section : Maint. Month : Apr ’16 Before After Rs 250000 Rs 50000
  52. 52. Best Practices : Quality Enhancement Activity Issue Improvement Result  Condenser checking station with automatic buzzer system  Designing of N2 purging station 28 Bar pressure Leadership Through Innovation  Quality improvement Implementation of N2 purging station NOT EXIST EARLIER Section : Maint. Month : Apr ’16
  53. 53. Best Practices : Safety Activity in Scrap yard Issue Improvement Result  Extra fire point tap provided in scrap area for safety purpose as it has EPS material  Installation of fire point tap in scrap yard Leadership Through Innovation  Safety Improvement New tap point installed for fire hydrant system NOT EXIST EARLIER Section : Maint. Month : Apr ’16
  54. 54. Best Practices : Testing facility installed at Assy. line Issue Improvement Result  FG line insulation, leakage ,earth & high voltage test setup implemented  Basic testing infrastructure not available Leadership Through Innovation  Quality Improvement Testing machine implementation NOT EXIST EARLIER Section : Maint. Month : Apr ’16
  55. 55. Best Practices : Productivity Improvement at FG line Issue Improvement Result  Operation Sequence changed in PLC programming 1 ODU unit stoppage issue hampering productivity so logic changed 2 Rectification - New logic implemented with push button to provide stoppage.  Ideal time more at LQC stage 1. Machine not stopping at dummy transfer area. 2. To stop kit operator has to press emergency Leadership Through Innovation  Productivity Improvement Operation sequence Changed in PLC programming at LQC stage NOT EXIST EARLIER Section : Maint. Month : May ’16
  56. 56. Best Practices : Efficiency Improvement at Press shop Issue Improvement Result  Grading implementation to improve machine health 1. All tools designed and arranged to carry out grading of m/c  M/C grading system not available Leadership Through Innovation  Efficiency Improvement M/c grading system implementation NOT EXIST EARLIER Section : Maint. Month : May ’16
  57. 57. Best Practices : Cost/machine eff. improvement Issue Improvement Result  Designed spare seal through local vendor Continuous oil leakages at Armstrong bending m/c 1. valve leakage seal not available - china make Leadership Through Innovation  Cost/Machine Eff. Improvement Oil leakages removal NOT EXIST EARLIER Before After Rs 10000 Rs 200 Section : Maint. Month : June ’16
  58. 58. Best Practices : Machine eff. Improvement at Press shop Issue Improvement Result  All Press m/c main motor housing & play check carried out  Motor in contenious run since 5 years Leadership Through Innovation Machine Eff. Improved 1. No. of motor checked – 22 Nos. 2. Major Problem observed – 5 M/c All main Motor internal housing check NOT EXIST EARLIER Section : Maint. Month : Apr ’16 Before After Rs 100000 Rs 20000 CI achieved
  59. 59. Best Practices : Safety improvement at LPG Gas Yard Issue Improvement Result  Sensor &alarm based system implemented to detect leakages in gas yard  No facility to detect LPG leakages Leadership Through Innovation Safety improvement Sensor & alarm system to detect LPG leakages NOT EXIST EARLIER Section : Maint. Month : June ’16
  60. 60. Best Practices : Safety improvement at shop floor Issue Improvement Result  Sensor based fire line system done in whole plant to deal with fire situations  No facility to detect and to rectify fire situation Leadership Through Innovation Safety improvement Automatic fire detection and prevention system NOT EXIST EARLIER Section : Maint. Month : June ’16
  61. 61. Best Practices : Infrastructure improvement at Weighing Scale Issue Improvement Result  Reconditioning of weighing done 1. Height increased with slope arrangement both side 2. Calibration done with installation of transparent window  Weighing scale issues 1. Contentious water penetration 2. Scale calibration & height expansion Leadership Through Innovation Safety improvement Weighing Scale reconditioning NOT EXIST EARLIER Section : Maint. Month : June ’16
  62. 62. Best Practices : TPM activity in press shop Issue Improvement Result  TPM implementation 1. All press m/c main motor overhauling carried out to make it production ready for new season  All press main motor Pro-active maintenance carried out Leadership Through Innovation TPM activity Press motor overhauling NOT EXIST EARLIER Section : Maint. Month : June ’16
  63. 63. TPM Activity – Press Shop v v v v
  64. 64. Best Practices : M/c Equipment improvement at dispatch Issue Improvement Result  Oil leakage elimination, m/c overhauling 1. Dock leveler bush & pin worn out , designed new one with manual greasing option 2. New seal developed for hydraulic cylinder to eliminate leakages 3. Overall overhauling done  Hydraulic dock leveler Safety issue and continuous leakages Leadership Through Innovation  Equipment improvement & cost saving M/c overhauling & Safety improvement NOT EXIST EARLIER Section : Maint. Month : July ’16
  65. 65. TPM Activity – Dock leveler v v v v
  66. 66. Best Practices : M/c Equipment improvement at Armstrong Issue Improvement Result  Gear movement not precise 1. New angular gear designed in place of conventional straight gear ie Feeder roller mechanism changed to angular type gear profile  Length variation issue Leadership Through Innovation  Equipment improvement M/c Efficiency improved by change in design Section : Maint. Month : July ’16
  67. 67. Best Practices : Basic safety & infra improvement Issue Improvement Result  In-house ladder designed & installed 1. Proper ladder designed to carry out man & material  No provision to work on shed safely 1. Ladder not available to reach on shed 2. No proper arrangement to transport material upside Leadership Through Innovation Safety improvement Overhead ladder to shed provided NOT EXIST EARLIER Section : Maint. Month : Aug ’16

×