3. 1 OUTLINE OF THE COMPANY
INCORPORATED IN 1972
TOTAL EMPLOYEES : 4818
TOTAL AREA : 26 ACRES
People Growing
Together
TURNOVER IN 2009-10 =
Rs. 7000 Million
GOVT. RECOGNISED R&D
4. 2 MAIN COMPANY DETAILS
TOTAL AREA
105,000 SQ.M
(26 Acres)
STAFF
500
602
3716
OFFICERS
WORKMEN
TOTAL EMPLOYEES 4818
NO OF M/CS
1400
8. 6. OUR GLOBAL OEM CUSTOMERS
FRANCE GERMANY/AUSTRALIA/ SOUTH AFRICA
During last few years SPRL has started export business with
6 new global OEM customers
KIA MOTORS HYUNDAI
HONDA MOTORIVECO
IRAN
USA/ CHINA
KOREA
ITALY
9. PRODUCT BRAND NAMES
No. 1
PISTON EXPORTS No. 1
RING EXPORTS
EXPORTS TO
OVER 30 COUNTRIES
7. EXPORTS
OEM
50%
Aftermarket
23%
Export
25%
Others
2%
12. 8 5
Process Flow of Aluminium Foundry
RISER CUTTING
CASTING
MELTING
HEAT TREATMENT
INSPECTION
RAW MATERIAL
ROUGH TURNING
& ROUGH
FACING
2. PROCESS OUTLINE OF ALUMINIUM FOUNDRY
13. 32
23 6
69
52
Total nos.of Equipments : 183
Numbers of Machines : Aluminium Foundry
Die Casting
Holding
Melting
Heat
Treat
Others
EQUIPMENT OUTLINE
• Variety of Equipment
Die Casting MachinesHolding Furnace
Metal Treatment
CNC Machines
Melting Furnace Heat Treatment
14. 1.2 Intensification of Time based inspection and maintenance activities on all PM-A and PM-B machines.
• 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 .
N O . I I I I II I V I I I I II I V I I I I I I I V I I I I I I IV I II II I IV I II II I IV I II II I IV I II I II I V I I I I II I V I I I I II I V I I I I II I V I I I I I I I V
1 O I L F IR E D F U R N A C E N O .1
:A LL GEA R,W ORM ,SPROCKET & CHA IN 0 3 M ONTH
C LEA N ING & GREA SING TO B E DONE
:B USH B EA RINGS GREA SING TO B E 0 6 M ONTH
D ONE OF A LL SHA FTS & W HEELS OF
TILTING A SSEM B LY
:OIL IN TILTIN G GEA R B OX TO B E 0 6 M ONTH
FILLED / REPLA CED
:D OOR B EA RING GREA SING TO B E 0 3 M ONTH
D ONE
2 O I L F IR E D F U R N A C E N O .2
:A LL GEA R,W ORM ,SPROCKET & CHA IN 0 3 M ONTH
C LEA N ING & GREA SING TO B E DONE
:B USH B EA RINGS GREA SING TO B E 0 6 M ONTH
D ONE OF A LL SHA FTS & W HEELS OF
TILTING A SSEM B LY
:OIL IN TILTIN G GEA R B OX TO B E 0 6 M ONTH
FILLED / REPLA CED
:D OOR B EA RING GREA SING TO B E 0 3 M ONTH
D ONE
:OIL TO B E FILLED IN A IR LUB RICA TOR 0 3 M ONTH
W ITH CLEA NING OF A IR FILTER
3 HE A T T R E A T M E N T F U R N A C E N O .1
:B EA RING GREA SING TO B E DON E 0 3 M ONTH
4 HE A T T R E A T M E N T F U R N A C E N O .2
:B EA RING GREA SING TO B E DON E 0 3 M ONTH
5 HE A T T R E A T M E N T F U R N A C E N O .3
:B EA RING GREA SING TO B E DON E 0 3 M ONTH
6 HE A T T R E A T M E N T F U R N A C E N O .4
:B EA RING GREA SING TO B E DON E 0 3 M ONTH
7 HE A T T R E A T M E N T F U R N A C E N O .5
:B EA RING GREA SING TO B E DON E 0 3 M ONTH
8 HE A T T R E A T M E N T F U R N A C E N O .6
:B EA RING GREA SING TO B E DON E 0 3 M ONTH
9 HE A T T R E A T M E N T F U R N A C E N O .7
:B EA RING GREA SING TO B E DON E 0 3 M ONTH
1 0 HE A T T R E A T M E N T F U R N A C E N O .8
:B EA RING GREA SING TO B E DON E 0 3 M ONTH
1 1 HE A T T R E A T M E N T F U R N A C E N O .9
:B EA RING GREA SING TO B E DON E 0 3 M ONTH
1 2 HE A T T R E A T M E N T F U R N A C E N O .1 0
:B EA RING GREA SING TO B E DON E 0 3 M ONTH
1 3 HE A T T R E A T M E N T F U R N A C E N O .1 1
:B EA RING GREA SING TO B E DON E 0 3 M ONTH
1 4 S O LU T I O N I S IN G F U R N A C E N O .1
:B EA RING GREA SING TO B E DON E 0 3 M ONTH
:TA NK M OV ING SPROCKET & B EA RIN G 0 3 M ONTH
GREA SING TO B E DONE
SHRIRAM PISTONS : GHAZIABAD
(ALUMINIUM FOUNDRY)
ANNUAL PREVENTIVE MAINTENANCE PLAN - YEAR 2003
M A C HI N E / A C T IV IT IE S F R E Q .
J A N F E B M A R A P R M A Y N O V D E C
R E M A R KS
J U N J U L A U G S E P O C T
Annual Maintenance Plan
2.1 Elimination of minor stoppages by Planned maintenance
on different equipments.
1. 1 Focussed Planned maintenance activities were done to reduce Major and Repetitive Failures.
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.
Hydraulic oil filtration Machine
Temperature Monitoring
69 Equipments
under CBM
SL.NO. MACHINE DETAILS
1 Sol. Cum Ageing Fur.-1 Minor stoppage due to bearing cooling pipe circuit chocked
3 D.C.M/C No.- 29 Minor stoppage due to Burning of flexible pipes of mould coling
4 D.C.M/C No.- 18 Minor stoppage due to misalignment of Eye pad holder box.
5 D.C.M/C No.- 4 , 5 Minor stoppage due to steam generation in water circuit
6 Riser Cutting M/C.-7 Minor stoppage due to overheating of TCT cutters.
7 D.C.M/C No.- 49 , 50 Minor stoppage due to frequent change of cooling pipes.
LIST OFMINORSTOPPAGES :BY PLANNEDMAINTENANCE
Frequency :1 Day Ref : AF/MAINT/10 Month -
Die Cas ting Activity : 1 2 3 4 5 6 7 8 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.Abnorm al Noise fr om M otor
Abnorm al Noise fr om Pum p
Coupling m ounting & Tyre condition
Hydraulic Press ure ( )
Oil level in res ervior
Oil tem perature ( M ax.58 Degree Cent.)
Pow er pack Flexible pipe condition
Die Cas ting Activity : 1 2 3 4 5 6 7 8 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.Abnorm al Noise fr om M otor
Abnorm al Noise fr om Pum p
Coupling m ounting & Tyre condition
Hydraulic Press ure ( )
Oil level in res ervior
Oil tem perature ( M ax.58 Degree Cent.)
Pow er pack Flexible pipe condition
Die Cas ting Activity : 1 2 3 4 5 6 7 8 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.Abnorm al Noise fr om M otor
Abnorm al Noise fr om Pum p
Coupling m ounting & Tyre condition
Hydraulic Press ure ( )
Oil level in res ervior
Oil tem perature ( M ax.58 Degree Cent.)
Pow er pack Flexible pipe condition
O.K. _/ Fitter
NOT O.K. x
Gauge Not OK O Checked By
SHRIRAM PISTONS : GHAZIABAD
( Aluminium Foundry )
DAILY CHECK CHART - DIE CASTING MACHINE
Jan-07
Daily check chart
57 Components /
Assemblies
for replacement
1. Breakdown Reduction
2. Elimination of Minor Stoppages
3. APPROACH FOR ZERO BREAKDOWN
15. MP
Information
Deep Analysis of
Failures
Horizontal
Replication
Maintenance
Record
Observe for 3
months
Implement
Identification of
potential failures
Study & Analyse
Identify Kaizen
Themes
OK
Not OK
Zero Breakdown
Approach
Observe for 3
months
Implement
OK
Not OK
Horizontal
Replication
Plan Corrective
Maintenance
Analysis of daily
failures with Jishu
Hozen
Review of
Maintenance
standard
APPROACH FOR ZERO BREAKDOWN
16. Breakage of piston rods in Pin assembly
Frequent failure of quench tank
Failure of eyepad assembly
Oil leakage in center tool assembly
Failure of hydraulic power pack
Water/oil leakage in cooling/hyd ckt
Not attaining required temp of molten metal
LIST OF FAILURES IN ALUMINIUM FOUNDRY
Die Casting
Holding & Metal
Treatment
Aluminium
Foundry
Leakage of heat from furnace doors
38 Kaizens
implemented
Heat Treat
Melting 12 Kaizens
implemented
11 Kaizens
implemented
Premature failure of crucibles
Breakage of lead screw in GBF M/C
Failure due to high temp in furnace coil
Failures in pipes of cooling circuit
Failure of blower bearings
Failure due to breakage of wire ropes
Leakage of heat from furnace doors
21 Kaizens
implemented
4. FAILURE ANALYSIS
17. 17
28
34
60
1
14
12
11
17
0 20 40 60 80
Strut Load assy
Water
Vertical assy
Centre tool assy
Bottom assy
Power pack
Mould assy
Pin assy
Eyepad assy
Nos. of Breakdowns / Year
Breakdowns Frequency in Die casting Machine
Assemblywise analysis
Breakdowns Frequency Trend
Die Casting
Melting 2 %
Heat Treat 3 %
91 %
Holding 2 % Others 2 %
1
3
2
1
0 20 40 60 80
Trolley assy
Basket
carrier
Baffle plate
Blower assy
Nos. of Breakdowns / Year
Breakdowns Frequency in Heat Treatment
Assemblywise analysis
1
2
1
1
0 20 40 60 80
Heating
element
Crucible
Furnace
lining
GBF
Nos. of Breakdowns / Year
Breakdowns Frequency in Holding Furnace
Assemblywise analysis
1
3
2
1
0 20 40 60 80
Trolley assy
Basket
carrier
Baffle plate
Blower assy
Nos. of Breakdowns / Year
Breakdowns Frequency in Melting Furnace
Assemblywise analysis
5. PROBLEM ANALYSIS
18. 1. Elimination of Repetitive Breakdown in eyepad assembly through modification of
guide rod
Reduction of Breakdown by 10 Nos. / Annum
• 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
•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
• No breakage of guide rods 10
0 0
0
4
8
12
GOOD
Nos.of
Breakdown/
Year
Problem Analysis :
Guide rod
20 O
20 O
1.5x45
14 O 14 O
M14x1.5P
Eyepad assembly Guide rod
Kaizen details :
1.5x45
28 O
20 O
20 O
28 O
M18x1.5P
Modified Guide rod
Result :
Breakdown Frequency Trend
(Guide Rod)
KAIZEN ON DIE CASTING MACHINE
6. KAIZEN
19. 2. Breakdown reduction of frequent jamming of eyepad slide by redesigning
eyepad holder boxes in Die Casting M/C
Eyepad holder
Eyepad holder
Self lubricating strip
• To provide solution to eliminate external lubrication
• Redesigning of holder boxes by providing self
lubricating strips on all rubbing surfaces
Eyepad
holder box
•No need of external lubrication
•Better machine static accuracy
• Life enhancement of eyepad holders from 1 years to 3 years
Eyepad
holder box
12
0 0
0
5
10
15
GOOD
Nos.of
Breakdown/
Year
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
Kaizen details :
Breakdown Frequency Trend
(Eyepad Holder)
Result :
Reduction of Breakdown by 12 Nos. / Annum
20. 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
• 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.
• No breakage of Piston rod & coupler
•Hydraulic oil saving by 50 Litres / Annuum
11
0
0
5
10
15
GOOD
Nos.of
Breakdown/
Year
Problem analysis : Piston rod
Coupler
Yoke
Quill pin
Cylinder
• Excessive load on Piston rod & coupler due to
jamming of any one pin in mould block
• The excessive load cause breakage of Piston
rod or coupler
• This breakage causes frequent breakdown of
Die Casting Machine
Quill pin
Yoke Piston rod Guide rod
Coupler
Kaizen details :
Result : Breakdown Frequency Trend
(Quill Pin Cylinder)
Reduction of Breakdown by 11 Nos. / Annum
21. 1. Breakdown reduction through modification of lead screw drive system in Gas
Bubbling Fixture machine
• To change the location of gear box assembly
• The gear box is relocated from top to bottom
• No breakage of guide rod of guide rod
Gear Box
Lead screw
Electrical
panel
Rotor
Gear Box
Lead screw
Electrical
panel
Rotor
2
0
0
1
2
3
Nos.of
Breakdown/
Year
GOOD
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
Kaizen details :
Breakdown Frequency Trend
(GBF)Result :
KAIZEN ON HOLDING & METAL TREATMENT
Reduction of Breakdown by 3 Nos. / Annum
22. 1. Elimination of minor stoppage in Solutionising & Aging Furnace due to variation
of water level
•
• Installed Water level controller and level sensor.
• To control water flow automatically by
interlocking level sensor with a solenoid valve.
• No stoppage due to water level variation
6
0
0
4
8
Nos.of
Stoppages/
Year
GOOD
Electrical panel
Manual valve
Heater
Electrical panel
Level
Controller
Level Sensor
Solenoid valve
Heater
Problem analysis :
• Manual control of water flow in quenching tank
• Stoppages due to breakdown of heaters due
to variation in water level
Kaizen details :
Minor Stoppage Trend
(Soln & Aging Furnace)
Result :
KAIZEN ON MINOR STOPPAGES
Life improvement of heaters from
1month – 1 year
