This document provides an update on motor testing and fault diagnosis. It details test results showing resistance measurements for different motor windings. Guidelines are given to maintain motors and include regular coil checks. Performance data is shown for January 2016, with overall availability at 97% but some equipment below targets. Charts show fault data for a forklift over the month, with the main fault being proximity switches. Applying six sigma concepts helped reduce variations and achieve zero faults after replacing the motor.

1. UPDATE : 2nd Febuary 2016
OK faulty
winding 1 2 winding 1 2 standard 1 2 3 4 5
U ∞ ∞ UV 19Ω 19Ω 1.18Ω 1.7Ω 1.19Ω 1.18Ω 1.17Ω
V ∞ ∞ UW 19Ω 19Ω
W ∞ ∞ VW 19Ω 19Ω 6 7 8 9 10 faulty
judgement judgement 1.17Ω 1.17Ω 1.17Ω 1.90Ω 1.17Ω 0.8Ω
HOW TO CONTROL :
INVESTIGATION
COUNTER-MEASURE
spare motor
spare motor
1.2kΩ
1. How to PREVENT to re-occurred?
2. How to PREDICT from re-occurring?
- Maintain the motor at good condition by
setting STANDARD COIL 1.2kΩ (±10% tolerance)
- Inclusion of "Brake motor coil checking"
on every INSPECTION JOB.
DEFINEMEASUREANALYZEIMPROVECONTROL
OK OK
ground test (insulation) line to line check (continuity)
AVAILABILITY : (JANUARY 2016 OVERALL PERFORMANCE)
FIXED EQUIPMENT
dnata CMT
COUNTER-MEASURE SUMMARY
minimum target : 95%
PCHS ASRS
OVERALL 97% 92%
97%
92%
90%
95%
100%
AVAILABILITY : JAN2016
90%
24hrs
23hrs
22hrs
NO GOOD !
VG !
3%lose
1 2 3 4 5 6 7 8 9 10111213141516171819202122232425262728293031
JANUARY 2016
L61E01 26211917721127293234341829262328302011111928221419172323241714
0
50
100
150
200
250
300
350
400
L61E01
FAULT : PROX. SWITCHES FORK IN CENTER
variations
12
1
T-CAR
18
2 1
STACKER
33
0
HOIST
repairedUNSOLVED
TARGET
upper limitlower limit
"ZERO"
0-6ơ +6ơ
dx step 1: REDUCE VARIATIONS
step 2 : sustain "ZERO" FAULT
brake comparison:
motor test:
motor replacement
sun mon tue wed thu fri sat
FAULT 88 77 0
0
50
100
L61E01RESULT AFTER REPLACEMENT
ZERO!
Applying 6ơ Sigma concept
as a counter-measure...
Effective for defect rate reduction
prepared by : STEPHEN AUSTRIA