This document analyzes the effectiveness of preventative maintenance for two critical pieces of equipment, a calendar and dual extruder, at Apollo Tyres over a 10 month period. It calculates the overall equipment effectiveness (OEE) using metrics like availability, performance, and quality. Pareto analysis identified the top 5 breakdown causes for each machine. Eliminating these primary issues could reduce breakdowns by 72-80%, and increase availability by 3-7% and OEE by 3-6%, saving over Rs. 90,000-120,000 in labor costs. The study aims to improve equipment uptime and identify opportunities to enhance availability.

2. INTRODUCTION AND OBJECTIVES.
OBJECTIVE
PRIMARY OBJECTIVE:
• To study the effectiveness of Preventive maintenance of critical equipment in Apollo Tyres.
SECONDARY OBJECTIVE:
• To analyse the mechanical down time and identify the opportunities of improvement of availability of critical
equipment.
Critical equipment – Dual Extruder and Calendar.
Tools used :
– OEE (Over all equipment effectiveness).
– OEE = Efficiency x Availability x Quality.
– Pareto Analysis – to find out major break downs.
Data Collection : Ten month’s data is used for analysis. And main emphasis is on secondary data.
– Primary Data :- Personal interview with maintenance department, production department, planning
department, quality control department and Industrial engineering department personals.
– Secondary Data :- Machine logs, Production reports, Company manuals, Industrial engineering journals.
LIMITATIONS.
• Due to confidentiality nature of quality and performance data, it was difficult to get certain details.
• Intervention from the employees union which made collection of data difficult.

3. OVER ALL EQUIPMENT
EFFECTIVENESS
• OEE OF CALENDAR
Month Availability Performance Quality OEE OEE% Avg Avail Avg OEE
Jul-13 0.9803 0.9462 0.996 0.92385 92.38496
Aug-13 0.9573 0.8911 0.9958 0.849467 84.94672
Sep-13 0.9488 0.9695 0.9957 0.915906 91.59062
Oct-13 0.9095 0.8414 0.9954 0.761733 76.17331
Nov-13 0.9548 0.9305 0.9957 0.884621 88.46211
Dec-13 0.9671 0.9243 0.9958 0.890136 89.01362 0.95298 86.40747
Jan-14 0.9331 0.9629 0.9957 0.894619 89.46185
Feb-14 0.968 0.8806 0.996 0.849011 84.90111
Mar-14 0.9347 0.906 0.9962 0.84362 84.36202
Apr-14 0.9762 0.8512 0.9962 0.827784 82.77839

4. • OEE OF DUAL EXTRUDER
Month Availability Performance Quality OEE OEE% Avg Avail Avg OEE
Jul-13 0.977 0.9221 0.916 0.82522 82.52
Aug-13 0.9091 0.8814 0.965 0.77324 77.32
Sep-13 0.9154 0.9121 0.932 0.77816 77.81
Oct-13 0.9264 0.8254 0.968 0.74018 74.01
Nov-13 0.9672 0.9157 0.956 0.8467 84.67
Dec-13 0.9034 0.9262 0.983 0.8225 82.25 0.928 79.11
Jan-14 0.9084 0.8949 0.968 0.78691 78.69
Feb-14 0.922 0.8493 0.986 0.77209 77.2
Mar-14 0.9081 0.878 0.971 0.77419 77.41
Apr-14 0.945 0.8656 0.979 0.7924 79.23

5. BREAK DOWN ANALYSIS
 Calendar.
• Total mechanical down = 306.67 hrs.
• From Pareto analysis we found out top 5
downtimes.
• That are Mill failure, Led off Feed roll break
failures, Feed conveyor related failures, mill
guide failures, Roller failures.
 Dual Extruder
 Total mechanical down = 541.43 hrs.
 From Pareto analysis we found out top 5
downtimes.
 That are Skiver not skiving, Mill break down,
head related general failures, Cooling conveyor
joint failures, belt conveyor failures.
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coolingconveyor…
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feedingmillbreak…
temprature…
Rollerconceyorfailure
speedfluctuation
Headrubberleakage
RubberJamBetween…
Skiveranglevariation
stockloaderfailure
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6. FINDINGS
CALENDAR
• The major five failures are Mill
failure, Led off Feed roll break
failures, Feed conveyor related
failures, mill guide failures, Roller
failures.
• After eliminating these failures:
– 72.15% of reduction in total
mechanical break down.
– 3.385% increase in availability, i.e. to
98.67%.
– 3.07% increase in OEE, I.e. to
89.44%.
– Rs. 94667.1 reduction in terms of man
power cost.
DUAL EXTRUDER.
• The major five failures are Skiver
not skiving, Mill break down, head
related general failures, Cooling
conveyor joint failures, belt
conveyor failures.
• After eliminating these failures:
– 80.12% of reduction in total
mechanical break down.
– 6.9% increase in availability, i.e. to
99.72%.
– 5.93% increase in OEE, I.e. to
85.04%.
– Rs. 122067.3 reduction in terms of
man power cost.

7. SUGGESTIONS