This document discusses the development of department-specific toolboxes to reduce machine downtime during maintenance. Currently, maintenance teams experience delays when they forget tools and have to return to retrieve them. The new toolboxes aim to be well-organized and contain all essential tools for each department to minimize downtime. They will be implemented first in key departments like Molding, Metalizing, Coating, and Assembly. The document also provides examples of ongoing and upcoming maintenance jobs and issues being addressed for different machines and systems.

1. Downtime
Reduction in
machine
maintenance
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2. 2
INTRODUCTION
BACKGROUND :-
• Whenever our team is engaged in corrective maintenance on a
machine that is in production, downtime is the primary factor to
consider.
• Proper tools play a very important role in reducing machine
downtime.
OBJECTIVES :-
• To enhance our processes, we are developing a department-specific
toolbox designed to reduce downtime. Because there is a risk of
forgetting essential tools, requiring us to return to the department for
retrieval. This results in significant additional time, contributing to
machine downtime.

3. 3
CURRENT STATE ANALYSIS
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PROCESS FLOW :-
Currently, when our team is assigned corrective maintenance tasks on a
machine in production, and while troubleshooting a task, they realize they
have forgotten some tools in the department. Subsequently, they need to
either call the department for the tools or return to retrieve them. This
process consumes a considerable amount of time, which is also factored
into the machine downtime.
In addition, when we need to locate a specific tool in the toolbox, it becomes
challenging as the tools are not organized in the bag, making it difficult to find
them, and at times, they might not be visible.

4. 4
EXISTING TOOLBOX
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BOTTLENECKS
 Does not follow safety standards.
 It is not organized.
 Tools are difficult to find.
 Reduces tools life.
 Does not carry many tools.

5. 5
DEPARMENT BREAKDOWNS
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The department-specific toolbox is designed for implementation in the primary departments
of EPL, particularly where there are numerous complaints.
 MOLDING DEPARTMENT.
 METALIZING DEPARTMENT.
 COATING DEPARTMENT.
 ASSEMBLY DEPARTMENT.
 GENERATOR AND COMPRESSOR ROOM.

6. 6
5S OF ELECTRICAL WIRING SYSTEMS
BEFORE
6
AFTER
POSSIBLE HAZZARDS:
1. Short Circuit in wiring causing electrical devices loss
2. Fire Incident in machine causing heavy losses
3. Leakage currents causing additional power consumptions

7. 7
MOLDING JOB CARDS (BREAKDOWN)
JOBS STATUS
LUBRICATION MOTOR INSTALL JSW 220
NOZZLE REPLACEMENT JSW 220
HMI (LCD) BLINKING NR 280-2
HEAT EXCHANGER CLEANING (6 MACHINES)
CRANE 5T SHEILING WIRE
MTC -(2) DIFFICULT TO WALK IN PROCESS
CYLINDER SEAL REPLACED SM 160
STABILIZER HR 620T
SSR , BREAKERS CHANGED NR 350T
SERVO MOTOR ERROR HR 620T
HYDRAULIC AND WATER LEAKING PROBLEMS
NOZZLE TIP ALLIGNMENT OF SM 160
MTC MOVEMENT FOR ALL MACHINES
HEAT TEMPERATURE VARIATION-NR-350
WATER MIXED IN AIR HR-620
MULTIPLE HEATERS AND THERMOCOUPLE MALFUNCTIONG
VALVE LEAKING NR 280-1
NOZZLE TEMPERATURE ISSUE NR 280-1
Legends
Job Done
Job Incomplete

8. 8
METALLIZING JOB CARDS (BREAKDOWN)
JOBS STATUS
PRV VALVE LACQUER TANK
LACQUER TANK MAINTENANCE
CHILLER REPAIRING/MAINTENANCE
ARZUFFI MACHINE SENSOR
OVEN TRIPPING (BURNER RELAY)
AC FILTER CLEANING
ARGON CYLINDER TESTING
BRASS FOOT VALVE OF PUMP
-----
Legends
Job Done
Job Incomplete

9. 9
ASSEMBLY JOB CARDS (BREAKDOWN)
JOBS STATUS
COUPLER NOT WORKING WS # 3
3 TESTING JIGS
CHILLER COMPRESSOR KE PHASE REVERSAL
HOLDER MACHINE COUNTER ISSUE
AIR PIPE LEAKAGE
3 PNEUMATIC AIR SCREW DRIVER
AIMING MACHINE CYLINDER TORQUE ISSUE
REQUIRED BREAKER FOR EVERY WORKSTATION
Legends
Job Done
Job Incomplete

10. 10
GENERAL MAINTENANCE JOB CARDS (BREAKDOWN)
JOBS STATUS
COLD STORAGE AC LEAKAGE
WOODEN RACK FOR FINISH GOOD (2X)
DISPENSOR MAINTENANCE (2X)
CANTEEN BREAKERS CHANGED
STAIRS FOR S AREA
COOLING TOWER MOTOR RUNNING REVERSE
LIFTER REPAIRED
OPERATION OFFICE NET
Legends
Job Done
Job Incomplete

11. 11
MOLD MAINTENANCE JOB CARDS (BREAKDOWN)
JOBS STATUS
NOZZLE MANUFACTURE HR 150, SM 160, JSW 220, KAWA 165
C 12 ULTRASONIC BASE SLIDE SYSTEM ALLIGNMENT
INSERT BOLT M6 CHECKING GAUGE
ROBOT NOZZLE OF 4 WHEELER
LACQUER MACHINE BLADE
SM 160 SHAFT PIN
B83 LENS SPREW BUSH BACK HOLE DAMAGE
CLAMPING BLOCK 280-1, 280-2, HEAD 280-1, 280-2
Legends
Job Done
Job Incomplete

12. 12
LACQUER MACHINE BLADE
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13. 13
NOZZLE MANUFACTURE HR 150, SM 160, JSW 220, KAWA 165
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14. 14
UPCOMING PROJECTS
 Improve 5S of Molding Machines
 LT , HT and Transformers Maintenance
BMC External Water Circulation System
 Automation of Vacuum Metalizing Oven
 NR-350 and SM-160 PLC and HMI Interface Designing
 Cost Saving Schemes Design to Reduce Power Consumptions

15. Thank You !
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