PLC problem troubleshooting in automation industries using new approach which is universal to all special purpose machines and cheap to install.

1. GLOBAL KEIHIN CIRCLE
PRESENTED BY
KEIHIN INDIA MANUFACTURING PVT. LTD
4th-AURAVA
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2. A
ANDON
U
UNIVERSAL
R
RIGHT SIZE TOOL OR DEVICE
A
AUTOMATION
V
VALUE STREAM MAPPING
A
AUTONOMATION
SIGNIFICANCE/意義/
महत्व
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3. LOCATION OF KEIHIN INDIA MANUFACTURING PVT. LTD. IN INDIA
ESTABLISHED : 1997
CUSTOMER : HONDA CARS INDIA LTD.
MARUTI SUZUKI INDIA LTD.
GENERAL MOTORS
PRINS EUROPE
YAMAHA MOTORS
CERTIFIED : TS 16949 DEC-03
ISO 14001 IN MAR-04
PRODUCTS : INTAKE MANIFOLD ASSY
PIPE FUELASSY (NGV)
INJECTOR ASSY (NGV)
FUEL PUMP MODULE
EMPLOYEES : 130

4. t
MFG. INTAKE MANIFOLD FOR
CITY, BRIO, AMAZE,JAZZ
MFG. PIPE FUELASSY.(NGV) FOR
EECO, ERTIGA, WAGON-R
MFG. PIPE FUELASSY.(NGV) FOR GENERAL MOTORS
MFG. INJECTORS ASSY. (NGV) FOR
PRINS 6 MODELS
MFG. FUEL PUMP MODULE FOR YAMAHA MOTOR
KEIHIN INDIA MANUFACTURING PVT. LTD. MAIN PRODUCTS

5. £”%^
$XX=
WHO ARE IN?
LET’S
BEGIN

6. Sales and purchase dept.
Business development
sales and
relations development
Sales and purchase dept.
sales and relations development
QA/QC dept.
control, and monitor all activities
related to Quality
Production dept.
ensures all products are manufactured
with utmost efficiency
Engineering and
maintenance dept.
maintainability, reliability,
and availability of
equipment
ADVISOR
SURAJ SAN
LEADER
SHASHANK
MEMBER
PRIYANK
MEMBER
DEEPAK
FACILITATOR
ALLAN SAN
Engineering and
maintenance dept.
Leading the
maintainability,
reliability, and
availability of equipment
MEMBER
MOHAN
TEAM 4TH AURAVA

7. STEPS RESPONSIBILITY TASK
Selection of
theme
Team Set kick-off meeting
Agree on objectives,
History research, Data
collection, Study on
scenario
Identification of
the most
important product
or process
Team prototype Dev.
Gaol setting
Technical Request
Analysis of
selected process
Shashank, Deepak,
Mohan
Testing over Machine
.
Development of
the proper
strategy for
critical process
Shashank, Deepak,
Mohan
Hardware configuration
Implementations
of actions
Shashank Operations
Dev. Complete
Final assessment Team Launch
AS PER IMPROVEMENT MODEL DEC JAN FEB MARCH APRIL MAY
1 2 3 4 5 1 2 3 4 5 1 2 3 4 5 1 2 3 4 5 1 2 3 4 5 1 2 3 4 5
ACTIVITY PLAN

8. SELECTION OF THEME
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$
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9. BRAINSTORMING FOR THEME SELECTION
Yeah! Including
inspection cutting
machine as well
Solar panel, how’s
about that …so that we
cad head to sustainable
development
In house
development, saved
so much, if we
consider the cost
saving as a goal
Guys, we will go
for something that
has been hidden
to others yet, we
need sum up of all

10. CONCLUSION OF THE DISSCUSION
TIME
TIME is the event that effects
all type of processes/products

11. BASIC FEATURES
INVOLVED IN THEME
Energy saving by solar
panel installation
Cost saving by
adopting in-house
modifications&
fabrications in
machine for DBW
project
Time saving by smart
troubleshooting
QUALITY AND
INNOVATION
COST SAVING
DIFFICULTY
COST INVOLVED
LEARNING
SAFETY
TOTAL
Taking the steps
to reduce
downtime in
manufacturing
settings can seem
overwhelming,
................................!!
but the money
saved, and
additional profits
earned from this
concept are
worthwhile.
TIMELESS
IMPRESSIVE
GOOD
AVERAGE
TERRIBLE
THEME SELECTION
C
O
N
C
L
U
S
I
O
N
Selection
of theme
is done

12. IDENTIFICATION OF
THE MOST IMPORTANT
PRODUCT OR PROCESS
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$
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13. 0
0.5
1
1.5
2
2.5
3
3.5
4
4.5
5
CHCOLLARM/C
LEAKTESTM/C
M5HEATINSERTMACHINE
CHCOLLARINSERTM/C
THCOLLARINSERTM/C
M6HEATINSERTMACHINE
IFCOLLARINSERTM/C
CHCOLLARPRESSFITM/C
CHCOLLARPRESSFITM/C
THCOLLARINSERTM/C
M5HEATINSERTMACHINE
THCOLLARINSERTM/C
IFCOLLARINSERTM/C
THCOLLARINSERTM/C
DOWN
TIME(HRS)
STANDARD
MTTR(HRS)
TARGET
MTTR(HRS)
ACTUAL
MTTR(HRS)
BEFORE IMPLEMENTATION APRIL TO JAN(16-17) INMANI LINE
MONTH WISE
0
0.5
1
1.5
2
2.5
3
3.5
APRIL
MAY
JUNE
JULY
AUG
SEP
OCT
NOV
DEC
JAN
DOWN
TIME(HRS)
STANDARD
MTTR(HRS)
TARGET
MTTR(HRS)
ACTUAL
MTTR(HRS)
MACHINE WISE
TARGET SET
SPECIFICALLY
FOR SMALL
AND MEDIUM
END MACHINE
OUR AIM
IS TO
MINIMIZE
AS MUCH
AS
POSSIBLE
IDENTIFICATION OF THE MOST IMPORTANT PRODUCT OR PROCESS
AIM
SO
Analysis of
selected
process

14. So, Identification
of the most
important
product or
process is done
1 2 3 4 5 6 7 8
8
1 2 3 4 5 6 7 8
8
BREAK
DOWN
MEAN
TIME TO
REPAIR
SO OUR
AIM IS
TO
REDUCE
MTTR BY
70%
AIM
POSSIBLE AREAS to reduce down time

15. ANALYSIS OF SLECTED
PROCESS
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16. Methods
Delay in
identifying
the fault in
machinery
MaterialsMeasurement
Environment Manpower Machines
Limited specified
Indications
Through PC
communication
•Time taking for
frequent error
•Usually without
comments over
commands
Spare parts
can't be use till the
cause is isolated
Unnecessarily
replacement or
fitment of spare
while hitting the
cause
Complicated
system and
vague cause
Old machines
Problem occurrence
becomes frequent
SOP(standard
operating
procedure) is
availed
Improvisation
Inexperienced
handler
Under
training
Lack of
manpower
Error indications isn’t
similar and sufficient
Mechanical,
electrical,
electronics etc.
Risk of approach
wrong
Some machines are with
two processors
CAUSE AND EFFECT DIAGRAM
Methods
Delay in
identifying
the fault in
machinery
Analysis of
selected
process
started

17. 3 6 9
2 4 6
1 2 3
RISK LEVEL
PROBABILITY
SEVERITY
1 2 3
123 1 : LOW
2: MODERATE
3: HIGH
PROBABILITY OF
ACCIDENT=P
SEVERITY OF
ACCIDENT=S
RISK LEVEL =P(1) *S(2)= 2
RISK LEVEL =P(2) *S(1)= 2
RISK LEVEL =P(.9) *S(3) = 2.7
P DEPENDS ON LEVEL OF M/C COMPLEXITY OR ITS
COMPONENTS EX.
• ROBOT
•HYDRAULIC PRESS CYLINDER
•PNEUMATIC CYLINDERS , ACTUATORS ETC
1 2 3 4 5
1

18. • EMERGENCY PREPAREDNESS AND RESPONSE (4.4.7)
• Identify likely OHS accident and emergency scenarios which may have impacts
on people, process, and have business risks.
• Determine potential OHS impacts.
• Develop[ simple rapid response procedures to control OHS impacts.
• Periodically test emergency procedures to control after incidents.
• Train staff in implementation of emergency controls.
CLAUSE FROM OHSAS:18001 (2007)
It also
supports the
clause from
OHSAS
SO FROM 1 AND 2,
WE NEED TO
MITIGATE THE
CHANCES OF
IMPACTS OVER
ANY LIFE
2

19. Sir machine
is not
starting
Hey…am
here only
!!
I will not start
Means no home
position, ok I ill
call
maintenance
What is being done while breakdown…!!
Here we have
analysed the
predefined process
of corrective
maintenance

20. Hmm…
let me
start from
1
•Photo electric sensor
•Load sensor
•Air pressure sensor
•Read switch on cylinder
•Area sensor
•Proximity sensor
•Switches
Input side
•PLC
•DRIVES
•PID
Process side
• Contactors
• Relays
• Solenoid valves
• Motor driver
• heater
• Alphanumeric
display
Output side
1 23
x
minutes
z
minutes
y
minutes
Problem
could be
anywhere
x + y + z minutesMax time to inspect the problem
Existing Troubleshooting approach

21. DEVELOPMENT OF
PROPER STRATEGY FOR
CRITICAL PROCESSES
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$
XX=

22. Demonstration over IF
collar press Machine
22
1
0
5
13
10
21
30
31
34
Let’s begin with
the development of
the proper strategy
for critical process

23. Input side devices
• AREA SENSOR
• READ SWITCH
• PHOTOELECTRIC SENSOR
• MAIN AIR PRESSURE

24. Input side devices
• SWITCHES
• LOAD CELL
(LOW PRESSURE)
• PROXIMITY
SENSORS

25. To eliminate the time of inspection spend on step 1
SENS.
WORK
WELL
OK
POLLS
OUT I/P
SIGNALS
HOW

26. 10 5
13
10
21 22 30
31 34
CONFIGURE
INTO PANEL
1
5
0
13
10
2122
3031
34
INSTALLED
IT ONTO
MACHINE
THEN
Here we are
assured from
the input side
of the machine
Let’s work
more

27. How justify ..
To eliminate the time of inspection spend on step 3
HOW
This way we
should go
This manner
Never mind
AS PER THE OBJECTIVE

28. U
• ULTIMATE
C
• CONCLUSION
A
• ANALYSIS
on
on
LAST ERROR=N+ 9
If the above
condition is
true then
machine unit
abnormal on
Here M504 is
having value
10000(BC)
i.e. 16
M504
M505
M506
M507
M508

29. M6 UNIT
ABNORMAL
PLC ERR.
BATT. ERR.
CYL. READ ERR.
ROBO ERR.
So we have
plans for
separation of
all pre-eminent
errors
AS PER THE OBJECTIVE Development of the proper strategy for
critical process is done over here

30. •Photo electric sensor
•Load sensor
•Air pressure sensor
•Read switch on cylinder
•Area sensor
•Proximity sensor
•Switches
Input side
•PLC
•DRIVES
•PID
Process side
• Contactors
• Relays
• Solenoid valves
• Motor driver
• heater
• Alphanumeric
display
Output side
x
minutes
y
minutes
z minutesz
minutes
Max
time to
inspect
the
problem
Eliminating the time of inspection spend on step 1 and 3
1 23
AS PER OBJECTIVE
Our strategy for
critical process
is eliminating
the time of
inspection

31. IMPLIMENTATION AND
TRIALS OF ACTIONS
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32. IMPLIMENTATION AND TRIALS
INDICATOR ON PRESS FIT
TYPE MACHINE
INDICATOR ON HEAT
INSERT TYPE MACHINE
PAPER TAG FOR ERROR SITE
TRIAL ON
PANEL SIDE
Implementations
of actions

33. FINALASSESSMENT OF
IMPLEMENTED ACTION
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34. 0
0.5
1
1.5
2
2.5
3
3.5
DOWN
TIME(HRS)
STANDARD
MTTR(HRS)
TARGET
MTTR(HRS)
ACTUAL MTTR
ANALYSIS AND FINAL ASSESSMENT OF IMPLEMENTED ACTION
AFTER IMPLEMENTATION FEB TO PRESENT (17 -18) INMANI LINE
MONTH WISEMACHINE WISE
0
0.5
1
1.5
2
2.5
3
3.5
DOWN
TIME(HRS)
STANDARD
MTTR(HRS)
TARGET
MTTR(HRS)
ACHIEVED
MTTR(HRS)
OUR CONCERN IS
OVER THE BD
RELATED TO
MACHINE
ABNORMAL
BEHAVIOUR
ACTUAL
MTTR(0.06) IS
MUCH BELLOW
THE TARGET
(0.1)MTTR
THESE ARE
MECHANICAL BD,
SO OUT OF
CONCERN
FINAL
ASSESSMENT OF
IMPLEMENTED
ACTION
STARTED

35. 0
0.5
1
1.5
2
2.5
3
3.5
DOWN
TIME(HRS)
STANDARD
MTTR(HRS)
TARGET
MTTR(HRS)
ACTUAL
MTTR(HRS)
0
0.5
1
1.5
2
2.5
3
3.5
DOWN
TIME(HRS)
STANDARD
MTTR(HRS)
TARGET
MTTR(HRS)
ACTUAL
MTTR(HRS)
ANALYSIS AND FINAL ASSESSMENT OF IMPLEMENTED ACTION
COMPARISION ON THE BASIS OF EFFECTIVENESS (MTTR)
AFTERBEFORE
HERE WE
ARRIVED TO THE
CONCLUSION
OUR WORK
FLUXES TO
ACHIEVE THE
IMPROVE MENT IN
%

36. 0
0.05
0.1
0.15
0.2
0.25
0.3
0.35
0.4
PREVIOUS
YEAR MTTR
SET TARGET
MTTR
ACHIEVED
TARGET MTTR
MTTR
MTTR
70.58
82.35
0.34
0.1
0.06
ANALYSIS AND FINAL ASSESSMENT OF IMPLEMENTED ACTION
RESULT OF FINAL OF IMPLEMENTED ACTION
BEFORE
IMPLEMENTATION
APRIL TO JAN(16-17)
INMANI LINE
SET TARGET
AS PER THE
DEVELOPRD
STRATEGY
AFTER
IMPLEMENTATION
FEB TO PRESENT
(17 -18) INMANI
LINE
WOW !
THAT’S
AMAZING
Let’s begin
the
assessment
over cost

37. COST ANALYSIS (REGULAR TIME)
S.NO. MACHINE
NAME
TOTAL BREAK DOWN TIME
W.R.T MACHINE (HRS.)
NO. OF
BD
LABOUR
COST
YEARLY
(Rupees)
ESTIMATED
COST PER PIECE
(Rupees)
NO.
REFUSED
PIECE
COST OF
REFUSED
PIECES
(Rupees)
1. Heat insert
machine m5
0.95+2.08+1.16 = 4.19 3 1414.125 1000 2*3=6 6000
2. Heat insert
machine m6
0.8+0.44+0.88+0.75 =2.87 4 968.625 1000 2*4=8 8000
3. Collar insert
machine CH
0.67+3.5+0.92+0.8 =5.89 4 1987.875 1000 2*4=8 8000
4. Collar insert
machine TH
0.5+0.8+0.3+0.26 =1.86 4 627.75 1000 2*4=8 8000
5. Collar press
fit machine
IF
0.92+2.42+0.66+0.17 =4.17 4 1407.375 1000 2*4=8 8000
TOTAL (Rupees) 18.98 19 6405.75 5000 38 38000
TOTAL (Rupees) = Total of LABOUR COST
+ Total of COST OF REFUSED PIECES
(Rupees)
= 44405.75 Amount that we
could have save
previous year
while regular
time
PREVIOUS
YEAR

38. S.NO. MACHINE
NAME
TOTAL BREAK DOWN TIME
W.R.T MACHINE (HRS.) =
OVER TIME FOR RECOVERY
NO. OF BD LABOUR COST
YEARLY (OT)
(Rupees)
1. Heat insert
machine m5
0.95+2.08+1.16 = 4.19 3 2178.8
2. Heat insert
machine m6
0.8+0.44+0.88+0.75 =2.87 4 1492.4
3. Collar insert
machine CH
0.67+3.5+0.92+0.8 =5.89 4 3062.8
4. Collar insert
machine TH
0.5+0.8+0.3+0.26 =1.86 4 967.2
5. Collar press fit
machine IF
0.92+2.42+0.66+0.17 =4.17 4 2168.4
TOTAL
(Rupees)
= Total of LABOUR COST
YEARLY (OT)
9869.6
COST ANALYSIS (OVER TIME)
Amount that we
could have save
previous year in
the expense of
OT
PREVIOUS
YEAR

39. S.NO. ITEMS USED QUANTITY OF
ITEM
COST OF ITEMS
MARKET PRICE(RUPEES)
1. Indicator (LED) 15 375
2. Acrylic sheet 1(244*211) 1000
3. Paper tag 5 5
4. Wire 10 meters 500
S.NO. ITEMS USED QUANTITY OF
ITEM
COST OF ITEMS
ACTUAL (RUPEES)
1. Indicator (LED) 15 200 (EXCLUDING SPARE)
2. Acrylic sheet 1(244*211) 0 (SCRAP)
3. Paper tag 5 0 (WASTES)
4. Wire 10 meters 0 (SPARE)
COST ANALYSIS (INVESTMENT)
TOTAL COST OF INVESTMENT
(RUPEES)
1880
TOTAL COST OF INVESTMENT
(RUPEES)
200
Right now we
are availed with
all items in
scrap and spare
PREVIOUS
YEAR

40. BEFORE
AFTER
CONCLUSION
S.NO. MACHINE LINE
SETUP IN
WORKSHOP
TOTAL TIME
SAVED(HRS.)
TOTAL MONEY
SAVED(Rupees)
1. IN MANI 37.96 9869.6 + 44405.75
= 54275.35
2. DBW
3. BOBBIN
COST ANALYSIS (CONCLUSION)
PREVIOUS
YEAR

41. SIMULATION OF THE CONCEPT

42. THANK YOU
t/1-√v2/c2