This project was concerned with breakdown issues with the Shot-Blasting machine for water heater manufacturing. A breakdown time analysis was conducted on a shot-blasting machine, using a fishbone diagram to categorize various reasons for the breakdown. A 5-Why Analysis shortlisted the top five reasons and their probable root causes were determined. A preventative maintenance program was suggested for the machine.

1. PROJECT BASED LEARNING
PRESENTATION
Starlite Lighting Limited
Harender Singh
PRN099
Ruchir Mishra
PRN131 STARLITE
LIGHTING LIMITED
Team:

2. Water Heater 10L
Water Heater 3L
Mixer Grinder
Room Heaters Led Lightings
Hand Blender
About Starlite
Starlite Lighting Limited is a Public incorporated on 04 July 1995. It is classified as Non-govt company
and is registered at Registrar of Companies, Mumbai.
Bajaj Electricals in 2021, bought the remaining stocks for a cash
consideration of around ₹60 crore from its promoters.
Product Range
and Others
Annual Turnover
100 crores
Legal Status of firm
Limited Company (Ltd./Pvt. Ltd.)
Year of Establishment
1995
Number of Employees
50-75 people
Nature of Business
Exporter and Manufacturer
CFL tubes
Retrofit tubes

3. Understanding Current
Preventive Maintenance and
breakdown reasons
We have gathered breakdown sheets,
trends of purchases and other details
to understand the operations of
machine better
Proposing and implementing
Changes related to
machine’s’ operations
Suggesting and implementing
changes related to machine
preventive maintenance to monitor if
validate if identified root causes are
the correct ones.
Analyzing and spotting the
gaps in current machine
operations
Here we wish to develop a fish-bone
diagram for the breakdown reasons
and try to conduct a 5C Analysis for
the same to understand the possible
root causes for the breakdown
Project Objective
Analyzing and reducing the breakdown time for the Shot-Blasting machine to improve productivity.
(Preventive Maintenance Plan)

4. EXECUTION
In this phase,
recommendatio
ns will be
shared with
Starlite people
INITIATION
Requirement
breakdown
sheet,
objectives,
understanding
project
PLANNING
Planning related
to maintenance
will take place
during this
phase.
MONITOR
This Phase will
be to check
whether the root
causes
identified aligns
to breakdown
reasons
CLOSURE
Project
completion and
timely delivery
to Starlite
Project Timeline
Analyzing and reducing the breakdown time for the Shot-Blasting machine to improve productivity.
(Preventive Maintenance Plan)
We opt to use an adaptive life cycle with Starlite Lighting Limited for our live project. It will be
change-driven, and we plan to conduct it in five phases.

5. Shot Blasting Machine
Spinner Hanger Type Shot Blasting Machine: Surface
treatment to cylinders, they comes handing and the
machines has 4 blasters for shots and 4 for cleaning it from
inside. Cylinders are transported by a hook with rotating
movement to ensure full abrasive cover.
Major Components of SBM
 Blast Unit
 Cabinet
 Work Handling Mechanism
 Elevator
 Separator
 Dust Collector
 Lifting driver
With first interaction with machine operators and
the maintenance people we understood that this
is the busiest line in the plant with a machine
utilization of over 80%.

6. Breakdown time Analysis
Breakdown time analysis for the Shot-Blasting machine, The data used for analysis is for May to July
0
100
200
300
400
500
600
700
800
900
Breakdown time (min) vs. reason for breakdown
Hose pipe
Puncture
58 Occurrences
Clamping Issues
12 Occurrences
Shots not
working
11 Occurrences
Electric Display Issue
11 Occurrences
Teflon bush
changed
10 Occurrences

7. Fishbone Diagram
Shot-Blasting machine, The fishbone diagram for categorizing down the various reasons for the
breakdown to occur.
Shot Blasting
Breakdown
Issues
Machine
Shots not working
Method
Manpower Material
Elevator rotation stoppage
Nozzle rotation stopped
Dryer belt problem
Wheel rotation
Lance problem
Lifting drive problem
Shots not working
Pressure Issue
Conveyor sensor setting
Door out of track
Electrical fault
MP Change
Dryer bearing
Diaphragm change
Elevator bearing change
Nozzle & plunge Issue
Hanger Change
Teflon bush changed
Stop Mode
Center break
Electric display Issue

8. 5 Why Analysis
For shortlisted the top five breakdown reasons and tried find their probable root causes using 5 Why
analysis
Hose Pipe
Puncture
Why hose pipe
puncture?
Why Misapplication
Why we an inferior
quality or low ppi pipe?
Why are we not able to
get the right hose pipe?
Finding substitute
and ensuring
preventive
checks every 4
hrs. of continuous
use
Clamping
Issue
Why Clamping Issue?
Why are the forces not
maintained?
Why not checked
properly?
Why is the preventive
plan – check sheet not
accurate?
Why was it modified ?
Ensuring
preventive checks
every 40hrs of use
Shots not
working
Why are blast shots not
working?
Why does this problem
occur?
Why is there no daily
maintenance check?
Ensuring
preventive
checks every 40
hrs. of use
Teflon bush
changes
Why is Teflon bush tear
and wear so quickly?
Why is dirt getting
accumulated on the
machine?
Why is there no daily
maintenance check for
the same?
Ensuring
preventive
checks every 160
hrs. of use
Conveyor
sensor setting
Why is conveyor
getting unset so
frequently?
Why are no
maintenance stops and
cleaning checks not put
in check sheet?
Why is the checks not
put in maintenance
check list?
Ensuring
preventive checks
160 hrs. of use

9. Recommendations
Shot blasting machine is subjected to abrasive wear therefore for safety and
efficiency it is essential to operate a preventative maintenance program. The
degree of wear is variable and is dependent upon many factors:-type and grade
of abrasive, blasting pressure, nozzle size, operator expertise, etc.
Maintenance Check List - after 4 hours use
Check List Category
Check the filter bag General Checks
Checking of Air and suction filter General Checks
Check the tension and temp on chain Enameling Maintenance
Verify the position of stainless steel Furnace Maintenance
Cleaning of floor of furnace Furnace Maintenance
Check condition of Air hoses New Checks!
Check condition of safety sieve New Checks!
Check the nozzle for blockages New Checks!
Hose Pipe
Puncture
Clamping Issue
Teflon bush
changes
Shots not
working
Conveyor
sensor setting

10. Recommendations
Maintenance Check List - after every 40 hours use
Check List Category
Check for wear in plates in blasting chamber General Checks
Check for abraissive distributor inside nozzle General Checks
Check the gasket on unit filter door General Checks
Check the elevator belt General Checks
Check the bucket on elevator General Checks
Check the rubber gasket on filter door General Checks
Check the Air and Abrassive hoses General Checks
Check the brushes General Checks
Check the filter cartridges General Checks
Check Tank clamping and De clamping General Checks
Checking the hydraulic fluid level in tank Enameling Maintenance
Check for screws and welds Enameling Maintenance
Supervision of spindle and greasing Enameling Maintenance
Bear greasing Enameling Maintenance
Check the air filter on ventilator Furnace Maintenance
Check oil level of geared momor Furnace Maintenance
Greasing of wheel and ball bearing Furnace Maintenance
Check the holding anchors Furnace Maintenance
Check the rods for radiant tube gaps Furnace Maintenance
Hose Pipe
Puncture
Clamping Issue
Teflon bush
changes
Shots not
working
Conveyor
sensor setting

11. Recommendations
Maintenance Check List - after every 160 hours use
Check List Category
Check the balance of air ventilation fan General Check
Check the ball bearings General Check
Check the rubber gasket on dust drain General Check
Clean the dust hose General Check
Send the sample of oil for conditionong General Check
Check Actuator General Check
Check Cylinder Seals General Check
Check for cleaning of hydraulic fluid level Enameling Maintenance
Supervision of strap flooding machine Enameling Maintenance
Hydraulic amoune and control leakege Enameling Maintenance
Check for conveyer gaps Furnace Maintenance
Check all connections and clamping of ventilator Furnace Maintenance
Replacement of belt Furnace Maintenance
Check for wear and tear in overall machine New Checks!
Check the vessel internally and externally for corrosion New Checks!
Hose Pipe
Puncture
Clamping Issue
Teflon bush
changes
Shots not
working
Conveyor
sensor setting

12. Recommendations
Hose pipe puncture
Hose Pipe
Puncture
Why hose pipe
puncture?
Why Misapplication
Why we an inferior
quality or low ppi pipe?
Why are we not able to
get the right hose pipe?
Finding substitute
and ensuring
preventive checks
every 4 hrs. of
continuous use
1. 3/4"X3 meter hose pipe, working
pressure 1300 psi
2. 3/4"X2 meter hose pipe, working
pressure 1300 psi
Hose pipe used
External Vendor
 Hitech Rubber Industries
 Indian Rubber & Hydraulics Co.
 Perfect Rubber Industries
As Hose pipe puncture is one the most
common breakdown reason, we recommend
changing it as per preventive maintence plan
and retest its strength for further use.
Moving from Condition based maintence to
time-based maintenance.

13. This presentation template was created by Slidesgo, including icons by
Flaticon, infographics & images by Freepik and illustrations by Stories
Thanks
Do you have any questions?
harender.singh@siom.in
+91 9812969049
STARLITE
LIGHTING LIMITED

14. Appendix I
Breakdown Reason Breakdown time (in min.)
Hose pipe puncture 855
Clamping Issue 500
Shots not working 415
Electric display Issue 330
Teflon bush changed 235
Stop Mode 190
Spindle Rotation 190
Conveyour sensor setting 160
Door out of track 158
Electrical fault 135
MP Change 125
Pressure Issue 110
Dryer bearing 90
Center break 90
Elevator rotation stoppage 75
Nozzle rotation stopped 70
Diaphragm change 65
Elevetor bearing change 55
Elevator bearing 50
Nozzle Issue 43
Plunger Issue 35
Conveyour chain setting 35
Dryer belt problem 30
Wheel rotation 15
Lance problem 10
Hanger Change 10
Lifting drive problem 5
Grand Total 4081
Breakdown time vs Breakdown Reason Breakdown Occurrence vs Breakdown reason
Breakdown Reason Number of Occurrences
Hose pipe puncture 58
Conveyour sensor setting 12
Clamping Issue 11
Teflon bush changed 10
Door out of track 10
Shots not working 8
Nozzle Issue 5
MP Change 4
Conveyour chain setting 3
Nozzle rotation stopped 3
Center break 3
Dryer bearing 2
Diaphragm change 2
Spindle Rotation 2
Lance problem 2
Electric display Issue 2
Stop Mode 2
Elevator rotation stoppage 2
Wheel rotation 2
Lifting drive problem 1
Dryer belt problem 1
Elevator bearing 1
Plunger Issue 1
Electrical fault 1
Pressure Issue 1
Elevetor bearing change 1
Hanger Change 1
Grand Total 151
Data used is for Month May-July 2022
External vendor selected for Hose pipe
 Hitech Rubber Industries
https://www.indiamart.com/indianrubberhydraulic
s/high-pressure-hydraulic-hose-pipe.html
 Indian Rubber & Hydraulics Co.
https://www.hitechrubber.net/
 Perfect Rubber Industries
https://www.indiamart.com/perfect-rubber-inds/

15. References
Sources and links:
• https://www.jxabrasives.com/maintenance-work-for-shot-blasting-machines.html
• https://shotblasting.org.in/maintenance-work-on-shot-blasting-machines.php
• https://www.tedbartinkerhire.co.uk/item%20downloads/blast-machine-maintenance.pdf
• https://shotblasting.org.in/best-shot-blasting-machine-manufacturer-and-supplier-company-india.php
• https://blog.bartellglobal.com/is-your-shot-blaster-dropping-too-much-
shot#:~:text=CHECK%20THE%20VACUUM,the%20shot%20from%20rebounding%20properly.
• https://www.indiamart.com/starlite-lighting-limited/aboutus.html
• https://www.zaubacorp.com/company/STARLITE-LIGHTING-LIMITED/U31300MH1995PLC090213
• https://dir.indiamart.com/impcat/sandblast-hose.html
• https://www.airoshotblast.net/blasting-machines/sand-blasting-machine/sand-blasting-hose/
• https://m.economictimes.com/industry/cons-products/electronics/bajaj-electricals-fully-acquires-jv-firm-
starlite-lighting/articleshow/82344940.cms
• https://www.airoshotblast.net/main-product/19-Shot-Blasting-Machine
• https://www.fiixsoftware.com/maintenance-strategies/preventative-maintenance/
• https://www.emaint.com/what-is-preventive-maintenance/
• https://home.akitabox.com/blog/preventive-maintenance-101/