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HISTORY OF ESCORTSThe genesis of escorts goes back to 1944 when two brothers, Mr. H.P nanda and Mr. yudi nanda, launches small house, escorts agent ltd. In Lahore. over the year, escorts has surged ahead and evolved Into one of indias largest conglomerates. In this journey of six decades, escorts has had the privileged of being associated with some of the world leaders in the engineering manufacturing space like Minneapolies Moline, massey Fergusn ,goetze, mahle , URSUS, CEKOP, FORD Moter company, J C bamford Excavators, Yamaha, class, carro, Lucky, goldstar, firest pacific company, hughes communications, jeumont Schneider , Schneider, dynapac. These treasures, which have helped us inculcate best in class manufacturing practices and to emerge as a technologically independent world class engineering organization. 1944 - launch of Escorts (Agents) Ltd. 1948 pioneered farm mechanization in the country by launching Escorts agricultural machines ltd. With a franchise from the U.S based Minneapolis Moline, for marketing tractors, implements, engine & other farm equipment . launch of Escorts (agriculture and machines) Ltd. 1949 franchise of massy Ferguson tractors for northern india. 1951 Escorts established indias firest private institute of farm Mechanisation at delhi. 1953 Escorts (Agent) Ltd. And escorts (Agriculture and machines) Ltd. Merged to form Escorts Agent Pvt. Ltd. 1954 1st industrial venture of Escorts to manufacture piston ring in collaboration with goetze of Germany, in an Era when joint venture of Indian firms with foreign companies were virtually unheard of. 1958 started importing Massey Ferrguson Tractors from Yugoslavia for marketing the same in india. 1959 collaboration with Mahle of Germony to manufacturing Pistons. Soon , Escorts became the largest producer of piston assembly in india. 1960 set up the Escorts Ltd. 1961 setting up of the manufacturing base at faridabaad for manufacture of tractors in collaboration with URSUS of Poland and 50% indigenous components, launch of Escorta

brand of tractors. collaboration with CEKOP of Poland for manufacture of motorcycle and scooters. Escorts moves into high gear by nurturing the two wheeler culture, The firest Rajdoot motorcycle rolls off the assembly line. 1969 Escorts Tractors Limited was born . a technical and financial joint venture with the global gaint ford motors company, USA , to manu facture ford tractors in india. Escorts institute of Farm mechanization (EIFM) established at banglore. Escorts Employees Ancillaries Ltd. (EEAL), a unique venture in industrial democresy comes into being. 1971 1st February, the first tractor ford 3000 rolled out of the factory. 1974 crossing national boundaries, Escorts experts for the firest time . After winning a global tender, 400 tractors were exported to Afghanistah, which was perhaps the worlds largest ever airlift of tractors. 1976 FORD 3600, an advancement in farm mechanization launched. Trial production of inplant manufacturing of engine parts. 1977 Escorts enters the world of self-developed technology by setting up its first independent R&d center. Escorts scientific Research marked its beginning at faridabaad by developing its own engines for E-27 and E-37. Due to constant technology absorption, indigenization level touched 72% for FORD tractors. 2nd Plant at banglore for manufacturing piston assemblies was set up. 1979 collaboration with JCB Excavators Ltd.,UK for manufacturing piston was set up. 1980 foray into healthcare, Escorts hospital and research center set up in faridabaad. 1983 Escorts tractors ltd established a state of the art research and development center of spearhead newer breakthroughs in farm mechanization and to maintain industry leadership . line concept introduces for engine block machining. 11000 ton floating dry dock Escorts launched. 1984 JV Escorts- Yamaha to manufacture motorcycles. Signing of agreement with the Japanese bike giant Yamaha to manufacture motorcycles with Yamaha technology. Collaboration with jeumont Schneider of france to manufacture EPABX systems collaboration with dynapac to Sweden to manufacture vibratory road compactors. 1985 Escorts tractors Limited offered its first bonus issue.

1988 Escorts heart institute and research centre a world class cardiac care facility launched in new delhi. 1989 joint venture with class of Germany to manufacture harvest combines. 1990-91-firest public issue in February 1991, over-subscribed four times . shares listed on delhi and Bombay stock exchanges. 1996- disengagement of joint venture collaboration with new Holland and launch of FARMTRAC Tractor. 1997- joint venture with carraro of Italy for manufacturing and marketing of transmission and axles. 1998-POWER TRAC series of tractor of tractors launched. Mou was signed with long manufacturing company , USA for setting up a point venture in USA. 2004- divested escorts heart institute and research centre to fortis Healthcare. 2006 divested in carraro india Ltd.

HISTORY OF ECELindias At escorts construction equipment limited, we have defined the evolution of construction equipment industry over the past 36 years. When necessary, even entered into partnerships with global technological leaders. In 1971, we introduce pick n carry Hydraulic cranes mobile cranes. We continue to be the worlds no. 1 manufacturer of this product.

We successfully pioneered the concept of backhoe loaders in late 70s.

The world class range of vibratory compactors that we first introduced in the late 80s is today reputed to provide the most effective compaction solution to the industry. Our innovation continuedExcavators, amongst the worlds most advanced, that revolutionized earth moving technology in india in the 90s. Forklift trucks that are today the preferred choice of the quality conscious users. In the new millennium, we presented a contemporary range of equipment-articulated boom crane, tower crane, and crawler crane & power & telecom utility material from the world leaders. We defined customer support by setting up the first pan india dealership network which has now strengthened to 80 plus strategic covering length & breadth of the country.

BRANDS & PRODUCTSMATERIAL HANDLING EQUIPMENTSy y y y y y y y y y Pick and carry cranes Slew cranes Crawlers cranes Truck cranes Articulated boom cranes Tower cranes Forklifts trucks Arial wok platforms Telehandlers Front end loader

ROAD CONSTRUCTION EQUIPMENTSy y Tandem vibratory roller Vibratory soil compactors

UTILITY EQUIPMENTSy Electric/telecommunications

PROJECT ASSEMBLYPICK & CARRY CRANESThe whole assembly of cranes is categorized into five sub-assemblies and final assembly. During each subassembly and final assembly, parts related to subsequent assemblies are fitted and eventually inspection is done. The five main sub-assemblies are:1. 2. 3. 4. 5. Engine block end sub-assembly Boom sub-assembly Cab base sub-assembly Hydraulic/ fuel tank sub-assembly Bonnet sub-assembly

Engine back end sub assembly in this sub-assembly engine and transmission system called back end are fitted together. main component used in this sub-assembly which are fitted to engine and backend are as follows:y Propeller shaft - it is fitted to engine y Diesel hoses three diesel hoses & pressure hoses are attached to engine assembly y Filter bracket- firstly filer bracket is attached to the engine and its requisite place and then mounting of dual filter bracket is taken place. y Fan- A line is attached from air compressor to engine to supply air. y Clutch- pressure plate with clutch plate is fitted to engine; a yellow mark is given to nut used to tighten the clutch to ensure that it is ok from engine sub-assembly department. y Gear oil- gear oil filled to the backend at proper level checked by oil rings. y Engine oil-all the nuts are tightened or checked for tightened to ensure proper fitting and prevent quality hazards. y Front support-engine oil is filled to the engine level checked by oil rings. y Hydraulic pump-next step to join the engine assembly to backend, the spline shaft of the backend which is projected forward meets its mating surface inside the clutch, now by the help of bolts they are fasten together y Hydraulic pipe support- this front support is attached to engine assembly y Section pipe- it is attached to the hydraulic pump. y Reverse gear switch- it is switch attached to backend assembly in engine and backend assembly. y Grease for greasing of brake cam shaft and drop shaft-greasing of cam shaft on two points and drop shaft on three points is done. y Pressure hoses y Dual filter

y

After this sub-assembly visual inspection is done . main points of the visual inspection are:y Inspection of engine oil y Inspection of hydraulic oil y Fitment of hoses y Fitment of transmission y Fitment of clutch and measure plate y Fitment of propeller shaft with flange y Fitment of dual oil filter y Fitment of front support y Fitment of hydraulic pump y H/L rod fitment y Reverse gear switch y Sensor fitment y Fitment of fuel hoses

CABIN SUB-ASSEMBLYIn this sub-assembly engine distributer , hoses , pedal , brakes , are connected to the cabin. Main component used in this sub-assembly which are as follows:y Dashboard y Distributer y Levers y Meter box y Brake pedal y Hoses y Elbow y T-adapter y Dashboard handle y Accelerator

DASHBOARD y Fuse box y Water temperature gauge y Ampere meter y Hrs/rpm meter y Toggle switch indicator y Toggle switch spot light y Hazard switch y Main switch cum parking y Head lamp switch

y y y y

Horn Indicator light Air pressure gauge Engine oil pressure gauge

-: PROCEDURE OF CABIN BASE SUB-ASSEMBLY :y y y y y y T-adapter and elbow attached to the outside of the cabin. Distributer and lever are connected to the cabin. Hoses are connected with elbow, t-adapter and distributer. Levers are joined with the distributer. Dashboard is prepared separately and fitted to the cabin. A meter box and the accelerator and brake pedal is attached to the cabin.

After the sub-assembly, the visual inspection of cabin assembly is done. Main points of the visual inspection are as follow:y Fitment of break and pedal y Fitment of distributor and levers y Hi/low lever fitment y Connection of hoses y Fitment of clutch pedal y Dashboard assembly and mounting y Fitment of dashboard handle

HYDRULIC/FUEL TANK SUB-ASSEMBLYIn this sub-assembly hydraulic tank and fuel tank are fasten together with the pipes and cleaners which flows is requisite place. Main component used in this sub-assembly which are cabin as follows:y Air breathe y Reverse oil filter y Diesel cap y Strainer y Fuel level pipe y Drain bolt y Fuel tank cap y Fuel cock y Hydraulic tank cover with gasket

PROCEDURE OF HYDRULIC/FUEL TANK SUB-ASSEMBLYy y y y y y Strainer is fitted inside the hydraulic tank to collect the impurities in the oil since it is reused. Air breathe is attached to the hydraulic Fuel tank with proper positioning of the gasket which is made of the rubber rubber to ensure proper tightening. Diesel cap is attached to the diesel tank for the chance to fill the diesel from this hole. Drain bolt are fitted , one to hydraulic tank & other to the diesel tank. These bolt are very important as they grasp the impurity of the oil by attracting it. Fuel pipe are attached, one to hydraulic tank and other to diesel tank to check the oil levels in the tank from the outside A projected part from the hydraulic tank is fitted with pipe so that connection between engine & tank takes place.

After the sub-assembly the visual inspection of the hydraulic tank/fuel sub assembly is done main points of the visual inspection are:y Coupling of hydraulic tank & fuel tank. y Strainer fitment. y H-tank cover with gasket & tightening of the bolt. y Hydraulic pipe y Fitment of the air breather y Fitment of the return line filter y Fitment of drain bolts y Fuel cock y Fuel tank cap

BOOM SUB-ASSEMBLYThis is sub-assembly of the boom of the H-12 slotted machine. All the cranes manufactured have different boom so there assembly & equipment is different rest from the others. Main component used in this sub-assembly which are cabin as follows:y Extensions y Winch y Mother boom y Grease y Nylon pads y Extension pulley y Mother boom pulley y Stings y Tie rods y Circles y Piston jack

y y y y y y y y y

Wire rope Over hoist brackets Over hoist limit switch Anchor plate Brake booster Brake shoe Counter brake valve Rollers Greece adapter

Procedure of boom sub-assemblyy y y y y y y y y y y y Nylon pads are attached to the first extension to ensure that no contect between mother boom & first ext. Piston jack is fitted to 1st extension with a pin at its position. Winch motor is fitted at slant provided on the mother boom A pulley is fixed to 1st extension to its matching surface Thick layer of grease is polished on the nylon pads & ropes are wrapped over pulley 2nd extension is covered by 1st extension from all sides area covered by 2nd extension is still of the projected piston inside the 1st extension. Locking of extensions pulley should be done properly Two pulley are inserted at the side of assembly, where the jack is projected outside, slots are provided to insert the pulley. Two more pulley are inserted at the space between 1st & 2nd extension at location other side from previous to fix the pulley by 48mm stud Now this assembly is covered by the mother boom bring in that the other hole is coaxial with two hole provided on the mother boom Locking between the mother boom & 1st & 2nd assembly by a pin provides proper tightening with circlips. Ropes are tightened with the help of the slings & tie rods. After the sub-assembly and visual inspection of the boom sub-assembly is done. Main points of visual inspection are:y y y y y y y y Fit extension tubes Insert jack in extension Insert above assy in mother boom Fit winch assy Fit winch motor assy Fit C.B valve Fit pully and spacers Fit side locating pads

y y y

Fix wire ropes on winch Winch oil level Extension upper and lower pad

Bonnet sub-assemblyIn bonnet sub-assembly air cleaner is fitted with its clamp proper tightening is provided by the rubber clips. Hoses & pipes are fitted to regulate the air supply. Visual inspection done to ensure the proper fitting of the parts.

Final assemblyAfter the five sub-assemblies it is turn to join them. In the final assembly with the chassis, cradle, yoe, a-frame above line sub-assembly are mounted & final machine is made.

Main component used in this final assembly y y y y y y y y y y y y y y y y y y y y y yA-frame Main frame Cradle Yoke Chassis Lift jack FM3-preesure relief valve Steering steel tubes Unloaded valve Slave cylinder Counter weight Parking assembly Brake assembly Bundy tubes Radiator Hub T-handle Snatch block Pin locking bolt Bumper Benzo U-clamp

y y y yy y

Filled tubes Servo & master cylinders Goose neck assembly Fan stay rod Hook & shackle arrangement Steering cylinder

Procedure of final assemblyy y y y y y y y y y A-frame chassis are joined together with the help of EOT & supports. Yoke, cradle & main frame are attached to above assembly with stud. Filled tubes , FM3 valve slave cylinder is fitted to chassis. Dressing of the goose neck is done. Is Engine is fitted to the assembly & the connection is made to the radiator to the fan stay rod & bonnet since they are attached after engine. Mounting of the goose neck is made. Mounting of the steering cylinder ensuring proper tightening. Hub fitment with the front braking arrangement which is simply externally expanding brake is done. Mounting of counter weight for proper balance of the machine during running conditions. Now place the cabin on above assembly such that oil rings should meet its matching surface which is a hole & some bolts are projected from cabin must insert in their corresponding mating holes. Connection of steering , winch , lift ,extension is made with the help of hoses & filled tube. Parking arrangement is done with the help of roller with an arrangement of up/and down motion and parking lever. Seats are fitted on the adjacent to parking lever on its corresponding positions. Knobs are attached to all levers. Battery connection are made one goes to starting motor at engine for self & at the cabin for the earth.

y y y y y

Main y y y y y y y

points of visual inspections after assembly :Goose neck dress up Mounting of chassis on cradle Mounting of the A-frame on the cradle Mounting of the steering steel tubes , 4 hoses & FM3 Fix cradle grease pipe & grease nipple Insertion of bundy tubes & clamping at A-frames Fitment of the steering cylinder & connections.

y y y y y y y y y y y y

Mounting of the TRUMPET housing Mounting of the fuel tank assy Servo and master cylinder fitment mounting of the goose neck & rear brake assy mounting of the counter weight, cabin base & lift jacks fitment of hub & anchor plates fitment of the front tyres and handle connections of all hoses fitment of the snatch block pneumatic brake system bonnet fitment fitment of hooks

Testing procedureAfter the final assembly the next step is testing , various tests and checks are performed to check machines performance test can be categorized as :y road test y functional test y performance test y load test y leakage and looseness test

Road testThis test is performed during running conditions to check the transmission system of the machine the following are checked during road test:y check the smooth gear shifting y no unwanted noise y check for clutch function y check for service brake and parking brakes effectiveness y wheel wobbling

functional testthis test is performed to check the all functional of the machine is working well during running conditions. The motion of each function is test from min. to max. limit & accordingly timings are observed, these observations should lie in permissible range. The following points are checked during functional test:y lift operation y steering clock/anti clock wise y extension y hoist up and down

Performance testUnder this test the engines performance is to be tested. After the starting of the machine, it is kept for warming up for min. & then this is performed . any leakage , crack , damage , shortage is determined by this test. y The following points are checked during performance test are:y idle & max rpm y engine oil pressure when warmed up y starting & stopping y engine smoke y rpm droppage y any abnormal noise

Load testUnder this test the capacity of the machine of carrying load is tested under varying conditions. Three tests performed to check the load capacity of the machine are as follows:y 13 ton load test : this is performed to check the strength of boom at the static motion of the machine. After this test machine is to checked for bending of the boom & its alignment with extension. y 8 ton load test : this test is to check the performance during dynamic conditions. After this test machine should be tested for any leakage , damage , shortage. y 5 ton load test : this test is performed to checkthe winch assy during running condition.

Leakage & looseness testAfter performing above 4 tests & before it is machine is checked for level of various fuel leakage , loosenessvv of the bolts & alignment of the several parts . the check points of this test :y Oil and water level y Machine should be thoroughly kept & cleaned & dried y Clutch free play adjustment y Hydraulic leakage y Brake circuit leakage y T-handle alignment y No ratting y Main frame pivot bush 7 yoke gap y Welding checks y Electrical functions Cabin-window locking , door lock, glass fitment, rpm etc

Quality auditQuality audit is the process of automatic examination of a quality system carried out by an internal or external auditor or an audit team , it is important part of the organizations quality management system & is a key element in the ISO quality system standard , ISO 9001

Quality audits are typically performed at predefined time intervals institution has clearly defined internal quality monitoring procedures action . this can help determine if the organization companies with system process & can involve procedural or results based assessment

& ensure that the linked to effective the defined quality criteria

With the upgrade of the ISO 9000 series of standards from the 1994 to 2000 series , the focus of the audits has shifted from purely procedural adherence towards measurement of the of a actual effectiveness of the quality management system (QMS) & the result that have been achieved through the implementation QMS. Quality audits can be an integral part of compliance or regulatory requirements. The principle of quality audit , in the sense we mean it here , are based on the style of quality standards used in several format national & international standards as ISO900 international quality standard. These standard do not in themselves create quality. The logic is as follows:Every organization should define comprehensive procedure by which their products or service can be delivered consistently to the desired level of quality. As was discussed in the section of quality management , maximum quality is rarely desired objective since it can cost too much & take too long. The average product or services provided a sensible compromises between quality and cost. There is also a legitimate market for products that are low cost & low quality. Standard authorities do not seek to make that business judgment & enforce it open businesses , except where certain min. standard must be met (e.g a;; cars must have seat belts that meet min. safety standard , but there is no attempt to define how elegant or comfortable they are). The principle is that each organization should create through controlled procedure for each of its processes. Those procedure should deliver the quality that is sought. The quality audit , therefore , only need to ensure that procedures have been defined , controlled , communicated and used. Processes will be put in place to deal with corrective actions when deviations occur. This principle can be applied to continuous business processes operations or recurring project work. It would not be normal to establish a set of quality controlled procedures for a one off situation since the emphasis is consistency. This principle may be applied whether or not the organization seeks to establish or maintain an externally recognized quality certification such as ISO-900X. to achieve a certification , the procedures will be subjected to internal & external scrutiny.

Pre dispatch inspectionProcess in the hardware manufacturing world , Is the last process flow before shipping a product. This process is established to ensure the following:y This unit has gone through all the manufacturing or test process. y The unit has passed through all the test process y The unit is in good quality This process not only include visual checking of the unit ( i.e labels has been placed properly , no scratches , oil LED/lights are functional ) but also checks that the correct

firmware & version plus configuration has been loaded properly (it applicable if some unit may not require firmware). It must power up according to specs as well. There are cases where separate out of the box audit (OBA) process is defined , but most of the time this can be combined as well . OBA is just a visual check making sure that the unit has , again , the correct labels plus all the manuals or other parts that needs to ships with it is also inside the box . labels from the unit should also match the ones outside the box. Besides chocking good quality of the unit , this process also must ensure that name of the configuration will be touched. Of course , there are cases where firmware tracks down the last power ON it had & thus leave some info. To the units. Although these changes are sometimes acceptable , good test engineer should always plan along with the firmware developers to put a feature in place to reset this info.

Fabrication of boom : cutting and weldingFabrication of the boom includes cutting of metal plate through metal cutting process like plasma cutting and oxy-acetylene cutting joining of plates in these first point is to place at the proper position and orientation with the help of welding manipulator and box assembly fixture and spots are made in order to join two plates through MIG welding. After that dressing is done by use of portable grinders . now the part is ready for the primer after that NDT is done eventually paint is done. Main process during the fabrication of the boom as follows:y Plate cutting y Box tagging y Fitment of parts y Full welding y Dressing y Primer y NDT testing y Final paint

Engine and transmissionEngines are manufactured by Simpsons. It is a 4-stroke incline diesel engine having the compression system of direct injection type. The bore radius of about 94.44 mm ( normal diameter ) having a stroke of 127 mm. cubic capacity of the engine is 3.33 L , compression ratio is 18.5 , firing order is 1-3-4-2. Fuel injection pump is MICO in line with mechanical governor and flange mounted and pressure feed oil system. It have ptype injector nozzle. The no. of the crankshaft is 2 and there are 4 valve for 4 cylinder engine . it has 12 port ignition system with water cooled system. Air compressor is fitted in the engine. BHP of the engine is 49.5 the lubricating oil is used in the engine to reduce the friction at the bearing surfaces by providing a oil film between them. It keeps temperature of the moving surfaces within the limits. The system of lubrication comprises of the pressure feed to main and big end bearing to 2 camshaft being rocker shaft and auxiliary drive. The pump draws oil from the strainer , from the sump and delivers and it by internal drilling within the crankcase to oil relief

valve cover fitted on the side of the cylinder block , from the oil pressure relief cover , the oil flows through an external pipe to the full fuel lubricating oil filter. Transmission system has four gears, 3 forward and 1 reverse and HI/LOW lever. After including HI/LOW there are total eight gears. The HI/LOW lever is used to increase the engine torque by decreasing its revolution. Inside the gear box sliding gears are used. Single dry clutch plate is used for power transmission. Clutches are made from cork.

Seven steps for seven QC stepsThe 7 QC steps process is a structured problem solving problem solving approach from improving weak processes. This approach is known as reactive improvement. The 7 QC step is easy to understand & learn , easy to use & easy to monitor. The 7 QC steps process is as:Step 1 :- select a theme. In this step , weakness in the process or the problem to be solved is clarified in a theme statement. A flow chart , a theme selection matrix , or a cause & effect diagram used as a tool in this step. Step 2 :- collect and analyze data. This step focuses facts about the problems & discovers what types of problems occurs frequently. When collecting data , you must think of all possible causes. Check sheets & pareto diagrams are the tools most often used. Step 3 :- analyze causes. With sufficient data from step 2 , the root cause , or fundamental cause , is founded by constructing a cause & effect diagram. Step 4 :- plan and implement solution. In this step , you brainstorm for ideas that are causing the problem & develop a solution that prevent the root cause from recurring. Then , you implement an adjustment in the process. The 4Ws & 1H matrix ( what , when , where , who & how matrix ) is used to develop a plan. Step 5 :- evaluate effects. You evaluate the effect of implemented solutions to make sure the solution works & done not have unacceptable results from the comparison of the data , before and after implementation of the solution in the step , comparative pareto charts & graphs are frequently used to identify the results. Step 6 :- standardize solution. A standardized solution is confirmed that the old process is replaced with an improved process & indicates that the solution is workable. Step 7 :- reflects of process & the next problem. In this step, you consider what the teams accomplishment was in the first 6 steps & recommend a weakness to work on next. Seven QC tools are fundamental instruments to improve the quality of the product. They are used to analyze the production process , identify the major problems , control fluctuations of product quality , & provide solution to avoid future defects. Statistical literacy is necessary to effectively use the seven QC tools. These tools use statistical techniques & knowledge to accumulate data & analyze them. Seven QC tools are utilize to organize the collected data in a way that it is easy to understand & analyze. Moreover , from using the seven QC tools , any specific problem in a process are identified.

7 QC tool always include :y y y Check sheets is used to easily collect the data. Decision making & actions are from the data. Pareto chart is used to define problems , to set their priority , to illustrate the problems detected , and determine their frequency in the process. Cause and effect diagram ( fishbone diagram ) is used to figure out any possible causes of a problem. After the major causes are known , we can solve the problem accurately. Histogram shows a bar chart of accumulated data and provides the easiest way to evaluate the distribution of data. Scatter diagram is a graphical tools that plots many points and shows a pattern of correlation between two variables. Flow chart shows the process step by step and can sometimes identify an unnecessary procedure. Control chart provides control limits which are generally three standard deviations above & below avg. whether or not our process is in control.

y y y y

Causes in a typical diagram are normally arranged into categories , the main ones of which :The 6 Ms :- machine , method , materials , maintenance , man & mother The 8 Ps :- price ,promotion , people , processes , places , policies , procedures , products The 4 Ss :- surroundings , supplier , systems , skills

OVERVIEW OF TOTAL PRODUCTIVE MAINTENANCETPM can be explained in elaborated way as total profit management through total perfect manufacturing through total productive maintenance through total people management i.e. overall it can be stated as total proud management. Let us mention the problem faced by companies for which it becomes absolutely necessary to implement these management system such as TPM : External problems y Tough competitions y Globalization y Increase in raw material & energy costs. Internal problem y Law productivity y Customer problems y Non adherence to delivery time y Increase in wages and salaries y Low knowledge & skill level of workers y Losses are high

Definition of TPM (production TPM)What is TPM ? y To set goal to maximize equipment efficiency (overall efficiency) y By establishing a total system for the entire life of equipment. y Participation by all department including equipment planning , operation &maintenance department y Involving all personnel , including top personnel to first operators y For promoting PM by motivation management namely by autonomous small group activities

TPM MEANS y Taking as a prime objective a company structure that pursues production y y y y yefficiency to its ultimate limits ( comprehensive efficiency) Putting together a practical shop-floor system to prevent losses before they occur throughout the entire production systems life cycle Zero accident , zero defects , zero breakdown etc Involving all functions , including production , development and sales & management Having all employee participate from top executives to front workers Achieving zero losses through overlapping small groups

INTANGIBLE EFFECTS OF TPMy y y y After introduction of autonomous maintenance activity , operators take care of machines by themselves without being ordered to With achievement of zero breakdown & zero defects , operators get new confident in their own abilities Workplaces that used to be covered with oil & chips are now as clean and pleasant as to be almost unrecognizable Improved image of the company , leading to the possibilities of increased orders

What TPM aims at ?To restructure the corporate culture through improvement of human resources and plant equipment y Improved human resources : educate & foster employees so that they can respond to the needs of FA 1. Operators : ability to perform jishu hozen ( autonomous maintenance ) 2. Maintenance man : ability to perform high quality maintenance 3. Production engineer : ability to execute maintenance free equipment

y

Improving plant equipment : 1. Attain efficiency through revamping of the existing equipment 2. LCC consider design of new equipment & minimizing their run up time

Basic idea of TPM y y y y y y Making profitable company constitution pursuit of economical efficiency , zero accident , zero defects and zero failures Philosophy of prevention prevent accident from happening Participation by all All plant in process keep the equipment in optimal conditions , visual control , Making a clean workshop Automation , unmanned operation making a workshop that require no manpower

TPM EIGHT PILLER APPROACHa) INDIVIDUAL IMPROVEMENTPURPOSE y Realize zero losses of all types such as failure losses & defects losses y Demonstrate ultimate production efficiency improvement Member : staff , line leader ACTIVITIES y Understanding the 16 major losses y Calculating & setting goals for overall equipment efficiency , productivity & production subsidiary resources y Implementation of PM analysis y Thorough pursuit it equipment & production as it should be b) AOTONOMOUS MAINTENANCE PURPOSE y Training of operators proficient in equipment y Protecting ones own equipment by ones staff Members : operators , line leader Activities: Implementation of seven steps y Initial clean up

y y y y y y

Counter measures for the source of problems & measures for difficult to access location Creation of tentative autonomous maintenance standards General of tentative autonomous maintenance standards General inspection Autonomous inspection Standardization

c) PLANNED MAINTENANCEPURPOSE y Improving efficiency of maintenance department to prevent eight major losses

Member : staff , leader & maintenance men of maintenance department ACTIVITIES y y y y y y Daily maintenance Time based maintenance (TBM) Condition based maintenance (CBM) Control of replacement parts Failure analysis & prevention of recurrence Lubrication control

d) QUALITY MAINTENANCEPURPOSE

y Achieve zero defects by supporting & maintenance equipment conditionMEMBERS y Qualities assurance staff , production engineering staff , line group manager

ACTIVITIES y y Verify qualities characteristics standards ; understand defects phenomena & performance Investigating the conditions for building in qualities , unit process and raw materials , equipments & methods

y y y

Investigating , analyzing & improving the conditions of malfunctions Setting 3M conditions ; setting the standards values for inspection Creation of standard that can be followed ; trend management

e) DEVELOPMENT MANAGEMENTPURPOSE y y y Reducing product development & prototyping time Reducing the development , design & fabrication time of equipment Improving first shot start up stability of products & equipment

Members y Research and development staff , production engineering Staff , maintenance staff

Activities y y y y y y y y Setting development & design goals Ease of production Ease of QA implementation Ease of use Ease of maintenance Reliabilities LCC Design release drawing Production : identify problems in the prototype , trail run & initial phase mass production control stages

f) OFFICE TPMPURPOSE y y y Achieve zero function losses Creation of efficient offices Implementation of service support functions for production department

MEMBERS y Leaders & members of administrative/indirect departments

ACTIVITIES

Autonomous maintenance activitiesy y y y y Initial clean up Work inventory Counter measure for problems Standardization Promotions of autonomous management activities of work

individual improvement through project activities y y y y Shortening of settlement schedule Improvement of distribution Improvement of purchasing & subcontracting Reform of production control system

g) EDUCATION & TRAININGPURPOSE y Establishment of technical education for operational & maintenance workers

MEMBERS : operators , maintenance workers ACTIVITIES y y y y y y y y Basic process maintenance Tightening nuts & bolts Aligning keys Maintenance of conductive parts Maintenance of bearing Prevention of leakage Maintenance of air pressure & oil pressure equipments Maintenance of electrical control equipment

h) SAFETY AND HEALTHPURPOSE y y Achievement & support of zero failures Realization of healthy & invigorating workplace that gives meaning to work

MEMBERS y y Safety , health & environment managers & specialized committee members Staff specializing in safety & health

ACTIVITIES y y y y y y Measures to improve equipment safety Measures to improve work safety Improvement of work environment Measure of prevent pollution Creation of healthy employees Promotion of invigorating activities

TESTING PROCEDURE OF PICK AND CARRY CRANESBefore starting the machine testing follows activities necessary to be done 1. Machine should be thoroughly jet cleaned and dried 2. Ensure greasing done in all parts detailed as below GREASE LOCATION Wheel hub Steering jack pivot pins A-frame pivot pins Main fream & yoke pivot pins Lift jack and pivot pins Cradle pivot pins Boom pivot pins Clutch shaft Clutch release bearing Rear wheel Winch NO. OF PARTS 2 4 1 2 , (H 12) 1 2/4 ,(H 12) 2 1 2 5

All hanger assembly/pulley and snatch block (with bush ) as per machine requirement 3. Ensure all oil levels and water levels detailed below Engine oil maximum dipstick Gear box maximum dipstick Reduction unit level plug Brake reservoir maximum level Water inside radiator up to neck Winch (H 10 & H12 ) level Hydraulic oil maximum level 4. Ensure tired air pressure detailed as below Front tires Rear tires 5. Ensure the y y y y y y

110 psi 35 psi

machine history filled in travel card for the following details Engine and backend assembly Boom sub-assembly Cab case sub-assembly Fuel/hydraulic tank assembly Bonnet sub-assembly Final sub assembly

y

History sheet

6. Ensure no such storage which could obstruct hot testing of the craned 7. Check the following gauge reading detailed below Battery charging Water temperature 80 degree Engine oil pressure 1.5 - 7 kd/cm2 Air pressure 8 kg/cm2 8. Check the following engine rpm with tachometer Idle rpm 625 (+50, -50) Maximum rpm 2420 (+50,-50) Engine oil pressure when engine is warm up (indication in green zone) Check rpm drop ensure at full throttle with any hydraulic service fully loaded , up to 800 , not more then that , also check for any abnormal noise from engine. 9. Ensure hydraulic pressure setting detail as below Control valve (145 bar 5E)180 bar at max rpm 5E , C8 , H8 ,H10 210 bar at max rpm

HOT TESTINGBrake testing 1. Check stopping distance ( in loaded condition ) for brake effectiveness should be 8.558 m should be in on condition 2. Check function (one should run the engine at least for 10 minutes to warm up the engine ) . all lights should be in on condition y Operate the machine for 05 cycle with load as specified on snatch block. One complete cycle means lifting the load i.e luff cylinder fully opened , fully extension of boom and hoist up/down and then all fully closed y Operate the o5 cycle of steering cylinders 3. Check following road testing points y Smooth gear shifting y No abnormal noise

y Check for the clutch function y Check for service brakes & parking brakes effectiveness 4. Check all electrical function y Parking light y Indicator light y Cab/fog light y Number light y Reverse light y Reverse buzzer working y Fan y Battery y Voltage y Fuse rating as per specified y Engine smoke 5. Any abnormal noise from pump , winch and hydraulic cylinders 6. Check for any customer specific requirement (fan , fire external , spark arrester etc ) 7. Check load testing as per annex attached 8. Check following safety systems y Overload warning system adjustment (sound signal) put boom in closed position , put load on winch as specified ; open the extension !/2 , check for buzzer is sounding y Safety brakes on winch (c8) lift the load on snatch block as specified , release the same , winch shouldnt move at its own y Over hoist warning system adjustment ( sound signal ) c8 : check when over hoist plate fouls with jib head buzzer should sound . in other model adjustment should be done through overloaded spring. 9. Boom extension /inclination : plum line to be checked by lowering the snatch block & checking the offset should be within 100mm. y Inner boom should be centered by adjusting the side pads y Greasing to be done properly for sliding all pads in position y Ropes guide/retainer in places 10. Wire rope winding for any fouling 11. Check rope compensation 12. Check the following gaps within specified limits y Yoke & fuel tank gap (min 30 mm) y T-handle alignment (max 20 mm ) y T-handle resting at jack guard ( max 5 mm) y Jack guard alignment (max 15 mm) y Tail counter weight inclination (max 15 mm)

y y y y y y y 13. Check y y y y 14. Check

Exhaust pipe fouling with suction pipe/bonnet Front support & chassis gap ( max 1 min) Hydraulic tank & cab bracket gap with chassis( max 1 mm) L bracket & chassis gap (max 1 mm ) Cradle & A-frame gap 33 mm (+4,-4) Main frame pivot and yoke gap (0.5 mm) Fan belt deflection (max ) the following leakage Hydraulic leakages Fuel line leakages Air circuit leakages Air line : check with soap solution the damages if any

TROUBLE SHOOTINGCAUSES 1. ENGINE DOESNOT TURNy y y Battery weak Starter or starter plug inoperative Engine is locked or seized

REMEDIESrecharge or replace batteries repair or replace affected parts this can be due to extended idle or storage period , in which case the parts may be rusted & seized can be due to rain water entering Uncover exhaust pipes leaking Cylinder heads . the engine should Disassembled to determine the cause And & necessary parts to be Replaced

y

Hydro-static lock

2. Engine does not starty Slow cranking speed specific gravity of battery may be Too low or the starter may not be Delivering its max torque to provide adequate cranking speed, replace the affected part. check fuel system and rectify test and repair or replace nozzle time fuel injection pump

y y

Insufficient supply of fuels Fuel injection nozzle not operating Fuel injection pump timed improperly

3. Engine hard to starty y y y Weak battery Insufficient fuel in fuel tank Incorrect grade of fuel Fuel injection nozzle operating Improperly y Air in fuel system y Insufficient supply of air to Cylinder y Incorrect tappet clearance recharge or replace battery check fuel level & fill the fuel drain fuel system test & repair nozzle correct air leaks clean air system check and adjust tappet clearance

y

Valved wrapped or pitted

recondition/replace valves

4. Engine stops frequentlyy y Idling speed too low Restricted fuel supply adjust low idling speed check fuel system and rectify

5. Engine stops suddenlyy y y y y No fuel in tank Restricted fuel supply Fan belt loose/broken Improper engine lubrication Water pump fail fill fuel tank with high speed diesel check fuel system & rectify adjust/replace check and rectify lubrication system check and repair

6. Engine shows loss of powery y y y y y y Insufficient supply air to cylinder Insufficient supply of fuel to Fuel injection Air in fuel system Improper valve clearance Clogged fuel filter Valve leaking Worn out piston rings & filter clean air system check and rectify system check for air leaks on suction side of Fuel pump & bleed fuel system. check and adjust change filter element replace the affected part replace the affected part

7. Engine emits blue smoke from exhausty Fuel injection nozzle not operating properly test and adjust nozzle

8. Engine not attaining the governed speedy y Throttle linkage detective Poor quality of fuel adjust throttle linkage drain & refill clean hi speed diesel.

9. Excessive fuel consumptiony y y y External and internal leakage Engine overloaded Fuel pump defective Restricted air intake check for leakage & rectify do not overload the engine repair fuel pump clean air cleaner & refill oil

10. Excessively lubricating oil consumptiony y y y External oil leaks Wrong grade of oil used Valve guide worn out Pistons , rings , linear , worn out check leakage & rectify drain oil & refill with proper grade oil replace the valve guide replace affected parts

11. No or low lubricating oil pressurey y y y y y Pressure gauge defective Lub oil pump suction strainer chocked Oil pressure valve defective Lub oil pump defective Insufficient oil the crankcase Oil lines loose/broken inside replace oil pressure gauge clean strainer clean strainer repair/replace the pump fill crankcase to proper level repair or replace affected parts

12. Excessive lubricating oil pressurey y y Pressure gauge defective Pump defective Oil pressure valve sticking check & replace pressure gauge repair/replace pump clean and replace relief valve

13. Clutch operating hard or stickyy y y Clutch not adjusted properly Worn clutch plate Spring tension poor adjust the clutch replace clutch plate replace springs

14. Clutch slippingy y y Clutch out of adjustment Worn clutch plate Spring tension poor adjust clutch replace clutch plate replace springs

15. Gear not engaging/slippingy y y y Clutch not disengaging Interlock jammed Worn gear teeth Fork lock loose adjust the clutch rectify replace gears tighten the lock

16. Unusual sound from geary Worn or broken gear teeth replace worn out parts

y

Incorrect lubricants & level too low Worn or broken gear teeth Incorrect lubricants & level too Low

check level

17. Differential nosilyy y replace worn out parts check level , use recommended oil

18. Differential overheatsy y Bearing adjusted or level too low Excessive wear on gear re-adjusted properly check gears for excessive wearing Scoring replace if necessary replace bearing replace worn out/broken parts replace worn out parts

19. Noise in reduction housingy y y Bearing worn out Gear & pinion teeth worn out/broken Splines on axle/wheel shaft Worn out

20. Vehicle dragging to to either sidey y y Brakes unequally adjusted Worn out lining Tyre pressure unequal adjust brake properly replace lining inflate all tyres to recommended Pressure check and rectify check and rectify

21. Unequal steering turns on two sidesy y Steering geometry distributed Stopper not set properly

22. Steering wrong directiony Incorrect plumbing of steering Unit Cold hydraulic oil check steering line plumbing

23. Hydraulic response poory y y y y y allow hyd. Oil to warm up the slow Engine speed Insufficient engine speed use recommended oil Air leak in suction line check & rectify Pump worn out get pump repaired replaced Oil leaking past o ring check & replace affected parts Clogged breather in hyd. Oil reservoir clean breather

y y

Mechanical linkage joints jammed Checked or partially clogged strainer In oil reservoir

clean and lubricated remove , clean & refit

24. Hydraulic system not respondingy y y y y y Insufficient oil in reservoir Insufficient relief valve pressure Pump badly worn out or damaged Worn distributor valve Broken oil lines Pump shaft , key or propeller shaft sheared add oil get relief valve reset to reqd. Pressure get pump repaired/replaced get distributor valve repaired check for leakage & repair oil lines check & replace affected parts

25. Boom fails to hold upy y y Leaking or broken all lines from Distributor valve to lift cylinders Internal leakage in hit cylinder Past o Rings & seals Internal leakage past distributed spool check for leaks check & replace affected parts get distributor spool repaired

26. Hydraulic oil over heatingy y y y y y y Incorrect relief valve pressure setting Incorrect grade of oil used Insufficient oil in hydraulic reservoir Dirty breather on hydraulic oil reservoirs Suction line restricted Worm pump valve or cylinder Air in the cylinder get relief valve reset to Recommended oil pressure use recommended oil fill tank to proper level clean or replace breather clean suction line/strainer replace affected parts check hydraulic system suction line

27. Oil foamingy y y y Kink or dent in oil lines Worn seal on pump shaft Incorrect grade of oil Oil contaminated in water replace oil lines get pump repaired or replaced use recommended oil drain hydraulic oil & refill oil

28. Noisy hydraulic operationsy Partially clogged suction line y Sludge & dirt in pump y Reservoir breather clogged y Oil viscosity high y Low hydraulic oil level y Engine speed too high 29. Steering response poor on one of the side y Internal leakage in steering jack y Piston rod bends y Blocked hose/pipe lines y Flow cum pressure relief Valve defective remove & clean suction line get pump cleaned thoroughly remove breather cap, flush it use recommended oil add hydraulic oil to proper level always maintain speed check & repair replace jeck clean/replace rectify/replace the assembly