maintenance improvement 15-16

Maintenance : Improvements list for 15-16

Amber Pune Unit

Process owner : Amrit Raj Jaiswal & Team

Best Practice : Water cooling arrangement for Bending & TPP

Result Details Issue Details

Process

Provision for heat exchangers with

cooling tower arrangement for

Armstrong bending m/c & TPP m/c.

M/c tripping problem due to heating reduced to zero.

Oil cooling proper now

M/c tripping due to heat up

O-ring damage problem.

Bending & TPP

Initial Status Breakthrough Idea Initial Status

Leadership Through Innovation

NOT EXIST EARLIER

Best Practice : R.O plant re-conditioning


Process

Cover boxes provided for all motors Painting activity done

Safety Improvement & 2’s Improvement

Poor 5 ‘S’ & no equipment safety

during rainy & dust

R.O Plant



Best Practice : Re-conditioning of main fire hydrant


Process

Cover boxes provided for all motors Painting activity done

Safety Improvement & 2’s Im-provement

Poor 5 ‘S’ & no equipment safety

during rainy & dust

Main fire hydrant



Best Practice : Press brake Safety improvement


Process

Hand operated switch with

protected cover

Safety Improvement Unsafe working condition due to

Foot operated switch , major cause

of accident

Press brake operating



Best Practice : Cost saving by In-house installation of new ITW Gama gun


Process

Proposed cost - Rs. 74000

(quote) Actual In-house cost - Rs. 24000

CI - Rs. 50000 New gun Installation cost higher

Auto Gun booth



Before After

74 K

24 K

67 %

Installation cost In Rs.

CI Benefit: Rs. 50 k CI Approved By :

Accounts GM (O) Plant Head

Best Practice : Installation of New compressor with capacity enhancement


Process

New compressor installation In-

house with added capacity

Capacity enhancement Lesser capacity of compressor with

added business volumes

Compressor



NOT EXIST EARLIER

Best Practice : Rack provision for PU sheet storage ( Trolley cover)


Process

Rack designed & mfg. , stored near

trolley rectification area

5 ‘S’ improvement Plastic corrugated sheets keeping

on floor, poor 5 ‘S’

PU Sheet Storege



Best Practice : VM on Motor for lubrication & rotation point.


Process

VM done by using vinyl sticker on

motors & m/c

VM improvement No identification mark for motor

rotation & lubrication point

Motor preventive measures



Best Practice : Cutter m/c mobile trolley with safety


Process

Mobile trolley in-house made for

operator’s safety & mobility

Safety improvement Unsafe working condition for

operator’ during pipe cutting

Fabrication work



Best Practice : Re-conditioning of dispatch ramp hyd. powerpack


Process

Dispatch Ramp motor cover to

avoid water entry during rainy

season & dust prevention & 2’s

Safety improvement & 2’s No motor safety provision for hyd.

Motor power pack , also poor 2

‘S’

Dispatch Ramp



Best Practice : Material rack provision & VM For fabrication material


Process

New material rack made

in-house with VM sticker on

the rack

VM & 2’s improvement No proper identification & space

for

fabrication material , poor 5 ‘S’

Fabrication area



NOT EXIST EARLIER

Best Practice : Transformer area re-conditioning


Process

Cleanliness & painting activity with

VM display

Utility



NOT EXIST EARLIER

Safety & 5 ‘S’ improvement Unsafe working condition & poor 5

‘S’ at transformer area

Best Practice : CI in localization in purchase of Vibration motor


Process

More efficient vibration motor

purchasing Local vendor developed for

vibration motor

CI – By Rs. 92 K

Supplier localization leads to easy for spare mgt.

Powder Choking Problem due to

vibration motor life ends

Imported motor ( ITW Gama) cost

too high

Powder recovery unit



Before After

80 %

Purchase cost In Rs.

1.04 L

0.12 L



Best Practice : Installation of a new Desiccant dryer for capacity enhancement


Process

New desiccant dryer installation

with double capacity Dew point with in (-40 )

Dry Air capacity increase Quality improvement

Lesser capacity of dry air in paint

shop dept.

Continuous quality issues related

to higher dew point ,reqd. (-40)

actual (-30)

Powder coating utility



Before After

Dry Air capacity

90 cfm

200cfm

Best Practice : Air set up time reduction during power cut


Process

Installed an accumulator in series

with input of a desiccant dryer for air

storage

During power cut air change over time reduced

During power cut , air pressure

lower due to no air accumulation ,

loss of air

Powder coating utility



Before After

Air change over time

10 min

ZeroNOT

EXIST EARLIER

Best Practice : Welding line re-layout with Jogging track creation


Process

All water , Air & Electrical lines

installed from roof side , line re-layout

done

Safety & VM improvement Jogging track creation from

wall side

Welding area water line /air line &

cabling not as per industrial norms ,

All line are on floor , unsafe

Weld shop layout



Best Practice : Fabrication Shed re-conditioning


Process

Re-conditioning done by wall

painting, providing display board &

switch covers

5’S & VM improvement Poor 5’S in fabrication shed

Fabrication shed



Best Practice : Dispatch ramp Elect panel safety improvement


Process

Emergency s/w provided Switch board re-conditioning

Safety improvement Elect switches in broken condition ,

unsafe

Dispatch ramp working panel



Best Practice : Re-conditioning of shop floor fans


Process

Fan guards cleanliness and

powder coating

Equipment efficiency improved Shop floor wall-mounted fans

condition poor , dust , color fade

Shop floor Infra



Best Practice : Transfer Pipes standardization – Color coding


Process

Pipe line color coding as per

Industry standardization

VM & safety improvement

As per Std. coding : Air – Blue Water – Green Gas – Yellow Fire – Red

All transfer pipelines no

standardization / identification for

water, air & gas pipes

Shop floor Infra



Best Practice : LT cable duct Fabricated covers provision


Process

Duct covering with fabricated

structure

Safety & VM improvement LT cable duct in open condition ,

unsafe

LT cable routing at outside area



Best Practice : PCO & WDO ducts Re-conditioning


Process

Internal duct and Damper broken

and worn out need to be repaired

Productivity & Quality im-provement

Improper temperature variation

observed at PCO & WDO due to duct

open & damper broken

Paint shop Area



Best Practice : Paint shop motors autonomous maintenance


Process

Complete overhauling with

varnish ,bearing check ,fan check &

coloring

Autonomous Maintenance Motor Preventive Maint. Not as

per TPM std.

Motor PM



Best Practice : Elect wiring /cables dressing in tray


Process

All open cable routed by providing

cable tray

Elect cables in paint shop are in

open condition , Unsafe working

Paint shop Infra



Safety/ VM improvement

Best Practice : Removal of excess cables & proper dressing


Process

All excess cable removed and

proper dressing done

Unwanted open cables in paint

shop area causes unsafe working

Paint shop Infra



VM Improvement

Best Practice : Safety guard on blower shaft


Process

Safety cover provided for safe

operation

Unsafe working condition at PT

line blower

Paint shop Infra



Safety improvement

Best Practice : Water level indication for low/high level


Process

Installation of Level indicator panel

to sense water level & avoid water

wastage

No level indicator t for identification

of low/high level of water in the tank

Paint shop Infra



VM improvement

Best Practice : Cable dressing at Conference hall


Process

All excess cable removed properly

dressed & covered

Unwanted open cables in

Conference room

Conference room



Safety & Equipment Efficiency

TPM PT line – Cleaning with meaning

v v vv

v v

Best Practice : Repairing of Solar street light


Process

Repairing activity carried out & 6

nos. of lights repaired

Solar street light not in working

condition

Plant



Energy efficiency

Before After

Power cost redn.



09 K

Best Practice : Closed area for DM & ETP line


Process

Fabricated shed installation , which

protect instruments

ETP line is open condition , no

infra safety

Paint shop Infra



Basic infrastructure safety

Best Practice : Re-conditioning of STP


Process

Re-conditioning with added

capacity of STP plant

Capacity less as per current

requirement , STP water not 100 %

usages

General Infra



Basic infrastructure improvement

Capacity added by 30 %

Best Practice : Elect power conservation activity


Process

Removal of all CFL cubes by LED

cubes of 30 W /Pc.

High power consumption of typical

CFL cubes (72W/Pc.)

Office Area



Energy efficiency – Total 15 no. of

cubes changed.

Before After

Power cost reduction34 K

CI Benefit: Avg. Rs. 34 k /Year CI Approved By :




Process


cubes of 30 W /Pc. Total 15 no. of cubes changed.


CFL cubes (72W/Pc.)

Office Area



Energy efficiency

Before After

Cost Saving

Before After

LUX level

32 K

600

1000





Process


cubes of 30 W /Pc.– Total 15 no. of cubes changed.


CFL cubes (72W/Pc.)

Office Area



Energy efficiency

Before After

Cost Saving

LUX level

32 K



Before After

600

1000

Best Practice : Maint office renovation


Process

Removal of Red Tag componentsRe-conditioning

Maint dept poor 5 ‘S’

Office Area



Basic infrastructure improvement

Best Practice : TPM activity board


Process

Design & display board on shop

floor

No TPM monitoring board display

at shop floor

Shop floor



TPM activity

NOT EXIST EARLIER

Best Practice : Greece & Oil storage room provision


Process

New location at Compressor room, No storage area for Grease & Oil

storage

Maint stores



Basic infrastructure.

NOT EXIST EARLIER

Best Practice : All utility equipment board display board


Process

Design of board & implementation Utility board display not available

Office Area



FI 05 activity

VM improvement

NOT EXIST EARLIER

Best Practice : Facility provision for Nano coating booth


Design & in-house fabrication

activity

No provision for fumes extraction

in Nano coating area

Operator unsafe activity



Cost saving by In-house red tag

material using

Operator safety ensured

NOT EXIST EARLIER

Best Practice : Design of Enclosure in PC panel


Design of enclosure &

implementation with Air conditioner

workingReduction in maint time

All wiring & panels are in open

condition, unsafe activity

Dust & temp. affects on panel

working, higher down time



Equipment safety

Lower maint B/down time

Best Practice : Facility provision at ETP plant


In-house fabricated ladder

installation with safe working in

inspection at ETP plant

No ladder in ETP plant, unsafe to

operator while working



Equipment Efficiency

Safety Improvement

NOT EXIST EARLIER

Best Practice : Re-design in sheet feeding process

Extra roller provided to hold the sheet

Issue Improvement Result

Extra Roller provided which hold the

sheet during feeding

In perforation Mc higher rejection due

to folding of sheet in working


Mc down time reduction due to

wrong sheet feeding

Before After

90

Avg. Mc BD time in min/day

100 %

Zero

Best Practice : Safety activity at HT area

Entrance gate reconditioning


Repairing of gate with in-house facility HT area unsafe due to entrance gate

not working

Safety Improvement


Best Practice : 110 T hydra. press BD time reduction


Re-design entire system with new

hardware locally available

Continuous BD of mc due to relay

design not suites in mass production ,

also spares not locally available

Old system replaced with New hardware system


BD time reduction

Before After

18

Avg. Mc BD hrs/month

100 %

Zero

Best Practice : Energy conservation in press shop

Replacement of MHSV lamp by LED for power cost saving


Power cost per Year

[Unit : INR ]

Installation of LED lights to replace the

conventional 250W MHSV lamp , replacing

08 nos. MHSV lamp to 4 nos. of LED lamps

with LUX level as per std.

Before After

49920

8986

LUX Level [Unit : Lumen ]

Before After

210 300

Higher power cost with low LUX level


70 %

35 %

Best Practices : Exhaust system design at Nano coating line

Issue Improvement

Result

Design of exhaust system as per process

std. & safety measures

No provision of exhaust Chimney in

Nano coating line , unsafe to operator


Safety improvement

NOT EXIST EARLIER

Design of Exhaust system with safety measures

Best Practices : Energy conservation at Street light working


Timer fitted which automatically OFF the

street light s & avoid power misusages

Street light getting ON during day if

person forgotten to OFF


Power saving

Design of Exhaust system with safety measures

Best Practices : Water wastages reduction


Hand spray pump installation to avoid

water spillage

During water dispensing , spillage &

wastages


Water wastage reduction

Hand spray pump for drinking water dispensing

Best Practices : Dummy designing with cost reduction


In-house Fabrication ,Designing & hardware

implementation of dummy

Designing & Preparation of in-house dummy


Cost Saving – INR 200000

In-house modification of Dummy for ODU checking

NOT EXIST EARLIER

Section : Maint. Month : Apr ’16

Before After

Rs 250000

Rs 50000

Best Practices : Quality Enhancement Activity


Condenser checking station with automatic

buzzer system

Designing of N2 purging station 28 Bar

pressure


Quality improvement

Implementation of N2 purging station

NOT EXIST EARLIER


Best Practices : Safety Activity in Scrap yard


Extra fire point tap provided in scrap area for

safety purpose as it has EPS material

Installation of fire point tap in scrap yard


Safety Improvement

New tap point installed for fire hydrant system

NOT EXIST EARLIER


Best Practices : Testing facility installed at Assy. line


FG line insulation, leakage ,earth & high voltage

test setup implemented

Basic testing infrastructure not available


Quality Improvement

Testing machine implementation

NOT EXIST EARLIER


Best Practices : Productivity Improvement at FG line


Operation Sequence changed in PLC

programming

1 ODU unit stoppage issue hampering productivity

so logic changed

2 Rectification - New logic implemented with

push button to provide stoppage.

Ideal time more at LQC stage

1. Machine not stopping at dummy transfer

area.

2. To stop kit operator has to press

emergency


Productivity Improvement

Operation sequence Changed in PLC programming at LQC stage

NOT EXIST EARLIER

Section : Maint. Month : May ’16

Best Practices : Efficiency Improvement at Press shop


Grading implementation to improve machine

health

1. All tools designed and arranged to carry out

grading of m/c

M/C grading system not available


Efficiency Improvement

M/c grading system implementation

NOT EXIST EARLIER

Section : Maint. Month : May ’16

Best Practices : Cost/machine eff. improvement


Designed spare seal through local vendor Continuous oil leakages at Armstrong

bending m/c

1. valve leakage seal not available - china

make


Cost/Machine Eff. Improvement

Oil leakages removal

NOT EXIST EARLIER Before After

Rs 10000

Rs 200

98 %

Section : Maint. Month : June ’16

Best Practices : Machine eff. Improvement at Press shop


All Press m/c main motor housing & play check

carried out

Motor in contenious run since 5 years


Machine Eff. Improved

1. No. of motor checked – 22 Nos.

2. Major Problem observed – 5 M/c

All main Motor internal housing check

NOT EXIST EARLIER


Before After

Rs 100000

Rs 20000

CI achieved

Best Practices : Safety improvement at LPG Gas Yard


Sensor &alarm based system implemented to

detect leakages in gas yard

No facility to detect LPG leakages


Safety improvement

Sensor & alarm system to detect LPG leakages

NOT EXIST EARLIER


Best Practices : Safety improvement at shop floor


Sensor based fire line system done in whole

plant to deal with fire situations

No facility to detect and to rectify fire

situation


Safety improvement

Automatic fire detection and prevention system

NOT EXIST EARLIER


Best Practices : Infrastructure improvement at Weighing Scale


Reconditioning of weighing done

1. Height increased with slope arrangement

both side

2. Calibration done with installation of

transparent window

Weighing scale issues

1. Contentious water penetration

2. Scale calibration & height expansion


Safety improvement

Weighing Scale reconditioning

NOT EXIST EARLIER


Best Practices : TPM activity in press shop


TPM implementation

1. All press m/c main motor overhauling carried

out to make it production ready for new season

All press main motor Pro-active

maintenance carried out


TPM activity

Press motor overhauling

NOT EXIST EARLIER


TPM Activity – Press Shop

v v

v v

Best Practices : M/c Equipment improvement at dispatch


Oil leakage elimination, m/c overhauling

1. Dock leveler bush & pin worn out , designed

new one with manual greasing option

2. New seal developed for hydraulic cylinder to

eliminate leakages

3. Overall overhauling done

Hydraulic dock leveler Safety issue and

continuous leakages


Equipment improvement & cost saving

M/c overhauling & Safety improvement

NOT EXIST EARLIER

Section : Maint. Month : July ’16

TPM Activity – Dock leveler

v v

v v

Best Practices : M/c Equipment improvement at Armstrong


Gear movement not precise

1. New angular gear designed in place of

conventional straight gear ie Feeder roller

mechanism changed to angular type gear

profile

Length variation issue


Equipment improvement

M/c Efficiency improved by change in design

Section : Maint. Month : July ’16

Best Practices : Basic safety & infra improvement


In-house ladder designed & installed

1. Proper ladder designed to carry out man &

material

No provision to work on shed safely

1. Ladder not available to reach on

shed

2. No proper arrangement to transport

material upside


Safety improvement

Overhead ladder to shed provided

NOT EXIST EARLIER

Section : Maint. Month : Aug ’16

maintenance improvement 15-16

Documents