sonagroup

Moving Towards Zero Breakdown

2/26/2013 Sona Okegawa Precision Forgings Ltd. 1

Ratanmani Kukreti

ContentsContents

Company Profile Group Structure Outline Of Company Products Customers Process Chain Of Precision Parts Approach Towards Zero Breakdown Step to achieve Zero Failure Case Study - 1 (Electrical Break Down) Case Study 2 (Mechanical Break Down) Results


Group Structure :

SONA GroupSONA Group

SONA AUTOCOMP USA

SONA AUTOCOMP USA

SONA KOYOSTEERINGSYSTEMSLTD.

SONA KOYOSTEERINGSYSTEMSLTD.

MAHINDRASONA LTD.

MAHINDRASONA LTD.

SONA OKEGAWAPRECISION

FORGING LTD.

SONA OKEGAWAPRECISION

FORGING LTD.

SONAeDESIGN &

TECH.

SONAeDESIGN &

TECH.

AUTO COMPONENTS AUTO COMPONENTS SERVICESERVICE

LEGALLEGAL

ITIT

Dr. Surinder KapurDr. Surinder Kapur

FINANCEFINANCE

GROUP SHARED SERVICESGROUP SHARED SERVICES

CONTROLLERCONTROLLER

FUJI AUTOTECH

EUROPE

FUJI AUTOTECH

EUROPE

GLOBAL

CORP. AFFAIRSCORP. AFFAIRS

SONA MOBILITY

SERVICES LTD (SIXT)

SONA MOBILITY

SERVICES LTD (SIXT)

MOBILITY

SONA AUTOCOMP EUROPE

SONA AUTOCOMP EUROPE

SONA STAMPINGSSONA STAMPINGS

FAFFAF

FABFAB

FKCFKC

FAABFAAB

SONA BLW PRECISION FORGING

EUROPE & USA

SONA BLW PRECISION FORGING

EUROPE & USA

JSAIJSAI

SFALSFAL

KOYO SONA ELECTRONICS LTD.

KOYO SONA ELECTRONICS LTD.

SOPL, PuneSOPL, Pune


Laurels

Brief History Sona Group is currently the largest manufacturer of steering systems and forged parts for passenger cars and

utility vehicle market in India. The group turnover is over `40 Billion ($ 810 Mn) with number of employees

over 3800. Sona group is diversified in auto components & services. It has 17 manufacturing plants with 4

companies overseas..

The Beginning Technology Tie-Ups

Extending Partnership

Growth for Domain Leadership

Global Footprint

Technical Agreement with Koyo for Manual Steering Gear and Column

Sona Steering enters a JV agreement with Maruti Udyog Ltd.

Sona Steering Systems Ltd. commences production

Sona Steering Systems Ltd., a JV with Maruti, lists through an IPO

Incorporation of Sona Somic Lemforder Components Ltd.

Incorporation of Mahindra Sona Ltd.

Mahindra Sona acquired the MSL Division of M & M

Technical Collaboration with Koyo for Power Steering Gear

Joint Venture company formed with MMTLSona Okegawa Precision forgings Ltd.

Incorporation of Sona e-Design

Koyo increases stake in Sona Koyo to 20.5%Sona Cold Forgings commences

productions

Sona Okegawa commences

production of bevel gears for domestic market & exports

Sona Koyo Steering Systems Ltd. receives Deming Prize

Acquire 21% stake in Fuji Autotech France S.A.S.

Merger of Sona Somic Lemforder and Sona Cold Forging Ltd.

20102005200019951990

New JVs

JTEKT-Sona Automotive India Ltd.

Sona Fuji Kiko Automotive Ltd.

Sona Okegawa,Pune started commencing Production

Acquisition Sona BLW

Prazisionsschmiede GmbH formed

Awards

Sona Okegawa Gurgaon Plant Received TPM Excellence Award

Certifications

Sona Okegawa Certified for IMS (QMS,EMS & OHSAS)

1985


Sona is a Company with a Global Footprint

Sona AutoComp USASouth Carolina, USA

100% Subsidiary of Sona Group

Sona BLW Precision ForgeNorth Carolina, USA


Fuji Autotech Brazil

Sona Group India16 Plants

Sona BLW Przisionsschmiede 3 Plants in Germany


Fuji Koyo Czech (FKC)

Sona AutoComp EuropeMontbeliard, France


Fuji Autotech EuropeMandeure, France

Sona 17%


Sona Group - Overview

The Sona Group it one of Indias leading companies

Turnover 11/12: > ` 40 billion ( $ 810 Million)Employees 11/12: > Over 3800

The Sona Group has a strong portfolio of established businesses that includes manufacturing and IT.

Manufacturing INFORMATION TECHNOLOGYMOBILITYSERVICES

SONA E-DESIGN AND

TECHNOLOGIESSIXT RENT A CAR

SONA KOYO STEERING SYSTEMS

MAHINDRA SONA

SONA OKEGAWAPRECISION FORGINGS

Steering and Driveline Systems

Propeller Shafts, Axle & Clutches Forgings,Differentials

2/26/2013 6Sona Okegawa Precision Forgings Ltd.

Company ProfileCompany Profile


Plant Layout

Hall 1

Hall 2


MilestonesMilestones

JV Company Promoted by Sona Koyo in Collaboration with MMC, Japan1995

20th Nov. Commercial Production & Exports to Japan Started1998

Synchronizer Ring Production Started2002

ISO / TS 16949 Certified in Nov.2003

ISO 14001:1996/EN ISO 14001in Feb2004

Commercial Production Started at Pune Plant2005

New Agreement Signed with MMTL2006

2007TPM Kickoff & Diff. Case Assembly started.

200830th Jan Acquisition of Sona BLW

TPM Re-Kickoff in Jan20092009

2011TPM Excellence in Dec 2011

OHSAS 18001Sep122012


Products


Steering column

Rear axle

Steering Gear Assy

Propeller shaftClutch diaphragm

Seat Recliner

Bevel Gear

Product Range

Speed Gear

Differential Assembly

2/26/2013 Sona Okegawa Precision Forgings Ltd.

11

Main ProductsMain Products

Over 250 Parts


Fiat India

(SKSSL)

Mahindra &

Mahindra

Maruti Suzuki

Spicer India Ltd.

Suzuki

Powertrain

Tata Motors

Ltd. (SKSSL)

Passenger

car & SUV

Albion

Automotive

American Axle

Automotive

Axle

Axle India

Axle Tech

Diamler India

Force Motors

HV Axle

Spicer India

Tata Motors

Volvo Eicher

Commercial

Vehicles

Carraro India

Escorts Tractors

International

Tractors Ltd.

John Deere

Mahindra &

Mahindra

Mahindra Swaraj

New Holland India

TAFE

TMTL (Eicher)

Tractor

Dana India

Grazziano

Lombardini

Mahindra &

Mahindra

Mahindra Swaraj

New Holland

india

TAFE

TMTL (Eicher)

Off Highway

Equipments

Case New

Holland (USA)

John Deere

(Iberica)

Tirth Agro

Farm

EquipmentConstruction

Equipments

JCB

Key ProductsPrecision Forged (net shaped) Bevel Gears, Differential Case Assemblies and

Synchronizer Rings for Automotive and Other applications.

Customers


Process Chain of Precision PartsProcess Chain of Precision Parts

Precision Hot Forging on Conventional press lines 300 t bis 1250 t

Cold Coining of the functional surface with hydraulic press lines700 t

Die Manufacturing

Machining on full automatic cutting lines

Broaching of precision forged parts

Heat Treatment exactly matching to product requirements

Flexible packaging according to customersrequirements

Continuous quality from tooling to finished part

Automotive World

Design


FacilitiesFacilitiesForging Capabilities

Friction Driven (800 Ton)

Servomotor Driven (1250 Ton)

Forging Press Type Age Qty.

Capability

L Wt.

1250 TonServomotor

Driven (Simplex)

2 Yrs 1 200 mm 300 mm 10 Kg

800 Ton Friction Driven (Duplex) 14 yrs 2 180 mm 220 mm 6.5 Kg

400 Ton Friction Driven (Duplex) 14 yrs 2 115 mm 75 mm 2 Kg

400 TonServomotor

Driven (Simplex)

5 yrs & 8 yrs 2 90 mm 70 mm 1 Kg

400 TonServomotor

Driven (Simplex)

1 yrs 1 90 mm 70 mm 1 Kg

300 TonServomotor

Driven (Simplex)

5 yrs 1 65 mm 30 mm 0.6 Kg


Facilities Machining Capabilities

Machine Make Age Qty.

Automated CNC Turning Centre Mazak 1yr 6 Nos.

CNC Turning Center Takisawa, Mazak, Ace, LMW 1 Yr. to 14 yrs 35 Nos.

Vertical Turning Lathe Takishawa 1yr 3 No.

Angular Head Grinder Micromatic 7 months to 12 yrs 3 Nos.

Drilling & Tapping Center AMS, Fanuc 1Yr to 4 yrs 3 Nos.

Broaching Taiga, Cranebell 6 yrs to 14 yrs 2 Nos.

Centerless Grinder HMT 1 Yr 1 No.

Honing Nagel 14 yrs 1 No.

Hobbing Cooper 22 yrs 2 Nos.

CNC Gear Hobbing Mitsubishi 1 yr 1No.

SPM (Case Line) Tasa 10 yrs 4 Nos.Shaving Kanzaki 1 yr 1 No.


Facilities Heat Treatment

Case CarburizingCase Carburizing

Carbo NitridingCarbo Nitriding

HardeningHardening

Machine Make Age Capacity Qty.

Sealed Quench Furnace Line

Oriental Engg. Japan

5 yrs 1000 Kg 3 Nos.



IPSEN India 1 yrs 1200 Kg 4 Nos.

Nitriding Furnace IPSEN India 1 Yrs 600 Kg 1 No.


Processes:Processes:

Facilities: Design & Development Software

UnigraphicsUnigraphics--NX7NX7Solid Edge V20Solid Edge V20 DeformDeform--Form SimulationForm Simulation

ANSYSANSYS Frenco Spline SoftwareFrenco Spline SoftwareHYPERMILLHYPERMILL


Pyrometer For Billet Temp.

Forging

Pressure Gauge For Coining Press

Coining

Dial & Gauges For Inspection

Soft Machining

Air Gauges & Dial For Inspection

Hard Machining

100 % Gauging Inspection

Process Confirmation

100 % Visual Inspection

Visual Inspection

Quality Assurance - Process Validation

Load & Pressure Gauge For Forging Press

Sequential Pokayoke

Diff. Case Assembly


Quality Assurance- Metrology & Metallurgical Lab

Gear Accuracy TesterBearing Contact Tester CMM

Metallurgical Microscope Micro Vickers Hardness Tester


Respect for the Individual

Service to the Customer

Excellence in the pursuit of our Goals

MOTTO

Think!

Create a Company That India is Proud of

To Make Sona A Partner Of Choice to Global Customers

MISSION

An organization of energized and involved employees.

Growing and achieving high profitability.

Supplying to major global OEMs directly or indirectly.

At least 50% of sales overseas,

Be #1 in every business line

VISION

Sona Vision 2020


Inter-relation of Companys overall Policies


Planned Maintenance Organisational Structure :


Relation Between TPM Policy And PM Pillar:

Planned Maintenance PillarTPM Policy

To enhance the operational

efficiency and equipments by

achieving Zero breakdowns and

Zero defects

Data collection of all the break

down, break down matrix, why-why

analysis and implementing PM,CBM

and TBM activities

Optimization of process and

resources

Optimization of process and resources by

eliminating minor stoppage and re-storing

optimal condition

Create Visual Factory Expose losses and problems

Trained ,Skilled and Motivated

employees for the first time right job

Motivations by autonomous maintenance

and Implementing MP Kaizen

To achieve a safe and green factory

through Zero accidents and Zero

Pollutions

By eliminating un-safe conditions, arresting

air, oil and water leakage and conservation

of natural resources


Methodology to achieve Zero Methodology to achieve Zero Break DownBreak Down


Zero Breakdown Approach

Problem Discussion with J-H

Problem Analysis with J-H

Root Cause Analysis

Countermeasures

Implementation of

Countermeasures

Horizontal Deployment

Problem Discussion with PM team

Problem Analysis with Electrical &

Mechanical Engineers

Root Cause Analysis

Countermeasures

Raise MP Sheet / Update Standards

Implementation of Countermeasures

Problem Analysis


Problem Discussion with DM

team

DO FMEA

Release DCN(Design Change

Note)

Monitor for 3 Months

Implementation of Design

Changes

Raise MP Sheet / Update

Standards


NO

IF OK

NO

IF OK

OPERATION (Operator error, Fatigue,

Equipment & personnel safety)

ENHANCING RELIABILITY (Accelerated Deterioration,

Restoration & Improvement of Equipment Condition)

ENHANCING DESIGN (

Uncontrolled Stresses &

Insufficient Stress)


Step Wise Activity for Zero Break Down

Step ActivityActivityActivityActivity

Step-1 Maintaining Basic Condition

Step-2 Restoring or Preventing Deterioration

Step-3 Maintaining Operating Standards

Step-4 Time Based Maintenance

Step-5 Predictive Maintenance (CBM)


Activity :

Step 1 Maintaining Basic Condition

Jishu- Hozen Keikaku Keikaku Keikaku Keikaku ---- HozenHozenHozenHozen

Initial Cleaning Analysis of Present Status


Step 2 Restoring Or Preventing Deterioration


Counter Measure Against SOC & HTARestoration and Improvement of the Deteriorated

Equipment


Step 3 Maintaining Operating Standards


Draft Tentative Cleaning, Oiling & Inspection Standards Tentative Standard Maintenance Procedure


Step 4 Time Based Maintenance

Keikaku Keikaku Keikaku Keikaku ---- HozenHozenHozenHozen

Time Based Maintenance

Methodology Example


Step 5 Predictive Maintenance (Cbm)

Keikaku Keikaku Keikaku Keikaku ---- HozenHozenHozenHozen

Predictive Maintenance (CBM)

Methodology Example


CASE STUDY


Equipment

Induction Heater Forging Press Slow Cooling Conveyor


Failure Analysis :- Analysis by Branch wise

Stratification of Mechanical & Electrical Failure ( Nos./Branch) 400 Ton press


Failure Analysis :- Analysis by Equipment Wise (Electrical)

Total 17 Phenomenon


Design Change Kaizen (Electricals)

Case Study- No. 11. Problem Description:- Convertor Failure Occurrence in Induction Heater Resulting in Tripping

Equipment Under Study- 250 KW Induction Heater

Induction Coil

Pusher

Induction Heater

Capacitor Bank

Billet Loader


Design Change Kaizen (Electricals)

Case Study- No. 12. Kaizen Theme:- To Eliminate Induction Heater Failure

S.NO. PhenomenonF08 F09 F10 F11 F12

F13 (Till 10 Jul' 2012)

Break Down Frequency

1 Induction Heater Trip 53 14 59 16 20 42 Converter Failure 17 6 21 10 6 53 LMD Wheel Not Working 14 3 10 3 0 04 Temp Problem 4 1 3 3 44 105 Starting Failure 1 1 1 1 1 7

6 Bus Bar Clamping Problem 0 3 12 3 1 07 Over Frequency Alarm 0 0 0 2 0 0

3. Data Collection:- Phenomenon wise Break Down Data for 250 Kw induction


Case Study- No. 1

4. Root Cause AnalysisProblem:- Induction Heater Tripping

Why Phenomenon Answer Action

Why -1 Converter Failure

Dc Voltage Is Not Converted In To Ac Single Phase

Check Inverter Section

Why-2

Dc Voltage Is Not Converted In To AC Single Phase

Inverter Circuit does Not perform

Check Protection Circuit

Why-3 Inverter Circuit does not perform Thyrister Blow off

Replace Thyrister

Why-4 Thyristor Blow off Not Known

Problem:- Induction Heater Tripping Why Phenomenon Answer Action

Why -1 Converter Failure Reset Induction Heater

Problem:- Induction Heater Tripping Why Phenomenon Answer Action

Why -1 Converter Failure

Dc Voltage Is Not Converted In To Ac Single Phase

Check Inverter Section

Why-2

Dc Voltage Is Not Converted In To Ac Single Phase Thyrister Failure

Replace Thyrister

Why-3 Thyrister Failure Insufficient Cooling Provide More Cooling

Why-4 Insufficient Cooling

Water Pressure (1kg/Cm2) & Flow (11 Lpm) Is Less At Heat Exchanger Inlet

Increase Water Pr. & Flow

Why-5

Water Pressure (1kg/Cm2) & Flow (11 Lpm) Is Less At Heat Exchanger Inlet Pump Efficiency Is Low

Increase Pump Efficiency

Problem:- Temperature Variation

Why Phenomenon Answer Action

Why -1 Billet Temperature Drops

Stop Induction Heater and reset

Every Individual part of the induction Heater was

replaced with New part including PCB cards, But

Problem could not be solved


Case Study- No. 1

What Next When No Root

Cause is found ?Why- Induction Heater Not Working ?Why- Convertor Failure Caption Illuminate ?

Why- Over Voltage, Over Frequency & Starting Failure LED "Glow " inspite of all the parameter within range ?Why- Temperature drop in Billet when 41 & above Diameter is heated ?

Cross Functional TeamName Dept.

Mr. Vipin ManufacturerMr. Vivek ManufacturerMr. Jaideep Project DesignMr. Amit Sharma Project DesignMr. Mukesh MaintenanceMr. Harcharan MaintenanceMr. Multan Maintenance

4. Brain Storming


Case Study- No. 1

12 PCB cards are attached to one Mother board

with interlocking to each other

5. Design Change for Electrical & Electronic Circuit


Case Study- No. 1

6. OutcomeOne Single Card was developed 7. Result For Induction Heater


Case Study No.- 2


Case Study- No. 2

1. Problem Description:- Interruption Due to Die Lubricant Equipment Under Study- Die Lubricant System

Die Lubrication Tank Diaphragm Valve with solenoid coil

Tank PumpStirrer Diaphragm Valve with solenoid

coil


Design Change Kaizen (Mechanical)

Case Study- No. 22. Kaizen Theme:- To Eliminate Die Lube Breakdown Phenomenon

S.NO. PhenomenonF08 F09 F10 F11 F12

Break Down Frequency

1 DIE LUB NOT WORKING 81 39 81 80 108

2 INDUCTION HEATER TRIP 53 14 59 16 20

3 MIDDLE CONVEYOR NOT WORKING 34 9 0 0 0

4 PRESS NOT WORKING UP & DOWN 27 10 30 26 16

5 PRESS LOAD PROBLEM 0 16 13 6 9

6 COIL LEAKAGE / WATER PIPE LEAKAGE 26 24 0 0 0

7 CONVERTER FAILURE 17 6 21 10 6

8 EJECTOR PIN NOT WORKING 16 14 0 0 0

9 LMD WHEEL NOT WORKING 14 3 10 3 0

10 FOOT SWITCH NOT WORKING 11 2 6 0 5

3. Data Collection:- Phenomenon wise Break Down Data for 400Ton Forging Press


Case Study- No. 24. Root Cause AnalysisPROBLEM:- INTERRUPTION DUE TO DIE LUBE FLOWING

CONTINUE FROM VALVEWHY PHENOMENON ANSWER ACTION

WHY -1

DIE LUBE FLOWING CONTINUOSLY FROM NOZZLE

DIE LUBE VALVE REMAIN OPEN CLOSE DIE LUBE VALVE

WHY-2

DIE LUBE VALVE REMAIN OPEN

VALVE DIAPHRAGM RAISED FROM ITS SEATING

ALLOW DIAPHRAGM TO SETTLE PROPERLY

WHY-3


DIE LUBE SEDIMENTS ACCUMULATE IN DIAPHRAGM SEAT

CLEAN DIAPHRAGM OF VALVE

WHY-4


SHARP BEND IN DIE LUBE TRANSFER PIPE LINE

ELIMINATE SHARP BENDS

WHY-5

SHARP BEND IN DIE LUBE TRANSFER PIPE LINE

DIE LUBE TANK TOO FAR FROM THE PRESS

BRING TANK NEAR TO THE PRESS

PROBLEM:- MTTR IS HIGH

WHY PHENOMENON ANSWER ACTION

WHY -1 MTTR IS HIGH FAULT DIAGNOSYS IS TIME CONSUMINGMAKE FAULT DIAGNOSYS EASY

WHY-2 FAULT DIAGNOSIS IS TIME CONSUMING

FIVE TIMERS , CONTACTORS AND RELAYS ARE INTER CONNECTED WITH TOO MANY WIRES

REDUCE THE WIRE

WHY-3

FIVE TIMERS , CONTACTORS AND RELAYS ARE INTER CONNECTED WITH TOO MANY WIRES

ELECTRICAL CIRCUIT IS MADE WITH RELAY LOGIC

CONVERT RELAY LOGIC TO PROGRAMME LOGIC

PROBLEM:- INTERRUPTION DUE TO DIE LUBE NOT FLOWING FROM VALVE

WHY PHENOMENON ANSWER ACTIONWHY -1

DIE LUBE STOPS FLOWING FROM NOZZLE

DIE LUBE VALVE DOES NOT OPEN

OPEN DIE LUBE VALVE

WHY-2

DIE LUBE VALVE DOES NOT OPEN VALVE OUTLET GETS CLOGGED

REMOVE CLOGGING

WHY-3

VALVE OUTLET ORIFICE GETS CLOGGED

DIE LUBE SEDIMENTS ACCUMULATE AT THE OUTLET ORIFICE OF VALVE CLEAN VALVE

WHY-4

DIE LUBE SEDIMENTS ACCUMULATE AT THE OUTLET ORIFICE OF VALVE ORIFICE SIZE IN ONLY 1MM

INCREASE ORIFICE SIZE

WHY-5 ORIFICE SIZE IN 1MM STANDARD DESIGN CHANGE DESIGN

PROBLEM:- INTERRUPTION DUE TO DIE LUBE FLOWING CONTINUE FROM VALVE


WHY -1

DIE LUBE FLOWING CONTINUOSLY FROM NOZZLE DIE LUBE VALVE REMAIN OPEN

CLOSE DIE LUBE VALVE

WHY-2




WHY-3




WHY-4


PILOT PRESSURE ORIFICE IS CLOGGED

CLEAN PILOT RESSURE ORIFICE

WHY-5

DIE LUBE SEDIMENTS ACCUMULATE IN PILOT ORIFICE ORIFICE SIZE IN ONLY 1MM


WHY-6 ORIFICE SIZE IS 1MM STANDARD DESIGN CHANGE DESIGN


Case Study- No. 24. Design Change for Die lube Pump and Valve


PROBLEM:- INTERRUPTION DUE TO DIE LUBE FLOWING CONTINUE FROM VALVE


WHY -1

DIE LUBE FLOWING CONTINUOSLY FROM NOZZLE


CLOSE DIE LUBE VALVE

WHY-2DIE LUBE VALVE REMAIN OPEN



WHY-3




WHY-4


PILOT PRESSURE ORIFICE IS CLOGGED

CLEAN PILOT RESSURE ORIFICE

WHY-5

DIE LUBE SEDIMENTS ACCUMULATE IN PILOT ORIFICE

ORIFICE SIZE IN ONLY 1MM


WHY-6ORIFICE SIZE IS 1MM STANDARD DESIGN

CHANGE DESIGN

06 DIAPHRAGM VALVES ARE USED

FOR SPRAYING DIE LUBE

1 MM ORIFICE

Case Study- No. 25. Design Change for Die lube Pump and Valve


02 Rotary Actuator with

less bends Introduced

Case Study- No. 2

4. Design Change for Die lube Pump and Valve


Kaizens done to eliminate Breakdown Phenomenon


Result for Die Lubrication Problem


Phenomenon

Reason

YEAR

81 39 82 80 108 50 0 52

Counter Measures2

F08 F09 F10 F11 F12F13

(NOV 12)

Dec-12 Jan-13

DIE LUB NOT

WORKING

Die Lub. Valve Choke 38 28 38 30 32 6 0 0 Diaphragm Valve Replaced with Rotary Actuator

Timer Setting Disturb 7 3 2 2 0 0 0 0 Relay Logic with timer Changed to PLC with MMI

Die Lub .Pump Problem 13 0 9 12 23 12 0 0 Pump Removed & Gravity Feeding Started From a height of 6 Mtr.

Relay Loose / Faulty 5 3 0 1 1 0 0 0 Relay Logic Changed to PLC Air Setting Disturb 2 0 0 0 0 0 0 0 JH Step 3Die Lub Pipe / Line Choke 7 0 6 2 23 19 0 0 No. of Bends Reduced & SS pipe

introduced

Die Lub Sensor / Cable Problem 9 0 2 0 1 1 0 0 Relay Logic Changed to PLC Die Lub Stand Broken 0 1 0 0 0 0 0 0 JH Step 3Die Lub Fitting Wear / Broken 0 4 3 0 4 4 0 0 No. of Bends Reduced Die Lub Valve Coil Faulty / Loose 0 0 6 6 2 0 0 0

Diaphragm Valve Replaced with Rotary

Actuator

Die Lub Filter Choke 0 0 13 23 19 0 0 0 Filtering element Removed & Stirer system Design Improved

MCB Trip / Supply Missing 0 0 1 0 0 0 0 1

Air Pressure Disturb 0 0 1 0 1 2 0 0 JH step 4 & 5 implementationWire Loose / Short 0 0 0 4 2 2 0 0 JH step 4 & 5 implementationDie Lub Cylinder Mounting Loose / Jam 0 0 0 0 0 2 0 1 JH step 4 & 5 implementationDie Lub Tank Empty 0 0 1 0 0 0 0 0 JH Step 3

81 39 82 80 108 48 0 2

Distribution of Kaizen to achieve Zero Break Down


Counter Measure :- %age Contribution of Activities


Background :


Distribution of Kaizen to achieve Zero Break Down

Zero Break Down Machine

Category Criteria for Zero B/D No of Machine

Platinum Zero B/D for last > 10 to 12 Month (

Thank You


sonagroup

Documents

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incorporation of mahindra

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