Tpm implementation oee increment
- 1. TEAM MEMBERS: 1. R.SAI PRABHU RAJ (111412114089) 2. S.SEDHU (111412114096) 3. S.VINOTH (111412114112) INTERNAL EXTERNAL PROJECT GUIDE: PROJECT GUIDE: Dr. S.MAHADEVAN G.SENTHIL KUMAR Senior Professor Section Manager Mechanical Department Caterpillar India Pvt. Ltd.
- 2. ABSTRACT Now a days there is a large competition among companies. Companies are trying their best to provide the products in a innovative, exciting, cost effective way in the present globalize and competitive market Maintenance department and people responsible for maintenance has the greatest Influence on the company assets. Without the support of the Quality and Maintenance it is not possible to meet the requirements of manufacturing plants and customers. Without effectively maintained equipment; it will not be possible to deliver the products in the competitive market that requires low cost products at a high quality. The TPM implementation methodology is suggested for improvement in the availability, performance efficiency and the quality rate, results in improvement of the overall equipment effectiveness of the equipment. The aim of this project is to suggest and study the implementation of the TPM program in Caterpillar India Pvt. Ltd. Located in Thiruvallur.
- 3. BRIEF ABOUT CASE COMPANY Caterpillar Inc., is an American corporation which designs, manufactures, markets and sells machinery, engines, financial products and insurance to customers Caterpillar is the world's leading manufacturer of construction and mining equipment, diesel and natural gas engines, industrial gas turbines and diesel-electric locomotives. Caterpillar India Pvt Ltd., MATERIAL HANDLING AND UNDERGROUND EQUIPMENT DIVISION (MH&U) plant is located in Mellanathur, Thiruvallur District, and Tamil Nadu. It currently employs more than 1000 employees and produces Wheel Loaders, Backhoe Loaders, and Quarry and Mining Trucks (OHT). In the CPIL, Thiruvallur plant, there are totally 12 bays are present. The bays include Warehouse, Assembly line, Tool room, hex bay, axle bay, fabrication bay, materials bay and along with two paint shops(loader paint shop and new paint shop).
- 5. S.no parameters 1. Welding type Metal Inert Gas Arc welding 2. Electrode Copper wire of gauge diameter =1.2 mm 3. Flux coated Gauge diameter =1.6 mm 4. Shielding gas Argon (90%) Carbondioxide (10%) 5. Robot axes 8 6. coolant Water SPECIFICATIONS:
- 6. TOTAL PRODUCTIVE MAINTENANCE Total Productive Maintenance (TPM) is a system of maintaining and improving the integrity of production and quality systems through the machines, equipment, processes, and employees that add business value to an organization. TPM focuses on keeping all equipment in top working condition to avoid breakdowns and delays in manufacturing processes. GOALS OF TPM: Enhance the volume of the production employee morale job satisfaction. In order for TPM to be effective, the full support of the total workforce is required.
- 7. OVERALL EQUIPMENT EFFECTIVENESS The main objective of TPM is to increase the Overall Equipment Effectiveness of plant equipment. .
- 10. ROOT CAUSE & CORRECTIVE ACTION (RCCA) 1.1 Problem Description : Oil leak observed in isolation transformer. Before: After: Machine Name & Type : Main frame robot Isolation transformer Corrective Action : Isolation Transformer oil leak arrested and visibility checked. Why ? Gauge area thread loosened. How ? Teflon added and thread tightness corrected. Future Sustenance ? During PM isolation transformed condition will be checked. PM point added.
- 11. 1.2. Problem Description : Coil drum emptiness cannot be identified during auto welding. Before: After: Machine Name & Type : Coil Drum. Corrective Action : A new sensor has been provided to find whether coil drum coil end has been reached or not. If reached alarm will be triggered. Why ? Coil drum emptiness cannot be identified during auto welding. How ? Sensor has been provided to find whether coil drum coil end has been reached or not.
- 12. 1.3. Problem Description : Panel cooler filter cleaning status has not been displayed. Before: After: Machine Name & Type : Main Frame robot UPS Corrective Action : Now a check sheet has been provided for filter cleaning. Why ? Panel cooler filter check sheet has not been provided. How ? New check sheet has displayed. Future Sustenance ? Check sheet activity will be carried out weekly.
- 13. Before 5S –Manframe Robot Layout: COLUMN MANUAL WELDING POWER SOURCE MASTER ROBOT W A Y G U I D E MASTER FRONIUS POWER SOURCE CHILLER UNIT MANUAL WELDING POWER SOURCE DUST COLLECTOR SLAVE FRONIUS POWER SOURCE COLUMN COLUMN COLUMN BALL PAC WIRE FEEDER (3,4,5,6) TAIL STOCK SLAVE ROBOT MASTER ROBOT BALL PAC WIRE FEEDER (1,2) ROBOT CONTROL PANEL WS-2 MAIN FRAME ROBOT 1 ELECTRICAL CONTROL PANEL TAIL STOCK SLAVE ROBOT G U I D E W A Y HEAD STOCK DUST COLLECTOR ROBOT CONTROL PANEL WS-1 SLAVE FRONIUS POWER SOURCE CHILLER UNIT HEAD STOCK MASTER FRONIUS POWER SOURCE COLUMN SAFETY LIGHT CURTAIN SAFETY LIGHT CURTAIN WAY IN/OUT WAY IN/OUT
- 14. After 5S Mainframe Robot layout: COLUMN MANUAL WELDING POWER SOURCE MASTER ROBOT W A Y G U I D E MASTER FRONIUS POWER SOURCE CHILLER UNIT MANUAL WELDING POWER SOURCE DUST COLLECTOR SLAVE FRONIUS POWER SOURCE COLUMN COLUMN COLUMN TOOLS CUPBOARD SCISSOR LIFT STEP LADDER TEACH PENDENT BALL PAC WIRE FEEDER (3,4,5,6) TAIL STOCK SLAVE ROBOT MASTER ROBOT BALL PAC WIRE FEEDER (1,2) ROBOT CONTROL PANEL WS-2 MAIN FRAME ROBOT 1 ELECTRICAL CONTROL PANEL TAIL STOCK SLAVE ROBOT TEACH PENDENT G U I D E W A Y HEAD STOCK DUST COLLECTOR ROBOT CONTROL PANEL WS-1 SLAVE FRONIUS POWER SOURCE CHILLER UNIT TOOLS CUPBOARD HEAD STOCK MASTER FRONIUS POWER SOURCE COLUMN SAFETY LIGHT CURTAIN SAFETY LIGHT CURTAIN WAY IN/OUT WAY IN/OUT
- 15. Sl.no Check points Impact matrics Inspectio nMethod Interval Machine status image 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 1 Check the TCP (tool centre point) by using the reference program (Alt FN+Z). Daily ON 2 Check the robot reference for Master & SLAVE by selecting the robot reference program and Ensure the robot reference is less than 1 mm for properweldforTwinandsingle torch once in2 frames ON 3 Check camera reference of master & slave by selecting the camera reference check program.Ensure the camera reference is less than 1mm forproperweld. once in2 frames ON 4 Check the condition of the gas nozzle.Nozzle should be free from damage,spatter and dust free.Ensure that contact tip is place centredof the gas nozzle Daily ON 5 Dailytorchservice:Checkandexchange the contacttipifwornout. Daily ON 6 Measure shieldinggas flowrate atthe weldingtorchgas nozzle Daily ON 7 Checkthe functionofeachemergencystopbutton andthe external safety devices(safetydoor,lightbarrier) Daily ON 8 Make sure,that all control cabinet doors are properly closed and the coolingfans/airconditionare working. Daily ON 9 Checkthe shildinggas manifoldpressure between4to5bar. Daily 10 Before switching off the robot system, move the robot system to parking position. Daily ON 11 Cleanthe exchangable protection glass of the laser camera with a cotton swabs and isopropyl alcohol or glass cleaner when the laser camera is switchedoff Daily ON 12 Make sure thatthe chillerunitwaterlevelbetweenminandmaxlimitand sure waterflowis greeninthe outputindicator Daily ON 13 Ensure the Teach pendant coil is twist free.If twist found ,remove and restore. Daily ON 14 Check the antispatter oil level at the back sink of 1st axis of the robotin masterandslave. Daily operatorsignature DateoftheMonth>> DailycheckpointsMFR-1------------------/2016 Operator performed maintanance (OPM) check sheet of igm robot welding systems
- 16. OEE CALCULATION
- 17. Overall Equipment Effectiveness (OEE) Overall Equipment Effectiveness = Availability x Performance x Quality Yield Availability = time available for production - downtime time available for production Performance = ideal cycle time x number of parts produced operating time Quality Yield = total number of parts produced - defect number total number of parts produced
- 18. S.NO DOWNTIME LOSSES TIME (minutes) 1. Setup loss 22:48 2. Breakdown loss 18:17 3. Startup loss 8:42 4. Tool change 7:38 5. Inspection 6:57 Total 63.02 ITEM DATA Shift Length 8 hours 30 minutes (510 minutes) Break (2) 10 minute and (1) 30 minute Down Time 63 minutes 02 seconds Standard time for welding of model:777 frame 4 hours 30 minutes. Before TPM-Downtime losses Availability data for shift-1
- 19. 1. Planned Production Time (Total Time): Formula: Total time = Shift Length − Break = 510 minutes − 50 minutes = 460 minutes 2. Run Time: Formula: Available time - losses = 460 minutes − 63 minute 02 seconds =396 minutes 58 sec. 3. Availability: Formula: Run Time / Total Time = 396 minutes 58 sec / 460 minutes = 0.8621 (86.21%) 4. Performance: Formula: (Standard Time× Total Count) / Run Time = (460 minutes × 0.65) / (396 min 58 sec) = 0.7539 (75.39%) 5. Quality: Formula: Good Count / Total Count = 2 (777 frame) / 2 (777 frame) = 1.00 (100%) Here Quality is 100% 6. OEE: Formula: Availability × Performance × Quality = 0.8621 × 0.7539 × 1.00= 0.6499~ (65%)
- 20. Availability data for shift-1 After TPM-Downtime losses S.NO DOWNTIME LOSSES TIME (minutes) 1. Setup loss 16:07 2. Breakdown loss 10:22 3. Startup loss 7:29 4. Tool change 6:41 5. Inspection 5:16 Total 45:15 ITEM DATA Shift Length 8 hours 30 minutes (510 minutes) Break (2) 10 minute and (1) 30 minute Down Time 53 minutes 02 seconds Standard time for welding of 777 frame 4 hours 30 minutes.
- 21. 1. Planned Production Time (Total Time): Formula: Total time = Shift Length − Break = 510 minutes − 50 minutes = 460 minutes 2. Run Time: Formula: Available time - losses = 460 minutes − 45 minutes = 415 minutes 3. Availability: Formula: Run Time / Total Time = 415 minutes / 460 minutes = 0.9021 (90.21%) 4. Performance: Formula: (Standard Time× Total Count) / Run Time = (460 minutes × 0.7) / (415 minutes) = 0.7869 (78.69%) 5. Quality: Formula: Good Count / Total Count = 2 (777 frame) / 2 (777 frame) = 1.00 (100%) Here Quality is 100% 6. OEE: Formula: Availability × Performance × Quality = 0.9021 × 0.7869 × 1.00 = 0.7098 ~ (70.98%)
- 22. Before vs After OEE 0 20 40 60 80 100 120 Availability Performance Quality OEE Chart Title Before After ITEMS Before After Availability 86.21% 90.21% Performance 75.39% 78.69% Quality 100% 100% OEE 65% 70.98%
- 23. Total productive maintenance (TPM) is one of the best tools for making our industries competitive and effective, in the field of maintenance. TPM may be the only thing that stands between success and total failure for some companies as far as maintenance is concerned. While implementing TPM we found some barriers for effective implementation of TPM and performed Root Cause Corrective Action (RCCA) to correct the issues. Also we corrected the basic layout of the IGM robot section with 5S requirements, by assigning the specific place for components like TEACH PENDENT, SCISSOR LIFT, TOOLS CUPBOARD. Then we prepared daily check sheet for the IGM robot welding machine so that by checking it daily, breakdown issues can be minimised as much as possible. By our activities we could increase Overall Equipment Effectiveness (OEE) from 65% to 70.98%. CONCLUSION