Implementation of TPM in industries machine problems by the action of 5S, OPM check sheet, RCCA- Why How analysis gives a result as 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).

4. ROBOT WELDING:

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.
.

9. OUR ACTIVITIES

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