Typ M2

Notifctn 10135873

Notif.date 01.08.2013

Equipment 8STN-403

BD type E

Description motor not run

MalfStrt 13:30:00

Malf.end 15:30:00

Downti me 2

Cause Motor fan not working, so motor heated up Motor heated up so MCB tripped

Work done/Action taken Changed motor fan and cool down the motor Reset MCB , checked all shorting and cool down motor remove the wedge and setting done

Attended by

Preventive Trg status action/Countermeasure date planned To make a hole in shaft or to fix 03.08.2 done the fan with bolt 013

Last PM Point checked / not done date checked in last PM Jun-13 yes

M2

10135869

01.08.2013

8STN-403

motor power short

10:30:00

12:00:00

1.5

Jun-13

M2

10135441

01.08.2013

H-402

spindle sound prob.

13:30:00

14:00:00

0.5

wedge got stuck

M2

10135872

01.08.2013

SRG-403

single phase alarm

11:10:00

12:40:00

1.5

M2

10135867

01.08.2013

SVM-402

x axes, y axes & z axes alarm 11:10:00 back chamfer motor trip prob. air pressure high & low

12:00:00

0.83

M2

10135874

02.08.2013

8STN-403

13:45:00

14:00:00

0.25

Checked all connector and one phase missing for A axis servo continuity in wiring, removed motor for roatry from amplifier motor side connector and fitted Checked brake motor and VRDY alarm repeated , Z axis coupling and Changed the brake motor heated up cable with FANUC eng., m/c Removed motor shaft and Motor heated up and found play in checked and found bend in spindle shaft motor shaft, changed with Air pressure low as Nitrogen plant Started another compressor run y-clamp bolt loose y-clamp bolt tightned

Jun-13 Analysis to be done to get the actual cause of bd as it comes first time 10.08.2 not done 013

May-13

Jun-13

M2

10135829

04.08.2013

SHD-403

20:20:00

20:30:00

0.17

Aug-13

M2

10135824

05.08.2013

H-402

sound prob.

10:20:00

10:30:00

0.17

M2

10135823

05.08.2013

H-403

spindle not run hydraulic pressure gauge offset/ rotary switch for hydraulic pressure gauage break shoo broken

16:30:00

17:20:00

0.83

belt damaged

Belt changed

M2

10135875

05.08.2013

SVM-402

15:30:00

17:15:00

1.75

Roatry switch for hydraulic changed o-ring after pressure gauge not working due to dismentteling of rotary switch one o-ring found damaged clutch liner loose Motor connection loose so motor heated up Motor connection loose so motor heated up changed new clutch liners

May-13

M2

10135825

07.08.2013

H-403

7:50:00

8:50:00

M2

10135831

07.08.2013

H-404

both m/c power connection 7:40:00 on panel motor not working 7:40:00

9:20:00

1.67

repaired the connections

M2

10135830

07.08.2013

H-405

9:20:00

1.67

repaired the connections To set the bolts of Parralism bolt to 30mm and to inspect fortnightly by maint. Person to 20.08.2 NOT DONE Jun-13 013 May-13

M2

10135879

07.08.2013

SRG-401

rotary over heat alarm

21:45:00

23:00:00

1.25

coolant entered inside rotary Remoeved the motor , cleaned motor due to parralism upset and and dry the motor and provide coolant leakage from there cover on rotary and set the Limit switch signal not coming due Changed new one with to element stucked inside damaged belt wear out due to wet condition change the belt with new one NC tripping problem due to lamp connection choke shorted cylinder fittment space problem Remove the connection and changed new one sheet grinded and make space

M2

10135878

07.08.2013

SVM-402

indexing prob.

8:00:00

9:10:00

1.17

M2

10135826

08.08.2013

8STN-404

back chamfer spindle prob.

0:20:00

0:45:00

0.42

Jun-13

M2

10135828

08.08.2013

8STN-404

power trip prob.

12:03:00

12:23:00

0.33

Jun-13

M2

10135832

08.08.2013

H-405

bush not ok

8:30:00

9:00:00

0.5

M2

10136372

08.08.2013

M-401

running time spindle stop

4:00:00

22:30:00

18.5

Spindle rotation gears bolt broken Removed and changed all bolts

1.To remove the handles after 08.08.2 NOT DONE RPM set 2. To check the Bolt 013 condition of bolts per month to Cleaning of FRL to be done Reason of belt damage to be analysed and action taken to eliminate the cause, to fix the 09.08.1 DONE 3 Aug-13

M2

10135833

08.08.2013

SHD-403

air pressure low

12:30:00

12:40:00

0.17

vary from FRL

FRL set

M2

10135891

08.08.2013

SVM-401

Spindle belt broken

16:30:00

17:20:00

0.83

belt ribs cut Belt wear out of 6th head backchamfer

belt changed

PM 20.08.2 checksheet May-13 013 modified , Jun-13

M2

10135827

09.08.2013

8STN-404

belt slip prob.

0:30:00

1:00:00

0.5

Changed new belt

M2

10135902

09.08.2013

CLTAP-401

spindle offset

12:50:00

13:00:00

0.17

footpaddle problem Variation in component due to rotary axis coupling slip down Ethernet adopter was creating problem and hanged Encoder cable loose

repaired the footpaddle Changed ETP classic coupling ETP-22 and set the pulley again Remoeved the program for On line TPM for fitment of new Ethernet adopter after checking Tightened the connector To check the ethernet setting and and to change with new one if faulty

M2

10135895

09.08.2013

SRG-401

rotary prob.

10:20:00

10:40:00

0.33

Jun-13 Now Online 15.08.2 May-13 TPM is 013 disabled in Jun-13

M2

10135892

09.08.2013

SVM-402

enter down reason alarm

7:30:00

9:30:00

M2

10135905

10.08.2013

SHH-401

home position forget prob.

10:10:00

10:30:00

0.33

M2

10136373

10.08.2013

SVM-403

air sensor not on

10:45:00

11:10:00

0.42

air sensor faulty Softkeys not working due to oil and so wrong data feeded in machine NC element creating problem Spindle not taking load due to push rod moutning loose Found spindle moving very tight and with sound as its face cover one bolt was not sitting properly in Wedge not coming outside due to one cylinder mounting was creating problem and not working

changed the air sensor Cleaned the oil from LCD and checked working, paste new LCD screen on LCD Changed new one To replace and inspect the LCD 15.08.2 not done screen on monthly base on all 013 LCD /CRT screen of CNC

Jun-13

M2

10136396

11.08.2013

SRG-404

x.y.a. delete alarm Cycle start push button not working

7:00:00

7:40:00

0.67

Jun-13

M2

10136397

13.08.2013

SHH-401

13:40:00

13:50:00

0.17

Jun-13

M2

10136380

14.08.2013

H-403

spindle prob.

7:30:00

8:50:00

1.33

tightened again the push rod Lossenes and checked and changed that bolt with new one Repaired the sheet of moutning and set the cylinder Nitrogen plant changeover valve to be changed with neworder has given 15.09.2 013 Aug-13

M2

10136395

16.08.2013

8STN-404

spindle jam prob.

19:30:00

20:00:00

0.5

Jun-13

M2

10136394

16.08.2013

H-403

spindle not stop prob.

12:45:00

13:30:00

0.75

M2

10136405

16.08.2013

SHD-403

air pressure low

16:30:00

16:40:00

0.17

Air pressure low as Nitrogen plant Started another compressor run coil connection loose Found belt in ok condition, but RPM slow down during running cycle brake shoe bolt setting disturbed connection tight properly Changed belt , but problem remain same , then checked top side ( motor side ) pulley and bolt setting done

M2

10136398

16.08.2013

SVM-401

clamping prob.

12:10:00

12:25:00

0.25

May-13 To cover the belt area to avoid coolant splashing 20.08.2 DONE 013

M2

10136950

17.08.2013

8STN-405

belt slip prob. In 2nd head

7:20:00

11:40:00

4.33

Jun-13

M2

10136951

17.08.2013

H-403

spindle not stop

0:10:00

1:00:00

0.83

M2

10136957

17.08.2013

H-404

both m/c power connection 7:00:00 connect spindle not run slide cover broken(Aprin cover for ball screw) chamfer more prob. 7:00:00

7:40:00

0.67

mpcb faulty of h-405 as both m/c changed the mpcb connected with same mcb Spindle motor heated up due to single phasing from MCB pole faulty and heavy sound Aprin cover for ball screw protection damaged as during tool change , force on aprin cover is Air pressure vary during operation Changed MCB with new one and changed 1 no. bearing 6205 Repaired tat one and instruct prod person to work safely Set the air pressure from regulator bolt setting done Jun-13

M2

10136956

17.08.2013

H-405

10:30:00

3.5

M2

10136959

17.08.2013

SFB-401

22:15:00

22:30:00

0.25

M2

10136958

17.08.2013

SHD-403

14:30:00

15:00:00

0.5

Aug-13

M2

10136952

18.08.2013

H-403

spindle not stop

9:00:00

9:10:00

0.17

brake shoe bolt setting disturbed Checked and found that encoder connector loose Cluthc liner not working

M2

10136966

19.08.2013

SHH-401

y axis home position forget

14:05:00

14:30:00

0.42

tightened the connector

Jun-13

M2

10136954

23.08.2013

H-403

load prob.

13:30:00

15:00:00

1.5

changed clutch liner under PM Need to check the LVDT connections /oil in LVDT 25.08.2 DONE 013 May-13

M2

10136953

23.08.2013

SHH-403

pulls miss alarm

12:00:00

12:10:00

0.17

Load on spindle

released manually

M2

10136962

23.08.2013

SVH-401

abnormal sound prob.

11:00:00

11:10:00

0.17

Sound came from Hydraulic pump Checked coupling , pressure , oil unit level , motor fan,

M2

10138708

25.08.2013

8STN-404

spindle not run

18:50:00

19:30:00

0.67

spindle pulley bolt open and stuck remove the bolt and tight it in belt and pulley properly one spiral coolant bud broken due Repaired that one and ordered to frequent motion on toll for for new one coolant setting relay malfunctioning relay changed

Jun-13

M2

10138766

26.08.2013

8STN-404

coolant bud broken

16:30:00

17:00:00

0.5

Jun-13

M2

10138767

26.08.2013

8STN-405

power trip prob, voltage stabilizer modification spindle jam prob.

17:10:00

17:30:00

0.33

Jun-13

M2

10138952

26.08.2013

DDG-401

8:10:00

8:30:00

0.33

steplizer not working in auto mode so setting done in manual due to card problem spindle coupling got shift due to bolt loose vary from FRL so tightned the bolt of coupling properly set the FRL Checked and tight the beltunder observation Changed bellow coupling bkl15 19x20 To change the regulator with another and to check the cause of variation Brg to be checked and to eliminate the cause of jerking after dismentteling of rotary Bellow coupling problem to be analysed and to indent spare

Jun-13

M2

10138768

26.08.2013

H-403

21:50:00

22:15:00

0.42

M2

10138951

26.08.2013

SHD-403

air pressure low rotary prob.(jerking in rotary) run out prob.

7:30:00

7:40:00

0.17

30.08.2 NOT DONE Aug-13 013 28.08.2 DONE 013 29.08.2 done 013 Jun-13

M2

10138939

27.08.2013

SRG-401

18:00:00

18:40:00

0.67

Checked and found belt may slip Bellow coupling may cause the problem

M2

10138765

27.08.2013

SVM-401

7:50:00

8:15:00

0.42

May-13

M2

10138941

29.08.2013

8STN-403

a axis o.v.c. alarm

17:15:00

18:10:00

0.92

tap head play due to spindle pulley change the key new fitted key wear out belt broken Hydraulic pressure reduced in pump NO-elemnt malfunctioning Foot padel wiring loose from inside Electrical Shorting of 24 V DC electrical panel due to one wire cut and touched with body belt chnaged To set the pressure at 35 kg after dismetelling the pump ring from inside 29.08.2 done 013

Jun-13

M2

10138935

29.08.2013

H-402

belt broken

21:45:00

0:00:00

M2

10138934

29.08.2013

SVM-403

hydraulic pressure low

17:15:00

18:00:00

0.75

Set the pressure again

Jun-13

M2

10138938

30.08.2013

DAM-407

clamp declamp prob.

3:30:00

3:50:00

0.33

change the NO element

M2

10138943

31.08.2013

SRG-403

foot pedal not working

13:40:00

13:50:00

0.17

Tightened connection To change the cable with new one 10.09.2 not done 013

Jun-13

M2

10138945

31.08.2013

SVM-402

power not available in panel 17:15:00 /LCD

18:40:00

1.42

Cut nd repaired that cable

lalit

May-13

Frequency Total m/c total available hrs. Total Break down Hrs. MTTR MTBF

58 92 50600 63.21 1.089827586 872.4137931

M/C code

SM-401 SVM-402 H-403 H-405 8STN-403 8STN-405 8STN-404 H-404 SRG-401 SRG-403 SVM-401 SHD-403 SVM-403 SHH-401 H-402 SRG-404 DAM-407 DDG-401 SFB-401 CLTAP-401 SHH-403 SVH-401

BD hrs. 18.5 7.17

1. 18.5 Hrs. - Gear unit bolts broken- changed bolt

16 4.66 2.92 2.25 1.67 1.5 1.18 1.17 0.92 0.67 0.67 0.33 0.33 0.25 0.17 0.17 0.17 60.7 Occurances 8 6 5 5 4 3 3 3 3 2 2 2 2 2 1 1 1 1

20 18

18.5 16

16 14

Hrs.

12 10 8 6 4 2 0 7.17 4.66

M/C code

H-403 8STN-404 SVM-402 SHD-403 8STN-403 H-405 SRG-401 SVM-401 SHH-401 8STN-405 H-404 SRG-403 SVM-403 H-402 SM-401 SRG-404 DAM-407 DDG-401

9 8 8 7 6 6 5 5 4 4 3 3 2 1 0 5

Nos.

SFB-401 CLTAP-401 SHH-403 SVH-401

1 1 1 1 58

BD hrs.- Aug-13
1. 2 hrs. -Enterdown reason came for Online TPM - ethernet adopter was creating problemremoved at time and changed. 2. 1.75 Hrs. - Hydraulic gauge rotary

BD hrs.

switch not working- found o-ring damaged inside-changed 3. 1.42 Hrs. - Shorting in electrical 24v DC one cable foun cut in operator panel

1. Clutch liner not working due to faceplate damaged/rubbed- rpetaed problem- will take in reconditioning after installation of Ingish machine

4.66 2.92 2.25 1.67

1.5

1.18

1.17

0.92

0.67

0.67

0.33

0.33

0.25

0.17

0.17

0.17

Machine name

Occurances- Aug-13

Occurances

3 2 2 2 2 2 1 1 1 1 1 1 1 1

Machine name

Repeated BD elimination

S.No.

M/C code

Problem

Cause

Hydraulic pressure in SVMSVM-403 HSRA line 403 machine going down from 30kg to 20 kg

Vane pump setting disturbed

Action Done date Effectiveness Dismentelled the pump and set the Pressure set is on 35 kg still ring and spring as 28.08.2013 maintained and not coming down per drawing of Pump

Preventive action Training manual to be made to set the pump if there is any variation in pressure due to pump setting distrubed

Monthly Inspection Schedule Date

Sr.No. Activity Planned Schedule

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20

Belt Inspection Pulley Inspection Operator panel inspection Lub oil leakage inspection Hydraulic oil leakage inspection Coolant leakage from machine inspection Mist collector cleaning SRG- rotary runout on Shunk Coolant entry in SRG rotary Parralalism bolt length in roatry plate Stabilser maintenance Thru coolant rotary coupling inspection Compressor service R.O. service Softner working / service

weekly weekly weekly fortnightly fortnightly fortnightly monthly weekly weekly weekly monthly monthly monthly monthly monthly

Line Intake Intake Intake Intake Intake

SHIFT A A A A B

Month August August August August August

Date 1-Aug-13 1-Aug-13 2-Aug-13 29-Aug-13 29-Aug-13

M/c 8STN-403 8STN-403 8STN-403 8STN-403 8STN-403

Description Back chamfer motor power short Back chamfer motor not run. Back chamfer motor trip SOUND PROB, A AXIS O.V.C. ALARM

Dept. 107 107 107 107 107

Type M2 M2 M2 M2 M2

Duration start time end time 90 10:30 12:00 120 13:30 15:30 15 13:45 14:00 10:30 14:10 55 17:15 18:10

Duration 90 120 15 220 55