Machine Availability Data ( Unit - 5)

Period : April -06 to April - 10

Loss of Days
Total
due to
Machine Name Available
breakdown /
Days
Overhaul

TWIN SHAFT DISPERSER -1 500 12

TWIN SHAFT DISPERSER -2 13 1
Electrical Panel 500 0
Capacitor Panel 500 0
Total 1513 13

Average per machine 378.25 3.25

Percentage Of Break Down 100 0.86

Percentage Of Availability 100 99.14

 Machine Availability Data ( Unit - 2)
Period : Sept -04 to Mar - 09

Loss of Days
Total
due to
Machine Name Available
breakdown /
Days
Overhaul
2-HSD 1 1375 0
2-HSD 2 1375 19
2-PM-1 1375 7
2-PM-2 1375 5
2-PM-3 1375 4
2-PM-4 1375 17
2-PM-5 900 33
2-PM-6 900 41
2-PM-7 1200 57
2-ACOM-1 1375 0
Stitching Mchine 1 & 2 1375 0
Chain Pulley Block 1 1375 0
Electronic Marking Machine 1375 2
Diesel Generator 1375 124
Pallet Traulies 1 and 2 1375 0
Electric Panel Board 1175 0
Pouch Filling Machine 1 & 2 2700 5

Total 23375 314

Average per machine 1375 18
Percentage Of Break Down 100 1.34
Percentage Of Availability 100 98.66
 Machine Availability Data ( Unit - 3)
Period : Sept -04 to Jan - 09

Loss of Days
Total
due to
Machine Name Available
breakdown /
Days
Overhaul
Attritor - 1 1375 0
Attritor - 2 1375 56
Attritor - 3 1375 8
Attritor - 4 1375 34
Attritor - 5 1375 2
Attritor - 6 1375 6
HSD - 1 1375 2
HSD - 2 1375 1
HSD - 3 1375 3
HSD - 4 1375 4
Diesel Generator 1375 10
Transformer 1375 0
HSD - 5 ( small ) 1375 1
Pug Mixer ( small ) 1375 1
Air Compressor - 1 1375 0
Roller Mill 1375 0
Chain Pulley Block - 1 1375 0
Chain Pulley Block - 2 1375 0
Attritor - 7 1275 44
Attritor - 8 1275 9
Attritor - 9 1275 28
Attritor - 10 1275 79
HSD - 6 1275 2
 Loss of Days
Total
due to
Machine Name Available
breakdown /
Days
Overhaul
Dyno mill - 1 1250 6
Filling Machine - Autopac 1250 19
Tanks( 1 to 35 ) 1375 8
Pallet Trolleys ( 1 to 5 ) 1375 0
Main Electrical Panels 1375 0
APFC ( capacitor ) Panels 1375 0
Dyno mill - 2 1200 8
HSD - 10 1250 2
HSD - 7 1225 14
HSD - 8 1275 56
HSD - 9 1275 16
Hydraulic Lift 1275 5
Belt Conveyor -2 1200 0
Slow Speed Stirrer 1 1275 0
Lab Attritor - 1 1075 0
Attritor - 11 1025 28
Lab Attritor - 2 1050 0
ball mill 1 500 1
ball mill 2 500 18
pug Mixer 2 500 122
slow speed stirrer 2 475 0
Sand mill 2 425 6
air Compressor - 2 1375 49

Total 56025 648

Average per machine 1218 14
Percentage Of Break Down 100 1.16
Percentage Of Availability 100 98.84
 Machine Availability Data ( Unit - 1)
Period : April -06 to April - 10

Loss of Days
Total
due to
Machine Name Available
breakdown /
Days
Overhaul
I-BM1 1225 22
I-BM2 1225 10
I-BM3 1225 70
I-BM4 1225 4
I-HSD 1 1225 8
I-HSD 2 1225 2
I-HSD 3 1225 13
I-HSD 4 1225 0
I-HSD 5 1225 0
Jar Mill 1225 7
Diesel Generator 1225 6
Electric Panel 1225 2
Bag Stitching Machine 1 to 4 1225 0
Chain Pulley Block 1 and 2 1225 7
Pallet Traulies 1 to 5 1225 0
Gyroshaker 1225 2
Vibroshaker 1225 0

Total 20825 153

Average per machine 1225 9
Percentage Of Break Down 100 0.73
Percentage Of Availability 100 99.27
 Summery of Machine Availability Data

Loss of Days
Total
due to
Plant Period Available
breakdown /
Days
Overhaul
Unit - 1 April -06 to Mar - 09 15300 61
Unit - 2 Sept -04 to Mar - 09 23375 314

Unit - 3 Sept -04 to Mar - 09 56025 648

Unit - 5 Sept -09 to Mar - 09 525 7

Total 95225 1030

Average per unit 23806 258

Percentage Of Break Down 100 1.08

Percentage Of Availability 100 98.92

Repairs & Maintenance Cost
( All manufacturing units )
Repairs & Maintenance Cost (
Year
Rs. )
2007-08 1042807
2006-07 1350006
2005-06 1640554
2004-05 2819047
2003-04 1082577
Average per
Year 1586998
 Major & repeatative Breakdown Analysis

Recurring
Machine Type Root Cause Plan Of Action
Problems

1)Minimum spares have to be

1) Oil filled starters.Spares or
kept.Overall condition of old starters
new starter is immediately not
Starter and bearing justifies to keep atleast one new
Ball Mill available. 2)Bearings tend to
problems complete set as delivery time is
shift with slightest mis
more than 45 days.2) Periodic re
alignment.
alignment

1) Periodic cleaning of
1) Dust tend to affect A.C.drive.Emergency spares to be
A.C.drive,central
electronic component of kept. 2) Major overhaul to grease /
bearing ,shaft
High Speed Disperser A.C.drive. 2) Lack of periodic replace main bearing and check
thoroughness and
overhaul for shaft system. shaft thoroughness to be
hydraulic pump
( Min.once in a year ) planned.3) Belt replacement at the
same time is also suggested.
 1) Misalignment is the main
1) Gear wheel / cause for gear wheel
fluid coupling damages apart from normal
Pug Mixer problem.2) Bearing wear out.2) Bearing gets
damages.3) damage as gland leakages
Electrical problem. enter the bearing.3) Failure of
old starters.
1) Periodic realignment to be done.(
Min once in 6 months ).2) Gland
leakages to be minimised by
periodic change of gland rope.3)
Keeping one complete set of starter
as spare ( It can be useful for
attritor as well )
 Recurring
Machine Type Root Cause Plan Of Action
Problems

1) Once in 6 months checking the

Shaft arm worn
condition of shaft / bottom by
out.Bottom sieve /
emptying out all grinding media is
shell worn Wearing out normal
Attritor suggested. 2) Recalibration with
out.Cooling jacket phenomena.
segregated balls,efficiency will also
leakges.Starter
improve.3) One spare starter is
failures.
suggested.

1) Periodic cleaning of sieve is the

1) Sand crushing was the
main reason for clogging.2)
Sieve clogging and
Dyno Mill Gear Pump wearing out faster
pump failures.
is normal for primers.3) Gland
leakages
only option.2) Piston pumps are
suggested for longer life & better
performance of mills 3)
Replacement of gland rope as other
option of mechanical seal is very
costly.

1) Sand crushing was the 1) Periodic cleaning of sieve is the

Sieve clogging and main reason for clogging.2) only option.2) Piston pumps are
Sand mill
pump failures. Gear Pump wearing out faster suggested for longer life & better
is normal for primers. performance of mills

Main shaft
1) Misalignment is the main 1) periodic checking of alignment is
thoroughness and
cause.2) Belt strength not necessary.2) Change the pulleys
Twin Shaft Disperser bearing,slow speed
sufficient for our product and type of belt to suit load
shaft looseness
profile. requirement.
and belt worn out