OBJECTIVES OF THE STUDY

The main objective of the study is to understand the working of operations maintenance department in the factory which will be achieved through following:

1. Preparation of database of all the machinery present in the factory and reconciling it

with the old database. 2. Identification of new machines and coding them to ensure easy make of history card for all the machines.
3. Analysis of the breakdown occurring in the factory during the month of July. 4. Understanding concepts of Predictive and Preventive maintenance of machines. 5. Brief overview of the overall working of the maintenance functions in the factory.

Page 1

RESEARCH METHODOLOGY
Meaning Research is a systematic collection; analysis and reporting of data and findings of specific idea or problem under review. It employs well-designed method to collect the data and analyses the results. It disseminates the findings to contribute to generalize able knowledge. Utility of Research
On the basis of research study, we can know in what direction the operations are heading

and what the loopholes are.

We can get to know about how to optimize the operations.

It can be known what the present condition of working is and what company can do to improve or sustain its working. It facilitates decision making for the future.

Page 2

DATA SOURCES
The methodology followed during the preparation of the report is collection of data through Primary sources. Keeping in mind the objective of the research i.e. studying operations maintenance policies of Venus Tools, the data collected primary in hand would be most useful in comprehending the working of the department.

Primary data:
When an investigator collects the data himself for a particular purpose, it is called primary data. The primary data can be collected through observations or questionnaires. Advantages The degree of accuracy of the study is high. The in-depth comprehensive knowledge can be collected.
Disadvantages-

The collection of data is both time consuming and costlier than secondary source. The primary data collection is subjective to the person responsible for collecting it.

Secondary data used:

When an investigator uses the data that has been already collected by others, it is called secondary data. The secondary data can be collected from newspapers, journals, reports, internet and various publications. In this report, I have used secondary data in profile of the organization which is collected from its site.
Page 3

LIMITATIONS OF THE STUDY:

Like every study, the study of this project has its own limitations which are as follows:

The collection of data is not extensive due to secrecy policies of the company. The scope of the data to be collected is restricted to operations occurring in the month of July which is one of peak production months so it can give erroneous results. The analysis is restricted to intra-firm and not a comprehensive inter-firm. The predictive and preventive maintenance schedules could not be extensively covered except their relevance due to time shortage

Page 4

CHAPTER 2

PROFILE OF THE ORGANIZATION

Page 5

VENUS TOOLS (P) LTD

CORPORATE PROFILE:
VENUS TOOLS PVT. LTD. is one of the leading manufacturers with a customer driven focus on delivery and excellence. It is an ISI and GS (VPA/TUV) certified company for product quality and reliability. It is also known with the name OSHO tools. Venus product range includes all kinds of hand operated tools such as Wrenches, pliers, Sockets, Plumbing Tools and other specialized garage and special application service tools. It is also catering to various OEMs for there tool kit requirements. It has also been certified with TS 16949 quality system by DNV. Winners of two National awards by government of India for product safety and quality. Venus Tools has a modern plant with dedicated production lines incorporating state of the art processing equipments from Europe and the USA. Osho Tools was incorporated in 1989 by Sh.Prem Nath Gupta a philanthropist, Sh. Ashok Gupta (B.tech from USA) and Sh.Bipin Gupta (M.A. PHD)

Venus Tools today employees more than 800 people with all the manufacturing activities and it has largest product range capacities under one roof.

The products are strictly made as per Indian Standards and as per the drawings provided by Customers.

It is one of the largest Original Equipment Suppliers in the country and also having about 450 strong dealers network.

Page 6

CORE BUSINESS MODEL

Four strong pillars People, Process, Infrastructure, and Technology, support our core business model. Together, these pillars ultimately contribute to two advantages for our valued customers

Superior products and solutions Time and cost efficiency

ACHIEVEMENTS:

Starting with only 2 Drop forge Hammers the Venus group today has 12 Drop forge hammers with complete ancillary machinery, well equipped laboratories and a state - of the - art R & D Department. With such facilities they have capacity to sustain an annual production of 40 million pieces of Hand Tools in House.

Suppliers to Govt. of India, Defence and other establishments.

Page 7

Registered with DGS & D(Directorate General of Supplies and Disposals) and ASRTU(Association of State Road Transport).

APPROVALS:

A TS-16949 Certified Company. An ISO 9002 certified company. OEM suppliers of complete tool kits to car majors, two wheelers as well as three wheeler segment. Over 600 strong loyal dealer network in India. Suppliers to Govt. Of india , Defence and other establishment.Registered with DGS & D, ASTRU. Golden Status Export House recognition by Govt of India.

Page 8

ORGANIZATIONAL CHART:

Page 9

The organizational structure of the company is function based. Since its hardcore function is manufacturing of tools therefore such structure is best suited to meet it needs.

PRODUCT CATEGORIES

Page 10

Spanners

Pliers

wrenches

Screw Drivers

Allen Kets

Tool Kits

Hammers

Tools Trolley $ Box

Socket Set

Others

FEATURED PRODUCTS:
Adjustable Wrench Bihexagon

Page 11

INFRASTRUCTURE
The building-blocks model is structured in a primarily functional way. Building-block types are defined for each type of infrastructure service. Within each organization, several variants of a building-block type will typically occur, depending on the environment. The building-blocks model recognizes the following service groupings:

Working AreaA set of infrastructure services that, at a general, logical level, provide a certain kind of infrastructure functionality, such as middleware, storage, network, and client. EnvironmentIn this context, a functionally demarcated domain (business context) in an organization's infrastructure landscape, such as "hospital workstations." Environments differ from each other primarily in the types of functionality that they offer. A further subdivision can be made according to location types, if infrastructure services at each location are different enough to justify a further breakdown.

Building BlockAn infrastructure service or set of closely related infrastructure services that, in the context
Page 12

of an environment, provides uniform and delineated infrastructure functionality, such as "backup storage." Several variants of a certain type of building block might occur within an organization, depending on the diversity of environments and locations. (For example, file and print services at a small location might be implemented differently from a large location.) ElementElements are technical components, functions, and/or protocols that are used to construct building blocks, such as TCP/IP or Linux. Quality AttributeQuality attributes, such as "response time," describes constraints on how a building block functions, and they are regarded as nonfunctional requirements. Quality attributes influence the elements that are used to construct a building block, and they can be applied to environments on a global level.

Page 13

QUALITY POLICIES:
Quality StandardsAll products, we make are as per specifications/drawings of our customers. These products are made normally as per DIN / JIS / BIS quality standards. Commitment to QualityOSHO TOOLS Pvt. Ltd. is totally committed to quality. Our Product Development is supported by CAD facility and Raw Materials are tested in Spectro Lab. Our products are passed through Hardness testing, Salt spray testing, Plating / Paint thickness testing, Torque testing, Load testing etc. Certification of QualityBeing an (OEM) Original Equipment Manufactures, we make (PDIR) Pre Delivery Inspection Reports with every lot of consignment that leaves our premise. On request reports are given to parties. Replacement GuaranteeOur products come with a Full Replacement Guarantee, if found defective. ISO 9001 - 2000 CertificationOSHO TOOLS Pvt. Ltd. is an ISO 9001-2000 certified Company

5S Policy:
1. 2.

Structurize -Take out unnecessary items Systematize Arrange unnecessary items in order
Page 14

3. 4. 5.

Sanitize Clean your workplace before and after work Standardize Maintain high standards of housekeeping Self-discipline Train people to follow good house-keeping independently

CONTACT DETAILS
Registered Office :65, Sant Nagar, Civil Lines, Ludhiana - 141 001. Ph: 0091-161-2222955, 2228562, 2226214 Village Jandiali, Chandigarh Road, Ludhiana - 141 112 Ph: 0091-161-2843638, 3297582 Fax : 0091-161-2843657 Mr.Inderjit Singh Ph: 0091-161-2222955, 2228562, 2226214 Fax : 0091-161-2220041 E-mail : oshotools@connectzone.in Website : www.oshotools.com

Works :-

OEM-Sales

Sales-Domestic Market :- Mr. Manish Mehra Ph: 0091-161-2222955, 2228562, 2226214 Fax : 0091-161-2220041 E-mail : care@oshotools.com Website : www.oshotools.com

Page 15

CHAPTER-3 ANALYSIS AND INTERPRETATION OF DATA

Page 16

MAINTENANCE DEPARTMENT:
The company has separate maintenance department which looks after the work of maintaining all the machines in the factory. It has a Head which reports directly to MR (Management Representative) department monthly. Under Head there is one supervisor. The span of management of supervisor is 5 i.e. five mechanics are there under him which looks after machine repairs and their scheduled maintenance. The maintenance department has 5 main functions:

Preparation of master list of machines along with their locations and coding Making and maintaining history card of each machine in which their history of maintenance and repairs along with the cost involved is recorded Issuing necessary guidelines to workers about predicting breakdown before it happens so that effective predictive maintenance can be carried out Preventing breakdown of machines through carrying out Preventive maintenance schedules An efficient breakdown maintenance so that machine and labour hours lost in the process can be reduced

Page 17

MAINTENANCE POLICY:
PURPOSE:
To establish procedure for breakdown, predictive and preventive maintenance machines & equipments in the organization to ensure health of equipment and safety of operation along with minimizing breakdown time

SCOPE:
Mechanical/Electrical aspects of all production equipments& utilities

RESPONSIBILITY:
Maintenance Incharge

PROCEDURE:
The above policy is achieved in the following way of implementation: Efficient breakdown repairs Predictive Maintenance Scheduled Preventive Maintenance

MAINTENANCE TYPES:

PREDICTIVE MAINTENANCE

PREVENTIVE MAINTENANCE

BREAKDOWN MAINTENANCE

Page 18

PREDICTIVE MAINTENANCE:
Predictive maintenance is condition based. Condition of critical equipment is assessed by careful observation and by measurement using suitable instruments for carrying out preventive maintenance before occurrence of breakdown. It, therefore, gives adequate time to plan requirement of spare parts and other resources thereby reducing breakdown time. Machines and equipments are categorized as: Critical Normal

Criticality of the machine/equipment is decided as follows:

1. All the production machines/equipments which are special purpose in nature & work on

these machines cannot be altered much can be considered as critical machine/equipment

2. Based on breakdown data of 6 months the criticality of the machine is evaluated. If the

total breakdown of any machine cross the limit of 5.5% shall be considered critical. Feedback may also be taken from production and maintenance regarding machines criticality. Some other important considerations are: The Maintenance Incharge shall keep the list of all the machinery and equipment along with the specifications

Vital and fast moving parts of all critical machines/equipments required for preventive maintenance and which are not locally available shall be considered as important spares Replacement, repairing & checking frequency of the parts of every machine is defined on the basis of manufacturer recommendation and past experiences. The action is planned and executed in scheduled preventive document.

Page 19

PREVENTIVE MAINTENANCE:
The purpose is to stop frequent breakdowns by executing long term counter measures. Preventive maintenance is time based servicing & repairs. It is done as follow: Annual plan of schedule preventive maintenance is made by Maintenance Incharge The spares required to carry planned maintenance work should be available in store After verifying stock in hand, purchase requisition for net quantities required shall be raised by Store Incoming(I/c).For indenting procedure refer to indenting system

The schedule and supportive work instruction/check list prepared shall indicate details of the work to be carried out Records of preventive and breakdown maintenance work carried out in the past Monthly breakdown analysis sheet is taken as reference Manufacturer recommendation in maintenance manual of the equipment, if available. These recommendation should be modified & used appropriately considering the conditions of the equipment Improvements decided in Management Review meeting The details of preventive maintenance carried out shall be recorded in the preventive maintenance record sheet Separate record for preventive maintenance

BREAKDOWN MAINTENANCE:
Breakdown refers to stopping of functioning of machine due to some reason. The breakdown results in unnecessary wastage of machine hours as well as labour hours. The method used for breakdown maintenance of machines is as follows: Whenever a breakdown of machine occurs ,the concerned production supervisor reports to the maintenance department and they are recorded in the register The maintenance Supervisor shall verify all the details, carry out necessary investigations & instruct the concerned maintenance person to carry out breakdown-maintenance

Page 20

After rectifying the problem the maintenance technicians shall note down to breakdown maintenance register which will be signed by Maintenance Incharge Analysis of the breakdown which have higher reoccurrence shall be discussed in the Management Review Meeting

REVIEW SYSTEM:
Review system is made to ensure that the framed systems are being implemented properly & to realize the need for any modification in the system Method: Random checking of documents and working procedure Responsibility: Maintenance Incharge A review meeting is held among all fitters and the Maintenance Incharge to review the performance of the department and a report that is to be given to management

SAFETY SYSTEM:
Safety is an integral part while working with machines. The company further ensures: The general safety rules of the company are followed as per company rules. Besides that if any specific rule is observed for safe working in maintenance shop it is mentioned. The injury score, severity rate & frequency rates are monitored as a measure to develop safe working condition The safety instructions & rules are displayed at workstations wherever necessary

Page 21

MAINTENANCE INCHARGE RESPONSIBILITIES:

The Maintenance Incharge is the head of maintenance department. The responsibilities and authority for actions is defined as follows :
1. To ensure adherence to preventive maintenance as per schedule prepared

2. Analyzing trends of breakdown & ensuring necessary corrective and preventive action in order to reduce breakdown 3. To ensure availability of all spare parts /accessories for all maintenance work i.e. monitoring of critical spares 4. To implement and maintain 5S activities in the area 5. Monitoring of all parameters and devices effecting safety features like Fire Extinguisher, Proper Earthing ,No loose wiring and Leakage control (Water & Oil) 6. Training to all departments on fire fighting system 7. To carry out predictive maintenance and continual improvement projects

Page 22

TOOL MAKING PROCESS:

1. Raw material - the raw material used is iron bars which are marked with different

colours for quality identification.

2. Blanking - the process of blanking cuts the iron bars into small parts which are to be

forged afterwards and hammered

3. Forging - the pieces blanked are forged in heating furnace at 1150-1180 degrees of

temperature which are then hammered on the dyes

4. Trimming - the hammered materials gets the shape after which the sides are trimmed in

trimming machine
5. Punching -The component is then punched to create the necessary holes 6. Broaching - soon after punching broaching machine is used to create broach inside the

punched matter to create a holding grip

7. Grinding - the component is then grinded on machine belts to create perfect shape 8. Cona & profile - the material is then given a profile on the basis of its through press

machine
9. Heat treatment - after profiling the tool is given heat treatment to ensure its hardness 10. Shot blaster - the tools are then shot blasted for at least 20 minutes 11. Gauging - the tool is then gauged with machine to see if it fits for use

Page 23

12. Polishing - the polishing is done after to reduce the chances of rust 13. Pre-inspection - it is important at this stage to pre-inspect material and reject or rework

faulty tools
14. Electroplating - once pre-inspected the tools are electroplated 15. Chemical processing- a series of chemical processing is done for various reasons such as

hardness, resistant to corrosion etc

16. Final inspection and Packing- the batch of tools is finally inspected after which they are

packed and dispatched to delivery

OBSERVATIONS:
Locations at which machines are placed:
The Following below locations are identified at which the machines are placed in the factory: 1. Machine Shop1 2. Machine Shop2 3. Assembly Shop1 4. Assembly Shop(WPP/SP) 5. Assembly Shop(Adjust wrench) 6. Electroplating section 7. Tool Room 8. Forging Shop1
Page 24

9. Forging Shop2 10. Pliers section 11. Pipe Wrench section

12. Assembly Shop(Pliers)

13. Assembly Shop(WPP) 14. Assembly Shop(Pipe Wrench)

15. Assembly Shop(S.D Ratchet)

16. Packing Section1 17. Packing Section2 18. Assembly Section(Kirloskar Dept) 19. Nano Section 20. Nano Department 21. Backside Nano(near heatreatment) 22. Backside Forging1 23. Backside Forging2 24. Heatreatment section(Nano backside)

MASTER LIST OF MACHINES:

OSHO TOOLS (P) LIMITED MASTER LIST OF MACHINES
Page 25

Doc: Date:15-7-2011

S.n o 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 32 33 34 35 36 37

Machine name Acid Zinc Barrel Acid Zinc Barrel Acid Zinc Barrel Acid Zinc Barrel Acid Zinc Barrel Acid Zinc Barrel Acid Zinc Barrel Acid Zinc Barrel Acid Zinc Barrel Acid Zinc Barrel Caustic Barrel Caustic Barrel Water Tank Water Tank Water Tank Water Tank Furnace Boiler Rectifier Rectifier Rectifier Rectifier Rectifier Rectifier Rectifier Rectifier Rectifier Rectifier Rectifier Zinc Barrel Filter Zinc Barrel Filter Zinc Barrel Filter Zinc Barrel Filter Zinc Barrel Filter Zinc Barrel Filter Zinc Barrel Filter Zinc Barrel Filter

Machine No. ZBN1 ZBN2 ZBN3 ZBN4 ZBN5 ZBN6 ZBN7 ZBN8 ZBN9 ZBN10 CB1 CB2 WT1 WT2 WT3 WT4 ON1 BN1 R1 R2 R3 R4 R5 R6 R7 R8 R9 R10 R11 F1 F2 F3 F4 F5 F6 F7 F8

Location Electroplating Section Electroplating Section Electroplating Section Electroplating Section Electroplating Section Electroplating Section Electroplating Section Electroplating Section Electroplating Section Electroplating Section Electroplating Section Electroplating Section Electroplating Section Electroplating Section Electroplating Section Electroplating Section Electroplating Section Electroplating Section Electroplating Section Electroplating Section Electroplating Section Electroplating Section Electroplating Section Electroplating Section Electroplating Section Electroplating Section Electroplating Section Electroplating Section Electroplating Section Electroplating Section Electroplating Section Electroplating Section Electroplating Section Electroplating Section Electroplating Section Electroplating Section Electroplating Section
Page 26

Remarks

Not marked

Not marked

Not marked

Not marked

38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72 73 74 75 76 77

Zinc Barrel Filter Zinc Barrel Filter Nickel Filter Nickel Filter Nickel Filter Nickel Filter Nickel Filter Nickel Filter Nickel Filter Nickel Filter Nickel Filter Nickel Filter Alkaline Filter Alkaline Filter Alkaline Filter Trivalent Dip Caustic Dip Alkaline Tank Alkaline Tank Alkaline Tank Cleaner Tank(Nickel) Cleaner Tank(Nickel) Cleaner Tank(Nickel) Chrome Water Tank Chrome Water Tank Diesel Tank For Boiler Hot Water Tank Hot Water Tank Hot Water Tank Nickel Chrome Tank Nickel Chrome Tank Nickel Chrome Tank Nickel Tank Nickel Tank Nickel Tank Nickel Water Tank Nickel Water Tank Nickel Water Tank Phospating tank Phospating tank

F9 F10 NF1 NF2 NF3 NF4 NF5 NF6 NF7 NF8 NF9 NF10 AF1 AF2 AF3 TDIP C.D ATN1 ATN2 ATN3 CLT1 CLT2 CLT3 CW1 CW2 DN1 HW1 HW2 HW3 CTN1 CTN2 CTN3 NCT1 NCT2 NCT3 NW NW NW PHN1 PHN2

Electroplating Section Electroplating Section Electroplating Section Electroplating Section Electroplating Section Electroplating Section Electroplating Section Electroplating Section Electroplating Section Electroplating Section Electroplating Section Electroplating Section Electroplating Section Electroplating Section Electroplating Section Electroplating Section Electroplating Section Electroplating Section Electroplating Section Electroplating Section Electroplating Section Electroplating Section Electroplating Section Electroplating Section Electroplating Section Electroplating Section Electroplating Section Electroplating Section Electroplating Section Electroplating Section Electroplating Section Electroplating Section Electroplating Section Electroplating Section Electroplating Section Electroplating Section Electroplating Section Electroplating Section Electroplating Section Electroplating Section
Page 27

Not marked

Not marked Not marked Not marked Not marked

Not marked Not marked Not marked Not marked Not marked Not marked

Not marked

78 79 80 81 82 83 84 85 86 87 88 89 90 91 92 93 94 95 96 97 98 99 100 101 102 103 104 105 106 107 108 109 110 111 112 113 114 115 116 117

Running Water Tank Running Water Tank Kerosene Tank Dryer Dryer Dryer Dryer Dryer Water Pump Cooling Tower Hydrogen Embrittlement Shot Blasting Machine DMW Water Tank B Quality Number Grinder Diesel Generator Single Lap Grinder Flexible Shaft Grinder Flexible Shaft Grinder Flexible Shaft Grinder Flexible Shaft Grinder Flexible Shaft Grinder Flexible Shaft Grinder Vertical Surface Grinder Broach Grinding Machine Broach Grinding Machine Broach Grinding Machine Broach Making Machine Broach Making Machine Broach Making Hydraulic Milling Machine Milling Machine Milling Machine Milling Machine Shaper Machine Shaper Machine Shaper Machine Shaper Machine Shaper Machine Lathe Machine Lathe Machine

RW RW CO1 D1 D2 D3 D4 D5 WP5 CT9 HEMB SB5 DMW T NCG1 DG3 SLG1 FSG1 FSG2 FSG4 FSG5 FSG6 FSG8 VSG1 BRG1 BRG2 BRG3 BMT1 BMT2 BMTH-1 M1 M2 M3 M4 SH1 SH2 SH3 SH4 SH5 LA1 LA2

Electroplating Section Electroplating Section Electroplating Section Electroplating Section Electroplating Section Electroplating Section Electroplating Section Electroplating Section Electroplating Section Electroplating Section Electroplating Section Electroplating Section Near Electroplating Electroplating Section(Backside) Time Keeping deptt(Backside) Tool Room Tool Room Tool Room Tool Room Tool Room Tool Room Tool Room Tool Room Tool Room Tool Room Tool Room Tool Room Tool Room Tool Room Tool Room Tool Room Tool Room Tool Room Tool Room Tool Room Tool Room Tool Room Tool Room Tool Room Tool Room
Page 28

Not marked Not marked

Not marked

Marked VSG2

Not marked Not marked(N) Not marked(N) Not marked

118 119 120 121 122 123 124 125 126 127 128 129 130 131 132 133 134 135 136 137 138 139 140 141 142 143 144 145 146 147 148 149 150 151 152 153 154 155 156 157

Lathe Machine Lathe Machine Radial Drill Machine Power Hacksaw Power Hacksaw Pantograph Machine Electrical Discharge M/C Electrical Discharge M/C Crane Crane Tool and Cutter Grinder Air Compressor Shot Blasting Machine Shot Blasting Machine Shot Blasting Machine Shot Blasting Machine Barrel Machine Barrel Machine Barrel Machine Barrel Machine Barrel Machine Barrel Machine Barrel Machine Barrel Machine Barrel Machine Barrel Machine Barrel Machine Barrel Machine Barrel Machine Barrel Machine Barrel Machine Barrel Machine Barrel Machine Barrel Machine Barrel Machine Barrel Machine Belt Grinder Face Belt Grinder Face Belt Grinder Belt Grinder

LA3 LA4 RD1 PH1 PH2 PN1 EDM1 EDM2 CRN1 CRN2 TCG1 CP2 SB1 SB2 SB3 SB4 BM1 BM2 BM3 BM4 BM5 BM6 BM7 BM8 BM9 BM10 BM11 BM12 BM13 BM14 BM15 BM16 BM17 BM18 BM19 BM20 BGF1 BGF2 BG1 BG2

Tool Room Tool Room Tool Room Tool Room Tool Room Tool Room Tool Room Tool Room Tool Room Tool Room Tool Room Tool Room Machine Shop Machine Shop Machine Shop Machine Shop Machine Shop Machine Shop Machine Shop Machine Shop Machine Shop Machine Shop Machine Shop Machine Shop Machine Shop Machine Shop Machine Shop Machine Shop Machine Shop(Backside) Machine Shop(Backside) Machine Shop(Backside) Machine Shop(Backside) Machine Shop(Backside) Machine Shop(Backside) Machine Shop(Backside) Machine Shop(Backside) Machine Shop Machine Shop Machine Shop Machine Shop
Page 29

Not marked

Not marked(N) Not marked(N) Not marked

Not marked Not marked Not marked Not marked Not marked Not marked Not marked Not marked Not marked Not marked Not marked Not marked Not marked Not marked Not marked Not marked Not marked Not marked Not marked Not marked Not marked Not marked Not marked Not marked Not marked

158 159 160 161 162 163 164 165 166 167 168 169 170 171 172 173 174 175 176 177 178 179 180 181 182 183 184 185 186 187 188 189 190 191 192 193 194 195 196 197

Belt Grinder Belt Grinder Belt Grinder Belt Grinder Belt Grinder Belt Grinder Belt Grinder Belt Grinder Belt Grinder Auto Shank Grinder Auto Shank Grinder Auto Shank Grinder Auto Shank Grinder Stone Grinder Stone Grinder Stone Grinder Stone Grinder Stone Grinder Stone Grinder Stone Grinder Stone Grinder Hand Press Rotary Machine Rotary Machine Ring Profile Belt Grinder Tempering Furnace Rotary Furnace DMW Water Tank Zinc Barrel Machine Broaching Machine Broaching Machine Broaching Machine Broaching Machine Broaching Machine Broaching Machine Broaching Machine Horizontal Surface Grinder Power Press Power Press Power Press

BG3 BG4 BG5 BG6 BG7 BG8 BG9 BG10 BG11 ASG1 ASG2 ASG3 ASG4 SG1 SG2 SG3 SG4 SG5 SG6 SG7 SG8 HP1 RF1 RF2 RBG TF5 RF3 DMWT ZBM1 BR1 BR2 BR3 BR4 BR5 BR6 BR7 HSG1 TP1 TP2 TP3

Machine Shop Machine Shop Machine Shop Machine Shop Machine Shop Machine Shop Machine Shop Machine Shop Machine Shop Machine Shop Machine Shop Machine Shop Machine Shop Machine Shop Machine Shop Machine Shop Machine Shop Machine Shop Machine Shop Machine Shop Machine Shop Machine Shop Machine Shop Machine Shop Machine Shop Machine Shop Machine Shop Machine Shop Machine Shop Forging Shop Forging Shop Forging Shop Forging Shop Forging Shop Forging Shop Forging Shop Forging Shop Forging Shop Forging Shop Forging Shop
Page 30

Not marked Not marked Not marked Not marked Not marked Not marked Not marked Not marked Not marked Not marked Not marked Not marked Not marked Not marked Not marked Not marked Not marked Not marked Not marked Not marked Not marked Not marked Not marked Not marked Not marked(N) Not marked Not marked Not marked

Marked HSG3

198 199 200 201 202 203 204 205 206 207 208 209 210 211 212 213 214 215 216 217 218 219 220 221 222 223 224 225 226 227 228 229 230 231 232 233 234 235 236 237

Power Press Power Press Power Press Power Press Blanking Press Blanking Press Blanking Press Blanking Press Friction Screw Press Radial Drill Machine Forging Hammer Forging Hammer Forging Hammer Forging Hammer Blank Heating Furnace Blank Heating Furnace Blank Heating Furnace Blank Heating Furnace Blank Heating Furnace Crane Welding Set Welding Set Air Blower Air Blower Air Blower Air Blower Flexible Shaft Grinder LDO Pump Diesel Pump Water Pump Cooling Tower Power Press Power Press Power Press Power Press Power Press Power Press Blanking Press Blanking Press Blanking Press

TP4 TP5 TP6 TP7 BP1 BP2 BP3 BP4 FSP1 RD2 H1 H2 H3 H4 BHF1 BHF2 BHF3 BHF4 BHF8 CRN3 WS1 WS2 AB1 AB6 AB7 AB4 FSG3 LDP DP WP1 CT8 TP8 TP9 TP10 TP11 TP24 TP12 BP5 BP6 BP7

Forging Shop Forging Shop Forging Shop Forging Shop Forging Shop Forging Shop Forging Shop Forging Shop Forging Shop Forging Shop Forging Shop Forging Shop Forging Shop Forging Shop Forging Shop Forging Shop Forging Shop Forging Shop Forging Shop Forging Shop Forging Shop Forging Shop Forging Shop Forging Shop Forging Shop Forging Shop Forging Shop Forging Shop (Backside) Forging Shop (Backside) Forging Shop (Backside) Forging Shop (Backside) Forging Shop 2 Forging Shop 2 Forging shop 2 Forging Shop 2 Forging shop 2 Forging Shop 2 Forging Shop 2 Forging Shop 2 Forging Shop 2
Page 31

Marked as TP4 Marked as TP5

Not marked

Not marked

Not marked Not marked Not marked Not marked Marked as TP10

Marked as TP11

238 239 240 241 242 243 244 245 246 247 248 249 250 251 252 253 254 255 256 257 258 259 260 261 262 263 264 265 266 267 268 269 270 271 272 273 274 275 276 277

Forging Hammer Forging Hammer Forging Hammer Blank Heating Furnace Blank Heating Furnace Blank Heating Furnace Blank Heating Furnace Salt Bath Hardening Salt Bath Hardening Salt Bath Hardening Tempering Furnace Tempering Furnace Tempering Furnace Tempering Furnace Crane Air Blower Air Blower Air Blower Stone Grinder Stone Grinder Stone Grinder Stone Grinder Stone Grinder Stone Grinder Stone Grinder Stone Grinder Stone Grinder Stone Grinder Belt Grinder Belt Grinder Belt Grinder Belt Grinder Belt Grinder Belt Grinder Belt Grinder Belt Grinder Belt Grinder Hydraulic Filter Pump Crane Belt Grinder Single Arm

H5 H6 H7 HBF5 HBF6 HBF7 HBF9 SBH1 SBH2 SBH3 TF1 TF2 TF3 TF4 CRN4 AB5 AB2 AB3 SG10 SG11 SG12 SG13 SG14 SG15 SG16 SG17 SG18 SG19 BG13 BG14 BG15 BG16 BG17 BG18 BG19 BG20 BG21 HFP1 CRN5 SBG1

Forging Shop 2 Forging Shop 2 Forging Shop 2 Forging shop 2 Forging shop 2 Forging shop 2 Forging shop 2 Forging Shop 2 Forging Shop 2 Forging Shop 2 Forging Shop 2 Forging Shop 2 Forging Shop 2 Forging Shop 2 Forging Shop 2 Forging Shop 2 Forging Shop 2 Forging Shop 2 Forging shop 2 Forging shop 2 Forging shop 2 Forging shop 2 Forging shop 2 Forging shop 2 Forging shop 2 Forging shop 2 Forging shop 2 Forging shop 2 Forging shop 2 Forging shop 2 Forging shop 2 Forging shop 2 Forging shop 2 Forging shop 2 Forging shop 2 Forging shop 2 Forging shop 2 Forging shop 2 Forging shop 2 Forging shop 2
Page 32

Not marked

Not marked Not marked Not marked Not marked

Not marked Not marked Not marked Not marked Not marked Not marked Not marked Not marked Not marked(N)

278 279 280 281 282 283 284 285 286 287 288 289 290 291 292 293 294 295 296 297 298 299 300 301 302 303 304 305 306 307 308 309 310 311 312 313 314 315 316 317

Belt Grinder Single Arm Belt Grinder Single Arm Duplex Grinder Duplex Grinder Duplex Grinder Oil Tank Zinc Barrel Machine Cooling Tower Water Pump Water Pump Water Pump Rectifier Air Compressor Diesel Generator Rectifier Shot Blasting Machine Shot Blasting Machine Shot Blasting Machine Broaching Machine Broaching Machine Broaching Machine Broaching Machine Stone Grinder Belt Grinder Belt Grinder Belt Grinder Belt Grinder Stone Grinder Stone Grinder Stone Grinder Stone Grinder Stone Grinder Stone Grinder Gattu Milling Machine Back Cutter Power Press Power Press Gattu Milling Machine Rivet Machine Power Press

SBG2 SBG3 DX1 DX2 DX3 OT-1 ZBM2 CT7 WP2 WP3 WP4 R16 CP1 DG2 R12 SB6 SB7 SB8 BR19 BR20 BR22 BR23 SG20 BG12 BG12-A BG13-A BG23 SG21 SG22 SG23 SG24 SG25 SG26 GM4 BC1 TP13 TP14 GM5 RM3 TP15

Forging shop 2 Forging shop 2 Forging shop 2 Forging shop 2 Forging shop 2 Forging shop 2 Forging shop 2 (Backside) Forging Shop 2(Backside) Forging Shop 2 (Backside) Forging Shop 2 (Backside) Forging Shop 2 (Backside) Forging Shop 2 Power Room Power House Power House Assembly Shop Assembly Shop Assembly Shop Assembly Shop Assembly Shop Assembly Shop Assembly Shop Assembly Shop(Pipe wrench) Assembly Shop(Pipe Wrench) Assembly Shop(Pipe Wrench) Assembly Shop(Pipe Wrench) Assembly Shop(Pipe Wrench) Assembly Shop(Pipe wrench) Assembly Shop(Pipe wrench) Assembly Shop(Pipe wrench) Assembly Shop(Pipe wrench) Assembly Shop(Pipe wrench) Assembly Shop(Pipe wrench) Assembly Shop(WPP/SP) Assembly Shop(WPP/SP) Assembly Shop(WPP/SP) Assembly Shop(WPP/SP) Assembly Shop(WPP/SP) Assembly Shop(WPP/SP) Assembly Shop(WPP/SP)
Page 33

Not marked Not marked Not marked Not marked Not marked Not marked Not marked(N)

Not marked(N) Not marked Not marked Not marked

Not marked(N) Not marked(N)

A not marked A not marked Not marked Not marked

Marked GM21 Marked RM2

318 319 320 321 322 323 324 325 326 327 328 329 330 331 332 333 334 335 336 337 338 339 340 341 342 343 344 345 346 347 348 349 350 351 352 353 354 355 356 357

Power Press Power Press Power Press Power Press Hand Press Hand Press Drill Machine Drill Machine Drill Machine Broaching Machine Broaching Machine Broaching Machine Broaching Machine Milling Machine Milling Machine Milling Machine Milling Machine Milling Machine Milling Machine Milling Machine Milling Machine Gattu Milling Machine Gattu Milling Machine Drill Machine Drill Machine Drill Machine Drill Machine Drill Machine Drill Machine Slotter Machine Slotter Machine Slotter Machine Slotter Machine Slotter Machine Slotter Machine Broaching Machine Broaching Machine Broaching Machine Broaching Machine Drill Machine

TP16 TP17 TP18 TP19 HP2 HP3 DM18 DM19 DM20 BR13 BR14 BR8 BR9 M10 M11 M12 M13 M14 M15 M16 M17 GM1 GM2 DM3 DM4 DM5 DM11 DM13 DM14 SL1 SL2 SL3 SL4 SL5 SL6 BR24 BR25 BR15 BR16 DM41

Assembly Shop(WPP/SP) Assembly Shop(WPP/SP) Assembly Shop(WPP/SP) Assembly Shop(WPP/SP) Assembly Shop(WPP/SP) Assembly Shop(WPP/SP) Assembly Shop(WPP/SP) Assembly Shop(WPP/SP) Assembly Shop(WPP/SP) Assembly Shop(Adjust Wrench) Assembly Shop(Adjust Wrench) Assembly Shop(Adjust Wrench) Assembly Shop(Adjust Wrench) Assembly Shop(Adjust Wrench) Assembly Shop(Adjust Wrench) Assembly Shop(Adjust Wrench) Assembly Shop(Adjust Wrench) Assembly Shop(Adjust Wrench) Assembly Shop(Adjust Wrench) Assembly Shop(Adjust Wrench) Assembly Shop(Adjust Wrench) Assembly Shop(Adjust Wrench) Assembly Shop(Adjust Wrench) Assembly Shop(Adjust Wrench) Assembly Shop(Adjust Wrench) Assembly Shop(Adjust Wrench) Assembly Shop(Adjust Wrench) Assembly Shop(Adjust Wrench) Assembly Shop(Adjust Wrench) Assembly Shop(Adjust Wrench) Assembly Shop(Adjust Wrench) Assembly Shop(Adjust Wrench) Assembly Shop(Adjust Wrench) Assembly Shop(Adjust Wrench) Assembly Shop(Adjust Wrench) Assembly Shop(Adjust Wrench) Assembly Shop(Adjust Wrench) Assembly Shop(Adjust Wrench) Assembly Shop(Adjust Wrench) Assembly Shop(Adjust Wrench)
Page 34

Marked as HP3 Marked as HP4

Not marked

Not marked(N) Not marked(N)

358 359 360 361 362 363 364 365 366 367 368 369 370 371 372 373 374 375 376 377 378 379 380 381 382 383 384 385 386 387 388 389 390 391 392 393 394 395 396 397

Buff Grinder Torque Testing Torque Testing Torque Testing Torque Testing Buff Grinder Milling Machine Drill Machine Drill Machine Drill Machine Turning Adda Turning Adda Milling Machine Bench Tool Grinder Gattu Milling Machine Milling Machine Lathe Machine Milling Machine Gattu Milling Machine Gattu Milling Machine Gattu Milling Machine Gattu Milling Machine Gattu Milling Machine Gattu Milling Machine Gattu Milling Machine Gattu Milling Machine Gattu Milling Machine Gattu Milling Machine Gattu Milling Machine Gattu Milling Machine Gattu Milling Machine Gattu Milling Machine Gattu Milling Machine Power Press Power Press Drill Machine Drill Machine Drill Machine Drill Machine Drill Machine

BFG1 TT1 TT2 TT3 TT4 BFG2 M20 DM2 DM6 DM9 TA4 TA5 M18 BTG1 GM3 M19 LA7 M6 GM7 GM8 GM10 GM11 GM12 GM13 GM14 GM15 GM16 GM17 GM18 GM19 GM20 GM21 GM9 TP22 TP23 DM15 DM17 DM21 DM22 DM23

Assembly Shop(Adjust Wrench) Assembly Shop(Adjust Wrench) Assembly Shop(Adjust Wrench) Assembly Shop(Adjust Wrench) Assembly Shop(Adjust Wrench) Assembly Shop(Adjust Wrench) Assembly Shop(S.D. Ratched) Assembly Shop(S.D. Ratched) Assembly Shop(S.D. Ratched) Assembly Shop(S.D. Ratched) Assembly Shop(S.D. Ratched) Assembly Shop(S.D. Ratched) Assembly Shop(S.D. Ratched) Assembly Shop(S.D Ratched) Assembly Shop(S.D Ratched) Assembly Shop(S.D Ratched) Assembly Shop(S.D Ratched) Plier Section Plier Section Plier Section Plier Section Plier Section Plier Section Plier Section Plier Section Plier Section Plier Section Plier Section Plier Section Plier Section Plier Section Plier Section Plier Section Plier Section Plier Section Plier Section Plier Section Plier Section Plier Section Plier Section
Page 35

Not marked

Marked as M19

Marked BTG3

Not marked Not marked

Not marked

Marked GM22 Not marked Not marked Not marked Not marked

398 399 400 401 402 403 404 405 406 407 408 409 410 411 412 413 414 415 416 417 418 419 420 421 422 423 424 425 426 427 428 429 430 431 432 433 434 435 436 437

Drill Machine Drill Machine Drill Machine Drill Machine Drill Machine Drill Machine Drill Machine Drill Machine Drill Machine Drill Machine Drill Machine Drill Machine Drill Machine Drill Machine Drill Machine Drill Machine Drill Machine Paint Chamber Paint Chamber Paint Chamber Paint Chamber Hydraulic Cutter Gattu Milling Machine Power Press Power Press Broaching Machine Broaching Machine Broaching Machine Broaching Machine Broaching Machine Broaching Machine Broaching Machine Stamp Press Stone Grinder Stone Grinder Water Pump Water Pump Water Pump Water Pump Water Pump

DM24 DM25 DM26 DM27 DM28 DM29 DM30 DM31 DM32 DM33 DM34 DM35 DM36 DM37 DM38 DM39 DM52 PC1 PC2 PC3 PC4 HC GM6 TP20 TP21 BR10 BR11 BR12 BR17 BR18 BR21 BR26 SP3 SG9 SG27 WP6 WP7 WP8 WP9 WP10

Plier Section Plier Section Plier Section Plier Section Plier Section Plier Section Plier Section Plier Section Plier Section Plier Section Plier Section Plier Section Plier Section Plier Section Plier Section Plier Section Plier Section Plier Section Plier Section Plier Section Plier Section Plier Section Plier Section Plier Section Plier Section Plier Section Plier Section Plier Section Plier Section Plier Section Plier Section Plier Section Plier Section Plier Section Plier Section Plier Section(Backside) Plier Section(Backside) Plier Section(Backside) Plier Section(Backside) Plier Section(Backside)
Page 36

Not marked

Not marked

Not marked(N) Not marked(N) Not marked(N) Not marked(N) Marked as GM4

Not marked Not marked Not marked

438 439 440 441 442 443 444 445 446 447 448 449 450 451 452 453 454 455 456 457 458 459 460 461 462 463 464 465 466 467 468 469 470 471 472 473 474 475 476 477

Water Pump Dryer Air Compressor Induct Hardening Furnace Induct Hardening Furnace Induct Hardening Furnace Induct Hardening Furnace Induct Hardening Furnace Cooling Tower Cooling Tower Cooling Tower Cooling Tower Cooling Tower Milling Machine Milling Machine Lathe Machine Rivet Machine Rivet Machine Drill Machine Drill Machine Drill Machine Drill Machine Drill Machine Turning Adda Turning Adda Turning Adda Turning Adda Mig Welding Mig Welding Riveting Press Lathe Machine Lathe Machine Hydraulic Drill Machine Hydraulic Drill Machine Hydraulic Drill Machine Hydraulic Drill Machine Hydraulic Drill Machine Hydraulic Drill Machine Lathe Machine Hydraulic Lathe Machine Hydraulic

WP11 D6 CP3 IHF1 IHF2 IHF3 IHF4 IHF5 CT1 CT2 CT3 CT4 CT5 M21 M22 LA10 RM1 RM2 DM47 DM48 DM49 DM50 DM51 TA1 TA2 TA3 TA6 MW1 MW2 RP1 LA5 LA11 DMH1 DMH2 DMH3 DMH4 DMH5 DMH6 LAH1 LAH2

Plier Section Plier Section(Side) Plier Section(Side) Pipe Wrench Pipe Wrench Pipe Wrench Pipe Wrench Pipe Wrench Pipe Wrench Pipe Wrench Pipe Wrench Pipe Wrench(Back side) Pipe Wrench(Back side) Pipe Wrench Pipe Wrench Pipe Wrench Pipe Wrench Pipe Wrench Nano Section Nano Section Nano Section Nano Section Nano Section Nano department Nano department Nano department Nano department Nano department Nano department Nano department Nano Section Nano Section Nano Section Nano Section Nano Section Nano Section Nano Section Nano Section Nano Section Nano Section
Page 37

Not marked(N) Not marked(N) Not marked Not marked

Marked as LA1

Not marked(N) Not marked(N)

Marked as TA6 Not marked Marked as TA8 Marked as TA9

Not marked(N) Not marked(N) Not marked(N) Not marked(N) Not marked(N) Not marked(N) Not marked(N) Not marked(N) Not marked(N) Not marked(N)

478 479 480 481 482 483 484 485 486 487 488 489 490 491 492 493 494 495 496 497 498 499 500 501 502 503 504 505 506 507 508 509 510 511 512 513 514 515 516 517

Lathe Machine Hydraulic Lathe Machine Hydraulic Lathe Machine Hydraulic Drill Machine Stamp Press Stamp Machine Stamp Machine Cooling Tower Rotary Furnace Rotary Furnace Rotary Furnace Water Tank Water Tank Milling Machine Milling Machine Milling Machine Milling Machine Lathe Machine Lathe Machine Lathe Machine Stamp Press Drill Machine Drill Machine Drill Machine Drill Machine Drill Machine Drill Machine Drill Machine Drill Machine Threading Machine Centreless Machine Packing Machine Dabba Stitching Machine Box Stitching Machine Crane Packing Machine Trimming Press Trimming Press Trimming Press Trimming Press

LAH3 LAH4 LAH5 DM1 SP2 SM1 SM2 CT6 RF4 RF5 RF6 WT5 WT6 M5 M9 M7 M8 LA6 LA8 LA9 SP1 DM12 DM16 DM42 DM43 DM44 DM45 DM7 DM8 THM1 CMC1 PCM1 DSM1 BSM1 CRN6 PCM2 TP25 TP26 TP27 TP28

Nano Section Nano Section Nano Section Nano Section Nano Section Nano Section Nano Section Nano Section Heatreatment Section Heatreatment Section Heatreatment Section Nano Section (Backside) Nano Section (Backside) Screw Jack Section Screw Jack Section Screw Jack Section Screw Jack Section Screw Jack Section Screw Jack Section Screw Jack Section Screw Jack Section Screw Jack Section Screw Jack Section Screw Jack Section Screw Jack Section Screw Jack Section Screw Jack Section Screw Jack Section Screw Jack Section Screw Jack Section Screw Jack Section Packing Section Packing Section Packing Section Packing Section Packing Section(OEM) New Plant New Plant New Plant New Plant
Page 38

Not marked(N) Not marked(N) Not marked(N) Not marked(N)

Not marked Not marked

Marked as M12 Marked as M21 Not marked Not marked Not marked

Not marked(N) Not marked(N)

Not marked(N) Not marked Not marked Not marked Not marked

Induction Hardening 518 Furnace Induction Hardening 519 Furnace 520 Hydraulic Forging Press 521 Hydraulic Forging Press 522 Rolling Machine 523 Rolling Machine 524 Trimming Press 525 Trimming Press 526 Welding Set 527 Air Receiver Tank 528 Air Receiver Tank 529 Cooling Tower 530 Cooling Tower 531 Air Compressor 532 Air Compressor 533 Packing Machine 534 Heater 535 Heater 536 Belt Grinder 537 Rectifier 538 Rectifier 539 Rectifier 540 Diesel Generator 541 Fork Lifter 542 Fork Lifter

IHF6 IHF7 HFH1 HFH2 ROM1 ROM2 TP29 TP30 WS3 AIR1 AIR2 CT10 CT11 CP4 CP5 PCM3 HT1 HT2 BG22 R13 R14 R15 DG1 FL1 FL2

New Plant New Plant New Plant New Plant New Plant New Plant New Plant New Plant New Plant New Plant New Plant New Plant New Plant New Plant New Plant New Plant New Plant New Plant New Plant New Plant New Plant New Plant New Plant(Backside)

Not marked Not marked Not marked Not marked Not marked Not marked Not marked Not marked Not marked Not marked Not marked Not marked Not marked Not marked Not marked Not marked Not marked Not marked Not marked Not marked Not marked Not marked Not marked

*The (N) mark in the remarks column indicates new machine. Points worth noting from the above prepared master list:

A total of 37 new machines have been added since the last prepared master list on Jan10,2009 out of which 27 are in new plant area

A total of 31 old machines have been found scrapped on reconciling with the old database of master list

Page 39

A total of 210 machines have been found not marked because either they are new or their marks have been tempered

12 machines were having similar codes which have been changed and recorded in remark column

The new machines will be given the machine history card each while old machines already have it. It helps in knowing the whole history of machines in terms of money, machine hours lost, basic breakdown reasons etc from its installation to being scrapped. Machine History Card format: Machine History Card Machine Name: Date Type of maintenance Preventive\Predictive\B.O Reason Machine Code: Action Time Total Taken Taken Cost Remarks

BREAKDOWN RECORDS:

OSHO TOOLS PRIVATE LIMITED

BREAKDOWN MAINTENANCE REGISTER Time when Nature of Root Action problem problem cause Taken caused

Doc : TSF/TR/01

S.no

Date

Machine code

Time when Machine OK

Total Time

1-Jul-11

LA-06

10:30 AM 1:30 PM

1-Jul-11

BM-06

Cooling Pump Filter problem Motor setting problem

Filter blocked Belt broken condition

Cleaned Belt changed

11:00 AM

00:30

2:00 PM

00:30

Page 40

1-Jul-11

HB1

4:40 PM

Cooling Pump not working Oil pump problem Cooling Pump not working Roller not working Motor not working Spindle not working Gear box problem Roller not working Cooler pump leakage Improper work Gear box problem Oil pump leakage Motor not working Wheel not working

Anvil crack condition Anvil problem Pump damaged Bearing crack Motor wire burnt Spindle break condition Gear broken Roller damage Pump area damage Bearing break Gear broken Pump damaged Motor bearing broken Wheel Key broken

Anvil changed Anvil changed Pump changed Bearing Changed Motor overhauling Spindle replaced Gear changed Roller changed Pump changed Bearing Changed Gear changed Pump changed Bearing changed Wheel key changed

5:20 PM

00:40

1-Jul-11

SB1

6:10 PM

6:40 PM

00:30

2-Jul-11

IHF5

9:45 AM 12:00 PM 12:15 PM 1:10 PM

10:15 AM

00:30

2-Jul-11

TF1

12:45 PM

00:45

2-Jul-11

H1

1:00 PM

00:45

2-Jul-11

M5

1:50 PM

00:40

2-Jul-11

ZB4

1:20 PM

2:00 PM

00:40

10

2-Jul-11

TF5

2:00 PM

2:30 PM

00:30

11

2-Jul-11

IHF1

2:20 PM

3:00 PM

00:40

12

2-Jul-11

SB1

5:30 PM

6:35 PM

01:05

13

2-Jul-11

HB2

6:00 PM 10:50 AM 9:00 AM

7:00 PM

01:00

14

3-Jul-11

BR19

11:20 AM

00:30

15

6-Jul-11

Barrel2

9:35 AM

00:35

16

6-Jul-11

Barrel9

9:05 AM

9:35 AM

00:30

Page 41

17

6-Jul-11

HB3

10:20 AM 1:30 PM

Casting water motor not working Gear not working Break spring not working Temper Bhatti not working Motor setting problem Oil leakage problem Barrel fitting problem Cooling motor not working Filter improper work Gear not working Cooling Pump not working Gear box problem Gear not working Gear box problem
Page 42

Pump motor burnt Gear teeth damaged Break spring broken Motor burnt Nut and belt loosen Oil pump Damage

Motor Changed Gear changed Spring changed Motor Changed Nut and belt tighten Pump changed

11:00 AM

00:40

18

6-Jul-11

TF1

2:00 PM

00:30

19

6-Jul-11

TP6

2:45 PM

3:15 PM

00:30

20

6-Jul-11

HB1

3:15 PM

3:40 PM

00:25

21

7-Jul-11

Barrel8

9:00 AM

9:15 AM

00:15

22

7-Jul-11

BR6

9:40 AM

10:20 AM

00:40

23

7-Jul-11

ZB3

9:50 AM 10:30 AM 11:20 AM 11:25 AM 1:00 PM

24

7-Jul-11

HB2

Barrel nut Nut and bolt and bolt tighten loose Motor Bearing bearing Changed crack Filter cracked Gear setting and nut bolt loose Cooling Motor broken Gear broken Gear teeth crack Gear teeth broken Filter changed Nut and belt tighten Motor Changed Gear changed Gear changed Gear changed

10:10 AM

00:20

11:00 AM

00:30

25

7-Jul-11

ZB6

11:55 AM

00:35

26

7-Jul-11

Barrel1

12:00 PM

00:35

27

7-Jul-11

IHF2

1:40 PM

00:40

28

7-Jul-11

TP7

2:10 PM

2:45 PM

00:35

29

7-Jul-11

TP11

4:05 PM 11:10 AM

4:35 PM

00:30

30

8-Jul-11

TP4

11:45 AM

00:35

31

9-Jul-11

DM27

9:30 AM 12:05 PM 9:10 AM

Machine not working Belt problem Filter leakage Motor not working Motor problem Gear box problem Oil supply not proper Motor problem Brake not working Motor problem Chain not working Brake not working Belt problem Stand bolt problem

32

9-Jul-11

Barrel8

Motor bearing problem Belt broken condition Pump damaged Motor bearing broken Motor burnt Gear teeth broken Oil pump Damage Bearing break Bolt broken Bearing break Pulley of chain broken Bolt broken V-Belt broken Stand bolt broken

Bearing Changed V-Belt changed Pump changed Bearing Changed Motor changed Gear changed Pump changed Bearing Changed Bolt changed Bearing Changed Pulley changed Bolt changed V-Belt changed Bolt changed

10:00 AM

00:30

12:25 PM

00:20

33

10-Jul-11

F1

9:35 AM

00:25

34

11-Jul-11

HT7

4:45 PM 11:30 AM 5:30 PM

5:35 PM

00:50

35

13-Jul-11

SB4

12:00 PM

00:30

36

13-Jul-11

HB3

6:05 PM

00:35

37

14-Jul-11

HT2

4:40 PM

5:00 PM

00:20

38

14-Jul-11

ZB2

6:30 PM

7:15 PM

00:45

39

14-Jul-11

TP3

5:30 PM 11:00 AM 11:10 AM 3:40 PM

6:00 PM

00:30

40

14-Jul-11

Barrel4

11:30 AM

00:30

41

14-Jul-11

IHF2

11:40 AM

00:30

42

15-Jul-11

TP3

4:05 PM

00:25

43

16-Jul-11

BG5

9:00 AM

9:10 AM

00:10

44

16-Jul-11

H3

9:30 AM

9:45 AM

00:15

Page 43

45

16-Jul-11

HB

10:00 AM 10:15 AM 10:55 AM 11:35 AM 3:20 PM

Motor not working Bearing problem Pump problem Pump problem Pump problem Hardening roller problem Bearing problem Machine not working Gear box problem V-Belt problem Oil pump leakage Motor problem Oil pump not working Wheel not working

Bearing break Bearing ring problem Pump area damage Pump area damage Pump broken Gear are broken Bearing break Side plate broken Gear cracked V-Belt broken Pump damaged Bearing break Pump area ring loose Wheel stopper and bolt loose

Bearing Changed Bearing ring changed Pump changed Pump changed Pump changed Gear changed Bearing Changed Side plate changed Gear changed V-Belt changed Pump changed Bearing Changed Pump area ring changed Nut and bolt tighten

10:45 AM

00:45

46

16-Jul-11

H7

11:00 AM

00:45

47

16-Jul-11

NCT2

11:35 AM

00:40

48

16-Jul-11

F3

12:00 PM

00:25

49

17-Jul-11

F6

3:55 PM

00:35

50

17-Jul-11

SBH2

3:30 PM

4:20 PM

00:50

51

17-Jul-11

H7

3:30 PM 11:10 AM 11:25 AM 9:00 AM

4:15 PM

00:45

52

18-Jul-11

ASG4

12:00 PM

00:50

53

18-Jul-11

ZB4

12:15 PM

00:50

54

20-Jul-11

LA2

9:20 AM

00:20

55

20-Jul-11

SBH1

9:45 AM 10:00 AM 11:55 AM 4:40 PM

10:35 AM

00:50

56

20-Jul-11

Barrel1

10:45 AM

00:45

57

20-Jul-11

SBH3

12:20 PM

00:25

58

20-Jul-11

BP1

5:10 PM

00:30

Page 44

59

21-Jul-11

IHF1

10:25 AM 12:50 PM 4:40 PM

60

21-Jul-11

CP2

61

21-Jul-11

DM1

Hardening Filter not working Compresso r not working Machine not working Bearing problem Machine not working Motor not working Gear box problem Gear problem Machine not working Motor problem Not working Gear box problem Pulley problem Motor stand problem

Roller damaged Valve are broken Pulley broken Bearing break Bearing break Motor Pulley broken Gear broken Nut and bolt loosen Bearing break Bearing break Break condition Gear box broken Pulley broken Stand broken

Roller changed Valve changed Pulley changed Bearing Changed Bearing Changed Pulley changed Gear changed Nut and bolt tighten Bearing Changed Bearing Changed Pump changed Gear box changed Pulley changed Stand replaced

11:10 AM

00:45

1:40 PM

00:50

5:00 PM

00:20

62

21-Jul-11

Barrel7

4:50 PM

5:30 PM

00:40

63

21-Jul-11

DM9

6:15 PM

7:20 PM

01:05

64

22-Jul-11

SB2

9:30 AM

10:45 AM

01:15

65

22-Jul-11

TP6

2:15 PM

3:10 PM

00:55

66

22-Jul-11

TP9

3:45 PM

4:00 PM

00:15

67

22-Jul-11

TP2

4:20 PM

5:00 PM

00:40

68

22-Jul-11

Barrel8 Oil pump ZB8

5:00 PM

5:45 PM

00:45

69

23-Jul-11

9:00 AM

9:35 AM

00:35

70

25-Jul-11

9:55 AM

10:25 AM

00:30

71

25-Jul-11

GM22

4:00 PM

4:30 PM

00:30

72

26-Jul-11

H2

9:15 AM

9:35 AM

00:20

Page 45

73

26-Jul-11

ZBM1

9:40 AM 10:00 AM 10:30 AM 11:05 AM 11:45 AM 12:05 PM 3:45 PM

Filter problem Motor problem Pump problem Filter problem Brake not working Machine not working Motor not working Roller not working Pulley problem Barrel fitting problem Chain not working Machine not working Pipe not working Motor not working

Filter broken Bearing break Pump broken Filter leakage Brake broken Bearing broken Bearing broken Roller gear broken Pulley broken

Filter changed Bearing Changed Pump changed Filter changed Brake changed Bearing changed Bearing changed Roller changed Pulley changed

10:35 AM

00:55

74

26-Jul-11

ZBM8

11:15 AM

01:15

75

26-Jul-11

IHF1

11:30 AM

01:00

76

26-Jul-11

NF2

11:45 AM

00:40

77

26-Jul-11

H4

1:25 PM

01:40

78

27-Jul-11

D2

1:10 PM

01:05

79

27-Jul-11

H5

5:00 PM

01:15

80

27-Jul-11

SB6

4:20 PM 11:10 AM 2:10 PM

5:40 PM

01:20

81

28-Jul-11

TP11

11:45 AM

00:35

82

28-Jul-11

ZBM10

Barrel nut Nut and bolt and bolt tighten loose Chain set broken Wheel Key broken Pipe damaged Bearing broken Chain set repaired Wheel key changed Pipe changed Bearing Changed

2:55 PM

00:45

83

28-Jul-11

ATN1

2:30 PM

3:15 PM

00:45

84

28-Jul-11

TP2

4:00 PM

6:15 PM

02:15

85

28-Jul-11

IHF1

4:45 PM

5:30 PM

00:45

86

29-Jul-11

DM27

4:40 PM

6:00 PM

01:20

Page 46

87

30-Jul-11

H7

11:50 AM 3:20 PM

Pipe not working Machine not working V-Belt problem Pipe leakage problem

Pipe damaged Bearing broken V-Belt broken Pipe damaged

Pipe changed Bearing Changed V-Belt changed Pipe changed

12:30 PM

00:40

88

30-Jul-11

DM37

4:00 PM

00:40

89

30-Jul-11

Barrel7

4:20 PM

4:45 PM

00:25

90

30-Jul-11

IHF1

5:00 PM

5:35 PM

00:35

The total time used up in making the breakdown maintenance is compared with the standard target hours set as 50 hours Total Time 58:00

The above records are taken from the breakdown maintenance register maintained daily by supervisor of maintenance department. These records will be analyzed in next pages.

ANALYSIS OF BREAKDOWN HOURS:

Breakdown data analysis

Actual hours

Target hours

46

48

50

52

54

56

58

60

Time (Hours)

Page 47

The above graphical diagram represents the difference between the target hours set and the actual number of hours breakdown has occurred in the factory during the month of July. Following are the points worth noting: The standard breakdown time for the month has been set as 50 hours The actual breakdown which occurred during the month is 58 hours which is above the standard hours set The breakdown has been exceeded by 8 hours(58-50) causing more wastage of labour hours, machine hours and resources than anticipated

Although the breakdown exceeded the target hours set but still it was under control considering the peak production period of July The same trends is expected for the month of August too since it is also peak production periods

ANALYSIS OF CAUSES:
S.no 1 2 3 4 5 6 7 8 9 Causes Filter problem Belt broken Anvil cracked Bearing Problem Gear problem Nut and Bolt loose Pulley problem Pump problem Miscellaneous TOTAL Hours:mm 5:10 10:00 6:00 13:05 10:15 6:00 2:15 3:15 2:00 58:00

Page 48

The data above in tabular form shows the cumulative number of hours of the causes due to which breakdown occurred. In all there are 8 main causes and some other causes grouped as miscellaneous. The following things are noticed:

The bearing problem occupy a dominant share in breakdown which shows that the machine is over-run at times causing friction to damage bearing The gear problem and belt broken have somewhat equal share in breakdown causes. The belt broken breakdown hours is normal considering the extensive use of belts in many machines such as grinding,autoshank etc The gear problem can be attributed to lack of maintenance and oiling causing frequent breakdown due to this reason The anvil cracks also causes considerable breakdown hours loss Nut and bolt loosen although a minor issue but still caused 6 hours of breakdown hours loss which attracts quick action to reduce the same Other issues causing breakdown such as pump problem, filter problem etc are result of normal processes although their fix down time can be reduced

PIE CHART ANALYSIS:

Page 49

The pie chart above represents the percentage share of different causes in the breakdown on dimension of time in terms of hours lost due to them. It brings to light the following issues:

Bearing problem occupy a big chunk in pie diagram i.e. 27%. It raises a question on the quality of bearings used and the need to check over-run causing damaged bearings The gear problem which is the 2nd largest chunk in the diagram shows the need to properly oil the gears before they are used Belt broken is certainly the only excusable cause in the pie at 3rd chunk occupying 17% because of the extensive use of belts in different machines and the effort to maintain quality due to which tempered belts are quickly replaced The anvil and nut problem occupy similar 10% share to the cause Other causes such as pump problem, pulley problem and miscellaneous causes contribute about 13% to it

Page 50

CHAPTER - 4

CONCLUSIONS AND RECOMMENDATIONS

Page 51

CONCLUSIONS:

From the report I have prepared I come to conclude the following things from my observations:

The maintenance department is one of the most crucial department for the uninterrupted smooth working of operations in the factory A well worked breakdown maintenance along with predictive and preventive maintenance has helped the Venus tools to keep the wastage of labour hours , machine hours and resources in control

The master list of machines revised revealed the new machines acquired and the old machines scrapped. It also facilitated the making of history cards for the new machines so that their maintenance history can be recorded

The breakdown hours from the standard set of 50 hours exceeded by 8 hours but considering the peak production periods of July it was still under a manageable limit

The top 3 causes of breakdown are the bearing problem, gear problem & belt broken contributing 58% combined to loss of hours. The gear problem can be reduced by proper oiling while bearing problem is more due to over-run of machines which need to be checked to reduce loss

The breakdown of machinery is inevitable but the loss of time and resources caused by it has been reduced significantly due to proper prior planning and quick action

Page 52

RECOMMENDATIONS:

From my stint of 6 weeks of internship in the maintenance department I would like to recommend following things for improvement: More repair mechanics should be recruited or the work shall be contracted for some special critical type machines like hammers,broaching machines etc especially during peak months to save the cost and time of breakdown repairs

Although instructions are placed to dry run machines once and oil them if needed when worker uses it for 1st time in a day, the supervisor of the departments should ensure that workers strictly adhere to these to reduce breakdown

The quality of material consumables in machines like bearings, belts etc which are profusely used should be properly checked before they are used to reduce frequent breakdown loss

The cost of the equipment being changed in machine although recorded in history card but effort should also me made to periodically review maintenance cost on critical machines

Last but not the least a cooperation should me made between maintenance and all production departments in which maintenance department should be informed well
Page 53

before in time of predictive maintenance of machines so that cost and time of machine stop time can be reduced

BIBLIOGRAPHY

Books:
Jacobs, R.; Operations Management, Sultan Chand and Sons, 2001. Madhavan, P.; Maintenance of machines, Excel Books, 2006.

Websites:

http://www.oshotools.com http://www.google.com/articles/245/predictive&preventivemaintenance.html http://www.wikipedia.com/operations/maintenance/443267.html http://www.yahoo.in/yahooanswers/operations&theirmaintenance.html

Page 54