Problem

Do You Want zero Breakdowns ???

 Follow me………..!

Machine
Operator
Technician
Sub-Admin
Admin
 Machine Says !

 Please make me PM Monthly.

 Please give me Lubrication, Grease
before my death slow.
 Operate me after take good Training
 Please Clean me daily.
 Please take daily maintain as per
check sheet.
 Don’t kill me by poor operator &
Technician.
 Machine Says !

 please touch me smoothly.

 Please don’t Spoil my capacity by
unsystematic operations
Pease Follow 5s on me & near to me

If You follow the terms of above then surly I will

give to you as target -1800/hr
 Operator Says!

 Give me well Training For Applicator setting.

 Don’t Manage By many P1 & P2 Officers at the same time.
 Don’t Give me Urgently Work order when running of the
Machine.
Give me the work order as priority & systematic.
Don’t change me Daily to other Machine.
Always I needs Maintenance Technician help.
Follow this process properly

machine operator

Admin Technician

Sub-Admin
 Why? Why? Why? Analysis

Why you didn’t take PM properly?

Why you stopping the machine due to no available of
spare parts?
Why the ex-Technician left from Company?
Why you Have more down times?
Why didn’t follow Morning meeting with Production
dept?
Why you have different down time between production &
A+ software?
Why you didn’t follow the Systematic inventory for the PES
spare parts maintaining.
 Why you have stopping of machine with long Time?
 ---Well Training?
 Why you put the operator before
Why you using the work order 10 days before date?
Why always you have urgently work order?
Cant you follow the Systematic operations?
Why many operators resigned his job very soon from joining
date ?
What is the reason for that?
Why you keeping the Applicator at wrong location?
Pro
Why always have poor communication between shift d uct
ion
supervisor?
 Processing Of Machines
Root cause of Schunk M/c.
This machine scraped due to problem not solved
After analysis and checked the control unit, found fault In PLC CPU
failure.
That unit replaced with another one CPU. then problem solved.
Now machine condition is ok, nothing but a problem of Measuring
height seems to be invalid.
I checked all Components relative to above Problem. I suspecting in
proportional Valve. It to be confirm with seniors help.
 PLC PCB to be service or new purchase .
PLC CPU
This problem to be solved in Schunk 11(scrapped ) M/c
 Ac 80-3 Machine Status
Root Cause of this M/c
This M/c not running due to CFM communication problem.
 Checked Trigger & CFM Out put communication between
Machine. Those condition is perfect.
System Parameter Value updated as per manual of that unit.
But there is no response in CFM Evaluation Unit.
I suspecting in CFM processing unit.
If we change that unit with another one, then may solve problem.
Otherwise must to be exchange the MX-20 model CFM.
If we made exchange, then we need Communication Cable, Force
sensor for bottom position.
 CFM Evaluated Unit

Trigger sensor Force sensor

 640 545
0
1 2 3 4
Weeks

wn Times of Auto Cutting Machines Feb-2011

Weekly down times

Date Machine Applicator schunk
1st - Week 15040 4740 6095
2nd- Week 3440 4440 3600
3rd- Week 3522 4735 1480

22002 13915 11175

Total Man hrs/ 366.7 231.917 186.25

Down Times For Feb-2011

16000 15040
14000
12000
In Man Mnts

10000 A/c Machine

8000 6095 AppLicator
6000 4740 4735
4440 Schunk
3522
3440 3600
4000
1480
2000
0
1 2 3
Weeks
To be must follow this process properly
 If You Follow Me then reduce the down Time by myself.
CWO Check Sheet (Applicator Status)

Date Shift Emp- Name Emp- Code App-No Put / Out Time Status Emp/sign Qty/sign Remarks Action Taken Maint/Sign

Aapproved By
 Follow this points for CWO Check sheet.
Do fill the Name, code, date, App-No, and put/out time as per check
sheet.
The Status column should be fill after take 3-sample with QA check &
QA sign.
If any remarks is in the used applicator then must to be informed to
Maintenance. (Do not keep in Location)
Problematic Applicator should be identify with Red alert card by
Quality.
After took all action, The Label to be stick on Applicator Ram Guard.
(Label details will be as Name, Date, Out time, used M/c No.)

Conditions for Operator

If any remarks during the setup of applicator, the only responsible for
that used Operator.
The Applicator should not be without Label, if any Applicator like that,
the responsible depends of Machine Operator.
Do Introduce me for unnecessary stop the Machine

Follow me……save the Machine running time from

unnecessary Stopping during the Power Change hour.
Time Details during the change hour .

Total Takes time for change hour 5.min / One time

Total Machine stopping time for change hour 4. min / One time

we have 3 change hour times per day for 26 machines

total Machine stopping time for change hour 4*3 12 min/ day for a Machine

Then total machine stopping for change hour 26 * 12 312 min/day

Total takestimefor Alarm method

Alarm will be turn ONN for 10 sec/ One time

for change hour 7 sec
then Total takes time for a day (10+7)* 3 51 sec/ day for a Machine

Total times for all machines 22.1 min/ day

then total saving time per day 312-22.1 289.9 min/day

 RFA Applicator Status
RFA Applicator (04- type) always running with twist variation
problem.
We took many action for solved problem. But frequently same
problem is arising.
Every time we are able to solve, for temporarily purpose . But
should be solved permanently.
Reasons found as per my experience.
1. If we use the crimp height according to the Mecal type
Applicator for 04- Applicator, there is no problem. But
Quality assurance will give poor result for this crimp height
modifying.
Same time we didn’t attend like this problem in Mecal type
Applicator.(so we can’t follow this process due to quality
assurance problem)
2. Design of TERMINAL is such that, surface is across to the
crimping support plate. It will twist the terminal during full
force crimping.
(Note: The Crimping support plate to be modified suitable for
Terminal design or Terminal design to be modified)

3. If we use the terminal Spool as Lot no-38P9878 , no problem

in Crimping occurs.
If we use the terminal Spool as Lot no-34P9732 , problem in Crimping
occurs.

(it to be Considered with Income Quality dept )

After analysis above terms we decided one thing. Modify the
04- Applicator crimping plate and Anvil according to the
Mecal type applicator Measurements as following below.
Now this process is going on.

Mecal 04-Applicator
plate
plate
Anvil
Anvil

1.48
1.47 1.65
1.63
 Heat shrinking machine Status
We have 4.Nos of Heat shrinking M/c, those machine was not
running up to 4 months nothing but One M/c.
After handovers to CWO implements Team. That corrected from
some Electronics and Mechanical fault.
Today 3 M/c is working with Production.

Root cause and analysis

A Machine had problem in PCB short circuit by rust, and
positioning sensor time out. Another Machine had problem in
Timer setting parameter, Key pad locked and password was not
known.
Last machine, having problem with MOTOR. It is to be solved as
early as possible.
 Not Running of the machine BEFORE

Komax 2 Not Running of the Machine

19
ac-80 2 20
mecal 1 15
schunk 2
heat srink 4 10
6
4
Ontal 6 5 2 2 1 2 2
tupe cuttin 2
0

Total 19

Not Running of the Machine

Not Running of the machine AFTER

Komax 0
ac-80 1 10 Not Running of the Machine 9
mecal 1 8
schunk 1
6 4
heat srink 1
Ontal 4 4
tupe cuttin 1 2 1 1 1 1 1
0
0
Total 9

Not Running of the Machine

To be Continued………..