Presenter Name:: Duration of Presentation Presentation: 10 Min Q & A: 05 Min

Progressive Maintenance
Presentation No 13 PM Pillar Activities
PM Analysis – Frame Numbering m/c
Presenter name :
Duration of presentation
Presentation : 10 Min
Q&A : 05 Min
Slide Number: 1 TVS Motor company – P2

Business Expectation & Progressive Maintenance
PM Pillar Activities
Objective
Eliminating line stoppers and reducing maintenance cost were the business
expectations from PM pillar.
The objective of PM pillar is to
 Improve availability of machines by achieving Zero Breakdown

 Reduce Maintenance cost & Energy Cost

Targets Progressive Maintenance
02-'03 Target %
Area of focus Category Measure UOM 03-'04 04-'05 05-'06 06-'07 07-'08
BM From BM
Line stopper Numbers 1344

Line stopper 0 0 0 0 0 100%
(Vehicles) /month
Break down Numbers 809
D 590 450 250 97 37 95%
frequency /month
Break down
Break down Hours 910 650 510 330 114 33 96%
hours /month
Manufacturing Maintenance Rupees 360
C 260 240 220 196 243 32%
cost cost /vehicles
Targets for PM

Layout of Plant 2 PM Pillar Activities

Process flow of Plant 2
N
Painting Unit
Engine
Vehicle Assembly Fabrication Unit
Assembly
Machining Machining
To Stores Unit Stores
Unit
vehicle
ware house
Vehicle MIW Parts Supplier parts

Introduction PM Pillar Activities
PC
NUMBERING HEAD
COMPONENT
CLAMPING
PRINTER

Machine Ranking Progressive Maintenance
Vehicle Assy PM Analysis – Frame Numbering m/c

Location Machine Name Machine No Rank
STAR VEHICLE ASSY CONVEYOR 204004300 A
STAR VEHICLE ASSY PETROL TANK LEAK TESTING M/C 506048000 A
STAR VEHICLE ASSY PETROL TANK LEAK TESTING M/C 506060700 A
STAR VEHICLE ASSY PRECITEC NUMBERING M/C 203000400 A
STAR VEHICLE ASSY CHASIS - I 506103400 B
STAR VEHICLE ASSY CHASIS - II 506103500 B
STAR VEHICLE ASSY CHASIS - III 506103600 B
STAR VEHICLE ASSY CHASIS - IV 506103700 B
STAR VEHICLE ASSY CHASIS - V 600012600 B
STAR VEHICLE ASSY CONE BOTTOM PRESSING 204020800 B
STAR VEHICLE ASSY FORK OIL FILLING M/C 506128000 B
STAR VEHICLE ASSY FRONT FORK SUB ASSY 202039900 B
STAR VEHICLE ASSY FRONT PANEL SPEEDOMETER ASSY 204020000 B
STAR VEHICLE ASSY PILLION FOOT REST RUBBER PRESSING 620008100 B
STAR VEHICLE ASSY SWING ARM BUSH PRESSING M/C 302014700 B
STAR VEHICLE ASSY SWING ARM BUSH PRESSING M/C 620138800 B
12 Equipment Failure details (06-07) UOM : Nos

8
9
5
FREQ
6 4
2
3
NUMB M/C LEAK TEST M/C 1 LEAK TEST M/C 2 CONVEYOR

Vehicle Assy layout Progressive Maintenance

Warehouse
Booking
Chassis dynamometer
Frame
numbering
m/c
Conveyor Main line

* Frame numbering m/c stoppage affects the conveyor.

•NUMBERING HEAD
•FRAME
NUMBERING IMPRESSION


Specify Phenomenon
NUMBERING NOT IN STRAIGHT LINE IN HORIZONTAL DIRECTION
Frame
MD6256F5271E63962
NOT OK NUMBERING
Understand Phenomenon

Numbering Path PM Pillar Activities
MD6256F5
271E63962
Stylus Marking path Stylus Movement path
Conclusion : The stylus takes the shortest path from the end point of a number to
starting point of the subsequent number.
Number shift pattern Progressive Maintenance

Type 1 Type 2 Type 3 Type 4
5 H 6 1 2 7 5 8
Only X axis moves Both X & Y axis moves
50 % 50 %
Movement path
STEP 1 : CLARIFY THE Progressive Maintenance
PHENOMENA WITH 5W 1H

DEFINE PHENOMENA :
Numbering Shifting from Center line on upper side
MD6256F5271E63962
OK FRAME
Shift
MD6256F5271E63962
NOT OK FRAME
STEP 2 : CONDUCT PHYSICAL Progressive Maintenance
ANALYSIS
Understand Machine functioning PM Analysis – Frame Numbering m/c
Power Signals Drive commands

PC DRIVE UNIT
NUMBERING HEAD
HYDRAULIC Frame
POWER PACK Clamping
Stylus
X Axis
Numbering Geometry
Y Axis

ANALYSIS
Understand M/c functioning PM Analysis – Frame Numbering m/c
Drive belt
Drive motor
Carriage Bush
Guide rods
Driven pulley
Carriage with guide rods
Driven pulley

ANALYSIS
A : Identify Operating Principle PM Analysis – Frame Numbering m/c
AXIS MOVEMENT
• The Stepper motors through
the timer belt move X & Y axes.
BLOCK DIAGRAM FOR AMPLIFIER UNIT ( NUMBERING M/C )
MMI KEYPAD & STEP DOWN

INDICATION LED'S TRANSFORMER
2. The amount of movement is decided by the

SMPS
OPTIONAL REGULATED POWER
CONNECTORS FOR SUPPLY SECTION
ADDON CARDS
pulses supplied to stepper motor by drive unit. CPU
LINE SURGE
SUPPOSER
OPERATING
VOLTAGE
SELECTION
UNIT 110V/220V
MEMORY SOL RELAY AXIS MOTOR SUPPLY

BATTERY CONTROL SECTION
X
Y
RS232 TO REMOTE POWER

PC INTERNET START/STOP NUMBERING
SUPPLY 230V AC 50 Hz
SIGNALS HEAD INPUT
3. The supply of pulses by the drive unit is controlled

by the processor with respect to the program fed by
the operator

ANALYSIS
A : Identify Operating Principle PM Analysis – Frame Numbering m/c
1. The numbering impression is created by hammering effect of the stylus.. The down
movement is controlled by the pneumatic pressure & up movement by a spring.
1c 1a STYLUS PARTS
1e 1a. Outer body
1d 1b. Stem Guide bush (brass)
1c. O ring
1d. Stem
1e. Spring
Stylus Assy
1. Stylus
2. The hammering effect is generated by
sequential operation of solenoid valves 18
18. Pneumatic solenoid
8a valves
in pneumatic circuit. 1
18a 18a. Solenoid control

3. This is controlled by the main processor cable
making 12 V supply ON & OFF to the
valves. 19a. Air inlet hose
22
19a 22.Air Outlet
ANALYSIS
B : Identify Operating Standards PM Analysis – Frame Numbering m/c
AXIS MOVEMENT
1. The reference point (home position) of the stylus should not go out of memory
3. The Co ordinate setting for the numbering should not be disturbed.
5. Y axis should be parallel to frame axis
B : Identify Operating Standards
1. The stylus needle point should be sharp
2. No welding spatter or beads should be present on frame surface
3. Air pressure should be maintained at 4~6 Kg / cm2
4. Hydraulic clamping pressure should be 40 ~ 50 kg / cm2
5. Voltage supply for solenoid valves should be 12V

ANALYSIS
PHENOMENA
Numbering Shifting from Center line on upper side
DEFINE RELATED CONDITIONS
Y AXIS A Y axis “A” &
Numbering axis “B”
NUMBERING 54864163E03220 B
MAD2
AXIS
QUANTIFY THE REALTIONSHIP BETWEEN INTERACTING ELEMENTS

Y AXIS A
C Distance “C” between Y axis “A”

NUMBERING 54864163E03220 B
AXIS
MAD2 & Numbering axis “B”
DEFINE QUANTITATIVE PHYSICAL CHANGE

Y AXIS A The distance [C]
r t C
between the Y axis [A] &
NUMBERING
AXIS
MAD2
54864163E03220 B
Numbering Axis [B]
varies [D]
D(r≠t) TVS Motor company – P2
Slide Number: 19
STEP 3 : IDENTIFY CONSTITUENT CONDITIONS Progressive Maintenance
STEP 4 : STUDY 4Ms FOR CAUSAL FACTORS

CONSTITUENT CONDITION PRIMARY 4 M ANALYSIS
1. Frame rotates/ moves while

1.1 Clamp force is less than the weight of
numbering.
frame.
1.2 Clamping stroke is not enough to hold

frame
9. The stylus slips
2.1 Play in needle / bush
2.2 Play between Stylus body & main housing


CONSTITUENT CONDITION PRIMARY 4 M ANALYSIS
3. Drive does not reach desired 31 Drive belt slips

position 3.2 Motor does not rotate by desired angle.
3.3 Slides Jam.
3.4 Not restarting from home position
A
Home for Y axis
r t
C
Shift Numbering axis
D(r≠t)


PRIMARY 4 M ANALYSIS SECONDARY 4 M ANALYSIS
1.1.1 Clamping fixture seating wear out.

1.1 Clamp force is less than the weight of 1.1.2 Hydraulic pressure is low
frame.
1.1.3 Frame seating surface damage
Frame Clamping cylinder
1.2 Clamping stroke is not enough to hold 1.2.1 Frame cone length less than spec
frame
Play 1.2.2 Clamping cylinder stroke is less.
Stroke not
enough


2.1 Play in needle / bush 2.1.1 Punching needle wear out

2.1.2 Brass bush wear out.
Guide Bush
Needle
Needle slipping
Due to play
2.2 Play between Stylus body & main 2.2.1 Mounting thread wash out.
housing 2.2.2 Stylus not tightened properly.
Guide Bush
Needle
Body is loose
Due to play


1 Drive belt slips 3.1.1 Belt teeth wear out.

3.1.2 Idler pulley mounting loose.
3.1.3 Drive gear teeth wear out
3.2.1 Faster sequencing

3.2 Motor does not rotate by desired angle.
3.2.2 More load
3.3.1 Guide bush misalignment

3.3 Slides Jam.
3.3.2 Lack of lubrication
3.3.3 Foreign material entry ( Burr )
3.4 Not starting from home position 3.4.1 No feedback of home positioning.

Kaizens implemented Progressive Maintenance
Abnormality Improvement
• Dust accumulation on guide rods •Provide bellow cover to avoid dust entry
• Stylus thread damaged •Introduce adapter piece between stylus &

housing bore.

Kaizens implemented PM Pillar Activities

• Dust entry in guide ways bush •Provide bellow cover between bush
• Home position not reached •Interlock home position sensing with

cycle start .
No
feedback
for home
positioning

• Clamp with low hydraulic pressure • Introduce Pressure switch & interlock
with cycle start
Only Hydraulic
pressure indicating
gauge available
• Correct stroke length as per spec in system &

• Stroke length of stylus more
lock with password.
Incorrect entry


• High air pressure than recommended •Provide regulated pressure with gauge
indication
Only pressure
indicating gauge
available
•Belt mounting loose Mounting •Provide double belt locking.

Bolt Additional
Body
backing
belt
Belt

ANALYSIS
Direction
Stator coils of rotation
Rotor
Operating principle
A stepper motor converts electrical energy into discrete motions or steps.
It consists of rotor which has projecting teeth which align with the magnetic fields of the
windings. When the coils are energized in sequence by direct current, the teeth follow the
sequence and rotate a discrete distance necessary to re-align with the magnetic field.
The number of coil and the number of teeth determines the number of steps (resolution) of
the motor. For eg , a 200 step per rev (spr) motor has 50 rotor teeth times 4 coil combinations
to equal 200 spr.

ANALYSIS
Direction
Stator coils of rotation
Rotor
Operating principle
 If 1 > 2, the rotor will slip.** Sequencing of pulses = 1
Rotor movement =2
 If the rotor slips (step loss), it will align with the next available magnetic pulse.
** This results in pulse missing for drive to move & stylus doesn't travel as desired.

Manufacturer recommendation Progressive Maintenance

Rated Actual
Number Marking Speed : 15 mm /sec 20 mm/sec **
Axis movement speed : 110 mm /sec 200 mm /sec
** This results in pulse missing for drive to move & stylus doesn't travel as desired.
** The numbering starts well above the reference line & results in NOT OK
Component.

Results Progressive Maintenance

10 EQUIPEMENT FAILURE – Frame numbering machine
9 Better
8
UOM : Frequency
7
3
2 2
2
1 1 1 1
1
0 0 0 0 0 0 0 0 0 0 0 0 0
0
Jan,07
Wk 10
Wk 8
Wk 9
Feb
Jun
Jun
Oct
Oct
Jul
Jul
May
May
Mar
Nov
Nov
Dec
Dec
Sep
Sep
Aug
Aug
Apr
Apr
Plan Actual Limit

Intangible benefits Progressive Maintenance
•Problem solving approach improved by understanding

machine functioning.

End of presentation

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Progressive Maintenance

Presentation No 13 PM Pillar Activities

PM Analysis – Frame Numbering m/c

Slide Number: 1 TVS Motor company – P2

The objective of PM pillar is to

 Improve availability of machines by achieving Zero Breakdown

Slide Number: 2 TVS Motor company – P2

PM Analysis – Frame Numbering m/c

Line stopper Numbers 1344

Slide Number: 3 TVS Motor company – P2

PM Analysis – Frame Numbering m/c

Vehicle MIW Parts Supplier parts

PM Analysis – Frame Numbering m/c

Slide Number: 5 TVS Motor company – P2

Vehicle Assy PM Analysis – Frame Numbering m/c

STAR VEHICLE ASSY PETROL TANK LEAK TESTING M/C 506048000 A

STAR VEHICLE ASSY PETROL TANK LEAK TESTING M/C 506060700 A

STAR VEHICLE ASSY PRECITEC NUMBERING M/C 203000400 A

STAR VEHICLE ASSY CHASIS - I 506103400 B

STAR VEHICLE ASSY CHASIS - II 506103500 B

STAR VEHICLE ASSY CHASIS - III 506103600 B

STAR VEHICLE ASSY CHASIS - IV 506103700 B

STAR VEHICLE ASSY CHASIS - V 600012600 B

STAR VEHICLE ASSY CONE BOTTOM PRESSING 204020800 B

STAR VEHICLE ASSY FORK OIL FILLING M/C 506128000 B

STAR VEHICLE ASSY FRONT FORK SUB ASSY 202039900 B

STAR VEHICLE ASSY FRONT PANEL SPEEDOMETER ASSY 204020000 B

STAR VEHICLE ASSY PILLION FOOT REST RUBBER PRESSING 620008100 B

STAR VEHICLE ASSY SWING ARM BUSH PRESSING M/C 302014700 B

STAR VEHICLE ASSY SWING ARM BUSH PRESSING M/C 620138800 B

12 Equipment Failure details (06-07) UOM : Nos

NUMB M/C LEAK TEST M/C 1 LEAK TEST M/C 2 CONVEYOR

Slide Number: 6 TVS Motor company – P2

PM Analysis – Frame Numbering m/c

Conveyor Main line

Slide Number: 7 TVS Motor company – P2

PM Analysis – Frame Numbering m/c

Slide Number: 8 TVS Motor company – P2

PM Analysis – Frame Numbering m/c

Slide Number: 9 TVS Motor company – P2

PM Analysis – Frame Numbering m/c

PM Analysis – Frame Numbering m/c

Slide Number: 12 TVS Motor company – P2

Numbering Shifting from Center line on upper side

Power Signals Drive commands

Slide Number: 14 TVS Motor company – P2

Carriage with guide rods

Slide Number: 15 TVS Motor company – P2

BLOCK DIAGRAM FOR AMPLIFIER UNIT ( NUMBERING M/C )

MMI KEYPAD & STEP DOWN

2. The amount of movement is decided by the

pulses supplied to stepper motor by drive unit. CPU

MEMORY SOL RELAY AXIS MOTOR SUPPLY

RS232 TO REMOTE POWER

3. The supply of pulses by the drive unit is controlled

Slide Number: 16 TVS Motor company – P2

18a 18a. Solenoid control

3. The Co ordinate setting for the numbering should not be disturbed.

5. Y axis should be parallel to frame axis

B : Identify Operating Standards

1. The stylus needle point should be sharp

2. No welding spatter or beads should be present on frame surface