"IMPROVING OVERALL EFFICIENCY OF THE CUTTING MACHINES BY IMPLETATION OF PILLARS OF TPM"project done at godrej&boyce........

Bharati Vidyapeeth College Of Engineering

UNIVERSITY OF MUMBAI A PROJECT REPORT ON IMPROVING OVERALL EFFICIENCY OF THE CUTTING MACHINES BY IMPLETATION OF PILLARS OF TPM

SUBMITTED BY YASHRAJ V. RANE HARSHAD V. SURYAWANSHI KALPESH D. KHOCHARE AMOL P. SHETKE DHIRAJ B. WAGHMARE

GUIDED BY PROF L. R. SURYAWANSHI

1

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Bharati Vidyapeeth College Of Engineering `

(INTERNAL GUIDE) DEPARTMENT OF MECHANICAL ENGINEERING BHARATI VIDYAPEETH’S COLLEGE OF ENGINEERING SECTOR -7,CBD BELAPUR,NAVI MUMBAI-400614 MUMBAI-400614 2009-2010

Bharati Vidyapeeth’s College of Engineering (Affiliated to the University of Mumbai) Sector 7,CBD,Navi Mumbai-400614

A PROJECT REPORT ON

IMPROVING OVERALL EFFICIENCY OF THE CUTTING MACHINES BY IMPLETATION OF PILLARS OF TPM SUBMITTED BY YASHRAJ V. RANE


























HARSHAD V. SURYAWANSHI KALPESH D. KHOCHARE AMOL P. SHETKE DHIRAJ B. WAGHMARE

GUIDED BY PROF L. R. SURYAWANSHI (INTERNAL GUIDE) DEPARTMENT OF MECHANICAL ENGINEERING APRIL-2010

Bharati Vidyapeeth’s College of Engineering (Affiliated to the University of Mumbai) Sector 7,CBD,Navi Mumbai-400614

CERTIFICATE DATE : This is to certify that the project titled


























IMPROVING OVERALL EFFICIENCY OF THE CUTTING MACHINES BY IMPLETATION OF PILLARS OF TPM

Is Submitted By KALPESH.D.KHOCHARE YASHRAJ.V.RANE

(4759) (4760)

HARSHAD.V.SURYAWANSHI

(4761)

AMOL.P.SHETKE

(4762)

DHIRAJ.B.WAGHMARE

(4766)

B.E. B.E.(M (Mec echa hani nica call engi engine neer erin ing) g) clas class s of Bhar Bharat atii Vi Vidy dyap apee eeth th’s ’s Coll Colleg ege e of Engi Engine neer erin ing, g, Navi Navi Mumb Mumbai ai in the year year 20 2009 09-2 -201 010 0 towards the fulfillment of the requirements for the award of the Degr Degree ee of Bach Bachel elor or of Engi Engine neer eriing und under the the Univ Univer ersi sitty of Mumbai.

Prof Prof L. R. Sury Suryawa awans nshi hi Prof.S.D. Jadhav (Internal (Internal Guide) (H.O.D)

Prof Prof R.K. R.K.Ag Agra rawal wal (Project (Project Co-ordinator) Co-ordinator)

Bharati Vidyapeeth’s College of Engineering


























(Affiliated to the University of Mumbai) Sector 7,CBD,Navi Mumbai-400614

DEPARTMENT OF MECHANICAL ENGINEERING A PROJECT REPORT ON

IMPROVING OVERALL EFFICIENCY OF THE CUTTING MACHINES BY IMPLETATION OF PILLARS OF TPM

Is Submitted By KALPESH.D.KHOCHARE YASHRAJ.V.RANE

(4759) (4760)

HARSHAD.V.SURYAWANSHI

(4761)

AMOL.P.SHETKE

(4762)

DHIRAJ.B.WAGHMARE

(4766)

Has been examined and approved as per the fulfillment of the req requi uirreme ements nts for for the award of the Degree of Bach achelor elor of Engine Engineeri ering ng (Mec (Mechan hanic ical al)) of the the Univ Univers ersit ity y of Mumb Mumbai ai in the the academic year 2009-2010.


























Signature Name : (External examiner) examiner)

Signature Name: (Internal





















































ACKNOWLEDGEMENT

At the very onset of this project, we would like to take this opportunity to express our heartfelt gratitude to the people whose unstinting help and co-operation has made this study a success. We would like to express our appreciation to Mr. Neel Shrivastava (Department Head) &

Mr. F. R. Bava-Adam (Divisional Personnel) for granting us permission to complete our

project in their prestigious organization iwala We expr expres esss our since sincere re grat gratit itude ude to our exte extern rnal al guid guidee Mr. T. A. Pooniwa (Maintainance Head) for providing us all the necessary information, training and valuable

guidance during the project We are thankful to Prof. Mr. L. K. Suryawanshi , our project guide who co-operated every now and then and took every effort to make this project a grand success. Humble thanks to our teachers and project co-coordinator Prof. Mr. R.K. Agrawal for their keen guidance. We would like expressing our indebtedness to our eminence to Respected principal , madam, m, our our head head of Mechanical Prof. Prof. Mr. Mr. D.P. D.P. Mishr Mishra a and Prof. Mrs. Mrs. S.N. S.N. Jadhav Jadhav mada


























Abstract Total Productive Maintenance (TPM) is a process that maximizes the productivity of equipment for its entire life. It fosters an environment where improvement efforts in safety, quality, cost, delivery, and creativity are encouraged through the participation of all employees. TPM TPM is not not simp simply ly a prev prevent entiv ivee main mainte tena nanc ncee prog progra ram. m. Rath Rather er,, it is a stra strate tegi gicc management initiative to increase capacity and end the vicious cycle of ‘breakdown’ or reactive repair repairss through through the use of autonom autonomous ous and predic predictiv tivee mainte maintenanc nance, e, as well well as equipme equipment nt modifications to facilitate optimum machine availability, quality, and performance. The TPM presen presentat tation ion focuse focusess on a result resultss orient oriented ed implem implement entati ation on method methodolo ology gy designed to minimize the 6 major equipment losses. Overall Equipment Effectiveness (OEE), an equipme equipment nt perfor performan mance ce assess assessmen mentt or measur measureme ement, nt, is introd introduce uced. d. By unders understan tandin ding g and


























Table Of Contents

Sr. No

Particulars

01

Chapter 1: INTRODUCTION TO COMPANY

02

Chapter 2: INTRODUCTION TO PROJECT

Pg. No. 1-9 10-20

























Bharati Vidyapeeth College Of Engineering ` 06

Chapter 6: SUGGESTION

39-42

07

Chapter 7: DESIGN

43-47

08

Chapter 8: SCOPE

48-49

09

Chapter 9: RESULTS AFTER IMPLEMENTATION

50-54

10

CONCLUSION

55-55

11

BIBLIOGRAPHY

56-56

FIGURES



























Bharati Vidyapeeth College Of Engineering ` FIGURE NO.

NAME OF THE FIGURES

PAGE NO.

FIGURE 1

Company Photo

02

FIGURE 2

Heat Exchanger

05

FIGURE 3

Heavy walled Reactor

06

FIGURE 4

High Pressure Vessel

06

FIGURE5

BEHRINGER BANDSAW

11

FIGURE 6

CNC GAS CUTTING MACHINE – SUAG

11

FIGURE 7

BEHRINGER BANDSAW

12

FIGURE 8

Band-saw Cutting Blade

14

FIGURE 9

CNC GAS CUTTING MACHINE - SUAG

16

FIGURE 10

Cutting Torch for CNC Gas Cutting Machine

17


























TABLES TABLE NO.

TABLE NO 01

TABLE NAME

SPECIFICATION OF BEHRINGER

PAGE NO.

15

BANDSAW TABLE NO 02

SPECIFICATION OF CNC GAS

19

CUTTING MACHINE - SUAG TABLE NO 03

Time study on Behringer Band Saw

32

Cutting M/C TABLE NO 04

TIME STUDY ON BEHRINGER BAND

35

























Bharati Vidyapeeth College Of Engineering ` TABLE NO 09

Improved OEE of Behringer Bandsaw after

52

implementing Scale TABLE NO 10

Result of Improved OEE of Behringer

52

Bandsaw after implementing Scale TABLE NO 11

Data recorded before Implementation on

53

CNC Gas cutting M/C - SUAG TABLE NO NO 12

Data re recorded af after Implementation on on

53

CNC Gas cutting M/C - SUAG TABLE NO 13

Improved OEE of CNC GAS CUTTING

54

M/C-SUAG TABLE NO 14

Result of Improved OEE of CNC GAS CUTTING M/C-SUAG

54














































































Fig.no-1: Company Photo In the year 1997, 1997, Godrej Godrej & Boyce Boyce celebr celebrate ated d their their centena centenary ry year. year. This This dynamic organization has progressed tremendously since its inception and has been gaining strength consistently. Quality is the hallmark of all the Godrej products and any product with the 'Godrej' mark represent quality, dependability & satisfaction to its customers. What now is a gainful industrial organization was a brainchild o f Mr. Ardeshir GODREJ, which through

























Bharati Vidyapeeth College Of Engineering ` security alarm systems, access control systems, closed circuit television systems and very highly sophisticated advanced electronic surveillance systems.

























Bharati Vidyapeeth College Of Engineering ` It is truly a mullet-faceted company. This is the major collaboration of Godrej with Boyce Company. The maximum of the business of Godrej is known by this name. At present all the divisions mentioned below come under this company.

OFFICE EQUIPMENT (O.E.) DIVISION: The manufacturing activities in this division are distributed in the following plants: ➢

Plant 1: Steel processing plant

























Bharati Vidyapeeth College Of Engineering ` such as heat exchangers, boiler shells, tower internals, etc., as well as equipment for nuclear and aerospace applications such as parts of atomic reactor, cryogenic engines and projects of ISRO (Indian Space Research Organisation).


























Product range – •

Heavy Walled Reactors















































































































































































































































































































































































































































































































































































































































































































































































































































































No:

Table 05


























Fig 17: OEE Chart for CNC GAS CUTTING MACHINE - SUAG


























Fig 18: Bar Chart for CNC GAS CUTTING MACHINE - SUAG CNC SUAG CUTTING M/C LOSSES SR.NO.

ACTIVITY

TIME in min

%

1.

Scheduled/Planned Stoppages

698

49.75

2.

Setting Time

17

1.22

3.

Start-up Losses[mock-up]

288

20.52

4.

Minor Stoppage[Time Loss]

20

1.42

5.

Non Availability of Material

340

24.24

6.

Non Availability of Operator

40

2.85

1403

100

TOTAL

Table No: 06 Fig 19: Pie Chart for CNC GAS CUTTING MACHINE - SUAG


























CHAPTER -6


























SUGGESTION

SUGGESTIONS BEHRINGER BAND SAW CUTTI CUTTING M/C:Three Major Losses in Behringer:1.

M/C Down Time.

2.

Setting Time.

3.

Measurement.

1. M/C Down Time REASON Break-down maintenance

SOLUTION Preventive Maintenance of M/C to be done on time to avoid maintenance while M/C is in production.

2. Setting time REASON




























Fatigue to Operator in Setting the Job.

SOLUTION Sensors are to be employ on machine.

3. Measurement REASON 1. Presently Presently measurement measurement is done done manuall manually y by operator. operator. 2. New measureme measurement nt type equipmen equipmentt must be procured procured to minimi minimize ze measurement measurement time. time.

SOLUTION Sensors assembly has to be done near to the machine blade so measurement time will w ill be minimum.

SUGGESTIONS CNC SUAG CUTTING M/C:Three Major Losses in CNC Suag:1.

Scheduled/Planned Stoppages.


























1. Loadin Loading g Time Time Of Of Plat Platee Is Too High. High. 2. Time Time consume consumed d for Sett Setting ing the the Job Job Plate. Plate.

SOLUTIONS 1. Loading Loading Time Should Should Be Minimized Minimized By Offline Offline Setting Setting Of Plate Plate.. 2. Special Special fixture fixture to be be Designed Designed for Quick Setti Setting ng of Job Plate. Plate.

2. Non Availability of Material REASON Improper & Unplanned Stacking of Plates.

SOLUTIONS 1. Proper Proper stack stacking ing of plate platess as per prior priorit ity. y. 2. Proper proactive proactive planning planning to feed feed the the m/c m/c as per plan. plan.

2. Start up Loss[mock-up] REASON


























1. Special Special Cleaning Cleaning staff staff to be provided provided for cleani cleaning ng of the m/c m/c before operato operatorr reports reports on the m/c during each shift. 2. Specia Speciall Fixtur Fixturee to be made made to avoid avoid Test Test Run. Run.


























CHAPTER -7


























DESIGN

Introduction to Rack Design Introduction

A rack is a device for locating, holding and supporting a workpiece

or plates plates durin during g a manufa manufactu cturin ring g operat operation ion.. Rack Rack are essent essential ial part part of pro produ duct ctio ion n proc proces esses ses as they they are are requ requir ired ed for for mate materi rial al hand handli ling ng of a particular materials. There are many many standard standard material material handling handling devices devices such as belt belt conveyor,tr conveyor,trolley olley etc. which which are widely widely used in workshops workshops and industries industries and are usually kept in stock for f or general applications. Rack are normally designed for a definite operation to process a specific workpiece and are designed and manufactured individually.




























Fig 20-a: Design given for Behringer Bandsaw Scale used for measurement


























Fig 20-b: Design given for Behringer Bandsaw Scale used for measurement



















































Fig 21 Design given for CNC GAS CUTTING MACHINE – SUAG

Stacking of plates


























sides. The length of each of the two equal sides id called leg. As a rule, the leg length h is equal to the plate thickness.

Fig 22: Welded Joint The throat is the minimum cross section of the weld located at 45o to the leg dimension. Therefore, t = h cos 45o or t = 0.707 h

Failure of the fillet weld occurs due to shear along the minimum cross section at the throat. It will be provided at a later stage in the above given section, that for parallel fillet weld, the inclination of the plane where maximum shear stress is induced is 45o to the leg dimension. The cross sectional area at the throat is (tl) or (0.707 hl ). ). The shear stress in the fillet weld is




























or P = 1.414 hl τ


























SCOPE


























1. Opera Operati tion on cos costt is is mor more. e.

2. Maintenance cost is more.




























































































































































































































































"IMPROVING OVERALL EFFICIENCY OF THE CUTTING MACHINES BY IMPLETATION OF PILLARS OF TPM"project done at godrej&boyce........

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