Sample slide for improvement

1. Maintenance/Utility/Process Engg
Meeting Discussion points
MONTH – JAN 2024

2. Index
 Breakdown Summary/Analysis – Assembly Lines, Sub Shops
 Improvement Points
 Automation Project Status
 Utility projects Status
 Power & Fuel saving Action Plan
 Project Activities
 MES Integration
 PM Plan vs Actual
 PE/ME activity Plan
 Civil Ongoing Activities
 Spare/Store Issues
 Pending Points ( PQCDSM)

3. Breakdown Summary
0
50
100
150
200
250
300
350
Sub Shop Monthly Breakdown Trend
Moulding shop Press Shop Paint Shop HE Shop CT Shop

4. Breakdown Analysis (Sub Shop_
Date Shop Machine Name
BD Time
(Min)
Issue Root Cause Corrective action Preventive action Target Date PIC Remark
01-Dec-23 CT Shop CNC Bending -3 15 Cutting unit not ok Grub screw loosen
Proper fitted the rod and
grub screw tighten
1. Both Side grub screw to be provided
2. All machine grub screw tightness to be check
10.12.23 Mayank
08-Dec-23 Press Shop Progressive Press 300 Lub Issue
Contaimination
inside grease
line/pump/manifold
Cleaned grease pump,
Grease line and manifold,
machine under observation.
1. Grease filling port nipple to be provide
2. Will check grease storage condition and keep grease
properly.
20.12.23
20.12.23
Arun
Mani
09-Dec-23 HE Shop EVA Line 6 Upside going issue Alignment not ok Stucking so alignment done 1. Alignment of lifte done 10.12.23 Mayank
09-Dec-23 HE Shop EVA Line 40
Loading Lifter not
working
Sensor Faulty
Door Sensor direct and
started line
1. Need to replace the door proxy Sensor 11.12.23 Arun
11-Dec-23 HE Shop
Auto Brazing-COND
Line
153
Up down
movement issue
One Ball Screw not
ok
Open timings belts and
alignment done for all four
ball screws then set height
ok.
1. Ball Screw Alignement Done
2. Need to Replace the one ball Screw
3. Inform to production team, till ball screw change, if any
model change over then call Maint team. Also Display notice
for same.
1. Done
2. 30.12.23
3. Immidiate
Mayank
13-Dec-23 Press Shop
Transfer Line 2
Manipulator
60
Manipulator cam
down
CAMFollower
bearing thread worn
out
Currently Manipulator take
at home position and line
started in manual mode
1. Need to replace CAMFollower
2. New Thread to be made
3. We will check all other manipulator for CAMfollower
4. Communicated to OEMfor this failure for root cause and
prevetive action
1. 14.12.23
2. 14.12.23
3. 18.12.23
4. 30.12.23
Arun
17-Dec-23 Moulding Chiller 120
Chiller Pressure
issue
Strainer not ok Cleaned the strainer
1. Informed all team that when ever chiller tank cleaning
done, clean Strainer also.
Done Arun
20-Dec-23 Paint Shop Powder Booth 45
Fan 1 too little
exhaust air
Recovery powder
not coming back
Open Both Cover and filters
cleaned also remove
powder from collection bin
1. Open pump and clean it
2. Training given to operators to check recovery powder in
pipe line daily
Done Arun
22-Dec-23 Press Shop SPMSpot welding-2 60 HMI not working HMI Faulty HMI Replaced with New
1. HMI Replaced with back up downloaded
2. Send mail to OEMfor HMI failure
Done Arun
23-Dec-23 Paint Shop PT Zone 150
Oxsillian pump
tipping issue
Pump Motor faulty
Replaced the pump motor
from DM3 spare pump
1. Inform to OEMfor this issue, They will visit and check the
root cause.
2. current use spare pump motor
30.12.23 Arun
27-Dec-23 Paint Shop Conveyor 45 Jerking issue
Drive clutch plate
issue
tighten all 3 drives cluth
plates
1. Tighten All 3 drive clutch plates under observation
2. Ask OEMto Check if any stucking due to Brushes in PT
Zone
27.12.23
01.01.24
Arun
28-Dec-23 HE Shop N2 Flushing 15 N2 not coming Coil faulty
Remove coil and directly
connected the n2 pipe
1. Coil Removed from there and provided Direct connection
2. Also provided Ball valve
28.12.23 Mayank
Breakdown Data Analysis - Sub Shops

5. Ongoing Improvements Summary

6. Automation Projects Status
• Strapping Machine number of strap selection option on all Strapping Machines
• Taping Machine Tape Sensor interlock
• Auto Model Change on Strapping Machine
• HVIR Robot on ODU Lines
• AMR

7. Utility Projects Status

8. Power & Fuel Saving Action Plan
Action Plan for Reduction :-

9. Project Activities
 Nano Coating Oven Shifting (Sunday) Improvement Points
 Lacing Table Granite Replacement ( Granite)Utility projects Status
 Duct Chimney Support need to be given
 Duct Opening for Paint Shop chimneys
 MES Integration
 Expander 3 Installation commissioning
 N2 Flushing Aluminum Jig Civil Ongoing Activities

10. MES Integration Status

11. PM Plan vs Actual Status

12. PM Plan vs Actual Status

13. Process Engineer/ME activity List

14. Civil Pending Points

15. Spares/Store/Purchase Issue
0.0
5.6
85.9
43.1
13.8
30.7
48.0
8.2
14.4
- - -
24.1
50 50 50 50 50 50 50 50 50 50 50 50 50
0.0
10.0
20.0
30.0
40.0
50.0
60.0
70.0
80.0
90.0
100.0
April.23 May.23 June.23 July.23 Aug.23 Sept.23 Oct.23 Nov.23 Dec.23 Jan.24 Feb.24 Mar.24 Total
Monthly R&M (911) Consumbale Cost Rs/Ac sets -2023-24
Actual Cost Rs/Set Target Cost Rs/Set

16. Pending Points PQCDSM