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Low Voltage Startability New Code & Sticker. LVS. A S A 51 R. Motor Type R : Run Capacitor S : Start Capacitor N : Induction Run. Rated Voltage & Frequency A : 220 – 240V/ 50Hz B : 220 – 240V/ 60Hz C :127V/ 60Hz. Displacement 51 : 5.11cc/rev. Revision No. A B C. Cooling Type - PowerPoint PPT Presentation
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Low Voltage StartabilityNew Code & Sticker
A S A 51 RRated Voltage & Frequency
A : 220 – 240V/ 50Hz
B : 220 – 240V/ 60Hz
C :127V/ 60Hz
Cooling Type
S : Static Cooling
Revision No.
A
B
C
Displacement
51 : 5.11cc/rev
Motor Type
R : Run Capacitor S : Start Capacitor N : Induction Run
LVS
IMPROVEMENTS OVER OLD COMPRESSOR
Compressor Improvements
Failure Reason Root Cause Old PracticeBest Prctice Implementation
High Amps
CRA Jam due to contamination
Graphite based Lubricant Water based lubricant used
Air Gap Shift Manual Rotor SkewingAuto Skew Rotor & stators to be started
Rotor concentricity more
electronic gauge inplemented at supplier's end
stator squareness not ok
squareness checking gauge implemented
No start at low voltageMotor Starting torque less
Starting Voltage ≤170V Starting Voltage ≤150V
Motor BurnMotor Overheating due
to oil starvationBlind oil hole in C/shaft
Hole Depth/ Dia verification with High Pressure cleaning
High NoiseDMA Assy bending improper
DMA Assy Manual Bending Bending Jig Implemented
checking procedure ` development of new gauges in process
IMPROVEMENTS
BEFORE AFTER
GRAPHITE BASED LUBRICANT WATER BASED LUBRICANT
EARLIER USED GAUGE FOR CHECKING
NEW GAUGE FOR CHECKING
INTRODUCTION OF WATER BASE D LUBRICANTS
INTRODUCTION OF NEW GAUGE & 100% CHECKING AT VENDOR'S END.
HEIGHT NOT OK
SPRING
ProblemComponent Action Plan
STAMPING OF UNIQUE CODE ON TOP LAMINATION STARTED
MIXING MODELS
STATOR
IMPURITIES DUE TO USE OF GRAPHITE BASED LUBRICANT
UPPER BEARING
NO STAMPING DONE STAMPING STARTED MODEL/DATE
IMPROVEMENTS
BEFORE AFTER
EARLIER USED GAUGE FOR CHECKING
NEW GAUGE FOR CHECKING
SEPARATE BINS & TRAYS
INTRODUCTION OF NEW GAUGE & 100% CHECKING
SQUARENESS NOT OKSTATORS
ProblemComponent Action Plan
DESIGN CHANGED & 100% IMPLEMENTATION
PUNCTURERUBBERCAPS
NO IDENTIFICATION & HENCE MIXINGROTORS
OLD DESIGN NEW DESIGN
NO IDENTIFICATION
IMPROVEMENTS
BEFORE AFTER
ONLY ID VERIFICATION ID + DEPTH VERIFICATION
EARLIER USED BINS
NEW BINS FOR STORAGE
BOTH ID & DEPHIS BEING VERIFIED
INTRODUCTION OF NEW BINS AT VENDOR'S END.
DENTS &DAMAGE
SHAFTS
ProblemComponent Action Plan
GUIDES PROVIDED FOR SAME.
BENDINGNOT PROPER
DMA
ONLY ID WAS BEING CHECKEDEARLIER
SHAFTS
BENDING DONE WITHOUT GUIDES
BENDING DONE WITH GUIDES
COMPONENT ACTION PLAN TARGET RESP. RESULTUPPER
BEARINGon & off timings to be changed from 20 min to 10 min. 9/9/2009 jayant
blow holes found <3 % & contamination increased >80%
temp from 470 changed to 650 9/9/2009 jayant special lot in front of mr joshi will be made & sent to VG 9/9/2009 jayant injection speed to be reduced 17/09/09 jayant done
to use ejector rods in place of bumper rods which are presently in use 17/09/09 jayant no improvement
water based die coat to be used instead of graphite based die coat 20/09/09 khotkar done raw material to be procured from new vendor 2/10/2009 Nimade done
ROTOR run out of machine mandrel to be checked after every hour. 9/9/2009 Khotkar done new gauge for checking of counter wt lamination to be received 9/9/2009 jayant done amps to be increased to 41amps for bluing at impulse 9/9/2009 jayant done Frequency of changing Plunger to 15 Days from 20 Days 19/09/09 Rahul done Online training for New operators 25.09.09 Rahul done
O D Turning in 1 Pass instead of 2 Pass. Production up by 50 % 26/09/09 Rahul done
New 200 Nos Pins will be available 10.10.09 Rahul done new fixture for done
Auto Temperature controller to be installed (at die casting process) 10.10.09 Rahul done
One spare Air Gauge set ( Electronics Column, AECM Unit, Adaptor & Ring Gauges ) 15.10.09 Khotkar done
SHELLS pdi check to be started/shift wise monitoring 10/9/2009 sandeep done to revisit the supplier to verify the process. 20/09/09 jayant done
SEAL PRESS. FAIL
all filtearation systems to be made ok with increased freequency of filteration.
15/09/09 Rahul done done
introduction of new rubbing process 3/10/2009 jayant doneLUG TAP. NOT OK
pieces with through drill/half to be given on line for tapping 25/08/09 drill breaking highpieces with through drill to be given on line for tapping
16/09/09 jayant100% ok tapping still problem of burr exists
drill length to be reduced before final tapping 3/10/2009 jayant AIR GAP without rib mufflers trial to be taken on line 28/08/09 jayant air gap improved
without rib mufflers trial to be taken on line 19/09/09 jayant air gap improved revised drawing without rib to be released 30/09/09 Dattu kr. done shuffling of operations 15/10/09 amol done
REF LINE REJECTION
high pressure cleaning of shaft to be started 30/08/09 venu donecounter on upper bearing to be started. 30/08/10 venu done
100% segregation of upper bearing to be started 20/09/09 rahul done
Action Plan & Results
IMPROVEMENTS TO REDUCE RUST/CONTAMINATION
BEFORE AFTERProblemComponent Action Plan
The Laminations were bound with binding wire by twisting the joints with the help of cutting pliers.
Refer hereunder the photograph in the Ref :Before section.
Now the two ends of the binding wire is being bent (By hand) in the side profile of the laminations as shown in the photograph Ref : After section A separate area is identified for keeping the segregated good lamination cores
Excess twisting was the reason which could cause the bend in the laminations
New binding method is introduced in the side profile of laminations which will eliminate the bend in the top & bottom lamination
Existing Packing method
1.Initially wooden box was covered with polythene stretch film.
2.Each & every layer was covered with vci paper .
3.Before closing ,the box was covered with the vci paper then it was covered with polythene stretch film.
4. Put the top wooden plate on box and belt strapped.
New packing method
1.Instead of using wooden box new carton box is introduced for packing the laminations
.
2.The carton box inside is covered with blue color & VCI coated polythene bag .
3. VCI paper is used in between the layers.
4.A top cover is used to close the box .Then box will be belt strapped
After completion of Annealing process, immediately the laminations are packed as per the new packing method.
A new packing method is introduced. It will be standardized based on the customer approval.
TopLaminationsBeing scraped
Laminationsreceived rusty