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HOT METAL MANAGEMENT

Hmm qc project

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Page 1: Hmm qc project

HOT METAL MANAGEMENT

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Design & fabrication of hydraulic bearing housing puller/pusher.

TEAM LEADER : Mr. RANA DHAVALTEAM MEMBERS : Mr. ANKIT PRAJAPATHI

Mr. ANANTH PATEL

Mr. MANJUNATH H

Mr. SATYAM PRUCHAK

FACILITATOR : Mr. B V REDDY

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• We are facilitated with ladle car for hot metal transportation. Each having capacity of 140 T consisting of two bogie assembly and each assembly have two numbers of wheel and axle set.

• Each wheel and axle having two bearing houses with Bearing(22336cck/cc3-Double spherical roller bearing).

• We have to remove bearing housing in cases of bearing damage and repair of wheel & axle sets.

Measure Analyze Control`DEFINE ImproveDEFINE

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• Initially we used manual method of bearing housing removal which results in more time consuming and chances of bearing damage due to improper bearing mounting

• Improper bearing mounting also cause failure of bearing components Like adaptor sleeve, Checknut bolts etc.

Measure Analyze Control`DEFINE ImproveDEFINE

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During hot metal ladle car maintenance work ,following damages or repair handled due to improper bearing housing seating•Sleeve damage :

•Overheating of bearing

•Check nut bolt damage

•Axle thread damage

•Bearing housing cover damage.

Analyze Control`ImproveDefine Measure

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Trend before project

Analyze Control`ImproveDefine Measure

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Why –Why analysis ?

Q1 . Why sleeve damage happened?

Ans : Sleeve damage occurred due to improper bearing mounting in bearing axle box.

Q2 :Why Check nut bolts broken ?

Ans : Check nut bolts are broken due to improper fitment of sleeve.

Q3 :Why axle housing front cover rubbing ?

Ans : Due to improper seating of sleeve.

All problem root cause is because of improper mounting of bearing housing box in wheel & axle set .

Analyze ImproveDefine Measure Control`

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We have designed & fabricated hydraulic bearing housing puller & pusher for easy installing & removing of bearing housing assembly from wheel & axle set in which we are using 100 ton lukas make hydraulic jack.

Analyze ImproveDefine Measure Control`

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Trend after project

ImproveAnalyzeDefine Measure Control`

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ControlAnalyzeDefine Measure Improve

• We have revised maintenance SOP to usage of hydraulic bearing housing puller & pusher

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Benefits:

• Reduce material consumption like sleeve, check nut bolts, grease ,etc.

• Breakdown time of hot metal ladle car reduce which will results 100 % avaibility of ladle cars.

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Queries …?