TEAM MEMBERS:

1. R.SAI PRABHU RAJ (111412114089)

2. S.SEDHU (111412114096)

3. S.VINOTH (111412114112)

INTERNAL EXTERNAL

PROJECT GUIDE: PROJECT GUIDE:

Dr. S.MAHADEVAN G.SENTHIL KUMAR

Senior Professor Section Manager

Mechanical Department Caterpillar India Pvt. Ltd.

ABSTRACT Now a days there is a large competition among companies. Companies are trying their best to provide the products in a innovative, exciting, cost effective way in the present globalizeand competitive market

Maintenance department and people responsible for maintenance has the greatest Influence on the company assets. Without the support of the Quality and Maintenance it is not possible to meet the requirements of manufacturing plants and customers.

Without effectively maintained equipment; it will not be possible to deliver the productsin the competitive market that requires low cost products at a high quality.

The TPM implementation methodology is suggested for improvement in the availability,performance efficiency and the quality rate, results in improvement of the overall equipment effectiveness of the equipment.

The aim of this project is to suggest and study the implementation of the TPM program inCaterpillar India Pvt. Ltd. Located in Thiruvallur.

BRIEF ABOUT CASE COMPANY

Caterpillar Inc., is an American corporation which designs, manufactures, markets and sellsmachinery, engines, financial products and insurance to customers

Caterpillar is the world's leading manufacturer of construction and mining equipment, diesel and natural gas engines, industrial gas turbines and diesel-electric locomotives.

Caterpillar India Pvt Ltd., MATERIAL HANDLING AND UNDERGROUND EQUIPMENT DIVISION (MH&U) plant is located in Mellanathur, Thiruvallur District, and Tamil Nadu.

It currently employs more than 1000 employees and produces Wheel Loaders, BackhoeLoaders, and Quarry and Mining Trucks (OHT).

In the CPIL, Thiruvallur plant, there are totally 12 bays are present.

The bays include Warehouse, Assembly line, Tool room, hex bay, axle bay, fabrication bay, materials bay and along with two paint shops(loader paint shop and new paint shop).

ROBOT WELDING:

S.no parameters

1. Welding type Metal Inert Gas Arc welding

2. Electrode Copper wire of gauge

diameter =1.2 mm

3. Flux coated Gauge diameter =1.6 mm

4. Shielding gas Argon (90%)

Carbondioxide (10%)

5. Robot axes 8

6. coolant Water

SPECIFICATIONS:

TOTAL PRODUCTIVE MAINTENANCE

Total Productive Maintenance (TPM) is a system of maintaining and improving the integrityof production and quality systems through the machines, equipment, processes, and employees that add business value to an organization.

TPM focuses on keeping all equipment in top working condition to avoid breakdowns and delays in manufacturing processes.

GOALS OF TPM:

Enhance the volume of the production employee morale job satisfaction.

In order for TPM to be effective, the full support of the total workforce is required.

OVERALL EQUIPMENT EFFECTIVENESS

The main objective of TPM is to increase the Overall Equipment Effectiveness of plant equipment.

.

OUR ACTIVITIES

ROOT CAUSE & CORRECTIVE ACTION (RCCA)

1.1 Problem Description : Oil leak observed in isolation transformer.

Before: After:

Machine Name & Type : Main frame robot Isolation transformer

Corrective Action : Isolation Transformer oil leak arrested and visibility checked.

Why ? Gauge area thread loosened.

How ? Teflon added and thread tightness corrected.

Future Sustenance ? During PM isolation transformed condition will be checked. PM point

added.

1.2. Problem Description : Coil drum emptiness cannot be identified during auto welding.

Before: After:

Machine Name & Type : Coil Drum.

Corrective Action : A new sensor has been provided to find whether coil drum coil end has been

reached or not. If reached alarm will be triggered.

Why ? Coil drum emptiness cannot be identified during auto welding.

How ? Sensor has been provided to find whether coil drum coil end has been reached or not.

1.3. Problem Description : Panel cooler filter cleaning status has not been displayed.

Before: After:

Machine Name & Type : Main Frame robot UPS

Corrective Action : Now a check sheet has been provided for filter cleaning.

Why ? Panel cooler filter check sheet has not been provided.

How ? New check sheet has displayed.

Future Sustenance ? Check sheet activity will be carried out weekly.

Before 5S –Manframe Robot Layout:

COLUMN

MANUAL WELDING POWER

SOURCE

MASTER ROBOT

W

A

Y

G

U

I

D

E

MASTER FRONIUS

POWER SOURCE

CHILLER UNIT

MANUAL WELDING POWER

SOURCE

DUST COLLECTOR

SLAVE FRONIUS

POWER SOURCE

COLUMN

COLUMN

COLUMN

BALL PAC WIRE

FEEDER

(3,4,5,6)

TAIL STOCK

SLAVE ROBOT

MASTER ROBOT

BALL PAC WIRE

FEEDER

(1,2)

ROBOT CONTROL

PANEL

WS-2

MAIN FRAME

ROBOT 1

ELECTRICAL

CONTROL PANEL

TAIL STOCK

SLAVE ROBOT

G

U

I

D

E

W

A

Y

HEAD STOCK

DUST COLLECTOR

ROBOT CONTROL

PANEL

WS-1

SLAVE FRONIUS

POWER SOURCE

CHILLER UNIT

HEAD STOCK

MASTER FRONIUS

POWER SOURCE

COLUMN SAFETY LIGHT

CURTAIN

SAFETY LIGHT

CURTAIN

WAY IN/OUT

WAY IN/OUT

After 5S Mainframe Robot layout:

COLUMN

MANUAL WELDING POWER

SOURCE

MASTER ROBOT

W

A

Y

G

U

I

D

E

MASTER FRONIUS

POWER SOURCE

CHILLER UNIT

MANUAL WELDING POWER

SOURCE

DUST COLLECTOR

SLAVE FRONIUS

POWER SOURCE

COLUMN

COLUMN

COLUMN

TOOLS CUPBOARD

SCISSOR LIFT

STEP LADDER

TEACH PENDENT

BALL PAC WIRE

FEEDER

(3,4,5,6)

TAIL STOCK

SLAVE ROBOT

MASTER ROBOT

BALL PAC WIRE

FEEDER

(1,2)

ROBOT CONTROL

PANEL

WS-2

MAIN FRAME

ROBOT 1

ELECTRICAL

CONTROL PANEL

TAIL STOCK

SLAVE ROBOT

TEACH PENDENT

G

U

I

D

E

W

A

Y

HEAD STOCK

DUST COLLECTOR

ROBOT CONTROL

PANEL

WS-1

SLAVE FRONIUS

POWER SOURCE

CHILLER UNIT

TOOLS CUPBOARD

HEAD STOCK

MASTER FRONIUS

POWER SOURCE

COLUMN SAFETY LIGHT

CURTAIN

SAFETY LIGHT

CURTAIN

WAY IN/OUT

WAY IN/OUT

Sl.no Check pointsImpact

matrics

Inspectio

n MethodInterva l

Machine

statusimage

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31

1 Check the TCP (tool centre point) by using the reference program (Alt

FN+Z).Daily ON

2 Check the robot reference for Master & SLAVE by selecting the robot

reference program and Ensure the robot reference is less than 1 mm for

proper weld for Twin and single torch

once in 2

framesON

3 Check camera reference of master & slave by selecting the camera

reference check program.Ensure the camera reference is less than 1 mm

for proper weld.

once in 2

framesON

4 Check the condition of the gas nozzle.Nozzle should be free from

damage,spatter and dust free.Ensure that contact tip is place centred of

the gas nozzle

Daily ON

5Daily torch service:Check and exchange the contact tip if worn out. Daily ON

6Measure shielding gas flow rate at the welding torch gas nozzle Daily ON

7 Check the function of each emergency stop button and the external safety

devices(safety door, light barrier)Daily ON

8 Make sure,that all control cabinet doors are properly closed and the

cooling fans/air condition are working.Daily ON

9Check the shilding gas manifold pressure between 4 to 5 bar. Daily

10 Before switching off the robot system, move the robot system to parking

position.Daily ON

11 Clean the exchangable protection glass of the laser camera with a cotton

swabs and isopropyl alcohol or glass cleaner when the laser camera is

switched off

Daily ON

12 Make sure that the chiller unit water level between min and max limit and

sure water flow is green in the output indicatorDaily ON

13 Ensure the Teach pendant coil is twist free.If twist found ,remove and

restore.Daily ON

14 Check the antispatter oil level at the back sink of 1st axis of the robot in

master and slave.Daily

operator signature

Date of the Month >>

Daily check points MFR-1------------------/2016

Operator performed maintanance (OPM) check sheet of igm robot welding systems

OEE CALCULATION

Overall Equipment Effectiveness (OEE)

Overall Equipment Effectiveness = Availability x Performance x Quality Yield

Availability = time available for production - downtime

time available for production

Performance = ideal cycle time x number of parts produced

operating time

Quality Yield = total number of parts produced - defect number

total number of parts produced

S.NO DOWNTIME LOSSES TIME (minutes)

1. Setup loss 22:48

2. Breakdown loss 18:17

3. Startup loss 8:42

4. Tool change 7:38

5. Inspection 6:57

Total 63.02

ITEM DATA

Shift Length 8 hours 30 minutes (510 minutes)

Break (2) 10 minute and (1) 30 minute

Down Time 63 minutes 02 seconds

Standard time for welding of model:777

frame

4 hours 30 minutes.

Before TPM-Downtime losses

Availability data for shift-1

1. Planned Production Time (Total Time):

Formula: Total time = Shift Length − Break

= 510 minutes − 50 minutes = 460 minutes

2. Run Time:

Formula: Available time - losses

= 460 minutes − 63 minute 02 seconds

=396 minutes 58 sec.

3. Availability:

Formula: Run Time / Total Time

= 396 minutes 58 sec / 460 minutes = 0.8621 (86.21%)

4. Performance:

Formula: (Standard Time× Total Count) / Run Time

= (460 minutes × 0.65) / (396 min 58 sec) = 0.7539 (75.39%)

5. Quality:

Formula: Good Count / Total Count

= 2 (777 frame) / 2 (777 frame) = 1.00 (100%)

Here Quality is 100%

6. OEE:

Formula: Availability × Performance × Quality

= 0.8621 × 0.7539 × 1.00= 0.6499~ (65%)

Availability data for shift-1

After TPM-Downtime losses

S.NO DOWNTIME LOSSES TIME (minutes)

1. Setup loss 16:07

2. Breakdown loss 10:22

3. Startup loss 7:29

4. Tool change 6:41

5. Inspection 5:16

Total 45:15

ITEM DATA

Shift Length 8 hours 30 minutes (510 minutes)

Break (2) 10 minute and (1) 30 minute

Down Time 53 minutes 02 seconds

Standard time for welding of 777 frame 4 hours 30 minutes.

1. Planned Production Time (Total Time):

Formula: Total time = Shift Length − Break

= 510 minutes − 50 minutes

= 460 minutes

2. Run Time:

Formula: Available time - losses

= 460 minutes − 45 minutes

= 415 minutes

3. Availability:

Formula: Run Time / Total Time

= 415 minutes / 460 minutes = 0.9021 (90.21%)

4. Performance:

Formula: (Standard Time× Total Count) / Run Time

= (460 minutes × 0.7) / (415 minutes) = 0.7869 (78.69%)

5. Quality:

Formula: Good Count / Total Count

= 2 (777 frame) / 2 (777 frame)

= 1.00 (100%)

Here Quality is 100%

6. OEE:

Formula: Availability × Performance × Quality

= 0.9021 × 0.7869 × 1.00

= 0.7098 ~ (70.98%)

Before vs After OEE

0

20

40

60

80

100

120

Availability Performance Quality OEE

Chart Title

Before After

ITEMS Before After

Availability 86.21% 90.21%

Performance 75.39% 78.69%

Quality 100% 100%

OEE 65% 70.98%

Total productive maintenance (TPM) is one of the best tools for making our industries competitive and effective, in

the field of maintenance.

TPM may be the only thing that stands between success and total failure for some companies as far as maintenance is

concerned.

While implementing TPM we found some barriers for effective implementation of TPM and performed Root Cause Corrective Action (RCCA) to correct the issues.

Also we corrected the basic layout of the IGM robot section with 5S requirements, by assigning the specific place for components like TEACH PENDENT, SCISSOR LIFT, TOOLS CUPBOARD.

Then we prepared daily check sheet for the IGM robot welding machine so that by checking it daily, breakdown issues can be minimised as much as possible.

By our activities we could increase Overall Equipment Effectiveness (OEE) from 65% to 70.98%.

CONCLUSION