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Finding out the effectiveness of two critical equipments using two tools ( OEE and Pareto analysis). And finding out the areas where to improve OEE.
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EFFECTIVENESS OF PREVENTIVE
MAINTENANCE IN CRITICAL
EQUIPMENTS AT APOLLO TYRES
JUSTIN THOMACHAN
INTRODUCTION AND OBJECTIVES.OBJECTIVE
PRIMARY OBJECTIVE:
• To study the effectiveness of Preventive maintenance of critical equipment in Apollo Tyres.
SECONDARY OBJECTIVE:
• To analyse the mechanical down time and identify the opportunities of improvement of availability of critical
equipment.
Critical equipment – Dual Extruder and Calendar.
Tools used :
– OEE (Over all equipment effectiveness).
– OEE = Efficiency x Availability x Quality.
– Pareto Analysis – to find out major break downs.
Data Collection : Ten month’s data is used for analysis. And main emphasis is on secondary data.
– Primary Data :- Personal interview with maintenance department, production department, planning department,
quality control department and Industrial engineering department personals.
– Secondary Data :- Machine logs, Production reports, Company manuals, Industrial engineering journals.
LIMITATIONS.
• Due to confidentiality nature of quality and performance data, it was difficult to get certain details.
• Intervention from the employees union which made collection of data difficult.
OVER ALL EQUIPMENT EFFECTIVENESS
• OEE OF CALENDAR
Month Availability Performance Quality OEE OEE% Avg Avail Avg OEE
Jul-13 0.9803 0.9462 0.996 0.92385 92.38496
Aug-13 0.9573 0.8911 0.9958 0.849467 84.94672
Sep-13 0.9488 0.9695 0.9957 0.915906 91.59062
Oct-13 0.9095 0.8414 0.9954 0.761733 76.17331
Nov-13 0.9548 0.9305 0.9957 0.884621 88.46211
Dec-13 0.9671 0.9243 0.9958 0.890136 89.01362 0.95298 86.40747
Jan-14 0.9331 0.9629 0.9957 0.894619 89.46185
Feb-14 0.968 0.8806 0.996 0.849011 84.90111
Mar-14 0.9347 0.906 0.9962 0.84362 84.36202
Apr-14 0.9762 0.8512 0.9962 0.827784 82.77839
• OEE OF DUAL EXTRUDER
Month Availability Performance Quality OEE OEE% Avg Avail Avg OEE
Jul-13 0.977 0.9221 0.916 0.82522 82.52
Aug-13 0.9091 0.8814 0.965 0.77324 77.32
Sep-13 0.9154 0.9121 0.932 0.77816 77.81
Oct-13 0.9264 0.8254 0.968 0.74018 74.01
Nov-13 0.9672 0.9157 0.956 0.8467 84.67
Dec-13 0.9034 0.9262 0.983 0.8225 82.25 0.928 79.11
Jan-14 0.9084 0.8949 0.968 0.78691 78.69
Feb-14 0.922 0.8493 0.986 0.77209 77.2
Mar-14 0.9081 0.878 0.971 0.77419 77.41
Apr-14 0.945 0.8656 0.979 0.7924 79.23
BREAK DOWN ANALYSIS
Calendar.
• Total mechanical down = 306.67 hrs.
• From Pareto analysis we found out top 5
downtimes.
• That are Mill failure, Led off Feed roll break
failures, Feed conveyor related failures, mill
guide failures, Roller failures.
Dual Extruder
Total mechanical down = 541.43 hrs.
From Pareto analysis we found out top 5
downtimes.
That are Skiver not skiving, Mill break down,
head related general failures, Cooling
conveyor joint failures, belt conveyor failures.
Skiver not skiving
Mill break down
Head related general failure
cooling conveyor joint failure
Belt conveyor failure
feeding mill break down
temprature fluctuation in TCU
Roller conceyor failure
speed fluctuation
Head rubber leakage
Rubber Jam
Between Coveyor and roller
Skiver angle variation
stock loader failure
0
2000
4000
6000
8000
020406080100
Mill Failure
feed conveyor related
roller failure
wind up acctuator roller bearing related
let off acctuator chain unbalance
center guide,hydraulic cylinder oil leak
winder chuck failure
acctuator hydraulic cylinder oil leak
wind up feed cylider air leak.
wind up acctuator roller bearing failures
web m
aster roll jammed rolling
let of acc sprocker shifting
0100020003000400050006000
020406080100
FINDINGSCALENDAR
• The major five failures are Mill failure, Led off Feed roll break failures, Feed conveyor related failures, mill guide failures, Roller failures.
• After eliminating these failures:– 72.15% of reduction in total
mechanical break down.– 3.385% increase in availability, i.e. to
98.67%.– 3.07% increase in OEE, I.e. to 89.44%.– Rs. 94667.1 reduction in terms of man
power cost.
DUAL EXTRUDER.• The major five failures are Skiver
not skiving, Mill break down, head related general failures, Cooling conveyor joint failures, belt conveyor failures.
• After eliminating these failures:– 80.12% of reduction in total
mechanical break down.– 6.9% increase in availability, i.e. to
99.72%.– 5.93% increase in OEE, I.e. to 85.04%.– Rs. 122067.3 reduction in terms of
man power cost.
SUGGESTIONS