Classified - Internal use

Project on

List of downtimes of overhead conveyor & closure of the same by PM check or by visual methodology

Project Name: Project #: Project Start/End Dates:

List of downtimes of overhead conveyor & closure of the same by PM check & visual methodology   30 May 2013 Project Lead: Naba kishore sarkar Executive Sponsor:

Arul Ram

Under Guidence of: Project Costs: (include required capital, expenses)

T. Rajya . SheshuPabitra Pradhan

- /- - Expenses:

 

 

Mission/Project Overview:

To find out the main problems behind the downtimes of over head conveyor

 

 

Objectives: (include beginning & ending KPI's) Net Benefits:

To improve SLE of RGB from current level Reduce downtimes

                                         

In Scope: OE Tools to be used: Out of Scope:                  

RGB overhead conveyor

Assumptions: Risks & Constraints:

Number of product changes will remain same or less than current ratio.  

Project Milestones: Dependencies:

Define : 30 June 2013  

Measure : 15 July 2013Analyze: Causes of downtimes    

Improve : Reduce the downtimes    

Control : Break down    

Project Lead Time: (Total time required to implement) 2Months Other Key Stakeholders & Areas Affected:   

Approvals:

Project Lead: Naba Kishore Sarkar Date:  Area Lead:   Date:  Finance:   Date:  Executive Sponsor/Steering Committee:  

Date:

 

PROJECT CHARTERList of downtimes of overhead conveyor

A conveyor system is a common piece of mechanical & electrical handling equipment that moves materials from one location to another. Conveyors are especially useful in applications involving the transportation of heavy or bulky materials.

Overhead conveyor which is used in HCCBPL is stainless steel flat top chain.

Introduction :

Process mapping

Empty yard( Loading Bay)

Slope conveyor(upward)

Slope conveyor(downward)

Horizontal

Spiral conveyor

Horizontal

Uncaser

1) Chain out from sprocket2) Motor trip3) Chain link bend4) Cable short5) Channel break6) Collar roller damage7) Bearing damage8) Strip damage (spiral conveyor)9) Sensor malfunction10)Broken crate

Types of problems occurs in overhead conveyor (Top ten)

Classified - Internal use

Overhead conveyor

stops

Overhead conveyor

stops

Technical skill

Training

Broken crate

Sensor malfunction

Cable short

Chain link bend

Strip damage in spiral conveyor

Channel break

Chain out from sprocket

MATERIAL

MACHINE

METHOD

MAN

Heavy dirt particles & heavy rain

Motor tripped

Fishbone analysis for Overhead conveyor failure

Lack of lubrication

Lack of awareness

Fluctuation of voltage supply

Over load & bearing failure

Lack of lubrication & life span of strip

Frequent use & lack of lubrication

Bearing damage

Lack of lubrication Wear and tearOver load ( sensor malfunction)Heavy dirt particlesBroken crate stuck Frequent start & stop ( Fluctuation of power)Life spanSprocket worn out

Causes of chain out

Classified - Internal use

* Stainless steel flat chains slides over plastic plates to get less friction and obtain better slide.

Improvement to reduce downtimes

Before After

No protection from rain New SS cover for sensor to avoid heavy rain

Improvement to reduce downtimes

By this modification heavy dirt particles coming with crate will get flushed & SS cover will avoid water contact with motor.

Pictures captured during breakdown

Strip broken on spiral conveyor SS flat chain link broken

Classified - Internal use

BEFORE AFTER

Classified - Internal use

BEFORE AFTER

Classified - Internal use

Classified - Internal use

BEFORE AFTER

Day 2 Fork Lift No : 14 (Double capacity , battery operated )

Date : 25 May 2013

Driver Name : Mr Kesar Gajendra

Shift: A

Sl. No. Time Workdone1 Workdone2 Workdone3 Workdone4 Remarks

Total Total

Palates cases

1 6:00-7:00 Was there in ware house till 6:30am Engine starts at 6:30am Shifting of palates till 7am NA NA NA NA

2 7:00-8:00 At 7:00 started working in ware house 7:55-8:00 No work NA NA Only shifted few palates which were not fully

loaded 11 581

3 8:00-9:00 Switched off engine at8:15 Went for breakfast NA NA Lifted few fully loaded palates 3 146

4 9:00-10:00 Engine starts at 9:00 Went to maintenance yard at 9:15 Engine switched off for battery change NA Did sourcing work 14 856

5 10:00-11:00 At 10:02 engine starts after battery changed. 10:08- 10:10 took rest 10:30-10:35 roamed without any

work 10:35-10:55 again took rest Here he worked in production, sourcing, dustbin shifting etc 19 976

6 11:00-12:00 Worked in sourcing of empty RGB 11:40-11:50 mango pulp drums shifting Worked for production This 1hr he worked at a good speed 74 ####

7 12:00-13:00 NA NA NA NA NA NA NA

8 13:00-14:00NA NA NA NA NA

NA NA

Initial running hour= 10107 Total no. palates =121

Final running hour =10111.5 Total no. cases=6079

Total running hour= 4.5hr BY- Naba Kishore Sarkar

Participated in taking the observation for determining forklift efficiency.

THANK YOU