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Improvement Project: Maintenance Engineers Training

This document summarizes a maintenance engineers training project to modify a flush coolant system. It describes collecting data on coolant-related breakdowns and machine details. Modifications made included reducing coolant pipe hole diameter, introducing a higher LPM pump, and modifying the coolant pipe line circuit. Breakdown histories are provided for several machines from May 2012 to November 2012. Diagrams show the pipe line modification. Power savings details show a reduction in kW, KW hours per day, and cost per month after the modifications. Listed benefits include power savings, reduced breakdowns, improved MTBF, less burr accumulation, increased telescopic cover life, and increased servo motor and cable life.

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gm9790
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© Attribution Non-Commercial (BY-NC)
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12 views

Improvement Project: Maintenance Engineers Training

This document summarizes a maintenance engineers training project to modify a flush coolant system. It describes collecting data on coolant-related breakdowns and machine details. Modifications made included reducing coolant pipe hole diameter, introducing a higher LPM pump, and modifying the coolant pipe line circuit. Breakdown histories are provided for several machines from May 2012 to November 2012. Diagrams show the pipe line modification. Power savings details show a reduction in kW, KW hours per day, and cost per month after the modifications. Listed benefits include power savings, reduced breakdowns, improved MTBF, less burr accumulation, increased telescopic cover life, and increased servo motor and cable life.

Uploaded by

gm9790
Copyright
© Attribution Non-Commercial (BY-NC)
Available Formats
Download as PPTX, PDF, TXT or read online on Scribd
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GABRIEL

Maintenance Engineers
Training

Improvement Project
Maintenance Engineers Training
Batch 6 2012 DEC

Anand University

GABRIEL
Maintenance Engineers
Training

TEAM
S.No 1 2 3 Name R.Balasubramanian Mr.B.Ratnagiri Mr.R.Srinivasan. Designation Maintenance Junior Engineer. Maintenance Manager Sr. Engineer Maintenance

GABRIEL
Maintenance Engineers
Training

PROJECT
Restoration and modification of flush coolant system
R.Balasubramanian Mando India Ltd, Chennai.

GABRIEL
Maintenance Engineers
Training

Data collection

v v v v v

Coolant related breakdown details taken. Machine available details . Coolant pump details taken (LPM & KW). No of machine and B/D details taken. All AMS VMC machine data taken.

GABRIEL
Maintenance Engineers
Training

Action Taken

v v v v

Modification done in coolant pipe line. Coolant pipe hole dia reduced . High LPM pump introduced . Coolant pipe line circuit modified.

GABRIEL
Maintenance Engineers
Training

MAJOR BREAKDOWN HISTORY ( MAY 2012 - NOV 2012) CELL:MCM 1 MACHINE: VMC MAKE: AMS MACHINE NO:M139

GABRIEL
Maintenance Engineers
Training

MAJOR BREAKDOWN HISTORY ( MAY 2012 - NOV 2012) CELL:MCM-1 MACHINE: VMC MAKE: AMS MACHINE NO:M044

GABRIEL
Maintenance Engineers
Training

MAJOR BREAKDOWN HISTORY ( MAY 2012 - NOV 2012) CELL:MCM 1 MACHINE: VMC MAKE: AMS MACHINE NO:M125

GABRIEL
Maintenance Engineers
Training

MAJOR BREAKDOWN HISTORY ( MAY 2012 - NOV 2012) CELL:CCM 1 MACHINE: VMC MAKE: AMS MACHINE NO:M064

Occurences

Time

GABRIEL
Maintenance Engineers
Training

MAJOR BREAKDOWN HISTORY ( MAY 2012 - NOV 2012) CELL:CHM-5 MACHINE: VMC MAKE: AMS MACHINE NO:M033

GABRIEL
Maintenance Engineers
Training

Before

Modification

After

GABRIEL
Maintenance Engineers
Training

Pipe Line modification


Before After

GABRIEL
Maintenance Engineers
Training

POWER SAVING DETAILS


DESCRIPTION
CAPACITY VOLT CURRENT DRAWN TOTAL WATTS TOTAL KW KWH/DAY COST/DAY COST/MONTH TOTAL COST IN Rs

BEFORE
2.6KW 415 V 1.1 415*1.1=456.5 2.6 2.6*21=54.6 54.6*6.5=354.9 354.9*26=9227 9227

AFTER
0.3 KW 415 V 0.7 415*0.7=290.5 0.3 0.3*21=6.3 6.3*6.5=40.95 40.95*26=1064 1064

GABRIEL
Maintenance Engineers
Training

Benefits

v v v v v v v v

Power saving. Machine breakdown reduced. MTBF improved. Burr not accumulate at machine. Telescopic cover life increased. Servo motor & cable life increased. 5s improved. Horizontal Deployment to be done for all AMS machines.

GABRIEL
Maintenance Engineers
Training

THANK YOU

Any Questions?

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