ConsolidationofFieldIssuesandOtherImprovementInitiatives

1.

RT880/TMS875TeleCylinderWearedeeplyconcernedwithrepetitivefailureofP3573TeleCylinder.

FailureModes (a)InternalLeakageCreep

(b)VisibleLeakagethroughRodseal

(c)Scoringofpistonrod

Summary

TotalFailureInstances9(excludingthecaseofweldarchinginJSPL)
NoofFailureInstancesofInternalLeakage/Creep4
NoofFailureInstancesofVisibleLeakagethroughRodSeal5
AffectedcustomersJSPL,ESSARProjectsandNCL
CylinderSerialNoSeriesK5,K7,K8andJZ
4Cylindersoutof9havebeenreturnedtoWIPRO,BLR
FailedCylindersdispatchedfromsiteon18Jun12
Outofthe4returnedcylinders,twoarefromJSPLandtwofromESSARProjects
Outofthe4returnedcylinders,twoarerelatedtocreepandanothertwoarerelatedtoVisibleLeakage
TILisyettoreceiveanyofficialfailureinvestigationreport
TILhassofarfitted75TeleCylinders
FailureRate12%
WeunderstandthatwefL5L00233WIPROhasimplementedsealingconceptofGROVE
Themachineswithmodifiedcylindersareyettoworksignificanthourstotakeadecision
Thecompletelistofcylindersfittedsofarwrtmachineserialnoshasbeenprovidedinthenextpage.Few
cylinderserialnosaremissing.
Theissueneedstobetakenupseriously

Page1of4
DateofReview11Sep2012

MachineModel
TMS875

SerialNo
38502

38503

38504

38507

38506

38505

38508

38509

406767

406959

406984

406985

407085

407263

407283

407305

407304

407264

407231

407233

407142

407086

CustomerName
CHANDI CRANES

SerialNo
K9L00391,KXL00373,

SHRADHA ENGINEERING

KYL00259,KZL00058

CHAUDHARY CRANES

L1L00229,L1L00119,

LARSEN& TOUBRO

L4L00082,L4L00210,

APOLLO ENTERPRISES

ARIHANT CARGO CARRIERS

L3L00530,L3L00657,

LARSEN& TOUBRO

L5L00233,L4L00066,

APOLLO ENTERPRISES

NEYVELI LIGNITE CORPORATION

L5L00449,L7L00162,

SHARMA FABRICATORS &ERECTORS

K2L00003,K3L00218, K3L00332

ESSAR PROJECTS

K3L00365,K5L00361, K5L00360

SEW INFRASTRUCTURE

K2L00008,K2L00079, K5L00355

JSPL

JZL00466,JZL00365, JZL00383

NORTHERN COALFIELDS

SOUTH EASTERN COALFIELDS

MAHANADI COALFIELDS

MAHANADI COALFIELDS

MAHANADI COALFIELDS

SOUTH EASTERN COALFIELDS

NORTHERN COALFIELDS LTD

BSC C&C'JV'

JSPL

L1L00183,L1L00075, KZL00336

RT880

407087

JSPL

RT880

407088

JSPL

RT880

407141

NORTHERN COALFIELDS

K7L00237,7L00247,K7L00241

K7L00259,K8L00006

8L00074,K8L00077,K8L00048

TMS875
TMS875
TMS875
TMS875
TMS875
TMS875
TMS875
RT880
RT880
RT880
RT880
RT880
RT880
RT880
RT880
RT880
RT880
RT880
RT880
RT880
RT880

L2L00245,L2L00073,

J5L00897,J5L01001, J5L01100

L3L00363,L3L00444, L3L00445
L3L00052,L3L00074, L3L00095
L1L00571,L2L00473,
L1L00561,L2L00002, L2L00005
L1L00376,L1L00419, L1L00148
KZL00155,ZL00130,KZL00103
KYL00077,KYL00003,
K7L00100,6L00307,K7L00133

Page2of4
DateofReview11Sep2012

2.

RT760(P8131/P9610)TeleCylinder

FailureModes(a)InternalLeakageCreep
Summary

3.

4.

5.
6.

7.

TotalFailureInstances3
AffectedcustomerUltratechCement
CylinderSerialNoSeriesJYandK3
OnecylinderhasbeenreturnedtoWIPRO,BLR
Thefailureinvestigationreportisnotconclusive
TILisyettoreceiveanyfeedbackonfutureCAPA

ExpediteAnalysisoffailedmaterialSometimesitistakingtoolongtimeeg825Telea/cArihantCargo
FailureModeCreepSealKitreplacedFailedmaterialreceivedatWIPROon29Feb12.Nofeedbackon
RCA.

TIL has approved improved version of design of following cylinders. No feedback on physical
implementation.

TypeofCylinder

MachineModel

WIPROP/NO

Lift

RT880

P9812

Lift

RT740B

P5226

O/RJack

RT880

P3545

O/RJack

RT760

P3698

O/RJack

RT740B

P3439

O/RRam

RT740B

P3124

O/RRam

RT760

P3347

O/RRam

RT880

P3357

O/RRam

TMS750B

P3423

Feedbackisrequiredonimplementationplanofwiperguardaswell.

TILhasnofeedbackonphysicalimplementationofUltrasonicCleaningBathinMHLineofHindupurPlant.It
wasscheduledtobeimplementedinJuly2012.

TILhasnofeedbackonphysicalimplementationofAssemblyFixturesinMHLineofHindupurPlant.Itwas
scheduledtobeimplementedinJuly2012.

Page3of4
DateofReview11Sep2012

8.

HYSTERLiftCylinder

FailureModes (a)PistonRodScoring

(b)OilSeepagethroughHECORing

Summary

NoFieldIssueatthemomentoncylinderswithmodifieddesign
MachineNo25withmodifieddesignhasclockedmorethan3200hrswithoutanyissueonpistonrod
CylinderswithimprovedsurfacefinishatHECORingseatinghavebeenfittedwefApril2012despatch.
Needstobemonitoredfurtherforeffectivenessoftheactions.
WIPROneedstosupportTILforpendingissuesrelatedtoLiftCylinderCampaignChange.

Page4of4
DateofReview11Sep2012