Beruflich Dokumente
Kultur Dokumente
WELDING MACHINE
TEAM MEMBERS:
1. R.SAI PRABHU RAJ (111412114089)
2. S.SEDHU
(111412114096)
3. S.VINOTH
(111412114112)
INTERNAL
PROJECT GUIDE:
Dr. S.MAHADEVAN
Senior Professor
Mechanical Department
EXTERNAL
PROJECT GUIDE:
G.SENTHIL KUMAR
Section Manager
Caterpillar India Pvt. Ltd.
ABSTRACT
a days there is a large competition among companies. Companies are trying thei
vide the products in a innovative, exciting, cost effective way in the present globa
mpetitive market
enance department and people responsible for maintenance has the greatest
e on the company assets. Without the support of the Quality and Maintenance
possible to meet the requirements of manufacturing plants and customers.
im of this project is to suggest and study the implementation of the TPM program
llar India Pvt. Ltd. Located in Thiruvallur.
pillar India Pvt Ltd., MATERIAL HANDLING AND UNDERGROUND EQUIPMENT DIVIS
plant is located in Mellanathur, Thiruvallur District, and Tamil Nadu.
rently employs more than 1000 employees and produces Wheel Loaders, Backho
s, and Quarry and Mining Trucks (OHT).
CPIL, Thiruvallur plant, there are totally 12 bays are present.
ays include Warehouse, Assembly line, Tool room, hex bay, axle bay, fabrication
ls bay and along with two paint shops(loader paint shop and new paint shop).
ROBOT
WELDING:
SPECIFICATIONS:
S.no
1.
2.
3.
4.
5.
6.
parameters
Welding
Metal Inert Gas Arc
type
welding
Electrode
Copper wire of gauge
diameter =1.2 mm
Flux coated Gauge diameter =1.6
mm
Shielding
Argon (90%)
gas
Carbondioxide (10%)
Robot axes
8
coolant
Water
LS OF TPM:
er for TPM to be effective, the full support of the total workforce is required.
OUR ACTIVITIES
After:
checked.
1.2. Problem Description : Coil drum emptiness cannot be identified during auto welding.
Before:
After:
1.3. Problem Description : Panel cooler filter cleaning status has not been displayed.
Before:
After:
W
A
Y
G
U
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D
E
W
A
Y
G
U
I
D
E
DUST COLLECTOR
COLUMN
MASTER FRONIUS
POWER SOURCE
SLAVE FRONIUS
POWER SOURCE
CHILLER UNIT
ROBOT CONTROL
PANEL
WS-1
COLUMN
MAIN FRAME
ROBOT 1
ELECTRICAL
CONTROL PANEL
ROBOT CONTROL
PANEL
WS-2
COLUMN
MANUAL WELDINGPOWER
SOURCE
CHILLER UNIT
COLUMN
MASTER FRONIUS
POWER SOURCE
SLAVE FRONIUS
POWER SOURCE
COLUMN
DUST COLLECTOR
HEAD STOCK
MASTER ROBOT
SLAVEROBOT
TAIL STOCK
HEADSTOCK
MASTER ROBOT
SLAVE ROBOT
TAIL STOCK
SAFETY
LIGHT
CURTAIN
SAFETY
LIGHT
CURTAIN
WAY
IN/OUT
WAY
IN/OUT
W
A
Y
G
U
I
D
E
W
A
Y
G
U
I
D
E
DUST COLLECTOR
COLUMN
MASTERFRONIUS
POWER SOURCE
SLAVEFRONIUS
POWERSOURCE
CHILLER UNIT
ROBOT CONTROL
PANEL
WS-1
COLUMN
MAIN FRAME
ROBOT 1
ELECTRICAL
CONTROLPANEL
ROBOT CONTROL
PANEL
WS-2
BALL PACWIRE
FEEDER
(1,2)
COLUMN
MANUAL WELDINGPOWER
SOURCE
CHILLERUNIT
COLUMN
MASTERFRONIUS
POWER SOURCE
SLAVEFRONIUS
POWERSOURCE
COLUMN
DUST COLLECTOR
MANUAL WELDINGPOWER
SOURCE
HEADSTOCK
MASTER ROBOT
SLAVEROBOT
TAIL STOCK
HEADSTOCK
MASTER ROBOT
SLAVEROBOT
TAIL STOCK
TOOLSCUPBOARD
TEACH PENDENT
TEACHPENDENT
TOOLSCUPBOARD
SAFETY
LIGHT
CURTAIN
SCISSOR LIFT
SAFETY
LIGHT
CURTAIN
STEP LADDER
WAY
IN/OUT
WAY
IN/OUT
OEE CALCULATION
DATA
8 hours 30 minutes (510
Break
minutes)
(2) 10 minute and (1) 30
Down Time
Standard time for welding of
minute
63 minutes 02 seconds
4 hours 30 minutes.
model:777 frame
O
1.
Setup loss
2.
Breakdown loss
18:17
3.
Startup loss
8:42
4.
Tool change
7:38
5.
Inspection
6:57
Total
63.02
(minutes)
22:48
Run Time:
Formula: Available time - losses
= 460 minutes 63 minute 02 seconds
=396 minutes 58 sec.
Performance:
Formula: (Standard Time Total Count) / Run Time
= (460 minutes 0.65) / (396 min 58 sec)
= 0.7539 (75.39%)
Quality:
Formula: Good Count / Total Count
= 2 (777 frame) / 2 (777 frame) = 1.00 (100%)
Here Quality is 100%
Availability:
Formula: Run Time / Total Time
= 396 minutes 58 sec / 460 minutes
= 0.8621 (86.21%)
OEE:
Formula: Availability Performance Quality
= 0.8621 0.7539 1.00= 0.6499~ (65%)
DOWNTIME LOSSES
TIME
O
1.
Setup loss
2.
Breakdown loss
10:22
3.
Startup loss
7:29
4.
Tool change
6:41
5.
Inspection
5:16
Total
45:15
(minutes)
16:07
DATA
8 hours 30 minutes (510
Break
minutes)
(2) 10 minute and (1) 30
Down Time
Standard time for welding of
minute
53 minutes 02 seconds
4 hours 30 minutes.
777 frame
Performance:
Formula: (Standard Time Total Count) / Run Time
= (460 minutes 0.7) / (415 minutes)
= 0.7869 (78.69%)
= 460 minutes
Run Time:
Formula: Available time - losses
Quality:
Availability:
OEE:
Chart Title
120
ITEMS
Before
After
Availability
86.21%
90.21%
Performance
75.39%
78.69%
Quality
100%
100%
OEE
65%
70.98%
100
80
60
40
20
Availability
Performance
Before
Quality
After
OEE