Nagel honing m/c

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TARGET MODEL MACHINE MY MACHINE CAMPAIGN
Induction Hardening m/c
300T ISGEC Press
Nagel honing m/c
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Abnormality Manual 7 types of abnormalities
1.MINOR FLAWS
2. UNFULFILLED BASIC CONDITIONS
3. INACCESSIBLE PLACES
4. CONTAMINATION SOURCES
5. QUALITY DEFECT SOURCES
6. UNNECCESSARY AND NON-URGENT ITEMS
7. UNSAFE PLACES
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1.MINOR FLAWS
Contamination Dust, Dirt, powder, oil, grease, rust, paint
Damage Cracking, crushing, deformation, chipping, bending,
Play Shaking, falling out, tilting, eccentricity, wear, distortion, corrosion,
Slackness Belts, Chains
Abnormal Phenomenon Unusual noise, overheating, Vibration, strange smells, discoloration, incorrect pressure or current
Adhesion Blocking, hardening, accumulation of debris, peeling, malfunction
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2. UNFULFILLED BASIC CONDITIONS
Lubrication Insufficient, Dirty, Unidentified, unsuitable, Leaking
Lubrication Supply Dirty, damaged or deformed lubricant inlets, faulty lubricant pipes
Oil level gauges Dirty, Damaged, leaking, No indication of correct level
Tightening Nuts and Bolts slackness, Missing, Cross-threaded, Too long, Crushed, Corroded, Unsuitable washers, wing nuts on backward
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3. INACCESSIBLE PLACES Hard to access places
Cleaning Machine construction, Covers, Layout, footholds, Space
Checking Construction, Covers, Layout, footholds, Instrument position and Orientation, Operating Range display
Lubricating Position of lubricant inlet, construction, height, footholds, lubricant outlets, space
Tightening Covers, Construction, Layout size, Space
Operation Machine layout, Position of valves, Switches and levers, Footholds
Adjustment Position of pressure gauges, thermometers, flow meters, moisture gauges, vacuum gauges, etc.
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4. CONTAMINATION SOURCES
Product Leaks, Spills, Spurts, Scattering, Overflow
Raw materials Leaks, Spills, Spurts, Scattering, Overflow
Lubricants Leaking, Spills, Seeping oils, Hydraulic fluids, Fuel oils, etc.
Gases Leaking compressed air, gases, steam, vapors, exhaust fumes, etc.
Liquids Leaking water, Hot, Cold, half finished products, Waste water, Leaking supply lines etc.
Scrap Flashes, cuttings, packaging materials, and non conforming products.
Others Contaminants by people Forklifts, Infiltration through cracked walls, broken windows etc.
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5. QUALITY DEFECT SOURCES
Foreign Matter Dust, Rust, powder, chips, moisture, wire scraps, wood pieces, paper pieces, stones etc.
Shock Dropping, Jolting, collision, Vibration etc.
Moisture Too little or Too much, infiltration
Gain Size Abnormalities in screens, Compressed air separators, centrifugal separators,
Concentration Inadequate warming, heating, compounding, mixing, evaporation, stirring etc.
Viscosity Inadequate warming, heating, compounding, mixing, evaporation, stirring etc.
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6. UNNECESSARY AND NON-URGENT ITEMS
Machinery Pumps, fans, compressors, columns, tanks etc.
Piping equipment Pipes, hoses, ducts, valves, dampers etc.
Measuring instruments Temperatures, pressure gauges, vacuum gauges, ammeters etc.
Electrical equipment Wiring, piping, power leads, switches, plugs etc.
Jigs Fixtures Tools General tools, cutting tools, jigs, molds, dies, frames etc.
Spare parts Standby equipment, spares, permanent stocks, auxiliary materials, etc.
Makeshift repairs Tape. String, wire, metal plates etc.
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7.Unsafe Places
Floors Unevenness, ramps, projections,
cracking, peeling, wear (steel deckplates) Step
s Too steep, irregular, peeling anti-slip
covering, corrosion, missing handrails Lights D
im, out of position, dirty or broken covers, no
safety or emergency stop devices Rotating
machinery Displaced, fallen off or broken covers,
no safety of emergency stop devices Lifting
gear Wires, hooks, brakes, and other parts of
cranes and hoists. Other Special substances,
solvents, toxic gases, insulating materials,
danger sign, protective clothing etc.
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STEP 0 THOROUGH CLEANING

• UNDERSTAND FUNCTIONS OF EQUIPMENT AND AUXILLARIES
• IDENTIFY FAILURES/BREAKDOWNS
• REFER TO THE OLD HISTORY RECORDS
• MAKE THE LIST OF
• HARD TO CLEAN AREAS
• HARD TO LUBRICATE
• HARD TO INSPECT
• HARD TO TIGHTEN
• HARD TO ADJUST
• AREAS TO VISUALISE
• RECORD CLEANING TIME
• CARRY OUT AUDIT ON 0 STEP
• MEETING AFTER THE DAILY ACTIVITIES

Areas / Parts
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STEP 0
STRUCTURE WISE MACHINE CLEANING EPH 250T Press
Hydraulic Power Pack
Hydraulic Power pack (K.Subramani )
Machine Frame (P.Balakrishnan)
Eph-250t Press
Lubrication Unit (N.Gopi)
Main Ram (B.Chandramurthy)
Control Panel E.Damodharan
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APPLICATIONS OF CLEANING AIDS
PUTTING WHITE TAGS
APPLICATIONS OF CLEANING AIDS
PUTTING RED TAGS
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Cleaning Kit - Examples
Cleaning tool picture Used for
Scrapper
Steel wire brush
1'' Wire Brush
2'' Wire Brush
Cleaning tool picture Used for
50 mm Paint brush
Cotton waste
Mull cloth
Red Tag White Tag
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Checkpoints for Nuts and Bolts
Slight Defects