1/20

Monthly Report of MTD – Jan’ 12

Contents:

- Monthly Report
- (i) ECU
- (ii) FP, Injector & Die
- (iii) Utility
 2/20
MTD ECU MONTHLY STATUS (JAN’12)
BM TIME BM COUNT (No's) MAJOR BREAK DOWN COUNT (No’s)
Status : X Status : Status : X
30 5
1400
(1st Half) Target : 840 Min/ M (2nd Half)

M B D C ounts(In N o.)
Target : 826 Min/M 25
Target : 0.8 No’s.

B /D Counts(In N o.)
1200 4
B/D Time(In min.)

1025 Target : 19 No’s.

1035
20

210 60
1000
PCB recognition
5 3
error in CM212-2
600

410

1560
800 6 3
15 12 2 1
252

35
663

40 4
370

9 5 9

30
10
235
600 5
One Major 5 2
6045125
90

8
228

0 B/D 10 00 4
95

95
4 8 1 1 1 1 1 1
400 2 2

600
5 10 1
285

0
290

5 3

85 130 145
400

2 2 3 2 1 0
100 245

135 5 00 2
360

200 0 2 2 2 0
325

0140 60

0 5
060120 4 2 4 1 1 1 1 1 1 1
155

4 3 2 3
3 3
75

10 2

50
0 25 1 1 1 1 1
0 0 0 0 0 0 0 0
' 11 ' 11 '1
1 11 '1
1
' 11 11 11 11 ' 12 '1
2 1 2
' T' V' C' R'

11
1

11
2
11

1
11

12

2
11

11

1
1

11

12

11

12
PR

11

1
UL AN

11

12
AY N G EP B

'1

'1

'1

'1

'1

'1
'1
'1

'1
'1
JU AU NO DE FE A

Y'
C

Y'
T'
L'

V'

T'
R'

L'

V'
P'

B'

R'
P'

B'
UG
J J

PR

UG
PR
A S

EC

N
N

EC
N
M O M

JU

OC

A
O

JU

OC
JA

O
SE

JA
FE

SE
JU

A
FE
JU
M

M
A

A
A

M
MA-1 MA-2 MA-3 MA-4 FA-1 FA-2 FA-3 MA-1 MA-2 MA-3 MA-4 FA-1 FA-2 FA-3 MA-1 MA-2 MA-3 MA-4 FA-1 FA-2 FA-3

PM RESULTS KAIZEN TRAINING

Status : X Status : Status :
110% 5 10
100% 100% 100% 102% 100% 100%100% 100%
100% 9
92%
90%
90% 4 8
C ounts(n N o.)

C ounts(In N o.)
Target : 100% Target : 3 No’s 8
PM (In % age)

80% 7 Target : 5 No’s

70% 3 6 7
60%
M/c not available 5
50% so PM finished on 2 4
40% 11.02.12
3 3 3 3 3 3 3 6 6 6
30% 5 5 5
1 2 2 2
20%
3
10%
1 1 1
0
1
0% 0
11
1

2
11

11

12
11

1
1

11

2
11

11
'1

'1

'1

1
1

2
1

11

11
11

11

12

'1

12
11

'1

'1

11

1
1

11

11

2
Y'

T'
L'

V'

'1
'1

R'

'1

'1
'1

'1

P'

'1
'1

'1
'1
'1

'1

UG
PR

N
EC
N

Y'
Y'

T'

V'
L'
T'

R'
V'
L'

P'
R'
P'

UG
PR
UG

JU

N
PR

EC
JA

B
EC

SE

A
N

FE
JU

JU

C
A

O
M
JU

JA
O
O

SE

A
A
JA

FE
JU
SE

A
FE

M
JU

O
M

A
O

M
A

D
M
A

Last month specially focus on mounting machine problem &

skill enhancement activity.
1 3/20
“Internal loss” Major Problem Solving Sheet
■ Problem Statement
Title PCB recognition error & changer mark position error was coming.
Machine Name CM212-2 (TBL-1) Occurrence Date 02nd Jan’12 (A-Shift)
Line Name MA-02 Breakdown Time 480Min+480Min(Maint.Time15/01/12)
Plant/Process DNHA/Chip component mounting Scrap Amount (Rs) 5957/- INR

Problem details Attach any supporting photo,illustrations, etc.

Working Diagram of PCB Camera
PCB recognition error & changer mark position error Monitor
was coming.

OK OK
No display on
Controller Monitor
Phenomenon:
Recognization
Cable
Image was not showing on screen Camera
N.G

Fudicial Points

PCB

■ Root cause
Root cause Analysis (repeat of ‘why?’)
Why? (step 1) Why? (step 2) Why?(step 3) Why? (step4) Why? (step 5)

Camera internally got Fudicial point not

PCB recognition No image captured Camera was
damage recognized by Actual cause not clear.
error came. by camera. damage.
camera.
 4/20
■ Countermeasure
Attach any supporting photo,
Countermeasure implementation Res. Date
illustrations, etc.
S. Jig Availability 02.01.12
1. Check recognition cable & card found OK. No
Calibration Name MTD (90 min)
DNHA Maker
2. Check camera found N.G so change with spare one with 1
Board Recognition MTD 02.01.12
maker support. Camera X-Y Axis Origin
(230 min)
(1st time problem so maker support required) 2
Board Positioning &
Replacement Height MTD 02.01.12
3. Calibration done as per maker recommendation. (60 min)
3 Plane Compensation
02.01.12
4. Production start but Component shifting observed in TB-01 MTD (100 min)
so temporary offset given in machine to Run production. 4 Pickup Position
15.01.12
5. Panasonic did calibration & CP-CPK after that ok. Maint. time
5 Nozzle Changer MTD (480 min)

■ Yokotenkai

Forward to Method Res. Date

We will confirm with maker about Jig availability in India so if

Discuss with Maker MTD 15/03/12
problem comes we can arrange it with maker.

■ Reoccurrence
Countermeasure
1. Now we can change this camera without maker support (3 hrs Camera Change).
2. We have prepared CP-CPK procedure to do it in house.

2/2
 MTD FUEL PUMP MONTHLY STATUS 5/20

BD TIME BD No's MAJOR BD No's

Status : 80 Status ::
Status
6000
5 Status :
5500 Problem in Choke coil 70

580
12 Target
60
Target60
Target60
5000 and B/H CNC 4 Problem in Choke coil
Target 2600 60 Target 55
4500 580 and B/H CNC
8

500
12
4000
2000

15

M B D N os
50 3

BD NOs
500

1955
Target 2760 6 12 18

1085
3500
Break down Time

0 1 1 Target 2
40 14
1116

1055
3000 10 9
3 10 0 2
2500 7 12 9
550 720 720

30

620

825 800
14 12
2000 800 16 11 14
9 6 1 1 1 1
647

8 6 1 9
1500 20 3 8 6 1 2
2115

1950

1887 7

720
8 11
1755

8
1000 3 1 1 1 1 1 1 1
1180

10 20 20 11
990
17 7 18 7
500

565
11
5 4
10
5
10 0 0
0 0

2
1

1
11
1

1
'1 1

r' 1
r l '1

y '1

ly '1

n '1

b '1
M 1

Au 1

g '1

v '1

c '1
O 1

t '1
Ju 1

12

12

2
11
11
1

12
1

2
1
11

12
1

11

p t'
11
1
1

1
'1

'1
'1

g'1

ne
'1

Ma
'1

'1

'1

'1
'1

g'1

Oc

Fe
'1

Ma

Ja
No
Au

De
Ap
'1

Ju
rl'

ly'

b'

b'
n'

Se
c'

rl'

n'
v'

c'
v'
pt

ar
ar

ay

ly
ay

pt
ct

Ju
ct
ne

ne
Ap

Fe
Ja
Au

No
Fe

De
Ja

Ap
Ju

No

De

Ju

M
Se

Se
M

O
Ju
Armature F/P Assy Molding SIFS Others Armature F/P Assy Molding SIFS Others Armature F/P Assy Molding SIFS Others

PM PERCENTAGE KAIZEN TRAINING

Status : Status : Status :
100% 100%100%100%100%100%100%100%100% 5 10
100% 94%
9
4 Target 3 8
80% 7
3 3 3 3 3 3 3 3 7 Target 5
PM Pergentage

No. of tranings
Kaizen Nos.

60%
3 6
5 5 5 5 5 5 5 5
2 5
40% 2 4
1 3
20% 1 2
1
1
0% 0
0

2
Au 11

M 2
M 11
Ju '11

Fe 2
Ja 1
O 11

De 11
Se 11

No 1
Ju 11
Au 1
M 1
Ju 11

O 1

2
Ja 1

M 2
Fe 2
De 1
Se 1

No 1

'1
Ju 1

1
1
1
'1
1

'1
1

'1

1
1

1
v'1
g'1

'1

ly'

b'
'1

rl '

n'
c'
g'

'

v'

ar
ay

Au 11
'

pt

2
M 11

M 2
ly'

ct

Ju '11

Ja 1
rl '

'

O 11

De 1

Fe 2
b'
c'
n'

Se 11

No 1
Ju 11
ne
ar
pt
ay

ct
ne

'1
1
Ap

1
1
v'1
'1
Ap

ly'
rl '

b'
c'
n'
'
g'
'

ar
ay

pt
ct
ne
Ap
Focus on Major Breakdown permanent Countermeasure and PM for Improving the Production Ratio.
 PM Pergentage B re a k d o w n T im e

0%
20%
40%
60%
80%
100%
0
500
1000
1500
2000
2500
3000
3500
Ap Ap

110 %
rl' r l '1
11
1

88%
M 1395
ay Ma
'1
1
y '1
1

82%
Ju
ne Ju 510
'1 ne
1 '1 1

Housing

82%
BD TIME

Ju
ly Ju 785
'1
1 ly ' 1
1
475
Target 3000

Au
g'1 Au
1 g '1
1
Se
2120

Cal 1
pt Se
'1
1
p t'
O
11
ct 690

PM PERCENTAGE
'1 Oc
1 t '1
No 1
v' No 1350
11 v '1

Cal 2
De 1
c' De 700
11 c '1
Ja 1
n'
12 Ja 2120
n '1
2

100% 100% 100% 100% 100% 100% 100%

Fe
1635

Assy.
b' Fe
12
b '1
M 2
ar

Status :
'1
Target 2500

Ma
Status :

2 r' 1
2

Target 100
Kaizen Nos. BD NOs

0
1
2
3
4
5
0
10
20
30
40
50
60

Ap
rl ' Ap
1 r l '1
1

0
5

M 1
29

ay Ma
' y '1
1

2
5

17

Ju 11
ne Ju
ne
Housing

'1 '1 1

3
17
Target 48

Ju 1
KAIZEN

Ju
BD No's

ly' ly '
1 11
3
2

13

Au 1 Au
g'1 g '1
1

2
8

Cal 1
17

Se 1 Se
pt pt
'1 ' 11
4

3
19

O 1 Oc
ct t '1
'1 1
1

3
13

No 1 No
Cal 2

v'1 v '1
1
6

3
18

De 1 De
c' c '1
1 1
1

3
29

Ja 1 Ja
n' n '1
1 2
3

3
22

Assy.

Fe 2 Fe
b' b '1
1 2
Target 45

M 2 Ma
Challenge Target 36
Status :

Status :

ar r' 1
'1
2 2
Target 3

No. of tranings MBD Nos

0
1
2
3
4
5

Ap
MTD INJECTOR MONTHLY STATUS

0
1
2
3
4
5
6

Ap r l '1
1
1

rl'
1 Ma
1

M 1 y '1
1
1

ay
' Ju
5

Ju 11 ne
Housing

ne '1 1
0

'1
5

Ju 1 Ju
l y '1
1
0

TRAINING

ly'
1
5

Au 1 Au
g '1
1
1

g'1
Cal 1

Se 1 Se
pt p t'
11
0

'1
5

O 1 Oc
ct t '1
'1 1
MAJOR BD No's

1
1

No 1 No
v'
Cal 2

1 v '1
1
0

5
Target 5

De 1 De
c'
1 c '1
1
5
2

Ja 1
n' Ja
1 n '1
5

2
1
1

Fe 2
Focus on Major Breakdown permanent Countermeasure and PM for Improving the Production Ratio.
Assy.

b' Fe
1 b '1
M 2 2
and winding machine
Problem in Static flow

ar Ma
'1
Status :

Status :

2 r' 1
2
Target 2
6/20
 MTD DIE MONTHLY STATUS 7/20

BD TIME PM PERCENTAGE
100 Status ::
Status Status :
140%
90 123% Spool Die BM Support
5- Shift
80 Part Stuck in spool die 120% 112% 109%
Target 30
100% 100%
70 100%

PM Pergentage
85% 85% 85%
Break down Time

60
14 80%
50 71%
42 66%
4
40 8 60%
30
40%
46
28
15

20 12
11 5

35
4
20

10 20%

17
7

15
10

8
8
6
2

0
0

0%
Aprl'11 May'11June'11July'11 Aug'11Sept'11Oct'11 Nov'11 Dec'11Jan'12 Feb'12 Mar'12

11

12

2
11

'11

1
11

1
'11

'1
'1

b'1
v'1

c'1
'1
B/H Suppoter Spool Flange Omni YG8 Case YY4 Subtank Sub Tank Housing YG8 Flange

rl '

ly'

n'
g'

pt

ar
ay

ct
ne

Fe
Ja
No
Au

De
Ap

Ju

M
Se
M

O
Ju
S No DIE NAME PROBLEM ROOT CAUSE ACTIONS TAKEN STATUS FUTURE ACTION DECIDED

1)Heating Temperature
reduced by 10 Deg. Discuss with DNJP Expert and
1 Spool Die Part Stuck Not Clear U/O
2) Die Trail done at JSW M/c. take countermeasure Accordingly.

Focus on Die PM for Improving the Breakdown ratio and Defect ratio.
 8/20
1 “Chokotei loss” / Major Breakdown Solving Sheet
■ Problem Statement
Problem Motor X –Axis does not rotate fault was coming
Line Name Molding Occurrence date 09/01/2012
Machine No. B/d Time (Min) .
Machine Name B/H CNC Chokotei Time (Min)

Problem details Attach any supporting photo,illustrations, etc.

Motor X-Axis Main Supply

does rotate and Motor ON sequence

main spindle Motor
clamping
MAIN
SUPPLY
+ BRAKE
SUPPLY
Brake Supply
responded fault
was coming. RELAY
N.G Break not released

■ Root cause
Root cause Analysis (repeat of ‘why?’)
Why? Why?
Why? (step 1) Why? (step 2) Why? (step 3)
X-Axis break (step4) (step 5)
release relay Machine stop in Turret X –Axis X-Axis motor X-Axis break Relay Contact
between auto motion was not brake release release relay got
was faulty run possible was not was doing Carbanised.
possible. malfunctioning.
 9/20
2 ■ Countermeasure / Action Taken
Attach any supporting
Countermeasure implementation Res. Date
photo,illustrations, etc.

Activity Status

1. Clamping pressure Adjusted. N.G.

MTD 09/01/2012
2. Changed the Relay with new one O.K.

■ Yokotenkai
Forward to Status. Res. Date

We will check other CNC machines break O.K. Kaushal/

release relay. Omveer 10/01/12

■ Re-Occurrence Countermeasure
# Will check the Relay contact life and relay change point will add accordingly.( T.D. 28/02/11)
 10/20
1 “Chokotei loss” / Major Breakdown Solving Sheet
■ Problem Statement
Problem Fault No.56 (robot -2 fault) coming on the machine.
Line Name BEARING HOLDER Occurrence date 27/01/2012
Machine No. EFFP-008 B/d Time (Min) 270 Min.
Machine Name CHOKE COIL WINDING Chokotei Time (Min)

Problem details Attach any supporting photo,illustrations, etc.

Jig Open/Close Jig

Clamping fault
coming

Jig

■ Root cause
Root cause Analysis (repeat of ‘why?’)
Why? Why?
Why? (step 1) Why? (step 2) Why? (step 3)
(step4) (step 5)
Wire get up Because wire get up Because wire Because the Continuo
Wire get up jig confirmation not cylinder not coming get up jig stuck jig was worn us
worn out coming. its end. on the winding out. use(10
jig lever. years)
 11/20
2 ■ Countermeasure / Action Taken
Attach any supporting
Countermeasure implementation Res. Date
photo,illustrations, etc.

Activity Status
1>Robot – 2 home position parameter checked. OK
2>Wire get up unit alignment checked. OK
MTD 27/01/2012
3>Jig dent removed by polishing and buffing. OK
4>Wire get up jig position adjusted according to
winding jig. OK

Damage jig
■ Yokotenkai
Forward to Status. Res. Date

All related jigs condition to be checked. OK MTD 02/02/12

■ Re-Occurrence Countermeasure
# All Jigs condition check point will add in PM(1/year)
 12/20
1■ Problem Statement
Problem Winding wire peel off from 3rd & 4th station .
Line Name Housing Occurrence date 16/01/12
Machine No. EIHS-31 B/d Time (Min) 10 hours.
Machine Name Wire Winding Chokotei Time (Min)

Problem details Attach any supporting photo,illustrations, etc.

In 3rd & 4th station start side winding WINDING UNIT
wire peel off during wrapping. During
wrapping
wire was
touching
with
terminal
hook

■ Root cause
Root cause Analysis (repeat of ‘why?’)
Why? (step 1) Why? (step 2) Why?(step 3) Why? (step4) Why? (step 5)

No gap between wire & terminal

hook. In 3rd & 4th Wire was There was Problem in MCH Suspected
station touching to insufficient program reason may be
start side terminal hook gap between Terminal rough
winding during wrapping. nozzle & edge.
wire peel off terminal hook.
during
wrapping.
 13/20
2 ■ Countermeasure / Action Taken
Attach any supporting
Countermeasure implementation Res. Date
photo,illustrations, etc.

1. Fix cutter changed due to its sharp edge found

damage.
2. Wire winding nozzle changed all station.
Gap 0
3. MCH program modify and make gap between Gap 0.2m.m MTD 16/01/12
nozzle & terminal hook.

NO Gap OK Gap

#30 (J1) -3.6 to -3.8, (J3) -8.2 to -7.2

#31 (J1) -4.5 to -6.0, (J3) -8.7 to -7.7

■ Yokotenkai
Forward to Method Res. Date
N/A N/A

■ Re-occurrence countermeasure
N/A
 14/20
1 “Chokotei loss” / Major Breakdown Solving Sheet
■ Problem Statement
Problem Servo motor fault was coming.
Line Name Calibration-2 Occurrence date 18/01/2012
Machine No. EICI-022 B/d Time (Min) 270 MIN.
Machine Name Static flow adjust and inspection machine-2 Chokotei Time (Min)

Problem details Attach any supporting photo,illustrations, etc.

Servo
motor
Load cell
wire
Adjustment
damaged.
pin ( Load )
Servo motor
fault was Table
jig
coming. Load cell Micro PLC
Load cell
amplifier computer

Damage Motor Servo

portion driver motor

■ Root cause
Root cause Analysis (repeat of ‘why?’)
Why? Why?
Why? (step 1) Why? (step 2) Why? (step 3)
(step4) (step 5)
Load cell wire Servo motor not Wrong signal was Load cell wire Due to Wire Suspected
was damage. return to home coming in micro damage Insulation cause due
position. . computer damage to Stress on
wire.
 15/20
2 ■ Countermeasure / Action Taken
Attach any supporting
Countermeasure implementation Res. Date
photo,illustrations, etc.

Activity Status
1>Cut the damaged area of the wire of NG
old load cell and checked the condition. 18/01/12
MTD
>2 Modify the load sensor mounting plate as
pitch of the mounting hole of new load cell is OK
different compare to old load cell.
3>New load cell assembled after modification OK Old New
of its base plate. (VCT Spares) Capacity 5KN 10KN
4>New load cell calibration done. OK Dia 73 mm 55mm

■ Yokotenkai
Forward to Status. Res. Date

Static m/c-1, Dynamic m/c 1 & 2 and OK. MTD 20/01/2012

connector press fit machine.

■ Re-Occurrence Countermeasure
# Arrange the load cell wire properly of all similar machine.
# We will add additional wire condition check point during load cell calibration time.(Feb’12)
 MTD UTILITY MONTHLY STATUS 16/20

MAJOR BD COUNT SAFETY POWER & FUEL COST

4 4 8000 Status : 80000

6 Status : X 6 Status :
7000 70000
5 5
6000 60000

N e a rm is s / m o n th
3 3
MBD / Month

Cumm. MBD

Rs. in '000
4 4 5000 50000

3 3 2 2 4000 40000

Target : 1 No’s. 3000 30000

2 2
1 1 2000 20000
1 1
Target : 0 Accident 1000 10000
0 0 0
0 0 0 0
1 1 1 1 11 1 1 11 11 2 1 2 r' 1 2
'1 '1 '1 l'1 ' '1 '1 ' '1
pr ay un ug ep ct ov ec
' n b'
Ju a

Se 1

2
A 1

N 1

D 1

Fe 2
1

M 2
11

Ja 1
Ja Fe

2
1

12
1
11

12
1

'1

'1

'1

'1
l' 1

'1

'1

1
A O

1
'1
J M

r '1

'1

'1

'1
M A S N D

l'1

t '1

'1
1

'1

n'
n'

b'
p'
pr

ct

ar
ay

ug
n'

ov

ec
n'

b'
p'

Ju
ar
ay

ug

ov

ec
Ap

Ju

Oc

Ju

O
A
Ja

Fe
Ju

Se

M
M
M

D
Count / Month Cumm. Target
Count / Month Cumm. Plan Actual Cumm Plan Cumm Actual

PM RESULT KAIZEN TRAINING

8 24
110 105 Status :
98 102 100 100 95 100 100 100Status
100 : Status :
100 7
90 Target : 100% 6
20 18
6
Target : 13 nos.

C ounts (in N o s.)

80
P M (in % ag e)

5 16 15
Kaizen (Nos.)

70 5 14 14
13 13 13 13 13 13
4 4 4
60 4 12
50 Target : 3
3
3
40 8
2 2
30 2
20 1
1 4
10 0
0 0
1

2
1

12
11

12
11

11

1 11 1 11 1 12
'1

'12
'1

1 1 1 1
'1

'1

'1
l' 1

12
'1

'1 y'1 n' l' 1 '1 '1 '1 '1

n'

t' n'
n'

b'

b'
p'

c'
pr

ar
ay

ug

ov

pr ug ep ov ec ar
ct
Ju

Ju
De

Ja

a
Fe
Ju

Ju c
Se

Ja Fe

'1 2
A

'11

Au 1
1

Se 1

De 1

Fe 2
No 1
M

2
O 1

Ja 1
O

A
A

M A S O N D M

l' 1
n '1

n '1
g '1

v '1
'1
r '1

b '1
p '1

c'1
ay

ar
Ju

ct
Ap

Ju

M
M
Need to Further Focus on strengthen Failure Analysis Skill to get actual root cause
1 17/20
“Internal loss” major problem Solving Sheet
■ Problem Statement
Title Plant Side (Non-UPS) Electrical Power Tripped.
Machine Name Gas Genset-4 & DG-3 Occurrence date 22.01.2012
Line Name Power Generation. Breakdown time 08:47 am
Plant/Process Plant side machine power. Scrap amount (Rs) 3000( Molding line) Approx.

Problem details Attach any supporting photo,illustrations, etc.

At 08:45am At 08:47 am
Tripped on fault
- DG-3 & GG-4 was running normal in Ignition 2R Got off Load dump
Stopped Running Stopped
parallel operation.
DG 1 DG 2 DG 3 GG 4 GG 5 DG 1 DG 2 DG 3 GG 4 GG 5
- After some time DG-3 stopped w/o any
Trip out
warning, shutdown & Gas Genset-4
load cut-off and show alarm of fault Main O/G VCB Bus A /volt. low.
Main O/G VCB
code of 1464 [ Load Dump – Load cut
immediately ]. Power supply to plant Power supply to plant

■ Root cause
Root cause Analysis (repeat of ‘why?’)
Why? (step 1) Why? (step 2) Why?(step 3) Why? (step4) Why? (step 5)
DG-3 local
panel T/
DG-03 local panel terminal strip one strip wire
DG-3 got
wire ( ferrule no - 0624) found very Plant side DG-3 & GG-4 not clamped
stopped
loose in connector & covered by power tripped tripped during & cover by
suddenly
sleeve. (Suspected Cause) operation. sleeve.[ Wire
[Non-UPS side] w/o any
no -624 ]
alarm. (Suspected
Cause)

1/2 Internal loss major problem Solving Sheet 0803

 18/20
2 ■ Countermeasure
Attach any supporting photo,
Countermeasure implementation Res. Date
illustrations, etc.
Engine stop two reasons :
Terminal
strip
[A] Fuel supply problem : 22.01.2012
Utility
Engine fuel supply system i.e. Pump, Valve etc checked,
624 no
ok.
wire out

[B] Emergency circuit Operation. Utility 22.01.2012

Checked all connections of Emergency circuit from remote
Utility
control panel for loose / improper problem. Ok. 22.01.2012
U/V, O/V, O/F etc relays checked for normal operation, ok.
Checked DG local panel for Emergency Circuit problem, Utility 04.02.2012
found wire loose [ No 624 ]. [ NOT OK ] DG-3 local panel

■ Yokotenkai
Forward to Method Res. Date
10/02/2012
1. Checked other DG set & all panels for eliminating Tighten all connection by
reoccurrence of the same problem. adjusting sleeve.

2. Point added in Electrical connection checking sheet.

Points addition with Photo. 17/02/2012

■ Re-Occurrence Prevention

1) PM check sheet review & Specific check point added for Terminal check.

2/2 Internal loss major problem Solving Sheet 0803

New Projects: 19/20

Project Name Target Actual Status

Zero Accident / No Zero Accident /

(i) T/Center Delay <2 Week Delay

Technical Center Job Status:

Job Up to 14rd Feb 2012 Final Finish Target Remarks
Date
Planned Actual

Main Building: 100 % 99% 20-feb-12 -Delayed

Service Center 100 % 98 % 17-feb-12 -Delayed

Utility Building 100 % 98 % 17-feb-12 -Delayed

Start of Technical Centre form 27-Feb-2012.

Front View T/c Backside View Service Center Utility Building

 20/20
Power & Fuel Analysis Sheet
Pow er & Fuel Cost (Plan Vs Actual 2011-12)
Jan 12:
8000 R. Plan: 7338, Actual: 5655, Diff.: 1683
Reason: T/Center one month dalay (1500)
7000

6000

5000
0
.('00)

4000
Rs

3000

2000

1000

0
n

n
a

a
la

la

la

la

la

la

la

la

la

la

la

la

la

la

la

la

la

la
l

l
tu

tu

tu

tu

tu

tu

tu

tu

tu

tu

tu

tu
P

.P

.P

.P

.P

.P

.P
c

c
R
V
A

A
R

R
v

v
Apr-11 May-11 Jun-11 Jul-11 Aug-11 Sep-11 Oct-11 Nov-11 Dec-11 Jan-12 Feb-12 Mar-12

DG Cost (HSD) Govt. Electric Cost LNG Cost

HSD Plan HSD Actual Govt Plan Govt Actual Gas Plan Gas Actual

Gas Generation
1) Gas Generator Utilization is increased in Jan 12 ( 82 %
Sourcewise Power Generation
82% 84%
in DNHA 2011
Target
to 84 % ) Mainly due to reliability improvement of GG
100%
80%
Set . (So Less Utilization of DG)
% MWh

60%
40% 2) Govt. Supply Utilization is less because of Delay in T/C
20%
0%
start up.
ov
ug

ec
ep

n
ct
ly

et
Ja
Ju

rg
N

D
S
A

3) Future Mainly Utilization of GG set up to 10,000 scmd

Ta

HSD Govt Gas

along with Govt. Supply to Keep Energy Cost.

In Future We Focus on Optimization of GG Set & Govt. Supply for Energy