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BE-F-008, R1, 01.04.13

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BE-F-008, R1, 01.04.13
Step-4: Action
S.
NO.
ROOT CAUSES WHY? WHY? WHY?
1.
M/C auto cycle start
push button faulty
Push button was
not working.
Push button broken. Contact faulty.
2. Low Oil level in Tank
Heavy leakage
from M/C.
Leakage through
Mech. Seal.
Mech. Seal Damage
of Pump.
3.
Heavy Oil leakage
from pump
Leakage through
Mech. Seal.
Mech. Seal Damage
of pump.
Mech. Seal housing
Seat damage.
4.
No Level indicator in
tank
No provision to
provide the level
indicator.
Tank is fully covered
From top.
Filter paper tray
Provision just under
The washing chamber























ACTION To eliminate each Root Cause
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BE-F-008, R1, 01.04.13
Development of Remedies
ROOT CAUSE REMEDY
M/C auto cycle start push
button faulty
Provided new Push button
Station & replaced cable.
Heavy Oil leakage from pump Provided New Grundfos Pump
instead of old KDS 532Pump.
No Level indicator in tank
Provided Float type Level
indicator to check easily the
level of tank.
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List of Root Causes, Remedies developed and Date of Implementation of each remedy
ROOT CAUSE REMEDY DATE OF
IMPLIMENTATION
STATUS
M/C auto cycle
start push button
faulty
Replaced Faulty push button/
panel with new Panel & Push
button station.
Sept.-2013 Done
Heavy Oil leakage
from pump
Replaced Old KDS -532 pump
with new Grundfos pump.
Sept.-2013 Done
No Level indicator
in tank
Provided Float type Level
indicator in tank.
Sept.-2013 Done
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Step-5 Check
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Step 5 Check






After Project Results : Till date ZERO Engine Loss of Assy. Line due to Break down of Cr. Shaft
Washing(32.01) after implement.
CHECK Confirmation of
Effectiveness of actions
























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Calculations

Cost saving = No. of Engine loss x Rate/Engine

No. of Engine Loss = 26 Nos. (Avg. Of 02 months)
Cost of One Engine = Rs.1.0 lac
Cost Savings=26 x 100000/-
= Rs 26 lac per month
= Rs.26x12
=Rs.312 lac Annually
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BE-F-008, R1, 01.04.13
Tangible Benefits:
Not able to calculate accurately as Engine loss may be Variable.
Intangible Benefits
1) Moral increased of operator
2) No Engine Loss due to Break Down of Cr. Shaft Washing M/C.
3) Reduction in Energy Consumption.
4) Better Aesthetic around the M/C.
5) Easy replacement of pipe/Rectification of leakages.
6) Reduction MTO consumption & In Oil Wastage.
Adverse Effects : Nil
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Step-6 Standardization
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STANDARDIZATION
Changes done for Mandatory use of Grundfos Pump incase planning of replacing
the old pump .
List of Documents changed
PM Schedule
Training given to concerned people
Assy. Operator / Supv. & Maintenance Team.
Additional audit checks introduced for
Monitoring Schedule made for Sunday.
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Step-7 Conclusion
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End of Presentation
7.1
Lessons Learnt :
DO THE RIGHT IN FIRST TIME.
7.2
Horizontal Deployment :
ALL WASHING MACHINE
7.3
Critiquing :
DO THE RIGHT IN VERY FIRST TIME
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BE-F-008, R1, 01.04.13
Thanks