pld report dec-16

This is a proprietary document of Kirloskar Brothers Limited 1May 3, 2023

Prepared by:- Prateek Rai


Cumulative MTBF & MTTR

Apr-

16

May

-16

Jun-

16

Jul-1

6

Aug-

16

Sep-

16

Oct

-16

Nov

-16

Dec

-16

0

10

20

30

40

50

13.96

21.1028.20

34.10 34.2036.40 36.15 37.51

33.14

25

MONTHS

DAY

S

TAR-GET - 25

MTBF Trend

GOODAp

r-16

May

-16

Jun-

16

Jul-1

6

Aug-

16

Sep-

16

Oct

-16

Nov

-16

Dec

-16

02468

1012141618

4.60 3.40 3.60 3.30 3.90

7.13 7.67 8.07

14.27

1.50

MONTHS

HOURS

TARGET – 1.5MTTR Trend

GOOD


PLD Equipment – Maintenance Performance

Apr

-16

May

-16

Jun-

16

Jul-1

6

Aug

-16

Sep-

16

Oct

-16

Nov

-16

Dec

-16

10

20

30

17.85

17.82 22.76 23.7022.62

20.76

13.88

20.4521.80

25

MONTHS

DAYS

TARGET - 25 MTBF Trend

GOOD

Apr

-16

May

-16

Jun-

16

Jul-1

6

Aug

-16

Sep-

16

Oct

-16

Nov

-16

Dec

-16

0

2

4

6

8

10

12

4.803.20

2.823.24

5.676.62

11.06

4.54

9.37

1.50

MONTHS

HOURS

TARGET – 1.5

MTTR Trend

GOOD

18

19

20

21

22

23

24

2524.2

20.2

FY 2015-16FY 2016-17

Days

012345678

1.82

5.70

FY 2015-16FY 2016-17

Hours


Foundry Equipment – Maintenance Performance

Apr-

16

May

-16

Jun-

16

Jul-1

6

Aug-

16

Sep-

16

Oct

-16

Nov

-16

Dec

-16

0

5

10

15

20

25

30

17.5216.50

21.8217.87

16.69

22.82

20.17 21.85 24.0225

MONTHS

DAY

S

TARGET - 25

MTBF Trend

GOOD

Apr-

16

May

-16

Jun-

16

Jul-1

6

Aug-

16

Sep-

16

Oct

-16

Nov

-16

Dec

-16

0

2

4

6

8

10

0.81

2.40

0.80 1.23

2.781.28

6.23

3.08

9.80

1.50

MONTHS

HOURS


GOOD


SMPD Equipment – Maintenance Performance

Apr-

16

May

-16

Jun-

16

Jul-1

6

Aug-

16

Sep-

16

Oct

-16

Nov

-16

Dec-

16

05

1015202530

25

20.25 13.73 15.87 16.08 13.4918.22 18.02 18.18

20.82

MONTHS

DAY

S

TARGET - 25

MTBF Trend

GOOD

Apr-

16

May

-16

Jun-

16

Jul-1

6

Aug-

16

Sep-

16

Oct

-16

Nov

-16

Dec-

16

02468

1012141618

10.7 5.8

4.74.6

8.9

15.5

4.73.0 1.8

1.50

MONTHS

HOURS

TAR-GET – 1.5

MTTR Trend

GOOD KVBT 65-Geometrical accuracy problemBoth ball screw repaired & bearing replaced

Miven 500(RKB)-Turret indexing problem


LPD Equipment – Maintenance Performance

Apr-

16

May

-16

Jun-

16

Jul-1

6

Aug-

16

Sep-

16

Oct

-16

Nov

-16

Dec

-16

0

10

20

30

40

50

15.78

23.2330.58 37.14

37.68

21.2416.11

21.03

21.6325

MONTHS

DAY

S

TAR-GET - 25

MTBF Trend

GOODAp

r-16

May

-16

Jun-

16

Jul-1

6

Aug-

16

Sep-

16

Oct

-16

Nov

-16

Dec

-16

0

6

12

18

24

2.93 1.44 2.973.88 5.34 3.07

21.60

5.37

15.60

1.50

MONTHS

HOURS


GOOD SK 40- Spindle gear box gear worn out.New gear & bearing fitted


7

Preventive maintenance

Aug-

16

Sep-

16

Oct

-16

Nov

-16

Dec

-16

0102030405060

47 4840 38

4347 4843

3846

PM

Plannedachieved

MONTHS

MACHINE

Aug-16 Sep-16 Oct-16 Nov-16 Dec-160

10

20

30

40

50

60

1116

2614

9

18

7

9

8

10

Breakdown monitoring of PM m/cs

Nov-16 m/csOct-16 m/csSep-16 m/csAug-16 m/cs


8

Bar chart-MTBF

DOOSAN HMC(RKB)

HELLER 250(DB) MIVEN 500(KPD) DYNA 100(KPDS) MIVEN 500(DB)0.002.004.006.008.00

10.0012.0014.0016.0018.00

4.38 4.615.83

12.40 12.60

Top m/c With lowest MTBF(SMPD)

Days

Turret indexing problemSet indexing proxy & pressure setting

YOUJI 2000(ATPD)

KBL 120 CNC WOTON RAPID

VW 4 AXIS MACHINE

CARANAGI0.00

2.00

4.00

6.00

8.00

10.00

12.00

3.51

6.85 7.278.18 8.27

Top m/c With lowest MTBF(LPD)

Days

I/o channel probSMPS changed

GF MIXER K-LINE SAND PLANT 28CFT SUPERTUMBLAST SHOT BLAST

BMD MOULDING DRAG CIF NEW SAND PLANT0.00

1.00

2.00

3.00

4.00

5.00

6.00

7.00

8.00

1.13

3.55 3.634.15 4.21

Top m/c With lowest MTBF(Foundry)

Days

Sand accumulation prob

Main chain driving shaft damageShaft & spockit changed

427 belt damageBelt changed427 belt damage

Belt changed

Spindle speed problemReplaced speed changing coil

Machine stabilizer problemCheck stabilizer & repaired

Sliding door problemReplaced door bearing


9

Bar chart-MTTR

KBL 46” V

TL

MAZA

K MULT

IPLEX

DOOSAN HM

C(SC)

HELLE

R 250 (KPD)

MKL C

-600(DB)

1

6

11

16

21

2624.16

6.53 6.06 5.11 4.13

Top m/c With lowest MTTR(SMPD)

Days

Door jamming problemadjusted flow control valve

Hydraulic pump problemReplaced hydraulic pump

MOULDING M/C NO-1 FAME SHAKE OUT CUPOLA FURNACE NO 1 RAW MATERIAL FEEDING SYSTEM FOR CUPOLA

PLATE CONVEYOR IN CIF-30.00

20.00

70.00

120.00

170.00

220.00

270.00235.35

157.00

27.06 27.069.45

Top m/c With lowest MTTR(FOUNDRY)

Days

STANKO VBM CARANAGI VBM TITAN 3300 VBM KBL 120 CNC YOUJI 2000(ATPD)

0.00

50.00

100.00

150.00

200.00

250.00

300.00

259.24

115.16

10.50 9.17 7.01

Top m/c With lowest MTTR(LPD)

Days

I/o channel probSMPS changed

Spindle rotating problem


Oil consumption

Apr-

16

May

-16

Jun-

16

Jul-1

6

Aug-

16

Sep-

16

Oct

-16

Nov

-16

Dec

-162350

245025502650275028502950305031503250

2478

2854

2584

2893

2795

3019

2612

25402677

2800

3150

PLD

ConsumptionTARGETBench mark

LITE

RS

0

1000000

2000000

3000000

4000000 3663300

2821980

1770353

FY 14-15 FY 15-16 FY 16-17

Oil cost in Rs

10006000

110001600021000260003100036000410004600051000 45830

37800

24451

FY 14-15 FY 15-16 FY 16-17

Oil in liters


11

Coolant oil consumption

0

5000001000000150000020000002500000300000035000004000000

3354978 3351559

2075131

Coolant oil cost in Rs

FY 14-15 FY 15-16 FY 16-17

0

500010000150002000025000300003500040000

31610

22855

13694

Coolant oil in liters

FY 14-15 FY 15-16 FY 16-17

Apr-

16

May

-16

Jun-

16

Jul-1

6

Aug-

16

Sep-

16

Oct

-16

Nov

-16

Dec-

16

500

1000

1500

2000

2500

1486

801

1330

1527.1

1836

1506.716

1825.2 1881.4

150117001900

PLD

ConsumptionTargetBench mark

LITE

RS


Power consumption

Apr-1

6

May

-16

Jun-

16

Jul-1

6

Aug-

16

Sep-

16

Oct-

16

Nov-

16

Dec-

16

1000000110000012000001300000140000015000001600000170000018000001900000

1320276

15094031555571 1589122

15481731636559 1621182 1640358

1775961

1497657

1422774

PLD

Consu...

KW

H

10000003000000500000070000009000000

110000001300000015000000170000001900000021000000

17677583 18132649

14196605

Power consumption in KWH

FY 14-15 FY 15-16 FY 16-17

10000020100000401000006010000080100000

100100000120100000140100000

111788470 109096400

127476360.350817

Power consumption in Rs

FY 14-15 FY 15-16 FY 16-17


Power consumption

Apr-

16

May

-16

Jun-

16

Jul-1

6

Aug-

16

Sep-

16

Oct

-16

Nov

-16

Dec-

16

50000

100000

150000

200000

250000

168420191651184222

189609 199918

232630

153983

178104

163632

SMPD Actual consump-tionExpected consumption

KWH

Apr-

16

May

-16

Jun-

16

Jul-1

6

Aug-

16

Sep-

16

Oct

-16

Nov

-16

Dec-

16

460000510000560000610000660000710000760000810000860000910000

699824

653189

870946

721641

694737

715493

731532

795914864502

Foundries

Actual consump-tionExpected consumption

KWH

FOUNDRY

Ap

r-16

May

-16

Jun-

16

Jul-1

6

Aug-

16

Sep-

16

Oct

-16

Nov

-16

Dec-

16

100000

120000

140000

160000

180000

200000

220000

147475158655

156329159450

143485154892

114069120844

140611

LPD Actual consump-tionExpected consumption

KWH

Apr-

16

May

-16

Jun-

16

Jul-1

6

Aug-

16

Sep-

16

Oct

-16

Nov

-16

Dec-

16

20000

30000

40000

5000060000

70000

80000

90000

29832

41263 43378

2767020603

5520161089

50178 48157

MONTHS

HRC

KWH


Cont..

Apr-

16

May

-16

Jun-

16

Jul-1

6

Aug-

16

Sep-

16

Oct

-16

Nov

-16

Dec-

16

20000

25000

30000

35000

40000

45000

50000

55000

24780

3225035337

31738319513726136774

33007

47264

MONTHS

KWH

Pump testing

Apr-

16

May

-16

Jun-

16

Jul-1

6

Aug-

16

Sep-

16

Oct

-16

Nov

-16

Dec-

16

140000

160000

180000

200000

220000

240000

155475

176718161764

179422186708

202614189442

196630202869

MONTHS

Com-pres-sor

KWH

CompressorAp

r-16

May

-16

Jun-

16

Jul-1

6

Aug-

16

Sep-

16

Oct

-16

Nov

-16

Dec

-16

6000

6500

7000

7500

8000

8500

9000

9500

10000

7043 70977314 7379 7215

7673

8293

90539494

MONTHS

Street light

KWH

Apr-

16

May

-16

Jun-

16

Jul-1

6

Aug-

16

Sep-

16

Oct

-16

Nov

-16

Dec-

16

30000

80000

130000

180000

230000

280000

330000

380000

87746

248580

96281

272213263556230795

326000

256628299432

MONTHS

Com-pres-sor K

WH

Others


15

Pareto chart for power consumption

Foundrie

s

Compressor

OtherSM

PDLP

D

Res & co

m complex HRC

Pump testi

ng

Stree

t ligh

t0

100000200000300000400000500000600000700000800000900000

1000000

0.00

20.00

40.00

60.00

80.00

100.00

120.00864502

202869 171534 163632 140611 12789848157 47264

9494

Power consump-tioncummulative


16

Apr-16 May-16 Jun-16 Jul-16 Aug-16 Sep-16 Oct-16 Nov-16 Dec-160

1000

2000

3000

4000

5000 41394630

30603874

4519

3090 3350 30853628

3128

Consumption pattern per million

Units/million saleBench mark

KWH

Apr-16 May-16 Jun-16 Jul-16 Aug-16 Sep-16 Oct-16 Nov-16 Dec-160.0

100.0200.0300.0400.0500.0600.0700.0800.0900.0

1000.0

717.2636.9

486.4572.5

467.2533.9

657.4529.7 526.2

863

Consumption pattern per pump

Units/pump saleBench mark

KWH

Electricity consumption pattern


17

• Titan 2700 vertical screw nut replaced by new one & hard limit dog position corrected to seize heavy oil leakage. • Titan CNC lubrication pressure low alarm problem corrected by replacing PLC card.• Carnaghi CNC Z ball screw was jammed. Ball screw repaired & fitted in machine. • 9B Lathe new rack & pinion fitted.• Spm boring contractor replaced.• FN3 milling noise problem solved.• Kws 500 new telescopic cover fitted. • Norton grinder gear box piston was damaged, New piston was prepared in house and fitted in machine.• Woton stabilizer starting in auto mode work completed.• VBM-150(MF) spindle disc spring replaced.• New sliding rack & pinion fitted in 9B lathe• Dyna-65 x & z axis ball screw overhauled.• NFF furnace lied cover repair & refitted.• Supetumblast machine main chain driving shaft and sprocket changed.• Tata shakeout overhauled.• GF mixer gear box hollow shaft changed.• K-Line sand plant Magnet belt changed.• 426 idler pulley remove, rework & fitted.• 436 belt drive end pulley remove rework & fitted.• 427 belt replaced• 116 belt replaced• cupola no 1 CI bricks lining done• Arp BMD 1300 cope new scraper ring & guide bar bush fitted.

Major work


18

Improvement

• Stanko VBM gear box & spindle motor overhauled.• Youji 2000 motor overloading ,ATC over travelled & lubrication pressure problems are permanently solved.• Pensotti CNC lubrication made functional.• 52” VTL panel reconditioning work started.• 437 Elevator Belt replaced by light weight SS fabricated Bucket in K-line.• Omega Sand Mixer(HF) arm made motor driven for movement.• Teflon scraper inserted to minimize sand contact to Table of BMD ARPA1300 & KBMD 450 Molding Machines.• Doosan(SC) oil leakage arrested.• Emergency stop problem solved in mazak multiplex.• Miven 500(DB) oil leakage from pump arrested.• KWS-500(SC) oil leakage arrested.


Encon

• Replacement of 30 nos of 67W PL lamps with 30 nos of 30W LED lamps.• Rescheduling of heavy foundry and HRC to maximize “A” zone utilization.• Introduction of cold washing

pld report dec-16

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