Autonomous Maintenance Programme on Grinding Machine for Job Base

Transcription

1 UNIVERSITI TEKNIKAL MALAYSIA MELAKA Autonomous Maintenance Programme on Grinding Machine for Job Base Report submitted in accordance with the requirements of the Universiti Teknikal Malaysia Melaka for the Bachelor s Degree in Manufacturing Engineering (Manufacturing Management) By Ilyana Binti Abdullah Faculty of Manufacturing Engineering April 2008

2 UTeM Library (Pind.1/2005) oval UNIVERSITI TEKNIKAL MALAYSIA MELAKA (UTeM) BORANG PENGESAHAN STATUS TESIS* JUDUL: AUTONOMOUS MAINTENANCE PROGRAMME ON GRINDING MACHINE FOR JOB BASE. SESI PENGAJIAN: 2007/2008 Saya ILYANA BINTI ABDULLAH mengaku membenarkan tesis (PSM/Sarjana/Doktor Falsafah) ini disimpan di Perpustakaan Universiti Teknikal Malaysia Melaka (UTeM) dengan syarat-syarat kegunaan seperti berikut: 1. Tesis adalah hak milik Universiti Teknikal Malaysia Melaka. 2. Perpustakaan Universiti Teknikal Malaysia Melaka dibenarkan membuat salinan untuk tujuan pengajian sahaja. 3. Perpustakaan dibenarkan membuat salinan tesis ini sebagai bahan pertukaran antara institusi pengajian tinggi. 4. **Sila tandakan ( ) SULIT TERHAD TIDAK TERHAD (TANDATANGAN PENULIS) (Mengandungi maklumat yang berdarjah keselamatan atau kepentingan Malaysia yang termaktub di dalam AKTA RAHSIA RASMI 1972) (Mengandungi maklumat TERHAD yang telah ditentukan oleh organisasi/badan di mana penyelidikan dijalankan) Disahkan oleh: Alamat Tetap: NO. 97 FELDA KEMAHANG 2, TANAH MERAH, KELANTAN Tarikh: 29 APRIL 2008 (TANDATANGAN PENYELIA) Cop Rasmi: Tarikh: * Tesis dimaksudkan sebagai tesis bagi Ijazah Doktor Falsafah dan Sarjana secara penyelidikan, atau disertasi bagi pengajian secara kerja kursus dan penyelidikan, atau Laporan Projek Sarjana Muda (PSM). ** Jika tesis ini SULIT atau TERHAD, sila lampirkan surat daripada pihak berkuasa/organisasi berkenaan dengan menyatakan sekali sebab dan tempoh tesis ini perlu dikelaskan sebagai SULIT atau TERHAD.

3 DECLARATION I hereby, declared this Bachelor s Project entitled Autonomous Maintenance Programme on Grinding Machine for Job Base is the result of my own research except as cited in references. Signature : Author s Name : Ilyana Binti Abdullah Date : iii

4 APPROVAL This Bachelor s Project submitted to the senate of UTeM and has been accepted as fulfilment of the requirement for the Degree of Bachelor of Manufacturing Engineering (Manufacturing Management) with Honours. The member of the supervisory committee is as follow: Mr. Wan Hasrulnizzam Wan Mahmood Project Supervisor Faculty of Manufacturing Engineering iv

5 ABSTRACT The heart of Total Productive Maintenance (TPM) is Autonomous Maintenance (AM), whose mainly principle lies in the first three steps of AM; Initial Cleaning, countermeasure at the source of the problems and cleaning and lubricating standard. This project spanned over a time period of seven weeks (16 January March 2008) on the shop floor of UTeM s Machine Shop Lab for performing the first three steps of AM on grinding machine (Model: BO 300A). There are three types of abnormalities (fuguai) identified; safety, physical, and function. The result shows that physical fuguai is a chronic problem whereas safety and function are more acute problem to the machine. A number of fuguai are difficult to be eliminated and some of them required high technical knowledge to be removed. v

6 ABSTRAK Penyelenggaraan Sendiri (AM) ialah jantung kepada TPM yang mana prinsipnya adalah berkaitan dengan 3 langkah utama dalam AM; Pembesihan Awal, cara mengatasi masalah pada peringkat punca masalah bermula, dan keseragaman pembersihan dan lubrikasi Projek ini dilaksanakan selama 7 minggu (16 Januari Mac 2008) di bahagian bengkel mesinsyop, UTeM dengan tujuan dan matlamat untuk melaksanakan 3 langkah awal di dalam AM pada mesin pencanai (Model: BO 300A). Terdapat tiga jenis kecacatan (fuguai) yang dijumpai iaitu kecacatan keselamatan, fizikal,dan fungsi. Hasil daripada projek ini menunjukkan bahawa kecacatan fizikal adalah masalah kronik kepada mesin sementara kecacatan fungsi dan kecacatan keselamatan adalah masalah genting kepda mesin. Beberapa kecacatan dikenal pasti adalah sukar untuk dihapuskan dan sebahagiannya memerlukan kepakaran teknikal yang tinggi untuk dihapuskan. vi

7 DEDICATIONS For my beloved parents: Abdullah Bin Omar Che Mah Binti Che Noh For my cherish brothers and sisters And my treasured friends vii

8 ACKNOWLEDGEMENTS Bismillahirrahmanirrahim This thesis would not have been possible without the contribution of several important people.there is a number of people I want to thank for their help and support in writing this thesis. Some of them are legends, like Taichi Ohno, Shigeo Shingo, W. Edwards Deming, and Siiechi Nakajima. Others have become anonymous in the mist of time. A special word of thanks is due to the people closer to me. Friends and colleagues who gave me opportunity to develop my writing, all UTeM lecturers and staffs especially to my PSM Supervisor, Mr. Wan Hasrulnizzam Bin Wan Mahmood who have taught and relayed the techniques and knowledge. I believe his guidance and advice has made this a much better thesis. Last, but not least, my gratitude to my family who have shown an extraordinary amount of patience and tolerate in supporting me writing this thesis. And with the blessing of Allah I could finish this thesis. My thanks and gratitude to you all. Ilyana Binti Abdullah viii

9 TABLE OF CONTENTS Declaration..... iii Approval......iv Abstract...v Abstrak...vi Dedication.....vii Acknowledgements......viii Table of Contents......ix List of Figures.....xiii List of Tables...xvi List of Abbreviations, Symbols, Specialized Nomenclature......xviii 1. INTRODUCTION Background Objectives Scope Importance of Project Outline of report.3 2. MAINTENANCE Introduction to Maintenance Evolution of Maintenance Concept Importance of Maintenance Types of Maintenance Breakdown Maintenance Preventive Maintenance (PM) Predictive Maintenance Time Based Maintenance (TBM) Also Called Periodic maintenance Corrective Maintenance Failure - Finding Maintenance Reactive Maintenance.15 ix

10 2.4.8 Reliability-Centered Maintenance (RCM) Total Productive Maintenance (TPM) TPM Definitions Pillars of TPM Pillar 1-5S Pillar 2 - AM or Jishu Hozen (JH) Pillar 3 - Kobetsu Kaizen Pillar 4 - Planned Maintenance Pillar 5 - Quality Maintenance Pillar 6 - Training and Education Pillar 7 - Office TPM Pillar 8 - Safety, Health and Environment Overall Equipment Effectiveness (OEE) Autonomous Maintenance Introduction to Autonomous Maintenance Steps to Autonomous Maintenance Step Zero Step 1- Initial Cleanup Step 2- Counter Measures Step 3- Cleaning and Lubrication Standard Step 4- General Inspection Step 5- Autonomous Inspection Step 6- Organization and Tidiness Step 7- Full Autonomous Maintenance Fuguai GRINDING MACHINE (MODEL: BO 300 A) Grinding Machine Types of Grinding Machine Grinding Wheels Grinding Fluids Grinding Machine (Model: BO 300 A) Technical Data Operating Instruction..50 x

11 3.2.3 Safety Rules Troubleshooting METHODOLOGY Planning of the Project Process Flow Gantt Chart Data Collection Primary Data Field Observation Archival Collections Fuguai Investigation Focus Group Discussion Site Visit Secondary Data Analytical Technique Frequency vs Fuguai Fuguai vs Area Fuguai Analysis ANALYSIS AND DISCUSSION S Initial Cleaning Fuguai Characteristic Defect Map on Grinding Machine (Model: BO 300A) Analysis of Fuguai Analysis of Fuguai versus Frequency Analysis of Fuguai versus Area Analysis of Types of Fuguai Why-Why Analysis CONCLUSIONS AND RECOMMENDATIONS Conclusions..94 xi

12 6.2 Recommendations Current Study Future Studies REFERENCES.98 APPENDICES A Main Spreadsheet for Fuguai Analysis B Check Sheet for Frequency of Each Fuguai Description C Check Sheet for Area of Each Fuguai Description D Check Sheet for Area of Each Fuguai Types xii

13 LIST OF FIGURES NO TITLE PAGE 2.1 The Evolution of Maintenance Concept The Importance of Maintenance Types of Maintenance Six Major Losses in Productivity S Pillars in TPM Seven Steps for Developing Autonomous Maintenance Improvement Categories Six Steps in Planned Maintenance Phase of Skills Overall Equipment Effectiveness Model Design of Autonomous Maintenance Example of Why-Why Analysis Step 4-General Inspection Step 5-Autonomous Inspection An Example of Belt Grinder An Example of Bench Grinder An Example of Cylindrical Grinder An Example of Surface Grinder An Example of Tool and Cutter Grinder An Example of Tool and Cutter Grinder Straight Wheel Cylinder Wheel 44 xiii

14 NO TITLE PAGE 3.9 Tapered Wheel Straight Cup Wheel Flaring Cup Wheel Dish Wheel Saucer Wheel Grinding Machine (Model: BO 300 A) Orthographic- Technical Drawing for Grinding Machine 48 (Model: BO 300A) 3.16 Isometrics- Technical Drawing for Grinding Machine 49 (Model: BO 300A) 3.17 Operating Instruction of Grinding Machine (Model: BO 300A) The Process Flow of the Project Red Tag Blue Tag Dust Coolant Spill Corrosion Cobweb Scratches Broken Hose Misspelling Label Misplace item 66 xiv

15 NO TITLE PAGE 5.9 Area1:- Front Area3:- Left Side Area1 Tagged with F-Tags Area2 and Area3 are Tagged with F-Tags The Trend Chart of Fuguai vs Week The Pareto Chart for Fuguai Fuguai and Weekly Chart Percentage of Fuguai for Each Area Fuguai Frequency versus Area Trend of Fuguai for Each Area Trend of Types of Fuguai Frequency versus Week Types of Fuguai versus Week for Area 1: Front Types of Fuguai versus Week for Area 2: Right Side Types of Fuguai versus Week for Area 3: Left Side Area 1: Front before Initial Cleaning Area 1: Front after Initial Cleaning Area 2: Right Side before Initial Cleaning Area 3: Left Side before Initial Cleaning Area 2: Right Side after Initial Cleaning Area 2: Right Side before Initial Cleaning 86 xv

16 LIST OF TABLES NO TITLE PAGE 2.1 Definition of TPM letters-acronym The Definitions of 5S Types of Grinding Machine Standard Types of Grinding Wheels Technical Data of Grinding Machine Grinding machine Troubleshooting Gantt Chart of the Project The Differences between Primary and Secondary Data The F-tags and the description The standard criteria for each fuguai Inspection checklist for Grinding Machine (Model: BO 300A) Data Collection Of Fuguai Frequency for Seven Week Data of Fuguai Frequency Frequency of Types of Fuguai in the Three Areas Frequency of Types of Fuguai Machine Condition Before and After Initial Cleaning Why-why analysis for Dust Why-why analysis for Coolant Spill Why-why analysis for Coolant Why-why analysis for Cobweb Why-why analysis for Misplace Item Why-why analysis for Broken Hose Why-why analysis for Scratches 93 xvi

17 LIST OF ABBREVIATIONS, SYMBOLS, SPECIALIZED NOMENCLATURE A - Availability AM - Autonomous Maintenance Anon - Anonymous BGSU - Bowling Green State University CBN - Cubic Boron Nitride db - decibel DVC - Diablo Valley Collage FKP - Fakulti Kejuruteraan Pembuatan F-tag - Fuguai Tag JH - Jishu Hozen JIPM - Japan Institute of Plant Maintenance JIT - Just-In-Time kg - kilogram KK - Kobetsu Kaizen kw - kilo watt MI - Maintainability Improvement min - minutes mm - milimeter MP - Maintenance Prevention NPC - National Productivity Corporation OEE - Overall Equipment Effectiveness PdM - Predictive Maintenance PE - Performance Efficiency P-M - Planned Maintenance PM - Preventive Maintenance QM - Quality Maintenance QR - Quality Rate RCM - Reliability Cantered Maintenance xvii

18 Rev - Revolution SOP - Standard Operating Procedure TBM - Time Based Maintenance TPM - Total Productive Maintenance TQM - Total Quality Management UWM - University of Wisconsin - Milwaukee WC - Work Centre WCM - World Class Manufacturing xviii

19 CHAPTER 1 INTRODUCTION 1.1 Background Most industrial production systems are subject to deterioration with usage and age. Such system deterioration may lead to higher production costs and lower product quality and the increased possibility of breakdown (Wang and Hwang, 2004). Therefore, a wellplanned maintenance management program is important to reduce costly breakdowns (Dohi et al., 2001). In some cases, system failure leads to uncountable costs, for example, the failure of an airplane engine during flight may bring property damage and loss of life. Therefore, extensive maintenance is necessary to improve the system availability (Murthy and Hwang, 1996). Total Productive Maintenance (TPM) is a proactive and cost-effective approach to equipment maintenance which is widely adopted in Japanese industries with successful results (Nakajima, 1988). The successful implementation of TPM depends on a number of factors, such as a culture of mutual trust, operators agreeable to providing basic care to their machines, and maintenance personnel trained in management and people skills (Albert and Chan, 2000). Tsang and Chan (2000) stated that TPM involves a restructuring of work relating to equipment maintenance. Being relieved of such routine tasks, the expertise in the maintenance unit can now be deployed to focus on more specialized activities such as major repairs, overhauls, tracking and improvement of equipment performance, and replacement or acquisition of physical assets. Instead of having to continuously fire-fight and attend to numerous minor chores, it can now devote its resources to address strategic issues such as formulation of maintenance strategies, establishment of maintenance 1

20 management information systems, tracking and introduction of new maintenance technologies, training and development of production and maintenance workers. Total employee involvements, autonomous maintenance, small group activities to improve equipment reliability, maintainability and productivity, and continuous improvement, or kaizen are the principles embraced by TPM (Tsang and Chan, 2000). One of the main arms of TPM is Autonomous Maintenance (AM), called as Jitshu Hozen (JH) in Japanese. The success of TPM, to a large extent, depends upon the success of AM. Grinding machine is extensively used in the Machine Shop Laboratory, University Teknikal Malaysia Melaka (UTeM) to perform the task given especially in manufacturing practice subject. The machine is exposed to the breakdown as it is not well maintained. Maintenance and machine could not be separate to each other. Machine needs maintenance like human needs water. Daily maintenance, although it is simple but still could improve the effectiveness and expand the life time of the machine. This project will provide an organized methodology to perform AM on the grinding machine. 1.2 Objectives The aims of this project are to: 1. Perform an AM programme on the grinding machine (Model: BO 300 A). 2. Identify and analyze the abnormalities on the grinding machine (Model: BO 300 A) and the remedies. 1.3 Scope The scope of this project is only focus on the development of AM programme. The grinding machine (Model: BO 300 A) which is used in Machine Shop Laboratory of FKP in UTeM is selected for the project. This project is only focused on the first three steps of AM; initial cleaning, counter measure at the source of the problem, and cleaning and lubrication standard (refer clause 2.6). The data is gathered from primary and secondary 2

21 data sources. The project is started from December 2007 until April The result of this project may not applicable to other types of grinding machines or other machines. 1.4 Importance of Project The importances of the project are to: 1. Promote the clean, neat and friendly workplace in FKP Machine Shop Laboratory. 2. Reduce the accident occurs in the FKP Machine Shop Laboratory. 3. Establish an orderly shop floor where any departure from normal conditions can be identified immediately. 4. Extends the machines life and improves availability and effectiveness. 5. Foster the development of knowledgeable students since most of the routine maintenance tasks are carried out by themselves. 6. As a reference for academic studies related to AM. 1.5 Outline of Report The organization of this report is as follows: Chapter 1 is the introduction of this project, describes the background and problem statement of the project. The objectives, scope, importance of the project and the project outlines are also presented in this chapter. Chapter 2 is the literature review about maintenance, describes the definition, concept and evolution of maintenance concept and Total Productive Maintenance. Besides, the importance of maintenance, characteristic of 8 types of maintenance and TPM are discussed. It is also includes 8 pillars of TPM, OEE, 7 steps in developing autonomous maintenance, and Fuguai. 3

22 Chapter 3 is the literature review about grinding machine (Model: BO 300A), discusses about types of grinding machines, grinding wheels and cutting fluid. Besides, this chapter also explain about grinding machine (Model: BO 300 A) operation, safety and the machine troubleshooting. Chapter 4 is the methodology, presents the appropriate methodology of this project. This chapter includes the project process planning, flowchart, Gantt chart, data gathering method and analytical which is includes Fuguai analysis. Chapter 5 is the analysis and discussion, presents findings of the project. This chapter also discussed the autonomous steps that were carried out and shows the results obtained. Chapter 6 is the conclusion, summarizing the project work that has been done. This chapter gives recommendation and proposes future work to improve the maintenance in FKP Machine Shop Laboratory in UTeM. 4

23 CHAPTER 2 MAINTENANCE Chapter 2 presents the literature review regarding the definition, concept and evolution of maintenance and Total Productive Maintenance. Besides, characteristics of maintenance with description of types and six big loses are discussed. It is also includes the literature review regarding TPM Pillars, Overall Equipment Effectiveness, autonomous maintenance, and fuguai. 2.1 Introduction to Maintenance Nowadays, organizations are under great pressure to enhance continuously their capability to create value to customers and improve the cost effectiveness of their operations (Campbell, 1995; Duffuaa and Al-Sultan, 1997; Shenoy and Bhadury, 1998; Tsang, 2002). In order to safeguard their performance, organizations need to formulate viable maintenance strategies and develop a fair measure of overall effectiveness aligning with industry's best practices (Al-Najjar, 1996).Once a system or a piece of equipment has been purchased, it must be maintained. The decisions made at purchasing always determine the type of future maintenance to be carried out (Levitt, 1997). Maintenance can be define as activities intended to preserve or promptly restore the safety, performance, reliability, and availability of plant structures, systems, and components to ensure superior performance of their intended function when required (Weinstein and Chung, 1999). Levitt (2005) defines maintenance as acting in the act of holding or keeping in a preserved state of the asset to avoid the failure. Maintenance also can be define as the combination of activities by which equipment or a system is kept in, 5

24 or restored to, a state in which it can perform its designated function (Duffuaa et al., 1999). Willmott and McCarthy (2001), state that the definition of maintenance of a Japanese person from a world class manufacturing company as maintenance means maintaining and improving the integrity of our production and quality system through the machine, processes, equipment and people who add value to the products and services, that is the operators and maintenance of the equipment. Whereas, the maintenance definition to a typical Western manufacturing company as carry out planned servicing at fix intervals or fix it when it break down. Maintenance can be defined most effectively by what it does, namely, the preservation or restoration of the desired function of a given process, at the lowest total cost (Narayan, 1998). Duffuaa et al. (1999) stated that maintenance as an integrated system that can provide a substantial edge in organization s ability to be competitive and provide quality products or services. Whereas, according to Campbell et. al. (1999), maintenance is defined by which equipment or a system is kept in, or stored to, a state in which it can perform its designated functions. According to Wireman (2004), maintenance is a unique business process. It requires an approach that is different from other business processes if it is to be successfully managed. Levitt (1997) define maintenance is war. The enemies are breakdown, deterioration, and the consequence of all types of unplanned event. Drury (1999) describe maintenance is a complex part of the lifetime of a dependable embedded system. Design and maintenance must be simultaneously planned in order to ensure an efficient and costeffective outcome over the life of the product. 6