chapter 5 operational & maintenance skill...

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Chapter 5

OPERATIONAL & MAINTENANCE SKILL DEVELOPMENT

5.1 INTRODUCTION

Training and development is vital for every organization to cope up with the

technological changes from time to time and to perform well. This helps in honing

skills, developing versatility and adaptability. Having a well designed approach

towards this is very important for every organization. Shirose et al. [2002] designed a

detailed education and training system describing its various levels as presented in

table 5.1.

Table 5.1 Education and training System [Shirose et al. 2002]

Levels On the job training Off the job training

Introduction Education on the job

(sectional education)

Guide to equipment maintenance (1)

Workshop exercise training

Quality control education (guide)

Developing basic

capability

Education on the job


Guide to equipment maintenance (2)

Workshop exercise training

How to view drawings (2)

Quality control education (initial level)

Developing professional

capability



Maintenance class (beginner's level)

Industrial engineering education (1)

Numerical control education

Quality control education (medium level)

Developing

management capability



Maintenance class (Medium level)

Industrial engineering education (2)

Quality control education (higher level)

Developing advanced

management capability



Maintenance class (Medium level)

Quality control circle leader education

(higher level)

The development of operational and maintenance skills of workmen is

described in the following sections.

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5.2 STEP 6: FORMULATION OF TRAINING POLICY AND CURRICULUM

Skill mapping exercise as presented in previous chapter the average skill

deficiencies in all skill attribute for workmen were worked out (presented in table

4.14 and figure 4.20). These skill deficiencies were adversely affecting the overall

performance of the manufacturing system (table 4.1 and 4.2). To bridge the skill gaps

of the workmen the following curriculum was developed -

(A) Off the job training

Training attributes common to all the H4 halogen bulb processing operators

1. Total productive maintenance

2. Autonomous maintenance

3. Quality maintenance.

4. Statistical quality control

5. Statistical process control

6. Q.C. tools

7. Connections of hydraulic and pneumatic pipes

8. Color coding of supply lines

9. Color coding of electrical connections

10. Methods of setting and taking reading with common gauges

11. Dealing with emergency

12. Safe operating conditions

13. 5S

Training attributes common to all the ball bearing processing operators

1. Total productive maintenance

2. Autonomous maintenance

3. Quality maintenance

4. Specifications of grinding wheel

5. Classifications of grinding wheel

6. Selection of grinding wheel

7. Glazing and loading of grinding wheel

8. Dressing of grinding wheel

9. Connections of hydraulic and pneumatic pipes

10. Color coding of supply lines

99

11. Color coding of electrical connections

12. Methods of setting and taking reading with common gauges

13. Dealing with emergency

14. Safe operating conditions

15. 5S

16. Statistical quality control

17. Statistical process control

18. Q.C. tools

(B) On the job training

On the job training is imparted to improve following skills related to their

respective processes -

H4 bulb forming process

1. Method of setting L.P.G., Oxygen and Air pressure with the help of regulator.

2. Method of setting correct gas flame by flow meter.

3. Procedure of setting body tube length as per drawing and measurement.

4. Ways of checking form hole and length of the forming.

5. Methods of inspection of diameter of form hole for centering and ovality and

corrective actions for defects.

6. Procedure to conduct visual inspection of form shell for roundness and clarity

and corrective actions for defects.

7. Tips on how to check condition of ‘O' ring and forming wheel and corrective

actions, if warned out.

8. Identification of the condition of bearing jammed / cracked.

9. Detecting the effect of variation in glass tube material.

10. Indications of the condition of direct working of regulator which results in

increased gas pressure and correction.

11. Measure to be taken for safe working conditions.

H4 bulb jointing process

1. Method of setting L.P.G., Oxygen and Air pressure with the help of regulator.

2. Method of setting gas flame by flow meter.

3. Method of setting correct exhaust tube blow air stream pressure.

4. Procedure of loading exhaust tube and form tube on machine correctly.

100

5. Ways of checking and setting dimensions of jointing as per drawing.

6. Method of inspection for straightness, leakage at joint, minimum hole

diameter and ring cut of jointing and corrective measures for non conformity.

7. Techniques of checking jointing for soundness of joint, no white particles on

jointing and no blow hole at joint and corrective actions for defects.

8. Methods of cleaning of machine and burners, lubrication & checking PVC

pipe condition.

9. Detection of the abnormal working of machine.

10. Identification of the condition of the bearing jammed / cracked.

11. Detecting the effect of variation in glass tube material

12. Measures to be taken for safe working.

H4 bulb sealing process

1. Method of setting L.P.G., Oxygen, Hydrogen and Air pressure with the help of

regulator.

2. Method of setting burner flame by flow meter.

3. Ways of checking pinch shape and corrective measures by setting punch

pressure / position and burner flame.

4. Method of checking filament mount for correct direction, no shift and no tilt

and corrective actions.

5. Procedure to check sealing stress, no bursting and no crack.

6. Method of setting correct vacuum level and detecting gas leakage and

corrective actions.

7. Methods of cleaning of machine and burners, lubrication & checking PVC /

metal pipe condition.


9. Ways of identifying condition of the bearing jammed / cracked & checking up/

down movement of head and use of rustolene oil, if jammed.

10. Detection of the effect of variation in glass tube material.


H4 bulb exhausting process

1. Method of setting L.P.G., Oxygen, Hydrogen and Air pressure with the help of

regulator.

2. Method of setting Nitrogen flow and Halogen gas mixture flow.

101

3. Method of setting burner flame by flow meter.

4. Method of loading of sealing on machine.

5. Ways to check capsule shape & tip size and take corrective measures by

setting cutting burner flame.

6. Method of setting proper vacuum in machine & detecting gas leakage and

taking corrective actions.

7. Method of cleaning machine & burners, lubricating the moving parts &

checking PVC / metal pipe conditions.


9. Method of identifying condition of the bearing jammed / cracked & checking

up / down movement of head and use of rustolene oil, if jammed.

10. Procedure of setting correct motions of mechanical links of the machine.


Ball bearing face grinding process

1. Reading & understanding specifications of grinding wheel.

2. Procedure of installing and setting of grinding wheel.

3. Method of setting correct direction of wheel rotation.

4. Procedure to check dresser diamond condition.

5. Procedure of dressing of grinding wheel.

6. Method to prepare grinding machine for operation.

7. Method of checking plate condition and setting.

8. Checking hydraulic, pneumatic, mechanical links and electrical connections of

machine.

9. Method of setting and reading gauge for checking width size, width variation,

flatness, buckle, track circle out and squareness.

10. Method of visual inspection of work piece for black face, eccentric O.D.,

punch mark and chatter on face, after face grinding.

11. Identifying loading (exhausting) of grinding wheel.

12. Identifying exhausting of feed mechanism rings and procedure of changing it.

13. Method of oiling and greasing of machine.

14. Method of setting drop lubrication and oil/grease level.

15. Detecting abnormal sound / working of machine and remedy

16. Measures for safe working.

102

17. Emergency and breakdown management.

Ball bearing outer diameter grinding process

1. Reading and understanding specifications of grinding wheel.

2. Method of installing and setting of grinding and regulating wheel.

3. Ways of checking dresser diamond condition.

4. Procedure of dressing of grinding / regulating wheel.

5. Preparing grinding machine for operation.

6. Method of checking plate condition and setting (Bottom/Top) as per job sizes.

7. How to check hydraulic, pneumatic, mechanical links and electrical

connections of machine.

8. Hydraulic and pneumatic connections (color coding of supply lines) and

mechanical links of machine and correct hydraulic oil level / air pressure.

9. Method of setting and reading gauges for checking outer diameter (O.D.) size,

surface taper, O.D. out of round, Jump and talyrond.

10. Method of visual inspection of work piece for black O.D., chatter on surface

and surface finish.

11. Identifying loading (exhausting) of grinding wheel.

12. Method of setting automatic feed rods of centreless grinding machine.

13. Procedure of oiling and greasing of machine.

14. Procedure of setting drop lubrication and oil/grease level.

15. Detection of abnormal sound / working of machine and its remedy

16. Measures for safe working.

17. Emergency and breakdown management.

Ball bearing IR / OR grinding lines

1. Method of mounting and setting of grinding wheel, dresser setting & dressing

of grinding wheel and preparing machine for operation.

2. Procedure of loading and unloading of work piece on machine center and

checking conveyor, sensor guided slide and push rod for correct working.

3. Hydraulic and pneumatic connections (color coding of supply lines) and

mechanical links of the machine.

4. Method of setting and reading gauges for checking track size, out of round,

wobble, TC out and curvature of track (for track grinding and honing of IR &

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OR) and knowledge of setting in process gauge for Track size (for track

grinding and honing of IR & OR).

5. Procedure for setting and reading gauges for checking bore size, out of round

& taper and setting in process gauge for bore size.

6. Interpretation of the results of the test performed in standard room about

roughness / telyrond / profile of track curvature / taper.

7. Corrective actions on the basis of the results of the standard room test.

8. Detection of exhausting of grinding wheel and abnormal sound / working of

machine.

9. Method of oiling and greasing of machine.

10. Procedure of lubrication of machine during operation.

11. Steps to be taken immediately after machine breakdown.

12. Measures to be adopted for safe working.

(C) One point lessons (OPL)

As discussed in chapter 2, one point lesson (OPL) is one of the most effective

methods of educating people focused on a single aspect of operating parameters and

methods of operating the equipment. This is a learning method frequently used by

workmen during daily work and daily meetings, lunch breaks etc. Each employee

come up with the ideas, discuss to make the issue more precise before preparation of

OPL. The OPL are prepared including visual images for better understanding of the

lesson. Numbers of one point lessons (74 nos.) were prepared to give learning to the

workmen of various training requirements related to their tasks. Few typical one point

lessons are presented here for illustration.

Illustrative one point lesson no. 1 is presented for the H4 forming process

which is prepared for training of skill attribute ‘D’ required for the process. During

study of the process it was observed that the operators of forming process are

expected to inspect the size of the forming using GO and NOGO gauges prepared

according to the designed size. On skill mapping of the workmen the skill deficiencies

were identified related to skill attribute ‘D’.

Illustrative one point lesson no.2 is presented for the H4 jointing process

which is prepared for training of skill ‘F’ required for the process. During study of the

process it was observed that the operators of jointing process are expected to visually

104

inspect the jointing for blow (glass) hole and crack at the joint of formed shell and

exhaust tube. On skill mapping of the workmen the skill deficiencies were identified

related to skill attribute ‘F’.

Illustrative one point lesson no.3 is presented for the IR/OR track grinding

process which is prepared for training of skill ‘A’ required for the process. During

study of the process it was observed that the operators of IR/OR grinding process are

expected to know the correct shape of the grinding wheel before it is mounted on the

spindle. On skill mapping of the workmen the skill deficiencies were identified

related to skill attribute ‘A’.

Illustrative one point lesson no.4 is presented for the IR/OR track grinding

process which is prepared for training of skill ‘A’. During study of the process it was

observed that the operators of IR/OR track grinding process are expected to correctly

shape the honing stone before it is mounted on the machine. On skill mapping of the

workmen the skill deficiencies were identified related to skill attribute ‘A’.

The respective operating executives and Setters (skilled operators) perform the

job of trainers, since, they are well qualified and knowledgeable about modern

manufacturing process and equipments and have vast exposure to the shop floor

practices. The setters of respective machines provide assistance during on the job

training.

Lesson plans and preparation of teaching materials

Excellent teaching methods were used, as discussed in previous pages to

implement education and training effectively. The self-enlightening training methods

were used and lesson plans were prepared in association with respective trainers for

each process / subject suitable for education and training. HRD division of concerned

companies helped in preparation of OPL and photograph for training.

Preparation of classrooms

Training activity was conducted on a one-on-one basis. A class size of 10-15

persons was organized. A room with a good environment, accommodating exercise

materials and slide display equipments, was used as class room. Company training

center was also well equipped with LCD projector, OHP and ergonomically design

seating arrangement necessary for effective training.

105

5.3 STEP 7: EXECUTION OF OPERATIONAL AND MAINTENANCE SKILL

DEVELOPMENT

As discussed above, education and training was carried out with emphasis on

both theoretical (off the Job) and practical (on the Job) exercises. Due emphasis was

given on the following considerations during education and training activity -

Education and training activity was directly linked with actual work to

effectively implement the "bodily learning".

For each training unit, one-point lessons suitable for the actual workshop were

prepared, containing problems and improvement cases and used in education

and training, thus better results were achieved.

The duration of off the job training classes on each topic was 45 minutes and for on

the job training it was 30 minutes.

Fig 5.1 Education and training resource persons

Training resource persons

External faculty / experts Shift engineer

Off the job training On the job training

One point lessons

Shift supervisor

Setter

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5.4 STEP 8: RE-SKILL MAPPING AND MEASUREMENT FOR

PERFORMANCE MEASUREMENT METRICS

The operational and maintenance skill development program was continued

for eight weeks. It was a rigorous exercise and supported whole heartedly by the

management and HRD in formulation of training policy and outsourcing general part

of the curriculum. It was also fully supported by engineers, supervisors and setters of

the companies to give valuable inputs for preparation of training curriculum and

executing it especially on the job. The workmen found it interesting and viewed it as a

key exercise in development of their skills. They were curious, supportive and

interactive all the way. To assess the effectiveness of the exercise the performance

measurement were taken.

The measurement taken were twofold i.e. operator skill levels and capability

indices Cp and Cpk were measured before training (presented in chapter 4) and after

completion of the training exercise whereas other performance measurement metrics

like Mean time between failures (MTBF), Mean time to repair (MTTR), Availability

rate, Performance rate, Quality rate, Overall equipment effectiveness (OEE), Overall

line effectiveness (OLE), Kaizen, Safety, health & environment events were

measured weekly. The weekly measurement were taken as 0 week (on the week the

performance was measured first time before start of the training program), -1week

(measurement for previous week of 0 week), 1 week (measurement after completion

of one week training), 2 week (measurement after completion of two week training)

and continued till 8 weeks completed. Their cumulative effect is presented in chapter

6 (results and discussion).

The re-skill mapping is presented in tables 5.2 (a-g) and spider charts prepared

after training are presented in figure 5.2 -5.8 (typical one spider chart is presented for

each process) in which blue line represents the desired skill levels, red line represents

skill level before training and the green line represents skill level after education and

training exercise. It is clear from the spider charts that skill levels of the workmen

have improved after training exercise.

111

Table 5.2 (a) Skill levels after training (H4 bulb forming process)

Sk

ill

att

rib

ute

s

Des

ired

sk

ill

lev

el

Skill gaps for

operators

FM01 FM02

A 3 O.K. O.K.

B 3 O.K. O.K.

C 3 O.K. O.K.

D 3 O.K. 3-2

E 3 3-2 O.K.

F 3 O.K. O.K.

G 3 O.K. 3-2

H 3 3-2 3-2

I 3 O.K. O.K.

J 3 O.K. O.K.

Operational / Maintenance skill attributes

A Ability to set correct L.P.G., Oxygen and Air pressure with the help of regulator.

B Ability to set gas flame by flow meter.

C Ability to measure and set up of body tube length as per drawing. Knowledge about loading

body tube on machine.

D Ability to check form hole size and formed shell length through GO and NO-GO gauges.

E Ability to check diameter for center and ovality. Ability of visual inspection for form shell

roundness and clarity.

F Ability to check 'O' ring, form wheel and cutter condition.

G Ability to detect condition of the bearing jammed / cracked.

H Ability to detect the effect of variation in glass tube material.

I Ability to identifying the condition of regulator direct (increased gas pressure) and correct it.

J Knowledge about measures to be taken for safe working.

112

Table 5.2 (b) Skill levels after training (H4 bulb jointing process)

Sk

ill

att

rib

ute

s

Des

ired

sk

ill

lev

el

Skill gaps for operators

JT01 JT02 JT03 JT04 JT05 JT06 JT07 JT08

A 3 O.K. O.K. O.K. O.K. 3-2 3-2 O.K. O.K.

B 3 O.K. O.K. 3-2 O.K. 3-2 3-2 O.K. O.K.

C 3 O.K. 3-2 3-2 O.K. 3-2 3-2 O.K. O.K.

D 3 O.K. 3-2 3-2 O.K. 3-2 3-2 O.K. O.K.

E 3 3-2 O.K. O.K. O.K. 3-2 3-2 O.K. 3-2

F 3 O.K. O.K. O.K. O.K. 3-2 3-1 O.K. O.K.

G 3 3-2 O.K. O.K. 3-2 3-1 3-2 O.K. O.K.

H 3 O.K. O.K. O.K. 3-2 3-2 3-2 3-2 3-2

I 3 3-2 O.K. 3-2 3-2 3-1 3-1 O.K. 3-2

J 3 O.K. O.K. O.K. O.K. O.K. 3-2 O.K. O.K.


A Ability to set correct L.P.G., Oxygen and Air pressure with the help of regulator. Ability to set

gas flame by flow meter.

B Ability to set correctly exhaust tube blow air stream pressure.

C Knowledge about loading exhaust tube and formed tube on machine correctly.

D Ability to check and set dimensions of jointing as per drawing.

E Ability to check straightness of jointing, leakage at joint, minimum jointing hole and ring cut

of jointing.

F Ability to check jointing for sound solidity, no white particles on jointing and no glass bubble

at joint.

G Ability to clean machine & burners, lubricate the moving parts & check PVC pipe condition

and identify the abnormal working of machine.

H Ability to detect the condition of the bearing jammed / cracked.

I Ability to understand the effect of variation in glass tube material.


113

Table 5.2 (c) Skill levels after training (H4 sealing process)

Sk

ill

att

rib

ute

s

Des

ired

sk

ill

lev

el Skill gaps for operators

SL01 SL02 SL03 SL04 SL05 SL06 SL07 SL08

A 3 O.K. O.K. O.K. O.K. O.K. O.K. O.K. O.K.

B 3 O.K. O.K. O.K. O.K. O.K. O.K. O.K. O.K.

C 3 O.K. O.K. O.K. O.K. 3-2 O.K. 3-2 3-2

D 3 O.K. 3-2 3-2 O.K. 3-2 O.K. 3-2 3-2

E 3 O.K. O.K. 3-2 O.K. 3-2 O.K. 3-2 3-2

F 3 O.K. O.K. O.K. O.K. O.K. O.K. O.K. 3-2

G 3 O.K. 3-2 O.K. 3-2 3-2 O.K. O.K. 3-2

H 3 O.K. O.K. 3-2 3-2 O.K. O.K. O.K. O.K.

I 3 3-2 3-2 3-2 3-2 3-2 O.K. O.K. 3-2

J 3 O.K. 3-2 O.K. O.K. 3-2 O.K. O.K. O.K.


A Ability to set correct L.P.G., Oxygen, Hydrogen and Air pressure with the help of regulator.

B Ability to set burner flame by flow meter.

C Knowledge about loading of Jointing and mount on machine.

D Ability to check pinch shape and take corrective measures by setting punch pressure / position

and burner flame.

E Ability to check mount for correct direction, no shift and tilt. Ability to check for sealing

stress, no bursting and no crack.

F Ability to check proper vacuum in machine and gas leakage, if any.

G Ability to clean machine & burners, lubricate the moving parts & check PVC pipe condition

and identify the abnormal working of machine.

H Ability to detect condition of the bearing jammed / cracked. Ability to check head up / down

movement and use of rustolene oil, if jammed.

I Ability to understand the effect of variation in glass tube material.


114

Table 5.2 (d) Skill levels after training (H4 exhausting process)

Sk

ill

att

rib

ute

s

Des

ired

sk

ill

lev

el Skill gaps for operators

EH01 EH02 EH03 EH04 EH05 EH06 EH07 EH08 EH09 EH10 EH11 EH12

A 3 O.K. O.K. O.K. O.K. O.K. O.K. O.K. 3-2 3-2 3-2 O.K. 3-2

B 3 O.K. O.K. O.K. O.K. O.K. O.K. O.K. 3-2 O.K. 3-2 O.K. 3-2

C 3 O.K. 3-2 3-2 O.K. 3-2 O.K. O.K. O.K. 3-2 O.K. O.K. O.K.

D 3 O.K. O.K. O.K. 3-2 O.K. O.K. 3-2 O.K. 3-1 3-2 3-2 3-2

E 3 3-2 3-2 O.K. O.K. 3-2 O.K. O.K. 3-2 3-2 O.K. 3-2 3-2

F 3 O.K. 3-2 3-2 O.K. O.K. O.K. O.K. 3-2 O.K. O.K. O.K. 3-2

G 3 O.K. 3-2 3-2 O.K. O.K. 3-2 3-2 O.K. 3-2 3-2 O.K. 3-2

H 3 3-2 O.K. 3-2 3-2 O.K. O.K. O.K. O.K. 3-2 O.K. O.K. 3-2.

I 3 O.K. 3-2 3-2 O.K. O.K. 3-2 3-2 3-2 3-2 3-2 3-2 3-2

J 3 O.K. O.K. 3-2 O.K. O.K. O.K. O.K. O.K. O.K. O.K. O.K. O.K.


A Ability to set correct L.P.G., Oxygen, Hydrogen and Air pressure with the help of regulator. Ability

to set Nitrogen flow and Halogen gas mixture flow.

B Ability to set burner flame by flow meter.

C Knowledge about loading of sealing on machine.

D Ability to check capsule shape & tip size and take corrective measures by setting cutting burner

flame.

E Ability to check sealing for leakage and black glass. Ability to check capsule for no bursting and no

crack.

F Ability to check proper vacuum in machine & gas leakage and take corrective actions.

G Ability to clean machine & burners, lubricate the moving parts & check PVC pipe condition and

identify the abnormal working of machine.

H Condition of the bearing jammed / cracked. Head up and down and use of rustolene oil if jammed.

I Ability to set motion of mechanical links of machine.


115

Table 5.2 (e) Skill levels after training (ball bearing face grinding process)

Sk

ill

Att

rib

ute

s

Des

ired

sk

ill

lev

el


FG01 FG02 FG03 FG04 FG05 FG06 FG07 FG08 FG09 FG10 FG11 FG12

A 3 O.K. O.K. 3-1 O.K. O.K. 3-2 O.K. O.K. O.K. O.K. O.K. O.K.

B 3 O.K. O.K. 3-2 O.K. O.K. 3-2 O.K. O.K. O.K. 3-2 O.K. O.K.

C 3 O.K. O.K. 3-1 O.K. O.K. O.K. 3-2 O.K. O.K. 3-2 O.K. 3-2

D 3 O.K. O.K. 3-2 O.K. O.K. O.K. O.K. O.K. O.K. 3-2 3-2 O.K.

E 3 O.K. O.K. 3-2 O.K. O.K. 3-2 3-2 O.K. O.K. O.K. O.K. O.K.

F 3 O.K. O.K. 3-2 O.K. O.K. 3-2 O.K. O.K. O.K. 3-2 3-2 O.K.

G 3 O.K. O.K. 3-2 O.K. O.K. 3-2 O.K. O.K. O.K. 3-2 O.K 3-2

H 3 O.K. O.K. 3-1 O.K. O.K. O.K. 3-2 O.K. O.K. 3-2 3-2 O.K.

I 3 O.K. O.K. 3-1 O.K. O.K. 3-2 O.K. O.K. O.K. 3-2 O.K. O.K.

J 3 O.K. O.K. 3-2 O.K. O.K. 3-2 3-2 O.K. O.K. 3-2 O.K. O.K.

Operational / Maintenance skill attribute

A Knowledge about installing and setting of grinding wheel and direction of wheel rotation and

specification of wheel.

B Knowledge about dressing and preparing grinding wheels (machine) for operation and checking

diamond condition.

C Knowledge about plate setting & plate condition.

D Knowledge about hydraulic and pneumatic connections (color coding of supply lines) and

mechanical links of the machine.

E Knowledge about setting and reading gauge for checking Width size, width variation, flatness,

buckle, T.C. out and squareness.

F Knowledge about visual inspection of work piece for black face, eccentric O.D., punch mark and

chatter on face, after face grinding.

G Awareness about exhausting of grinding wheel and feed mechanism rings and abnormal sound /

working of the machine.

H Knowledge about cleaning work place and cleaning, oiling and greasing of machine and drop

lubrication and oil/grease level.

I Knowledge about steps to be taken immediately after machine breakdown.

J Knowledge about measures to be adopted for safe working.

116

Table 5.2 (f) Skill levels after training (ball bearing OD grinding process)

Contd…

Operational / Maintenance skill attribute

A Knowledge about installing and setting of grinding as well as regulating wheel and specification of

grinding wheel.

B Knowledge about dressing of grinding / regulating wheel and preparing (setting) machine for

operation.

C Knowledge about plate setting (Bottom & Top) for different job sizes and plate condition.

D Knowledge about hydraulic and pneumatic connections (color coding of supply) and mechanical

links of the machine and hydraulic oil level / air pressure etc.

E Knowledge about setting and reading gauges for checking O.D. size, taper, O.D. out of round, Jump

and talyrond.

F Knowledge about visual inspection of work piece for black O.D., chatter, surface finish etc.

G Awareness about exhausting of grinding / regulating wheel and abnormal sound / working of the

machine.


lubrication and oil/grease level.

I Knowledge about steps to be taken immediately after machine breakdown


Sk

ill

att

rib

ute

Des

ired

sk

ill

lev

el


OD01 OD02 OD03 OD04 OD05 OD06 OD07 OD08 OD09 OD10 OD11 OD12

A 3 3-2 3-2 3-2 O.K. O.K. O.K. O.K. 3-2 O.K. O.K. O.K. O.K.

B 3 3-1 3-2 3-2 O.K. O.K. O.K. O.K. O.K. O.K. O.K. O.K. 3-2

C 3 3-2 O.K. O.K. O.K. O.K. O.K. O.K. 3-2 3-2 O.K. O.K. O.K.

D 3 3-1 3-2 3-2 O.K. O.K. O.K. 3-2 3-2 O.K. O.K. O.K. 3-2

E 3 O.K. 3-2 3-2 O.K. 3-2 O.K. O.K. 3-2 O.K. O.K. O.K. O.K.

F 3 3-2 3-2 3-2 O.K. O.K. O.K. O.K. O.K. O.K. O.K. O.K. O.K.

G 3 3-2 O.K. 3-2 3-2 O.K. 3-2 3-2 3-2 3-2 O.K. 3-2 O.K.

H 3 3-2 3-2 O.K. O.K. 3-2 O.K. O.K. O.K. O.K. O.K. O.K. O.K.

I 3 O.K. O.K. 3-1 O.K. O.K. O.K. O.K. O.K. O.K. O.K. O.K. O.K.

J 3 O.K. 3-2 3-2 O.K. O.K. O.K. O.K. O.K. O.K. O.K. O.K. O.K.

117

…Contd.

Table 5.2 (f) Skill levels after training (ball bearing OD grinding process) S

kil

l a

ttri

bu

tes

Des

ired

sk

ill

lev

el


OD13 OD14 OD15 OD16 OD17 OD18 OD19 OD20 OD21 OD22 OD23 OD24

A 3 3-2 O.K O.K. O.K. 3-2 O.K. 3-2 O.K. 3-1 O.K. 3-2 3-2

B 3 3-2 O.K. O.K. O.K. 3-2 O.K. O.K. 3-2 3-1 O.K. O.K. 3-2

C 3 3-2 O.K. O.K. 3-2 3-2 O.K. O.K. O.K. 3-2 O.K. 3-2 3-2

D 3 3-2 3-2 O.K. O.K. 3-2 O.K. 3-2 O.K. 3-2 O.K. 3-2 3-2

E 3 3-2 3-2 O.K. 3-2 3-2 O.K. O.K. O.K. 3-1 O.K. 3-2 3-2

F 3 3-2 O.K. O.K. O.K. 3-2 O.K. O.K. O.K. 3-1 O.K. 3-2 3-2

G 3 3-2 O.K. O.K. 3-2 3-2 O.K. 3-2 3-2 3-2 O.K. O.K. 3-2

H 3 3-2 O.K. O.K. O.K. O.K. O.K. O.K. O.K. 3-2 O.K. 3-2 3-2

I 3 3-2 O.K. O.K. 3-2 O.K. O.K. 3-2 O.K. 3-2 O.K. 3-2 3-2

J 3 3-2 O.K. 3-2 O.K. 3-2 O.K. 3-2 3-2 3-2 O.K. O.K. 3-2

118

Table 5.2 (g) Skill levels after training (ball bearing IR/OR grinding lines)

Sk

ill

att

rib

ute

s

Des

ired

sk

ill

lev

el


GL01 GL02 GL03 GL04 GL05 GL06 GL07 GL08 GL09 GL10 GL11 GL12

A 3 O.K. O.K. 3-2 O.K. O.K. O.K. O.K. O.K. 3-2 O.K. O.K. O.K.

B 3 O.K. 3-2 3-2 O.K. O.K. O.K. O.K. O.K. O.K. O.K. O.K. O.K.

C 3 O.K. 3-2 3-2 O.K. O.K. 3-2 O.K. O.K. O.K. O.K. O.K. O.K.

D 3 O.K. 3-2 3-2 O.K. O.K. O.K. O.K. O.K. O.K. O.K. O.K. O.K.

E 3 O.K. O.K. 3-2 O.K. O.K. O.K. O.K. O.K. O.K. O.K. O.K. 3-2

F 3 3-2 3-2 3-2 O.K. 3-2 3-2 O.K. O.K. 3-2 3-2 O.K. 3-2

G 3 O.K. O.K. 3-2 O.K. O.K. O.K. O.K. O.K. O.K. O.K. O.K. O.K.

H 3 3-2 3-2 3-2 O.K. O.K. 3-2 O.K. O.K. 3-2 O.K. O.K. O.K.

I 3 O.K. O.K. 3-2 O.K. O.K. O.K. O.K. O.K. O.K. O.K. O.K. O.K.

J 3 O.K. O.K. 3-2 O.K. O.K. O.K. O.K. O.K. O.K. O.K. O.K. O.K.


A Knowledge about mounting and setting of grinding wheel, diamond condition and dresser setting

& dressing of grinding wheel and preparing the machine for operation.

B

Knowledge about loading and unloading of work piece on machine center and working of

conveyor (working of sensor guided slide / push rod / equipments etc.)and knowledge about

hydraulic and pneumatic connections ( color coding of supply lines ) and mechanical links of the

machine.

C

Knowledge about setting and reading gauges for checking Track size, out of round, wobble, TC

out and curvature of track (for track grinding and honing of IR & OR) and knowledge of setting

in process gauge for track size (track grinding of IR & OR).

D Knowledge about setting and reading gauges for checking Bore size, Out of round and taper and

knowledge of setting in process gauge for bore size.

E Ability to Interpret the results of the test performed in standard room about roughness / telyrond /

profile of track curvature / Taper.

F Ability to take corrective actions, if needed.

G Awareness about exhausting of grinding wheel and abnormal sound / working of the machine.


lubrication of m/c during operation.

I Knowledge about steps to be taken immediately after machine breakdown.


Contd…

119

…Contd.

Table 5.2 (g) Skill levels after training (ball bearing IR/OR grinding lines)

S

kil

l

att

rib

ute

s

Des

ired

sk

ill

lev

el


GL13 GL14 GL15 GL16 GL17 GL18 GL19 GL20

A 3 O.K. 3-2 O.K. O.K. O.K. O.K. O.K. O.K.

B 3 O.K. 3-2 O.K. O.K. O.K. O.K. O.K. O.K.

C 3 O.K. O.K. O.K. O.K. O.K. O.K. O.K. O.K.

D 3 O.K. O.K. O.K. O.K. 3-2 O.K. O.K. O.K.

E 3 O.K. O.K. O.K. O.K. O.K. 3-2 O.K. O.K.

F 3 O.K. O.K. O.K. O.K. O.K. 3-2 O.K. O.K.

G 3 O.K. O.K. O.K. O.K. O.K. O.K. O.K. O.K.

H 3 O.K. 3-2 O.K. O.K. O.K. O.K. O.K. O.K.

I 3 3-2 O.K. O.K. O.K. O.K. O.K. O.K. 3-2

J 3 O.K. O.K. O.K. O.K. O.K. O.K. O.K. O.K.

127

5.5 COMPARISON OF SKILL LEVELS BEFORE AND AFTER TRAINING

The comparison between skill gaps before and after training for the workmen

is presented in table 5.3 and figure 5.9 which show a significant improvement in the

skills of the workmen. The observations for calculation of capability indices Cp and

Cpk after training are presented in tables 5.4 (a-h) for various processes under study

and corresponding X-bar chart, R-chart and histogram are presented in figures 5.10

(a-c) to 5.17 (a-c). The calculated values of capability indices Cp and Cpk are

presented in the tables 5.5 to 5.12.

The measurements for performance measurement metrics MTBF, MTTR,

availability rate, performance rate, quality rate, OEE, Kaizen and SHE issues are

presented in tables 5.13, 5.14, 5.15, 5.18, 5.19, 5.20, 5.21 and 5.22 respectively. The

actual production v/s target production and rejection v/s actual production is presented

in tables 5.16 and 5.17 respectively.

Table 5.3 Comparison of skill levels before and after training

Processes

Average skill

deficiencies in all the

skill attributes for a

workman

(before training)

Average skill

deficiencies in all

the skill attributes

for a workman

(after training)

% improvement

H4 forming 10 3.5 65%

H4 jointing 14 4.875 65.17%

H4 sealing 11.125 3.375 69.66%

H4 exhausting 12.667 4.25 66.45%

Ball bearing face

grinding 8.58 3.08 64.10%

Ball bearing OD

grinding 11.125 4.375 60.67%

Ball bearing IR/OR

grinding lines 6.05 1.75 71.07%

128

Fig 5.9 Comparison of skill levels before and after training

10

14

11.125

12.667

8.58

11.125

6.05

3.5

4.875

3.375

4.25

3.08

4.375

1.75

0

2

4

6

8

10

12

14

16

Comparison of skill levels before and after training

Average skill deficiencies in all the

skill attributes for a workman

(before training)

Average skill deficiencies in all the

skill attributes for a workman (after

training)

137

Fig. 5.10 (a) X-Bar chart (Forming process)

Fig. 5.10 (b) R-Bar chart (Forming process)

Fig. 5.10 (c) Histogram (Forming process)

Table 5.5 Capability indices (Forming process) after training

USL LSL Cp Cpk

44.50 mm 43.50 mm 1.50 1.28

43.8200

43.9200

44.0200

44.1200

44.2200

44.3200

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20

Av

erag

e

Sub group no.

X -Bar chart (after training)

H4 forming process

0.0000

0.1000

0.2000

0.3000

0.4000

0.5000

0.6000

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20

Ra

ng

e

Sub group no.

R-chart (after training)

H4 forming process

0

10

20

30

40

43.125 43.25 43.375 43.5 43.625 43.75 43.875 44 44.125 44.25 44.375 44.5 44.625 44.75 44.875

Fre

qu

ency

Histogram - H4 forming process (after training)

http://www.qimacros.com/formulas.html#histogram

http://www.qimacros.com/formulas.html#Cpk

138

Fig. 5.11 (a) X-Bar chart (Jointing process)

Fig. 5.11 (b) R-Bar chart (Jointing process)

Fig. 5.11 (c) Histogram (Jointing process)

Table 5.6 Capability indices (Jointing process) after training

USL LSL Cp Cpk

84.00 mm 82.00 mm 2.62 2.38

82.8400

82.9400

83.0400

83.1400

83.2400

83.3400

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20

Av

erag

e

Sub group no.

X-bar chart (after training)

H4 jointing process

0.0000

0.2000

0.4000

0.6000

0.8000

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20

Ra

ng

e

Sub group no.


H4 jointing process

0

20

40

60

80

81.25 81.5 81.75 82 82.25 82.5 82.75 83 83.25 83.5 83.75 84 84.25 84.5 84.75

Fre

qu

ency

Histogram - H4 jointing process (after training)



139

Fig. 5.12 (a) X-Bar chart (Sealing process)

Fig. 5.12 (b) R-Bar chart (Sealing process)

Fig. 5.12 (c) Histogram (Sealing process)

Table 5.7 Capability indices (Sealing process) after training

USL LSL Cp Cpk

15.50 mm 15.30 mm 1.60 1.54

15.3600

15.3700

15.3800

15.3900

15.4000

15.4100

15.4200

15.4300

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20

Av

erag

e

Sub group no.

X-bar chart (after training)

H4 sealing process

0.0000

0.0200

0.0400

0.0600

0.0800

0.1000

0.1200

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20

Ra

ng

e

Sub group no.

R- chart (after training)

H4 sealing process

0

10

20

30

40

50

60

15.225 15.25 15.275 15.3 15.325 15.35 15.375 15.4 15.425 15.45 15.475 15.5 15.525 15.55 15.575

Fre

qu

ency

Histogram - H4 sealing process (after training)



140

Fig. 5.13 (a) X-Bar chart (Exhausting process)

Fig. 5.13 (b) R-Bar chart (Exhausting process)

Fig. 5.13 (c) Histogram (Exhausting process)

Table 5.8 Capability indices (Exhausting process) after training

USL LSL Cp Cpk

6.50 mm 5.50 mm 2.22 2.09

11.9948

11.9953

11.9958

11.9963

11.9968

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20

Av

erag

e

Sub group no.


H4 exhausting process

0.0000

0.0005

0.0010

0.0015

0.0020

0.0025

0.0030

0.0035

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20

Ra

ng

e

Sub group no.



0

10

20

30

40

50

60

70

11.99075 11.9915 11.99225 11.993 11.99375 11.9945 11.99525 11.996 11.99675 11.9975 11.99825 11.999 11.99975 12.0005 12.00125

Fre

qu

ency

Histogram - H4 exhausting process (after training)



141

Fig. 5.14 (a) X-Bar chart (Face grinding process)

Fig. 5.14 (b) R-Bar chart (Face grinding process)

Fig. 5.14 (c) Histogram (Face grinding process)

Table 5.9 Capability indices (Face grinding process) after training

USL LSL Cp Cpk

9.99 mm 9.95 mm 1.46 1.44

11.9946

11.9951

11.9956

11.9961

11.9966

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20

Av

erag

e

Sub group no.


Face grinding process

0.0000

0.0005

0.0010

0.0015

0.0020

0.0025

0.0030

0.0035

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20

Ra

ng

e

Sub group no.


Face grinding process

0

10

20

30

40

50

60

70

11.99075 11.9915 11.99225 11.993 11.99375 11.9945 11.99525 11.996 11.99675 11.9975 11.99825 11.999 11.99975 12.0005 12.00125

Fre

qu

ency

Histogram -Face grinding process (after training)



142

Fig. 5.15 (a) X-Bar chart (OD grinding process)

Fig. 5.15 (b) R-Bar chart (OD grinding process)

Fig. 5.15 (c) Histogram (OD grinding process)

Table 5.10 Capability indices (OD grinding process) after training

USL LSL Cp Cpk

31.999 mm 31.990 mm 2.02 1.75

11.9948

11.9953

11.9958

11.9963

11.9968

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20

Av

erag

e

Sub group no.


OD grinding process

0.0000

0.0010

0.0020

0.0030

0.0040

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20

Ra

ng

e

Sub group no.


OD grinding process

0

10

20

30

40

50

60

70

11.99075 11.9915 11.99225 11.993 11.99375 11.9945 11.99525 11.996 11.99675 11.9975 11.99825 11.999 11.99975 12.0005 12.00125

Fre

qu

ency

Histogram - OD grinding process (after training)



143

Fig. 5.16 (a) X-Bar chart (OR grinding line)

Fig. 5.16 (b) R-Bar chart (OR grinding line)

Fig. 5.16 (c) Histogram (OR grinding line)

Table 5.11 Capability indices (OR grinding line) after training

USL LSL Cp Cpk

28.036 mm 27.986 mm 3.74 3.49

11.9948

11.9953

11.9958

11.9963

11.9968

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20

Av

erag

e

Sub group no.


OR grinding line

0.0000

0.0010

0.0020

0.0030

0.0040

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20

Ra

ng

e

Sub group no.


OR grinding line

0

10

20

30

40

50

60

70

11.99075 11.9915 11.99225 11.993 11.99375 11.9945 11.99525 11.996 11.99675 11.9975 11.99825 11.999 11.99975 12.0005 12.00125

Fre

qu

ency

Histogram -OR grinding line



144

Fig. 5.17 (a) X-Bar chart (IR grinding line)

Fig. 5.17 (b) R-Bar chart (IR grinding line)

Fig. 5.17 (c) Histogram (IR grinding line)

Table 5.12 Capability indices (IR grinding line) after training

USL LSL Cp Cpk

11.999 mm 11.993 mm 1.49 1.41

11.9948

11.9953

11.9958

11.9963

11.9968

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20

Av

erag

e

Sub group no.


IR grinding line

0.0000

0.0005

0.0010

0.0015

0.0020

0.0025

0.0030

0.0035

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20

Ra

ng

e

Sub group no.


IR grinding line

0

10

20

30

40

50

60

70

11.99075 11.9915 11.99225 11.993 11.99375 11.9945 11.99525 11.996 11.99675 11.9975 11.99825 11.999 11.99975 12.0005 12.00125

Nu

mb

er

Histogram - IR grinding line (after training)



145

Table 5.13 Mean time between failures (MTBF)

Processes

Week-wise MTBF (in days)

-1 0 1 2 3 4 5 6 7 8

H4 forming 2.33 1.75 2.33 2.33 3.5 3.5 2.33 3.5 3.5 3.5

H4 jointing 1.75 2.33 2.33 2.33 3.5 2.33 3.5 3.5 3.5 7

H4 sealing 1.75 1.4 2.33 2.33 2.33 3.5 3.5 2.33 3.5 3.5

H4 exhausting 1.75 1.75 1.75 2.33 1.75 2.33 2.33 2.33 2.33 3.5

Ball bearing

face grinding 0.875 0.875 1 1.116 1 1.75 1.4 1.4 1.75 1.75

Ball bearing OD

grinding 1.116 1 1.116 1.75 2.333 1.75 2.333 2.333 3.5 3.5

Ball bearing IR

grinding lines 0.7 0.777 0.777 1 0.875 1 1 1.116 1.4 1.4

Ball bearing OR

grinding lines 0.777 0.636 0.875 1.116 1 1.116 1.4 1.75 1.4 1.75

146

Table 5.14 Mean time to repair (MTTR)

Processes

Week-wise MTTR in hrs.

-1 0 1 2 3 4 5 6 7 8

H4 forming 1.5 1.5 1.25 1.25 1.25 1.75 1.25 1.5 1 1

H4 jointing 1.5 1.75 1.5 1.25 1.25 1.25 1.25 1 1 1

H4 sealing 1.25 1 1 0.8 1.2 0.75 0.75 0.75 0.75 0.75

H4 exhausting 1.5 1.5 1.25 1 1.25 1 1 1 1 1

Ball bearing

face grinding 1.6 1.6 1.35 1.6 1.433 1.1 1.1 1.233 1.1 1.0

Ball bearing

OD grinding 1.833 1.6 1.533 1.4 1.25 1.33 1.25 1.25 1.15 1.083

Ball bearing

IR grinding

lines

1.5 1.5 1.333 1.25 1.166 1.25 1.0 1.0 0.833 0.75

Ball bearing

OR grinding

lines

1.5 1.4 1.4 1.333 1.25 1.2 1.166 1.0 0.75 0.833

147

Table 5.15 Availability rate

Processes

Week-wise availability rate

-1 0 1 2 3 4 5 6 7 8

H4 forming 0.903 0.89 0.911 0.918 0.922 0.924 0.923 0.932 0.939 0.939

H4 jointing 0.903 0.908 0.916 0.918 0.927 0.924 0.931 0.937 0.936 0.939

H4 sealing 0.90 0.90 0.916 0.923 0.916 0.936 0.94 0.936 0.942 0.941

H4 exhausting 0.907 0.908 0.915 0.927 0.915 0.931 0.931 0.932 0.933 0.94

Ball bearing

face grinding 0.673 0.655 0.675 0.689 0.690 0.736 0.729 0.735 0.755 0.763

Ball bearing

OD grinding 0.684 0.691 0.730 0.751 0.752 0.767 0.769 0.765 0.804 0.798

Ball bearing

IR grinding

lines

0.910 0.919 0.927 0.947 0.944 0.948 0.957 0.964 0.975 0.977

Ball bearing

OR grinding

lines

0.918 0.908 0.933 0.952 0.947 0.957 0.965 0.976 0.977 0.980

148

Table 5.16 Week-wise production (target / actual) (units)

Processes Week-wise production (units)

-1 0 1 2 3 4 5 6 7 8

H4 forming Actual 157495 155367 161362 168836 169105 171911 169525 174009 175255 175586

Target 182160 180240 181500 185100 186000 186000 183900 187800 189396 189396

H4 jointing Actual 77750 79325 82232 84316 86142 85958 87850 89128 87810 89233

Target 127500 129752 130900 131112 130900 131962 133025 133875 132175 134155

H4 sealing Actual 74112 72318 77895 81796 82206 83440 84574 84891 85757 84610

Target 128605 127075 130900 131835 130815 132175 134300 133662 134580 132880

H4

exhausting

Actual 73650 73323 74952 78014 80530 83134 82668 82028 83445 83188

Target 114375 114502 115350 115500 115350 117375 117375 116122 117622 118500

Ball bearing

face grinding

Actual 246020 239107 246202 250738 260612 279836 278511 276452 288592 291816

Target 346505 336863 347117 350178 354981 378645 375278 373549 388287 392726

Ball bearing

OD grinding

Actual 164452 164122 176808 183677 184897 185814 189721 189956 199378 196523

Target 219768 219382 234483 241359 241645 243518 246996 245659 258176 253176

Ball bearing

IR grinding

lines

Actual 43905 44183 46872 46905 48370 48316 48800 50174 52297 53542

Target 60894 61491 62293 63381 63151 63381 63282 64476 65206 65371

Ball bearing

OR grinding

lines

Actual 44185 44598 46355 48276 48087 49056 50016 50488 52177 53079

Target 60695 60734 62406 63687 62585 63998 64543 65272 64575 65537

149

Table 5.17 Week-wise production / rejection (units)

Processes Week-wise production (units)

-1 0 1 2 3 4 5 6 7 8

H4 forming Rejection 1876 1762 1812 1773 1677 1153 1004 1014 1136 923

Actual

production 157495 155367 161362 168836 169105 171911 169525 174009 175255 175586

H4 jointing Rejection 724 756 652 705 655 623 609 651 559 565

Actual

production 77750 79325 82232 84316 86142 85958 87850 89128 87810 89233

H4 sealing Rejection 1074 1010 972 930 808 868 732 721 639 552

Actual

production 74112 72318 77895 81796 82206 83440 84574 84891 85757 84610

H4

exhausting

Rejection 1168 1182 1084 991 1089 1022 880 832 739 699

Actual

production 73650 73323 74952 78014 80530 83134 82668 82028 83445 83188

Ball bearing

face grinding

Rejection 378 356 342 304 328 261 234 195 167 163

Actual

production 246020 239107 246202 250738 260612 279836 278511 276452 288592 291816

Ball bearing

OD grinding

Rejection 232 248 227 199 184 158 155 134 120 118

Actual

production 164452 164122 176808 183677 184897 185814 189721 189956 199378 196523

Ball bearing

IR grinding

lines

Rejection 74 81 73 61 63 52 46 48 42 40

Actual

production 43905 44183 46872 46905 48370 48316 48800 50174 52297 53542

Ball bearing

OR grinding

lines

Rejection 76 74 65 70 64 49 42 43 39 35

Actual

production 44185 44598 46355 48276 48087 49056 50016 50488 52177 53079

150

Table 5.18 Performance rate

Processes

Week-wise performance rate

-1 0 1 2 3 4 5 6 7 8

H4 forming 0.864 0.862 0.889 0.912 0.909 0.924 0.921 0.926 0.925 0.927

H4 jointing 0.609 0.611 0.628 0.643 0.658 0.651 0.660 0.665 0.664 0.665

H4 sealing 0.576 0.569 0.595 0.620 0.628 0.631 0.629 0.635 0.637 0.636

H4 exhausting 0.643 0.640 0.649 0.675 0.698 0.708 0.704 0.706 0.709 0.702

Ball bearing

face grinding 0.71 0.709 0.709 0.716 0.734 0.739 0.742 0.74 0.743 0.743

Ball bearing

OD grinding 0.748 0.748 0.754 0.761 0.765 0.763 0.768 0.773 0.772 0.776

Ball bearing

IR grinding

lines

0.721 0.718 0.752 0.74 0.765 0.762 0.771 0.778 0.802 0.819

Ball bearing

OR grinding

lines

0.727 0.734 0.742 0.758 0.768 0.766 0.774 0.773 0.808 0.809

151

Table 5.19 Quality rate

Processes

Week-wise quality rate

-1 0 1 2 3 4 5 6 7 8

H4 forming 0.988 0.988 0.988 0.989 0.990 0.993 0.994 0.994 0.993 0.994

H4 jointing 0.990 0.990 0.992 0.991 0.992 0.992 0.993 0.992 0.993 0.993

H4 sealing 0.985 0.986 0.987 0.988 0.990 0.989 0.991 0.991 0.992 0.993

H4 exhausting 0.984 0.983 0.985 0.987 0.986 0.987 0.989 0.989 0.991 0.991

Ball bearing

face grinding 0.9984 0.9985 0.9986 0.9987 0.9987 0.999 0.9991 0.9992 0.9994 0.9994

Ball bearing

OD grinding 0.9985 0.9984 0.9987 0.9989 0.999 0.9991 0.9991 0.9992 0.9993 0.9993

Ball bearing

IR grinding

lines

0.9983 0.9981 0.9984 0.9986 0.9986 0.9989 0.9990 0.9990 0.9991 0.9992

Ball bearing

OR grinding

lines

0.9982 0.9983 0.9985 0.9985 0.9986 0.9990 0.9991 0.9991 0.9992 0.9993

152

Table 5.20 Overall equipment effectiveness

Processes

Week-wise overall equipment effectiveness

-1 0 1 2 3 4 5 6 7 8

H4 forming 0.77 0.757 0.8 0.828 0.829 0.847 0.844 0.857 0.862 0.865

H4 jointing 0.544 0.549 0.57 0.584 0.605 0.596 0.61 0.618 0.617 0.62

H4 sealing 0.51 0.504 0.537 0.565 0.569 0.584 0.585 0.589 0.595 0.594

H4 exhausting 0.573 0.571 0.584 0.617 0.629 0.65 0.648 0.65 0.655 0.653

Ball bearing

face grinding 0.477 0.463 0.477 0.492 0.505 0.543 0.54 0.543 0.56 0.566

Ball bearing

OD grinding 0.51 0.516 0.549 0.57 0.574 0.584 0.59 0.59 0.62 0.618

Ball bearing

IR grinding

lines 0.654 0.658 0.695 0.699 0.721 0.721 0.737 0.749 0.781 0.799

Ball bearing

OR grinding

lines 0.666 0.665 0.691 0.72 0.726 0.732 0.746 0.753 0.788 0.792

153

Table 5.21 Kaizen

Processes Fortnightly kaizen

-1 0 1 2 3 4

H4 forming 0 2 4 5 6 6

H4 jointing 1 1 2 6 5 6

H4 sealing 2 1 3 5 5 5

H4 exhausting 1 2 4 4 5 6

Ball bearing face

grinding 3 4 4 6 5 8

Ball bearing OD

grinding 6 5 7 9 8 10

Ball bearing IR/OR

grinding lines 2 4 5 7 7 7

Table 5.22 Safety, health and environment issues

Processes

Fortnightly safety health and environment

-1 0 1 2 3 4

H4 forming 6 6 4 5 3 2

H4 jointing 5 4 3 3 2 2

H4 sealing 6 5 4 4 2 1

H4 exhausting 6 7 5 5 4 2

Ball bearing face


Ball bearing OD


Ball bearing IR


Ball bearing OR


Based on data related to the performance measurement metrics furnished in

the tables 5.13 - 5.15 and tables 5.18 - 5.22 the charts were prepared which are

presented as figure 5.10 – 5.17.

154

(a)

(b)

(c)

-1 0 1 2 3 4 5 6 7 8

MTBF 2.33 1.75 2.33 2.33 3.5 3.5 2.33 3.5 3.5 3.5

0

1

2

3

4

MT

BF

(Day

s)

Weeks

MTBF

H4 forming process

-1 0 1 2 3 4 5 6 7 8

MTBF 1.75 2.33 2.33 2.33 3.5 2.33 3.5 3.5 3.5 7

0

2

4

6

8

MTB

F (D

ays)

Weeks

MTBF

H4 jointing process

-1 0 1 2 3 4 5 6 7 8

MTBF 1.75 1.4 2.33 2.33 2.33 3.5 3.5 2.33 3.5 3.5

0

1

2

3

4

MTB

F (D

ays)

Weeks

MTBF

H4 sealing process

155

(d)

(e)

(f)

-1 0 1 2 3 4 5 6 7 8

MTBF 1.75 1.75 1.75 2.33 1.75 2.33 2.33 2.33 2.33 3.5

0

1

2

3

4

MTB

F (D

ays)

Weeks

MTBF


-1 0 1 2 3 4 5 6 7 8

MTBF 0.875 0.875 1 1.116 1 1.75 1.4 1.4 1.75 1.75

0

0.5

1

1.5

2

MTB

F (D

ays)

Weeks

MTBF


-1 0 1 2 3 4 5 6 7 8

MTBF 1.116 1 1.116 1.75 2.333 1.75 2.333 2.333 3.5 3.5

0

1

2

3

4

MTB

F (D

ays)

Weeks

MTBF

Ball bearing OD grinding process

156

(g)

(h)

Fig 5.18 Mean time between failures (MTBF)

(a) H4 forming process (b) H4 jointing process

(c) H4 sealing process (d) H4 exhausting process

(e) Ball bearing face grinding process (f) Ball bearing OD grinding process

(g) Ball bearing inner race grinding line (h) Ball bearing outer race grinding line

-1 0 1 2 3 4 5 6 7 8

MTBF 0.7 0.777 0.777 1 0.875 1 1 1.116 1.4 1.4

0

0.2

0.4

0.6

0.8

1

1.2

1.4

1.6

MTB

F (D

ays)

Weeks

MTBF

Ball bearing IR grinding line

-1 0 1 2 3 4 5 6 7 8

MTBF 0.777 0.636 0.875 1.116 1 1.116 1.4 1.75 1.4 1.75

0

0.5

1

1.5

2

MTB

F (D

ays)

Weeks

MTBF

Ball bearing OR grinding line

157

(a)

(b)

(c)

-1 0 1 2 3 4 5 6 7 8

MTTR 1.5 1.5 1.25 1.25 1.25 1.75 1.25 1.5 1 1

0

0.5

1

1.5

2

MTT

R (

in h

rs.)

Weeks

MTTR

H4 forming process

-1 0 1 2 3 4 5 6 7 8

MTTR 1.5 1.75 1.5 1.25 1.25 1.25 1.25 1 1 1

0

0.5

1

1.5

2

MTT

R (

in h

rs.)

Weeks

MTTR

H4 jointing process

-1 0 1 2 3 4 5 6 7 8

MTTR 1.25 1 1 0.8 1.2 0.75 0.75 0.75 0.75 0.75

0 0.2 0.4 0.6 0.8

1 1.2 1.4

MTT

R (

in h

rs.)

Weeks

MTTR

H4 sealing process

158

(d)

(e)

(f)

-1 0 1 2 3 4 5 6 7 8

MTTR 1.5 1.5 1.25 1 1.25 1 1 1 1 1

0

0.5

1

1.5

2

MTT

R (

in h

rs.)

Weeks

MTTR


-1 0 1 2 3 4 5 6 7 8

MTTR 1.6 1.6 1.35 1.6 1.433 1.1 1.1 1.233 1.1 1

0

0.5

1

1.5

2

MTT

R (

in h

rs.)

Weeks

MTTR


-1 0 1 2 3 4 5 6 7 8

MTTR 1.833 1.6 1.533 1.4 1.25 1.33 1.25 1.25 1.15 1.083

0

0.5

1

1.5

2

MTT

R (

in h

rs.)

Weeks

MTTR

Ball Bearing OD grinding process

159

(g)

(h)

Fig 5.19 Mean time to repair (MTTR)





-1 0 1 2 3 4 5 6 7 8

MTTR 1.5 1.5 1.333 1.25 1.166 1.25 1 1 0.833 0.75

0 0.2 0.4 0.6 0.8

1 1.2 1.4 1.6

MTT

R (

in h

rs.)

Weeks

MTTR


-1 0 1 2 3 4 5 6 7 8

MTTR 1.5 1.4 1.4 1.333 1.25 1.2 1.166 1 0.75 0.833

0

0.5

1

1.5

2

MTT

R (

in h

rs.)

Weeks

MTTR


160

(a)

(b)

(c)

-1 0 1 2 3 4 5 6 7 8

A.R. 0.903 0.89 0.911 0.918 0.922 0.924 0.923 0.932 0.939 0.939

0.86

0.88

0.9

0.92

0.94

0.96

Ava

ilab

ility

rat

e

Weeks

Availabilty rate

H4 forming process

-1 0 1 2 3 4 5 6 7 8

A.R. 0.903 0.908 0.916 0.918 0.927 0.924 0.931 0.937 0.936 0.939

0.88 0.89

0.9 0.91 0.92 0.93 0.94 0.95

Ava

ilab

ility

rat

e

Weeks

Availabilty rate

H4 jointing process

-1 0 1 2 3 4 5 6 7 8

A.R. 0.9 0.9 0.916 0.923 0.916 0.936 0.94 0.936 0.942 0.941

0.86

0.88

0.9

0.92

0.94

0.96

Ava

ilab

ility

rat

e

Weeks

Availability rate

H4 sealing process

161

(d)

(e)

(f)

-1 0 1 2 3 4 5 6 7 8

A.R. 0.907 0.908 0.915 0.927 0.915 0.931 0.931 0.932 0.933 0.94

0.89 0.9

0.91 0.92 0.93 0.94 0.95

Ava

ilab

ility

rat

e

Weeks

Availability rate


-1 0 1 2 3 4 5 6 7 8

A.R. 0.673 0.655 0.675 0.689 0.69 0.736 0.729 0.735 0.755 0.763

0.6

0.65

0.7

0.75

0.8

Ava

ilab

ility

rat

e

Weeks

Availability rate


-1 0 1 2 3 4 5 6 7 8

A.R. 0.684 0.691 0.73 0.751 0.752 0.767 0.769 0.765 0.804 0.798

0.6

0.65

0.7

0.75

0.8

0.85

Ava

ilab

ility

rat

e

Weeks

Availability rate


162

(g)

(h)

Fig 5.20 Availability rate





-1 0 1 2 3 4 5 6 7 8

A.R. 0.91 0.919 0.927 0.947 0.944 0.948 0.957 0.964 0.975 0.977

0.86

0.88

0.9

0.92

0.94

0.96

0.98

1

Ava

ilab

ility

rat

e

Weeks

Availability rate


-1 0 1 2 3 4 5 6 7 8

A.R. 0.918 0.908 0.933 0.952 0.947 0.957 0.965 0.976 0.977 0.98

0.86

0.88

0.9

0.92

0.94

0.96

0.98

1

Ava

ilab

ility

rat

e

Weeks

Availability rate


163

(a)

(b)

(c)

-1 0 1 2 3 4 5 6 7 8

P.R. 0.864 0.862 0.889 0.912 0.909 0.924 0.921 0.926 0.925 0.927

0.82

0.84

0.86

0.88

0.9

0.92

0.94

Pe

rfo

rman

ce r

ate

Weeks

Performance rate

H4 forming process

-1 0 1 2 3 4 5 6 7 8

P.R. 0.609 0.611 0.628 0.643 0.658 0.651 0.66 0.665 0.664 0.665

0.58

0.6

0.62

0.64

0.66

0.68

Pe

rfo

rman

ce r

ate

Weeks

Performance rate

H4 jointing process

-1 0 1 2 3 4 5 6 7 8

P.R. 0.576 0.569 0.595 0.62 0.628 0.631 0.629 0.635 0.637 0.636

0.52 0.54 0.56 0.58

0.6 0.62 0.64 0.66

Pe

rfo

rman

ce r

ate

Weeks

Performance rate

H4 sealing process

164

(d)

(e)

(f)

-1 0 1 2 3 4 5 6 7 8

P.R. 0.643 0.64 0.649 0.675 0.698 0.708 0.704 0.706 0.709 0.702

0.6 0.62 0.64 0.66 0.68

0.7 0.72

Pe

rfo

rman

ce r

ate

Weeks

Performance rate


-1 0 1 2 3 4 5 6 7 8

P.R. 0.71 0.709 0.709 0.716 0.734 0.739 0.742 0.74 0.743 0.743

0.69 0.7

0.71 0.72 0.73 0.74 0.75

Pe

rfo

rman

ce r

ate

Weeks

Performance rate


-1 0 1 2 3 4 5 6 7 8

P.R. 0.748 0.748 0.754 0.761 0.765 0.763 0.768 0.773 0.772 0.776

0.73

0.74

0.75

0.76

0.77

0.78

Pe

rfo

rman

ce r

ate

Weeks

Performance rate


165

(g)

(h)

Fig 5.21 Performance rate





-1 0 1 2 3 4 5 6 7 8

P.R. 0.721 0.718 0.752 0.74 0.765 0.762 0.771 0.778 0.802 0.819

0.66 0.68

0.7 0.72 0.74 0.76 0.78

0.8 0.82 0.84

Pe

rfo

rman

ce r

ate

Weeks

Performance rate


-1 0 1 2 3 4 5 6 7 8

P.R. 0.727 0.734 0.742 0.758 0.768 0.766 0.774 0.773 0.808 0.809

0.68

0.7

0.72

0.74

0.76

0.78

0.8

0.82

Pe

rfo

rman

ce r

ate

Weeks

Performance rate


166

(a)

(b)

(c)

-1 0 1 2 3 4 5 6 7 8

Q.R. 0.988 0.988 0.988 0.989 0.99 0.993 0.994 0.994 0.993 0.994

0.984 0.986 0.988

0.99 0.992 0.994 0.996

Qu

alit

y ra

te

Weeks

Quality rate

H4 forming process

-1 0 1 2 3 4 5 6 7 8

Q.R. 0.99 0.99 0.992 0.991 0.992 0.992 0.993 0.992 0.993 0.993

0.988 0.989

0.99 0.991 0.992 0.993 0.994

Qu

alit

y ra

te

Weeks

Quality rate

H4 jointing process

-1 0 1 2 3 4 5 6 7 8

Q.R. 0.985 0.986 0.987 0.988 0.99 0.989 0.991 0.991 0.992 0.993

0.98

0.985

0.99

0.995

Qu

alit

y ra

te

Weeks

Quality rate

H4 sealing process

167

(d)

(e)

(f)

-1 0 1 2 3 4 5 6 7 8

Q.R. 0.984 0.983 0.985 0.987 0.986 0.987 0.989 0.989 0.991 0.991

0.975

0.98

0.985

0.99

0.995

Qu

alit

y ra

te

Weeks

Quality rate


-1 0 1 2 3 4 5 6 7 8

Q.R. 0.9984 0.9985 0.9986 0.9987 0.9987 0.999 0.9991 0.9992 0.9994 0.9994

0.9975

0.998

0.9985

0.999

0.9995

Qu

alit

y ra

te

Weeks

Quality rate


-1 0 1 2 3 4 5 6 7 8

Q.R. 0.9985 0.9984 0.9987 0.9989 0.999 0.9991 0.9991 0.9992 0.9993 0.9993

0.9975

0.998

0.9985

0.999

0.9995

Qu

alit

y ra

te

Weeks

Quality rate


168

(g)

(h)

Fig 5.22 Quality rate





-1 0 1 2 3 4 5 6 7 8

Q.R. 0.9983 0.9981 0.9984 0.9986 0.9986 0.9989 0.999 0.999 0.9991 0.9992

0.9974 0.9976 0.9978

0.998 0.9982 0.9984 0.9986 0.9988

0.999 0.9992 0.9994

Qu

alit

y ra

te

Weeks

Quality rate


-1 0 1 2 3 4 5 6 7 8

Q.R. 0.9982 0.9983 0.9985 0.9985 0.9986 0.999 0.9991 0.9991 0.9992 0.9993

0.9976 0.9978

0.998 0.9982 0.9984 0.9986 0.9988

0.999 0.9992 0.9994

Qu

alit

y ra

te

Weeks

Quality rate


169

(a)

(b)

(c)

-1 0 1 2 3 4 5 6 7 8

OEE 0.77 0.757 0.8 0.828 0.829 0.847 0.844 0.857 0.862 0.865

0.7

0.75

0.8

0.85

0.9

OEE

Weeks

OEE

H4 forming process

-1 0 1 2 3 4 5 6 7 8

OEE 0.544 0.549 0.57 0.584 0.605 0.596 0.61 0.618 0.617 0.62

0.5

0.55

0.6

0.65

OEE

Weeks

OEE

H4 jointing process

-1 0 1 2 3 4 5 6 7 8

OEE 0.51 0.504 0.537 0.565 0.569 0.584 0.585 0.589 0.595 0.594

0.45

0.5

0.55

0.6

0.65

OEE

Weeks

OEE

H4 sealing process

170

(d)

(e)

(f)

-1 0 1 2 3 4 5 6 7 8

OEE 0.573 0.571 0.584 0.617 0.629 0.65 0.648 0.65 0.655 0.653

0.5

0.55

0.6

0.65

0.7

OEE

Weeks

OEE


-1 0 1 2 3 4 5 6 7 8

OEE 0.477 0.463 0.477 0.492 0.505 0.543 0.54 0.543 0.56 0.566

0.4

0.45

0.5

0.55

0.6

OEE

Weeks

OEE


-1 0 1 2 3 4 5 6 7 8

OEE 0.51 0.516 0.549 0.57 0.574 0.584 0.59 0.59 0.62 0.618

0.4

0.45

0.5

0.55

0.6

0.65

OEE

Weeks

OEE


171

(g)

(h)

Fig 5.23 Overall Equipment effectiveness (OEE)





-1 0 1 2 3 4 5 6 7 8

OEE 0.654 0.658 0.695 0.699 0.721 0.721 0.737 0.749 0.781 0.799

0.6

0.65

0.7

0.75

0.8

0.85

OEE

Weeks

OEE


-1 0 1 2 3 4 5 6 7 8

OEE 0.666 0.665 0.691 0.72 0.726 0.732 0.746 0.753 0.788 0.792

0.6

0.65

0.7

0.75

0.8

0.85

OEE

Weeks

OEE


172

(a)

(b)

(c)

-1 0 1 2 3 4

Kaizen 0 2 4 5 6 6

0

2

4

6

8

Kai

zen

Fortnightly

Kaizen

H4 forming process

-1 0 1 2 3 4

Kaizen 1 1 2 6 5 6

0

2

4

6

8

Kai

zen

Fortnightly

Kaizen

H4 jointing process

-1 0 1 2 3 4

Kaizen 2 1 3 5 5 5

0

1

2

3

4

5

6

Kai

zen

Fortnightly

Kaizen

H4 sealing process

173

(d)

(e)

(f)

-1 0 1 2 3 4

Kaizen 1 2 4 4 5 6

0

2

4

6

8

Kai

zen

Fortnightly

Kaizen


-1 0 1 2 3 4

Kaizen 3 4 4 6 5 8

0

2

4

6

8

10

Kai

zen

Fortnightly

Kaizen

BB face grinding process

-1 0 1 2 3 4

Kaizen 6 5 7 9 8 10

0 2 4 6 8

10 12

Kai

zen

Fortnightly

Kaizen

BB outer diameter grinding process

174

(g)

Fig 5.24 Kaizen




(g) Ball bearing inner race / outer race grinding line

-1 0 1 2 3 4

Kaizen 2 4 5 7 7 7

0

2

4

6

8

Kai

zen

Fortnightly

Kaizen

BB IR/OR grinding lines

175

(a)

(b)

(c)

-1 0 1 2 3 4

SHE 6 6 4 5 3 2

0

2

4

6

8

SHE

Fortnight

SHE

H4 forming process

1 2 3 4 5 6

SHE 5 4 3 3 2 2

0 1 2 3 4 5 6

SHE

Fortnight

SHE

H4 jointing process

1 2 3 4 5 6

SHE 6 5 4 4 2 1

0

2

4

6

8

SHE

Fortnight

SHE

H4 sealing process

176

(d)

(e)

(f)

1 2 3 4 5 6

SHE 6 7 5 5 4 2

0

2

4

6

8

SHE

Fortnight

SHE


1 2 3 4 5 6

SHE 4 3 2 1 2 1

0

1

2

3

4

5

SHE

Fortnight

SHE

BB face grinding process

1 2 3 4 5 6

SHE 3 3 2 2 2 1

0

1

2

3

4

SHE

Fortnight

SHE

BB outer diameter grinding process

177

(g)

(h)

Fig 5.25 Safety, health and environment issues





1 2 3 4 5 6

SHE 3 5 2 2 1 1

0

1

2

3

4

5

6

SHE

Fortnight

SHE

BB inner race grinding line

1 2 3 4 5 6

SHE 3 2 2 1 1 1

0

1

2

3

4

SHE

Fortnight

SHE

BB outer race grinding line

chapter 5 operational & maintenance skill...

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