Root Cause Analysis Reducing Breakdown
Root Cause Analysis Reducing Breakdown
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Cijo Mathew
Mar Athanasius College of Engineering
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211
International Journal of Emerging Technology and Advanced Engineering
Website: www.ijetae.com (ISSN 2250-2459, ISO 9001:2008 Certified Journal, Volume 3, Issue 1, January 2013)
III. ROOT C AUSE ANALYSIS 14 Washing brush not working 3
The Root Cause Analysis is a four-step process 15 Steam line leak 3
involving the following: 16 Stripping jet not working 3
1. Data collection 17 Jacket cooling water line leak 2
2. Cause charting 18 Hot air blower belt broken 2
3. Root cause identification 19 Mould cooling motor not working 1
4. Recommendation.
20 Dipping tank agitator not working 1
A. Data Collection and Analysis 21 Agitator belt broken 1
Breakdown data was collected for 8 months (from 22 Ammonia line leak 1
01/12/2012 to 02/08/2012) from the shift log book of the 23 Spin dryer not working 1
company and is tabulated (Tab. 1). The breakdowns and
24 Slurry auto valve not working 1
frequency of occurrence are:
25 Hot air blower not working 1
TABLE I 26 Mould jerking 1
BREAKDOWNS OCCURRED AND FREQUENCY
27 Body brush not working 1
Sl. No. Breakdown occurred Frequency 28 Hot water gland leak 1
1 Edge roller not working 98 29 Conveyor chain loose 1
2 Vulcanization Barrel not working 68 30 Quenching barrel block 1
3 Chain slipping 20
Breakdown data collected consist of all breakdowns
4 Mould touching the tank 12 that occur in a manufacturing firm. But our area of
5 Washing machine not working 9 interest is the breakdown causing production stoppages.
6 Waste water pump not working 8 Stoppage of one minute causes 140 pieces of products
7 Quenching barrel choot block 7 wasted. Calculating the loss in rupees, each product
8 Carry fan not working 6 cause a loss of profit of Rs. 4.5/-, i.e., a loss of about Rs.
630/- per minute.
9 Dehydrator not working 6
The breakdowns causing stoppages of production
10 Slurry pump not working 4 process were identified from the data. The time spend to
11 Dehydrator chain slip 3 rectify the breakdowns was also noted. The Fig. 1 gives
12 Feed valve block 3 the major breakdowns causing production losses.
13 Stripping line block 3
From the chart it is clear that Edge roller breakdown The times spend for getting back the equipment for
(40%) accounts for the most of the breakdown causing work was also collected and analysed. Fig. 2 gives the
production loss to the company. Vulcanization barrel percentages of time spend for different breakdown
breakdown (28%), Chain slipping (8%) etc… are other maintenance. The chain slipping (63%) accounts for the
major breakdowns in the company as per the data major time loss of production. Edge roller breakdown
collected. (13%) and slurry pump breakdown (13%) also accounts
for a considerable loss of production for the industry.
212
International Journal of Emerging Technology and Advanced Engineering
Website: www.ijetae.com (ISSN 2250-2459, ISO 9001:2008 Certified Journal, Volume 3, Issue 1, January 2013)
1. Root Cause Identification of Edge Roller Breakdown:
Time Spend
3% Chain slipping
Edge roller is unit used to roll up the edges of the
product produced in the company. It mainly consists of a
8% Edge roller pulley belt arrangement, motor, bevel gear, and a long
13% brush mounted on a shaft. The edge roller unit is a major
Slurry pump
13%
contributor to the time loss to production due to its
63% Vulcanization frequent breakdowns.
barrel
Others
213
International Journal of Emerging Technology and Advanced Engineering
Website: www.ijetae.com (ISSN 2250-2459, ISO 9001:2008 Certified Journal, Volume 3, Issue 1, January 2013)
214
International Journal of Emerging Technology and Advanced Engineering
Website: www.ijetae.com (ISSN 2250-2459, ISO 9001:2008 Certified Journal, Volume 3, Issue 1, January 2013)
A detailed study was conducted on causes for In the case of edge roller, belt deterioration and
breakdown due to chain slipping and final cause and Improper alignment checking of the unit after
effect diagram is prepared as given in Fig. 6. Reasons for readjustment were identified as the root cause for edge
vibration of the chain were the lower tension of the chain roller breakdown. A higher grade belt like EPDM belt,
due to its stretching or wearing and wearing of other which can withstand higher temperature and longer life,
parts of the moulding machine. Chain becomes loose due can be used for the purpose. Other cause is improper
to stretching or wearing due to its longer and continuous alignment checking of edge roller, for this, workers
use. Contamination due to improper cleaning on the should be given proper training for checking the
equipment was also identified as a reason for chain alignment of the edge roller unit.
slipping. These causes can be eliminated by performing Root cause for chain slippage was identified as the
proper maintenance techniques like preventive improper tightening of pinion and the mould. Presently
maintenance, planned maintenance etc… pinion is tightened manually to the mould. So there will
The major reason for chain slipping was the be variations in the tightness due to the force applied by
breakdown caused due to pinion breakage in the human hand. A proper means for tightening should be
moulding machine. The different causes of pinion adopted to avoid this cause for the breakdown due to
breakage was improper design of pinion, improper chain slipping. Using a torque wrench is suggested as a
checking methods employed for incoming pinion from counter measure for avoiding the chain slippage.
suppliers, and pinion getting stuck at the sprocket of the
machines. By adopting a inspection method for incoming IV. P ARALLEL IMPROVEMENT OPPORTUNITIES
material, the first two causes can be avoided. Pinion get In the case of edge roller, belt deterioration and
stuck at the sprocket due to contaminations (like Improper alignment checking of the unit after
lubricant and dust mixture), over speed, and the readjustment were identified as the root cause for edge
movement of pinion without mould. Mould gets roller breakdown. To avoid this breakdown an
withdrawn from the pinion due to improper tightening, improvement in the present setup can be made. By using
while entering the rack section. A proper implementation a direct drive for each edge roller unit, parts like belt,
of tightening mechanism can avoid the occurrence of this pulley and bevel gear can be avoided from the present
breakdown. setup. Thus avoiding the breakdown caused by belt and
C. Recommendations bevel gear, which accounts for the most of edge roller
From cause and effect diagram, the root causes of breakdowns of the machine.
breakdowns caused due to chain slipping and edge roller A. Technical Feasibility
was identified. The technical detail of the motor that runs the edge
roller is given below.
215
International Journal of Emerging Technology and Advanced Engineering
Website: www.ijetae.com (ISSN 2250-2459, ISO 9001:2008 Certified Journal, Volume 3, Issue 1, January 2013)
Speed of motor = 1400rpm Increase in profit/month
Gear ratio = 1:10 = 378000 – 168000
Torque required = 170Nm
Maximum weight permissible = Rs. 2, 10,000/-
= 14kg
V. CONCLUSION
Direct drive specification available in the market
The main objective of study was to identify the major
[12]:
breakdowns causing the production loss to the company.
Model = Root cause analysis was conducted for the major
Unicase helical bevel gear unit (BIM 1040) breakdowns causing production loss to the company.
Make = NordIndia, Pune Root causes of breakdowns were identified using cause
Gear ratio = 5.4 – 200 and effect diagram. Counter measures and parallel
Power range = 0.12 – 9.2kW improvement opportunities for major breakdowns
Torque range = 48 – 670Nm causing production stoppage was also suggested.
REFERENCES
[1 ] Hicham Jabrouni, Bernard Kamsu-Foguem, Laurent Geneste,
Christophe Vaysse “Continuous improvement through
knowledge-guided analysis in experience feedback” Engineering
Applications of Artificial Intelligence 24 (2011) 1419–1431.
[2 ] F.T.S. Chan, H.C.W. Lau, R.W.L. Ip, H.K. Chan, S. Kong
“Implementation of total productive maintenance: A case study”
Int. J. Production Economics 95 (2005) 71–94
[3 ] A. Mark Doggett, Humboldt State University, “Root Cause
Analysis: A Framework for Tool Selection” Quality Management
Journal VOL. 12, NO. 4/ 2005, ASQ
[4 ] Abhishek Jayswal, Xiang Li, Anand Zanwar, Helen H. Lou,
Fig 10: Direct drive, NordIndia make. Yinlun Huang, “Sustainability root cause analysis methodology
and its application” Computers and Chemical Engineering 35
B. Economic Feasibility (2011) 2786– 2798
Cost of a single direct drive [5 ] Swanson L., “Linking maintenance strategies to performance”.
= Rs. 8000/- International Journal of Production Economics 70(3), (2001),
237–244.
Installation cost (for 14 machines)
[6 ] F. Ireland and B.G. Dale “A study of total productive maintenance
= 14*4000 implementation”, Journal of Quality in Maintenance Engineering,
= 56000/- Vol. 7 No. 3, (2001), pp. 183-191.
Total investment for implementation [7 ] Ki-Young Jeong, Don T. Phillips “Operational efficiency and
= 14 * 8000+56000 effectiveness measurement” International Journal of Operations &
= Rs. 1, 68,000/- Production Management, Vol. 21 No. 11,( 2001), pp. 1404-1416.
[8 ] Dr. Anthony Mark Doggett, “A Statistical Comparison of Three
No. of products produced in 1 minute Root Cause Analysis Tools” Journal of Industrial Technology,
Volume 20, Number 2 - February 2004
= 140 in one line
Average no. of breakdowns/month [9 ] James J. Rooney and Lee N. Vanden Heuvel, “Root Cause
Analysis for Beginners”, Quality Progress Discussion Board,
= 15 nos. ASQ.
Average time taken for rectification [10 ] Dale H. Besterfield, Carol Besterfield, Glen H. Besterfield &
= 20 minutes Mary Besterfield, “Total Quality Management”, Person Education
Loss in profit/product (2008 ).
= Rs. 4.50/- [11 ] Surhone, L., Timpledon, M., & Marseken, S. (2010). “Pareto
Loss due to breakdown of edge roller analysis: Statistics, decision making, Pareto principle, fault tree
analysis, failure mode and effects analysis. Pareto distribution”,
(Considering 2 lines of production) Wikipedia Betascript Publishing.
= 280*15*20*4.50
[12 ] Product catalogue – geared motors, NordIndia, Drive system,
= Rs. 3, 78,000/- Pune.
Implementation of direct drive will reduce the
breakdown due to edge roller to zero and company can
increase their profit.
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