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Effectiveness of preventive maintenance in critical equip at Apollo tyres

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Justine Thomachan
Justine Thomachan

This document analyzes the effectiveness of preventative maintenance for two critical pieces of equipment, a calendar and dual extruder, at Apollo Tyres over a 10 month period. It calculates the overall equipment effectiveness (OEE) using metrics like availability, performance, and quality. Pareto analysis identified the top 5 breakdown causes for each machine. Eliminating these primary issues could reduce breakdowns by 72-80%, and increase availability by 3-7% and OEE by 3-6%, saving over Rs. 90,000-120,000 in labor costs. The study aims to improve equipment uptime and identify opportunities to enhance availability.

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Effectiveness of preventive maintenance in critical equip at Apollo tyres
INTRODUCTION AND OBJECTIVES. OBJECTIVE PRIMARY OBJECTIVE: To study the effectiveness of Preventive maintenance of critical equipment in Apollo Tyres. SECONDARY OBJECTIVE: To analyse the mechanical down time and identify the opportunities of improvement of availability of critical equipment. Critical equipment Dual Extruder and Calendar. Tools used : OEE (Over all equipment effectiveness). OEE = Efficiency x Availability x Quality. Pareto Analysis to find out major break downs. Data Collection : Ten months data is used for analysis. And main emphasis is on secondary data. Primary Data :- Personal interview with maintenance department, production department, planning department, quality control department and Industrial engineering department personals. Secondary Data :- Machine logs, Production reports, Company manuals, Industrial engineering journals. LIMITATIONS. Due to confidentiality nature of quality and performance data, it was difficult to get certain details. Intervention from the employees union which made collection of data difficult.
OVER ALL EQUIPMENT EFFECTIVENESS OEE OF CALENDAR Month Availability Performance Quality OEE OEE% Avg Avail Avg OEE Jul-13 0.9803 0.9462 0.996 0.92385 92.38496 Aug-13 0.9573 0.8911 0.9958 0.849467 84.94672 Sep-13 0.9488 0.9695 0.9957 0.915906 91.59062 Oct-13 0.9095 0.8414 0.9954 0.761733 76.17331 Nov-13 0.9548 0.9305 0.9957 0.884621 88.46211 Dec-13 0.9671 0.9243 0.9958 0.890136 89.01362 0.95298 86.40747 Jan-14 0.9331 0.9629 0.9957 0.894619 89.46185 Feb-14 0.968 0.8806 0.996 0.849011 84.90111 Mar-14 0.9347 0.906 0.9962 0.84362 84.36202 Apr-14 0.9762 0.8512 0.9962 0.827784 82.77839
OEE OF DUAL EXTRUDER Month Availability Performance Quality OEE OEE% Avg Avail Avg OEE Jul-13 0.977 0.9221 0.916 0.82522 82.52 Aug-13 0.9091 0.8814 0.965 0.77324 77.32 Sep-13 0.9154 0.9121 0.932 0.77816 77.81 Oct-13 0.9264 0.8254 0.968 0.74018 74.01 Nov-13 0.9672 0.9157 0.956 0.8467 84.67 Dec-13 0.9034 0.9262 0.983 0.8225 82.25 0.928 79.11 Jan-14 0.9084 0.8949 0.968 0.78691 78.69 Feb-14 0.922 0.8493 0.986 0.77209 77.2 Mar-14 0.9081 0.878 0.971 0.77419 77.41 Apr-14 0.945 0.8656 0.979 0.7924 79.23
BREAK DOWN ANALYSIS Calendar. Total mechanical down = 306.67 hrs. From Pareto analysis we found out top 5 downtimes. That are Mill failure, Led off Feed roll break failures, Feed conveyor related failures, mill guide failures, Roller failures. Dual Extruder Total mechanical down = 541.43 hrs. From Pareto analysis we found out top 5 downtimes. That are Skiver not skiving, Mill break down, head related general failures, Cooling conveyor joint failures, belt conveyor failures. 0 10 20 30 40 50 60 70 80 90 100 0 1000 2000 3000 4000 5000 6000 7000 8000 Skivernotskiving Millbreakdown Headrelatedgeneral coolingconveyor Beltconveyorfailure feedingmillbreak temprature Rollerconceyorfailure speedfluctuation Headrubberleakage RubberJamBetween Skiveranglevariation stockloaderfailure 0 10 20 30 40 50 60 70 80 90 100 0 1000 2000 3000 4000 5000 6000
FINDINGS CALENDAR The major five failures are Mill failure, Led off Feed roll break failures, Feed conveyor related failures, mill guide failures, Roller failures. After eliminating these failures: 72.15% of reduction in total mechanical break down. 3.385% increase in availability, i.e. to 98.67%. 3.07% increase in OEE, I.e. to 89.44%. Rs. 94667.1 reduction in terms of man power cost. DUAL EXTRUDER. The major five failures are Skiver not skiving, Mill break down, head related general failures, Cooling conveyor joint failures, belt conveyor failures. After eliminating these failures: 80.12% of reduction in total mechanical break down. 6.9% increase in availability, i.e. to 99.72%. 5.93% increase in OEE, I.e. to 85.04%. Rs. 122067.3 reduction in terms of man power cost.
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Effectiveness of preventive maintenance in critical equip at Apollo tyres
Effectiveness of preventive maintenance in critical equip at Apollo tyres

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Effectiveness of preventive maintenance in critical equip at Apollo tyres

  • 2. INTRODUCTION AND OBJECTIVES. OBJECTIVE PRIMARY OBJECTIVE: To study the effectiveness of Preventive maintenance of critical equipment in Apollo Tyres. SECONDARY OBJECTIVE: To analyse the mechanical down time and identify the opportunities of improvement of availability of critical equipment. Critical equipment Dual Extruder and Calendar. Tools used : OEE (Over all equipment effectiveness). OEE = Efficiency x Availability x Quality. Pareto Analysis to find out major break downs. Data Collection : Ten months data is used for analysis. And main emphasis is on secondary data. Primary Data :- Personal interview with maintenance department, production department, planning department, quality control department and Industrial engineering department personals. Secondary Data :- Machine logs, Production reports, Company manuals, Industrial engineering journals. LIMITATIONS. Due to confidentiality nature of quality and performance data, it was difficult to get certain details. Intervention from the employees union which made collection of data difficult.
  • 3. OVER ALL EQUIPMENT EFFECTIVENESS OEE OF CALENDAR Month Availability Performance Quality OEE OEE% Avg Avail Avg OEE Jul-13 0.9803 0.9462 0.996 0.92385 92.38496 Aug-13 0.9573 0.8911 0.9958 0.849467 84.94672 Sep-13 0.9488 0.9695 0.9957 0.915906 91.59062 Oct-13 0.9095 0.8414 0.9954 0.761733 76.17331 Nov-13 0.9548 0.9305 0.9957 0.884621 88.46211 Dec-13 0.9671 0.9243 0.9958 0.890136 89.01362 0.95298 86.40747 Jan-14 0.9331 0.9629 0.9957 0.894619 89.46185 Feb-14 0.968 0.8806 0.996 0.849011 84.90111 Mar-14 0.9347 0.906 0.9962 0.84362 84.36202 Apr-14 0.9762 0.8512 0.9962 0.827784 82.77839
  • 4. OEE OF DUAL EXTRUDER Month Availability Performance Quality OEE OEE% Avg Avail Avg OEE Jul-13 0.977 0.9221 0.916 0.82522 82.52 Aug-13 0.9091 0.8814 0.965 0.77324 77.32 Sep-13 0.9154 0.9121 0.932 0.77816 77.81 Oct-13 0.9264 0.8254 0.968 0.74018 74.01 Nov-13 0.9672 0.9157 0.956 0.8467 84.67 Dec-13 0.9034 0.9262 0.983 0.8225 82.25 0.928 79.11 Jan-14 0.9084 0.8949 0.968 0.78691 78.69 Feb-14 0.922 0.8493 0.986 0.77209 77.2 Mar-14 0.9081 0.878 0.971 0.77419 77.41 Apr-14 0.945 0.8656 0.979 0.7924 79.23
  • 5. BREAK DOWN ANALYSIS Calendar. Total mechanical down = 306.67 hrs. From Pareto analysis we found out top 5 downtimes. That are Mill failure, Led off Feed roll break failures, Feed conveyor related failures, mill guide failures, Roller failures. Dual Extruder Total mechanical down = 541.43 hrs. From Pareto analysis we found out top 5 downtimes. That are Skiver not skiving, Mill break down, head related general failures, Cooling conveyor joint failures, belt conveyor failures. 0 10 20 30 40 50 60 70 80 90 100 0 1000 2000 3000 4000 5000 6000 7000 8000 Skivernotskiving Millbreakdown Headrelatedgeneral coolingconveyor Beltconveyorfailure feedingmillbreak temprature Rollerconceyorfailure speedfluctuation Headrubberleakage RubberJamBetween Skiveranglevariation stockloaderfailure 0 10 20 30 40 50 60 70 80 90 100 0 1000 2000 3000 4000 5000 6000
  • 6. FINDINGS CALENDAR The major five failures are Mill failure, Led off Feed roll break failures, Feed conveyor related failures, mill guide failures, Roller failures. After eliminating these failures: 72.15% of reduction in total mechanical break down. 3.385% increase in availability, i.e. to 98.67%. 3.07% increase in OEE, I.e. to 89.44%. Rs. 94667.1 reduction in terms of man power cost. DUAL EXTRUDER. The major five failures are Skiver not skiving, Mill break down, head related general failures, Cooling conveyor joint failures, belt conveyor failures. After eliminating these failures: 80.12% of reduction in total mechanical break down. 6.9% increase in availability, i.e. to 99.72%. 5.93% increase in OEE, I.e. to 85.04%. Rs. 122067.3 reduction in terms of man power cost.