PM ANALYSIS

ON
FRAME NUMBERING
MACHINE

Slide Number:
Slide 1 1
Number: TVS
TVS Motor company– –Plant
Motor Company P2 2
VEHICLE ASSY – MACHINE RANKING
Location Machine Name Machine No Rank
STAR VEHICLE ASSY CONVEYOR 204004300 A

STAR VEHICLE ASSY PETROL TANK LEAK TESTING M/C 506048000 A

STAR VEHICLE ASSY PETROL TANK LEAK TESTING M/C 506060700 A

STAR VEHICLE ASSY PRECITEC NUMBERING M/C 203000400 A

STAR VEHICLE ASSY CHASIS - I 506103400 B

STAR VEHICLE ASSY CHASIS - II 506103500 B

STAR VEHICLE ASSY CHASIS - III 506103600 B

STAR VEHICLE ASSY CHASIS - IV 506103700 B

STAR VEHICLE ASSY CHASIS - V 600012600 B

STAR VEHICLE ASSY CONE BOTTOM PRESSING 204020800 B

STAR VEHICLE ASSY FORK OIL FILLING M/C 506128000 B

STAR VEHICLE ASSY FRONT FORK SUB ASSY 202039900 B

STAR VEHICLE ASSY FRONT PANEL SPEEDOMETER ASSY 204020000 B

STAR VEHICLE ASSY PILLION FOOT REST RUBBER PRESSING 620008100 B

STAR VEHICLE ASSY SWING ARM BUSH PRESSING M/C 302014700 B

STAR VEHICLE ASSY SWING ARM BUSH PRESSING M/C 620138800 B

12 Equipment Failure details (06-07) UOM : Nos

8
9
FREQ

5 4
6
2
3

NUMB M/C LEAK TEST M/C 1 LEAK TEST M/C 2 CONVEYOR

Slide Number:
Slide 2 2
Number: TVS
TVS Motor company– –Plant
Motor Company P2 2
Vehicle Assy layout
Warehouse
Booking

Chassis dynamometer

Frame
numbering
m/c

Conveyor Main line

* Frame numbering m/c stoppage affects the conveyor.

Slide Number:
Slide 3 3
Number: TVS
TVS Motor company– –Plant
Motor Company P2 2
PM ANALYSIS ON FRAME NUMBERING MACHINE

PC

NUMBERING HEAD

COMPONENT
CLAMPING
PRINTER

Slide Number:
Slide 4 4
Number: TVS
TVS Motor company– –Plant
Motor Company P2 2
COMPONENTS

•NUMBERING HEAD

•FRAME

NUMBERING IMPRESSION

Slide Number:
Slide 5 5
Number: TVS
TVS Motor company– –Plant
Motor Company P2 2
SPECIFY PHENOMENON.

NUMBERING SHIFTNG IN HORIZONTAL LINE

TYPE-1

TYPE-2

Slide Number:
Slide 6 6
Number: TVS
TVS Motor company– –Plant
Motor Company P2 2
STEP 1 : CLARIFY THE PHENOMENA WITH 5W 1H

5W 1H ELEMENT ANSWER

WHO ANY VARIATION AMONG THE PEOPLE (OPERATOR ) INVLOVED ? X

SPECIFIC FRAME MODEL X
WHAT ANY VARIATION DUE TO PRODUCTION MATERIAL ( FRAME) ? SPECIFIC FRAME LOT X
SPECIFIC FRAME SUPPLIER X
ANY VARIATION DUE TO EQUIPEMENT INVOLVED? (NUMBERING HEAD)
WHERE ANY VARIATION DUE TO FIXTURE INVOLVED? (MODEL SETTING) STAR & VICTOR

ANY VARIATION DUE TO TOOL INVOLVED? (STYLUS)

AFTER LUNCH / TEA TIME X

END OF SHIFT X
WHEN ANY VARIATION RELATED TO THE TIME OR PERIOD ? START OF SHIFT X
MODEL CHANGEOVER

SYSTEM CORRECTION

WHICH ARE THER ANY CHARACTERISTIC TREND OVER TIME ? ( A, B, C TYPE) B TYPE

OCCURING FREQUENTLY OR RARELY FREQUENTLY

OCCURING ABRUPTLY OR GRADUALLY ABRUPTLY

HOW ANY VARIATION IN CIRCUMSTANCES OF OCCURRENCE?
OCCURING CONTINOULSY OR DISCONTINOUSLY DISCONTINOUSLY

OCCURING REGUALR OR IRREGUALR INTERVALS IRREGUALR INTERVALS

Slide Number:
Slide 7 7
Number: TVS
TVS Motor company– –Plant
Motor Company P2 2
DEFINE PHENOMENA :

NUMBERING POSITION SHIFTS FROM CENTERLINE OF AXIS ON BOTH SIDE.

OK FRAME

SHIFT RANGE

NOT
NOT OKOKFRAME
FRAME
Slide Number:
Slide 8 8
Number: TVS
TVS Motor company– –Plant
Motor Company P2 2
STEP 2 : CONDUCT PHYSICAL ANALYSIS

Understand Machine functioning

Power Signals Drive commands

PC DRIVE UNIT

NUMBERING HEAD

HYDRAULIC Frame
POWER PACK Clamping

Stylus
X Axis
Numbering Geometry

Y Axis

Slide Number:
Slide 9 9
Number: TVS
TVS Motor company– –Plant
Motor Company P2 2
STEP 2 : CONDUCT PHYSICAL ANALYSIS

Understand Machine functioning

Slide Number:
Slide 10 10
Number: TVS
TVS Motor company– –Plant
Motor Company P2 2
STEP 2 : CONDUCT PHYSICAL ANALYSIS
X - Axis Slide
Understand Machine functioning Assembly

AIR LINE
TO STYLLUS TIMER PULLEY
X AXIS MOTOR X AXIS GUIDE ROD
MTG HOLE
X AXIS
GUIDE ROD

IDLER PULLEY

PNEU CYLINER
AIR DRIER
TIMER BELT

TENSION
ROLLER
DC VALVE

M
A
I
N POWER INLET

A
I
R

L
I
N
E HOMRE
PCB HOME
SENSOR
SENSOR

Slide Number:
Slide 11 11
Number: TVS
TVS Motor company– –Plant
Motor Company P2 2
STEP 2 : CONDUCT PHYSICAL ANALYSIS
Y - Axis Slide
Understand Machine functioning Assembly

BUSH LOCK SCREW

GUIDE ROD
BUSH (GM) MTG SCREWS
HOME SENSOR Y CARRIER ASSY Y AXIS GUIDE ROD

Y AXIS GUIDE ROD

TENSIONER
TIMER BELT IDLER ROLLER
STYLLUS ASSY

TIMER PULLEY

Slide Number:
Slide 12 12
Number: TVS
TVS Motor company– –Plant
Motor Company P2 2
STEP 2 : CONDUCT PHYSICAL ANALYSIS AXIS MOVEMENT
A : Identify Operating Principle

• The Stepper motors through the timer belt move X & Y axes.

• The amount of movement is decided by the pulses supplied to stepper motor by

BLOCK DIAGRAM FOR AMPLIFIER UNIT ( NUMBERING M/C )

drive unit. MMI KEYPAD &

INDICATION LED'S
STEP DOWN
TRANSFORMER

SMPS
OPTIONAL REGULATED POWER
CONNECTORS FOR SUPPLY SECTION
ADDON CARDS

CPU
OPERATING
LINE SURGE VOLTAGE
SUPPOSER SELECTION
UNIT 110V/220V

MEMORY SOL RELAY AXIS MOTOR SUPPLY

BATTERY CONTROL SECTION

X
Y

RS232 TO REMOTE POWER

PC INTERNET START/STOP NUMBERING
SUPPLY 230V AC 50 Hz
SIGNALS HEAD INPUT

3. The supply of pulses by the drive unit is controlled by the processor with respect to the
program fed by the operator

Slide Number:
Slide 13 13
Number: TVS
TVS Motor company– –Plant
Motor Company P2 2
STEP 2 : CONDUCT PHYSICAL ANALYSIS NUMBERING IMPRESSION
A : Identify Operating Principle
1. The numbering impression is created by hammering effect of the stylus. The
stylus moves up & down at high frequency. The down movement is controlled
by the pneumatic pressure & up movement by a spring.

1c 1a
1e
1d

STYLUS PARTS
1a. Outer body
1b. Stem Guide bush (brass)
1c. O ring Stylus Assy
1d. Stem
1e. Spring
Slide Number:
Slide 14 14
Number: TVS
TVS Motor company– –Plant
Motor Company P2 2
STEP 2 : CONDUCT PHYSICAL ANALYSIS NUMBERING IMPRESSION
A : Identify Operating Principle

2. The hammering effect is generated by sequential operation of solenoid valves in pneumatic circuit.
3. This is controlled by the main processor making 12 V supply ON & OFF to the valves

1. Stylus
8a. Timer belt (Y Axis)

18 8a
18. Pneumatic solenoid valves
1 18a. Solenoid control cable
19a. Air inlet hose
18a
22.Air Outlet

22
19a

Slide Number:
Slide 15 15
Number: TVS
TVS Motor company– –Plant
Motor Company P2 2
STEP 2 : CONDUCT PHYSICAL ANALYSIS AXIS MOVEMENT
B : Identify Operating Standards

1. The reference point (home position) of the stylus should not go out of memory

3. The Co ordinate setting for the numbering should not be disturbed.

5. The speed of the numbering should be 15 mm / sec ( for character ).

7. The speed of free movement of stylus should be 110 mm / sec.

9. Y axis should be parallel to frame axis

Slide Number:
Slide 16 16
Number: TVS
TVS Motor company– –Plant
Motor Company P2 2
STEP 2 : CONDUCT PHYSICAL ANALYSIS NUMBERING IMPRESSION
B : Identify Operating Standards

1. The stylus needle point should be sharp

2. No welding spatter or beads should be present on frame surface

3. Air pressure should be maintained at 4~6 Kg / cm2

4. Hydraulic clamping pressure should be 40 ~ 50 kg / cm2

5. Voltage supply for solenoid valves should be 12V

Slide Number:
Slide 17 17
Number: TVS
TVS Motor company– –Plant
Motor Company P2 2
STEP 2 : CONDUCT PHYSICAL ANALYSIS

C : Identify interacting elements

Y AXIS STYLUS
MOVEMENT LINE B

DISLOCATED C
AXIS

MD25948675E00301 D
X AXIS

NUMBERING
AXIS
A

FRAME Y AXIS

Slide Number:
Slide 18 18
Number: TVS
TVS Motor company– –Plant
Motor Company P2 2
STEP 2 : CONDUCT PHYSICAL ANALYSIS
PHENOMENA
Numbering Shifting from Center line on both side
DEFINE RELATED CONDITIONS
Y AXIS A

NUMBERING 54864163E03220 B
MAD2
AXIS

Y axis “A” & Numbering axis “B”

QUANTIFY THE REALTIONSHIP BETWEEN INTERACTING ELEMENTS
Y AXIS A

C
NUMBERING 54864163E03220 B
MAD2
AXIS

Distance “C” between Y axis “A” & Numbering axis “B”

DEFINE QUANTITATIVE PHYSICAL CHANGE
Y AXIS A The distance [C]
r t C
between the Y axis [A] &
NUMBERING
AXIS
MAD2
54864163E03220 B
Numbering Axis [B]
varies [D]
D(r≠t)
Slide Number:
Slide 19 19
Number: TVS
TVS Motor company– –Plant
Motor Company P2 2
 STEP 2 : CONDUCT PHYSICAL ANALYSIS

C : Identify interacting elements

D : Identify Quantitative changes

ABNORMAL INTERACTING QUANTITATIVE PHYSICAL

CONTACT DIAGRAM
PHENOMENA ELEMENTS CHANGE
Y AXIS STYLUS
MOVEMENT B
LINE

DISTANCE ( C )
NUMBERING DISTANCE ( C ) BETWEEN
C BETWEEN NUMBERING
POSITION SHIFTS DISLOCATED NUMBERING AXIS (A) &
AXIS AXIS (A) &
FROM CENTRE Y AXIS MOVMENT LINE ( B)
LINE MD25948675E00301 D
X AXIS Y AXIS MOVMENT LINE
( B)
VARIES ( D )
NUMBERING
AXIS
A

FRAME Y AXIS

Slide Number:
Slide 20 20
Number: TVS
TVS Motor company– –Plant
Motor Company P2 2
STEP 3 : IDENTIFY CONSTITUENT CONDITIONS
STEP 4 : STUDY 4Ms FOR CAUSAL FACTORS

CONSTITUENT CONDITION PRIMARY 4 M ANALYSIS

1. Frame rotates/ moves while numbering.

2. The stylus slips

STYLUS NOT
3. Stylus housing has play
REACHING THE
NUMBERING 4. Drive motor does not rotate
AXIS
5. Drive Belt slips

6. Sliding mechanism is jam

7. Stylus home position varies

Slide Number:
Slide 21 21
Number: TVS
TVS Motor company– –Plant
Motor Company P2 2
STEP 4 : STUDY 4Ms FOR CAUSAL FACTORS

PRIMARY 4 M ANALYSIS SECONDARY 4 M ANALYSIS

1. Frame rotates/ moves while 1.1 Frame locating centers wear out.
numbering. 1.2 Distance between centers is more than
frame length
1.3 Hydraulic pressure low
1.4 Seating surface of frame damage
1.5 Frame length variation

2.1 Needle worn out (dia)

2.2 Needle tip worn out
9. The stylus slips 2.3 Frame surface roundness out of spec
2.4 Stylus bush wear out
2.5 Needle stroke is more than 4 mm
2.6 Spring jam

Slide Number:
Slide 22 22
Number: TVS
TVS Motor company– –Plant
Motor Company P2 2
STEP 4 : STUDY 4Ms FOR CAUSAL FACTORS

PRIMARY 4 M ANALYSIS SECONDARY 4 M ANALYSIS

3. Stylus housing play 3.1 Mounting thread wear out on carriage bore
3.2 Mounting thread wear out on stylus housing
3.3 Stylus not tightened

4. Drive motor not rotating 4.1 No supply / pulses to motor

4.2 Running RPM higher than rated RPM
4.3 Motor jam

5. Drive belt slips 5.1 Belt tension loose

5.2 Drive pulley loose
5.3 Driven pulley loose
5.4 Belt teeth not matching with pulley
5.5 Belt wear out / damaged.

Slide Number:
Slide 23 23
Number: TVS
TVS Motor company– –Plant
Motor Company P2 2
STEP 4 : STUDY 4Ms FOR CAUSAL FACTORS

PRIMARY 4 M ANALYSIS SECONDARY 4 M ANALYSIS

6. Sliding mechanism jam 6.1 Guide rod bush wear out & misaligned
6.2 Guide rod mounting loose
6.3 More loading of stylus
6.4 Less lubrication

7. Home position change 7.1 Home position not reached

Slide Number:
Slide 24 24
Number: TVS
TVS Motor company– –Plant
Motor Company P2 2
STEP 4 : STUDY 4Ms FOR CAUSAL FACTORS THE CAUSE & EFFECT CHAIN

Slide Number:
Slide 25 25
Number: TVS
TVS Motor company– –Plant
Motor Company P2 2
Kaizens

Slide Number:
Slide 26 26
Number: TVS
TVS Motor company– –Plant
Motor Company P2 2
Kaizens implemented
Abnormality Improvement

• Dust accumulation on guide rods •Provide bellow cover to avoid dust entry

• Stylus thread damaged •Introduce adapter piece between stylus &

housing bore.

Slide Number:
Slide 27 27
Number: TVS
TVS Motor company– –Plant
Motor Company P2 2
Kaizens implemented
Abnormality Improvement
• Dust entry in guide ways bush •Provide bellow cover between bush

• Home position not reached •Interlock home position sensing with

cycle start .

No
feedback
for home
positioning

Slide Number:
Slide 28 28
Number: TVS
TVS Motor company– –Plant
Motor Company P2 2
Kaizens implemented
Abnormality Improvement

• Higher running RPM than rated for •Set rated RPM & lock with password
axis movement

Rated Actual
Marking Speed : 15 mm /sec 20 mm/sec Marking Speed : 15 mm/sec
Axis speed : 110 mm /sec 200 mm /sec Axis speed : 110 mm /sec

• Stroke length of stylus more • Correct stroke length as per spec in system &
lock with password.

Incorrect entry

Slide Number:
Slide 29 29
Number: TVS
TVS Motor company– –Plant
Motor Company P2 2
Kaizens implemented
Abnormality Improvement

• High air pressure than recommended •Provide regulated pressure with gauge indication

Only pressure
indicating gauge
available

•Belt mounting loose •Provide double belt locking.

Mounting
Bolt Additional
Body
backing
belt

Belt

Slide Number:
Slide 30 30
Number: TVS
TVS Motor company– –Plant
Motor Company P2 2
Kaizens implemented
Abnormality Improvement

• Clamp with low hydraulic pressure • Introduce Pressure switch & interlock with cycle

Only pressure
indicating gauge
available

Slide Number:
Slide 31 31
Number: TVS
TVS Motor company– –Plant
Motor Company P2 2
Inspection Checklist

Slide Number:
Slide 32 32
Number: TVS
TVS Motor company– –Plant
Motor Company P2 2
EQUIPEMENT FAILURE – Frame numbering machine
UOM : Frequency

Better
10

3
2 2
2
1 1 1 1
1
0 0 0 0 0 0 0 0 0 0 0 0 0 0
0
Jan,07

Wk.52

Wk.01

Wk.02

Wk.05

Wk.06

Wk 10
Wk.51

Wk.03

Wk.04

Wk 8
Wk 7

Wk 9
Feb
Jun

Oct
Jul

wk.50
May

Nov

Dec
Sep
Aug
Apr

Plan Actual Limit

Slide Number:
Slide 33 33
Number: TVS
TVS Motor company– –Plant
Motor Company P2 2