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Henrob Limited

Total Preventive Maintenance Sheet for Forging Machine 10


Machine / Equipment
2561 Equipment Type Salvi 663/TR
Serial Reference
Equipment Location Cold Forging Specification Rev / Date 1 / October 03 2001
Daily, Monthly, Six
Date of Last Review 6/13/2001 Maintenance Frequency
Monthly, Yearly
On-line since November-98

Minimum Process Capability & Performance between 01/01/2001 and 03/10/2001


Cpk Cp Ppk Pp
2.1084 2.4168 1.4733 1.5818
Minimum Process Capability & Performance between

Minimum Process Capability & Performance between

Predictive Maintenance Methods


Performed  or  Performed  or 
Any manufacturer's Infrared monitoring of
recommendations circuits and vibration
analysis
Tool Wear Fluid Analysis
Optimisation of uptime Perishable tooling
Review of SPC data

Packaging and Preservation of equipment, tooling and gauging requirements

Maintenance Requirements Responsibility


Daily
1. Check the Machine Brake for functionality Rivets Team Leader
2. Turn the Oil Filter handles twice Rivets Team Leader
3. Check the oil level in the tanks and top up if needed Rivets Team Leader
4. Clean the machine down and replace all hand tools onto the board Rivets Team Leader
5. Check the oil level in the drawing die box and the condition Rivets Team Leader
6. Clean the machine area Rivets Team Leader
Monthly
1. Change the oil filter elements. Rivets Team Leader
2. Clean the oil filtration magnets Rivets Team Leader
3. Grease the grease points Rivets Team Leader
4. Empty the oil sumps, clean the sump and refill with new oil. Rivets Team Leader
5. Check the drive belts and replace if damaged Rivets Team Leader
6. Drain away the water in the pneumatic system Rivets Team Leader
7. Check the machine air system Rivets Team Leader
Six Monthly
1. Change oil filter elements Rivets Team Leader
2. Clean filtration magnets Rivets Team Leader
3. Grease all grease points Rivets Team Leader
4. Check drive belts. Replace if damaged. Rivets Team Leader
5. Drain any water in the pneumatic system Rivets Team Leader
6. Check the machine air system. Rivets Team Leader
7. Check machine guards and interlock switches. Rivets Team Leader
8. Check oil pumps. Refurbish or replace if worn. Rivets Team Leader
9. Check wire feed clutch and replace the oil. Rivets Team Leader
10. Check the electric motor drive. Rivets Team Leader
11. Check gears and bearings for wear. Rivets Team Leader
12. Check machine brakes, clutch assembly. Replace pads if worn. Rivets Team Leader
13. Check machine lubrication system for leaks and blockages. Rivets Team Leader
14. Check the tooling lubrication system for leaks and blockages. Rivets Team Leader
15. Check play in the ram and report on the condition. Rivets Team Leader
16. Drain the gearbox and refill with new oil. Rivets Team Leader
17. Check the belt for damage. Replace if necessary. Rivets Team Leader
18. Check Fluid Analysis a minimum of six months. Rivets Team Leader
Yearly
1. Get Allport to perform annual maintenance on Filter Mist Rivets Team Leader

Special Instructions
None

F3094-02/2.1
03/10/2001
No. of
Breakdown cause for machine 10 Time (hours) occurrences
New CJC Filter 7 2 Chart to show causes of downtime on Forger No 10
Intermittent lube faulty pump 6 1 Total hours = 57.7
Broken Grase nipple (1st Stn) 6 1 Time (hours) No. of oc currenc es

Ruptured air supply pipe 5.5 1 8 3

Rivets jammed under guidestrips 5 2 7

Knockout bar (3rd Stn) 4.5 2 6

Replaced missing grease nipple (5th Stn) 4.5 1 5


2
N
o
Rivets sticking on conveyor 3.25 1 4 .
Broken knockout bar - general 3.25 1 3 o
1
Broken grease nipple on transfer finger assy 2.5 1 H 2
f

Knockout bar (5th Stn) 1.5 1 o


u
o
c
1
Broken stud in punch block (5th Stn) 1.5 1 r c
s 0 0 u
Contaminated oil 1.5 1 r

Missing bleed grub screw and lock nut


Changed oil
Broken knockout bar - general

Contaminated oil
Intermittent lube faulty pump

Ruptured air supply pipe

Broken stud in punch block (5th Stn)

CarouselTiming Wrong

Improved use of cover

Improved filter feed pipe

Improved conveyor guide


New CJC Filter

Broken Grase nipple (1st Stn)

Knockout bar (3rd Stn)

Replaced missing grease nipple (5th Stn)

Rivets sticking on conveyor

Knockout bar (5th Stn)

Worn cam bearings (4th Stn)

Worn cam bearings (2nd Stn)


Broken grease nipple on transfer finger assy
Rivets jammed under guidestrips
e
Changed oil 1.5 1 n
c
Carousel Timing Wrong 1 1 e
s
Improved use of cover 1 1
Worn cam bearings (4th Stn) 0.75 1
Worn cam bearings (2nd Stn) 0.75 1
Missing bleed grub screw and lock nut 0.5 1
Improved filter feed pipe 0.1 1 Cause of breakdown

Improved conveyor guide 0.1 1

Total 57.7
No. of
Breakdown cause for machine 5 Time (hours) occurrences
Worn bearings on side shaft 32 1 Intermittent lube faulty pump 47 3 Improved oil filter 20 1
Broken pin rod (3rd Station) 27 5 Jammed Conveyor 17.75 4 Collapsed bearing on ejection lever (4th Station) 16 2
Improved filtration system 27 1 Faulty Scavenge pump 7 2 Collapsed bearing on ejection lever (5th Station) 9 1
Improved machine set-up 23 1 Extrusion wedge worn 7 1 Faulty motor on wire drawer 6 1
Faulty conveyor 20 2 Hole on diaphragm brake actuator 6 1 Fit analogue readouts 4.5 1
Worn out cylinders on transfer unit 13.5 1 Oil leak at rear of pump 5 1 Perspex window broken 3.75 1
Installed filter 10 1 Ejection cam damaged 5 1 Serviced filter system 3.5 1
Faulty wire feed 8 1 Damaged cams and cam followers 4 1 Jammed operating lever 3 1
Loose grubscrew on pivot shaft 7 2 Intermittent fault on wire feed clutch 3.5 1 Broken pin rod (5th Station) 2.5 2
Broken safety switches 7 1 Collapsed bearing 3.5 1 Broken knockout bar (1st Station) 2 1
Seized magnalloy couplings 6.5 1 Broken nipple 3 1 Broken pin rod (1st Station) 1.25 1
Worn seal on power transfer box 6 1 Worn extrusion cam 2.5 1 Oil contamination 1.25 1
Broken locks on access doors 4.5 1 Ejection wedge seized 2.5 1 Oil drainage leak 1 1
Machine speed fault 4 1 Intermittent fault on tooling oil supply 2.5 1 Oil leak on wire drawer 0.75 1
Broken grease nipples on wire feed 4 1 Fitted Flexi-hoses 2 1 Missing bolt from transfer assembly 0.2 1
Broken pin rod (1st Station) 3.5 1 Gears broken on oil pump 2 1 Improved filter feed pipe 0.2 1
Broken studs in die block (4th Station) 3.5 1 Air leak on supply pipe 1 1 Air leak 0.2 1
Broken studs in die block (5th Station) 3.5 1 Burst air line pipe 0.5 1 Broken oil feed pipe 0.2 1
Installed analogue readouts 3.5 1 Broken bolt on wire feed rollers 0.33 1
Worn tacho generator 3.5 1 New CJC Filter 7 2
Faulty pump 3 1 Joining oil tanks 24 1 Intermittent lube faulty pump 6 1
Faulty conveyor motor 3 1 Fitted CJC filters 20 1 Broken Grase nipple (1st Stn) 6 1
Missing bolt on flywheel 2.5 1 Improved machine set-up 19 1 Ruptured air supply pipe 5.5 1
Wire feed clutch slipping 2.5 1 Rivets jammed in conveyor 15.5 4 Rivets jammed under guidestrips 5 2
Broken pin rod (2nd Station) 2.5 1 Part not replaced during previous bre 11.5 1 Knockout bar (3rd Stn) 4.5 2
New CJC Filter 2 2 Worn cam tension spring 11 1 Replaced missing grease nipple (5th Stn) 4.5 1
Broken wedge (5th Station) 2 1 Broken pin rod (3rd Station) 10 2 Rivets sticking on conveyor 3.25 1
Blocked filter mist return pipe 1.5 1 Worn shaft & bearing on transfer finger 9 1 Broken knockout bar - general 3.25 1
Rivets jammed in conveyor 1 1 Worn seals in transfer finger 9 2 Broken grease nipple on transfer finger assy 2.5 1
Air leak 1 1 Part replaced incorrectly 8 1 Knockout bar (5th Stn) 1.5 1
Intermittent lube gauge fitted 0.5 1 Loose grub screw on pivot shaft 6 1 Broken stud in punch block (5th Stn) 1.5 1
Worn follower cam bearings 6 1 Contaminated oil 1.5 1
Knockout bar (2nd Stn) 22.75 2 Motor malfunction 6 1 Changed oil 1.5 1
Jammed Conveyor 21 6 Worn tooling lube pump 5.5 1 Carousel Timing Wrong 1 1
Broken ejection lever (1st Stn) 18.5 1 Broken pin rod (1st Station) 5 1 Improved use of cover 1 1
Broken drive pin on clutch brake assemb 16 1 Oil contamination 5 2 Worn cam bearings (4th Stn) 0.75 1
New CJC Filter 14 1 Ejection lever broken (2nd Station) 4.75 1 Worn cam bearings (2nd Stn) 0.75 1
Knockout bar (1st Stn) 13.5 4 Broken stud (3rd Station) 4.5 1 Missing bleed grub screw and lock nut 0.5 1
Broken studs (general) 7.5 4 Broken tooling lubrication pump 4.5 1 Improved filter feed pipe 0.1 1
Bent cutter bar 7.5 2 Jammed conveyor 4 1 Improved conveyor guide 0.1 1
Broken turn-buckle assembly 7 2 Broken oil lube pump 4 1
Worn cam follower 7 1 Worn bushes on transfer bracket 4 1 Improved in-line filter 10 1
Incorrect setting-up of machine 6.75 2 Broken oil pump 3.5 1 Burst Air Supply Pipe 0.25 1
Tooling lube overflowing 6.5 1 Damaged threads on cut-off block 2.5 1
Worn drive belts 6 1 Rivet chute modified 2 1
Collapsed die ejection cam follower 5.5 1 Backlash brake on wire clutch oiled 2 1
Worn bearings on ejector wedge 5 1 Oil ingress into air manifold area 2 1
Collapsed bearing 5 1 CJC filter 1 1
Manufactured filter stand 4 1 Magnalloy coupling seized up 1 1
Insufficient oil in sump 3.5 1 Blocked oil return pipe 1 1
Sheared bolts 3 1 Broken guard on sideshaft 0.5 1
Loose locking screw on wire stop assemb 2 1 Hole in air pipe 0.2 1
Broken fan cover on conveyor motor 2 1
Changed CJC filter element 1 1
Henrob Limited
Key Equipment Spares Sheet for Cold Forging Machines

Part Number Description Minimum Stock Level Lead Time for Part Required for Cold Forging Machine #

1130001 Pin 0 3 days 4, 5


1130002 Pin 0 3 days 4, 5
113004 Finger Holder 1 3 days 7
1130005 Finger Holder 1 3 days 7
1130006 Knockout Bar 1 3 days 7
113007 Knockout Bar 1 3 days 4, 5, 7, 10, 11
1130021 Pin Lever 0 3 days 4, 5, 9, 10, 11
1130022 Pin Lever Insert 0 3 days 4, 5, 9, 10, 11
1130023 Pin Lever Key 0 3 days 4, 5, 9, 10, 11
1130024 Pin Lever Bolt 0 3 days 4, 5, 9, 10, 11
1130046 Stripper Cam 0 3 days 9
1130047 Stripper Cam 0 3 days 4, 5, 10
1130061 Bearing 0 Same Day 7
1130066 Bearing 0 Same Day 4, 5, 9, 10, 11
1130068 Bearing 0 Same Day 7
1130071 Bearing 0 Same Day 4, 5, 9, 10,11
1130077 Bearing 0 Same Day 4, 5, 9, 10,11
1130078 Bearing 0 Same Day 4, 5, 9, 10,11

F3094-08/1.1
28/05/2002