"IMPROVING OVERALL EFFICIENCY OF THE CUTTING MACHINES BY IMPLETATION OF PILLARS OF TPM"project Done at Godrej&boyce........

Bharati Vidyapeeth College Of Engineering
UNIVERSITY OF MUMBAI
A PROJECT REPORT ON
IMPROVING OVERALL EFFICIENCY OF THE CUTTING MACHINES BY

IMPLETATION OF PILLARS OF TPM
SUBMITTED BY
YASHRAJ V. RANE
HARSHAD V. SURYAWANSHI
KALPESH D. KHOCHARE
AMOL P. SHETKE
DHIRAJ B. WAGHMARE
GUIDED BY
PROF L. R. SURYAWANSHI
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(INTERNAL GUIDE)
DEPARTMENT OF MECHANICAL ENGINEERING
BHARATI VIDYAPEETH’S COLLEGE OF ENGINEERING
SECTOR -7,CBD BELAPUR,NAVI MUMBAI-400614
2009-2010
Bharati Vidyapeeth’s College of Engineering

(Affiliated to the University of Mumbai)
Sector 7,CBD,Navi Mumbai-400614
A PROJECT REPORT ON
IMPROVING OVERALL EFFICIENCY OF THE CUTTING

MACHINES BY IMPLETATION OF PILLARS OF TPM
SUBMITTED BY
YASHRAJ V. RANE
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HARSHAD V. SURYAWANSHI
KALPESH D. KHOCHARE
AMOL P. SHETKE
DHIRAJ B. WAGHMARE
GUIDED BY
PROF L. R. SURYAWANSHI
(INTERNAL GUIDE)
APRIL-2010

CERTIFICATE
DATE :
This is to certify that the project titled
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Is
Submitted By
KALPESH.D.KHOCHARE (4759)
YASHRAJ.V.RANE (4760)
HARSHAD.V.SURYAWANSHI (4761)
AMOL.P.SHETKE (4762)
DHIRAJ.B.WAGHMARE (4766)
B.E.(Mechanical engineering) class of Bharati Vidyapeeth’s

College of Engineering, Navi Mumbai in the year 2009-2010
towards the fulfillment of the requirements for the award of the
Degree of Bachelor of Engineering under the University of
Mumbai.
Prof L. R. Suryawanshi Prof R.K.Agrawal

Prof.S.D. Jadhav
(Internal Guide) (Project Co-ordinator)

(H.O.D)
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A PROJECT REPORT ON

Is
Submitted By
KALPESH.D.KHOCHARE (4759)
YASHRAJ.V.RANE (4760)
HARSHAD.V.SURYAWANSHI (4761)
AMOL.P.SHETKE (4762)
DHIRAJ.B.WAGHMARE (4766)
Has been examined and approved as per the fulfillment of the

requirements for the award of the Degree of Bachelor of
Engineering (Mechanical) of the University of Mumbai in the
academic year 2009-2010.
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Signature Signature
Name : Name:
(External examiner) (Internal
examiner)
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ACKNOWLEDGEMENT
At the very onset of this project, we would like to take this opportunity to express our
heartfelt gratitude to the people whose unstinting help and co-operation has made this study a
success.
We would like to express our appreciation to Mr. Neel Shrivastava (Department Head)
& Mr. F. R. Bava-Adam (Divisional Personnel) for granting us permission to complete our
project in their prestigious organization
We express our sincere gratitude to our external guide Mr. T. A. Pooniwala

(Maintainance Head) for providing us all the necessary information, training and valuable
guidance during the project
We are thankful to Prof. Mr. L. K. Suryawanshi, our project guide who co-operated
every now and then and took every effort to make this project a grand success. Humble thanks
to our teachers and project co-coordinator Prof. Mr. R.K. Agrawal for their keen guidance.
We would like expressing our indebtedness to our eminence to Respected principal,

Prof. Mr. D.P. Mishra and Prof. Mrs. S.N. Jadhav madam, our head of Mechanical
Department for their constant inspiration, guidance and encouragement.
Finally we thank all people, our colleagues who offered their valuable time, guidance,
suggestions and assistance directly to us to carry out this educative report
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Abstract
Total Productive Maintenance (TPM) is a process that maximizes the productivity of

equipment for its entire life. It fosters an environment where improvement efforts in safety,
quality, cost, delivery, and creativity are encouraged through the participation of all employees.
TPM is not simply a preventive maintenance program. Rather, it is a strategic

management initiative to increase capacity and end the vicious cycle of ‘breakdown’ or reactive
repairs through the use of autonomous and predictive maintenance, as well as equipment
modifications to facilitate optimum machine availability, quality, and performance.
The TPM presentation focuses on a results oriented implementation methodology

designed to minimize the 6 major equipment losses. Overall Equipment Effectiveness (OEE), an
equipment performance assessment or measurement, is introduced. By understanding and
implementing TPM, companies can use it as a foundation and fundamental discipline to facilitate
Condition Based Maintenance (CBM) effectively.
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Table Of Contents
Sr. No Particulars Pg. No.

01 Chapter 1: INTRODUCTION TO COMPANY 1-9
02 Chapter 2: INTRODUCTION TO PROJECT 10-20
03 Chapter 3: LITERATURE REVIEW 21-25
04 Chapter 4: METHODOLOGY 26-29
05 Chapter 5: ANALYSIS 30-38
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06 Chapter 6: SUGGESTION 39-42
07 Chapter 7: DESIGN 43-47

08 Chapter 8: SCOPE 48-49
09 Chapter 9: RESULTS AFTER IMPLEMENTATION 50-54

10 CONCLUSION 55-55
11 BIBLIOGRAPHY 56-56
FIGURES
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FIGURE NO. NAME OF THE FIGURES PAGE NO.
FIGURE 1 Company Photo 02

FIGURE 2 Heat Exchanger 05
FIGURE 3 Heavy walled Reactor 06
FIGURE 4 High Pressure Vessel 06
FIGURE5 BEHRINGER BANDSAW 11
FIGURE 6 CNC GAS CUTTING MACHINE – SUAG 11
FIGURE 7 BEHRINGER BANDSAW 12
FIGURE 8 Band-saw Cutting Blade 14
FIGURE 9 CNC GAS CUTTING MACHINE - SUAG 16
FIGURE 10 Cutting Torch for CNC Gas Cutting Machine 17
FIGURE 11 Pillars of TPM 22
FIGURE 12 Fishbone Diagram 25
FIGURE 13 Flow Chart 29
FIGURE 14 OEE Chart for BEHRINGER BANDSAW 33
FIGURE 15 Bar Chart for set up time and measurement 34
FIGURE 16 Pie Chart BEHRINGER BANDSAW 35
FIGURE 17 OEE Chart CNC GAS CUTTING 37
MACHINE - SUAG
FIGURE 18 Bar Chart for CNC GAS CUTTING 37
MACHINE - SUAG
FIGURE 19 Pie Chart for CNC GAS CUTTING 38
MACHINE - SUAG
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TABLES
TABLE NO. TABLE NAME PAGE NO.
TABLE NO 01 SPECIFICATION OF BEHRINGER 15

BANDSAW
TABLE NO 02 SPECIFICATION OF CNC GAS 19
CUTTING MACHINE - SUAG
TABLE NO 03 Time study on Behringer Band Saw 32
Cutting M/C
TABLE NO 04 TIME STUDY ON BEHRINGER BAND 35
SAW CUTTING M/C LOSSES
TABLE NO 05 Time study on CNC Gas cutting M/C - 36
SUAG
TABLE NO 06 TIME STUDY ON CNC SUAG 38
CUTTING M/C LOSSES
TABLE NO 07 Data recorded before Implementation on 51
Behringer Bandsaw
TABLE NO 08 Data recorded after Implementation on 51
Behringer Bandsaw
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TABLE NO 09 Improved OEE of Behringer Bandsaw after 52

implementing Scale
TABLE NO 10 Result of Improved OEE of Behringer 52
Bandsaw after implementing Scale
TABLE NO 11 Data recorded before Implementation on 53
CNC Gas cutting M/C - SUAG
TABLE NO 12 Data recorded after Implementation on 53
CNC Gas cutting M/C - SUAG
TABLE NO 13 Improved OEE of CNC GAS CUTTING 54
M/C-SUAG
TABLE NO 14 Result of Improved OEE of CNC GAS 54
CUTTING M/C-SUAG
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CHAPTER -1
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INTRODUCTION TO COMPANY
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Fig.no-1: Company Photo
In the year 1997, Godrej & Boyce celebrated their centenary year. This
dynamic organization has progressed tremendously since its inception and has been gaining
strength consistently. Quality is the hallmark of all the Godrej products and any product with
the 'Godrej' mark represent quality, dependability & satisfaction to its customers. What now
is a gainful industrial organization was a brainchild of Mr. Ardeshir GODREJ, which through
the help dedicated men with tremendous foresight and finely honed engineering and
marketing skills, has become one of the biggest houses in India.
Godrej also made a significant contribution to self-reliance of the century by

building the engine for the PSLRU locker launched by India. In the year 1978 Godrej
diversified in to the field of chemicals by starting the manufacturing of soaps and further
diversified into production of chemicals for various industries like textile mills, pharmacies,
confectioneries, etc.
The most recent achievement by Godrej was made when it acquired the ISO 9000,
ISO 9001 and ISO 14000 certificate, which former reinforced the rest of not only the Indian
market but also the global market in the product of Godrej Today Godrej employee over
15,000 people and has grown in to a multi-core professionally managed group with far
reaching service and distribution network. "Economy and Services” are being the main motto
of Godrej they have already diversified in to field of Indian industry thus helping in the
economic growth of the country.
Century old brand name, 'Godrej', it now also provides electronic security systems
products and is angered with the supply and installation of the electronics safes, electronics
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security alarm systems, access control systems, closed circuit television systems and very
highly sophisticated advanced electronic surveillance systems.
VARIOUS PLANTS IN GODREJ
GODREJ & BOYCE MFG. CO LTD.:-
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It is truly a mullet-faceted company. This is the major collaboration of Godrej with

Boyce Company. The maximum of the business of Godrej is known by this name. At present
all the divisions mentioned below come under this company.
 OFFICE EQUIPMENT (O.E.) DIVISION: -

The manufacturing activities in this division are distributed in the following plants:
➢ Plant 1: Steel processing plant
➢ Plant 4 & 14: Furniture systems plant
➢ Plant 13: Industrial storage system
➢ Plant 17: Security equipment
➢ LOCKS DIVISION: -Plant 18 A

➢ TYPEWRITER DIVISION: – Plant 18 B
➢ MATERIAL HANDLING DIVISION: -Plant 16
➢ MACHINE TOOL DIVISION: -Plant 9 & 19
➢ TOOL ROOM DIVISION: -Plant 7

➢ OFFICE AUTOMATION DIVISION: -Plant 19 A
➢ PROCESS EQUIPMENT DIVISION: -Plant 15
This division is located in Plant 15 and it designs and fabricates a large range of
custom-made sophisticated equipment for chemicals, petrochemicals and fertiliser industries
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such as heat exchangers, boiler shells, tower internals, etc., as well as equipment for nuclear
and aerospace applications such as parts of atomic reactor, cryogenic engines and projects of
ISRO (Indian Space Research Organisation).
Fig.no-2: Heat Exchanger
The process equipment division consists of five main production

departments as follows:
♦ Columns.
♦ Heat exchanger.
♦ Reactors & Vessels.
♦ Aerospace Division.
♦ Trays & tower internals.
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Product range –
• Heavy Walled Reactors
• Equipment Internals
• Fractionating / Distillation Columns
• High Pressure Shell & Tube Heat Exchangers Custom built
Equipment
Fig.no-4:-High Pressure Vessels

Fig.no-3:-Heavy Walled Reactor
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INTRODUCTION TO MACHINE SHOP DEPARTMENT
Machine shop department is one of the vital departments in the ‘Process Equipment
Division’. It possesses machines that are required for machining the various components
of the pressure vessel assembly. The department produces components that are related to
the heat exchanger of the pressure vessel assembly. The machine shop department is a
service department and works in tandem with other departments of the plant.The
components produced in machine shop department can be given as follows: -
♦ Tube sheets
♦ Baffles
♦ Tie rods
♦ Spacers
♦ Flanges
The various machines used in the machine shop department can be given as
follows:
➢ CNC DRILLING MACHINES: -
♦ ARBOGA 1
♦ ARBOGA 2
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♦ HARTFORD 1
♦ HARTFORD 2
♦ BATLIBOI
♦ KOLB
➢ DRILLING MACHINES:- The Drilling machine is in tends fro drilling

medium to large and heavy work pieces. The machine consists of a heavy round, vertical
column mounted on a large base. The column supports a radial arm which can be raised
and lowered to accommodate work pieces to different heights.
♦ RADIAL 1,2,3,4,5,6,7
➢ CNC LATHE MACHINE:-
➢ HMT LATHE
➢ HORIZONTAL LATHE MACHINES:- The Lathe has got all the basic
parts e.g. Bed, Headstock and Tailstock. The Headstock contains mechanisms for driving
a spindle at multiple speeds. Lathe can feed the tool both in cross and longitudinal
direction with reference to lathe axis. A lathe receives its power from an individual motor
known as motor driven lathe.
♦ BOMBAY LATHE
♦ THREE JAW LATHE
♦ MODULAR LATHE
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♦ BECO LATHE
♦ NEW LATHE
➢ VERTICAL LATHE MACHINES:- This type of boring machine

combines the advantages of vertical boring machine and turret lathe. It has an indexable
turret lathe mounted the cross rail above the table for multiple tooling. A four station
square turret side head which enables facing, turning under cutting and many other
operations.
♦ VTL1 SINGLE ARM (CNC)
♦ VTL5 DOUBLE ARM (CNC)
♦ VTL6 (FARREL)
➢ HORIZONTAL BORING MACHINE:- In a Horizontal Boring machine,

the work is supported on a table which is stationary and the tool revolves in a horizontal
axis. A Horizontal machine can perform boring, reaming, turning, threading, facing,
milling, milling, grooving, recessing and any other operation with suitable tools.
➢ VERTICAL MILLING MACHINES:- A Milling machine is a machine

tool that removes metal as the work is fed against a rotating multipoint cutter. In a
vertical milling machine position of the spindle is vertical or perpendicular to the work
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table. The spindle head can be swivelled at an angle. This machine is adapted for
machining grooves, slots and flat surfaces.
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CHAPTER-2
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INTRODUCTION TO PROJECT
“IMPROVING OVERALL EFFICIENCY OF THE

CUTTING MACHINES BY IMPLEMENTATION OF PILLARS
OF TPM”
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Fig 5: MACHINE 1: BEHRINGER BANDSAW
Fig 6:
MACHINE 2: CNC GAS CUTTING MACHINE – SUAG
MACHINE DETAILS: (BEHRINGER BANDSAW)
Fig 7
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Morgantown, PA (April 7, 2010) – A new line of bandsaws engineered to

accommodate and cut large diameter tubing quickly and efficiently is available from
Behringer Saws, Inc. HBP-800AXL Automatic and HBP-800XL Semi-Automatic Series
Bandsaws allow companies to save on upfront capital expenditures and avoid buying
more expensive bandsaws for everyday cutting while expanding their capability to
specifically cut large tubes when needed.
The HBP-800AXL Automatic and HBP-800XL Semi-Automatic Bandsaws
deliver all the performance and capabilities of “standard” HBP-800 Series Bandsaws
cutting solid bars and structurals up to 31.5”. In addition, these new bandsaws allow for
the cutting of tubes up to 39" in diameter. Companies can now purchase a lower cost
bandsaw to handle day-to-day production cutting needs at the standard size range while
utilizing this additional feature to accept new projects requiring the cutting of large
diameter tubing.All HBP-800 Bandsaws are built with strong cast iron frame construction
and a twin column parallel down feed design for proper saw blade tensioning to deliver
quick, efficient and forceful low vibration cutting for smooth cuts. These bandsaws also
come with a heavy-duty roller conveyor for quick and efficient handling of heavy
materials pre- and post-cut.
HBP-800 Bandsaws feature a frequency controlled 14.7 horsepower main drive
motor with a variable speed range of between 55-393 Surface Feet Per Minute (SFM)
which is easily selected at the operator’s control panel. Hydraulic and hardened clamping
jaws on the bandsaw ensures steady and precise cuts at all speeds.
This bandsaw is available in both automatic and semi-automatic versions and
requires minimal operator intervention as it is controlled by a programmable logic
controller (PLC). It features an easy-to-use operator’s terminal with diagnostic display,
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data entry and program storage. The speed is easily set, controlled and monitored before
and during the cutting process.
Behringer Saws, Inc. provides a full range of sawing and turnkey pre- and post-cut
material handling productivity-enhancing products. Behringer supplies world-class
quality automatic bandsaws to corporations, service centers, job shops and manufacturers
throughout the world. The company also offers the Behringer Eisele brand of manual,
semi-automatic and automatic miter circular cold saws, high performance circular cold
saws utilizing bi-metal or carbide saw blades and CNC miter circular sawing systems.
Also, the Vernet Behringer line of structural fabricating equipment includes high
performance drilling, punching, shearing, notching and marking machines along with
beam coping and drilling and sawing lines.
For more information on the HBP-800AXL and HBP-800XL Bandsaws, contact
Behringer Saws, Inc., 721 Hemlock Road, Morgantown, PA 19543. Call toll-free at 888-
234-7464.
Description of machine: -
Stainless steel and tool steel. Tempered steel, special alloys and aluminum. In
different thicknesses, shapes and diameters. Singly, in bundles of fixed lengths. Whatever
you aim to saw, our HBP, HBV and HBM high-performance and automatic bandsaw
series offer the solution you are looking for. In every cutting range. Despite their
outstanding performance, our machines are all designed to offer maximum operating
simplicity and space savings. And like everything from BEHRINGER, they are
unbeatable in terms of speed, precision and quality.
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BAND-SAW CUTTING BLADE:
Fig 8: Band-saw Cutting Blade

The typical metal cutting bandsaw machine is used for simple cutting of solid
steel, tubing, and odd shaped material. The material to be cut is mounted in a vise
attached to the bed of the machine.
An electric motor drives the bandsaw blade through a belt and pulley arrangement
from which three speeds may be obtained. The sawing machine frame, upon which the
drive wheel, idler wheel, bandsaw blade, and motor are mounted, pivots from one corner
of the sawing machine bed. The frame is counterbalanced by a tension spring between the
frame and the bed.
Feed is controlled by positioning a sliding weight along a bar fixed to the top side
of the sawing machine frame. A dashpot is positioned between the frame and bed to
stabilize the feed movement and prevent any quick movement of the frame that could
cause damage to the bandsaw blade.
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The vise used to hold the material being cut is a quick-positioning type and can be
adjusted easily to any angle. An adjustable work piece stop is provided for rapid
positioning of production work pieces.
SPECIFICATION OF BEHRINGER BANDSAW:-
Model HBP 413A
Cutting range 90° round (inch) 16.1

90° flat (W x H) (inch) 19.7x15.7
90° square (W x H) (inch) 15.7x15.7
75° meter left dia. / flat (W x H) (inch) -
Working height (inch) 31.5
Single stroke of the feeding gripper (inch) 15.7
Drive motor (H.P.) – frequency controlled 5.4
Cutting speed (FPM) 65-459
Cutting capacities 47.2" x 31.5"
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Saw blade dimensions 19’0”x1-1/2”x .050”

Weight (lbs) 5,170
Space requirement (inch) 116x77
Large dual column - parallel down-feed design
Solid cast bow frame
Cast Meehanite band wheels
Fully automatic hydraulic blade tensioning & carbide blade guides
Table No: 01
MACHINE DETAILS: (CNC GAS CUTTING MACHINE - SUAG)
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Fig 9
The RUM is the latest generation of CNC profile cutting machine that combines
the quality of construction of the MAXI machine with the advantages of the price/output
ratio of RUR machine. Standard equipment of the RUM includes all available automation
facilities.
 Basic equipment
 fully welded beam without bolted joints
 linear bearing in cross axis
 AC servomotors
 digital synchronization in longitudinal axis
 BURNY 10 LCD Plus control system with touch screen
 membrane keyboard
 floating cutting heads
 electric ignition
 capacitive height control of oxy-fuel torch
 automatic gas console
 torch selection from control panel
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 automatic initial height sensing of plasma torch

 arc voltage height sensing of plasma torch
 parking facility for heads out of cutting area
 limit switch in each axis
 Optional equipment
 plasma system by customer request
 pneumatic anti-collision system
 pneumatic, plasma or inkjet marker
 air cooling of portal frame
 control system heating (for winter operation)
CUTTING TORCH:
A cutting torch head is used to cut metal. It is similar to a welding torch, but can be
identified by having three pipes that go to a 90 degree nozzle and by the oxygen-blast
trigger.
Only iron and steel can be cut using this method. The metal is first heated by the
flame until it is cherry red. Once this temperature is attained, oxygen is supplied to the
heated parts by pressing the "oxygen-blast trigger". This oxygen reacts with the metal,
forming iron oxide and producing heat. It is this heat which continues the cutting process.
The cutting torch only heats the metal to start the process; further heat is provided by the
burning metal.
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Fig 10: Cutting Torch for CNC Gas Cutting Machine

Acetylene is the primary fuel for oxy-fuel welding and is the fuel of choice for
repair work and general cutting and welding. Acetylene gas is shipped in special
cylinders designed to keep the gas dissolved.
Oxygen is not the fuel: It is what chemically combines with the fuel to produce the
heat for welding. This is called 'oxidation', but the more general and more commonly
used term is 'combustion'.
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SPECIFICATION OF CNC GAS CUTTING MACHINE - SUAG:-

RUM 3500 4000 4500
max. number of torches 6
rail span 3500 mm 4000 mm 4500 mm
cutting width * - 1 torch 3100 mm 3600 mm 4100 mm
cutting width * - 2 torches 3100 mm 3600 mm 4100 mm
cutting length by customer request
min. parallel cut 90 mm
cutting speed 0 - 20000 mm/min.
standard cutting thickness 200 mm
machine width 4100 mm 4600 mm 5100 mm
machine length 1200 mm
machine height incl. rails 1700 mm
cutting table height 700 mm
plasma system by customer request
supply voltage 230V/50Hz
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Plate widths 1,000 to 2,000mm

Speed 0 to 8,000mm/min
Track 2,000mm (standard) 1,000mm (optional)
Drives: Longitudinal Rack and pinion Transverse Rack and pinion
Plasma: Upto 200amp plasma system. Full height sense and heavy duty head
Gas and heads: Hi Lo preheat (standard) 2 stage pierce (optional)
Cutters: 2 Maximum
Controller: C.N.C. controller mounted on a pedestal
Table No: 02
Key features:
 Burny 1250 control system includes a fully-integrated Burny 2.5 CNC Shape
Cutting Control, Plasma process controls and a servopak 120 watt pulse with
modulated drive
 CNC Width 2000mm
 Track length to be advised
 Maximum Cutting Speed 6000mm/min
 Maximum Cutting Thickness with gas 300mm
 Single sided drive
 Combined gas and plasma post with ESAB Cool jet Cutting Post
 Operational Manuals
 Mains input would require 240 volts single phase
 Photographs taken on site PRIOR to any work commencing.
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CHAPTER-3
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LITERATURE REVIEW
Literature Review:
AN INTRODUCTION TO TOTAL PRODUCTIVE MAINTENANCE
(TPM):
In today’s industrial scenario huge losses/wastage occur in the manufacturing shop
floor. This waste is due to operators, maintenance personal, process, tooling problems
and non-availability of components in time etc.
Other forms of waste includes idle machines, idle manpower, break down
machine, rejected parts etc are all examples of waste.
The quality related waste are of significant importance as they matter the company
in terms of time, material and the hard earned reputation of the company. There are also
other invisible wastes like operating the machines below the rated speed, start up loss,
break down of the machines and bottle necks in process.
Zero oriented concepts such as zero tolerance for waste, defects, break down and
zero accidents are becoming a pre-requisite in the manufacturing and assembly industry.
In this situation, a revolutionary concept of TPM has been adopted in many industries
across the world to address the above said problems. chapter deals in length about this
TPM.
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Pillars of TPM
Fig 11
TPM Pillars To Implement
PILLAR 1 - JISHU HOZEN (Autonomous maintenance):

This pillar is geared towards developing operators to be able to take care of small
maintenance tasks, thus freeing up the skilled maintenance people to spend time on more
value added activity and technical repairs. The operators are responsible for upkeep of
their equipment to prevent it from deteriorating.
PILLAR 2 – KOBETSU KAIZEN:

"Kai" means change, and "Zen" means good (for the better). Basically kaizen is for
small improvements, but carried out on a continual basis and involve all people in the
organization. Kaizen is opposite to big spectacular innovations. Kaizen requires no or
little investment. The principle behind is that "a very large number of small
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improvements are move effective in an organizational environment than a few

improvements of large value. This pillar is aimed at reducing losses in the workplace that
affect our efficiencies. By using a detailed and thorough procedure we eliminate losses in
a systematic method using various Kaizen tools. These activities are not limited to
production areas and can be implemented in administrative areas as well.
1. METHODS:
 Time to process Raw-material.
 Lack of proper understanding.
1. PEOPLE:
 Lack of availability of designers.
 Conflicting mindsets of designers.
 Inadequate skill-mapping.
 Lack of motivation & understanding.
1. MANPOWER:
 Dedicated personnel for planning.
 Lesser no. of designers involved.
 Dynamics of self-help groups.
1. POLICIES:
 Government oriented(Time-consuming) paper work.
 Lack of finance to create larger SHG’s.
 Investment.
1. PLACE:
 Time & cost incurred.
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 Proximity to large markets slightly less.

1. SURROUNDING:
 Traditional barriers & mind-sets.
 Linguistic barriers(biggest issues).
1. PROCEDURES:
 Material constraints.
 Requires fine tuning of mind towards market.
 Requires deeper market understandings by designers.
1. SKILLS:
 Newer skills not impaired.
 Imbalance in skills.
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Fig 12: Fishbone Diagram
CHAPTER-4
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METHODOLOGY
Application of critical examination results into number of alternatives since all

points are not practicable, only few of them are to be developed.
Following are the key points for the development of new methods:-
 Elimination of all unnecessary operation.

 Sensors for measurement of jobs.
 Designing the process wherever required.
We will be developing new methodology in the following stages.
1. Recognition of problems:
Every development process starts with recognition or identification of need.
Recognition of need is to outcome of either the requirement of the discontent of the
existing system.
2. Definition of problem:
The difference the statements of need the identification of the problem lies in the fact
of the problem is more specific. Definition of problem must include all inputs ,
parameters, functional requirement and constraints of the system.
3. Evaluation and Synthesis:
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After detail study of TPM tools, we have obtained number of alternatives and by
evaluation we shortlisted the number alternatives and decided whether all alternatives
should be accepted or not. By pillars of TPM, we selected process, manpower and
machinery as an area of development.
Synthesis is a process of selecting the mechanism so as to get desired output by given
input.
It involves number of iterations. By synthesis we decided to synchronize the first three
operations.
4. Investigation:
Once the number of alternatives are shortlisted in the evaluation step it becomes
necessary to convert these alternatives in to practical needs. Investigation does this. It
usually involves preparation of making prototype, considering trial run etc.
Initially we are trying to synchronize cutting operations.
The following operations we are going to perform to increase production and efficiency
of machines.
 Elimination of all unnecessary operations.
 Sensors of measurement of jobs.
 Designing the process wherever required.
1. Final Design:
On successful synchronization of all processes, we will make final design and decide
parameters for smooth functioning of developed process with increased productivity.
The design will be based on following parameters.
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 Investment needed.
 Rate of production.
 Production cost per unit.
 Return of investment.
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Fig 13: Flow Chart
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CHAPTER-5
33
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ANALYSIS
Today, with competition in industry at an all time high, TPM may be the only
thing that stands between success and total failure for some companies. It has been
proven to be a program that works. It can be adapted to work not only in industrial plants,
but also in construction, building maintenance, transportation, and in a variety of other
situations. Employees must be educated and convinced that TPM is not just another
"Program of the month" and that management is totally committed to the program and the
extended time frame necessary for full implementation. If everyone involved in a TPM
program does his or her part, an unusually high rate of return compared to resources
invested may be expected.
As shown below we have shown the information with the help of Time Study
charts with proper description of whatever the losses affecting the production. On the
basis of Time Study charts we have drawn the pie-charts.
We have developed an OEE chart (Overall Equipment Efficiency) and collected
all the Time Study data and implemented it on OEE chart. From these OEE charts we
have listed following major losses:
BEHRINGER BAND SAW CUTTING M/C
 M/C down time
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 Setting of JOB
 Measurement
CNC GAS CUTTING M/C- SUAG
 Scheduled/Planned Stoppages
 Non Availability of Material
 Non Availability of EOT Crane
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Time study on Behringer Band Saw Cutting M/C
Table No: 03
36
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37
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Fig 14: OEE Chart
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Fig 15: Bar Chart for set up time and measurement
TIME STUDY ON BEHRINGER BAND SAW CUTTING M/C

LOSSES
SR.NO. ACTIVITY TIME in min %
1. Setting of JOB 115 19.79
2. Measurement 83 14.28
3. Operator non availability 35 4.30
4. Crane waiting time 15 2.58
5. M/C down time 313 53.87

6. Tool changing time 30 5.16
TOTAL 581 100
Table No: 04
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Fig 16: Pie Chart

TIME STUDY ON CNC GAS CUTTING M/C - SUAG
40
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41
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Table
No: 05
42
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Fig 17: OEE Chart for CNC GAS CUTTING MACHINE - SUAG
43
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Fig 18: Bar Chart for CNC GAS CUTTING MACHINE - SUAG
CNC SUAG CUTTING M/C LOSSES
SR.NO. ACTIVITY TIME in min %

1. Scheduled/Planned Stoppages 698 49.75
2. Setting Time 17 1.22
3. Start-up Losses[mock-up] 288 20.52
4. Minor Stoppage[Time Loss] 20 1.42
5. Non Availability of Material 340 24.24
6. Non Availability of Operator 40 2.85
TOTAL 1403 100
Table No: 06
Fig 19: Pie Chart for CNC GAS CUTTING MACHINE - SUAG
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CHAPTER -6
45
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SUGGESTION
SUGGESTIONS BEHRINGER BAND SAW CUTTING M/C:-

Three Major Losses in Behringer:-
1. M/C Down Time.

2. Setting Time.
3. Measurement.
1. M/C Down Time
REASON
Break-down maintenance
SOLUTION
Preventive Maintenance of M/C to be done on time to avoid maintenance while M/C is

in production.
2. Setting time
REASON
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Fatigue to Operator in Setting the Job.
SOLUTION
Sensors are to be employ on machine.
3. Measurement
REASON
1. Presently measurement is done manually by operator.

2. New measurement type equipment must be procured to minimize measurement time.
SOLUTION
Sensors assembly has to be done near to the machine blade so measurement time will
be minimum.
SUGGESTIONS CNC SUAG CUTTING M/C:-
Three Major Losses in CNC Suag:-
1. Scheduled/Planned Stoppages.
2. Non Availability of Material.
3. Start up Loss[mock-up].
1. Scheduled/Planned Stoppages
REASON
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1. Loading Time Of Plate Is Too High.

2. Time consumed for Setting the Job Plate.
SOLUTIONS
1. Loading Time Should Be Minimized By Offline Setting Of Plate.

2. Special fixture to be Designed for Quick Setting of Job Plate.
2. Non Availability of Material
REASON
Improper & Unplanned Stacking of Plates.
SOLUTIONS
1. Proper stacking of plates as per priority.

2. Proper proactive planning to feed the m/c as per plan.
2. Start up Loss[mock-up]
REASON
1. No cleaning before Operator reports the machine.

2. Major time consumed in Test Run.
SOLUTIONS
48
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1. Special Cleaning staff to be provided for cleaning of the m/c before operator reports
on the m/c during each shift.
2. Special Fixture to be made to avoid Test Run.
49
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CHAPTER -7
50
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DESIGN
Introduction to Rack Design
Introduction
A rack is a device for locating, holding and supporting a workpiece
or plates during a manufacturing operation. Rack are essential part of
production processes as they are required for material handling of a
particular materials.
There are many standard material handling devices such as belt
conveyor,trolley etc. which are widely used in workshops and industries
and are usually kept in stock for general applications.
Rack are normally designed for a definite operation to process a specific
workpiece and are designed and manufactured individually.
51
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Fig 20-a: Design given for Behringer Bandsaw

Scale used for measurement
52
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Fig 20-b: Design given for Behringer Bandsaw

Fig 20-c: Design given for Behringer Bandsaw

53
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54
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Fig 21 Design given for CNC GAS CUTTING MACHINE – SUAG

Stacking of plates
The cross section of the fillet weld consists

of a right angled triangle having two equal
55
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sides. The length of each of the two equal sides id called leg. As a rule, the leg length h is
equal to the plate thickness.
Fig 22: Welded Joint

The throat is the minimum cross section of the weld located at 45o to the leg dimension.
Therefore,
t = h cos 45o
or
t = 0.707 h
Failure of the fillet weld occurs due to shear along the minimum cross section at the throat. It
will be provided at a later stage in the above given section, that for parallel fillet weld, the
inclination of the plane where maximum shear stress is induced is 45o to the leg dimension.
The cross sectional area at the throat is (tl) or (0.707 hl). The shear stress in the fillet weld is
given by,
τ=P0.707 hl
Rearranging the term of the above equation, the strength equation of the parallel fillet weld is
written in the following form,
P = 0.707 hlτ
where,
P = tensile force on plates (N)
h = leg of weld (mm)
l = length of weld (mm)
τ = permissible shear stress for the weld (N/mm2)
Usually there are two welds of equal length on two sides of vertical plate. In that case
P = 2 (0.707 hlτ)
56
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or
P = 1.414 hlτ
CHAPTER -8
57
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SCOPE
Due to following advantages, our project is having a greater future scope:
ADVANTAGES:
1. Reduction in manufacturing time.
2. High accuracy.
3. Smooth operation.
4. Better transmission motion.
But it has also disadvantages;
DISADVANTAGES:
58
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1. Operation cost is more.
2. Maintenance cost is more.
CHAPTER -9
59
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DATE OF PERFORMANCE MEASUREMENT TIME

4/9/2009 20
11/9/2010 30
RESULTS AFTER IMPLEMENTATION
BEFORE
Table No: 07
60
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Fig No: 23
AFTER
DATE OF PERFORMANCE MEASUREMENT TIME
22/04/2010 15
23/04/2010 24
Table No: 08
Fig No: 24
61
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Improved OEE of Behringer Bandsaw after implementing Scale
Table No: 09
DATE 04/09/2009 22/04/2010 11/9/2010 23/04/2010
62
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BEFORE OEE 90.34 48.86
AFTER OEE 92.3 60.87
Table No: 10
BEFORE
DATE OF PERFORMANCE AVAILABILITY OF MATERIAL
11/9/2009 30
25/09/2009 20
Table No: 11
Fig No: 25
AFTER
DATE OF PERFORMANCE AVAILABILITY OF MATERIAL
22/04/2010 12
63
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23/04/2010 15
Table No: 12
Fig No: 26
Improved OEE of CNC GAS CUTTING M/C-SUAG
64
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65
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Table No: 13
Table No: 14
CONCLUSION
As defined in this paper, Total Productive Manufacturing (TPM) is a structured

equipment-centric continuous improvement process that strives to optimize production
effectiveness by identifying and eliminating equipment and production efficiency losses
throughout the production system life cycle through active teambased participation of
employees across all levels of the operational hierarchy. Although TPM is historically
equipment-focused, effective implementation offers a continuous improvement methodology
to increase overall manufacturing productivity. TPM methodology provides enterprises with
the tools required to explore, increase, document, and proliferate organizational
learning.improved machine performance is the result of improved behaviors from people
DATE 11/09/2009 22/04/2010 25/09/2009 23/04/2010
BEFORE OEE 84.1 78.3
AFTER OEE 91.3 83
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involved in the machine’s life cycle. Improved behavior comes from new learning.
Continuous improvement is born of continuous learning.” Research and case studies indicate
that TPM implementation can have significant positive impact on manufacturing
performance.
After the implementation of TPM, it can be seen that from above Results that O.E.E.
of the machines improved by 3% to 7%.
BIBLIOGRAPHY:
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COMPANY GUIDE:
Trivesh pooniwala.(Dy.Manager-
maintenance)P.E.D.pooni@godrej .com,
www.godrej.com
REFERENCES:
1. Ames, V. A. (1996). Implementing the Complete TPM Process. SEMATECH

TPM/OEE Case Study
2. Workshop, Tempe, AZ, SEMATECH. Ames, V. A. (2003). TPM Interview. T.
Pomorski. Austin, Tx.
3. Asaka, T. and K. Ozeki (1990). Handbook of Quality Tools, The Japanese Approach.
Cambridge, MA,Productivity Press.Bahrani, A. (1995).
4. TPM Management. SEMATECH TPM/OEE Case Study Workshop, Austin, TX,
SEMATECH. Bamber, C. J., J. M. Sharp, et al. (1999). “Factors Affecting Successful
Implementation of Total
5. Productive Maintenance: A UK Manufacturing Case Study Perspective.” Journal of
Quality in Maintenance Engineering 5(3): 162-181.
WEBSITE:
1. www.wekipedia.com
2. www.google.com
3. www.scribd.com
4. www.3brooks.com/tmp/2110.pdf
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Bharati Vidyapeeth College Of Engineering

IMPROVING OVERALL EFFICIENCY OF THE CUTTING MACHINES BY

BHARATI VIDYAPEETH’S COLLEGE OF ENGINEERING

SECTOR -7,CBD BELAPUR,NAVI MUMBAI-400614

Bharati Vidyapeeth’s College of Engineering

IMPROVING OVERALL EFFICIENCY OF THE CUTTING

DEPARTMENT OF MECHANICAL ENGINEERING

Bharati Vidyapeeth’s College of Engineering

This is to certify that the project titled

IMPROVING OVERALL EFFICIENCY OF THE CUTTING

B.E.(Mechanical engineering) class of Bharati Vidyapeeth’s

Prof L. R. Suryawanshi Prof R.K.Agrawal

(Internal Guide) (Project Co-ordinator)

Bharati Vidyapeeth’s College of Engineering

(Affiliated to the University of Mumbai)

DEPARTMENT OF MECHANICAL ENGINEERING

IMPROVING OVERALL EFFICIENCY OF THE CUTTING

Has been examined and approved as per the fulfillment of the

We express our sincere gratitude to our external guide Mr. T. A. Pooniwala

We would like expressing our indebtedness to our eminence to Respected principal,

Total Productive Maintenance (TPM) is a process that maximizes the productivity of

TPM is not simply a preventive maintenance program. Rather, it is a strategic

The TPM presentation focuses on a results oriented implementation methodology

Sr. No Particulars Pg. No.

04 Chapter 4: METHODOLOGY 26-29

05 Chapter 5: ANALYSIS 30-38

06 Chapter 6: SUGGESTION 39-42

07 Chapter 7: DESIGN 43-47

09 Chapter 9: RESULTS AFTER IMPLEMENTATION 50-54

FIGURE NO. NAME OF THE FIGURES PAGE NO.

FIGURE 1 Company Photo 02

TABLE NO 01 SPECIFICATION OF BEHRINGER 15

TABLE NO 09 Improved OEE of Behringer Bandsaw after 52

Fig.no-1: Company Photo

Godrej also made a significant contribution to self-reliance of the century by

VARIOUS PLANTS IN GODREJ

GODREJ & BOYCE MFG. CO LTD.:-

It is truly a mullet-faceted company. This is the major collaboration of Godrej with

 OFFICE EQUIPMENT (O.E.) DIVISION: -

➢ Plant 1: Steel processing plant

➢ Plant 4 & 14: Furniture systems plant

➢ Plant 13: Industrial storage system

➢ Plant 17: Security equipment

➢ LOCKS DIVISION: -Plant 18 A

➢ MACHINE TOOL DIVISION: -Plant 9 & 19

➢ TOOL ROOM DIVISION: -Plant 7

Fig.no-2: Heat Exchanger

The process equipment division consists of five main production

♦ Reactors & Vessels.

♦ Trays & tower internals.

Fig.no-4:-High Pressure Vessels

INTRODUCTION TO MACHINE SHOP DEPARTMENT

➢ CNC DRILLING MACHINES: -

➢ DRILLING MACHINES:- The Drilling machine is in tends fro drilling

♦ THREE JAW LATHE

➢ VERTICAL LATHE MACHINES:- This type of boring machine

♦ VTL1 SINGLE ARM (CNC)

♦ VTL5 DOUBLE ARM (CNC)

➢ HORIZONTAL BORING MACHINE:- In a Horizontal Boring machine,

➢ VERTICAL MILLING MACHINES:- A Milling machine is a machine

“IMPROVING OVERALL EFFICIENCY OF THE

Fig 5: MACHINE 1: BEHRINGER BANDSAW

MACHINE 2: CNC GAS CUTTING MACHINE – SUAG