Sundaram Brake Linings Limited

Plant :

Date :
For the date :
Daily Work Management Sheet

Cell Incharge
Cell Technician
Maintenance Engineer

Review Yesterdays
output
Collect data for the day

Quality Engineer

Caluculate Availability,
Performance & Quality
rates

KK Representative

Analyse each losses

Output Log

Countermeasure &
Preventive action

Plan counter measure &

preventive action

CELL :
SUB CELL :

Reason for Gap

OUTPUT PLANNED :
OUTPUT ACHIEVED :
GAP:
TOTAL AVAILABLE TIME
SHIFT 1

B
C
D
E
F
G
H
I
J
K
L

SHIFT 2

SHIFT 3

JH TIME
PLANNED DOWN TIME(WANT OF MATL,PM etc..)
PROCESS SCRAP(PROCESSING TIME IN MTS)
ACTUAL AVAILABLE TIME (A-B)
DOWNTIME(B/D, SETUP,ADJUSTMENT)
ACTUAL UPTIME (C-D)
EQUIPMENT AVAILABILITY IN %(E/C)X100)
QUANTITY PRODUCED
THEORITICAL CYCLE TIME IN MTS
PERFORMANCE RATE((HXG)/E X 100))
QUANTITY REJECTED
QUALITY RATE ((G-J)/G X 100))
OVERALL EQUIPMENT EFFECTIVENESS

AVAILABILITY =
TARGET = 95%
GAP=
LOSSES IN MTS
SET UP =
ADJUSTMENT =
BREAKDOWN =

PERFORMANCE =
TARGET = 90%
GAP =
LOSSES IN MTS
STARTUP DELAY =
MINOR STOPPAGE =
REDUCED SPEED =

QUALITY =
TARGET = 99%
GAP =
LOSSES
SCRAP IN NOS
PHENOMENA

Sundaram Brake Linings Ltd

Padi Plant

WHY WHY ANALYSIS SHEET

WW.C5:NO:
EQUIPMENT / MACHINE

Date
Time

Shift

1 2 3

Breakdown / Physical Phenomenon

What is your final action ?
( Part Replacement )
Describe Countermeasure:
In case of spare part replacement
( Adjustment )
In case of spare-part no replacement
Why did you take above action ?

Due to

Why 1

Why 2

Why 3

Why 4

Why 5
Root cause :
Root cause is one of the following 5 items.
(1)

Poor Basic Condition

(2)

Poor Operating Condition

(3)

Deterioration

(4)

Weak Design

(5)

Poor Skill

(Note: Please fill up this form in pencil immediately after machine is started)

Kaizen Idea and Schedule.

JH

PM

Design

E&T Skill

ABNORMALITIES REGISTER FOR CELL-5