International Journal of Emerging Technology and Advanced Engineering

Website: www.ijetae.com (ISSN 2250-2459, Volume 2, Issue 10, October 2012)

Improving Productivity of Jaw Crusher through OTIF

Delivery by Reducing Down Time
Shivam Choudaha1, Sunil Kumar Tiwari2, Sarang Pande3
1
PG Scholar, Department of Mechanical Engineering, JUET, Guna, M.P.
2
Lecturer, Department of Mechanical Engineering, JUIT, Waknaghat, H.P.
3
Astt. Professor, Department of Mechanical Engineering, JUET, Guna, M.P.

Abstract Crushers are machines used to break or This department provides flexible, cost economy and
compress using the metallic plates during mining of materials. timely services to the alumina plant, boiler and co-
The chronic problem of High Maintenance cost and extensive generation, fabrication plant, and reduction plant. The
downtime in Jaw crusher. major services are supply of water, painting jobs, metal
In this paper this problem is solved by implementing various
casting, machining and repairing jobs, motor repairing, raw
techniques like process mapping, why why analysis, Brain
storming and appropriate use of plan-do-check-act (PDCA) material unloading and bath crushing etc. to the entire
cycle. The developments achieved by these techniques led to plant. The smelter has a by-product as loose bath being
increase in customer satisfaction and productivity generated in lumps and these lumps / chunks are brought to
enhancement. bath crushing plant via dumpers from smelter plant. The
Keywords Just in Time (JIT), On Time In Full, Overall crushing plant has jaw crusher, which reduces size of bath
Equipment Effectiveness, POT, PDCA. from 5 to 1. The big size chunks above 5 are first
broken manually to smaller pieces up to 5 and then fed to
I. INTRODUCTION jaw crusher, around 250 MT of loose bath is crushed per
Crushers are commonly classified by the degree to day [1, 5, 6, 11].
which they fragment the starting material with primary and
secondary crushers handling coarse materials and tertiary
and quaternary crushers reducing ore particles to finer
gradations. A jaw or toggle crusher consists of a set of
vertical jaws, one jaw being fixed and the other being
moved back and forth relative to it by a
cam or pitman mechanism. The jaws are attached apart at
the top than at the bottom, forming a tapered chute so that
the material is crushed to smaller size as it travels
downward till it escapes from the opening at bottom. The
movement of the jaw can be quite small, since complete
crushing is not performed in one stroke. The inertia
required to crush the material is provided by a weighted
flywheel that moves a shaft creating an eccentric motion
that causes the closing of the gap. Jaw crusher functions
Figure 1: Jaw Crusher
and parts shown in figure 1. [5]

II. FUNCTIONS OF THE PLANT III. SPECIFICATIONS OF JAW CRUSHER

The increased demand of bath in the smelter led to
The utilities department provides a support function to
purchase and installation of an old jaw crusher from the
the entire plant and comprises of many departments such as
auto shop, foundry, carpentry and painting, refractory, nearby area / stone crushing factory.
transport, electrical repair, bath crushing plant etc.

403
 International Journal of Emerging Technology and Advanced Engineering
Website: www.ijetae.com (ISSN 2250-2459, Volume 2, Issue 10, October 2012)
Dismantling of crank shaft assembly from main
The equipment Specification is given below: crusher body.
Capacity = 8 TPH, RPM = 300, Input Size = 6, Output Shifting of crankshaft assembly to workshop (1 KM
Size = 1, Motor = 25 HP away from job site) for dismantling and refitting of
Since the installation of this equipment, chronic problem of pulley, fly wheel and bearings etc, as these was press
breakage of supporting bearing had been observed. The fitted. Hydraulic Press for removal and fittings.
detail of Breakdown is shown in the (Figure 2). Reshifting of crank shaft assembly to crusher area
The replacement of supporting bearing was very time (fitted with new bearing).
consuming process and involved a lot of resources Crank shaft assembly mounting on crusher, inspection
deployment, which used to take around 32 Hrs to restart the and trial and handing over to operation.
machine [9]. Data of Bearing Failure C. Tool and Techniques used for Problem Solving
39
The problem is solved using following steps:
37 Avg. B/D frequency is 14 days
& Repair Time is 32 Hrs. Why-Why Analysis: This tool was used to find out
B/D HOURS

35
the root cause of problem by asking question (Why).
33
TABLE I
31
36
35
29
34 34 WHY-WHY ANALYSIS FOR PROBLEM IDENTIFICATION
32 32 32 32 32 32 32
30 30
27 S.No PROBLEM REASON ACTION
25
19/6/11
5/6/11

5/7/11

1 Why crushed bath The jaw crusher Data collection

17/5/11
18/1/11

17/2/11

19/3/11

3/4/11

18/4/11

1/5/11
7/1/11

2/2/11

2/3/11

material not supplied availability is less. done as per

B/D DATE as per costumer (Figure 1)
Figure 2: Bar chart of bearing failure requirement

IV. ANALYSIS OF BREAKDOWN DATA 2 Why availability of Frequent failure of Analysis of

The data of last six month was analyzed and found that jaw crusher is less supporting bearing above data
the frequency of breakage of bearings is once in a fortnight 3 Why frequent Heavy jerk transfer Analysis of
and it was taking around 32 hrs to replace the bearing. As it failure of supporting to support bearing above data
has been mentioned earlier that 100% availability of the bearing during bath
crusher was need and demand of the smelter plant for crushing
continuous operation of aluminum production, hence team 4 Why Heavy jerk Hidden foreign Manual
members selected this project to be taken on priority to find during bath crushing material (Bolts, segregation
the solution. Nuts, Aluminum being done but
chips etc) present in 100%
A. Need to Reduce Down Time of Jaw Crusher the loose bath being removable was
Customer requirement was not fulfilled on time. The crushed not possible as
cost incurred for Spares i.e. bearings (Rs 49,540 / most of them
breakdown) was very high. Around 85% of the are not visible
maintenance cost incurred in the maintenance of crusher.
Dependency with other departments for arrangement of Brain Storming: Brainstorming is an excellent way of
truck, hydra and cranes for crankshaft dismantling and developing many creative alternate solutions to a
assembly, was a perennial problem and thus challenging. problem. It is designed to break out of thinking
Even after lot of valuable resources like energy and patterns into new way of looking at things.
manpower was being consumed in this process, our main Many ideas generated in Brainstorming session were
aim of customer satisfaction was not being fulfilled. simultaneously argued, analyzed and evaluated.
B. Problem Detail and Analysis Idea-1: - Belt magnetic separator shown in Fig 3 can be
When the Supporting Bearing fails following Major provided for segregation of foreign material to avoid
steps needed to be taken for bearing replacement. damage.

404
 International Journal of Emerging Technology and Advanced Engineering
Website: www.ijetae.com (ISSN 2250-2459, Volume 2, Issue 10, October 2012)
Analysis:-It could segregate only the ferrous material This process mapping as the existing activities were broken
however most of non-ferrous material could not be into three stages:
separated out. (A) Dismantling activity at Crusher Area
Action: - In our case 80% of foreign material is non ferrous (B) Activity at workshop
(Aluminum) so the idea did not seem to be feasible. This
(C) Final assembly at Crusher Area as detailed below [7,
idea was dropped and led to further discussion.
10, 12].
Idea-2: - Metal detector shown in Fig 4 to be provided for
segregation of ferrous as well as non-ferrous materials TABLE II

Analysis: - It will detect all foreign materials including PROCESS MAPPING FOR BEARING REPLACEMENT OF CRANK SHAFT
Aluminum chips, which will trip the belt to take out the S.no Job Description Before VA/
detected foreign material. It was impossible to find out in in hrs. NVA
which chunk of Bath the foreign material is present and
will delay the Crushing processing. A Activity at Crusher Area for Dismantling

Action: - This idea was also not found feasible. 1 Dismantling of crusher for taken out the Crank 2 NVA
Idea-3: - As the above 2 ideas could not work for Shaft Assembly
elimination of bearing failure problem it was decided to 2 Arrangement of Hydra and Truck for 4 NVA
minimize the repairing time for Bearing replacement. transportation to Workshop
Analysis: -Though this was a short term solution but was
3 Shifting of crankshaft assembly to workshop 2 NVA
the only way out at that time. By reducing the repairing (1 KM away from job site)
time at least the productivity would amplify.
B Activity at Workshop for Dismantling and
Action: - According a detailed process mapping was
Assembly
carried out for the existing procedure of bearing
replacement [10, 11, 12]. 1 Crankshaft assembly unloading by E.O.T. 1 NVA
crane

2 Dismantling of Fly wheel and pulley through 3 NVA

Press

3 Dismantling of Bearing 2 VA

4 Cleaning of bearing housing and crank shaft 2 VA

5 Straightness checking of crank shaft 2 VA

Figure 3: Idea-1 6 Replacement of Roller bearing 2 VA

7 Fitting of Pulley and Fly wheel by press 2 NVA

8 Arrangement of Hydra and Truck for 4 NVA

transportation to crusher area

9 Shifting of crankshaft assembly from 2 NVA

workshop to Jaw crusher for fitting

C Activity at Crusher Area for Assembly

Figure 4: Idea-2 1 Assembly of crank shaft 2 VA

Process Mapping: Methods used to identify potential 2 Assembly of Jaw crusher and trial 2 NVA
Improvement; the process mapping gives us various
Total 32
opportunities for improvement (NVA elimination).

405
 International Journal of Emerging Technology and Advanced Engineering
Website: www.ijetae.com (ISSN 2250-2459, Volume 2, Issue 10, October 2012)
Pie Chart: It represents relative proportion of different
attribute in visual form.
The outcome of this exercise was very fruitful.
Out of the total 32 hours of repairing time around 22 hours
was a Non Value Adding activity and 10 hrs were Value
Adding activity. The major contribution of NVA due to
Shifting of crankshaft assembly to workshop which was
taking 13 hrs (40% of total repair time).The dismantling
and assembly were taking 11 hrs.
(34% of total repair time) and bearing replacement was
taking 8 hrs. So we decided to reduce/ eliminate the
shifting activity, for this we again had a brainstorming
session to address this issue [10, 12].
(NVA)
69%
31% (VA)
Figure 5: Pie chart
Why- Why Analysis and brainstorming analysis gave us a
direction to look for different procedure for bearing
replacement. So following alternate was generated during
discussion and analyzed the same.
Alternate-1: - To install Hydraulic press and EOT Crane for
dismantling of the flywheel and pulley at job site
Analysis: -The cost of procurement and installation of
Hydraulic Press and EOT crane was very high and not
economical for single job
Action: -The alternate 1 was not feasible
Alternate-2: -As the roller Bearings are circular and can be
replaced only after removing the flywheel and pulley. So
an alternative of bearing was thought which could be
replaced without removal of flywheel and pulley.
Analysis: - As in crankshaft of engines the Bearing are in
two halves same can be used and replaced at site thereby
eliminating major NVA of dismantling and assembly of
crank shaft.
Action: -Then the team further built up on the idea with lot
of thought process among the members and arrived at
decision to use Bush/Babbited bearing in two halves.

The brainstorming session and why - Why analysis was

conducted to find out solution for eliminating the NVA and PDCA Cycle: This is a structured approach for
thereby reducing the MTTR as detailed below: effectively implementation of project.
TABLE III
PLAN
The improvement initiative was executed with the help of
WHY-WHY ANALYSIS FOR EVALUATION
PDCA cycle. The planning phase was divided in five parts:
S.No PROBLEM REASON ACTION (i) Dimension selection of bearing
1 Why Repair Complete crankshaft Review of data
(ii) Material selection of bearing
time (MTTR) is assembly with flywheel
very high? and pulley shifted to (iii) Material planning
central workshop for (iv)Arrangement for lubrication of Bearing
bearing replacement?
(v) Arrangement for Mono Rail and Chain block
2 Why Complete There is no facility for Review of data NEW DESIGNED TWO HALF
assembly dismantling of Press fitted BUSH BEARING
shifted to Flywheel, Pulley and
Central Bearing at job site
White metal
Workshop for bush bearing
bearing
replacement
3 Why Pulley and Flywheel is Brainstorming
C.I. Bearing
Dismantling of fitted at both side of done for housing

Flywheel and crankshaft. For bearing different

Pulley replacement first we need procedure of
required? to dismantled Pulley and bearing
Flywheel replacement at Figure 6: Bearing Design
job site.

406
 International Journal of Emerging Technology and Advanced Engineering
Website: www.ijetae.com (ISSN 2250-2459, Volume 2, Issue 10, October 2012)
Dimension selection of bearing
Developed a sketch (As shown in figure 6) of two halves
bearing as per diagram1 and consulted Design department
for further designing and drawing to suit the desired
application, which was finally approved with two halves
babbited bearing.
Material selection of bearing
The R&D Department suggested the appropriate material
composition to be used for outer body carbon steel casting
grade 230-450 W as per IS-1030 and for inner bush babbit
metal lead tin base bearing alloy Sn-75%, Sb-12%, Pb-9.3
10.7% (max) Cu-3%, Fe-0.08%(max) AS -0.15%(max)
Material Planning
On the approval from design department it was planned to
get casting done from our foundry shop as per approved
material composition and size.
Arrangement for lubrication of bearing:
Another major task was to provide continous lubrication to
bush bearing. We designed the tank drawing was made
which was to be provided at the location.
Arrangement of mono rail and chain block
For replacement of bearing the crankshaft had to be lifted.
It was planned for making arrangement of monorail and
chain block. The design department was consulted for the
size of chain block and location for installation of
monorail.
DO
After receiving of casting following actions were taken:
Casting and machining of bush bearing: Casting received
from Foundry Shop was sent to machine shop for final
machining as shown in fig 7 and 8.
Figure 7: Casting of Bush Bearing
Figure 8: Machining of Bush Bearing
407
Arrangement for lubrication of bearing: A BSP
tapped hole was provided in the housing for grease to pass
into the bearing. Two numbers of fabricated lubrication
tanks were fitted at either side of housing of crank shaft as
shown in Fig 9.
Installation of mono rail and chain block: A spare chain
block at our workshop which was lying idle due to
dismantling of a machine so we used the monorail and
installed at our shed (Shown in Fig 10)
Figure 9: Monorail Figure 10: Sprak Chain Block
Process of bearing replacement: Before modification
initially 2 numbers of roller bearing part number 22326
(Figure 11) was fitted on both sides of crank shaft and then
the fly wheel and pulley were used to be fited on both ends.
After implementation the bush bearing is being replaced by
lifting the crank shaft assembly with the help of chain
block at job site. Upper half top cover with 4 nos Bolts are
removed after crankshaft assembly is lifted up by chain
block provided and the lower half is also removed. Then
new lower bush bearing is placed at the location and crank
shaft assembly is lowered down with the help of chain
block and new top bush bearing is placed and finally top
cover being provided and all bolts are tighted. Finally
toggle plate, V belt, all other accessories, guard etc are
provided and trial is taken and handed over to operation.
Crank
Shaft
Figure 11: Bearing
CHECK
As the crusher was taken in operation with the new bush
bearings we had a regular check of the crusher Bush
Bearing and condition using LLF techniques. Still there
were some teething problems observed.
 International Journal of Emerging Technology and Advanced Engineering
Website: www.ijetae.com (ISSN 2250-2459, Volume 2, Issue 10, October 2012)
Firstly a rise in temperature was observed. The bearing 9 Shifting of crankshaft assembly 2 0 NVA
was dismantled and we found that the Lubrication was not from workshop to Jaw crusher
for fitting
appropriate on the sides. Hence an additional groove was
provided in the bearing. Lubrication tank was also modified C Activity at Crusher Area for assembly
and two points were provided at each bearing for proper 1 Assembly of crank shaft 2
Lubrication.
2 Assembly of Jaw crusher and 2
Secondly high vibration was observed in the 4th week. trial
On dismantling a scratch was observed on the crankshaft.
On discussion with R&D the material of bearing was
TOTAL 32 3
changed from lead base to tin base bearing alloy ASTM-
B-23 Alloy 2
After modification the activity S.No B (1, 2, 5, 7, 8 and
ACT
9) eliminated and B (3, 4 and 6) done at Job site in 2 hrs
To avoid any further damage on the crankshaft instead of 6 hrs.
developed check sheets and made a schedule was The analysis of Process mapping revealed that most of
developed. A Monthly Schedule was made for Preventive NVAs have been eliminated and VAs has also been
Maintenance, Supporting Bearing Replacement and reduced to 2.5 hrs from10.hrs. And now the replacement of
Vibration Analysis [2, 3, 4, 8, and 10]. Bush Bearing is being done at job site during Time Based
Preventive Maintenance [13].
V. PROCESS MAPPING
S.No Job Description Before After VA/ VI. RESULTS
in Hrs. in Hrs. NVA
Tangible Gains
A Activity at Crusher Area for dismantling S. no Description UOM Before After
1 Dismantling of crusher for taken 2 NVA
out the Crank Shaft Assembly Break Downs Per
1 No 02 NIL
Month
2 Arrangement of Hydra and 4 0 NVA
Truck for transportation to
Workshop Down Time ( Per
2 Hours 32 3.5
Break Down)
3 Shifting of crankshaft assembly 2 0 NVA
to workshop(1 KM away from
job site) 3 Manpower Cost Rs. 3840 420
B Activity at Workshop
1 Crankshaft assembly unloading 1 0 NVA Materials / Spares
4 Rs. 49,540/ 14,230/
by E.O.T. crane Cost
2 Dismantling of Fly wheel and 3 0 NVA
pulley through Press Operating cost of 00.00
5 Rs. 300
Press Machine
3 Dismantling of Bearing (now 2 1 (i) V
this activity done at Crusher A
area) 6 Transportation Cost Rs. 840 00.00
4 Cleaning of bearing housing and 2 VA Total Replacement
crank shaft (now this activity 7 Cost per Set Rs 54, 520/- 14, 650/-
done at Crusher area)
( 3+4+5+6)
5 Straightness checking of crank 2 0 VA
shaft Total Replacement 54520 X 2 14650 X 1
8 Rs.
6 Replacement of Roller bearing 2 VA Cost per Month = 1,09,040/- = 14,650/-
(now this activity done at
Crusher area) 9 Saving Per Month Rs. 109040 14650 = 94,390/-
7 Fitting of Pulley and Fly wheel 2 0 NVA 10 Saving Per Year Rs. 94390 X 12 = 11,32,680/-
by press
8 Arrangement of Hydra and 4 0 NVA
Truck for transportation to
crusher area

408
 International Journal of Emerging Technology and Advanced Engineering
Website: www.ijetae.com (ISSN 2250-2459, Volume 2, Issue 10, October 2012)
As it is evident from the above table that before Intangible Gains
modification, the Monthly breakdowns used to be 2 in No 1. Improved maintenance and project implementation
and Total Down Time was of 64 hrs per month, which has skill of team members
been reduced to zero and 3 hrs. Also this 3 hrs are not 2. Uninterrupted supply of bath to Smelter Plant
Breakdown Maintenance Hrs but it is being consumed for 3. High satisfaction of Customer
Time Based Preventive Maintenance. This has led to a 4. On Time In Full Delivery (OTIF)
recurring saving of Rs 11.32 Lac annually.
VII. CONCLUSION
The Customer requirement of Crushed Bath has been
fulfilled by increasing the availability by 17%, Eliminating
Breakdown, Reducing the MTTR by 89% and Maintenance
Cost by 86% of Jaw Crusher. The study is helpful for
gaining improvement in similar field as well as also in
others.

Figure 12: Maintenance cost ACKNOWLEDGEMENT

Mean Time To Repair The authors would like to acknowledge Mr. R. K. Gupta,
Manager (WCM, Hindalco Industries Ltd, Renukoot, UP,
40
India) for his support in providing the valuable information.
30 Reduced by 89%
Hours

20 32
10 REFERENCES
10 3.5
[1] Shrivastava, A. K., and Sharma, A. K. 2012, A Review on Study of
0
Before After target
Jaw Crusher, International Journal of Modern Engineering Research,
Vol. 2, Issue 3, pp 885-888.
[2] Moen, R., and Norman, C., 2009, Evolution of the PDCA cycle.
Figure 13: Mean time to repair API. Publications, pp. 59.
[3] Doulah, A.B.M.S.,. Islam M.I, and Farzana I., 2012, Improve The
Customer Satisfaction Index Quality Of Products In Woven Apparel Industries By Plan-Do-Check-
Act (PDCA) Cycle, Journal of Innovation & Development Strategy,
100 vol.6, Issue 1, pp 49-53.
Increased by 25%
90 [4] Castro A.D.J.D; Pinheiro A., and Ginoris Y.P., 2011, Application of
80 91.6 the PDCA problem-solving method in treatment of wastewater from
% poultry processing, An Interdisciplinary Journal of Applied Science,
85
70 pp 231-238.
60 68.3 [5] Jaw crusher<,http://en.wikipedia.org/wiki/Jaw_crusher#Jaw_crusher>
50 accessed on 5 august, 2011
Jul'10 Jan'11 Jul'11 [6] Bheda R, Narag A.S., and Singla M.L., 2003, Apparel manufacturing
a strategy for productivity improvement, Journal of Fashion
Marketing and Management, Vol. 7, No. 1, pp 12-22.
Figure 14: Customer satisfaction Index [7] Bisen, V., and Srivastava S., 2009, Production and Operation
Management, Lucknow, India Global Media, p. 175.
Production [8] Carr H., 1988, Technology of Clothing Manufacture, Blackwell
Science Inc, ISBN 978-06320.
5800 [9] Charles H.D., 1981, Point load deformation relationships and design
5600 of jaw crusher plates Department of Civil Engineering. Northwestern
MT/Month

Increased by 13% 5678

5400 University. Evanston., IL (U.S.A.)
5200
5000 [10] Corwin J., Puckett R. 2009, Japans manufacturing competitiveness
4800 4960 strategy: challenges for Japan, opportunities for the United States,
4600 US Department of Commerce, International Trade Administration.

Before After [11] Country profiler, 2011, Country Report, Malta, global edition.
[12] Danneels E., 2008, Organizational antecedents of second order
competencies, Strategic Management Journal, Vol. 29, pp 519543 .
Figure 15: Production
409
 International Journal of Emerging Technology and Advanced Engineering
Website: www.ijetae.com (ISSN 2250-2459, Volume 2, Issue 10, October 2012)
[13] Muchiri P., and Pintelon L., 2008, Performance measurement using
overall equipment effectiveness (OEE): Literature review and
practical application discussion, International Journal of Production
Research, Vol. 46, No.13, pp. 3517-3535.

410