Chapter 5 OPERATIONAL & MAINTENANCE SKILL DEVELOPMENT

Transcription

1 Chapter 5 OPERATIONAL & MAINTENANCE SKILL DEVELOPMENT 5.1 INTRODUCTION Training and development is vital for every organization to cope up with the technological changes from time to time and to perform well. This helps in honing skills, developing versatility and adaptability. Having a well designed approach towards this is very important for every organization. Shirose et al. [2002] designed a detailed education and training system describing its various levels as presented in table 5.1. Table 5.1 Education and training System [Shirose et al. 2002] Levels On the job training Off the job training Introduction Developing basic capability Developing professional capability Developing management capability Developing advanced management capability Education on the job (sectional education) Education on the job (sectional education) Education on the job (sectional education) Education on the job (sectional education) Education on the job (sectional education) Guide to equipment maintenance (1) Workshop exercise training Quality control education (guide) Guide to equipment maintenance (2) Workshop exercise training How to view drawings (2) Quality control education (initial level) Maintenance class (beginner's level) Industrial engineering education (1) Numerical control education Quality control education (medium level) Maintenance class (Medium level) Industrial engineering education (2) Quality control education (higher level) Maintenance class (Medium level) Quality control circle leader education (higher level) The development of operational and maintenance skills of workmen is described in the following sections. 97

2 5.2 STEP 6: FORMULATION OF TRAINING POLICY AND CURRICULUM Skill mapping exercise as presented in previous chapter the average skill deficiencies in all skill attribute for workmen were worked out (presented in table 4.14 and figure 4.20). These skill deficiencies were adversely affecting the overall performance of the manufacturing system (table 4.1 and 4.2). To bridge the skill gaps of the workmen the following curriculum was developed - (A) Off the job training Training attributes common to all the H4 halogen bulb processing operators 1. Total productive maintenance 2. Autonomous maintenance 3. Quality maintenance. 4. Statistical quality control 5. Statistical process control 6. Q.C. tools 7. Connections of hydraulic and pneumatic pipes 8. Color coding of supply lines 9. Color coding of electrical connections 10. Methods of setting and taking reading with common gauges 11. Dealing with emergency 12. Safe operating conditions 13. 5S Training attributes common to all the ball bearing processing operators 1. Total productive maintenance 2. Autonomous maintenance 3. Quality maintenance 4. Specifications of grinding wheel 5. Classifications of grinding wheel 6. Selection of grinding wheel 7. Glazing and loading of grinding wheel 8. Dressing of grinding wheel 9. Connections of hydraulic and pneumatic pipes 10. Color coding of supply lines 98

3 11. Color coding of electrical connections 12. Methods of setting and taking reading with common gauges 13. Dealing with emergency 14. Safe operating conditions 15. 5S 16. Statistical quality control 17. Statistical process control 18. Q.C. tools (B) On the job training On the job training is imparted to improve following skills related to their respective processes - H4 bulb forming process 1. Method of setting L.P.G., Oxygen and Air pressure with the help of regulator. 2. Method of setting correct gas flame by flow meter. 3. Procedure of setting body tube length as per drawing and measurement. 4. Ways of checking form hole and length of the forming. 5. Methods of inspection of diameter of form hole for centering and ovality and corrective actions for defects. 6. Procedure to conduct visual inspection of form shell for roundness and clarity and corrective actions for defects. 7. Tips on how to check condition of O' ring and forming wheel and corrective actions, if warned out. 8. Identification of the condition of bearing jammed / cracked. 9. Detecting the effect of variation in glass tube material. 10. Indications of the condition of direct working of regulator which results in increased gas pressure and correction. 11. Measure to be taken for safe working conditions. H4 bulb jointing process 1. Method of setting L.P.G., Oxygen and Air pressure with the help of regulator. 2. Method of setting gas flame by flow meter. 3. Method of setting correct exhaust tube blow air stream pressure. 4. Procedure of loading exhaust tube and form tube on machine correctly. 99

4 5. Ways of checking and setting dimensions of jointing as per drawing. 6. Method of inspection for straightness, leakage at joint, minimum hole diameter and ring cut of jointing and corrective measures for non conformity. 7. Techniques of checking jointing for soundness of joint, no white particles on jointing and no blow hole at joint and corrective actions for defects. 8. Methods of cleaning of machine and burners, lubrication & checking PVC pipe condition. 9. Detection of the abnormal working of machine. 10. Identification of the condition of the bearing jammed / cracked. 11. Detecting the effect of variation in glass tube material 12. Measures to be taken for safe working. H4 bulb sealing process 1. Method of setting L.P.G., Oxygen, Hydrogen and Air pressure with the help of regulator. 2. Method of setting burner flame by flow meter. 3. Ways of checking pinch shape and corrective measures by setting punch pressure / position and burner flame. 4. Method of checking filament mount for correct direction, no shift and no tilt and corrective actions. 5. Procedure to check sealing stress, no bursting and no crack. 6. Method of setting correct vacuum level and detecting gas leakage and corrective actions. 7. Methods of cleaning of machine and burners, lubrication & checking PVC / metal pipe condition. 8. Detection of the abnormal working of machine. 9. Ways of identifying condition of the bearing jammed / cracked & checking up/ down movement of head and use of rustolene oil, if jammed. 10. Detection of the effect of variation in glass tube material. 11. Measures to be taken for safe working. H4 bulb exhausting process 1. Method of setting L.P.G., Oxygen, Hydrogen and Air pressure with the help of regulator. 2. Method of setting Nitrogen flow and Halogen gas mixture flow. 100

5 3. Method of setting burner flame by flow meter. 4. Method of loading of sealing on machine. 5. Ways to check capsule shape & tip size and take corrective measures by setting cutting burner flame. 6. Method of setting proper vacuum in machine & detecting gas leakage and taking corrective actions. 7. Method of cleaning machine & burners, lubricating the moving parts & checking PVC / metal pipe conditions. 8. Detection of the abnormal working of machine. 9. Method of identifying condition of the bearing jammed / cracked & checking up / down movement of head and use of rustolene oil, if jammed. 10. Procedure of setting correct motions of mechanical links of the machine. 11. Measures to be taken for safe working. Ball bearing face grinding process 1. Reading & understanding specifications of grinding wheel. 2. Procedure of installing and setting of grinding wheel. 3. Method of setting correct direction of wheel rotation. 4. Procedure to check dresser diamond condition. 5. Procedure of dressing of grinding wheel. 6. Method to prepare grinding machine for operation. 7. Method of checking plate condition and setting. 8. Checking hydraulic, pneumatic, mechanical links and electrical connections of machine. 9. Method of setting and reading gauge for checking width size, width variation, flatness, buckle, track circle out and squareness. 10. Method of visual inspection of work piece for black face, eccentric O.D., punch mark and chatter on face, after face grinding. 11. Identifying loading (exhausting) of grinding wheel. 12. Identifying exhausting of feed mechanism rings and procedure of changing it. 13. Method of oiling and greasing of machine. 14. Method of setting drop lubrication and oil/grease level. 15. Detecting abnormal sound / working of machine and remedy 16. Measures for safe working. 101

6 17. Emergency and breakdown management. Ball bearing outer diameter grinding process 1. Reading and understanding specifications of grinding wheel. 2. Method of installing and setting of grinding and regulating wheel. 3. Ways of checking dresser diamond condition. 4. Procedure of dressing of grinding / regulating wheel. 5. Preparing grinding machine for operation. 6. Method of checking plate condition and setting (Bottom/Top) as per job sizes. 7. How to check hydraulic, pneumatic, mechanical links and electrical connections of machine. 8. Hydraulic and pneumatic connections (color coding of supply lines) and mechanical links of machine and correct hydraulic oil level / air pressure. 9. Method of setting and reading gauges for checking outer diameter (O.D.) size, surface taper, O.D. out of round, Jump and talyrond. 10. Method of visual inspection of work piece for black O.D., chatter on surface and surface finish. 11. Identifying loading (exhausting) of grinding wheel. 12. Method of setting automatic feed rods of centreless grinding machine. 13. Procedure of oiling and greasing of machine. 14. Procedure of setting drop lubrication and oil/grease level. 15. Detection of abnormal sound / working of machine and its remedy 16. Measures for safe working. 17. Emergency and breakdown management. Ball bearing IR / OR grinding lines 1. Method of mounting and setting of grinding wheel, dresser setting & dressing of grinding wheel and preparing machine for operation. 2. Procedure of loading and unloading of work piece on machine center and checking conveyor, sensor guided slide and push rod for correct working. 3. Hydraulic and pneumatic connections (color coding of supply lines) and mechanical links of the machine. 4. Method of setting and reading gauges for checking track size, out of round, wobble, TC out and curvature of track (for track grinding and honing of IR & 102

7 OR) and knowledge of setting in process gauge for Track size (for track grinding and honing of IR & OR). 5. Procedure for setting and reading gauges for checking bore size, out of round & taper and setting in process gauge for bore size. 6. Interpretation of the results of the test performed in standard room about roughness / telyrond / profile of track curvature / taper. 7. Corrective actions on the basis of the results of the standard room test. 8. Detection of exhausting of grinding wheel and abnormal sound / working of machine. 9. Method of oiling and greasing of machine. 10. Procedure of lubrication of machine during operation. 11. Steps to be taken immediately after machine breakdown. 12. Measures to be adopted for safe working. (C) One point lessons (OPL) As discussed in chapter 2, one point lesson (OPL) is one of the most effective methods of educating people focused on a single aspect of operating parameters and methods of operating the equipment. This is a learning method frequently used by workmen during daily work and daily meetings, lunch breaks etc. Each employee come up with the ideas, discuss to make the issue more precise before preparation of OPL. The OPL are prepared including visual images for better understanding of the lesson. Numbers of one point lessons (74 nos.) were prepared to give learning to the workmen of various training requirements related to their tasks. Few typical one point lessons are presented here for illustration. Illustrative one point lesson no. 1 is presented for the H4 forming process which is prepared for training of skill attribute D required for the process. During study of the process it was observed that the operators of forming process are expected to inspect the size of the forming using GO and NOGO gauges prepared according to the designed size. On skill mapping of the workmen the skill deficiencies were identified related to skill attribute D. Illustrative one point lesson no.2 is presented for the H4 jointing process which is prepared for training of skill F required for the process. During study of the process it was observed that the operators of jointing process are expected to visually 103

8 inspect the jointing for blow (glass) hole and crack at the joint of formed shell and exhaust tube. On skill mapping of the workmen the skill deficiencies were identified related to skill attribute F. Illustrative one point lesson no.3 is presented for the IR/OR track grinding process which is prepared for training of skill A required for the process. During study of the process it was observed that the operators of IR/OR grinding process are expected to know the correct shape of the grinding wheel before it is mounted on the spindle. On skill mapping of the workmen the skill deficiencies were identified related to skill attribute A. Illustrative one point lesson no.4 is presented for the IR/OR track grinding process which is prepared for training of skill A. During study of the process it was observed that the operators of IR/OR track grinding process are expected to correctly shape the honing stone before it is mounted on the machine. On skill mapping of the workmen the skill deficiencies were identified related to skill attribute A. The respective operating executives and Setters (skilled operators) perform the job of trainers, since, they are well qualified and knowledgeable about modern manufacturing process and equipments and have vast exposure to the shop floor practices. The setters of respective machines provide assistance during on the job training. Lesson plans and preparation of teaching materials Excellent teaching methods were used, as discussed in previous pages to implement education and training effectively. The self-enlightening training methods were used and lesson plans were prepared in association with respective trainers for each process / subject suitable for education and training. HRD division of concerned companies helped in preparation of OPL and photograph for training. Preparation of classrooms Training activity was conducted on a one-on-one basis. A class size of persons was organized. A room with a good environment, accommodating exercise materials and slide display equipments, was used as class room. Company training center was also well equipped with LCD projector, OHP and ergonomically design seating arrangement necessary for effective training. 104

9 5.3 STEP 7: EXECUTION OF OPERATIONAL AND MAINTENANCE SKILL DEVELOPMENT As discussed above, education and training was carried out with emphasis on both theoretical (off the Job) and practical (on the Job) exercises. Due emphasis was given on the following considerations during education and training activity - Education and training activity was directly linked with actual work to effectively implement the "bodily learning". For each training unit, one-point lessons suitable for the actual workshop were prepared, containing problems and improvement cases and used in education and training, thus better results were achieved. The duration of off the job training classes on each topic was 45 minutes and for on the job training it was 30 minutes. Training resource persons Off the job training On the job training External faculty / experts One point lessons Shift engineer Shift supervisor Setter Fig 5.1 Education and training resource persons 105

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14 5.4 STEP 8: RE-SKILL MAPPING AND MEASUREMENT FOR PERFORMANCE MEASUREMENT METRICS The operational and maintenance skill development program was continued for eight weeks. It was a rigorous exercise and supported whole heartedly by the management and HRD in formulation of training policy and outsourcing general part of the curriculum. It was also fully supported by engineers, supervisors and setters of the companies to give valuable inputs for preparation of training curriculum and executing it especially on the job. The workmen found it interesting and viewed it as a key exercise in development of their skills. They were curious, supportive and interactive all the way. To assess the effectiveness of the exercise the performance measurement were taken. The measurement taken were twofold i.e. operator skill levels and capability indices Cp and Cpk were measured before training (presented in chapter 4) and after completion of the training exercise whereas other performance measurement metrics like Mean time between failures (MTBF), Mean time to repair (MTTR), Availability rate, Performance rate, Quality rate, Overall equipment effectiveness (OEE), Overall line effectiveness (OLE), Kaizen, Safety, health & environment events were measured weekly. The weekly measurement were taken as 0 week (on the week the performance was measured first time before start of the training program), -1week (measurement for previous week of 0 week), 1 week (measurement after completion of one week training), 2 week (measurement after completion of two week training) and continued till 8 weeks completed. Their cumulative effect is presented in chapter 6 (results and discussion). The re-skill mapping is presented in tables 5.2 (a-g) and spider charts prepared after training are presented in figure (typical one spider chart is presented for each process) in which blue line represents the desired skill levels, red line represents skill level before training and the green line represents skill level after education and training exercise. It is clear from the spider charts that skill levels of the workmen have improved after training exercise. 110

15 Skill attributes Desired skill level Table 5.2 (a) Skill levels after training (H4 bulb forming process) Skill gaps for operators FM01 FM02 A 3 O.K. O.K. B 3 O.K. O.K. C 3 O.K. O.K. D 3 O.K. 3-2 E O.K. F 3 O.K. O.K. G 3 O.K. 3-2 H I 3 O.K. O.K. J 3 O.K. O.K. Operational / Maintenance skill attributes A B C D E F G H I J Ability to set correct L.P.G., Oxygen and Air pressure with the help of regulator. Ability to set gas flame by flow meter. Ability to measure and set up of body tube length as per drawing. Knowledge about loading body tube on machine. Ability to check form hole size and formed shell length through GO and NO-GO gauges. Ability to check diameter for center and ovality. Ability of visual inspection for form shell roundness and clarity. Ability to check 'O' ring, form wheel and cutter condition. Ability to detect condition of the bearing jammed / cracked. Ability to detect the effect of variation in glass tube material. Ability to identifying the condition of regulator direct (increased gas pressure) and correct it. Knowledge about measures to be taken for safe working. 111

16 Skill attributes Desired skill level Table 5.2 (b) Skill levels after training (H4 bulb jointing process) Skill gaps for operators JT01 JT02 JT03 JT04 JT05 JT06 JT07 JT08 A 3 O.K. O.K. O.K. O.K O.K. O.K. B 3 O.K. O.K. 3-2 O.K O.K. O.K. C 3 O.K O.K O.K. O.K. D 3 O.K O.K O.K. O.K. E O.K. O.K. O.K O.K. 3-2 F 3 O.K. O.K. O.K. O.K O.K. O.K. G O.K. O.K O.K. O.K. H 3 O.K. O.K. O.K I O.K O.K. 3-2 J 3 O.K. O.K. O.K. O.K. O.K. 3-2 O.K. O.K. A B C D E F G H I J Operational / Maintenance skill attributes Ability to set correct L.P.G., Oxygen and Air pressure with the help of regulator. Ability to set gas flame by flow meter. Ability to set correctly exhaust tube blow air stream pressure. Knowledge about loading exhaust tube and formed tube on machine correctly. Ability to check and set dimensions of jointing as per drawing. Ability to check straightness of jointing, leakage at joint, minimum jointing hole and ring cut of jointing. Ability to check jointing for sound solidity, no white particles on jointing and no glass bubble at joint. Ability to clean machine & burners, lubricate the moving parts & check PVC pipe condition and identify the abnormal working of machine. Ability to detect the condition of the bearing jammed / cracked. Ability to understand the effect of variation in glass tube material. Knowledge about measures to be taken for safe working. 112

17 Skill attributes Desired skill level Table 5.2 (c) Skill levels after training (H4 sealing process) Skill gaps for operators SL01 SL02 SL03 SL04 SL05 SL06 SL07 SL08 A 3 O.K. O.K. O.K. O.K. O.K. O.K. O.K. O.K. B 3 O.K. O.K. O.K. O.K. O.K. O.K. O.K. O.K. C 3 O.K. O.K. O.K. O.K. 3-2 O.K D 3 O.K O.K. 3-2 O.K E 3 O.K. O.K. 3-2 O.K. 3-2 O.K F 3 O.K. O.K. O.K. O.K. O.K. O.K. O.K. 3-2 G 3 O.K. 3-2 O.K O.K. O.K. 3-2 H 3 O.K. O.K O.K. O.K. O.K. O.K. I O.K. O.K. 3-2 J 3 O.K. 3-2 O.K. O.K. 3-2 O.K. O.K. O.K. Operational / Maintenance skill attributes A B C D E F G H I J Ability to set correct L.P.G., Oxygen, Hydrogen and Air pressure with the help of regulator. Ability to set burner flame by flow meter. Knowledge about loading of Jointing and mount on machine. Ability to check pinch shape and take corrective measures by setting punch pressure / position and burner flame. Ability to check mount for correct direction, no shift and tilt. Ability to check for sealing stress, no bursting and no crack. Ability to check proper vacuum in machine and gas leakage, if any. Ability to clean machine & burners, lubricate the moving parts & check PVC pipe condition and identify the abnormal working of machine. Ability to detect condition of the bearing jammed / cracked. Ability to check head up / down movement and use of rustolene oil, if jammed. Ability to understand the effect of variation in glass tube material. Knowledge about measures to be taken for safe working. 113

18 Skill attributes Desired skill level Table 5.2 (d) Skill levels after training (H4 exhausting process) Skill gaps for operators EH01 EH02 EH03 EH04 EH05 EH06 EH07 EH08 EH09 EH10 EH11 EH12 A 3 O.K. O.K. O.K. O.K. O.K. O.K. O.K O.K. 3-2 B 3 O.K. O.K. O.K. O.K. O.K. O.K. O.K. 3-2 O.K. 3-2 O.K. 3-2 C 3 O.K O.K. 3-2 O.K. O.K. O.K. 3-2 O.K. O.K. O.K. D 3 O.K. O.K. O.K. 3-2 O.K. O.K. 3-2 O.K E O.K. O.K. 3-2 O.K. O.K O.K F 3 O.K O.K. O.K. O.K. O.K. 3-2 O.K. O.K. O.K. 3-2 G 3 O.K O.K. O.K O.K O.K. 3-2 H O.K O.K. O.K. O.K. O.K. 3-2 O.K. O.K I 3 O.K O.K. O.K J 3 O.K. O.K. 3-2 O.K. O.K. O.K. O.K. O.K. O.K. O.K. O.K. O.K. Operational / Maintenance skill attributes A Ability to set correct L.P.G., Oxygen, Hydrogen and Air pressure with the help of regulator. Ability to set Nitrogen flow and Halogen gas mixture flow. B Ability to set burner flame by flow meter. C Knowledge about loading of sealing on machine. D Ability to check capsule shape & tip size and take corrective measures by setting cutting burner flame. E Ability to check sealing for leakage and black glass. Ability to check capsule for no bursting and no crack. F Ability to check proper vacuum in machine & gas leakage and take corrective actions. G Ability to clean machine & burners, lubricate the moving parts & check PVC pipe condition and identify the abnormal working of machine. H Condition of the bearing jammed / cracked. Head up and down and use of rustolene oil if jammed. I Ability to set motion of mechanical links of machine. J Knowledge about measures to be taken for safe working. 114

19 Skill Attributes Desired skill level Table 5.2 (e) Skill levels after training (ball bearing face grinding process) Skill gaps for operators FG01 FG02 FG03 FG04 FG05 FG06 FG07 FG08 FG09 FG10 FG11 FG12 A 3 O.K. O.K. 3-1 O.K. O.K. 3-2 O.K. O.K. O.K. O.K. O.K. O.K. B 3 O.K. O.K. 3-2 O.K. O.K. 3-2 O.K. O.K. O.K. 3-2 O.K. O.K. C 3 O.K. O.K. 3-1 O.K. O.K. O.K. 3-2 O.K. O.K. 3-2 O.K. 3-2 D 3 O.K. O.K. 3-2 O.K. O.K. O.K. O.K. O.K. O.K O.K. E 3 O.K. O.K. 3-2 O.K. O.K O.K. O.K. O.K. O.K. O.K. F 3 O.K. O.K. 3-2 O.K. O.K. 3-2 O.K. O.K. O.K O.K. G 3 O.K. O.K. 3-2 O.K. O.K. 3-2 O.K. O.K. O.K. 3-2 O.K 3-2 H 3 O.K. O.K. 3-1 O.K. O.K. O.K. 3-2 O.K. O.K O.K. I 3 O.K. O.K. 3-1 O.K. O.K. 3-2 O.K. O.K. O.K. 3-2 O.K. O.K. J 3 O.K. O.K. 3-2 O.K. O.K O.K. O.K. 3-2 O.K. O.K. A B C D E F G H I J Operational / Maintenance skill attribute Knowledge about installing and setting of grinding wheel and direction of wheel rotation and specification of wheel. Knowledge about dressing and preparing grinding wheels (machine) for operation and checking diamond condition. Knowledge about plate setting & plate condition. Knowledge about hydraulic and pneumatic connections (color coding of supply lines) and mechanical links of the machine. Knowledge about setting and reading gauge for checking Width size, width variation, flatness, buckle, T.C. out and squareness. Knowledge about visual inspection of work piece for black face, eccentric O.D., punch mark and chatter on face, after face grinding. Awareness about exhausting of grinding wheel and feed mechanism rings and abnormal sound / working of the machine. Knowledge about cleaning work place and cleaning, oiling and greasing of machine and drop lubrication and oil/grease level. Knowledge about steps to be taken immediately after machine breakdown. Knowledge about measures to be adopted for safe working. 115

20 Skill attribute Desired skill level Table 5.2 (f) Skill levels after training (ball bearing OD grinding process) Skill gaps for operators OD01 OD02 OD03 OD04 OD05 OD06 OD07 OD08 OD09 OD10 OD11 OD12 A O.K. O.K. O.K. O.K. 3-2 O.K. O.K. O.K. O.K. B O.K. O.K. O.K. O.K. O.K. O.K. O.K. O.K. 3-2 C O.K. O.K. O.K. O.K. O.K. O.K O.K. O.K. O.K. D O.K. O.K. O.K O.K. O.K. O.K. 3-2 E 3 O.K O.K. 3-2 O.K. O.K. 3-2 O.K. O.K. O.K. O.K. F O.K. O.K. O.K. O.K. O.K. O.K. O.K. O.K. O.K. G O.K O.K O.K. 3-2 O.K. H O.K. O.K. 3-2 O.K. O.K. O.K. O.K. O.K. O.K. O.K. I 3 O.K. O.K. 3-1 O.K. O.K. O.K. O.K. O.K. O.K. O.K. O.K. O.K. J 3 O.K O.K. O.K. O.K. O.K. O.K. O.K. O.K. O.K. O.K. Contd A B C D E F G H I J Operational / Maintenance skill attribute Knowledge about installing and setting of grinding as well as regulating wheel and specification of grinding wheel. Knowledge about dressing of grinding / regulating wheel and preparing (setting) machine for operation. Knowledge about plate setting (Bottom & Top) for different job sizes and plate condition. Knowledge about hydraulic and pneumatic connections (color coding of supply) and mechanical links of the machine and hydraulic oil level / air pressure etc. Knowledge about setting and reading gauges for checking O.D. size, taper, O.D. out of round, Jump and talyrond. Knowledge about visual inspection of work piece for black O.D., chatter, surface finish etc. Awareness about exhausting of grinding / regulating wheel and abnormal sound / working of the machine. Knowledge about cleaning work place and cleaning, oiling and greasing of machine and drop lubrication and oil/grease level. Knowledge about steps to be taken immediately after machine breakdown Knowledge about measures to be adopted for safe working. 116

21 Skill attributes Desired skill level Contd. Table 5.2 (f) Skill levels after training (ball bearing OD grinding process) Skill gaps for operators OD13 OD14 OD15 OD16 OD17 OD18 OD19 OD20 OD21 OD22 OD23 OD24 A O.K O.K. O.K. 3-2 O.K. 3-2 O.K. 3-1 O.K B O.K. O.K. O.K. 3-2 O.K. O.K O.K. O.K. 3-2 C O.K. O.K O.K. O.K. O.K. 3-2 O.K D O.K. O.K. 3-2 O.K. 3-2 O.K. 3-2 O.K E O.K O.K. O.K. O.K. 3-1 O.K F O.K. O.K. O.K. 3-2 O.K. O.K. O.K. 3-1 O.K G O.K. O.K O.K O.K. O.K. 3-2 H O.K. O.K. O.K. O.K. O.K. O.K. O.K. 3-2 O.K I O.K. O.K. 3-2 O.K. O.K. 3-2 O.K. 3-2 O.K J O.K. 3-2 O.K. 3-2 O.K O.K. O.K

22 Skill attributes Desired skill level Table 5.2 (g) Skill levels after training (ball bearing IR/OR grinding lines) Skill gaps for operators GL01 GL02 GL03 GL04 GL05 GL06 GL07 GL08 GL09 GL10 GL11 GL12 A 3 O.K. O.K. 3-2 O.K. O.K. O.K. O.K. O.K. 3-2 O.K. O.K. O.K. B 3 O.K O.K. O.K. O.K. O.K. O.K. O.K. O.K. O.K. O.K. C 3 O.K O.K. O.K. 3-2 O.K. O.K. O.K. O.K. O.K. O.K. D 3 O.K O.K. O.K. O.K. O.K. O.K. O.K. O.K. O.K. O.K. E 3 O.K. O.K. 3-2 O.K. O.K. O.K. O.K. O.K. O.K. O.K. O.K. 3-2 F O.K O.K. O.K O.K. 3-2 G 3 O.K. O.K. 3-2 O.K. O.K. O.K. O.K. O.K. O.K. O.K. O.K. O.K. H O.K. O.K. 3-2 O.K. O.K. 3-2 O.K. O.K. O.K. I 3 O.K. O.K. 3-2 O.K. O.K. O.K. O.K. O.K. O.K. O.K. O.K. O.K. J 3 O.K. O.K. 3-2 O.K. O.K. O.K. O.K. O.K. O.K. O.K. O.K. O.K. A B C D E F G H I J Operational / Maintenance skill attributes Knowledge about mounting and setting of grinding wheel, diamond condition and dresser setting & dressing of grinding wheel and preparing the machine for operation. Knowledge about loading and unloading of work piece on machine center and working of conveyor (working of sensor guided slide / push rod / equipments etc.)and knowledge about hydraulic and pneumatic connections ( color coding of supply lines ) and mechanical links of the machine. Knowledge about setting and reading gauges for checking Track size, out of round, wobble, TC out and curvature of track (for track grinding and honing of IR & OR) and knowledge of setting in process gauge for track size (track grinding of IR & OR). Knowledge about setting and reading gauges for checking Bore size, Out of round and taper and knowledge of setting in process gauge for bore size. Ability to Interpret the results of the test performed in standard room about roughness / telyrond / profile of track curvature / Taper. Ability to take corrective actions, if needed. Awareness about exhausting of grinding wheel and abnormal sound / working of the machine. Knowledge about cleaning work place and cleaning, oiling and greasing of machine and drop lubrication of m/c during operation. Knowledge about steps to be taken immediately after machine breakdown. Knowledge about measures to be adopted for safe working. Contd 118

23 Skill attributes Desired skill level Contd. Table 5.2 (g) Skill levels after training (ball bearing IR/OR grinding lines) Skill gaps for operators GL13 GL14 GL15 GL16 GL17 GL18 GL19 GL20 A 3 O.K. 3-2 O.K. O.K. O.K. O.K. O.K. O.K. B 3 O.K. 3-2 O.K. O.K. O.K. O.K. O.K. O.K. C 3 O.K. O.K. O.K. O.K. O.K. O.K. O.K. O.K. D 3 O.K. O.K. O.K. O.K. 3-2 O.K. O.K. O.K. E 3 O.K. O.K. O.K. O.K. O.K. 3-2 O.K. O.K. F 3 O.K. O.K. O.K. O.K. O.K. 3-2 O.K. O.K. G 3 O.K. O.K. O.K. O.K. O.K. O.K. O.K. O.K. H 3 O.K. 3-2 O.K. O.K. O.K. O.K. O.K. O.K. I O.K. O.K. O.K. O.K. O.K. O.K. 3-2 J 3 O.K. O.K. O.K. O.K. O.K. O.K. O.K. O.K. 119

24 120

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27 123

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30 126

31 5.5 COMPARISON OF SKILL LEVELS BEFORE AND AFTER TRAINING The comparison between skill gaps before and after training for the workmen is presented in table 5.3 and figure 5.9 which show a significant improvement in the skills of the workmen. The observations for calculation of capability indices Cp and Cpk after training are presented in tables 5.4 (a-h) for various processes under study and corresponding X-bar chart, R-chart and histogram are presented in figures 5.10 (a-c) to 5.17 (a-c). The calculated values of capability indices Cp and Cpk are presented in the tables 5.5 to The measurements for performance measurement metrics MTBF, MTTR, availability rate, performance rate, quality rate, OEE, Kaizen and SHE issues are presented in tables 5.13, 5.14, 5.15, 5.18, 5.19, 5.20, 5.21 and 5.22 respectively. The actual production v/s target production and rejection v/s actual production is presented in tables 5.16 and 5.17 respectively. Table 5.3 Comparison of skill levels before and after training Processes Average skill deficiencies in all the skill attributes for a workman (before training) Average skill deficiencies in all the skill attributes for a workman (after training) % improvement H4 forming % H4 jointing % H4 sealing % H4 exhausting % Ball bearing face grinding Ball bearing OD grinding Ball bearing IR/OR grinding lines % % % 127

32 16 Comparison of skill levels before and after training Average skill deficiencies in all the skill attributes for a workman (before training) Average skill deficiencies in all the skill attributes for a workman (after training) Fig 5.9 Comparison of skill levels before and after training 128

33 129

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40 136

41 Frequency Range Average X -Bar chart (after training) H4 forming process Sub group no. Fig (a) X-Bar chart (Forming process) R-chart (after training) H4 forming process Sub group no. Fig (b) R-Bar chart (Forming process) 40 Histogram - H4 forming process (after training) Fig (c) Histogram (Forming process) Table 5.5 Capability indices (Forming process) after training USL LSL Cp Cpk mm mm

42 Frequency Range Average X-bar chart (after training) H4 jointing process Sub group no. Fig (a) X-Bar chart (Jointing process) R-chart (after training) H4 jointing process Sub group no. Fig (b) R-Bar chart (Jointing process) Histogram - H4 jointing process (after training) Fig (c) Histogram (Jointing process) Table 5.6 Capability indices (Jointing process) after training USL LSL Cp Cpk mm mm

43 Frequency Range Average X-bar chart (after training) H4 sealing process Sub group no. Fig (a) X-Bar chart (Sealing process) R- chart (after training) H4 sealing process Sub group no. Fig (b) R-Bar chart (Sealing process) 60 Histogram - H4 sealing process (after training) Fig (c) Histogram (Sealing process) Table 5.7 Capability indices (Sealing process) after training USL LSL Cp Cpk mm mm

44 Frequency Range Average X -Bar chart (after training) H4 exhausting process Sub group no. Fig (a) X-Bar chart (Exhausting process) R-chart (after training) H4 exhausting process Sub group no. Fig (b) R-Bar chart (Exhausting process) Histogram - H4 exhausting process (after training) Fig (c) Histogram (Exhausting process) Table 5.8 Capability indices (Exhausting process) after training USL LSL Cp Cpk 6.50 mm 5.50 mm

45 Frequency Range Average X -Bar chart (after training) Face grinding process Sub group no. Fig (a) X-Bar chart (Face grinding process) R-chart (after training) Face grinding process Sub group no. Fig (b) R-Bar chart (Face grinding process) Histogram -Face grinding process (after training) Fig (c) Histogram (Face grinding process) Table 5.9 Capability indices (Face grinding process) after training USL LSL Cp Cpk 9.99 mm 9.95 mm

46 Frequency Range Average X -Bar chart (after training) OD grinding process Sub group no. Fig (a) X-Bar chart (OD grinding process) R-chart (after training) OD grinding process Sub group no. Fig (b) R-Bar chart (OD grinding process) 70 Histogram - OD grinding process (after training) Fig (c) Histogram (OD grinding process) Table 5.10 Capability indices (OD grinding process) after training USL LSL Cp Cpk mm mm

47 Frequency Range Average X -Bar chart (after training) OR grinding line Sub group no. Fig (a) X-Bar chart (OR grinding line) R-chart (after training) OR grinding line Sub group no. Fig (b) R-Bar chart (OR grinding line) 70 Histogram -OR grinding line Fig (c) Histogram (OR grinding line) Table 5.11 Capability indices (OR grinding line) after training USL LSL Cp Cpk mm mm

48 Number Range Average X -Bar chart (after training) IR grinding line Sub group no. Fig (a) X-Bar chart (IR grinding line) R-chart (after training) IR grinding line Sub group no. Fig (b) R-Bar chart (IR grinding line) Histogram - IR grinding line (after training) Fig (c) Histogram (IR grinding line) Table 5.12 Capability indices (IR grinding line) after training USL LSL Cp Cpk mm mm

49 Table 5.13 Mean time between failures (MTBF) Processes Week-wise MTBF (in days) H4 forming H4 jointing H4 sealing H4 exhausting Ball bearing face grinding Ball bearing OD grinding Ball bearing IR grinding lines Ball bearing OR grinding lines

50 Table 5.14 Mean time to repair (MTTR) Processes Week-wise MTTR in hrs. H4 forming H4 jointing H4 sealing H4 exhausting Ball bearing face grinding Ball bearing OD grinding Ball bearing IR grinding lines Ball bearing OR grinding lines

51 Table 5.15 Availability rate Processes Week-wise availability rate H4 forming H4 jointing H4 sealing H4 exhausting Ball bearing face grinding Ball bearing OD grinding Ball bearing IR grinding lines Ball bearing OR grinding lines

52 Table 5.16 Week-wise production (target / actual) (units) Processes H4 forming H4 jointing H4 sealing H4 exhausting Ball bearing face grinding Ball bearing OD grinding Ball bearing IR grinding lines Ball bearing OR grinding lines Week-wise production (units) Actual Target Actual Target Actual Target Actual Target Actual Target Actual Target Actual Target Actual Target

53 Table 5.17 Week-wise production / rejection (units) Processes H4 forming H4 jointing H4 sealing H4 exhausting Ball bearing face grinding Ball bearing OD grinding Ball bearing IR grinding lines Ball bearing OR grinding lines Week-wise production (units) Rejection Actual production Rejection Actual production Rejection Actual production Rejection Actual production Rejection Actual production Rejection Actual production Rejection Actual production Rejection Actual production

54 Table 5.18 Performance rate Processes Week-wise performance rate H4 forming H4 jointing H4 sealing H4 exhausting Ball bearing face grinding Ball bearing OD grinding Ball bearing IR grinding lines Ball bearing OR grinding lines

55 Table 5.19 Quality rate Processes Week-wise quality rate H4 forming H4 jointing H4 sealing H4 exhausting Ball bearing face grinding Ball bearing OD grinding Ball bearing IR grinding lines Ball bearing OR grinding lines

56 Table 5.20 Overall equipment effectiveness Processes Week-wise overall equipment effectiveness H4 forming H4 jointing H4 sealing H4 exhausting Ball bearing face grinding Ball bearing OD grinding Ball bearing IR grinding lines Ball bearing OR grinding lines

57 Processes Table 5.21 Kaizen Fortnightly kaizen H4 forming H4 jointing H4 sealing H4 exhausting Ball bearing face grinding Ball bearing OD grinding Ball bearing IR/OR grinding lines Processes Table 5.22 Safety, health and environment issues Fortnightly safety health and environment H4 forming H4 jointing H4 sealing H4 exhausting Ball bearing face grinding Ball bearing OD grinding Ball bearing IR grinding lines Ball bearing OR grinding lines Based on data related to the performance measurement metrics furnished in the tables and tables the charts were prepared which are presented as figure

58 MTBF (Days) MTBF (Days) MTBF (Days) MTBF H4 forming process MTBF (a) MTBF H4 jointing process MTBF (b) MTBF H4 sealing process MTBF (c) 154

59 MTBF (Days) MTBF (Days) MTBF (Days) MTBF H4 exhausting process MTBF (d) 2 MTBF Ball bearing face grinding process MTBF (e) 4 MTBF Ball bearing OD grinding process MTBF (f) 155

60 MTBF (Days) MTBF (Days) MTBF Ball bearing IR grinding line MTBF (g) MTBF Ball bearing OR grinding line MTBF (h) Fig 5.18 Mean time between failures (MTBF) (a) H4 forming process (b) H4 jointing process (c) H4 sealing process (d) H4 exhausting process (e) Ball bearing face grinding process (f) Ball bearing OD grinding process (g) Ball bearing inner race grinding line (h) Ball bearing outer race grinding line 156

61 MTTR (in hrs.) MTTR (in hrs.) MTTR (in hrs.) MTTR H4 forming process MTTR (a) MTTR H4 jointing process MTTR (b) MTTR H4 sealing process MTTR (c) 157

62 MTTR (in hrs.) MTTR (in hrs.) MTTR (in hrs.) MTTR H4 exhausting process MTTR (d) MTTR Ball bearing face grinding process MTTR (e) MTTR Ball Bearing OD grinding process MTTR (f) 158

63 MTTR (in hrs.) MTTR (in hrs.) MTTR Ball bearing IR grinding line MTTR (g) MTTR Ball bearing OR grinding line MTTR (h) Fig 5.19 Mean time to repair (MTTR) (a) H4 forming process (b) H4 jointing process (c) H4 sealing process (d) H4 exhausting process (e) Ball bearing face grinding process (f) Ball bearing OD grinding process (g) Ball bearing inner race grinding line (h) Ball bearing outer race grinding line 159

64 Availability rate Availability rate Availability rate Availabilty rate H4 forming process A.R (a) Availabilty rate H4 jointing process A.R (b) Availability rate H4 sealing process A.R (c) 160

65 Availability rate Availability rate Availability rate Availability rate H4 exhausting process A.R (d) Availability rate Ball bearing face grinding process A.R (e) Availability rate Ball bearing OD grinding process A.R (f) 161