Chapter 5 OPERATIONAL & MAINTENANCE SKILL DEVELOPMENT

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

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

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

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

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

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

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

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 10-15 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

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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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 5.2-5.8 (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

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 3 3-2 O.K. F 3 O.K. O.K. G 3 O.K. 3-2 H 3 3-2 3-2 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

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. 3-2 3-2 O.K. O.K. B 3 O.K. O.K. 3-2 O.K. 3-2 3-2 O.K. O.K. C 3 O.K. 3-2 3-2 O.K. 3-2 3-2 O.K. O.K. D 3 O.K. 3-2 3-2 O.K. 3-2 3-2 O.K. O.K. E 3 3-2 O.K. O.K. O.K. 3-2 3-2 O.K. 3-2 F 3 O.K. O.K. O.K. O.K. 3-2 3-1 O.K. O.K. G 3 3-2 O.K. O.K. 3-2 3-1 3-2 O.K. O.K. H 3 O.K. O.K. O.K. 3-2 3-2 3-2 3-2 3-2 I 3 3-2 O.K. 3-2 3-2 3-1 3-1 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

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. 3-2 3-2 D 3 O.K. 3-2 3-2 O.K. 3-2 O.K. 3-2 3-2 E 3 O.K. O.K. 3-2 O.K. 3-2 O.K. 3-2 3-2 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. 3-2 3-2 O.K. O.K. 3-2 H 3 O.K. O.K. 3-2 3-2 O.K. O.K. O.K. O.K. I 3 3-2 3-2 3-2 3-2 3-2 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

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. 3-2 3-2 3-2 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. 3-2 3-2 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. 3-1 3-2 3-2 3-2 E 3 3-2 3-2 O.K. O.K. 3-2 O.K. O.K. 3-2 3-2 O.K. 3-2 3-2 F 3 O.K. 3-2 3-2 O.K. O.K. O.K. O.K. 3-2 O.K. O.K. O.K. 3-2 G 3 O.K. 3-2 3-2 O.K. O.K. 3-2 3-2 O.K. 3-2 3-2 O.K. 3-2 H 3 3-2 O.K. 3-2 3-2 O.K. O.K. O.K. O.K. 3-2 O.K. O.K. 3-2. I 3 O.K. 3-2 3-2 O.K. O.K. 3-2 3-2 3-2 3-2 3-2 3-2 3-2 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

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. 3-2 3-2 O.K. E 3 O.K. O.K. 3-2 O.K. O.K. 3-2 3-2 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. 3-2 3-2 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. 3-2 3-2 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. 3-2 3-2 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

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 3 3-2 3-2 3-2 O.K. O.K. O.K. O.K. 3-2 O.K. O.K. O.K. O.K. B 3 3-1 3-2 3-2 O.K. O.K. O.K. O.K. O.K. O.K. O.K. O.K. 3-2 C 3 3-2 O.K. O.K. O.K. O.K. O.K. O.K. 3-2 3-2 O.K. O.K. O.K. D 3 3-1 3-2 3-2 O.K. O.K. O.K. 3-2 3-2 O.K. O.K. O.K. 3-2 E 3 O.K. 3-2 3-2 O.K. 3-2 O.K. O.K. 3-2 O.K. O.K. O.K. O.K. F 3 3-2 3-2 3-2 O.K. O.K. O.K. O.K. O.K. O.K. O.K. O.K. O.K. G 3 3-2 O.K. 3-2 3-2 O.K. 3-2 3-2 3-2 3-2 O.K. 3-2 O.K. H 3 3-2 3-2 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. 3-2 3-2 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

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 3 3-2 O.K O.K. O.K. 3-2 O.K. 3-2 O.K. 3-1 O.K. 3-2 3-2 B 3 3-2 O.K. O.K. O.K. 3-2 O.K. O.K. 3-2 3-1 O.K. O.K. 3-2 C 3 3-2 O.K. O.K. 3-2 3-2 O.K. O.K. O.K. 3-2 O.K. 3-2 3-2 D 3 3-2 3-2 O.K. O.K. 3-2 O.K. 3-2 O.K. 3-2 O.K. 3-2 3-2 E 3 3-2 3-2 O.K. 3-2 3-2 O.K. O.K. O.K. 3-1 O.K. 3-2 3-2 F 3 3-2 O.K. O.K. O.K. 3-2 O.K. O.K. O.K. 3-1 O.K. 3-2 3-2 G 3 3-2 O.K. O.K. 3-2 3-2 O.K. 3-2 3-2 3-2 O.K. O.K. 3-2 H 3 3-2 O.K. O.K. O.K. O.K. O.K. O.K. O.K. 3-2 O.K. 3-2 3-2 I 3 3-2 O.K. O.K. 3-2 O.K. O.K. 3-2 O.K. 3-2 O.K. 3-2 3-2 J 3 3-2 O.K. 3-2 O.K. 3-2 O.K. 3-2 3-2 3-2 O.K. O.K. 3-2 117

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. 3-2 3-2 O.K. O.K. O.K. O.K. O.K. O.K. O.K. O.K. O.K. C 3 O.K. 3-2 3-2 O.K. O.K. 3-2 O.K. O.K. O.K. O.K. O.K. O.K. D 3 O.K. 3-2 3-2 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 3 3-2 3-2 3-2 O.K. 3-2 3-2 O.K. O.K. 3-2 3-2 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 3 3-2 3-2 3-2 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

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 3 3-2 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

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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 5.12. 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 10 3.5 65% H4 jointing 14 4.875 65.17% H4 sealing 11.125 3.375 69.66% H4 exhausting 12.667 4.25 66.45% Ball bearing face grinding Ball bearing OD grinding Ball bearing IR/OR grinding lines 8.58 3.08 64.10% 11.125 4.375 60.67% 6.05 1.75 71.07% 127

16 Comparison of skill levels before and after training 14 14 12.667 12 11.125 11.125 10 10 8.58 8 6 4 3.5 4.875 3.375 4.25 3.08 4.375 6.05 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) 2 1.75 0 Fig 5.9 Comparison of skill levels before and after training 128

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Frequency Range Average 44.3200 X -Bar chart (after training) H4 forming process 44.2200 44.1200 44.0200 43.9200 43.8200 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 Sub group no. Fig. 5.10 (a) X-Bar chart (Forming process) 0.6000 0.5000 0.4000 0.3000 0.2000 0.1000 0.0000 R-chart (after training) H4 forming process 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 Sub group no. Fig. 5.10 (b) R-Bar chart (Forming process) 40 Histogram - H4 forming process (after training) 30 20 10 0 43.125 43.25 43.375 43.5 43.625 43.75 43.875 44 44.125 44.25 44.375 44.5 44.625 44.75 44.875 Fig. 5.10 (c) Histogram (Forming process) Table 5.5 Capability indices (Forming process) after training USL LSL Cp Cpk 44.50 mm 43.50 mm 1.50 1.28 137

Frequency Range Average 83.3400 83.2400 X-bar chart (after training) H4 jointing process 83.1400 83.0400 82.9400 82.8400 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 Sub group no. Fig. 5.11 (a) X-Bar chart (Jointing process) 0.8000 0.6000 R-chart (after training) H4 jointing process 0.4000 0.2000 0.0000 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 Sub group no. Fig. 5.11 (b) R-Bar chart (Jointing process) 80 60 Histogram - H4 jointing process (after training) 40 20 0 81.25 81.5 81.75 82 82.25 82.5 82.75 83 83.25 83.5 83.75 84 84.25 84.5 84.75 Fig. 5.11 (c) Histogram (Jointing process) Table 5.6 Capability indices (Jointing process) after training USL LSL Cp Cpk 84.00 mm 82.00 mm 2.62 2.38 138

Frequency Range Average 15.4300 15.4200 15.4100 15.4000 15.3900 15.3800 15.3700 15.3600 X-bar chart (after training) H4 sealing process 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 Sub group no. Fig. 5.12 (a) X-Bar chart (Sealing process) 0.1200 0.1000 0.0800 0.0600 0.0400 0.0200 0.0000 R- chart (after training) H4 sealing process 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 Sub group no. Fig. 5.12 (b) R-Bar chart (Sealing process) 60 Histogram - H4 sealing process (after training) 50 40 30 20 10 0 15.225 15.25 15.275 15.3 15.325 15.35 15.375 15.4 15.425 15.45 15.475 15.5 15.525 15.55 15.575 Fig. 5.12 (c) Histogram (Sealing process) Table 5.7 Capability indices (Sealing process) after training USL LSL Cp Cpk 15.50 mm 15.30 mm 1.60 1.54 139

Frequency Range Average 11.9968 X -Bar chart (after training) H4 exhausting process 11.9963 11.9958 11.9953 11.9948 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 Sub group no. Fig. 5.13 (a) X-Bar chart (Exhausting process) 0.0035 0.0030 0.0025 0.0020 0.0015 0.0010 0.0005 0.0000 R-chart (after training) H4 exhausting process 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 Sub group no. Fig. 5.13 (b) R-Bar chart (Exhausting process) 70 60 50 40 30 20 10 Histogram - H4 exhausting process (after training) 0 11.99075 11.9915 11.99225 11.993 11.99375 11.9945 11.99525 11.996 11.99675 11.9975 11.99825 11.999 11.99975 12.0005 12.00125 Fig. 5.13 (c) Histogram (Exhausting process) Table 5.8 Capability indices (Exhausting process) after training USL LSL Cp Cpk 6.50 mm 5.50 mm 2.22 2.09 140

Frequency Range Average 11.9966 X -Bar chart (after training) Face grinding process 11.9961 11.9956 11.9951 11.9946 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 Sub group no. Fig. 5.14 (a) X-Bar chart (Face grinding process) 0.0035 0.0030 0.0025 0.0020 0.0015 0.0010 0.0005 0.0000 R-chart (after training) Face grinding process 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 Sub group no. Fig. 5.14 (b) R-Bar chart (Face grinding process) 70 60 50 40 30 20 10 Histogram -Face grinding process (after training) 0 11.99075 11.9915 11.99225 11.993 11.99375 11.9945 11.99525 11.996 11.99675 11.9975 11.99825 11.999 11.99975 12.0005 12.00125 Fig. 5.14 (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 1.46 1.44 141

Frequency Range Average 11.9968 X -Bar chart (after training) OD grinding process 11.9963 11.9958 11.9953 11.9948 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 Sub group no. Fig. 5.15 (a) X-Bar chart (OD grinding process) 0.0040 R-chart (after training) OD grinding process 0.0030 0.0020 0.0010 0.0000 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 Sub group no. Fig. 5.15 (b) R-Bar chart (OD grinding process) 70 Histogram - OD grinding process (after training) 60 50 40 30 20 10 0 11.99075 11.9915 11.99225 11.993 11.99375 11.9945 11.99525 11.996 11.99675 11.9975 11.99825 11.999 11.99975 12.0005 12.00125 Fig. 5.15 (c) Histogram (OD grinding process) Table 5.10 Capability indices (OD grinding process) after training USL LSL Cp Cpk 31.999 mm 31.990 mm 2.02 1.75 142

Frequency Range Average 11.9968 X -Bar chart (after training) OR grinding line 11.9963 11.9958 11.9953 11.9948 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 Sub group no. Fig. 5.16 (a) X-Bar chart (OR grinding line) 0.0040 R-chart (after training) OR grinding line 0.0030 0.0020 0.0010 0.0000 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 Sub group no. Fig. 5.16 (b) R-Bar chart (OR grinding line) 70 Histogram -OR grinding line 60 50 40 30 20 10 0 11.99075 11.9915 11.99225 11.993 11.99375 11.9945 11.99525 11.996 11.99675 11.9975 11.99825 11.999 11.99975 12.0005 12.00125 Fig. 5.16 (c) Histogram (OR grinding line) Table 5.11 Capability indices (OR grinding line) after training USL LSL Cp Cpk 28.036 mm 27.986 mm 3.74 3.49 143

Number Range Average 11.9968 X -Bar chart (after training) IR grinding line 11.9963 11.9958 11.9953 11.9948 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 Sub group no. Fig. 5.17 (a) X-Bar chart (IR grinding line) 0.0035 0.0030 0.0025 0.0020 0.0015 0.0010 0.0005 0.0000 R-chart (after training) IR grinding line 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 Sub group no. Fig. 5.17 (b) R-Bar chart (IR grinding line) Histogram - IR grinding line (after training) 70 60 50 40 30 20 10 0 11.99075 11.9915 11.99225 11.993 11.99375 11.9945 11.99525 11.996 11.99675 11.9975 11.99825 11.999 11.99975 12.0005 12.00125 Fig. 5.17 (c) Histogram (IR grinding line) Table 5.12 Capability indices (IR grinding line) after training USL LSL Cp Cpk 11.999 mm 11.993 mm 1.49 1.41 144

Table 5.13 Mean time between failures (MTBF) Processes Week-wise MTBF (in days) H4 forming 2.33 1.75 2.33 2.33 3.5 3.5 2.33 3.5 3.5 3.5 H4 jointing 1.75 2.33 2.33 2.33 3.5 2.33 3.5 3.5 3.5 7 H4 sealing 1.75 1.4 2.33 2.33 2.33 3.5 3.5 2.33 3.5 3.5 H4 exhausting 1.75 1.75 1.75 2.33 1.75 2.33 2.33 2.33 2.33 3.5 Ball bearing face grinding Ball bearing OD grinding Ball bearing IR grinding lines Ball bearing OR grinding lines 0.875 0.875 1 1.116 1 1.75 1.4 1.4 1.75 1.75 1.116 1 1.116 1.75 2.333 1.75 2.333 2.333 3.5 3.5 0.7 0.777 0.777 1 0.875 1 1 1.116 1.4 1.4 0.777 0.636 0.875 1.116 1 1.116 1.4 1.75 1.4 1.75 145

Table 5.14 Mean time to repair (MTTR) Processes Week-wise MTTR in hrs. H4 forming 1.5 1.5 1.25 1.25 1.25 1.75 1.25 1.5 1 1 H4 jointing 1.5 1.75 1.5 1.25 1.25 1.25 1.25 1 1 1 H4 sealing 1.25 1 1 0.8 1.2 0.75 0.75 0.75 0.75 0.75 H4 exhausting 1.5 1.5 1.25 1 1.25 1 1 1 1 1 Ball bearing face grinding Ball bearing OD grinding Ball bearing IR grinding lines Ball bearing OR grinding lines 1.6 1.6 1.35 1.6 1.433 1.1 1.1 1.233 1.1 1.0 1.833 1.6 1.533 1.4 1.25 1.33 1.25 1.25 1.15 1.083 1.5 1.5 1.333 1.25 1.166 1.25 1.0 1.0 0.833 0.75 1.5 1.4 1.4 1.333 1.25 1.2 1.166 1.0 0.75 0.833 146

Table 5.15 Availability rate Processes Week-wise availability rate H4 forming 0.903 0.89 0.911 0.918 0.922 0.924 0.923 0.932 0.939 0.939 H4 jointing 0.903 0.908 0.916 0.918 0.927 0.924 0.931 0.937 0.936 0.939 H4 sealing 0.90 0.90 0.916 0.923 0.916 0.936 0.94 0.936 0.942 0.941 H4 exhausting 0.907 0.908 0.915 0.927 0.915 0.931 0.931 0.932 0.933 0.94 Ball bearing face grinding Ball bearing OD grinding Ball bearing IR grinding lines Ball bearing OR grinding lines 0.673 0.655 0.675 0.689 0.690 0.736 0.729 0.735 0.755 0.763 0.684 0.691 0.730 0.751 0.752 0.767 0.769 0.765 0.804 0.798 0.910 0.919 0.927 0.947 0.944 0.948 0.957 0.964 0.975 0.977 0.918 0.908 0.933 0.952 0.947 0.957 0.965 0.976 0.977 0.980 147

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 157495 155367 161362 168836 169105 171911 169525 174009 175255 175586 Target 182160 180240 181500 185100 186000 186000 183900 187800 189396 189396 Actual 77750 79325 82232 84316 86142 85958 87850 89128 87810 89233 Target 127500 129752 130900 131112 130900 131962 133025 133875 132175 134155 Actual 74112 72318 77895 81796 82206 83440 84574 84891 85757 84610 Target 128605 127075 130900 131835 130815 132175 134300 133662 134580 132880 Actual 73650 73323 74952 78014 80530 83134 82668 82028 83445 83188 Target 114375 114502 115350 115500 115350 117375 117375 116122 117622 118500 Actual 246020 239107 246202 250738 260612 279836 278511 276452 288592 291816 Target 346505 336863 347117 350178 354981 378645 375278 373549 388287 392726 Actual 164452 164122 176808 183677 184897 185814 189721 189956 199378 196523 Target 219768 219382 234483 241359 241645 243518 246996 245659 258176 253176 Actual 43905 44183 46872 46905 48370 48316 48800 50174 52297 53542 Target 60894 61491 62293 63381 63151 63381 63282 64476 65206 65371 Actual 44185 44598 46355 48276 48087 49056 50016 50488 52177 53079 Target 60695 60734 62406 63687 62585 63998 64543 65272 64575 65537 148

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 1876 1762 1812 1773 1677 1153 1004 1014 1136 923 Actual production 157495 155367 161362 168836 169105 171911 169525 174009 175255 175586 Rejection 724 756 652 705 655 623 609 651 559 565 Actual production 77750 79325 82232 84316 86142 85958 87850 89128 87810 89233 Rejection 1074 1010 972 930 808 868 732 721 639 552 Actual production 74112 72318 77895 81796 82206 83440 84574 84891 85757 84610 Rejection 1168 1182 1084 991 1089 1022 880 832 739 699 Actual production 73650 73323 74952 78014 80530 83134 82668 82028 83445 83188 Rejection 378 356 342 304 328 261 234 195 167 163 Actual production 246020 239107 246202 250738 260612 279836 278511 276452 288592 291816 Rejection 232 248 227 199 184 158 155 134 120 118 Actual production 164452 164122 176808 183677 184897 185814 189721 189956 199378 196523 Rejection 74 81 73 61 63 52 46 48 42 40 Actual production 43905 44183 46872 46905 48370 48316 48800 50174 52297 53542 Rejection 76 74 65 70 64 49 42 43 39 35 Actual production 44185 44598 46355 48276 48087 49056 50016 50488 52177 53079 149

Table 5.18 Performance rate Processes Week-wise performance rate H4 forming 0.864 0.862 0.889 0.912 0.909 0.924 0.921 0.926 0.925 0.927 H4 jointing 0.609 0.611 0.628 0.643 0.658 0.651 0.660 0.665 0.664 0.665 H4 sealing 0.576 0.569 0.595 0.620 0.628 0.631 0.629 0.635 0.637 0.636 H4 exhausting 0.643 0.640 0.649 0.675 0.698 0.708 0.704 0.706 0.709 0.702 Ball bearing face grinding Ball bearing OD grinding Ball bearing IR grinding lines Ball bearing OR grinding lines 0.71 0.709 0.709 0.716 0.734 0.739 0.742 0.74 0.743 0.743 0.748 0.748 0.754 0.761 0.765 0.763 0.768 0.773 0.772 0.776 0.721 0.718 0.752 0.74 0.765 0.762 0.771 0.778 0.802 0.819 0.727 0.734 0.742 0.758 0.768 0.766 0.774 0.773 0.808 0.809 150

Table 5.19 Quality rate Processes Week-wise quality rate H4 forming 0.988 0.988 0.988 0.989 0.990 0.993 0.994 0.994 0.993 0.994 H4 jointing 0.990 0.990 0.992 0.991 0.992 0.992 0.993 0.992 0.993 0.993 H4 sealing 0.985 0.986 0.987 0.988 0.990 0.989 0.991 0.991 0.992 0.993 H4 exhausting 0.984 0.983 0.985 0.987 0.986 0.987 0.989 0.989 0.991 0.991 Ball bearing face grinding Ball bearing OD grinding Ball bearing IR grinding lines Ball bearing OR grinding lines 0.9984 0.9985 0.9986 0.9987 0.9987 0.999 0.9991 0.9992 0.9994 0.9994 0.9985 0.9984 0.9987 0.9989 0.999 0.9991 0.9991 0.9992 0.9993 0.9993 0.9983 0.9981 0.9984 0.9986 0.9986 0.9989 0.9990 0.9990 0.9991 0.9992 0.9982 0.9983 0.9985 0.9985 0.9986 0.9990 0.9991 0.9991 0.9992 0.9993 151

Table 5.20 Overall equipment effectiveness Processes Week-wise overall equipment effectiveness H4 forming 0.77 0.757 0.8 0.828 0.829 0.847 0.844 0.857 0.862 0.865 H4 jointing 0.544 0.549 0.57 0.584 0.605 0.596 0.61 0.618 0.617 0.62 H4 sealing 0.51 0.504 0.537 0.565 0.569 0.584 0.585 0.589 0.595 0.594 H4 exhausting 0.573 0.571 0.584 0.617 0.629 0.65 0.648 0.65 0.655 0.653 Ball bearing face grinding Ball bearing OD grinding Ball bearing IR grinding lines Ball bearing OR grinding lines 0.477 0.463 0.477 0.492 0.505 0.543 0.54 0.543 0.56 0.566 0.51 0.516 0.549 0.57 0.574 0.584 0.59 0.59 0.62 0.618 0.654 0.658 0.695 0.699 0.721 0.721 0.737 0.749 0.781 0.799 0.666 0.665 0.691 0.72 0.726 0.732 0.746 0.753 0.788 0.792 152

Processes Table 5.21 Kaizen Fortnightly kaizen -1 0 1 2 3 4 H4 forming 0 2 4 5 6 6 H4 jointing 1 1 2 6 5 6 H4 sealing 2 1 3 5 5 5 H4 exhausting 1 2 4 4 5 6 Ball bearing face grinding Ball bearing OD grinding Ball bearing IR/OR grinding lines 3 4 4 6 5 8 6 5 7 9 8 10 2 4 5 7 7 7 Processes Table 5.22 Safety, health and environment issues Fortnightly safety health and environment -1 0 1 2 3 4 H4 forming 6 6 4 5 3 2 H4 jointing 5 4 3 3 2 2 H4 sealing 6 5 4 4 2 1 H4 exhausting 6 7 5 5 4 2 Ball bearing face grinding Ball bearing OD grinding Ball bearing IR grinding lines Ball bearing OR grinding lines 4 3 2 1 2 1 3 3 2 2 2 1 3 5 2 2 1 1 3 2 2 1 1 1 Based on data related to the performance measurement metrics furnished in the tables 5.13-5.15 and tables 5.18-5.22 the charts were prepared which are presented as figure 5.10 5.17. 153

MTBF (Days) MTBF (Days) MTBF (Days) MTBF H4 forming process 4 3 2 1 0 MTBF 2.33 1.75 2.33 2.33 3.5 3.5 2.33 3.5 3.5 3.5 (a) MTBF H4 jointing process 8 6 4 2 0 MTBF 1.75 2.33 2.33 2.33 3.5 2.33 3.5 3.5 3.5 7 (b) MTBF H4 sealing process 4 3 2 1 0 MTBF 1.75 1.4 2.33 2.33 2.33 3.5 3.5 2.33 3.5 3.5 (c) 154

MTBF (Days) MTBF (Days) MTBF (Days) MTBF H4 exhausting process 4 3 2 1 0 MTBF 1.75 1.75 1.75 2.33 1.75 2.33 2.33 2.33 2.33 3.5 (d) 2 MTBF Ball bearing face grinding process 1.5 1 0.5 0 MTBF 0.875 0.875 1 1.116 1 1.75 1.4 1.4 1.75 1.75 (e) 4 MTBF Ball bearing OD grinding process 3 2 1 0 MTBF 1.116 1 1.116 1.75 2.333 1.75 2.333 2.333 3.5 3.5 (f) 155

MTBF (Days) MTBF (Days) MTBF Ball bearing IR grinding line 1.6 1.4 1.2 1 0.8 0.6 0.4 0.2 0 MTBF 0.7 0.777 0.777 1 0.875 1 1 1.116 1.4 1.4 (g) MTBF Ball bearing OR grinding line 2 1.5 1 0.5 0 MTBF 0.777 0.636 0.875 1.116 1 1.116 1.4 1.75 1.4 1.75 (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

MTTR (in hrs.) MTTR (in hrs.) MTTR (in hrs.) MTTR H4 forming process 2 1.5 1 0.5 0 MTTR 1.5 1.5 1.25 1.25 1.25 1.75 1.25 1.5 1 1 (a) MTTR H4 jointing process 2 1.5 1 0.5 0 MTTR 1.5 1.75 1.5 1.25 1.25 1.25 1.25 1 1 1 (b) MTTR H4 sealing process 1.4 1.2 1 0.8 0.6 0.4 0.2 0 MTTR 1.25 1 1 0.8 1.2 0.75 0.75 0.75 0.75 0.75 (c) 157

MTTR (in hrs.) MTTR (in hrs.) MTTR (in hrs.) MTTR H4 exhausting process 2 1.5 1 0.5 0 MTTR 1.5 1.5 1.25 1 1.25 1 1 1 1 1 (d) MTTR Ball bearing face grinding process 2 1.5 1 0.5 0 MTTR 1.6 1.6 1.35 1.6 1.433 1.1 1.1 1.233 1.1 1 (e) MTTR Ball Bearing OD grinding process 2 1.5 1 0.5 0 MTTR 1.833 1.6 1.533 1.4 1.25 1.33 1.25 1.25 1.15 1.083 (f) 158

MTTR (in hrs.) MTTR (in hrs.) MTTR Ball bearing IR grinding line 1.6 1.4 1.2 1 0.8 0.6 0.4 0.2 0 MTTR 1.5 1.5 1.333 1.25 1.166 1.25 1 1 0.833 0.75 (g) MTTR Ball bearing OR grinding line 2 1.5 1 0.5 0 MTTR 1.5 1.4 1.4 1.333 1.25 1.2 1.166 1 0.75 0.833 (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

Availability rate Availability rate Availability rate Availabilty rate H4 forming process 0.96 0.94 0.92 0.9 0.88 0.86 A.R. 0.903 0.89 0.911 0.918 0.922 0.924 0.923 0.932 0.939 0.939 (a) Availabilty rate H4 jointing process 0.95 0.94 0.93 0.92 0.91 0.9 0.89 0.88 A.R. 0.903 0.908 0.916 0.918 0.927 0.924 0.931 0.937 0.936 0.939 (b) Availability rate H4 sealing process 0.96 0.94 0.92 0.9 0.88 0.86 A.R. 0.9 0.9 0.916 0.923 0.916 0.936 0.94 0.936 0.942 0.941 (c) 160

Availability rate Availability rate Availability rate Availability rate H4 exhausting process 0.95 0.94 0.93 0.92 0.91 0.9 0.89 A.R. 0.907 0.908 0.915 0.927 0.915 0.931 0.931 0.932 0.933 0.94 (d) Availability rate Ball bearing face grinding process 0.8 0.75 0.7 0.65 0.6 A.R. 0.673 0.655 0.675 0.689 0.69 0.736 0.729 0.735 0.755 0.763 (e) Availability rate Ball bearing OD grinding process 0.85 0.8 0.75 0.7 0.65 0.6 A.R. 0.684 0.691 0.73 0.751 0.752 0.767 0.769 0.765 0.804 0.798 (f) 161