preventive maint. schedle planned and executed from Oct.

2019 t
Month Plan Actual
Oct-19 127 126
Nov-19 136 136
Dec-19 141 141
Jan-20 140 140
Feb-20 137 135
Mar-20 145 96
May-20
Jun-20 125 125

preventive maint
Month Plan
Jul-20 127
Nov-19 136
Dec-19 141
Jan-20 140
Feb-20 137
Mar-20 145
May-20
Jun-20 125
nt. schedle planned and executed from Oct.2019 to june2020
Remark Reason
SAC 1 Air Compressor filter fliter was light damaged***

Man power enggaged with another Job so

STC1 and SFW 22 Could not be taken for Prev. Maint.
taken on next due date.
22.03.2020 onwords Lockdown was imposed
not scheduled as only single shift working

*** Air filter found little dameged so not

cleaned and an old filter provided as
temporary arrangment. After receiving,
new air filter installed on 02.01.2020
preventive maint. schedle planned and executed from July 2020 To O
Month Plan Actual Remark Reason
Jul-20 118 118
Aug-20 113 113
Sep-20 116 116
Oct-20 113 113

Month MTTR Achived MTBF Achived Remark

Jul-20 20 min. 28.57 14.00 Hrs 25.36
Aug-20 20 min. 23.97 14.00 Hrs 25.89
Sep-20 20 min. 23.04 14.00 Hrs 30.02
Oct-20 20 min. 14.00 Hrs
from July 2020 To Oct.2020
son

Remark
Observation of maximum Breakdown attended during Dec.2019 to June 2020
Date Name of M/C M/C B/D M/C Total
No. Report H.O. Time
Full Welding (Set No.18) 6 16:17 16:33 0:16
Re work Welding (Set No.22) 17:55 18:14 0:19
Tack Welding (Set No.11) 2 16:29 16:38 0:09
Re work Welding (Set No.22) 11:44 11:56 0:12
Full Welding (Set No.14) 6 9:52 10:41 0:49
Full Welding (Set No.7) 2 16:23 17:23 1:00
Full Welding (Set No.16) 5 8:37 8:53 0:16
22-Jun-20 Re work Welding (Set No.22) 7:51 8:36 0:45
Full Welding (Set No.05) 1 8:00 8:23 0:23
25-Jun-20 Full Welding (Set No.06) 1 8:00 8:22 0:22
Full Welding (Set No.14) 4 9:01 9:15 0:14
Full Welding (Set No.14) 4 9:28 9:40 0:12
Full Welding (Set No.14) 4 15:09 15:31 0:22
29-Jun-20 Re work Welding (Set No.22) 8:50 9:21 0:31
Full Welding (Set No.14) 4 9:45 9:58 0:13
30-Jun-20 Full Welding (Set No.14) 4 7:39 7:50 0:11
Full Welding (Set No.5) 1 16:18 16:41 0:23
6:37

Date Name of M/C M/C B/D M/C Total

No. Report H.O. Time
9-May-20 Full Welding (Set No.14) 2 14:49 15:02 0:13
11-May-20 Full Welding (Set No.15) 4 10:56 11:05 0:09
15-May-20 Tack Welding (Set no.12) 2 12:01 12:12 0:11
19-May-20 Full Welding (Set No.15) 5 10:07 10:35 0:28
20-May-20 Full Welding (Set No.15) 5 8:05 8:09 0:04
20-May-20 Full Welding (Set No.18) 6 11:49 12:11 0:22
21-May-20 Full Welding (Set No.7) 2 8:22 8:33 0:11
21-May-20 Full Welding (Set No.21) 8:22 8:34 0:12
22-May-20 Crane 2
25-May-20 Full Welding (Set No.18) 6 9:42 9:54 0:12
25-May-20 Full Welding (Set No.15) 5 12:44 12:59 0:15
27-May-20 Rework area(Set No.21) 8:05 8:11 0:06
27-May-20 Tack Welding (Set no.12) 2 13:32 13:50 0:18
2:41:00

1-Feb-20 Full Welding (Set No.14) 4 6:53 7:04 0:11

1-Feb-20 Full Welding (Set No.15) 5 16:32 16:49 0:17
3-Feb-20 Full Welding (Set No.12) 2 8:06 8:30 0:24
 3-Feb-20 Full Welding (Set No.14) 4 10:19 10:36 0:17
6-Feb-20 Full Welding (Set No.6) 2 9:20 9:34 0:14
7-Feb-20 Full Welding (Set No.17) 6 18:18 18:26 0:08
8-Feb-20 Full Welding (Set No.11) 2 0:13 0:19 0:06
10-Feb-20 Full Welding (Set No.18) 6 6:39 6:56 0:17
10-Feb-20 Full Welding (Set No.6) 1 19:09 19:18 0:09
11-Feb-20 Tack Welding (Set No.12) 2 23:25 23:33 0:08
11-Feb-20 Full Welding (Set No.13) 5 1:09 1:14 0:05
11-Feb-20 Hand Grinder 1:25 1:55 0:30
14-Feb-20 Full Welding (Set No.14) 4 6:48 7:01 0:13
17-Feb-20 Tack Welding (Set No.20) 4 17:04 17:26 0:22
18-Feb-20 Tack Welding (Set No.11) 2 0:32 0:39 0:07
19-Feb-20 Tack Welding (Set No.12) 2 6:49 7:06 0:17
19-Feb-20 Rework Welding (Set No.22) 15:07 15:13 0:06
19-Feb-20 Full Welding (Set No.8) 2 15:50 15:56 0:06
20-Feb-20 Full Welding (Set No.15) 5 6:48 6:53 0:05
22-Feb-20 Tack Welding (Set No.10) 3 18:14 18:21 0:07
24-Feb-20 ttack Welding (Set No.12) 2 16:57 17:22 0:25
25-Feb-20 Full Welding (Set No.15) 4 7:21 7:29 0:08
25-Feb-20 Tack Welding (Set No.1) 2 11:16 11:25 0:09
25-Feb-20 Full Welding (Set No.14) 4 16:04 16:08 0:04
26-Feb-20 Full Welding (Set No.16) 5 17:24 17:41 0:17
26-Feb-20 Full Welding (Set No.14) 4 23:25 23:36 0:11
26-Feb-20 Full Welding (Set No.6) 5 3:28 3:37 0:09
27-Feb-20 Full Welding (Set No.5) 2 12:40 12:50 0:10
27-Feb-20 Full Welding (Set No.7) 2 12:40 12:50 0:10
28-Feb-20 Tack Welding (Set No.12) 2 22:36 22:50 0:14
29-Feb-20 Full Welding (Set No.8) 2 0:00 0:00 0:00
29-Feb-20 Full Welding (Set No.14) 4 23:21 23:27 0:06
29-Feb-20 Full Welding (Set No.5) 1 12:27 12:32 0:05
6:17

M/C B/D M/C Total

Date Name of M/C No. Report H.O. Time
1-Jan-20 Full Welding ( Set No. 5) 1 12:43 13:15 0:32
2-Jan-20 Full Welding ( Set No. 7) 2 7:18 7:28 0:10
2-Jan-20 Full Welding ( Set No. 7) 2 8:15 8:30 0:15
2-Jan-20 Full Welding ( Set No. 5) 1 18:09 18:37 0:28
2-Jan-20 Full Welding ( Set No. 16) 5 20:02 20:22 0:20
6-Jan-20 Full Welding ( Set No. 8) 2 8:33 8:54 0:21
8-Jan-20 Full Welding ( Set No.9) 3 7:08 7:29 0:21
8-Jan-20 Full Welding ( Set No.18) 6 7:29 7:54 0:25
8-Jan-20 Full Welding ( Set No.9) 3 10:16 11:04 0:48
9-Jan-20 Full Welding ( Set No.18) 6 10:02 10:35 0:33
 9-Jan-20 Full Welding ( Set No.8) 2 20:15 20:40 0:25
17-Jan-20 Full Welding ( Set No.7) 2 12:19 12:46 0:27
17-Jan-20 Full Welding ( Set No.18) 6 16:03 16:30 0:27
18-Jan-20 Full Welding ( Set No.18) 6 12:09 12:21 0:12
20-Jan-20 Full Welding ( Set No.7) 2 11:21 11:38 0:17
20-Jan-20 Full Welding ( Set No.9) 3 13:09 13:29 0:20
20-Jan-20 Full Welding ( Set No.10) 13:09 13:29 0:20
21-Jan-20 Full Welding ( Set No.15) 5 8:40 9:29 0:49
21-Jan-20 Full Welding ( Set No.18) 6 9:32 9:50 0:18
21-Jan-20 Full Welding ( Set No.16) 5 17:59 18:15 0:16
21-Jan-20 Full Welding ( Set No.10) 3 18:11 18:22 0:11
22-Jan-20 Full Welding ( Set No.10) 3 9:27 9:39 0:12
22-Jan-20 Full Welding ( Set No.18) 6 20:58 21:15 0:17
23-Jan-20 Full Welding ( Set No.7) 2 13:02 13:16 0:14
23-Jan-20 Full Welding ( Set No.8) 2 18:39 19:13 0:34
24-Jan-20 Full Welding ( Set No.6) 1 7:58 8:24 0:26
24-Jan-20 Full Welding ( Set No.18) 6 20:15 21:15 1:00
25-Jan-20 Full Welding ( Set No.7) 2 13:37 13:58 0:21
25-Jan-20 Full Welding ( Set No.14) 4 17:23 17:43 0:20
27-Jan-20 Full Welding ( Set No15) 6 6:52 7:19 0:27
27-Jan-20 Full Welding ( Set No.7) 2 8:18 8:43 0:25
28-Jan-20 Full Welding ( Set No.9) 3 17:37 18:18 0:41
29-Jan-20 Full Welding ( Set No.7) 2 11:49 12:03 0:14
29-Jan-20 Full Welding ( Set No.7) 2 17:14 17:30 0:16
30-Jan-20 Full Welding ( Set No.9) 3 13:24 13:31 0:07
31-Jan-20 Full Welding ( Set No.7) 2 6:43 7:00 0:17
31-Jan-20 Full Welding ( Set No.16) 5 17:00 17:22 0:22
14:28

Date Name of M/C M/C B/D M/C Total

No. Report H.O. Time
2-Dec-19 Full Welding ( Set No. 15) 5 9:25 9:50 0:25
2-Dec-19 Full Welding ( Set No. 17) 6 13:46 14:48 1:02
3-Dec-19 Full Welding ( Set No. 7) 2 8:00 8:22 0:22
3-Dec-19 Full Welding ( Set No. 5) 1 12:30 12:45 0:15
4-Dec-19 Full Welding ( Set No. 9) 3 11:18 11:47 0:29
5-Dec-19 Full Welding ( Set No. 16) 5 9:18 9:32 0:14
7-Dec-19 Full Welding ( Set No.9) 3 8:30 8:48 0:18
7-Dec-19 Full Welding ( Set No.18) 6 9:09 9:31 0:22
10-Dec-19 Full Welding ( Set No.15) 5 10:24 10:55 0:31
11-Dec-19 Full Welding ( Set No.18) 6 9:36 9:49 0:13
11-Dec-19 Full Welding ( Set No.13) 4 9:51 10:06 0:15
11-Dec-19 Full Welding ( Set No.6) 1 12:14 12:47 0:33
11-Dec-19 Full Welding ( Set No.17) 6 13:19 13:35 0:16
11-Dec-19 Full Welding ( Set No.5) 1 14:04 14:19 0:15
14-Dec-19 Full Welding ( Set No.15) 5 15:52 16:16 0:24
16-Dec-19 Full Welding ( Set No.6) 1 13:16 13:31 0:15
16-Dec-19 Full Welding ( Set No.13) 4 15:56 16:12 0:16
16-Dec-19 Full Welding ( Set No.14) 4 18:40 18:49 0:09
20-Dec-19 Full Welding ( Set No.14) 4 20:51 21:03 0:12
23-Dec-19 Full Welding ( Set No.7 ) 2 16:23 16:53 0:30
24-Dec-19 Full Welding ( Set No.7 ) 2 8:53 9:19 0:26
24-Dec-19 Full Welding ( Set No.13) 4 8:58 9:14 0:16
24-Dec-19 Full Welding ( Set No.9 ) 3 9:43 10:26 0:43
24-Dec-19 Full Welding ( Set No.17) 6 9:49 10:40 0:51
24-Dec-19 Full Welding ( Set No.18) 6 10:17 10:41 0:24
24-Dec-19 Full Welding ( Set No.10) 3 11:10 11:27 0:17
24-Dec-19 Full Welding ( Set No.13) 4 16:34 16:52 0:18
24-Dec-19 Full Welding ( Set No.13) 4 20:56 21:16 0:20
25-Dec-19 Tack Welding ( Set No.12) 2 7:35 8:41 1:06
25-Dec-19 Full Welding ( Set No.7) 2 17:03 17:35 0:32
26-Dec-19 Full Welding ( Set No.7) 2 7:54 8:54 1:00
26-Dec-19 Full Welding ( Set No.9) 3 8:02 8:52 0:50
26-Dec-19 Full Welding ( Set No.13) 4 13:06 13:31 0:25
26-Dec-19 Full Welding ( Set No.12) 2 13:52 14:10 0:18
26-Dec-19 Full Welding ( Set No.14) 4 13:53 14:20 0:27
27-Dec-19 Full Welding ( Set No.9) 3 11:57 12:13 0:16
27-Dec-19 Full Welding ( Set No.18) 6 12:22 13:01 0:39
30-Dec-19 Full Welding ( Set No.18) 6 13:16 13:28 0:12
31-Dec-19 Full Welding ( Set No.8) 2 8:14 8:25 0:11
31-Dec-19 Full Welding ( Set No.9) 11:31 11:56 0:25
31-Dec-19 Full Welding ( Set No.17) 6 17:54 18:47 0:53
18:05:00
ec.2019 to June 2020
Observed Problem Activity/ Spares used
Mig Wire poblem Liner replaced
Mig Wire poblem Liner Cleaned
Liner problem Liner, tip, Tip holder Replaced
Liner problem Liner replaced Tip replaed
Wire problem Liner replaced
Wire problem Liner Cleaned
Wire problem Liner and tip Replaced
Liner problem Liner Cleaned
Liner problem Liner Cleaned
Liner problem Liner replaced
Wire problem Limner and tip cleaned
Liner problem Liner and tip Replaced
Liner problem Liner replaced
Liner problem Liner clean and tip replaced
Liner problem Liner replaced
Liner problem :Liner cleaned
Wire problem Liner cleaned

Observed Problem Activity/ Spares used

Liner Problem Liner nad Tip Changed
Tip and liner problem Tip and liner replaced
Tip problem Tip and Cap replaced
Liner Problem Liner Changed
Liner Problem Liner Changed
Liner Problem Liner Changed
Tip problem Tip replaced
Liner Problem Tip replaced

Liner Problem Liner Cleaned

Liner Problem Liner Cleaned
Tip problem Tip and Tip holder replaced
mig Wire problem Liner cleaned

Cap problem Cap replaced

Cap problem Cap,Diffuser and Tip replaced
insulator problem Cap, insulator replaced
Tip problem Cap , tip replaced
Cap problem Cap replaced
Tip problem Cap changed
Cap problem Cap replaced
Cap not found cap replaced
Cap problem Cap replaced
Cap problem Cap replaced
Cap problem Cap replaced
not working Cable cut , New joint made
Cap problem Cap changed
Cap not found Cap provided
Cap, tip problem Cap, Tip replaced
Cap problem Cap Provided
Cap problem cap short, replaced
Cap problem Cap replaced
Cap and diffuser problem Capo and Diffuser replaced
Cap problem Cap Short , replaced
Cap problem Cap replaced
Cap Not found Cap Diffuser ,Tip ,Tipholder provided
Cap problem cap, insulator installed
Cap problem Cap replaced
Earthing problem Cap replaced
Cap problem Cap replaced
Cap problem Cap replaced
Cap problem Cap replaced
Cap problem Cap replaced
Cap problem Cap, tip, tip holder replaced
Cap not found Cap rprovided
Cap problem Cap replaced
Cap problem Cap replaced

Observed Problem Activity/ Spares used

Liner problem Liner and Tip cleaned
Liner problem Liner cleaned
Mig wire problem Liner replaced
Liner problem Liner replaced
Mig wire problem Liner cleaned
Liner problem Liner cleaned
Liner problem Liner cleaned
Liner problem Liner and Tip clean
Liner problem Liner changed
Liner problem Liner & diffuser changed
Liner problem Liner replaced
Liner problem Liner Cleaned
Mig Wire oroblem Liner Cleaned
Mig Wire problem Liner cleaned
Mig Wire problem Liner cleaned
Mig Wire problem Liner cleaned
Mig Wire problem Liner cleaned
Liner problem Liner Cleaned
Liner problem Liner and tip Cleaned
Liner problem Liner Cleaned
Liner problem Liner Cleaned
Mig wire problem Liner Cleaned
Mig wire problem Liner Cleaned
Mig wire problem Liner Cleaned
Mig wire problem Liner Cleaned
Liner problem Liner & tip Cleaned
Mig wire problem Liner Cleaned
liner problem Liner, tip cleaned
Liner problem Liner replaced
Liner problem Liner cleaned
Liner problem Liner Cleaned
Liner problem Liner replaced
Mig wire problem Liner cleaned Tip changed
Mig wire problem Liner changed
Mig wire problem Liner cleaned
Mig Wire problem Liner replaced
Mig Wire problem Liner cleaned

Observed Problem Activity/ Spares used

Liner Problem Liner Replaced
Liner problem Liner cleaned
Liner problem Liner replaced
liner problem Liner replaced
Liner problem Liner cleaning done
Liner problem Liner cleaned
Liner problem Liner & Tip cleaning done
Mig wire problem Liner Replaced diffuser replaced
Mig wire problem Liner cleaned up
Liner& tip problem Liner& tip cleaned
Liner& tip problem Liner& tip cleaned
Liner& tip problem Liner& tip cleaned
Liner& tip problem Liner& tip cleaned
Liner& tip problem Liner& tip cleaned
not working Liner cleaned
Liner probleb Lineer cleaned
Liner problem Liner replaced
Liner problem Liner replaced
Liner problem liner replaced
Mig Wire problem Liner & Tip replaced
Mig Wire problem Liner cleaned up
Mig Wire problem Liner cleaned up
Mig Wire problem Liner & Tip cleaned up
Mig Wire problem Liner & Tip cleaned up
Mig Wire problem Liner replaced
Mig Wire problem Liner replaced
Mig Wire problem Liner cleaned up
Mig Wire problem Liner & Tip cleanedup
Mig Wire problem Liner and Tip cleaned up
Liner problem Liner cleaned
Liner problem Liner cleaned, Tip, Diffuser changed
Liner problem Liner cleaned, Tip changed
Liner problem Liner cleaned, Tip changed
Liner problem Liner cleaned
Liner problem, Cap changed Liner cleaned
Liner problem Liner cleaned,
Liner problem Liner cleaned,
Mig wire problem Liner clean
Liner problem Liner cleaned
Liner problem Liner cleaned
Liner problem Liner cleaned
 Total Total
Value Dispatch Spare
Month Reason
Value cost %

Oct-19 28035 2781000 1.01 Liner+ Nack

Nov-19 46928 3894000 1.21 Liner + Heater+ Torch
Dec-19 55800 4295000 1.30 Seal+Liner + Nack
Jan-20 87837 6005793 1.46 Seal+ Gland+ Liner + Nozle
Feb-20 62499 7554465 0.83 Regulator + NACK + Liner
Mar-20 69514 7032273 0.99 Liner + Heater
May-20 9530 917696 1.04 Liner + Heater
Jun-20 88631 2210000 4.01 Regulator + Liner

CED Pump No. 2 New Mechanical seal fitted

Why It's a gland packing system was implemented
Why The Old seal was Leaking
Why Because of prolong running it was worn out
UF Feed Pump New Mechanical seal fitted
Why It's a gland packing system was implemented
Why The Old seal was Leaking
Why Because of prolong running it was worn out

water Rinsing and surface conditioning Pump Both the pump converted in Glan
Why Bothe seal were leaking
Why Seal was damaged due to weared out
Why prolong ruuning may be the reason for this

The Cost include in this job is Rs. 58000/-

Hyd. Cylinder this cylinder replaced on Jig no. 2

Why the Old Cylindernot working
Why Seal leakage
Why Because of running continiously

Total Cost is include Rs. 13000/-

 Total
Extra

684
2405
34844
48648
4018
1875
2584
1720

l fitted
plemented
g
s worn out
l fitted
plemented
g
s worn out

e pump converted in Gland

red out
on for this

0/-

on Jig no. 2
ng

ously
 Total Brk. Total Brk. Total Total
Month Fabrication Min. MTTR
Hrs Hrs Brk Brk. Hrs

Jan-20 92:11:00 69:08:00 Cap problem 25 607 24.28 6:19

Liner problem 58 607 10.47

Feb-20 95:13:00 69:33:00 Liner problem 49 767 15.65 17:51

Gas leakage 19 527 27.74

Mar-20 61:53:00 48:09:00 Liner problem 49 360 7.35 5:39

Tip Problem 31 341 11.00

May-20 16:57 9:16 Liner Problem 8 124 15.50 1:00

Jun-20 57:20:00 23:48:00 Liner problem 23 399 17.35 5:49

Gas leakage 22 470 21.36

Jul-20 69:31:00 33:07:00 Liner Problem 29 607 20.93 20:27

Gas leakage 16 258 16.13

2864
47.7333333333333 ###
2820
21360
 Total Total Total
Paint Shop Min MTTR Utility Min MTTR
Brk Brk. Hrs Brk

Gun pressure is low 217 5 43.4 16:14 Hoist Not Working 674 17 39.65

Spray Pressure Low 190 4 47.5 5:07 Hoist Not workin 4:12 16 0.01094

Air Problem 139 5 27.8 5:39 Hoist not workin 326 14 23.2857
Sensor Problem 134 4 33.5

Wagon 1 1 60 6:41 Hoist not workin 366 5 73.2

OVEN burner 216 3 72 21:03 Crane and Hoist 1269 26 48.81

Wagon 1 756 2 378 15:56 Hoist 887 23 38.57

Comparison of liner consumption in last Four month

Sr. Month No. Of Liner Per

No. Frame Cons. Frame

1 May-20 74 5 14.8
2 Jun-20 248 10 24.8
3 Jul-20 348 12 29
4 Aug-20 192 2 96