MID REVIEW

Acknowledge Approved Checked Prepared

PT TOYOTA MOTOR MFG INDONESIA IMPROVE MTBF ASSY BY ELIMINATING T2AT PROBLEM
ASSY & PAINTING DIVISION
MAINTENANCE DEPARTEMENT (Pull Dolly Skid Lock Release Conf. Fault 1 & 2)
Mr BachtiarW Mr Sulasdi Mr Soleh F Mr Briyan Y
BACKGROUND III. SETTING TARGET
Maintenance Departement Action Plan:
1. Achieve Production Efficiency 97% (FY'16)
2. Achieve Line Stop Machine Impact to Production Efficiency < 1% (FY'16)
Eliminating Problem Photo
Logistic
Process Reduce problem 100% on Sensor can't detect Skid Lock at
Oct 2016
97% efficiency
0,5%
1%
T2AT month average 19 times to
Target 97% on Mar '16
0,5% 1% zero until Oct 2016
Quality
3%
Maintenance

I. CLARIFY THE PROBLEM IV. ROOT CAUSE ANALYSIS

ULTIMATE PHOTO SENSOR CAN'T DETECT SKID LOCK
ULTIMATE GOAL
GOAL
No
No Line
Line Stop
Stop cause
cause by
by Equipment
Equipment
Sensing System not function/Abnormal Skid Lock position out of sensor area
MTBF FY'15 target avg > 1
Ideal hours
Target 2.9 minute
Situation ESN avg = 237times Photo Sensor Photo Photo Sensor wire didn't Skid Lock stuck (make
Dolly x Photo Sensor Plat cover sensor at Skid
detect too fast Sensor NG connect correctly to PLC positon skid lock too Lock didn't center
high ) position didn't center
GAP std: 3 second
act: 3 second
std: can detect skid lock
act: can detect skid lock
std: can send signal to PLC
act: can send signal to PLC

MTBF average = 0.15 hours

ESN avg = 52 times Plat Cover At horizontal
Plat Stopper Skid Lock Bearing x Hole Skid At horizontal At vertical Skid Lock
Interference with skid dimension out Locator out position(based on
Current MTBF avg.(Apr'15-Dec'15) stopper
dimension interference position position of standart of position center wheel)
Situation = 0.85 hours std : centering by clamp std : 20 mm std : 135 mm std : 420 mm
ESN avg = 289 times act : centering by clamp act : 20 mm act : 135 mm (tol : 3mm) act : 420 mm (tol : 3mm)

MTBF : Mean Time Between Failure (hours) : Time between problem occur Skid Repottion when Hole at skid too Diameter bearing
Target 1 hour Photo sensor height Dolly height (based on
transfered small too big
MTTR : Mean Time To Repair (minutes) : Time that used for repairing problem didn't standart skid lock center) didn't
ESN : Equip Stop Number : Value that count of how much problem occur std : 40 mm standart
act : 40 mm std : 35mm
act : 35 mm std : 480 mm std : 491 mm
act : 480 mm act : 490 mm (tol : 3mm)

II. BREAKDOWN THE PROBLEM Skid width too small Guide Dolly too width X std: x= 1905 mm
std : 1900mm std : 1905mm act : some dolly didn't standart (x=1920)mm
MTBF not achieve because Number of act : 1900 mm (tol:5mm) act : some dolly didn't standart (tol : 3mm)

Equipment Stop (ESN) was too big , ESN can assume as the indicator of how good MTBF is. More MACHINE SYSTEM DETAIL SMOOTH
small ESN more good MTBF Value
=(
)/
T2AT SYSTEM SKID LOCK SYSTEM

Plat Stopper Skid Lock

Interference when skid
repotition

STUCK

FLOW PROCESS V. COUNTERMEASURE

1 2
SKID LOCK
2

1
 ROOT CAUSE AN

DOLLY
CONDITION A B
NORMAL CONDITON 5 5
ABNORMAL CONDITION
std: 3 second
act: 3 second
CAUSE ANALYSIS
NO Condition A B JDG No
1 Normal 5mm 5mm O
2 Abnormal 15mm 2-3mm X
 PHOTO SENSOR CAN'T DETECT SKID LOCK

Photo Sensor not function/Abnormal Skid Lock position out of sensor area

Photo Sensor Photo Photo Sensor wire didn't Skid Repotition when Skid x Skid Lock Dimension Mechanical Skid Lock NG
detect too fast Sensor NG connect correctly to PLC transfered interference each others

std: can detect skid lock std: can send signal to PLC
std: 3 second act: can send signal to PLC
act: 3 second act: can detect skid lock

Hole at skid too Diameter bearing Spring NG (didn't Bearing NG

Skid x Dolly Cylinder Pusher (didn't rotate)
Move too fast small too big function)
cleareance too big

std : 35mm std : Spring OK std : Bearing Rotate

std pneumatic : 2 bar std : 40 mm act : Bearifng Rotate
act pneumatic : 2 bar act : 40 mm act : 35 mm act : Spring OK

Skid width too small Guide Dolly too width

std : 1900mm
act : 1900 mm (tol:5mm) std : 1905mm
act : some dolly didn't standart (tol : 3mm)
 std: Wire connect
act: Wire connect

std: 3 second
act: 3 second
std: unknown
act: 60 Hz

std: Can detect skid lock

act: Can detect skid lock

PHOTO SENSOR C

ELECTRICAL

Photo Sensor PLC (I/O) Solenoid

5 1 2 std: can control cylinder
act: can control cylinder

Photo Sensor detect Photo Sensor NG

Photo Sensor wire didn't
too fast connect correctly to PLC

std: 3 second std: can detect skid lock std: can send signal to PLC std: 1900 mm
act: 3 second act: can detect skid lock act: can send signal to (tol : 5 mm)
PLC act : 1900 mm
(tol: 5 mm)
Normal Condition

Stopper

Abnormal Condition
 Stopper

sensor area

Mechanical Skid Lock NG

Bearing NG
(didn't rotate)

std : Bearing Rotate

act : Bearifng Rotate
 std: centering by clamp
act: centering by clamp

PHOTO SENSOR CAN'T DETECT SKID LOCK

ELECTRICAL MECHANICAL

Solenoid Skid Cylinder Pusher Dolly

Guide Traverser Feed
std: can control cylinder 6 3
Co.
6
act: can control cylinder
4 std: 1915 mm
act: 1920 mm

Guide Dolly (too width) Mechanical Skid

Skid Lock hole
7
Cylinder move too fast (make Lock
Skid Width dimension repotition skid)
std: 1915 mm
act : some dolly didn't standart
nd signal to PLC std: 1900 mm std: 40 mm
nd signal to (tol : 5 mm) act : 40 mm
act : 1900 mm
(tol: 5 mm)
Bearing Skid Lock Stick Spring
std : 35 mm
act : 35 mm

Plat cover photo sensor Skid Lock Stick dimension

dimension interference Plat Stopper Skid Lock Interference
intererence
 Skid Lock

Stopper

Skid Lock
Stopper
 PHOTO SENSOR CAN'T DETECT SKID LOCK

ELECTRICAL MECHANICAL

Photo Sensor PLC (I/O) Solenoid Skid Cylinder

5 1 2std: can control cylinder 6 Pusher
act: can control cylinder
4
Photo Sensor Photo Sensor Photo Sensor wire didn't Skid Skid Lock hole Cylinder move too fast
detect too fast NG connect correctly to PLC Width dimension (make repotition skid)

std: 3 second std: can detect skid lock std: can send signal to PLC std: 1900 mm std: 40 mm
act: 3 second act: can detect skid lock act: can send signal to (tol : 5 mm) act : 40 mm
PLC act : 1900 mm
(tol: 5 mm) Bearing
std : 35 mm
act : 35 mm

Plat cover photo sensor Plat Stopper Skid Lock Interference

dimension interference
R CAN'T DETECT SKID LOCK

MECHANICAL

Cylinder Guide Traverser Dolly

Pusher
3 Feed Co.
std: 1915 mm
6
act: 1920 mm
 std: 1915 mm
act: 1920 mm

Guide Dolly (too Mechanical Skid

7
Cylinder move too fast width) Lock
(make repotition skid)
std: 1915 mm
act : some dolly didn't standart

Bearing Skid Lock Stick Spring

std : 35 mm
act : 35 mm

Skid Lock Stick dimension

Plat Stopper Skid Lock Interference intererence
 Cyl.Skid Skid Lock
Skid Dolly Release
Present (Trim Doll
Adv. Up.

Skid
Dolly Stopper Pus
Present Down Adv
 Skid
Dolly Stopper Pus
Present Down Adv
Skid Lock Skid Skid
(Trim Dolly) Puller Puller
Up. Adv.. Return

Skid Skid Lock

Pusher Follow Skid Lock
Adv. Skid Down
Track
Skid
Pusher Follow Skid Lock
Adv. Skid Down
Track
 Point of Occurance

Skid Lock
id Cyl.Skid Dolly (Trim
ller Release Ret. Dolly)
turn Down

Skid Lock Pull Dolly Skid

Down Lock Conf. Pusher
Complete Ret.
Skid Lock Pull Dolly Skid
Down Lock Conf. Pusher
Complete Ret.

Point of Occurance
rance

ock
Traverse
Feed Stopper
Rotary.
Up

kid Signal ready

usher to Input
et. Body
kid Signal ready
usher to Input
et. Body

Signal Ready To Skid

Body Input Pusher
Ret.

Cyl.Skid
Dolly Skid
Release Puller
Ret. Ret. .
 Point of Occurance

Skid Pully Dolly Skid

Pusher Lock Conf. Pusher
Ret. Complete Adv.

Skid Skid Cyl.Skid

Puller Puller Dolly
Ret. . Adv.. Release Adv.
 Stopper Dolly Stopper
r Present Up
Down

kid
Skid
ase Adv. Present
Stopper Traverse
Up Feed
Rotary.
TRIMMING 2 CV
TRIMMING 2 CV

TRIMMING 2
U - TURN
 SKID

T2 AT

G 2 CV DOLLY
G 2 CV DOLLY

G2
N
SKID
TAKE BY TOWING
TO INPUT BODY
Cyl. D
Lock
SKID LOCK
 PRIORITIZED
ING
ODY
yl. Dolly Skid
Lock Relase
IZED PROBLEM
kid
e
SKID
EM
D
SKID
SKID

Traver

Skid
Traver
(SKID LOCK
Traverser Feed Rotary

Skid Pusher Cylinder

Traverser Feed Rotary
 PROBLEM SITUATION
D LOCK CAN'T LOCK COM

PRO
TO T

GAP
ry
ON
K COMPLETE)

PROBLEM
TO TACKLE

P
 2015
APR MAY JUN JUL AUG SEP OCT
MTTR 2.7 2.4 2.4 2.7 3.1 3.6 3.9
TARGET (m 2.9 2.9 2.9 2.9 2.9 2.9 2.9
 2016
NOV DEC JAN FEB MAR APR MAY JUNE JULY AUG
2.6 2.8
2.9 2.9 2.9 2.9 2.9 2.9 2.9 2.9 2.9 2.9
Photo Sensor wire
connect correctly
 ELECTRICAL

Photo Sensor wire didn't Photo Sensor detect too

connect correctly to PLC fast
 PH

RICAL

detect too
t Photo Sensor NG
 Skid lock spring

Skid Lock can't back to

home position
PHOTO SENSOR CAN'T DETECT

Skid Lock dimension &

mechanical NG
 Skid Lock dimension &
mechanical NG

Skid lock spring NG Diameter bearing skid lock

interference with diameter
skid hole

ck to Skid Lock can't move follow

n the track to skid hole
 MECHANICAL

Fix Position Dolly x Track S

T2AT did'nt center
 Fix Position Dolly x Track S
T2AT did'nt center

Std: Center
Act: Center

Skid Lock position too high

above skid hole
ECHANICAL

tion Dolly x Track Skid Skid & Dolly Dime

AT did'nt center Interference each
tion Dolly x Track Skid Skid & Dolly Dime
AT did'nt center Interference each

Skid dimension not

standart
Skid & Dolly Dimension
Interference each other
Skid & Dolly Dimension
Interference each other

Dolly dimension not

standart
 Photo Sensor Can't Detect
PROBLEM
TO TACKLE

Photo Sensor
Receiver
GAP

STOPPER

SKID
SKID
an't Detect

Photo Sensor
Transmitter
 REAR DOLLY SKID

Roller Traverser
Motor Co. STOPPER

SKID
SKID
B
SKID
B

Normal Condition

Photo Sensor
Transmitter

Photo Sensor
Receiver

PHOTO SENSOR CAN DETECT

SKID LOCK
 PROBLEM TO
TACKLE

GAP
SKID FRONT DOLLY

Roller Traverser
Motor Co.

B
 B

Abn

PHOTO SENSOR

Photo Sensor
Transmitter

Photo Sensor
Receiver

ETECT
Skid Lock Position out of
sensor area
 Photo Sensor Can't Detect

Photo Sensor Photo Sensor

Transmitter Receiver

PROBLEM TO
TACKLE
A

Roller Traverser
STOPPER Motor Co.

SKID
B
 SKID
B

Abnormal Condition

PHOTO SENSOR CAN'T DETECT SKID LOCK

Photo Sensor
Transmitter

Photo Sensor
Receiver

osition out of Sensing System not

or area functon/abnormal
SKID LOCK STUCK
 SKID LOCK STUCK

Photo Sensor
Transmitter

sing System not

cton/abnormal
REAR DOLLY SKID

B
FRONT DOLLY
NO ACTIVITY DETAILS PIC FEB
I II

1 Study & Analysis Problem Briyan (Mnt. Eng)

2 Analysis Drawing Dolly & Skid Briyan (Mnt. Eng)

3 Measuring Dolly & Skid on Assy Shop Briyan (Mnt. Eng)

Trial Auto Process with skid at an angle Briyan, Agung T. &

4 extremly at T2AT Ridwan

Discussion with maker (NKC) about dolly & Briyan &

5 skid standart Denny(NKC)

Calibration Dolly (Install sim at Dolly Briyan &

6
Problem) & Monitoring Workshop
Standaritation item check on Preventive
7 Briyan (Mnt. Eng)
Maintenance

8 Study & Analysis Result Improvement Briyan (Mnt. Eng)

 2016
FEB MAR APR MAY JUN JUL
III IV I II III IV I II III IV I II III IV I II III IV I II III IV
 ###
###
EVA ###
###
 PHOTO SENSOR CAN'T DETECT

ELECTRICAL MECHANICAL

Photo Sensor Wire didn't Photo Sensor Skid & Dolly DImension Skid Repotition when
detect too fast Photo Sensor NG Interference each other
connect correctly to PLC transfered

std: Wire connect std: 3 second std: Indicator Lamp work

act: 3 second act: Indicator Lamp work std: centering by clamp
act: Wire connect act: centering by clamp

Urethane Stopper at Skid x Dolly Traverser Stopper

cleareance too Traverser Motor too
Dolly didn't level fast Position didn't correct
each other much

std: 60 Hz
std: Urethane level each other act: 60 Hz
act: Urethane level each other

SKID

DOLLY
SKID LOCK SKID

CYLINDER
PHOTO PUSHER
SENSOR

TRAVERSER
MOTOR

SOLENOID

PLC ID OD AIR SUPLLY

v

SKID LOCK

PHOTO SENSOR

PLC
PLC
 MECHANICAL

Repotition when Fix Position Dolly x

transfered Track Skid T2AT
didn't center

std: centering by clamp

act: centering by clamp

Traverser Stopper
Position didn't correct

SKID

SKID LOCK

SOLENOID

v
 v

AIR SUPLLY

DOLLY

CYLINDER PUSHER

PHOTO SENSOR

TRAVERSER MOTOR

SOLENOID

PLC ID OD
PLC ID OD
SKID LOCK

Traverser Feed
Rotary

Cylinder
Pusher

SOLENOID

T T v Traverser Feed
Rotary
 T T v Traverser Feed
Rotary

TRAVERSER
AIR SUPLLY MOTOR

PHOTO
SENSOR
DOLLY

SKID