Instructions for use

sushil@polyplasticsindia.com 04/090513
Company Name POLYPLASTICS INDUSTRIES (I) PVT. LTD.
Fill complete information in "Machine Master" before entering data in "Data Sheet". Date to be
filled in "MM/DD/YY" format only
S.No. Sheet Name Description
1 Instructions This sheet shows only guidelines for use of this package.

This sheet is the main sheet, in which data is to be filled. Only variable data
2 Data Sheet
to be filled in sheet, standard data will be picked by cells automatically.

This sheet shows Mean Time to repair (MTTR) & Mean Time Between
3 MTTR_MTBF
Failure (MTBF).
This sheet shows dept-wise summary for breakdowns in term of
4 MIS-F-11
HW/NW/SW/IFS category.
Machine History This sheet shows the History Card for the machines. To generate the
5
Card history card, you can select any machine from drop down list.
Machine History This sheet shows the History Card for the machines. To generate the
6
Card history card, you can select any machine from drop down list.
In this sheet you, you have to provide basic info for all machines. This data
7 Machine Master
will be used in other sheets.

If there is any concern, please contact QMS Dept.

sushil@polyplasticsindia.com
 Revision History

Rev. No. Date Sheet

00 9-Jan-13 ---

01 24-Jan-13 Data Entry

02 7-Feb-13 AW Hrs

03 1-Apr-13 Data Sheet

04 9-May-13 MTTR_MTBF
 Revision History

Change Description

First Issue

Month calculation made automatic in place of drop down

Sheet added to calculate % breakdown alongwith no of hrs.

Formula corrected for location.
Production loss corrected for Corrective B/D only not for
Preventive & Predictive.

Provision made for calculatation of 40 machines.

 POLYPLASTICS INDUSTRIES (I) PVT. LTD.
BREAKDOWN SUMMARY SHEET
Year: 2013
B/D No Date Month Dept. M/C Name Type of Maint. Category Problem Description
6126 2-Dec-12 Dec Moulding Shop Sigma-50-I Corrective Mech cusion zero after some shots
6128 3-Dec-12 Dec Moulding Shop Sigma-110-II Corrective Electrical Refilling not working properly
6138 3-Dec-12 Dec Moulding Shop Sigma-50-I Corrective Electrical mold not close
6164 4-Dec-12 Dec Moulding Shop Polo-80 Corrective Mech Refilling not working properly
6148 4-Dec-12 Dec Moulding Shop Sigma-50-II Corrective Mech injection unit problem
6154 4-Dec-12 Dec Moulding Shop Sigma-80II Corrective Electrical nozzel heating low
6155 4-Dec-12 Dec Moulding Shop Polo-80 Corrective Hyd barrel temp not maintained
6156 4-Dec-12 Dec Moulding Shop Sigma-50-II Corrective Mech nozzel heating low
6167 6-Dec-12 Dec Moulding Shop Sigma-80II Corrective Mech material autofedding problem
6178 6-Dec-12 Dec Moulding Shop Sigma-80I Corrective Electrical clamping pressure not ok
6180 7-Dec-12 Dec Moulding Shop O-660 Corrective Hyd front gate not working
6181 7-Dec-12 Dec Moulding Shop L&T-200 Corrective Mech locking problem
6182 7-Dec-12 Dec Moulding Shop Sigma-50-II Corrective Electrical Refilling not working properly
N/A 7-Dec-12 Dec Moulding Shop O-660 Corrective Electrical gate open close problem
6194 7-Dec-12 Dec Moulding Shop Sigma-80II Corrective Mech material autofedding problem
6195 7-Dec-12 Dec Moulding Shop Sigma-80I Corrective Electrical clamping pressure not ok
6198 8-Dec-12 Dec Moulding Shop Polo-80 Corrective Electrical Refilling not working properly
6199 8-Dec-12 Dec Moulding Shop Sigma-110-I Corrective Electrical mtc not working
6271 17-Dec-12 Dec Moulding Shop Sigma-50-I Corrective Electrical material autofedding problem
6272 17-Dec-12 Dec Moulding Shop Omega-450 Corrective Electrical barrel temp not maintained
6273 17-Dec-12 Dec Moulding Shop O-660 Corrective Electrical hrtc problem
6287 18-Dec-12 Dec Moulding Shop Sigma-50-I Corrective Electrical nozzel heating low
6290 18-Dec-12 Dec Moulding Shop L&T-200 Corrective Electrical hrtc problem
6292 18-Dec-12 Dec Moulding Shop Polo-80 Corrective Electrical nozzel heating low
6293 18-Dec-12 Dec Moulding Shop L&T-200 Corrective Electrical hrtc problem
6294 19-Dec-12 Dec Moulding Shop Sigma-110-II Corrective Mech Refilling not working properly
6318 21-Dec-12 Dec Moulding Shop O-660 Corrective Electrical front gate not working
6322 21-Dec-12 Dec Moulding Shop Sigma-80I Corrective Electrical nozzel heating low
6330 22-Dec-12 Dec Moulding Shop Sigma-110-II Corrective Mech clamping pressure not ok
6334 22-Dec-12 Dec Moulding Shop Sigma-110-I Corrective Electrical clamping pressure not ok
6339 23-Dec-12 Dec Moulding Shop Sigma-110-II Corrective Electrical clamping pressure not ok
6343 24-Dec-12 Dec Moulding Shop L&T-200 Corrective Electrical nozzel heating low
6345 24-Dec-12 Dec Moulding Shop SP-80 Corrective Mech mold not open
6305 20-Dec-12 Dec Moulding Shop Sigma-50-I Corrective Electrical front gate emergency problem
6354 31-Dec-12 Dec Moulding Shop L&T- 85 Corrective Electrical restart semi button not working

MNT-F-41/01/171211/4314
 6363 1-Jan-13 Jan Moulding Shop L&T-200 Corrective Electrical locking problem
6366 1-Jan-13 Jan Moulding Shop Sigma-80I Corrective Mech front gate problem
6368 2-Jan-13 Jan Moulding Shop Polo-80 Corrective Electrical Refilling not working properly
6373 2-Jan-13 Jan Moulding Shop Omega-450 Corrective Electrical machine temp problem
6374 2-Jan-13 Jan Moulding Shop Sigma-110-II Corrective Electrical nozzel heater connection
6379 3-Jan-13 Jan Moulding Shop Sigma-50-I Corrective Electrical mould heating not proper
6381 4-Jan-13 Jan Moulding Shop Sigma-80I Corrective Mech front gate problem
6385 4-Jan-13 Jan Paint Shop Paint Shop Corrective Electrical zone no-5 is not working
6386 4-Jan-13 Jan Moulding Shop Sigma-80I Corrective Mech gate open close problem
6394 6-Jan-13 Jan Press Shop Press Shop Corrective Electrical tape cutting m/c not working
6409 8-Jan-13 Jan Press Shop Press Shop Corrective Mech tape cutting m/c not working
6411 8-Jan-13 Jan Moulding Shop O-660 Corrective Electrical hrtc problem
6413 9-Jan-13 Jan Moulding Shop Multiplast-55 Corrective Electrical nozzel temp high
6418 10-Jan-13 Jan Moulding Shop Magna-80 Corrective Electrical motor tripping problem
6427 11-Jan-13 Jan Moulding Shop Polo-80 Corrective Electrical locking problem
6429 12-Jan-13 Jan Moulding Shop Polo-80 Corrective Electrical locking problem
6435 14-Jan-13 Jan Moulding Shop L&T-200 Corrective Electrical oil temprature not maintained
6441 14-Jan-13 Jan Moulding Shop Polo-80 Corrective Electrical locking problem
6446 15-Jan-13 Jan Moulding Shop Polo-80 Corrective Electrical locking problem
6447 15-Jan-13 Jan Moulding Shop Sigma-110-II Corrective Electrical injection pressure drop
N/A 16-Jan-13 Jan Moulding Shop Sigma-110-II Corrective Mech cusion zero after some shots
6470 18-Jan-13 Jan Moulding Shop Sigma-80II Corrective Electrical display hang
6471 18-Jan-13 Jan Moulding Shop Sigma-50-II Corrective Electrical locking problem
6478 19-Jan-13 Jan Moulding Shop Sigma-80II Corrective Electrical sensor problem
6483 21-Jan-13 Jan Moulding Shop Sigma-110-I Corrective Electrical clamp status problem
N/A 22-Jan-13 Jan Moulding Shop O-660 Corrective Electrical hrtc problem
6488 22-Jan-13 Jan Moulding Shop Sigma-50-I Corrective Electrical temprature low problem
6493 22-Jan-13 Jan Moulding Shop Sigma-110-I Corrective Electrical locking problem
6495 22-Jan-13 Jan Moulding Shop O-660 Corrective Electrical hrtc problem
6497 23-Jan-13 Jan Moulding Shop O-660 Corrective Electrical hrtc problem zone-6 temp. low
6500 23-Jan-13 Jan Moulding Shop SP-80 Corrective Mech injection pressure drop
6501 23-Jan-13 Jan Moulding Shop Magna-80 Corrective Electrical locking problem
N/A 23-Jan-13 Jan Tool Room Tool Room Corrective Electrical cnc m/c not working
N/A 25-Jan-13 Jan Moulding Shop SP-80 Corrective Mech injection pressure drop
6506 25-Jan-13 Jan Moulding Shop O-660 Corrective Mech front gate not working
6509 28-Jan-13 Jan Moulding Shop SP-180 Corrective Mech material autofedding problem
N/A 29-Jan-13 Jan Moulding Shop Sigma-50-II Corrective Electrical injection limit switch not working proper
6517 29-Jan-13 Jan Moulding Shop SP-180 Corrective Mech injection pressure drop
6520 30-Jan-13 Jan Moulding Shop SP-180 Corrective Electrical Refilling not working properly
6527 31-Jan-13 Jan Moulding Shop L&T-200 Corrective Electrical oil temprature not maintained
6529 1-Feb-13 Feb Moulding Shop L&T-200 Corrective Mech material autofedding problem
6535 1-Feb-13 Feb Moulding Shop Omega-450 Corrective Electrical hrtc not working
MNT-F-41/01/171211/5314
 6542 2-Feb-13 Feb Moulding Shop L&T-200 Corrective Electrical locking problem
6541 2-Feb-13 Feb Moulding Shop Omega-450 Corrective Electrical Refilling not working properly
6546 3-Feb-13 Feb Moulding Shop Omega-450 Corrective Mech material autofedding problem
N/A 4-Feb-13 Feb Moulding Shop O-660 Corrective Electrical moud not close
N/A 4-Feb-13 Feb Moulding Shop Omega-450 Corrective Electrical sensor problem
6547 4-Feb-13 Feb Jig Shop Jig Shop Corrective Mech oven blower fan not workin
6563 7-Feb-13 Feb Moulding Shop Omega-450 Corrective Electrical mould not open
6564 7-Feb-13 Feb Moulding Shop O-660 Corrective Electrical core-2 not pulled
6572 9-Feb-12 Feb Moulding Shop SP-180 Corrective Electrical mould not close
6573 9-Feb-13 Feb Moulding Shop Sigma-80II Corrective Electrical Refilling not working properly
6574 9-Feb-13 Feb Jig Shop Jig Shop Corrective Electrical oven heater fault
6583 11-Feb-13 Feb Moulding Shop Polo-80 Corrective Electrical Refilling not working properly
6586 12-Feb-13 Feb Moulding Shop SP-80 Corrective Mech retraction cylinder leakage
6587 12-Feb-13 Feb Moulding Shop Polo-80 Corrective Electrical locking problem
N/A 13-Feb-13 Feb Moulding Shop Polo-80 Corrective Electrical locking problem
6622 15-Feb-13 Feb Moulding Shop Sigma-110-II Corrective Electrical locking problem
6623 15-Feb-13 Feb Moulding Shop Sigma-50-II Corrective Electrical locking problem
6639 19-Feb-13 Feb Moulding Shop Sigma-80II Corrective Electrical mtc not working
6640 19-Feb-13 Feb Moulding Shop L&T- 85 Corrective Electrical barrel temp not maintained
N/A 19-Feb-13 Feb Moulding Shop O-660 Corrective Electrical hrtc not working
6649 20-Feb-13 Feb Moulding Shop Polo-80 Corrective Electrical Refilling not working properly
6653 21-Feb-13 Feb Moulding Shop L&T-200 Corrective Electrical motor tripping problem
6664 22-Feb-13 Feb Moulding Shop Sigma-110-II Corrective Electrical Refilling not working properly
6667 22-Feb-13 Feb Moulding Shop Sigma-80I Corrective Electrical front gate not working
6671 23-Feb-13 Feb Moulding Shop L&T- 85 Corrective Electrical material autofedding problem
6674 24-Feb-13 Feb Moulding Shop Sigma-80I Corrective Electrical rear gate not working proper
6678 25-Feb-13 Feb Moulding Shop L&T- 85 Corrective Electrical ejector not working
6681 26-Feb-13 Feb Moulding Shop O-660 Corrective Electrical hrtc not working
6684 26-Feb-13 Feb Moulding Shop O-660 Corrective Electrical main motor not start
6685 26-Feb-13 Feb Moulding Shop Polo-80 Corrective Mech Refilling not working properly
6701 28-Feb-13 Feb Moulding Shop Sigma-50-II Corrective Mech cusion zero after some shots
1-Jan-13 Jan Auto Plant Auto Plant Corrective Electrical
8-Jan-13 Jan Auto Plant Auto Plant Corrective Electrical
15-Jan-13 Jan Auto Plant Auto Plant Corrective Electrical
22-Jan-13 Jan Auto Plant Auto Plant Corrective Electrical
1-Feb-13 Feb Auto Plant Auto Plant Corrective Electrical
9-Feb-12 Feb Auto Plant Auto Plant Corrective Electrical
15-Feb-13 Feb Auto Plant Auto Plant Corrective Electrical
24-Feb-13 Feb Auto Plant Auto Plant Corrective Electrical
6702 1-Mar-13 Mar Moulding Shop SP-80 Corrective Electrical Nozzel heater not working
6703 1-Mar-13 Mar Moulding Shop L&T- 85 Corrective Electrical Stroke measurement problem
N/A 1-Mar-13 Mar Jig Shop Jig Shop Corrective Electrical oven heater fault
MNT-F-41/01/171211/6314
 6712 2-Mar-13 Mar Moulding Shop Sigma-110-II Corrective Mech Refilling not working properly
6716 2-Mar-13 Mar Moulding Shop L&T- 85 Corrective Electrical mould open stoped not reached
6723 4-Mar-13 Mar Moulding Shop Sigma-110-I Corrective Electrical hrtc not working
6724 4-Mar-13 Mar Moulding Shop O-660 Corrective Electrical Nozzel heater not working
6747 5-Mar-13 Mar Moulding Shop Sigma-110-II Corrective Electrical hrtc not working
6757 7-Mar-13 Mar Moulding Shop Sigma-80I Corrective Electrical display hang
6767 8-Mar-13 Mar Moulding Shop O-660 Corrective Electrical hrtc zone-6 temp. variation
6770 8-Mar-13 Mar Moulding Shop Sigma-110-I Corrective Electrical mould closing problem
6771 8-Mar-13 Mar Moulding Shop Polo-80 Corrective Electrical not functioning at anymode
6797 10-Mar-13 Mar Paint Shop Paint Shop Corrective Mech air pressure not maintained
6799 11-Mar-13 Mar Moulding Shop O-660 Corrective Electrical hrtc not working
6801 11-Mar-13 Mar Moulding Shop Polo-80 Corrective Electrical Refilling not working properly
6815 12-Mar-13 Mar Moulding Shop Sigma-110-II Corrective Electrical Refilling not working properly
6823 13-Mar-13 Mar Moulding Shop Sigma-80II Corrective Electrical mould hight not working proper
machine work directly without pressing
6830 14-Mar-13 Mar Press Shop Press Shop Corrective Electrical
push button
6831 14-Mar-13 Mar Moulding Shop Sigma-80I Corrective Electrical gate open close problem
6832 14-Mar-13 Mar Moulding Shop O-660 Corrective Electrical ejector not working
6833 14-Mar-13 Mar Moulding Shop L&T- 85 Corrective Mech feed zone temp low
6849 16-Mar-13 Mar Moulding Shop Sigma-110-II Corrective Electrical mould not open
6856 17-Mar-13 Mar Moulding Shop Sigma-110-II Corrective Electrical injection and clamping problem
N/A 17-Mar-13 Mar Moulding Shop Sigma-80I Corrective Mech front gate not working
6857 18-Mar-13 Mar Moulding Shop L&T-200 Corrective Electrical motor tripping problem
5858 18-Mar-13 Mar Moulding Shop Sigma-50-II Corrective Electrical mould not open
6863 18-Mar-13 Mar Moulding Shop SP-80 Corrective Electrical injection not working
6874 19-Mar-13 Mar Moulding Shop Sigma-80II Corrective Mech gate open close problem
6876 19-Mar-13 Mar Moulding Shop L&T-200 Corrective Electrical ejector not working
6878 19-Mar-13 Mar Paint Shop Paint Shop Corrective Mech air pressure seting prblem
6882 19-Mar-13 Mar Moulding Shop SP-80 Corrective Electrical injection not working
6894 20-Mar-13 Mar Moulding Shop Sigma-110-II Corrective Electrical locking problem
6910 22-Mar-13 Mar Moulding Shop Sigma-80I Corrective Electrical front gate not working
6911 22-Mar-13 Mar Moulding Shop Sigma-50-I Corrective Mech oil level low m/c stope
6912 23-Mar-13 Mar Moulding Shop Sigma-50-III Corrective Mech ejector not working
6927 26-Mar-13 Mar Moulding Shop Omega-450 Corrective Electrical locking problem
6931 28-Mar-13 Mar Moulding Shop Magna-80 Corrective Electrical mtc not working
6932 28-Mar-13 Mar Jig Shop Jig Shop Corrective Electrical oven temprature meter fault
6936 28-Mar-13 Mar Moulding Shop Sigma-80II Corrective Electrical m/c locking problem
6937 28-Mar-13 Mar Moulding Shop SP-80 Corrective Mech locking problem
6940 30-Mar-13 Mar Moulding Shop Sigma-50-I Corrective Mech mtc not working
1-Mar-13 Mar Auto Plant Auto Plant Corrective Electrical
8-Mar-13 Mar Auto Plant Auto Plant Corrective Electrical
15-Mar-13 Mar Auto Plant Auto Plant Corrective Electrical
MNT-F-41/01/171211/7314
 22-Mar-13 Mar Auto Plant Auto Plant Corrective Electrical
6944 1-Apr-13 Apr Moulding Shop Sigma-50-I Corrective Electrical locking problem
6948 1-Apr-13 Apr Moulding Shop Sigma-80I Corrective Mech front gate not working
6954 2-Apr-13 Apr Moulding Shop Sigma-80I Corrective Mech front gate not working
6965 3-Apr-13 Apr Moulding Shop O-660 Corrective Electrical ejector not working
6967 4-Apr-13 Apr Moulding Shop Polo-80 Corrective Electrical Refilling not working properly
6968 4-Apr-13 Apr Moulding Shop Polo-80 Corrective Electrical Refilling not working properly
nozzel temp and cold start protection
6983 6-Apr-13 Apr Moulding Shop L&T-200 Corrective Electrical
prob.
6989 6-Apr-13 Apr Moulding Shop L&T- 85 Corrective Electrical mould heating not proper
7021 11-Apr-13 Apr Moulding Shop SP-80 Corrective Electrical Refilling not working properly
7024 11-Apr-13 Apr Moulding Shop Sigma-50-III Corrective Electrical locking problem
7025 11-Apr-13 Apr Moulding Shop L&T- 85 Corrective Electrical Nozzel heater not working
7028 11-Apr-13 Apr Moulding Shop Sigma-50-I Corrective Electrical Nozzel heater not working
7035 11-Apr-13 Apr Moulding Shop L&T- 85 Corrective Electrical crane not working
7178 13-Apr-13 Apr Moulding Shop L&T-200 Corrective Electrical display off problem
7050 15-Apr-13 Apr Moulding Shop Sigma-50-I Corrective Electrical nozzel heating not proper
7063 16-Apr-13 Apr Moulding Shop Sigma-110-II Corrective Electrical m/c heating problem
7069 17-Apr-13 Apr Moulding Shop Magna-80 Corrective Electrical Refilling not working properly
7111 20-Apr-13 Apr Moulding Shop Sigma-50-II Corrective Mech mould open problem
7116 20-Apr-13 Apr Moulding Shop Sigma-80II Corrective Electrical front gate not working
N/A 23-Apr-13 Apr Moulding Shop Sigma-80I Corrective Mech front gate not working
7126 23-Apr-13 Apr Moulding Shop Sigma-50-I Corrective Mech mould not open close
7145 25-Apr-13 Apr Moulding Shop Polo-80 Corrective Mech low oil level alarm
7155 26-Apr-13 Apr Moulding Shop Sigma-50-I Corrective Mech mould open close problem
7159 27-Apr-13 Apr Moulding Shop Magna-80 Corrective Mech Refilling not working properly
7166 29-Apr-13 Apr Moulding Shop Polo-80 Corrective Mech oil leakage
1-Apr-13 Apr Auto Plant Auto Plant Corrective Electrical
11-Apr-13 Apr Auto Plant Auto Plant Corrective Electrical
20-Apr-13 Apr Auto Plant Auto Plant Corrective Electrical
29-Apr-13 Apr Auto Plant Auto Plant Corrective Electrical
N/A 1-May-13 May Moulding Shop Polo-80 Corrective Electrical locking problem
N/A 1-May-13 May Moulding Shop Sigma-50-III Corrective Mech oil level low m/c stope
7185 1-May-13 May Moulding Shop Omega-450 Corrective Electrical hrtc temp problem
7187 1-May-13 May Moulding Shop Sigma-50-I Corrective Electrical motor not run
N/A 1-May-13 May Moulding Shop Sigma-110-II Corrective Electrical locking problem
7199 3-May-13 May Moulding Shop L&T-200 Corrective Mech marerial auto feeding not working
7200 3-May-13 May Moulding Shop Sigma-50-I Corrective Mech feed zone temp high
7201 3-May-13 May Moulding Shop L&T- 85 Corrective Electrical plc not working
7213 6-May-13 May Moulding Shop Sigma-50-II Corrective Electrical mold not open
7214 6-May-13 May Moulding Shop Polo-80 Corrective Electrical refiling and locking problem
7217 6-May-13 May Moulding Shop Sigma-110-II Corrective Electrical heating not ok
MNT-F-41/01/171211/8314
 7223 7-May-13 May Moulding Shop O-660 Corrective Mech oil temprature not maintained
7234 8-May-13 May Paint Shop Paint Shop Corrective Electrical power cut
7237 9-May-13 May Moulding Shop L&T- 85 Corrective Electrical display all functions zero
7239 9-May-13 May Moulding Shop Sigma-50-I Corrective Electrical cusion zero after some shots
7243 9-May-13 May Moulding Shop Polo-80 Corrective Electrical locking problem
N/A 9-May-13 May Moulding Shop L&T- 85 Corrective Electrical plc not working
7244 9-May-13 May Moulding Shop Sigma-80II Corrective Electrical mold not close
7245 9-May-13 May Moulding Shop Sigma-80II Corrective Electrical locking problem
N/A 9-May-13 May Moulding Shop O-660 Corrective Electrical hrtc not working
7250 10-May-13 May Moulding Shop Sigma-80II Corrective Mech injection pressure not working
7253 10-May-13 May Moulding Shop Magna-80 Corrective Electrical temprature low problem
7254 10-May-13 May Moulding Shop Omega-450 Corrective Electrical auto feeding preblem
7258 11-May-13 May Moulding Shop O-660 Corrective Electrical hrtc temp problem
7263 11-May-13 May Moulding Shop L&T- 85 Corrective Electrical motor tripping problem
7264 11-May-13 May Moulding Shop Polo-80 Corrective Electrical locking problem
7268 11-May-13 May Moulding Shop Sigma-50-III Corrective Electrical mold not close
7277 12-May-13 May Moulding Shop Sigma-80II Corrective Electrical locking problem
7278 12-May-13 May Moulding Shop O-660 Corrective Electrical hrtc temp problem
7279 12-May-13 May Moulding Shop Sigma-50-II Corrective Electrical crane not working
7281 13-May-13 May Moulding Shop Sigma-80I Corrective Electrical front gate not working
7285 13-May-13 May Moulding Shop O-660 Corrective Electrical nozzel heater fault
7293 13-May-13 May Moulding Shop L&T-200 Corrective Electrical all functions off
7298 15-May-13 May Moulding Shop Polo-80 Corrective Electrical Refilling not working properly
7299 15-May-13 May Moulding Shop Sigma-80I Corrective Electrical Nozzel heater not working
7300 15-May-13 May Paint Shop Paint Shop Corrective Electrical motor not working
7306 15-May-13 May Moulding Shop L&T-200 Corrective Electrical main motor tripping problem
N/A 17-May-13 May Moulding Shop L&T- 85 Corrective Electrical motor tripping problem
7319 18-May-13 May Moulding Shop Polo-80 Corrective Electrical locking problem
7324 19-May-13 May Moulding Shop O-660 Corrective Electrical oil temprature not maintained
7334 21-May-13 May Moulding Shop L&T-200 Corrective Electrical plc not working
7336 21-May-13 May Moulding Shop SP-80 Corrective Mech oil leakage
7342 21-May-13 May Moulding Shop L&T-200 Corrective Electrical front gate not working
7345 21-May-13 May Moulding Shop Sigma-80I Corrective Mech front gate not working
7356 22-May-13 May Moulding Shop O-660 Corrective Electrical hrtc not working
7357 23-May-13 May Moulding Shop L&T-200 Corrective Electrical all functions off
7362 23-May-13 May Moulding Shop Multiplast-55 Corrective Electrical abnormal sound
7370 24-May-13 May Moulding Shop L&T-200 Corrective Electrical heating off and motor tripping problem
N/A 28-May-13 May Moulding Shop Multiplast-55 Corrective Electrical motor tripping problem
N/A 26-May-13 May Moulding Shop O-660 Corrective Electrical any function not working
N/A 27-May-13 May Tool Room Tool Room Corrective Electrical up down not work
7387 28-May-13 May Press Shop Press Shop Corrective Electrical machine safety sensor not working
N/A 29-May-13 May Moulding Shop L&T-200 Corrective Electrical mtc not working
MNT-F-41/01/171211/9314
 N/A 29-May-13 May Moulding Shop L&T-200 Corrective Electrical motor over load problem
7406 30-May-13 May Moulding Shop Sigma-80I Corrective Mech front gate not working
7408 30-May-13 May Moulding Shop Sigma-110-I Corrective Electrical mold not open
7-May-13 May Auto Plant Auto Plant Corrective Electrical
14-May-13 May Auto Plant Auto Plant Corrective Electrical
21-May-13 May Auto Plant Auto Plant Corrective Electrical
28-May-14 May Auto Plant Auto Plant Corrective Electrical

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MNT-F-41/01/171211/85314
MNT-F-41/01/171211/86314
MNT-F-41/01/171211/87314
MNT-F-41/01/171211/88314
MNT-F-41/01/171211/89314
MNT-F-41/01/171211/90314
MNT-F-41/01/171211/91314
MNT-F-41/01/171211/92314
MNT-F-41/01/171211/93314
MNT-F-41/01/171211/94314
MNT-F-41/01/171211/95314
MNT-F-41/01/171211/96314
MNT-F-41/01/171211/97314
MNT-F-41/01/171211/98314
MNT-F-41/01/171211/99314
 Opening Closing Closing Time Taken
Root Cause Action Taken/ Plan
Time Date Time (Hours)
Ring plunger damage ring plunger changed 8:00am 2-Dec-12 4:00pm 4.00
software problem setting changed 7:00am 3-Dec-12 11:30am 4.50
valve problem valve cleaned 8:00am 3-Dec-12 0.47916667 3.50
wire connecter loose wire connncter tightened 4:00am 4-Dec-12 6:00am 2.00
limit switch faulty limit switch changed 8:00am 4-Dec-12 11:30am 3.50
setting problem reseting carried out 4:30pm 4-Dec-12 5:30pm 1.00
thermocople found broken thermocouple changed 4:00pm 4-Dec-12 7:00pm 3.00
wiring found short wireing short problem rectified 8:15pm 4-Dec-12 9:45pm 1.50
line found choke pipe line cleaned 6:00pm 6-Dec-12 6:30pm 0.50
valve supply not ok wire repaired 10:30pm 6-Dec-12 12:00am 1.50
ball joint nut found broken new nut tightened 12:00am 7-Dec-12 1:00am 1.00
software problem reseting carried out 6:00am 7-Dec-12 7:00am 1.00
feeding problem in hopper hopper cleaned 4:00am 7-Dec-12 5:00am 1.00
limit switch faulty limit switch changed 5:00pm 7-Dec-12 6:00pm 1.00
pipe line choke pipe line cleaned 6:45pm 7-Dec-12 7:15pm 0.50
software problem setting changed 8:00pm 8-Dec-12 4:00am 8.00
wire connecter loose wire connncter tightened 12:00am 8-Dec-12 12:30am 0.50
error E-01 shown error reseting carried out 3:00am 8-Dec-12 4:00am 1.00
mcb found turn off reseting carried out 4:00am 17-Dec-12 4:30am 0.50
faulty heater zone-2 heater repaired 12:00am 17-Dec-12 1:00am 1.00
fuses of zone-2&4 card get blown new fuses fitted 12:00am 17-Dec-12 2:00am 2.00
heater faulty heater repaired 5:40am 18-17-12 6:40am 1.00
card faulty card changed 7:00pm 18-Dec-12 7:30pm 0.50
heater faulty heater repaired 7:30pm 19-Dec-12 2:30am 7.00
card faulty card changed 9:30pm 18-Dec-12 10:00pm 0.50
lumps in barrel barrel cleaned 7:30am 19-Dec-12 9:30am 1.00
limit switch faulty limit switch changed 12:30am 21-Dec-12 1:00am 0.50
heater faulty heater changed 2:00pm 21-Dec-12 2:30pm 0.50
clamping cylinder tie rod broken new tie rods fitted 7:00am 22-Dec-12 6:00pm 7.00
software problem setting changed 9:30am 22-Dec-12 10:00am 0.50
software problem setting changed 1:30am 23-Dec-12 2:00am 0.50
heater faulty heater repaired 7:00am 24-Dec-12 8:00am 1.00
relief valve problem valve cleaned 10:00am 24-Dec-12 12:00pm 2.00
supply fault wireing problem rectified 2:00am 20-Dec-12 3:00am 1.00
push button faulty push button repaired 10:30am 31-Dec-12 3:00pm 4.50

MNT-F-41/01/171211/100314
 software problem reseting carried out 2:45pm 1-Jan-13 5:00pm 2.75
wheel loose wheel tightened 7:30pm 1-Jan-13 0.36111111 1.00
connecter loose connecter tightened 12:00am 2-Jan-13 1:00am 1.00
supply fault wiring rectified 5:30pm 2-Jan-13 6:10pm 0.50
heater faulty nozzel heater fitted 10:00pm 2-Jan-13 10:30pm 0.50
mtc got tripped mtc resetting carried out 10:45am 3-Jan-13 12:00am 1.25
gate wheel problem gate setting carried out 8:15am 4-Jan-13 10:00am 2.00
switch malfunctioning switch repaired 9:00am 4-Jan-13 10:00am 1.00
wheel loose wheel tightened 08:45am 4-Jan-13 9:45am 1.00
contactor not working proper contactor changed 2:00pm 7-Jan-13 2:00pm 24.00
gear check nut loose check nut tightened 4:00pm 8-Jan-13 6:00pm 2.00
heater faulty heater repaired 9:00pm 8-Jan-13 9:30pm 0.50
thermocople found broken thermocouple changed 12:00pm 9-Jan-13 4:00pm 4.00
software problem reseting carried out 12:05am 10-Jan-13 12:35am 0.50
software problem reseting carried out 5:00pm 11-Jan-13 6:00pm 1.00
sensor problem sensor problem rectified 12:00am 12-Jan-13 8:00am 8.00
thermocople faulty thermocouple repaired 12:00am 14-Jan-13 10:30am 10.50
software problem reseting carried out 10:00pm 14-Jan-13 11:00pm 1.00
ejector transducer setting not ok error reseting carried out 1:00am 15-Jan-13 9:30am 8.50
software problem reseting carried out 6:30am 15-Jan-13 8:00am 1.50
Ring plunger damage ring plunger changed 6:00am 18-Jan-13 3:00pm 57.00
software problem reseting carried out 10:00am 18-Jan-13 11:00am 1.00
sensor problem sensor problem rectified 9:00am 18-Jan-13 10:30am 1.50
sensor setting not proper sensor problem rectified 4:00pm 19-Jan-13 5:00pm 1.00
software problem reseting carried out 6:00pm 21-Jan-13 7:00pm 1.00
heater faulty heater repaired 7:30am 22-Jan-13 8:00am 0.50
software problem reseting carried out 2:15pm 22-Jan-13 2:45pm 0.50
software problem reseting carried out 6:10pm 22-Jan-13 7:25pm 1.25
wiring found short wiring rectified 9:15pm 22-Jan-13 11:00pm 1.75
wiring found short wiring rectified 7:00am 23-Jan-13 8:00am 1.00
valve problem valve cleaned 4:30pm 23-Jan-13 6:30pm 2.00
software problem reseting carried out 7:45pm 23-Jan-13 8:45pm 1.00
ccontactor faulty contactor changed 15:40pm 23-Jan-13 6:30pm 3.00
hydraulic pipe damage hydraulic pipe changed 4:00pm 25-Jan-13 10:00pm 6.00
tie rod opened tie rod tightened 9:30pm 25-Jan-13 10:30pm 1.00
line found choke line cleaned 1:45am 28-Jan-13 2:45am 1.00
limit switch faulty limit switch changed 1:30am 29-Jan-13 2:00am 0.50
valve problem valve cleaned 6:00pm 29-Jan-13 7:00pm 1.00
connecter loose connecter tightened 9:00am 30-Jan-13 9:30am 0.50
relay problem reseting carried out 3:00pm 31-Jan-13 3:30pm 0.50
flapper not workin proper flapper changed 8:00am 1-Feb-13 10:30am 2.50
fuses of card get blown fuses changed 7:00pm 1-Feb-13 9:00pm 2.00
MNT-F-41/01/171211/101314
 ejector transducer setting not ok ejecter setting carried out 3:00pm 2-Feb-13 3:45pm 0.75
transducer wire loose transducer wire tightened 2:30pm 2-Feb-13 3:30pm 1.00
flapper not workin proper flapper repaired 12:00am 3-Feb-13 1:00am 1.00
limit switch faulty limit switch setting carried out 12:00am 4-Feb-13 12:30am 0.50
transducer wire loose transducer wire tightened 2:00am 4-Feb-13 4:00am 2.00
bearings found damage bearings replaced 8:00am 5-Feb-13 8:00am 0.00
software problem reseting carried out 12:00am 7-Feb-13 1:00am 1.00
mould limit s/w problem mould limit s/w setting carried out 12:00am 7-Feb-13 2:00am 2.00
limit switch faulty limit s/w setting carried out 6;00am 9-Feb-13 9:00am 3.00
software problem reseting carried out 12:00am 9-Feb-13 12:45am 0.75
heater become short heater changed 15:20pm 9-Feb-13 16:20pm 1.00
valve connecter loose valve connecter tightened 1:30pm 11-Feb-13 3:30pm 2.00
seal kit damage seal kit changed 12:00am 12-Feb-13 12:00pm 12.00
transducer loose transducer nut tightened 12:00am 12-Feb-13 12:30am 0.50
transducer problem transduce setting carried out 8:30am 13-Feb-13 12:30pm 4.00
software problem reseting carried out 6:00am 15-Feb-13 9:15am 3.25
limit switch faulty limit s/w setting carried out 3:00am 15-Feb-13 4:30am 1.50
relay problem reseting carried out 1:00am 19-Feb-13 1:30am 0.50
heater supply fault heater supply fault rectified 12:30am 19-Feb-13 1:00am 0.50
wiring found short wiring rectified 7:15pm 19-Feb-13 0.3125 0.25
lumps in barrel barrel cleaned 1:00pm 20-Feb-13 2:00pm 1.00
software problem reseting carried out 7:00am 21-Feb-13 7:30am 0.50
wire connecter loose wire tighetend 9:15am 22-Feb-13 10:00am 0.75
supply fault wire tighetend 10:30am 22-Feb-13 1:00am 2.50
line found choke line cleaned 6:30am 23-Feb-13 7:00am 0.50
limit switch faulty limit switch repaired 2:30am 6-Mar-00 3:30am 1.00
transducer problem transducer repaired 8:00am 25-Feb-13 1:00pm 5.00
wiring found short wiring rectified 3:30am 26-Feb-13 5:30am 2.00
timer faulty star delta timer changed. 2:00pm 26-Feb-13 4:30pm 2.50
valve found jam valve cleaned 1:00pm 26-Feb-13 2:00pm 1.00
Ring plunger slipage ring plunger changed 11:00pm 1-Mar-13 7:30pm 20.00
15.00
15.00
15.00
18.00
3.00
4.00
4.00
2.50
faulty heater heater replaced 9:30am 1-Mar-13 10:00am 0.50
transducer problem transducer cleaned 11:00am 1-Mar-13 2:00pm 3.00
heater supply fault heater wire repaired 2:30pm 1-Mar-13 3:45pm 1.25
MNT-F-41/01/171211/102314
 lumps in barrel hopper cleaned 12:00am 2-Mar-13 2:00am 2.00
transducer problem transducer cleaned 9:00am 2-Mar-13 10:00am 1.00
switch malfunctioning switch repaired 12:00am 4-Mar-13 1:00am 1.00
mcb found trip mcb resetting carried out 7:00am 4-Mar-13 8:00am 1.00
supply fault hrtc repaired 10:00pm 5-Mar-13 11:00pm 1.00
software problem reseting carried out 7:00am 7-Mar-13 8:30am 1.50
software problem reseting carried out 5:00am 8-Mar-13 6:00am 1.00
software problem reseting carried out 3:00pm 8-Mar-13 4:00pm 1.00
data setting problem data seting carried out 3:00pm 8-Mar-13 4:00pm 1.00
filter choked filter cleaned 11:30am 10-Mar-13 13:30am 2.00
card faulty card changed 12:00am 11-Mar-13 3:30am 2.50
setting problem data seting carried out 12:00pm 11-Mar-13 1:30pm 1.50
data setting problem data seting carried out 9:00pm 13-Mar-13 7:00am 10.00
sensor not woking proper sensor problem rectified 12:00pm 13-Mar-13 2:00pm 2.00
push button faulty NC element changed. 11:00am 14-Mar-13 13:30pm 2.50
on off switch faulty on off switch changed 11:00am 14-Mar-13 1:30pm 2.50
limit switch faulty limit switch repaired 11:00am 14-Mar-13 1:30pm 2.50
cooling exceeds min level temprature maintained 4:30pm 14-Mar-13 5:30pm 1.00
gate valve supply fault gate valve supply fault rectified 7:00am 16-Mar-13 8:00am 1.00
setting problem setting changed 12:30pm 17-Mar-13 3:00pm 2.50
gate movement not ok gate repaired 12:30pm 17-Mar-13 1:30pm 1.00
limit switch faulty limit switch setting carried out 12:00am 18-Mar-13 1:00am 1.00
excess locking pressure increased 12:00am 18-Mar-13 1:00am 1.00
heater not working heater repaired 9:30am 18-Mar-13 0.4375 1.00
gate movement not ok gate repaired 12:10am 19-Mar-13 1:14am 1.00
limit switch faulty limit swicth repaired 7:30am 19-Mar-13 8:00am 0.50
air pressure gauge not working proper air pressure gauge repaired 10:00am 19-Mar-13 5:30pm 7.50
limit switch faulty limit switch repaired 10:00am 19-Mar-13 10:30am 0.50
software problem reseting carried out 5:00am 20-Mar-13 6:00am 1.00
no nc element malfunctioning no nc element changed 2:30pm 22-Mar-13 4:30pm 2.00
oil level low oil level maintained 6:00pm 22-Mar-13 7:30pm 1.50
transducer setting not ok transducer seting carried out 2:00am 23-Mar-13 4:00am 2.00
software problem reseting carried out 6:00am 26-Mar-13 6:30am 0.50
reverse connection connection changed 7:30am 28-Mar-13 8:00am 0.50
temp. meter not ok temp. meter and thermocouple changed. 8:40am 28-Mar-13 12:10pm 3.50
sensor not woking proper sensor changed 4:45pm 28-Mar-13 6:15pm 1.50
locking cylinder seals become damage locking cylinder sealkit changed 6:00pm 29-Mar-13 11:00pm 30.00
triping poblem reseting carried out 1:00pm 30-Mar-13 5:30pm 4.50
4.00
4.00
4.00
MNT-F-41/01/171211/103314
 3.75
sensor not woking proper sensor setting carried out 8:30am 1-Apr-13 11:00am 2.50
wheel loose wheel tightened 9:00pm 1-Apr-13 10:00pm 1.00
wheel loose wheel tightened 6:00pm 2-Apr-13 7:00pm 1.00
setting problem ejecter setting carried out 11:10pm 3-Apr-13 11:40p 1.00
heating not proper heating setting carried out 7:00am 4-Apr-13 8:00am 1.00
supply fault contactor changed 12:30pm 4-Apr-13 7:00pm 6.50
software problem reseting carried out 12:20pm 6-Apr-13 12:50pm 0.50
mtc not working no nc element changed 7:15pm 6-Apr-13 7:45pm 0.50
supply fault wire repaired 12:00am 11-Apr-13 8:00am 8.00
transducer setting not ok transducer seting carried out 12:30am 11-Apr-13 5:00am 4.50
supply fault supply fault rectified 2:00am 11-Apr-13 4:00am 2.00
nozzel heater faulty nozzel heater changed 7:00am 11-Apr-13 8:00am 1.00
relay problem relay repaired 4:30pm 11-Apr-13 7:00pm 2.50
programm and data not found new flash drive fitted and programe loaded 12:00am 19-Apr-13 11:00am 143.00
nozzel heater faulty nozzel heater changed 12:15am 15-Apr-13 02:15am 2.00
software problem reseting carried out 6:00am 16-Apr-13 7:00am 1.00
supply fault supply fault rectified 2:00pm 17-Apr-13 4:00pm 2.00
gate valve supply fault gate valve setting carried out 4:40am 20-Apr-13 5:40am 1.00
valve supply not ok supply fault rectified 10:15am 20-Apr-13 11:15am 1.00
wheel jam front gate repaired 12:00am 23-Apr-13 1:00am 1.00
gate valve problem gate valve setting carried out 1:00am 23-Apr-13 3:00am 2.00
oil level low oil level maintained 6:00am 25-Apr-13 9:00am 3.00
gate valve not working proper gate valve setting carried out 12:00pm 26-Apr-13 2:30pm 2.50
valve supply not ok valve supply fault rectified 2:30pm 27-Apr-13 9:30pm 7.50
o-ring damage o-ring replaced 3:30pm 29-Apr-13 4:30pm 1.00
5.00
5.00
5.00
6.00
data setting problem data seting carried out 7:00pm 1-May-13 9:00pm 2.00
oil level low oil level maintained 10:30pm 1-May-13 12:00am 1.50
connection not ok connection changed 1:00am 1-May-13 1:30am 0.50
relay problem reseting carried out 12:00am 1-May-13 12:30am 0.50
error problem cylinder nut tightened 8:00am 1-May-13 8:30am 0.50
flapper not workin proper flaper repaird 1:00pm 3-May-13 1:30pm 0.50
cooling not ok water circulation problem rectified 9:00am 12-Mar-00 10:00am 1.00
cumnication problem reseting carried out 6:30pm 3-May-13 9:00pm 2.50
supply fault supply fault rectified 12:00pm 6-May-13 1:00pm 1.00
data setting problem data seting carried out 3:30pm 6-May-13 4:30pm 1.00
variations in temp reseting carried out 7:00pm 6-May-13 9:00pm 1.00
MNT-F-41/01/171211/104314
 cooling not ok water circulation problem rectified 6:00am 7-May-13 7:00am 1.00
power supply not available powersupply arranged 11:00am 8-May-13 11:00am 0.50
communication problem re setting carried out 0.52083333 9-May-13 0.5625 1.00
temp setting not ok temp. setting carried out 7:30am 9-May-13 8:30am 1.00
supply fault supply fault rectified 5:30pm 9-May-13 6:30pm 1.00
communication problem reseting carried out 12:00am 9-May-13 5:30pm 15.00
limit switch faulty limit s/w repaired 7:00pm 9-May-13 8:00pm 1.00
software problem data seting carried out 9:00pm 9-May-13 10:00pm 1.00
air pressure not working proper compressor problem rectified 12:30pm 9-May-13 1:00pm 0.50
error problem clamping cylinder rod setting carried out 9:30am 10-May-13 11:00am 1.50
supply fault wire repaired 6:30pm 10-May-13 7:00pm 0.50
sensor not woking proper supply fault rectified 6:45pm 10-May-13 7:15pm 0.50
card problem reseting carried out 2:30am 11-May-13 3:30am 1.00
communication problem reseting carried out 12:30am 13-May-13 5:30am 11.00
software problem data seting carried out 12:30pm 11-May-13 4:00pm 3.50
setting problem mold setting carried out 6:45pm 11-May-13 7:15pm 0.50
error problem transducer seting carried out 11:00am 12-May-13 2:00pm 3.00
card problem reseting carried out 10:00am 12-May-13 11:00am 1.00
wiring found short wire repaired 8:00am 12-May-13 9:00am 1.00
gate wheel problem gate wheel tightened 4:00am 13-May-13 5:00am 1.00
wiring found broken wire repaired 12:00am 13-May-13 1:30am 1.50
communication problem reseting carried out 9:00pm 13-May-13 1:00pm 4.00
plc wire faulty plc wire no 124 repaired 12:00am 15-May-13 5:00am 5.00
wire found short wire repaired 4:00am 15-May-13 5:00am 1.00
contactor not working proper contactor changed 9:00am 15-May-13 11:00am 2.00
communication problem reseting carried out 7:00pm 27-May-13 11:30am 86.00
variations in ejector stoke ejecter transducer changed with cable 7:30pm 18-May-13 3:30pm 10.00
software problem data seting carried out 3:30am 18-May-13 9:00am 5.50
coolig not ok cooling fan reset 8:00pm 13-Jul-00 9:00pm 1.00
communication problem reseting carried out 12:00am 21-May-13 13:00am 1.00
seal found damage seal kit changed 8:00am 21-May-13 1:00pm 5.00
gate limit swich error reseting carried out 3:30pm 21-May-13 4:30pm 1.00
gate wheel problem wheel tightened 5:00am 21-May-13 5:30am 0.50
heater wire found broken wire repaired 6:00pm 22-May-13 8:00pm 2.00
communication problem reseting carried out 12:00am 23-May-13 1:00am 1.00
motor cover loose motor cover tightened 2:30pm 23-May-13 3:00pm 0.50
communication problem reseting carried out 12:30pm 24-May-13 1:00pm 0.50
no nc element malfunctioning no nc element changed 12:00am 28-May-13 10:30am 10.50
software problem reseting carried out 3:15am 26-May-13 5:15am 1.00
contactor not working proper contactor cleaned 9:50am 27-May-13 10:50am 1.00
clutch problem break clutch changed 8:00am 28-May-13 10:00am 2.00
error problem reseting carried out 4:00am 29-May-13 5:00am 1.00
MNT-F-41/01/171211/105314
 relay problem reseting carried out 5:00am 29-May-13 5:30am 0.50
wheel loose wheel tightened 5:00pm 30-May-13 6:00pm 1.00
supply fault supply fault rectified 5:00pm 30-May-13 6:00pm 1.00
5.00
5.00
5.00
4.00

MNT-F-41/01/171211/106314
MNT-F-41/01/171211/107314
MNT-F-41/01/171211/108314
MNT-F-41/01/171211/109314
MNT-F-41/01/171211/110314
MNT-F-41/01/171211/111314
MNT-F-41/01/171211/112314
MNT-F-41/01/171211/113314
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MNT-F-41/01/171211/116314
MNT-F-41/01/171211/117314
MNT-F-41/01/171211/118314
MNT-F-41/01/171211/119314
MNT-F-41/01/171211/120314
MNT-F-41/01/171211/121314
MNT-F-41/01/171211/122314
MNT-F-41/01/171211/123314
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MNT-F-41/01/171211/125314
MNT-F-41/01/171211/126314
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MNT-F-41/01/171211/129314
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MNT-F-41/01/171211/189314
MNT-F-41/01/171211/190314
MNT-F-41/01/171211/191314
MNT-F-41/01/171211/192314
MNT-F-41/01/171211/193314
MNT-F-41/01/171211/194314
MNT-F-41/01/171211/195314
 Prod. Loss Spare Part Used, if
Reason for delay SP Cost (₹) Maint Carried Out by Remarks
(₹) any
48000 3000 Ashok Handa
18000 1000
42000
18000
45500
7000
27000
19500
3500
9000
5000
1000
13000
5000
3500
48000
4500
3000
6000
3000
10000
12000
500
63000
500
4000
2500
3000
28000
1500
2000
1000
16000
12000
22500

MNT-F-41/01/171211/196314
 2750
6000
9000
1500
2000
15000
12000
16000
6000
480000
40000
2500
44000
5000
9000
72000
10500
9000
76500
6000
228000
7000
19500
7000
3000
2500
6000
3750
8750
5000
16000
10000
57000
48000
5000
2000
6500
2000
1000
500
2500
6000
MNT-F-41/01/171211/197314
 750
3000
3000
2500
6000
0
3000
10000
6000
5250
22000 Devi Dayal
18000
96000
4500
36000
13000
19500
3500
2500
1250
9000
500
3000
15000
2500
6000
25000
10000
12500
9000
260000
225000
225000
225000
270000
45000
60000
60000
37500
4000
15000
27500
MNT-F-41/01/171211/198314
 8000
5000
3000
5000
4000
9000
5000
3000
9000
32000
12500
13500
40000
14000
50000
15000
12500
5000
4000
10000
6000
1000
13000
8000
7000
500
120000
4000
4000
12000
18000
28000
1500
5000
77000
10500
240000
54000
60000
60000
60000
MNT-F-41/01/171211/199314
 56250
30000
6000
6000
5000
9000
58500
500
2500
64000
63000
10000
12000
12500
143000
24000
4000
20000
13000
7000
6000
24000
27000
30000
75000
9000
75000
75000
75000
90000
18000
21000
1500
6000
2000
500
12000
12500
13000
9000
4000
MNT-F-41/01/171211/200314
 5000
8000
5000
12000
9000
75000
7000
7000
2500
10500
5000
1500
5000
55000
31500
7000
21000
5000
13000
6000
7500
4000
45000
6000
32000
86000
50000
49500
5000
1000
40000
1000
3000
10000
1000
5500
500
115500
5000
19000
40000
1000
MNT-F-41/01/171211/201314
 500
6000
3000
75000
75000
75000
60000

MNT-F-41/01/171211/202314
MNT-F-41/01/171211/203314
MNT-F-41/01/171211/204314
MNT-F-41/01/171211/205314
MNT-F-41/01/171211/206314
MNT-F-41/01/171211/207314
MNT-F-41/01/171211/208314
MNT-F-41/01/171211/209314
MNT-F-41/01/171211/210314
MNT-F-41/01/171211/211314
MNT-F-41/01/171211/212314
MNT-F-41/01/171211/213314
MNT-F-41/01/171211/214314
MNT-F-41/01/171211/215314
MNT-F-41/01/171211/216314
MNT-F-41/01/171211/217314
MNT-F-41/01/171211/218314
MNT-F-41/01/171211/219314
MNT-F-41/01/171211/220314
MNT-F-41/01/171211/221314
MNT-F-41/01/171211/222314
MNT-F-41/01/171211/223314
MNT-F-41/01/171211/224314
MNT-F-41/01/171211/225314
MNT-F-41/01/171211/226314
MNT-F-41/01/171211/227314
MNT-F-41/01/171211/228314
MNT-F-41/01/171211/229314
MNT-F-41/01/171211/230314
MNT-F-41/01/171211/231314
MNT-F-41/01/171211/232314
MNT-F-41/01/171211/233314
MNT-F-41/01/171211/234314
MNT-F-41/01/171211/235314
MNT-F-41/01/171211/236314
MNT-F-41/01/171211/237314
MNT-F-41/01/171211/238314
MNT-F-41/01/171211/239314
MNT-F-41/01/171211/240314
MNT-F-41/01/171211/241314
MNT-F-41/01/171211/242314
MNT-F-41/01/171211/243314
MNT-F-41/01/171211/244314
MNT-F-41/01/171211/245314
MNT-F-41/01/171211/246314
MNT-F-41/01/171211/247314
MNT-F-41/01/171211/248314
MNT-F-41/01/171211/249314
MNT-F-41/01/171211/250314
MNT-F-41/01/171211/251314
MNT-F-41/01/171211/252314
MNT-F-41/01/171211/253314
MNT-F-41/01/171211/254314
MNT-F-41/01/171211/255314
MNT-F-41/01/171211/256314
MNT-F-41/01/171211/257314
MNT-F-41/01/171211/258314
MNT-F-41/01/171211/259314
MNT-F-41/01/171211/260314
MNT-F-41/01/171211/261314
MNT-F-41/01/171211/262314
MNT-F-41/01/171211/263314
MNT-F-41/01/171211/264314
MNT-F-41/01/171211/265314
MNT-F-41/01/171211/266314
MNT-F-41/01/171211/267314
MNT-F-41/01/171211/268314
MNT-F-41/01/171211/269314
MNT-F-41/01/171211/270314
MNT-F-41/01/171211/271314
MNT-F-41/01/171211/272314
MNT-F-41/01/171211/273314
MNT-F-41/01/171211/274314
MNT-F-41/01/171211/275314
MNT-F-41/01/171211/276314
MNT-F-41/01/171211/277314
MNT-F-41/01/171211/278314
MNT-F-41/01/171211/279314
MNT-F-41/01/171211/280314
MNT-F-41/01/171211/281314
MNT-F-41/01/171211/282314
MNT-F-41/01/171211/283314
MNT-F-41/01/171211/284314
MNT-F-41/01/171211/285314
MNT-F-41/01/171211/286314
MNT-F-41/01/171211/287314
MNT-F-41/01/171211/288314
MNT-F-41/01/171211/289314
MNT-F-41/01/171211/290314
MNT-F-41/01/171211/291314
POLYPLASTICS INDUSTRIES (I) PVT. LTD.
Available & Running Hours
Jan Jan1 Feb Feb1 Mar Mar1 Apr
AH WH AH WH AH WH AH

O-660 671 620 557 557

Omega-450 532 448 407 405.5

SP-300 498 362 507 492.5

L&T-200 630 593 607 607

SP-180 390 347 350 344.8

Sigma-110-I 672 640 608 604.5

Sigma-110-II 584 651 528 528

L&T- 85 652 626 497 495

Sigma-80I 485 469 520 520

Sigma-80II 505 487 520 520

SP-80 720 720 672 672

Polo-80 720 710 672 672

Magna-80 720 720 672 672

Multiplast-55 720 720 672 672

Sigma-50-I 505 487 448 448

Sigma-50-II 720 720 672 672

Sigma-50-III 720 720 672 672

Auto Plant 720 720 288 288

Paint Shop 720 720 288 288

Assembly 720 720 288 288

Vacuum 720 720 288 288

Tool Room 720 720 288 288

Press Shop 720 713 672 630

QA Lab 720 720 672 672

Jig Shop 720 720 672 672

0 720 720 672 671

0 720 690 672 670.5

0 720 720 672 672

0 720 720 672 672

0 720 720 672 672

0 720 720 672 672

0 720 720 672 672

0
0
0
0
0
0
0
0
21244 20803 17741 17669.8 0 0 0
Apr1 May May1 Jun Jun1 Jul Jul1 Aug Aug1
WH AH WH AH WH AH WH AH WH
0 0 0 0 0 0 0 0 0
Sep Sep1 Oct Oct1 Nov Nov1 Dec Dec1
AH WH b1 WH AH WH AH WH
0 0 0 0 0 0 0 0
 POLYPLASTICS INDUSTRIES (I) PVT. LTD.
MTTR/ MTBF
For the period 2-Dec-12 to 28-Dec-17
Days Between Days Days
1st Failure Last Failure No. of
S.No Machine Name 1st & Last Excluding Excluding
date Date Failures
Failure Sundays Down Time
1 O-660 7-Dec-12 26-May-13 27 169 146 144.6
2 Omega-450 17-Dec-12 10-May-13 10 143 125 124.6
3 SP-300 25-Nov-37 30-Dec-99 0 -985645 -857142 -857142.0
4 L&T-200 7-Dec-12 29-May-13 23 172 149 138.1
5 SP-180 9-Feb-12 30-Jan-13 4 351 306 305.8
6 Sigma-110-I 8-Dec-12 30-May-13 7 172 149 148.7
7 Sigma-110-II 3-Dec-12 6-May-13 18 153 133 129.0
8 L&T- 85 31-Dec-12 17-May-13 15 137 119 116.5
9 Sigma-80I 6-Dec-12 30-May-13 19 174 151 149.7
10 Sigma-80II 4-Dec-12 12-May-13 15 158 137 136.3
11 SP-80 24-Dec-12 21-May-13 10 147 128 125.2
12 Polo-80 4-Dec-12 18-May-13 26 164 143 140.0
13 Magna-80 10-Jan-13 10-May-13 6 120 104 103.5
14 Multiplast-55 9-Jan-13 28-May-13 3 139 120 119.4
15 Sigma-50-I 2-Dec-12 9-May-13 17 157 137 135.7
16 Sigma-50-II 4-Dec-12 12-May-13 11 158 137 135.6
17 Sigma-50-III 23-Mar-13 11-May-13 4 48 43 42.6
18 Auto Plant 9-Feb-12 28-May-14 20 829 720 714.5
19 Paint Shop 4-Jan-13 15-May-13 5 131 113 112.5
20 Assembly 25-Nov-37 30-Dec-99 0 -985645 -857142 -857142.0
21 Vacuum 25-Nov-37 30-Dec-99 0 -985645 -857142 -857142.0
22 Tool Room 23-Jan-13 27-May-13 2 124 107 106.8
23 Press Shop 6-Jan-13 28-May-13 4 142 123 121.7
24 QA Lab 25-Nov-37 30-Dec-99 0 -985645 -857142 -857142.0
25 Jig Shop 4-Feb-13 28-Mar-13 4 54 46 45.8
26 0 25-Nov-37 30-Dec-99 0 -985645 -857142 -857142.0
27 0 25-Nov-37 30-Dec-99 0 -985645 -857142 -857142.0
28 0 25-Nov-37 30-Dec-99 0 -985645 -857142 -857142.0
29 0 25-Nov-37 30-Dec-99 0 -985645 -857142 -857142.0
30 0 25-Nov-37 30-Dec-99 0 -985645 -857142 -857142.0
31 0 25-Nov-37 30-Dec-99 0 -985645 -857142 -857142.0
32 0 25-Nov-37 30-Dec-99 0 -985645 -857142 -857142.0
33 0 25-Nov-37 30-Dec-99 0 -985645 -857142 -857142.0
34 0 25-Nov-37 30-Dec-99 0 -985645 -857142 -857142.0
35 0 25-Nov-37 30-Dec-99 0 -985645 -857142 -857142.0
36 0 25-Nov-37 30-Dec-99 0 -985645 -857142 -857142.0
37 0 25-Nov-37 30-Dec-99 0 -985645 -857142 -857142.0
38 0 25-Nov-37 30-Dec-99 0 -985645 -857142 -857142.0
39 0 25-Nov-37 30-Dec-99 0 -985645 -857142 -857142.0
40 0 25-Nov-37 30-Dec-99 0 -985645 -857142 -857142.0

MTTR (Hrs) MTBF (Days)

90.0
80.0 76
70.0
60.0
50.0
40
40.0
 80.0 76
70.0
60.0
50.0
40
40.0
30.0 21
20.0 17
12 11.3 9 13
8 8
10.0 1.2
5
1.0
6
1.4 1.0
5.37 4.08 1.6 1.2
6.7
2.85 2.0 5.0 1.8
0.0

Sigma-110-II

Multiplast-55
Sigma-110-I
O mega-450

Sigma-50-I
Sigma-80II
Sigma-80I

Magna-80
L&T-200

L&T- 85

Polo-80
SP-300

SP-180
O -660

SP-80
Action Plan/ Remarks:

Date: Compiled by
ICS INDUSTRIES (I) PVT. LTD.
MTTR/ MTBF

Total Repair MTTR MTBF

Time (Hrs) (Hrs) (Days)

33.5 1.2 5
10.0 1.0 12
0.0 #DIV/0! #DIV/0!
261.0 11.3 6
5.5 1.4 76
6.8 1.0 21
96.0 5.3 7
60.0 4.0 8
31.0 1.6 8
17.3 1.2 9
67.0 6.7 13
72.5 2.8 5
12.0 2.0 17
15.0 5.0 40
30.3 1.8 8
33.5 3.0 12
8.5 2.1 11
132.3 6.6 36
13.0 2.6 22
0.0 #DIV/0! #DIV/0!
0.0 #DIV/0! #DIV/0!
4.0 2.0 53
30.5 7.6 30
0.0 #DIV/0! #DIV/0!
5.8 1.4 11
0.0 #DIV/0! #DIV/0!
0.0 #DIV/0! #DIV/0!
0.0 #DIV/0! #DIV/0!
0.0 #DIV/0! #DIV/0!
0.0 #DIV/0! #DIV/0!
0.0 #DIV/0! #DIV/0!
0.0 #DIV/0! #DIV/0!
0.0 #DIV/0! #DIV/0!
0.0 #DIV/0! #DIV/0!
0.0 #DIV/0! #DIV/0!
0.0 #DIV/0! #DIV/0!
0.0 #DIV/0! #DIV/0!
0.0 #DIV/0! #DIV/0!
0.0 #DIV/0! #DIV/0!
0.0 #DIV/0! #DIV/0!
Average 3.4 19.7

MTTR (Hrs) MTBF (Days)

40
36
 L&T- 85

4.08
1.6
Sigma-80I

8
1.2
Sigma-80II 9
6.7

SP-80
13

Polo-80
2.85
2.0

Magna-80
17
5.0

Multiplast-55
40

1.8

Sigma-50-I
8
3.0

Sigma-50-II
12
2.1

Sigma-50-III
11

Approved by
6.6

Auto Plant
36

sushil@polyplasticsindia.com
 POLYPLASTICS INDUSTRIES (I) PVT. LTD.
BREAKDOWN HOURS
REASONS Maintenance Obje
Available % BD
M/C NO./ AREA B/D HRS Production Loss
Hours Hours Mech Electrical Hyd Others Maint. Cost (₹)
(₹)
O-660 0 9.0 1.0 8.0 0.0 0.0 45000 App. Cost (A) S.P. Cost (B)
Omega-450 0 1.0 0.0 1.0 0.0 0.0 3000 0
SP-300 0 0.0 0.0 0.0 0.0 0.0 0
B/D Hrs. (N
L&T-200 0 95.5 0.5 95.0 0.0 0.0 95500 250
211
SP-180 0 0.0 0.0 0.0 0.0 0.0 0
200
Sigma-110-I 0 1.0 0.0 1.0 0.0 0.0 3000
150
Sigma-110-II 0 1.5 0.0 1.5 0.0 0.0 6000
L&T- 85 0 39.5 0.0 39.5 0.0 0.0 197500 100
Sigma-80I 0 3.5 1.5 2.0 0.0 0.0 21000 50
12
Sigma-80II 0 6.5 1.5 5.0 0.0 0.0 45500
0
SP-80 0 5.0 5.0 0.0 0.0 0.0 40000
Mech Electrical
Polo-80 0 18.0 0.0 18.0 0.0 0.0 162000
Magna-80 0 0.5 0.0 0.5 0.0 0.0 5000 B/D Hrs. v/s Available Hou
1.2
Multiplast-55 0 11.0 0.0 11.0 0.0 0.0 121000 1.0
Sigma-50-I 0 2.5 1.0 1.5 0.0 0.0 30000 1.0

Sigma-50-II 0 2.0 0.0 2.0 0.0 0.0 26000 0.8

Sigma-50-III 0 2.0 1.5 0.5 0.0 0.0 28000
0.6 0.5
Auto Plant 0 19.0 0.0 19.0 0.0 0.0 285000
Paint Shop 0 2.5 0.0 2.5 0.0 0.0 40000 0.4

Assembly 0 0.0 0.0 0.0 0.0 0.0 0 0.2

Vacuum 0 0.0 0.0 0.0 0.0 0.0 0
0.0
Tool Room 0 1.0 0.0 1.0 0.0 0.0 19000 Jan Feb Mar Apr May Jun Ju
Press Shop 0 2.0 0.0 2.0 0.0 0.0 40000
2500000
2208250 Cost (₹)
QA Lab 0 0.0 0.0 0.0 0.0 0.0 0
Jig Shop 0 0.0 0.0 0.0 0.0 0.0 0 2000000

0 0 0.0 0.0 0.0 0.0 0.0 0 1500000 1212500

1151750
0 0 0.0 0.0 0.0 0.0 0.0 0 976000
1000000 819250
0 0 0.0 0.0 0.0 0.0 0.0 0
0 0 0.0 0.0 0.0 0.0 0.0 0 500000
0 0
0 0 0.0 0.0 0.0 0.0 0.0 0 0
Jan Feb Mar Apr May Jun Ju
 500000
0 0
0
Cumulative 0 #DIV/0! 223 12 211 0 0 1212500 Jan Feb Mar Apr May Jun Ju

Reasons Action Taken

Prepared By: Approved By:

POLYPLASTICS INDUSTRIES (I) PVT. LTD.

BREAKDOWN HOURS
REASONS MAINTENANCE OBJ
Working % BD
M/C NO./ AREA B/D HRS Production Loss
Hours Hours Mech Electrical Hyd Others Maint. Cost (₹)
(₹)
O-660 0 9 1 8 0 0 45000 App. Cost (A) S.P. Cost (B)
Omega-450 0 1 0 1 0 0 3000 0
SP-300 0 0 0 0 0 0 0
B/D Hrs. (N
L&T-200 0 95.5 0.5 95 0 0 95500 250
211
SP-180 0 0 0 0 0 0 0
200
Sigma-110-I 0 1 0 1 0 0 3000
150
Sigma-110-II 0 1.5 0 1.5 0 0 6000
L&T- 85 0 39.5 0 39.5 0 0 197500 100
Sigma-80I 0 3.5 1.5 2 0 0 21000 50
12
Sigma-80II 0 6.5 1.5 5 0 0 45500
0
SP-80 0 5 5 0 0 0 40000 Mech Electrical
Polo-80 0 18 0 18 0 0 162000
Magna-80 0 0.5 0 0.5 0 0 5000 B/D Hrs. v/s Working Hou
1.2
Multiplast-55 0 11 0 11 0 0 121000 1.1
Sigma-50-I 0 2.5 1 1.5 0 0 30000 1.0
Sigma-50-II 0 2 0 2 0 0 26000 0.8
Sigma-50-III 0 2 1.5 0.5 0 0 28000 0.6 0.5
Auto Plant 0 19 0 19 0 0 285000
0.4
Paint Shop 0 2.5 0 2.5 0 0 40000
Assembly 0 0 0 0 0 0 0 0.2
Vacuum 0 0 0 0 0 0 0 0.0
Tool Room 0 1 0 1 0 0 19000 Jan Feb Mar Apr May Jun Ju
 0.0
Jan Feb Mar Apr May Jun Ju

Press Shop 0 2 0 2 0 0 40000

2500000
2208250 Cost
QA Lab 0 0 0 0 0 0 0
Jig Shop 0 0 0 0 0 0 0 2000000

0 0 0 0 0 0 0 0 1500000 1212500
1151750
0 0 0 0 0 0 0 0 976000
1000000 819250
0 0 0 0 0 0 0 0
0 0 0 0 0 0 0 0 500000
0 0
0 0 0 0 0 0 0 0 0
Cumulative 0 #DIV/0! 223.0 12 211 0 0 1212500 Jan Feb Mar Apr May Jun Ju

Reasons Action Taken

Prepared By: Approved By:

 Month: May
Prioritized Problems (Machine-Wis
Year: 2013
12
Maintenance Objectives

t (₹) Prod. Loss (₹) Total Cost (₹) 10

Total C=(A+B) Cost (D) (C+D)

8
0 1212500 1212500

B/D Hrs. (Nos) 6

5 5
211
4
4
3 3 3 3
2
2

Sigm a-110-I
Auto Plant

L&T-200

L&T-200

L&T-200

L&T-200
O-660

O-660
Electrical 0
Hyd 0

s. v/s Available Hours (%)

r May Jun Jul Aug Sep Oct Nov Dec

Cost (₹)

1212500
00

512000

0 0 0 0 0 0

May Jun Jul Aug Sep Oct Nov Dec

 512000

0 0 0 0 0 0

May Jun Jul Aug Sep Oct Nov Dec

Action Taken

MIS In charge:

Month: May 5

Year: 2013 May1

INTENANCE OBJECTIVES
t (₹) Prod. Loss (₹) Total Cost (₹)

Total C=(A+B) Cost (D) (C+D)

0 1212500 1212500

B/D Hrs. (Nos)

211

Electrical 0
Hyd 0

. v/s Working Hours (%)

r May Jun Jul Aug Sep Oct Nov Dec

r May Jun Jul Aug Sep Oct Nov Dec

Cost

1212500
00

512000

0 0 0 0 0 0

May Jun Jul Aug Sep Oct Nov Dec

Action Taken

MIS In charge:
 L&T-200

3
L&T-200

3
L&T-200

3
L&T-200

Sigm a-110-I
Prioritized Problems (Machine-Wise)

Sigm a-110-I
2

Sigma-110-I
2

Sigma-110-I

Other
10
 POLYPLASTICS INDUSTRIES (I) PVT. LTD.
MACHINE HISTORY CARD
M/C DescriptiO-660 Year of Installation.: 1990 Location:
Specification:660T, Bed Size 4'X8'
PM=Preventive, CM=Corrective Maintenance, M=Mechanical, E=Electrical

Date Details of Jobs/ Maint. Carried Out B/D Hrs. Type of Maint. Spares Replaced
7-Dec-12 front gate not working 1 Corrective Hyd 0
7-Dec-12 gate open close problem 1 Corrective Electrical 0
17-Dec-12 hrtc problem 2 Corrective Electrical 0
21-Dec-12 front gate not working 0.5 Corrective Electrical 0
8-Jan-13 hrtc problem 0.5 Corrective Electrical 0
22-Jan-13 hrtc problem 0.5 Corrective Electrical 0
22-Jan-13 hrtc problem 1.75 Corrective Electrical 0
23-Jan-13 hrtc problem zone-6 temp. low 1 Corrective Electrical 0
25-Jan-13 front gate not working 1 Corrective Mech 0
4-Feb-13 moud not close 0.5 Corrective Electrical 0
7-Feb-13 core-2 not pulled 2 Corrective Electrical 0
19-Feb-13 hrtc not working 0.25 Corrective Electrical 0
26-Feb-13 hrtc not working 2 Corrective Electrical 0
26-Feb-13 main motor not start 2.5 Corrective Electrical 0
4-Mar-13 Nozzel heater not working 1 Corrective Electrical 0
8-Mar-13 hrtc zone-6 temp. variation 1 Corrective Electrical 0
11-Mar-13 hrtc not working 2.5 Corrective Electrical 0
14-Mar-13 ejector not working 2.5 Corrective Electrical 0
3-Apr-13 ejector not working 1 Corrective Electrical 0
7-May-13 oil temprature not maintained 1 Corrective Mech 0
9-May-13 hrtc not working 0.5 Corrective Electrical 0
11-May-13 hrtc temp problem 1 Corrective Electrical 0
12-May-13 hrtc temp problem 1 Corrective Electrical 0
13-May-13 nozzel heater fault 1.5 Corrective Electrical 0
19-May-13 oil temprature not maintained 1 Corrective Electrical 0
22-May-13 hrtc not working 2 Corrective Electrical 0
26-May-13 any function not working 1 Corrective Electrical 0
TICS INDUSTRIES (I) PVT. LTD.
MACHINE HISTORY CARD
Moulding Shop

Carried Out By
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
Machine Master
Year of
S.No. Machine Description Specification Location
Installation
1 O-660 660T, Bed Size 4'X8' 1990 Moulding Shop

2 Omega-450 1991 Moulding Shop

3 SP-300 Moulding Shop

4 L&T-200 Moulding Shop

5 SP-180 Moulding Shop

6 Sigma-110-I Moulding Shop

7 Sigma-110-II Moulding Shop

8 L&T- 85 Moulding Shop

9 Sigma-80I Moulding Shop

10 Sigma-80II Moulding Shop

11 SP-80 Moulding Shop

12 Polo-80 Moulding Shop

13 Magna-80 Moulding Shop

14 Multiplast-55 Moulding Shop

15 Sigma-50-I Moulding Shop

16 Sigma-50-II Moulding Shop

17 Sigma-50-III Moulding Shop

18 Auto Plant Auto Plant

19 Paint Shop Paint Shop

20 Assembly Assembly

21 Vacuum Vacuum

22 Tool Room Tool Room

23 Press Shop Press Shop

24 QA Lab QA Lab

25 Jig Shop Jig Shop

26

27

28

29

30

31

32
33

34

35

36

37

38

39

40
Production Loss/
Month Category Maint. Type Operator Name
Hr (Rs/-)
5000 Jan Mech Preventive Ashok Handa

3000 Feb Electrical Corrective Devi Dayal

2000 Mar Hyd Preidictive Neeraj Dogra

1000 Apr Others Satish Kumar

2000 May Raj Kumar

3000 Jun Raj Kumar Saini

4000 Jul Shiv Dayal

5000 Aug Moti Lal

6000 Sep Gurvinder

7000 Oct

8000 Nov

9000 Dec

10000

11000

12000

13000

14000

15000

16000

17000

18000

19000

20000

21000

22000