MONTHLY ANALYSIS REPORT SPIL-Transmission

LINE Gear Line

MONTH Aug-10 NO OF MACHINES HOD Maint Advisor Maint Manager Maint Line incharge Prepared By

SHIFTS 3714 NO OF B/D 89

Taget vs. Actual Breakdown

OPERATION TIME 1782501 NO OF MAJOR B/D 54

20000
18305
LINE BREAKDOWN 18305 MTBF (TARGET) 396.96 6747
18000 Column O
Column P
16000
MTBF(MIN) 19822.43
14000

12000 11520
MTTR (TARGET) 46.81
10000
8481
MTTR(MIN) 205.67 7530 7695
8000 6312

6000 5335

4000

2000

0
Apr May Jun July Aug Sept Oct Dec Jan Feb March

WORST MACHINES BREAKDOWN (MIN) `

7000 18000
16395
16335
Worst Machine By Beakdown Frequency
5760 15800
15720 15950
15875 16155
16095
16025 16275
16215 16000
6000 1 1
5090 1
5180 15450
15360
5270 15630
15540 4.5 16
1
14655
14535
14415 1
4775 1
48854990
14055
13925
13790 14295
14175 14000 4 15
1 13360
13210
3060 13650
13510 4 14
5000 1
12500 1
27102890
11780 12260
12020 12000 13
10940 11530
11260 3.5
4000 10610 12
977010190 10000 3
11
86909290 3
10
3000 7760 8000
2.5 9
2000
5760 6000 2 2 2 2 8
2000 2
4000 7
930 6
1000 600 480 420 420 2000 1.5
330 320 270 250 240 240 240 210 180 170 150 150 150 140 140 135 130 120 120 120 120 120 120 110 105 100
90 90 90 90 90 90 90 80 75 75 75 70 60 60 60 60 60 4 4
0 0 1
IGH603

MSH105

AGG203

MSH106

IGH203

IGH404

AGG705

SNH404

SNH504

SNH604

HGG501

CSH208

SNH302

SNH404

SNH406
ISH110

ISH108

CSH301

MGH107

ISH210

HGH302

AGH606

ISH201

CSG105

CSG405

ISH302

SGH107

SNH503

ISH213

ISH201

AGG301

FGH202

HGH704

ISH408

HGH601

ISH311

SNH101

ISH201

SGH201

SGH106

ISH209

ISH205

IGG403

CSG104

CSH105

CSH404

CSH207

SGH205

SNH504
ISH319

0.5 2
WEEK 2 0 0
SNH404 ISH201 FGH202 HGG501 IGH203 ISH110
Next Countermeasure Plan

Effective
Date Shift Line Machine No Break down From Up To Work Done Countermeasures Date Status
Time(In MIN)

29/9/2010 1.To check the Lubrication in other Mitsubishi machines 2.To

8/10/2010 Done
11:50PM maintain the inventory of bearing of other machines
22/9/2010 B Ittai gear IGH603 Component profile NG problem 7:00 5760 Change the Bearing now ok

Every LMW machine to be checked thoroughly once in evry 2 month and

Check the ATC arm spring & cam follower bearing & tight it and change the pin also but 10/30/2010
ATC allignment kit to be arranged
1/9/10 A Input shaft ISH110 ATC falling tool 8:30 16:00 2000 problem not solve
Proper inventory of all critical bearings to be arranged and scope for
10/30/2010
30/9/2010 B Input shaft ISH319 Spindle motor over load alarm 5:00 8:30 930 Change the new bearing now ok lubrication point at TS bearing to be checked
ONE-POINT Lesson to be made for this Alarm and all couplings to be
12/1/2010
7/9/10 B Input shaft ISH108 445 X axis soft disconnect 7:00 17:00 600 Change the coupling & done referencing now ok checked in Dec. Shutdown

Programme selector switch to be arranged and the switch to be covered

Programme not select & RH spindle REV not to prevent Oil entry
08/09/10 C Counter shaft CSH301 run 3:00 11:30 480 Programme s/w bypass in hard wiring & contactor change
Part carrier cylinder up/down mounting bolt
Drilled and M8 bolt to be fitted 14/09/2010 Done
08/09/10 A Two wheeler MGH107 broken 7:00 14:00 420 Bolt changed
Every LMW machine to be checked thoroughly once in evry 2 month and
Monthly
14/9/2010 B Input shaft ISH210 M/c tool falling problem 16:00 19:05 420 Change its ATC cam follower bearing ATC allignment kit to be arranged

13/9/2010 A Two wheeler MSH105 M/C control not On 7:00 12:30 330 Change the soleniod valve as there was shorting now ok
Wire Routing to be check in other M/c 20/09/2010 Pending
14/9/2010 B Hira gear HGH302 Turret Indexing abort alarm 16:30 23:30 320 Repair the wire by resoldering
To inform to other people about it 13/10/2010 Pending
20/9/2010 B Atsunyu gear grindi AGG203 Lub pump not ok 8:15 12:30 270 Pump O ring found damage so changed the O ring
Could not find the manual till 11:30, M/c manual is in the machine. 18/09/2010 Done
18/9/2010 A Two wheeler MSH106 alarm no. 300 & 307 7:00 12:00 250 M/C Refrencing done
Manpower not available, check the door condition in other Kanzaki
10/10/2010 Done
14/9/2010 B Atsunyu gear AGH606 M/c door open close problem 16:30 20:00 240 Welding done machines

Manpower not available

16/9/2010 C Ittai gear IGH203 Component not clamp and declamp 3:00 7:00 240 Check by manually operate but not ok so pending
All WiDMA M/c to be checked for Chucknut Tightness and provision for
10/30/2010
22/9/2010 C Input shaft ISH201 LH slide not in home position 12;30 4:30 240 Took axis to position & chuck nut tight double chucknut/locknut to be checked

27/9/2010 A Counter shaft grindi CSG105 Foot stocknot advance 8:00 11:30 210 Filled the hyd. Oil now ok
Maintain the inventory of it and clean the Solenoid valve 12/10/2010 Done
10/09/10 A Ittai gear IGH404 Part stand not working 8:00 3:30 180 Check & change the soleniod valve now ok
90 min Manpower not available
22/9/2010 B Atsunyu gear grindi AGG705 Unloader not working 4:00 7:40 170 Replaced the photo senser now ok
Maintain the inventory of seals 16/10/2010 Pending
20/9/2010 B Sleeve line SNH404 Front door problem 3:45 7:30 160 Change the seal

All TOYODA m/c door mounting and cylinder to be checked 9/30/2010 Closed
1/9/10 A Counter shaft grindi CSG405 Auto door fault 10:30 12:30 150 Welding done
Each WIDMA m/c Pulley,stud and Belt Tightness to be checked atleast
Every Month
7/9/10 B Input shaft ISH301 Z axis 0VC soft thermal alarm 18:00 20:30 150 Change the bolt once in every month
Keep in stock the pipe 10/9/2010 Done
7/9/10 B Sleeve line SGH107 Part carrier up down hyd pipe broken 14:00 18;30 150 Change the hyd. Pipe
Check & found clamp unclamp working ok in Manual but problem coming in auto applied
08/09/10 B Sleeve line SNH503 Component clamp/unclamp fault 6:20 8:40 140 M61, M62 code with MDI working ok instead of M12 & M13

24/9/2010 A Input shaft ISH213 Chuck centre not working 8;40 11:15 140 Change the spring & pressure s/w now ok M/c spares to be checked and kept
All WiDMA M/c to be checked for Chucknut Tightness and provision for
3/9/10 A Input shaft ISH201 LH slide down 13:30 15;45 135 Tight the cylinder chuck nut double chucknut/locknut to be checked
16/9/2010 B Atsunyu gear grindi AGG301 lub motor trip & pressure not build up 6:20 8:30 130 Checked & clean the pump then fitted the pump from other stopped line M/c OK The "O" ring was faulty, changed it Done
Auto cycle not run & cutter slide continuously
6/9/10 B Final gear FGH202 rotate 4:30 6:30 120 Change the vertical slide senser & set horizental slode home senser First Laptop not available, set the sensor Done
Check in other V chamfering machines 12/10/2010 Done
11/9/10 B Sleeve line SNH404 Auto door problem 17:20 0.8125 120 Welding done
Check the lubricator Drop in other Mitsubishi machines 18/102010 Pending
18/9/2010 A Hira gear HGH704 Part carrier Raise problem 7:15 9:15 120 Check Hyd. Pr. & cylinder found ok clean soleniod now ok
Miantain the inventory of seals 22/10/2010 Pending
20/9/2010 A Sleeve line SNH504 Auto door not working 1;30 3:30 120 So open the cylinder and changed cylinder seal

all Wheel Head assembly O-Ring to be checked in Dec ShutDown Dec Shutdown
28/9/2010 A Input shaft ISH408 Lubrication oil leakage problem 8:00 10:00 120 change the wheel head assembly O ring
Check in other Moriseiki Machines 10/10/2010 Done
28/9/2010 B Hira gear HGH601 Auto door Obstacle detection alarm 16:00 18:00 120 Check & auto door Rubber shielding clean & tight connection

18/9/2010 A Input shaft ISH311 Door open close problem 9:10 11:00 110 Repair safety s/w now ok

Maintain the inventory of valves(Available) Done

20/9/2010 C Sleeve line SNH604 Broach cutting coolant not coming 11:30 0.072916667 105 Change the Soleniod valve now ok
Man power not available, check the tension in other similar grinding M/c 18/10/2010 pending
16/9/2010 C Hira gear grinding HGG501 Motor over load alarm 2:20 0.166666667 100 Adjust the conveyor Tension now ok

1/9/10 C Sleeve line SNH101 Broaching m/c hyd pipe have leakage 12;30 0.083333333 90 New pipe fitted
All WiDMA M/c to be checked for Chucknut Tightness and provision for
3/9/10 B Input shaft ISH201 LH slide down 16:00 17;30 90 Remove the broken bolt then fitted new bolt now ok double chucknut/locknut to be checked
Ordered the new LIMIT S/w from Omron 20/102010 Pending
7/9/10 B Sleeve line SGH201 Pull head open close both LS faulty 11:55 0.0625 90 Fitted one LS from SNH101 & bypass another LS
Order the NPN pr. S/w more 7/10/2010 Done
9/9/10 A Sleeve line SGH106 Cycle not complete 7:30 0.375 90 Replaced the pressure s/w
sensor to be protected from oil 10/15/2010
16/9/2010 C Input shaft ISH209 Component present senser not working 5:00 0.270833333 90 change the senser
Procedure for Bypass through ladder to be put in M/C History file and
10/15/2010
20/9/2010 B Input shaft ISH205 Area senser continuously high 4:00 0.229166667 90 Bypass area senser check for reasons for Area sensor faulty
Deburring motor to be kept in spare and its wirng joints to be completely
10/30/2010
27/9/2010 B Counter shaft CSH208 Deburing motor not ok 10:45 0.503472222 80 Chanege the belt & pulley refitted covered from coolant
All Shigiya m.c shutter door and cylinder mounting to be checked 30-Sept.2010
8/9/10 B Counter shaft grindi CSG104 Foot stock advance alarm 7:00 0.34375 75 change the bolt
Check in other AMS machines 10/10/2010 Done
15/9/2010 C Sleeve line SNH302 Pusher not working 4:45 0.25 75 Welding done
CKD Cylinder to be kept in spare
3/9/10 A Counter shaft CSH404 Out chute not working 7:20 0.347222222 60
Component presence sensors to be covered from Oil.
18/9/2010 B Counter shaft CSH207 M/C master not On 3:45 0.197916667 60 Shorting in Component present senser so by pass it
Check the mounting in other machines. 28/10/2010 Pending
22/9/2010 C Sleeve line SGH205 Auto door open close problem 2:00 0.125 60 Welding done

24/9/2010 C Sleeve line SNH504 Auto cycle starting over time 2:00 0.125 60 Soleniod valve cleaned and fitted.
To clean all the gripper cylinder in other machines 10/10/2010 Done
25/9/2010 C Sleeve line SNH406 Unloader gripper open close problem 3:00 0.166666667 60 So open the gripper cylinder and clean now ok
Sum of Effective Time(In MIN) Count of Effective Time(In MIN)
Machine No Total Machine No Total
IGH603 5760 SNH404 4
ISH110 2040 ISH201 3
ISH319 930 FGH202 2
ISH108 600 HGG501 2
CSH301 480 IGH203 2
ISH201 465 ISH110 2
ISH210 460 ISH210 2
MGH107 420 MGH105 2
SNH404 395 SGH201 2
MSH105 330 SNH504 2
HGH302 320 AGG203 1
AGG203 270 AGG301 1
IGH203 270 AGG704 1
MSH106 250 AGG705 1
AGH606 240 AGH202 1
FGH202 230 AGH503 1
CSG105 210 AGH601 1
IGH404 180 AGH604 1
SNH504 180 AGH606 1
AGG705 170 AGH704 1
CSG405 150 CSG104 1
HGG501 150 CSG105 1
ISH302 150 CSG201 1
SGH107 150 CSG403 1
ISH213 140 CSG405 1
SNH503 140 CSH105 1
SGH201 135 CSH108 1
AGG301 130 CSH207 1
HGH601 120 CSH208 1
HGH704 120 CSH209 1
ISH408 120 CSH301 1
ISH311 110 CSH404 1
SNH604 105 FGG302 1
IGG403 90 HGG401 1
IGH303 90 HGH302 1
IGH402 90 HGH601 1
ISH205 90 HGH701 1
ISH209 90 HGH704 1
SGH106 90 HGH804 1
SNH101 90 HGH903 1
CSH208 80 IGG403 1
MGH105 80 IGH303 1
CSG104 75 IGH402 1
CSH105 75 IGH404 1
SNH302 75 IGH501 1
CSH207 60 IGH603 1
CSH404 60 IGH801 1
SGH205 60 IGH901 1
SNH406 60 ISG203 1
AGH202 55 ISG204 1
AGH604 55 ISG405 1
CSG403 55 ISH108 1
FGG302 55 ISH205 1
IGH801 55 ISH209 1
MGH106 55 ISH213 1
AGG704 50 ISH302 1
AGH601 50 ISH310 1
CSH108 50 ISH311 1
CSH209 50 ISH319 1
ISG405 50 ISH402 1
MSH104 50 ISH408 1
SNH506 50 MGH106 1
HGH804 45 MGH107 1
ISH310 45 MSH104 1
AGH503 40 MSH105 1
IGH901 40 MSH106 1
ISG204 40 SGH101 1
AGH704 30 SGH106 1
CSG201 30 SGH107 1
HGG401 30 SGH205 1
HGH903 30 SNH101 1
ISH402 30 SNH302 1
ISG203 25 SNH406 1
SGH101 25 SNH503 1
HGH701 20 SNH506 1
IGH501 20 SNH604 1
(blank) (blank)
Grand Total 18305 Grand Total 89
IGH603 5760 5760
ISH110 2000 7760
ISH319 930 8690
ISH108 600 9290
CSH301 480 9770
MGH107 420 10190
ISH210 420 10610
MSH105 330 10940
HGH302 320 11260
AGG203 270 11530
MSH106 250 11780
AGH606 240 12020
IGH203 240 12260 SNH404 4 4
ISH201 240 12500 ISH201 3 7
CSG105 210 12710 FGH202 2 9
IGH404 180 12890 HGG501 2 11
AGG705 170 13060 IGH203 2 13
CSG405 150 13210 ISH110 2 15
ISH302 150 13360
SGH107 150 13510
SNH503 140 13650
ISH213 140 13790
ISH201 135 13925
AGG301 130 14055
FGH202 120 14175
SNH404 120 14295
HGH704 120 14415
SNH504 120 14535
ISH408 120 14655
HGH601 120 14775
ISH311 110 14885
SNH604 105 14990
HGG501 100 15090
SNH101 90 15180
ISH201 90 15270
SGH201 90 15360
SGH106 90 15450
ISH209 90 15540
ISH205 90 15630
IGG403 90 15720
CSH208 80 15800
CSG104 75 15875
CSH105 75 15950
SNH302 75 16025
SNH404 70 16095
CSH404 60 16155
CSH207 60 16215
SGH205 60 16275
SNH504 60 16335
SNH406 60 16395
Date Shift Line Machine No From Up To Effective Ti

29/9/2010
11:50PM
22/9/2010 B Ittai gear IGH603 7:00 5760

1/9/10 A Input shaft ISH110 8:30 16:00 2000

30/9/2010 B Input shaft ISH319 5:00 8:30 930

7/9/10 B Input shaft ISH108 7:00 17:00 600

08/09/10 C Counter shaft CSH301 3:00 11:30 480

08/09/10 A Two wheeler MGH107 7:00 14:00 420

14/9/2010 B Input shaft ISH210 16:00 19:05 420

13/9/2010 A Two wheeler MSH105 7:00 12:30 330

14/9/2010 B Hira gear HGH302 16:30 23:30 320

20/9/2010 B Atsunyu gear grindinAGG203 8:15 12:30 270

18/9/2010 A Two wheeler MSH106 7:00 12:00 250

14/9/2010 B Atsunyu gear AGH606 16:30 20:00 240

16/9/2010 C Ittai gear IGH203 3:00 7:00 240

22/9/2010 C Input shaft ISH201 12;30 4:30 240

27/9/2010 A Counter shaft grindi CSG105 8:00 11:30 210

10/09/10 A Ittai gear IGH404 8:00 3:30 180

22/9/2010 B Atsunyu gear grindinAGG705 4:00 7:40 170

20/9/2010 B Sleeve line SNH404 3:45 7:30 160

1/9/10 A Counter shaft grindi CSG405 10:30 12:30 150

7/9/10 B Input shaft ISH301 18:00 20:30 150

7/9/10 B Sleeve line SGH107 14:00 18;30 150

08/09/10 B Sleeve line SNH503 6:20 8:40 140

24/9/2010 A Input shaft ISH213 8;40 11:15 140

3/9/10 A Input shaft ISH201 13:30 15;45 135

16/9/2010 B Atsunyu gear grindinAGG301 6:20 8:30 130

6/9/10 B Final gear FGH202 4:30 6:30 120

11/09/10 B Sleeve line SNH404 17:20 19:30 120

18/9/2010 A Hira gear HGH704 7:15 9:20 120

20/9/2010 A Sleeve line SNH504 1;30 3:30 120

28/9/2010 A Input shaft ISH408 8:00 10:00 120

28/9/2010 B Hira gear HGH601 16:00 20:00 120

7/9/10 A Final gear FGH202 7:40 9:30 110

18/9/2010 A Input shaft ISH311 9:10 11:00 110

20/9/2010 C Sleeve line SNH604 11:30 1:45 105

16/9/2010 C Hira gear grinding HGG501 2:20 4:00 100

1/9/10 C Sleeve line SNH101 12;30 2:00 90

3/9/10 B Input shaft ISH201 16:00 17;30 90

7/9/10 B Sleeve line SGH201 11:55 1:30 90

09/09/10 A Sleeve line SGH106 7:30 9:00 90

16/9/2010 C Input shaft ISH209 5:00 6:30 90

20/9/2010 B Input shaft ISH205 4:00 5:30 90

23/9/2010 B Ittai gear IGH303 17:30 19; 90

23/9/2010 B Ittai gear grinding IGG403 6:30 8:00 90

28/9/2010 C Ittai gear IGH402 4:36 6:20 90

27/9/2010 B Counter shaft CSH208 10:45 12:05 80

08/09/10 B Counter shaft grindi CSG104 7:00 8:15 75

11/09/10 C Counter shaft CSH105 12:45 2:00 75

15/9/2010 C Sleeve line SNH302 4:45 6:00 75

09/09/10 A Sleeve line SNH404 1:00 2:10 70

3/9/10 A Counter shaft CSH404 7:20 8:20 60

18/9/2010 B Counter shaft CSH207 3:45 4:45 60

22/9/2010 C Sleeve line SGH205 2:00 3:00 60

24/9/2010 C Sleeve line SNH504 2:00 3:00 60

25/9/2010 C Sleeve line SNH406 3:00 4:00 60

1/9/10 A Two wheeler MGH106 10:30 11:30 55

4/9/10 B Final gear grinding FGG302 19:00 19:55 55

6/9/10 A Atsunyu gear AGH604 7:40 9:00 55

10/09/10 A Counter shaft grindi CSG403 9:40 10:35 55

16/9/2010 C Ittai gear IGH801 1:55 3:00 55

22/9/2010 C Atsunyu gear AGH202 5:00 6:00 55

3/9/10 B Atsunyu gear grindinAGG704 10:00 111;30 50

4/9/10 B Sleeve line SNH506 7:40 8;30 50

20/9/2010 A Two wheeler MSH104 7:10 8:15 50

21/9/2010 B Counter shaft CSH108 9:00 9:50 50

28/9/2010 B Hira gear grinding HGG501 7:00 7:50 50

28/9/2010 B Counter shaft CSH209 6:00 7:00 50

29/9/2010 A Input shaft grinding ISG405 2:10 3:00 50

30/9/2010 C Atsunyu gear AGH601 12:30 1:20 50

4/9/10 B Input shaft ISH310 3:45 4:30 45

7/9/10 B Sleeve line SNH404 3;30 4:15 45

18/9/2010 C Sleeve line SGH201 1:15 2:00 45

27/9/2010 A Hira gear HGH804 1:30 2:15 45

18/9/2010 C Ittai gear IGH901 12:20 1:00 40

25/9/2010 A Two wheeler MGH105 7:50 8;30 40

25/9/2010 C Input shaft ISH110 1:00 1:40 40

27/9/2010 A Two wheeler MGH105 7:00 8;40 40

28/9/2010 B Input shaft grinding ISG204 9:00 9:40 40

29/9/2010 A Input shaft ISH210 11:45 12:25 40

30/9/2010 B Atsunyu gear AGH503 5:00 5:40 40

6/9/10 C Input shaft ISH402 12:45 1:15 30

7/9/10 B Counter shaft grindi CSG201 6:00 6:30 30

21/9/2010 A Atsunyu gear AGH704 12:00 12:30 30

27/9/2010 C Hira gear HGH903 4:45 5:15 30

27/9/2010 C Hira gear grinding HGG401 3:00 3:30 30

29/9/2010 B Ittai gear IGh203 10;30 11:00 30

7/9/10 B Input shaft grinding ISG203 7:15 7:40 25

09/09/10 B Sleeve line SGH101 8:20 8:45 25

09/09/10 B Ittai gear IGH501 11:00 11:20 20

10/09/10 A Hira gear HGH701 10:40 11:00 20

 Breakdown
Found its LH side facing
pulley spindle ring phase
open or break so to be
Component profile Hob spindle Bearing check in Sunday now m/c
NG problem faulty Change the Bearing now ok running

Check the ATC arm spring & cam

follower bearing & tight it and Check & filled gas in
change the pin also but problem chiller unit & restart now
ATC falling tool Unknown not solve ok
Spindle motor over Tail stock spindle
load alarm bearing faulty Change the new bearing now ok

445 X axis soft X axis motor Change the coupling & done Proper meshing done
disconnect coupling broken referencing now ok & push button repair
Programme
Programme not select selsector s/w faulty
& RH spindle REV & Rev contactor Programme s/w bypass in hard
not run burn wiring & contactor change Change the wire now ok
Part carrier cylinder
up/down mounting Change another motor
bolt broken Unknown Bolt changed now ok

M/c tool falling Change its ATC cam follower

problem Pending from A shift bearing Change the rotary s/w

Due to clamp /
declamp soi. Found
M/C control not On short Change the soleniod valve now ok welding done
Turret indexing
Turret Indexing abort motor encoder wire
alarm broken Repair the wire by resoldering change the belt

Pump not build up Pump O ring found damage so Change the relay now
Lub pump not ok pressure changed the O ring m/c ok
Z axis home
alarm no. 300 & 307 position not ok M/C Refrencing done So put new wire now ok
M/c door open close Door broken from
problem one side Welding done connect wire
Component not Check by manually operate but not
clamp and declamp Unknown ok so pending change the push button
 When check & found
fixture clamp read
s/w malfunction then
LH slide not in home LH slide chuck nut Took axis to position & chuck nut set it properly
position open & fall down tight
Foot stocknot
advance Hyd. Oil level low Filled the hyd. Oil now ok Set the senser now ok
Part stand not Check & change the soleniod key pad changed now
working Soleniod valve jam valve now ok ok
Part present photo Replaced the photo senser now
Unloader not working senser faulty ok So set it now ok

Cylinder seal Due to &

Check dog bolt broken
change pump,
Front door problem damage Change the seal so modifythe
suction dog now ok
filter, coupling,
relief valve, motor but still
noise coming.Then
due to mounting change the sucktion pipe
Auto door fault broken Welding done fitting,M/C OK
Rh slide centering
pully belt tension
Z axis 0VC soft mounting bolt
thermal alarm broken Change the bolt Weld the block

Change the bolt

Part carrier up down
hyd pipe broken Due to vibration Change the hyd. Pipe
Check & found clamp unclamp
working ok in Manual but problem
coming in auto applied M61, M62
Component May be programme code with MDI working ok instead Loading arm alignment
clamp/unclamp fault fault of M12 & M13 done
Because its air
Chuck centre not regulator spring & Change the spring & pressure s/w
working pressure s/w faulty now ok LS change

cylinder chuck not Gripper cylinder

LH slide down open Tight the cylinder chuck nut interchange with CSH110

lub motor trip & Set the lifter locking pin

pressure not build up Pump jam Checked & clean the pump now ok then ok
Auto cycle not run &
cutter slide Vertical slide senser Change the vertical slide senser &
continuously rotate not working set horizental slode home senser Change the hose pipe
Its mounting plate change the senser
Auto door problem damage Welding done faulty
Part carrier Raise Check Hyd. Pr. & cylinder found ok
problem Unknown clean soleniod now ok Set the read s/w
 Due to cylinder seal So open the cylinder and changed
Auto door not working jam cylinder seal Weld the plate
Lubrication oil change the wheel head assembly
leakage problem O ring damage O ring Reset the power now ok

Auto door Obstacle Auto door rubber Check & auto door Rubber So check & clean now
detection alarm shielding not ok shielding clean & tight connection ok
Because its motor So done teaching of
Chamfering L slide pulley not set with loader arm but not ok
motor not stop after change pulley and So fitted & proper set the locking then Loader arm
auto cycle complete locking plate open plate alignment done
Door open close Found its Safety s/w Connect PB wire now
problem faulty Repair safety s/w now ok ok
Broach cutting Coolant line SOI Change the Soleniod valve now So change the senser
coolant not coming valve faulty ok now ok
Adjust the conveyor Tension now Alignment done &
Motor over load alarm Input conveyor jam ok up/down flow adjust
Broaching m/c hyd Table down pipe Arm alignment done
pipe have leakage broken New pipe fitted Many times then ok
MPCB top handle
Remove the broken bolt then fitted remove & unloader dog
LH slide down Pending from A shift new bolt now ok setting done
Pull head open close Limit s/w plunger Fitted one LS from SNH101 &
both LS faulty stucked bypass another LS Clean the cylinder
Chuck clamp
Cycle not complete pressure s/w faulty Replaced the pressure s/w Alignment done now ok
Component present So clean the senser &
senser not working senser faulty change the senser adjust now ok
Area senser Change the senser now
continuously high Area senser faulty Bypass area senser ok
Drill broken again & Spindle coolant not Check valve faulty so bypass the
again coming valve now ok clean the valve now ok
Conveyor input
sepretaor cylinder
Auto cycle not run not working Clean the cylinder change the pipe now ok
Found chips
conveyor stuck and
Turret not clamp may be its air catch Clean the chips & bypass air catch
alarm senser faulty senser then reset alarm Remove AC connection
Deburing motor not
ok Its belt broken Chanege the belt & pulley refitted Tight it
Foot stock advance Shutter mounting
alarm bolt broken change the bolt Piston rod again fitted
Due to part present Change the stooper
Auto cycle not start senser not working By pass the senser now ok
Gripper cylinder Manually operate the
Gripper not working mounting broken Welding done turret now ok

Auto door not working Mounting plate bend Straight the plate now ok Welding done
 Change the cylinder
seal but its pusher not
return because X2b
due to guide way input high so dog
Out chute not working rod jam clean the guide way setting done
Due to control Shorting in Component present Open motor & send
M/C master not On supply shorting senser so by pass it for rewinding
Auto door cylinder
open the cover then
Auto door open close mounting plat clean limit s/w now
problem broken Welding done ok
Auto cycle starting Auto door soleniod
over time faulty Soleniod valve changed bypass the door s/w
Unloader gripper So open the gripper cylinder and so check & forward limit
open close problem Gripper jam clean now ok s/w bypass

Check & change Servo

AMP. But problem not
solve then change motor
but motor heat up then
done its meshing
properly but after this m/c
control trip again & again
Part unload photo Due to oil in junction clean its junction box & replaced so clean motor all
senser faulty box the amplifier connector now ok

Change power supply

Seprator No-2 sol clean the cylinder and change flow but not ok then change
abnormal alarm Cylinder jam control the shorted senser

Ring loader servo Ring loader motor

Amp malfunction referencing lost Done referencing So replace the new pump
LM bush mounting
open, Railing wear So check and fitted the bush and Took out thermo
out, Cyl. Air input rail falling and change the air fitting couplel clean it &
Auto door not working fitting broken now m/c ok refitted now ok
Gripper setting
disturb & part carrier
Part carrier not cylinder piston rod Setting done & Piston rod
working open reconnect change the senser
 Hose pipe alignment
done
Part clamping Part clamp unclamp part unclamp senser dog miss so
unclamping fault both senser high bolt provided
Check & change pump
Auto door but not ok then modify
connected strip the logic now under
Auto door not working broken Welding done observation
Interchange the coolant
valve & flow s/w & modify
Auto door open close door cylinder guide logic now under
fault plate broken Welding done observation
clean the guide bush &
NC alarm Referencing lost Referencing done lubrication done now ok

Unloader not ejecting Soleniod valve

component in auto faulty Inter changed the soleniod valve welding done
Seprator 2 open clean the pull head now
close alarm Photo senser faulty change the photo senser ok
Deburing unit not Deburing unit bolt
working broken New bolt fitted Setting done
3rd station
Component overlap component present
problem senser faulty change the senser setting done
Part catcher detect Read s/w
alarm continuous high Alarm bypass
cycle stop during Pusher read s/w Repair the wire then
Auto signal fluctuation Change the read s/w refitted now ok

Door mounting bolt Bypass the shutter open

Door not working broken New bolt fitted senser now ok
Tool lifter Sol. Pull head cylinder
Abnormal piston rod open Tight the piston rod change the pipe
A axis INV. Current
excess Unknown A axis drive clean & refitted now ok gap s/w bypass
MSTB air single off Auto door not open Strip found broken so welding
alarm close done Change the senser
 Its relay fuse found Dog ram down pressure
Ram up down not ok blown Change th fuse now ok s/w set
Unloader up/down So Auto locator cylinder
problem Unloader soi. Faulty clean the soleniod now ok nut tight now ok
M/c forget home
NC alarm position So Refrencing done Change the senser
Foot stock linear
Foot stock adv. Alarm scale fault So bypass it Bypass the signal
Deburing motor to be Motor to be fitted
fitted after rewinding Motor fitted now ok cleaned the fan

Component
part loader up down unloader senser not So component unloading senser
problem sense in dog setting dog proper set
component
unloading limit s/w So check & cut the wire and joint Clean the pressure s/w
Auto cycle not start wire faulty the wire now ok
NG component Change the Air catch
Cycle not start signal not coming Set the photo senser senser
Door stuck with
Auto door not working track Alignment done S/w selsection made ok
Part ejector not Found its flow
working control faulty change the flow control Clean the senser now ok
Found unloader not Took unloader to home position
Robot not working in position now ok read s/w setting done

Auto cycle not start Clamp signal miss Senser adjust So clean the slide now ok

Shutter open close Shutter close signal Change the Soft Key Pad
fault not come Bypass the senser from Sleeve line
Table up-down cyl. So changed its soleniod
Pipe fitting was So tight the pipe fitting of check the valve but not ok so need
Hydraulic oil leakage loose oil leakage ok to change the cylinder
Spindle motor over Spindle motor fan Alarm resent hand over C shift change the new cylinder
weak not work motor fan clear now ok

componentfomd in Fitted its original J com

component and unit after interchanged
Overload trip OLR reset Same the touch screen
All push
buttons
to be
changed
in CSH
113 and
also
proper
screen
and
Push
Button
cover to
be
provided
Keep the
pump in
spare for
all Widma
Gun
drilling
machines
and exact
size pipe
fitting to
be kept in
spare

All shigiya
machine
Shutter
door
cylinder
mounting
and
Proximity
sensors
to be
checked
Rajamane
120LPM
pump to
be kept in
spare and
old pump
Impeller
to be
made
new
All shigiya
machine
Shutter
door
cylinder
mounting
and
Proximity
sensors
to be
checked
All
Operator
Panles to
be
covered
by plastic