KRA 1 For FY 15 _ Arresting heavy Hydraulic oil leakage of sq.

roller system and plunger seal with its assly

GOAL:- Reduction by 50 % of last year hyd oil (176)consumption due to hydraulic le

APPROACH 1:Low hanging fruit (easy and fast adoptable with high return)
Completion Time :- Six month (Start with continuous adoption till full chan

S.N Action Plan comes from design analysis, why why

o. analysis, & brain storming with L1 team.
1 Damaged Scratched plunger to be replaced with new
Hard crome plated Plunger.
2 All hydraulic plunger Guide cover bushing to be
replaced
3 All guide of Sq. roller bearing housing to be replaced

4 Bearing housing segment replacement with New ,

and Replacement of plunger segment with SS moc
ipo of existing MS.

5 Oil collecting nipple with ken to be adopted during

any minor / major leakage of cylinder seal observe.

APPROACH 2: High Hanging fruit. (invention & long time development work )
Completion Time :-One year (With adopting at one system for its successor

S.n Action Plan comes from design analysis.

o.
1 Adoption of wiper seal at hyd. plunger guide cover
flange
2 Adoption of guide seal ipo of PB bush in hyd. Plunger
guide cover.

3 Replacement of Hard crome plated plunger with new

MOC having inbuilt hardness property i.e. Black
nitride (iron nitride:Fe3N )

4 Provision of guide seal inside hyd. Cylinder for

plunger guide .
avy Hydraulic oil leakage of sq. roller system and plunger seal with its assly life.improvement if Aft ( 1 to 9)

- Reduction by 50 % of last year hyd oil (176)consumption due to hydraulic leakage.

y and fast adoptable with high return)

Completion Time :- Six month (Start with continuous adoption till full change.

Expected benefit

Seal life improvement due to plunger surface condition

improvement
Align the plunger lifting in vertical movement & guide hyd.
Seal to avoid damage.
Align the plunger lifting in vertical movement causing
plunger life improvement.
Self align the hyd. Plunger movement due to self lubrication
property.

Oil recovery during any leakage which is re used for

lubrication

ntion & long time development work )

ompletion Time :-One year (With adopting at one system for its successor rate)

Expected benefit

Projection of plunger surface from abrasive partial and

chemical hazardous.
Removing of Plunger surface, metal to metal, contact to
increase life of plunger hard surface causing seal life
increment.

High depth hardness achieving property with high corrosion

resistance and no. surface pitting causing plunger life
improvement ( expected minimum three time of existing)

Removing of Plunger surface, metal to metal, contact to

increase life of plunger hard surface causing seal life
increment.
 Date :- 17.05.2014
l with its assly life.improvement if Aft ( 1 to 9)

e to hydraulic leakage.

tion till full change.

Remark / Status

As per condition to be replaced ( 08 nos replaced

out of 36 nos)
New bush on order expected will come May
2014
Part material already came, to be replaced
during PMT
Part material already came & SS segment to be
made ( target May 14 ) after that , one by one in
set ( one ss Female & one MS Male ) to be
replaced during M/C stoppage.

Immediate adopted as per condition.

or its successor rate)

Remark / Status

two seals are under fitting process ( Jun 14 ) for

adoption , rest will be after this success.
Vender & item code development under progress
( Target to order jun 14)

Vender & item code development under progress

( Target to order July 14)

Adoption after above three changes & its

success . Simultaneously vender & design to be
fix for improvement( July 14)
 Hyd. System oil leak last six month due hyd. Sys. Failure.
Month Nov-13 Dec-13 Jan-14 Feb-14 Mar-14 Apr-14
M/C #
1 50 60 60 80 105
2 70 15 30 15
3 180 30 225 65
4 50 70 75 60
5 30 40 180 330 60
6 100 15
7 90
10 30 15

Total 130 100 365 490 635 410

16.06.14 Aft # 3 , ecc. No. 8 housing front cover leakage ( loss 70 ltrs)
01.06.14 Aft # 5, ecc. No. 8 housing front cover leakage ( loss 70 ltrs)
21.06.14 Aft # 5 ,Ecc no. 5-9 housing front cover leakage (loss 80 ltrs)
ys. Failure.
May-14
Upto 8 may
355
95 225
500
15 270
15 655
15 130
90
45

140 2270
.