MINISTRY OF EDUCATION & TRAINING

UNIVERSITY OF TECHNOLOGY AND EDUCATION

-----------------o0o-------------------
MAINTENANCE IN INDUSTRY

Chapter 5

QUALITY CONTROL TRAINING

Date: 25/04/2022

Class: Maintenance in Industry_ Nhom 01CLC

Group: 3
Leader: Trần Anh Tú
Members list:

No ID Name Assessment

1 19144083 Nguyễn Thanh Phúc

2 19144058 Cù Nhật Khang

3 19144049 Nguyễn Phan Hồng Anh

4 19144079 Trần Anh Tú

5 19144067 Trần Nhật Quang

6 19144077 Phạm Công Thuận

1
* Check sheet data
Failure/Defect Freq
Motor overheating 20
Broken belt 15
Premature of chain (wear) 10
Pneumatic pressure variation 5
Pump flowrate variation 150
Lossing sensor signal 18
Motor high vibration 100
Hydraulic system pressure drops 12
High temperature of gearbox 6
Belt slipped 4
Gearbox noise 60
Total 400

Part 1: Pareto chart analyzing (2.5 point)

- Data processing

Failure/Defect Cumulative
Failure/Defect Freq
Percentage percentage

Pump flowrate variation 150 37.5% 37.50%

Motor high vibration 100 25% 62.50%
Gearbox noise 60 15% 77.50%
Motor overheating 20 5% 82.50%
Lossing sensor signal 18 4.5% 87.00%
Broken belt 15 3.75% 90.75%
Hydraulic system pressure drops 12 3% 93.75%
Premature of chain (wear) 10 2.5% 96.25%
High temperature of gearbox 6 1.5% 97.75%
Pneumatic pressure variation 5 1.25% 99.00%
Belt slipped 4 1% 100.00%
Total 400

2
- Pareto chart:

- Conclusion: We have 3 failure that cause 80% consequence:

➢ Pump flowrate variation
➢ Motor high vibration
➢ Gearbox noise

3
Part 2: Fishbone Diagram (3 point)
Practicing with the first 3 problems that cause 80% of the consequences shown from the Pareto chart in part 1.
- Failure/Defect 1: Pump flowrate variation

CAUSE EFFECT
Man Material Method

Operation Hardness Assembly

Design Homogeneity
Lubrication
schedule
Pump
Wrong
Composition
lubrication way
Bearing
flowrate
Dusty Fatigue Failed
variation
Temperature Wear-out
Stucked
Rust, corrosion
Out of date

Mother nature Machine

4
➢ - Failure/Defect 2: Motor high vibration

CAUSE EFFECT
Man Material Method

Operation Hardness LooseAssembly

foundation
Foundation
Design Homogeneity misalignmen
Lubrication
t
Wrong schedule
Composition
lubrication way
Bearing
Motor high
Dusty Bearing Fatigue
malfunctions vibration
Failed
Temperature Wear-out
Stucked
Rust, corrosion
Out of dategears
Misaligned

Mother nature Machine

5
 ➢ Failure/Defect 3: Gearbox noise

CAUSE EFFECT
Man Material Method

Operation Hardness Assembly

Design Homogeneity
Lubrication
Wrong schedule
lubrication way
Composition
Gearbox
Bearing
noise
Dusty Fatigue Failed
Temperature Wear-out
Stucked
Rust, corrosion
Out of date

Mother nature Machine

6
Part 3: CIL Standard (3 point)
Setting up the CIL (Cleaning - Inspection - Lubrication) table for the system that contents the failure in part 2
- Failure/Defect 1: Pump flowrate variation

CLEAN – INSPECTION – LUBRICATION STANDARD

Run/
Photograph No Check point Freq Time Standard Method Tool
Stop

15 Max temp
1 Pump pressure D Run
sec 90oC
30
2 Fastener M Stop Tightened
sec
30
3 Fastener M Stop Tightened
sec
30
4 Fastener M Stop Tightened
sec
15 Max temp
5 Pump pressure D Run
sec 90oC

7
Failure/Defect 2: Motor high vibration

CLEAN – INSPECTION – LUBRICATION STANDARD

Check Run/
Photograph No Freq Time Standard Method Tool
point Stop
30
1 1 Handle D Tightened
2 sec
15
2 Hangers W Stop
sec
3 15 Max temp
3 Wire D Run
sec 90oC
5
Inspecting
4 30 Tightened,
4 the W Stop
sec alignment
coupling
Not
60 stretched,
5 Belt W Stop
sec Not
broken

Failure/Defect 3: Gearbox noise

8
 CLEAN – INSPECTION – LUBRICATION STANDARD
Check Run/
Photograph No Freq Time Standard Method Tool
point Stop

60 No
1 Shaft W Stop
sec bending

No
60
2 Gear W Stop deviation
sec
or wear
5
60 No
3 Shaft W Stop
4 sec bending

2 3 No
1 60
4 Gear W Stop deviation
sec
or wear

60 No
5 Shaft W Stop
sec bending

9
Part 4: Visual Control (1 point)
Setting up a visual monitoring system for test points in CIL to make inspection work
faster. Mark the points showing Visual Control on the system image that the team found
in part 3.
No Test Point Images

Inspecting the foot

1
mount bolts

10
Part 5: Kaizen (0.5 point) Marking the improvements on the system image that the team
found in part 3.

Improvement
No Images
Point

1
Cylindrical gear
-> bevel gear
→
11
2 Belt -> V belt
→

12