Abstract
Quality plays a very important role in today's highly competitive industrial environment. Quality leads to an improvement in the productivity. Quality control tools are used to solve more than 90% of the problems faced by the organizations in improving its effectiveness and meeting the customer expectation on a continuous basis. The success of the quality control procedure depends greatly on the method of data collection and its accuracy. Quality control tools are used worldwide in manufacturing industries for continual improvement and are implemented in different steps of manufacturing process to define the problem, measure its impact, finding out its root cause and its removal to ensure the production of non-defective items. The present work includes collection of failure data of intermix and dump mill of a tyre manufacturing unit located in Karnataka. The failure data collected for one year has been analysed to find out the major causes of breakdown. Quality control tools such as Pareto chart, Bar chart, Histogram, Fish bone diagram have been used to find out the root causes and identifying the action plans to eradicate them. Reliability assessment (theoretical) of intermix and dump mill has been conducted using the failure data. The reliability and maintainability curves speak about the present state of working of maintenance department in regard to addressing of breakdown problems and also help in setting future working standards.
Highlights
Machinery and other service facilities of any industry are continuously subjected to deterioration upon their use and exposure to environmental conditions
The failure data was analysed with the help of quality control tools such as Bar charts and Histograms, Pareto charts and Fish bone diagram to find out the root causes of failure and the possible ways to eliminate them
The major causes for failures have been analyzed with the help of quality control tools such Pareto chart and Fishbone diagram
Summary
Machinery and other service facilities of any industry are continuously subjected to deterioration upon their use and exposure to environmental conditions. With the passage of time, machinery will be subjected to wear and tear and their performance as well as reliability decreases. Maintenance helps the plant and machinery to be maintained in good operating condition so as to maximize the output, reliability and profitability [1]. Failure data are the backbone of reliability studies as they provide very useful information to reliability engineers, design engineers and managers [3]. Various sources of collecting failure data are available, but inspection records, log books generated by maintenance, quality control or manufacturing groups are widely used
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