97 Chapter 5 OPERATIONAL & MAINTENANCE SKILL DEVELOPMENT 5.1 INTRODUCTION Training and development is vital for every organization to cope up with the technological changes from time to time and to perform well. This helps in honing skills, developing versatility and adaptability. Having a well designed approach towards this is very important for every organization. Shirose et al. [2002] designed a detailed education and training system describing its various levels as presented in table 5.1. Table 5.1 Education and training System [Shirose et al. 2002] Levels On the job training Off the job training Introduction Education on the job (sectional education) Guide to equipment maintenance (1) Workshop exercise training Quality control education (guide) Developing basic capability Education on the job (sectional education) Guide to equipment maintenance (2) Workshop exercise training How to view drawings (2) Quality control education (initial level) Developing professional capability Education on the job (sectional education) Maintenance class (beginner's level) Industrial engineering education (1) Numerical control education Quality control education (medium level) Developing management capability Education on the job (sectional education) Maintenance class (Medium level) Industrial engineering education (2) Quality control education (higher level) Developing advanced management capability Education on the job (sectional education) Maintenance class (Medium level) Quality control circle leader education (higher level) The development of operational and maintenance skills of workmen is described in the following sections.
This document is posted to help you gain knowledge. Please leave a comment to let me know what you think about it! Share it to your friends and learn new things together.
Transcript
97
Chapter 5
OPERATIONAL & MAINTENANCE SKILL DEVELOPMENT
5.1 INTRODUCTION
Training and development is vital for every organization to cope up with the
technological changes from time to time and to perform well. This helps in honing
skills, developing versatility and adaptability. Having a well designed approach
towards this is very important for every organization. Shirose et al. [2002] designed a
detailed education and training system describing its various levels as presented in
table 5.1.
Table 5.1 Education and training System [Shirose et al. 2002]
Levels On the job training Off the job training
Introduction Education on the job
(sectional education)
Guide to equipment maintenance (1)
Workshop exercise training
Quality control education (guide)
Developing basic
capability
Education on the job
(sectional education)
Guide to equipment maintenance (2)
Workshop exercise training
How to view drawings (2)
Quality control education (initial level)
Developing professional
capability
Education on the job
(sectional education)
Maintenance class (beginner's level)
Industrial engineering education (1)
Numerical control education
Quality control education (medium level)
Developing
management capability
Education on the job
(sectional education)
Maintenance class (Medium level)
Industrial engineering education (2)
Quality control education (higher level)
Developing advanced
management capability
Education on the job
(sectional education)
Maintenance class (Medium level)
Quality control circle leader education
(higher level)
The development of operational and maintenance skills of workmen is
described in the following sections.
98
5.2 STEP 6: FORMULATION OF TRAINING POLICY AND CURRICULUM
Skill mapping exercise as presented in previous chapter the average skill
deficiencies in all skill attribute for workmen were worked out (presented in table
4.14 and figure 4.20). These skill deficiencies were adversely affecting the overall
performance of the manufacturing system (table 4.1 and 4.2). To bridge the skill gaps
of the workmen the following curriculum was developed -
(A) Off the job training
Training attributes common to all the H4 halogen bulb processing operators
1. Total productive maintenance
2. Autonomous maintenance
3. Quality maintenance.
4. Statistical quality control
5. Statistical process control
6. Q.C. tools
7. Connections of hydraulic and pneumatic pipes
8. Color coding of supply lines
9. Color coding of electrical connections
10. Methods of setting and taking reading with common gauges
11. Dealing with emergency
12. Safe operating conditions
13. 5S
Training attributes common to all the ball bearing processing operators
1. Total productive maintenance
2. Autonomous maintenance
3. Quality maintenance
4. Specifications of grinding wheel
5. Classifications of grinding wheel
6. Selection of grinding wheel
7. Glazing and loading of grinding wheel
8. Dressing of grinding wheel
9. Connections of hydraulic and pneumatic pipes
10. Color coding of supply lines
99
11. Color coding of electrical connections
12. Methods of setting and taking reading with common gauges
13. Dealing with emergency
14. Safe operating conditions
15. 5S
16. Statistical quality control
17. Statistical process control
18. Q.C. tools
(B) On the job training
On the job training is imparted to improve following skills related to their
respective processes -
H4 bulb forming process
1. Method of setting L.P.G., Oxygen and Air pressure with the help of regulator.
2. Method of setting correct gas flame by flow meter.
3. Procedure of setting body tube length as per drawing and measurement.
4. Ways of checking form hole and length of the forming.
5. Methods of inspection of diameter of form hole for centering and ovality and
corrective actions for defects.
6. Procedure to conduct visual inspection of form shell for roundness and clarity
and corrective actions for defects.
7. Tips on how to check condition of ‘O' ring and forming wheel and corrective
actions, if warned out.
8. Identification of the condition of bearing jammed / cracked.
9. Detecting the effect of variation in glass tube material.
10. Indications of the condition of direct working of regulator which results in
increased gas pressure and correction.
11. Measure to be taken for safe working conditions.
H4 bulb jointing process
1. Method of setting L.P.G., Oxygen and Air pressure with the help of regulator.
2. Method of setting gas flame by flow meter.
3. Method of setting correct exhaust tube blow air stream pressure.
4. Procedure of loading exhaust tube and form tube on machine correctly.
100
5. Ways of checking and setting dimensions of jointing as per drawing.
6. Method of inspection for straightness, leakage at joint, minimum hole
diameter and ring cut of jointing and corrective measures for non conformity.
7. Techniques of checking jointing for soundness of joint, no white particles on
jointing and no blow hole at joint and corrective actions for defects.
8. Methods of cleaning of machine and burners, lubrication & checking PVC
pipe condition.
9. Detection of the abnormal working of machine.
10. Identification of the condition of the bearing jammed / cracked.
11. Detecting the effect of variation in glass tube material
12. Measures to be taken for safe working.
H4 bulb sealing process
1. Method of setting L.P.G., Oxygen, Hydrogen and Air pressure with the help of
regulator.
2. Method of setting burner flame by flow meter.
3. Ways of checking pinch shape and corrective measures by setting punch
pressure / position and burner flame.
4. Method of checking filament mount for correct direction, no shift and no tilt
and corrective actions.
5. Procedure to check sealing stress, no bursting and no crack.
6. Method of setting correct vacuum level and detecting gas leakage and
corrective actions.
7. Methods of cleaning of machine and burners, lubrication & checking PVC /
metal pipe condition.
8. Detection of the abnormal working of machine.
9. Ways of identifying condition of the bearing jammed / cracked & checking up/
down movement of head and use of rustolene oil, if jammed.
10. Detection of the effect of variation in glass tube material.
11. Measures to be taken for safe working.
H4 bulb exhausting process
1. Method of setting L.P.G., Oxygen, Hydrogen and Air pressure with the help of
regulator.
2. Method of setting Nitrogen flow and Halogen gas mixture flow.
101
3. Method of setting burner flame by flow meter.
4. Method of loading of sealing on machine.
5. Ways to check capsule shape & tip size and take corrective measures by
setting cutting burner flame.
6. Method of setting proper vacuum in machine & detecting gas leakage and
taking corrective actions.
7. Method of cleaning machine & burners, lubricating the moving parts &
checking PVC / metal pipe conditions.
8. Detection of the abnormal working of machine.
9. Method of identifying condition of the bearing jammed / cracked & checking
up / down movement of head and use of rustolene oil, if jammed.
10. Procedure of setting correct motions of mechanical links of the machine.
11. Measures to be taken for safe working.
Ball bearing face grinding process
1. Reading & understanding specifications of grinding wheel.
2. Procedure of installing and setting of grinding wheel.
3. Method of setting correct direction of wheel rotation.
4. Procedure to check dresser diamond condition.
5. Procedure of dressing of grinding wheel.
6. Method to prepare grinding machine for operation.
7. Method of checking plate condition and setting.
8. Checking hydraulic, pneumatic, mechanical links and electrical connections of
machine.
9. Method of setting and reading gauge for checking width size, width variation,
flatness, buckle, track circle out and squareness.
10. Method of visual inspection of work piece for black face, eccentric O.D.,
punch mark and chatter on face, after face grinding.
11. Identifying loading (exhausting) of grinding wheel.
12. Identifying exhausting of feed mechanism rings and procedure of changing it.
13. Method of oiling and greasing of machine.
14. Method of setting drop lubrication and oil/grease level.
15. Detecting abnormal sound / working of machine and remedy
16. Measures for safe working.
102
17. Emergency and breakdown management.
Ball bearing outer diameter grinding process
1. Reading and understanding specifications of grinding wheel.
2. Method of installing and setting of grinding and regulating wheel.
3. Ways of checking dresser diamond condition.
4. Procedure of dressing of grinding / regulating wheel.
5. Preparing grinding machine for operation.
6. Method of checking plate condition and setting (Bottom/Top) as per job sizes.
7. How to check hydraulic, pneumatic, mechanical links and electrical
connections of machine.
8. Hydraulic and pneumatic connections (color coding of supply lines) and
mechanical links of machine and correct hydraulic oil level / air pressure.
9. Method of setting and reading gauges for checking outer diameter (O.D.) size,
surface taper, O.D. out of round, Jump and talyrond.
10. Method of visual inspection of work piece for black O.D., chatter on surface
and surface finish.
11. Identifying loading (exhausting) of grinding wheel.
12. Method of setting automatic feed rods of centreless grinding machine.
13. Procedure of oiling and greasing of machine.
14. Procedure of setting drop lubrication and oil/grease level.
15. Detection of abnormal sound / working of machine and its remedy
16. Measures for safe working.
17. Emergency and breakdown management.
Ball bearing IR / OR grinding lines
1. Method of mounting and setting of grinding wheel, dresser setting & dressing
of grinding wheel and preparing machine for operation.
2. Procedure of loading and unloading of work piece on machine center and
checking conveyor, sensor guided slide and push rod for correct working.
3. Hydraulic and pneumatic connections (color coding of supply lines) and
mechanical links of the machine.
4. Method of setting and reading gauges for checking track size, out of round,
wobble, TC out and curvature of track (for track grinding and honing of IR &
103
OR) and knowledge of setting in process gauge for Track size (for track
grinding and honing of IR & OR).
5. Procedure for setting and reading gauges for checking bore size, out of round
& taper and setting in process gauge for bore size.
6. Interpretation of the results of the test performed in standard room about
roughness / telyrond / profile of track curvature / taper.
7. Corrective actions on the basis of the results of the standard room test.
8. Detection of exhausting of grinding wheel and abnormal sound / working of
machine.
9. Method of oiling and greasing of machine.
10. Procedure of lubrication of machine during operation.
11. Steps to be taken immediately after machine breakdown.
12. Measures to be adopted for safe working.
(C) One point lessons (OPL)
As discussed in chapter 2, one point lesson (OPL) is one of the most effective
methods of educating people focused on a single aspect of operating parameters and
methods of operating the equipment. This is a learning method frequently used by
workmen during daily work and daily meetings, lunch breaks etc. Each employee
come up with the ideas, discuss to make the issue more precise before preparation of
OPL. The OPL are prepared including visual images for better understanding of the
lesson. Numbers of one point lessons (74 nos.) were prepared to give learning to the
workmen of various training requirements related to their tasks. Few typical one point
lessons are presented here for illustration.
Illustrative one point lesson no. 1 is presented for the H4 forming process
which is prepared for training of skill attribute ‘D’ required for the process. During
study of the process it was observed that the operators of forming process are
expected to inspect the size of the forming using GO and NOGO gauges prepared
according to the designed size. On skill mapping of the workmen the skill deficiencies
were identified related to skill attribute ‘D’.
Illustrative one point lesson no.2 is presented for the H4 jointing process
which is prepared for training of skill ‘F’ required for the process. During study of the
process it was observed that the operators of jointing process are expected to visually
104
inspect the jointing for blow (glass) hole and crack at the joint of formed shell and
exhaust tube. On skill mapping of the workmen the skill deficiencies were identified
related to skill attribute ‘F’.
Illustrative one point lesson no.3 is presented for the IR/OR track grinding
process which is prepared for training of skill ‘A’ required for the process. During
study of the process it was observed that the operators of IR/OR grinding process are
expected to know the correct shape of the grinding wheel before it is mounted on the
spindle. On skill mapping of the workmen the skill deficiencies were identified
related to skill attribute ‘A’.
Illustrative one point lesson no.4 is presented for the IR/OR track grinding
process which is prepared for training of skill ‘A’. During study of the process it was
observed that the operators of IR/OR track grinding process are expected to correctly
shape the honing stone before it is mounted on the machine. On skill mapping of the
workmen the skill deficiencies were identified related to skill attribute ‘A’.
The respective operating executives and Setters (skilled operators) perform the
job of trainers, since, they are well qualified and knowledgeable about modern
manufacturing process and equipments and have vast exposure to the shop floor
practices. The setters of respective machines provide assistance during on the job
training.
Lesson plans and preparation of teaching materials
Excellent teaching methods were used, as discussed in previous pages to
implement education and training effectively. The self-enlightening training methods
were used and lesson plans were prepared in association with respective trainers for
each process / subject suitable for education and training. HRD division of concerned
companies helped in preparation of OPL and photograph for training.
Preparation of classrooms
Training activity was conducted on a one-on-one basis. A class size of 10-15
persons was organized. A room with a good environment, accommodating exercise
materials and slide display equipments, was used as class room. Company training
center was also well equipped with LCD projector, OHP and ergonomically design
seating arrangement necessary for effective training.
105
5.3 STEP 7: EXECUTION OF OPERATIONAL AND MAINTENANCE SKILL
DEVELOPMENT
As discussed above, education and training was carried out with emphasis on
both theoretical (off the Job) and practical (on the Job) exercises. Due emphasis was
given on the following considerations during education and training activity -
Education and training activity was directly linked with actual work to
effectively implement the "bodily learning".
For each training unit, one-point lessons suitable for the actual workshop were
prepared, containing problems and improvement cases and used in education
and training, thus better results were achieved.
The duration of off the job training classes on each topic was 45 minutes and for on
the job training it was 30 minutes.
Fig 5.1 Education and training resource persons
Training resource persons
External faculty / experts Shift engineer
Off the job training On the job training
One point lessons
Shift supervisor
Setter
106
107
108
109
110
5.4 STEP 8: RE-SKILL MAPPING AND MEASUREMENT FOR
PERFORMANCE MEASUREMENT METRICS
The operational and maintenance skill development program was continued
for eight weeks. It was a rigorous exercise and supported whole heartedly by the
management and HRD in formulation of training policy and outsourcing general part
of the curriculum. It was also fully supported by engineers, supervisors and setters of
the companies to give valuable inputs for preparation of training curriculum and
executing it especially on the job. The workmen found it interesting and viewed it as a
key exercise in development of their skills. They were curious, supportive and
interactive all the way. To assess the effectiveness of the exercise the performance
measurement were taken.
The measurement taken were twofold i.e. operator skill levels and capability
indices Cp and Cpk were measured before training (presented in chapter 4) and after
completion of the training exercise whereas other performance measurement metrics
like Mean time between failures (MTBF), Mean time to repair (MTTR), Availability