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

roller system and plunger seal with its assl

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

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

S. Action Plan comes from design analysis, why why

No 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 successo

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 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 )

Completion 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
al with its assly life.improvement 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.

r 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)
 COMPARISON WITH ADVANTAGES OF BLACK NITRIDE (NITROSTEEL) HYD. CYL. ROD OVER CONVENTIO

1 General view

2 MOC Carbon and Alloy NitroSteel® Bars ( NITRO-100™ alloy 100,000 PSI
min. yield (690 Mpa))

3 Manufacturing Process begins with the grinding and polishing of steel bars or honed
process and polished steel tubes. In preparation for treatment, the bars or
tubes are cleaned, fixture vertically, and lowered into an electrically
heated pit furnace.

The furnace sequence entails nitrocarburizing the steel lengths at

elevated temperatures in an ammonia atmosphere with exothermic
gases followed by an oxidizing step.

4 Hardness This process generates a thin (0.001") uniform and extremely hard
(64 to 71 Rc) iron nitride(Fe3N) layer infused with a film of iron
oxide. Beneath the iron nitride layer is a nitrogen-enriched hardened
diffusion zone. The diffusion zone functions as a light hardened case
with a hardness gradient ranging from the mid-50's Rc just below
the iron nitride layer to approximately 40 Rc at 0.015" depth.
 5 Corrosion Superior corrosion resistance (Tested to ASTM B-117, 150 hours
resistance minimum with zero corrosions)

6 Surface finish 0.40 micrometer- Ra max. & alternative finish available

7 Life Life three times that of conventional chrome,
8 Improved wear resistance
9 Better lubrication retention
10 Dent resistance without induction hardening
11 Environmentally friendly
12 NO surface pitting , flaking or hydrogen embrittlement.
 Date :- 07.05.2014
TEEL) HYD. CYL. ROD OVER CONVENTIONAL HARD CROME PLATED CYL. ROD.

EN8 (Hard Chrome is classed as a "COLD" process, the operating temperature of

50 - 60°C ensures no detrimental effects to the physical or mechanical properties
of the base materials. Hard Chrome can be deposited successfully and
advantageously onto most metallic substrate materials.)

Hard Chrome plating is an electrolytic method of depositing Chrome for

engineering applications, from a Chromic acid solution.

Deposits can be applied from .25 - 1,000 microns thickness for a wide range of
applications. The thinner deposits being used to substantially increase the life of
components in wear applications or corrosive environments, and the thicker
deposits being used for salvage and repair of worn, damaged or mis-machined
components.

Electro-deposited Chrome is extremely hard, with typical values of 850 - 1050 HV

(63 - 70 HRc), hence the term "Hard" Chrome. This makes it an excellent coating
for wear resistant and abrasion resistant applications such as sliding components.
Chrome lacks dimensional uniformity.
Hard Chrome has an extremely high resistance to atmospheric oxidation, and a
good resistance to most oxidising and reducing agents.(with the exception to
Chlorides and other Halides), hence its wide-spread use in the Food and Chemical
Industries. But Chrome plate has
"micro-cracks" which allow moisture penetration and rust.

Ra(micrometer) 0.05 to0 .30

Good resistance to abrasive and erosive wear.

Plating creates pits and has inherent adhesion problems

Chrome plating is environmentally hazardous.
Flakes and slivers will destroy seals and glands
 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

s. Failure.
May-14
Upto 8 may
355
95 225
500
15 270
15 655
15 130
90
45

140 2270
.
 Grasim Industries Ltd. (SFD,Nagda)
Date:-19.03.2014
WHY WHY ANALYSIS Department:

M/c No: M/c Description:AFT#5 , First sq. roller DS hydraulic cylinder Team Aftmt-1 K Jain / Abhinav Sinha
Breakdown Action Plan:- (1) Timely
Physical replacement of guide plates & other spares ( during pmt) as per condition
Phenomenon ( Focus area:-More frequent cylinder leakage area).
Cylinder seal leakage (2) Cylinder assly to be done as per Drg.with
In case of no replacement of spare parts tolerable clearance.
What is your Replaced cylinder assly with new
final action to chrome plated Plunger.
restart the
equipment?
What was the
symptom before
breakdown?
Hydraulic cylinder and its system working as per process requirement.
Why did you take above action Due to Root cause is always one of the following 5 reasons

Why 1
(Please tick here
For Breakdowns/ For Accidents
Defect/
Why plunger seal of cylinder leaked Scratches and Pitting foud at Plunger surface. Abnormalities

Why 2 √ 1. Poor basic 1. Unsafe basic Condition

Why Scratches and Pitting found Uneven movement of plunger at position. condition
Inner side guide plate of hyd. Cylinder got badly 2.Poor operating 2. Unsafe action
Why 3 damage which created cleance to fix the cyl. Assly. condition

Why uneven movement of plunger

Bottom housing Bearing housing side step & its 3.Deterioration 3. Deterioration
guide plate (inside & outside) got damaged which
Why 4 √
creates unequal load at plunger to lift.

Plunger segment & sq. roller housing segment got 4.Weak design 4. Weak design
Why 5
badly corroded which restrict to plunger lift in align.
Clearance increased inside plunger due to top cover 5. Poor Skill 5. Untrained / unskilled person
Why 6
inner dia and cylinder dia tolerance increased.

Root Cause Deterioration of plunger assly parts and bottom sq. roller bearing housing fixing
arrangement(guide plate,segments,brg housing,top cover)
Operator can check:
He did not
( Real root
Old used plunger assembled cylinder is fitted in previous replacement( 11.03.2014) due to
cause)
unavailability of spare.
Manufa
cturing
Proces
s

50 (2000) 25 (1000) 12.5 (500) 6.3 (250) 3.2 (125)

Flame
Cutting
Snagging
Sawing
Planing,
Shaping
Drilling
Chemical
Milling

Elect
Discharge
Machining
Milling

Broaching
Reaming
Electron
Beam
Laser
Electro-
Chemical
Boring,
Turning
Barrel
Finishing
50 (2000) 25 (1000) 12.5 (500) 6.3 (250) 3.2 (125)

Electrolyti
c Grinding
Roller
Burnishin
g
Grinding
Honing
Electro-
Polish
Polishing
Lapping
Super
Finishing
Sand
Casting
Hot
Rolling
Forging
Permane
nt Mold
Casting

Investme
nt Casting
Extruding
Cold
Rolling,
Drawing
Die
Casting
50 (2000) 25 (1000) 12.5 (500) 6.3 (250) 3.2 (125)
 Roughness Average

Top Number - Micrometers

Bottom Number - (Microinches)
3.2 (125) 1.6 (63) 0.80 (32) 0.40 (16) 0.20 (8) 0.10 (4)

3.2 (125) 1.6 (63) 0.80 (32) 0.40 (16) 0.20 (8) 0.10 (4)
3.2 (125) 1.6 (63) 0.80 (32) 0.40 (16) 0.20 (8) 0.10 (4)
0.10 (4) 0.05 (2) 0.025 (1) 0.012 (.5)

0.10 (4) 0.05 (2) 0.025 (1) 0.012 (.5)

0.10 (4) 0.05 (2) 0.025 (1) 0.012 (.5)
0.012 (.5)

0.012 (.5)
0.012 (.5)
Item Code Nitrosteel hyd Plunger # 4WAFT0840---

Long text:- Iron nitride (fe3N) for hydraulic plunger of squeeze roller # 4WAFT0840---
External Diameter accuracey:g6(-0.14 to 0.039 mm)
Suface roughnes:Ra (micrometer) 0.025 to 0.10
Suface hardness: 64 to 71 HRC of Iron Nitride layer 0.0254mm thichness per side.
Harness diffusion zone , beneath the wear layer ,( hardness gradient from low 50 's Rc to 40 Rc
Material:Carbon and alloy Nitrosteel -NITRO-100 TM ALLOY 100,000 PSI min.yield (690 Mpa)
Straightnes: 0.15 mm to .25 mm / 1000 mm
Corrosion resistance:Tested to ASTM B-117, 150 hours minimum with zero corrosion

Party in india: Deck India Engineering Pvt. Ltd.

Office &
Works :

Telefax :

Mobile :
E-mail :
Chakan Unit

Office :
Our Sister Concern
Kaizen Technology

Works :

Mobile :
E-mail :

ALFA
HEAT
Party No 2 TECH

Works : W - 154, ‘S' Block, M.I.D.C., Bhosari,

Pune - 411 026, Maharashtra, India

Tel. No. : +91 - 20 - 27128393

Cell Nos. : +91 - 96048 66824, 90114 52944, 97674 00401, 98308 82951
Party NO.3

Foreign party
Foreign Party2 :-

Foreign Party2 :-
hyd Plunger # 4WAFT0840---

e (fe3N) for hydraulic plunger of squeeze roller # 4WAFT0840---

iameter accuracey:g6(-0.14 to 0.039 mm)
ghnes:Ra (micrometer) 0.025 to 0.10
dness: 64 to 71 HRC of Iron Nitride layer 0.0254mm thichness per side.
ffusion zone , beneath the wear layer ,( hardness gradient from low 50 's Rc to 40 Rc at 0.381 mm depth) generate significate dent resista
arbon and alloy Nitrosteel -NITRO-100 TM ALLOY 100,000 PSI min.yield (690 Mpa)
s: 0.15 mm to .25 mm / 1000 mm
resistance:Tested to ASTM B-117, 150 hours minimum with zero corrosion

Deck India Engineering Pvt. Ltd.

S. No. 671, Kudalwadi (Chikhali), Behind Telco Pimpri, Tal. Haveli, Pune - 412 114, Maharashtra, India.

+ 91 - 98224 02717
+ 91 - 98224 02717 ( Mr. D.K. Salunkhe)
+ 91 - 95610 65641 to 50
(10 Lines)

Unit
Plot No. 53, WMDC Industrial Area, Chakan-Ambethan Road, Kharabwadi,
Chakan,Tal - Khed, Pune - 410 501
r Concern
Kaizen Technology
Sector No. 10, 128 C, PCNTDA, Bhosari, Pune 411 026, Maharashtra, India.

+91 - 98224 02717

Works : W - 154, ‘S' Block, M.I.D.C., Bhosari,

Pune - 411 026, Maharashtra, India

Tel. No. : +91 - 20 - 27128393

Cell Nos. : +91 - 96048 66824, 90114 52944, 97674 00401, 98308 82951
 Contact Details
Metals IndiaMr. Ankit Gupta
-9910012535
-4060866
-4060867
-4060868
Plot No. 128, 130 & 139, Sector 25, BallabgarhFaridabad - 121004, Haryana, India

http://www.metalsindia.com

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