Acknowledgement

I am extremely grateful to Shri.K.Vasudevan, Prop.Balaji Container

Terminal, Heavy equipment carriers for his kind permission to work on this thesis.

I express my profound respect and sincere thanks to Shri.S.Padmanaban,

Managing Director, SATTVA HITECH CONWARE LTD – MANALI, who was

always by the side of me for this thesis to be completed successfully.

I express my sincere gratitude to Mr.Desigan, General Manager of

SATTVA HITECH CONWARE LTD – MANALI

I am indebted and thankful to Shri.Kumar, Maintanence Enggineer,

SATTVA HITECH CONWARE LTD – MANALI, who was a standing

inspiration for me & I am very much owned to him for his valuable guidence.

I am thankful to Shri.Krishnakumar Operations Manager SATTVA

HITECH CONWARE LTD – MANALI

Finally, I wish to thank one and all the staff members who have helped by

sharing their valuable time for this thesis.

Synopsis

The idea behind thesis is as follows. In container handling operations, the

equipments for stacking /de-stacking of various containers, stuffing/ de-stuffing of

cargos ,(Reach stackers, Fork lifts, Escort cranes,655 cranes etc., ) in operating

condition forms a major part of operations. But the equipments at ready condition

always is an impossible task. As these process is an unavoidable , we must be in a

position to minimize these breakdown times of equipments as much as possible

.At the same time enhancing the life time of the equipments which inturn enhances

the productivity and the life of the terminal. This inturn depends upon the

effeciency of the maintanence procedure of the concern.

So it is Highly needed to keep this effeciency of the maintanence procedure

as high as possible which inturn may lead to many savings such as (1) Increased

productivity, (2) Money savings (3) work quality or worth fullness for the work

etc. Creating awareness towards the improved effeciency (optimization) of

maintanence procedure Initializing those measure is the background of this case

study or thesis.

MAINTENANCE

Maintenance is the corporate effort directed towards upkeep a repair of equipment

and production facilities for their trouble – free operation, throughout its economic life.

A concern cannot be successful to achieve proper productivity without proper

maintenance.

It is the only way, on effective application the gap between the achieved and

achievable productivity can be minimized.

Maintenance varies from plant to plant depending on :

(1) Size

(2) Policies

(3) Technology and

(4) Prevailing conditions of an individual concern.

Types of Maintenance:

Maintenance

Planned Unplanned

Scheduled Predictive Preventive Emergency or Break Down

Unplanned Maintenance or Emergency:

The unplanned procedures permit failure to take place before any maintenance

work is done.

It involves (1) less direct maintenance cost,

(2) But enhances probabilities of downtime of the machineries.

Planned Maintenance:

Incorporates all functions like, planning, scheduling, Executing or dispatching,

recording, analysis and controlling or decision making.

PLANNED MAINTENANCE

Scheduled Maintenance:

Such a Type of maintenance is a stitch in time procedure to avoid break down. A

schedule is framed for an instrument / machine / equipment maintaining.

The instruction of the manufactures and applying the concept gained through

experience incorporating inspection, lubrication, repair and Overhaul.

Predictive Maintenance:

Sensing, measuring or monitoring Techniques are followed usually to recognize

the cause of any change of physical conditions if a system. Today, a large number if

commercial instruments such as vibration analyzing optical devices etc. are available to

conduct tests and to predict used for repairing of any particular component of a system.

Maintenance

Work Planning

Decision

MakingScheduling

AnalysingDespatching or Executing

Data Recording

Preventive Maintenance:

Maintenance carried out to keep equipment in satisfactory operational conditions

by providing systematic replacement of components before they are expected to fail.

Breakdown Maintenance:

It is suitable for small scale industries because of its less direct cost involvement,

The maintenance work such as repairing, replacement etc., are performed only when

break down occurs.

Repair Complexity:

It is a relative index to give a comparative of the complexity idea of the machine

and takes into account the mechanical gearings, hydraulic & pneumatic units, guide

surface and other Transmission units incorporated in the machine.

Repair completely is used to determine:

(1) The percentage breakdown and hence efficiency etc,

(2) Estimate the annual repair cost of the machine.

(3) The size of the mechanical maintenance department the requirement of staff and

workers.

(4) The materials & spares requirement of maintenance workers.

For a periodic maintenance to be truly effective, It is necessary to have

good record and report of the system.

These reports include:

(1) Type of symptoms encountered How they are detected and date.

(2) The description of replacement of parts, amount of downtime and date.

(3) Records of dates when oil was tested added or changed. Dates of filter change

should also be recorded.

There are three distinct failure rate for any component during its working life as

shown in fig.

Phase I :- Higher initial failure rate due to built in defects, installation errors etc.,

Phase II :-Lower mid life. Failure rate, when the only failure may arise from

occasional overloads.

Phase III :-Higher final failure rate due to wearing out, corrosion, fatigue etc.,

So, It is important to maintain a equipment between A & B, so as to minimize the

failure rates.

Advantage of Preventive Maintenance:

Following are some of the important advantages of efficiently planned and well

accounted preventive maintenance program.

(1) Reduction in Production downtime.

(2) Lesser over Time pay, for maintenance personal.

(3) Lesser number of stand by equipments are needed.

(4) Less expenditure on repairs.

(5) Due to planned spare parts replacements lesser spare parts are needed to remain in

store at all the time.

(6) Greater safety to employees because of reduced breakdowns.

Failure Rate

Time in service

Higher Initial Failure

Lower Final Failure

Higher Final Failure

Economics Of Preventive Maintenance:

Maintenance ScheduleElements of Preventive Maintenance

(1) Inspection or check ups

(2) Lubrication

(3) Planning and Scheduling

(4) Records & analysis

(5) Training to maintenance staff.

(6) Storage of spare parts.

Implementation of Management Techniques in Practical case

The following are the various management techniques which may or surely be

advantageous unlike it is followed at our site. The various advantages and disadvantages

can be illustrated with a simple current case study.

Cost

Total Cost

Scheduled Maintenance

Break down Maintenance

Optimum Value of Scheduled Maintenance

Background of the problem:

At our existing site there was a need for alteration of the floating type twist lock

to be replaced with fixed type of twist lock.

Steps involved:

For any newly implemented ideas the analysis should be as follows:

(i) Quality is an important criteria, because quality always has its

dimensions such as safety, perfect ness, worthy…etc.,

Therefore every project should undergo a common practice for a quality

output .here we follow a technique called Deming’s wheel of quality, which is a very

simple one to be neglected for such a alteration process involving safety of the

equipment.

Deming’s wheel of Quality :

Generally before going to plan we must analyse the defect. Which may be easier for any system by using relation & affinity diagram.

Affinity Diagram :

PLAN DO

I II

III IVCHECK ACT

Planning:

To achieve the right quality these are the steps to be followed:

I st study the existing system

II nd Analyze the drawback of the existing system.

III rd Advantages of the implementing system.

IVth How much the organization suffers for implementation in various aspects

(i)economical (ii)safety (iii)operational efficiency i.e. affected by any productivity,(iv)

any new alteration in originality so that the equipment do not suffer ,(v) number of days

for implementation .

I PLAN To Alter floating type oflock to be a fixed type of lock.

Advantages Sl. No., PARAMETERS FLOATING TYPE - I FIXED TYPE - II

A II 1 Play There will be a noticeable play

Very minimized play or no play

AII 2 No. of components 23 Nos., 13 Nos.,

A II 3Maintenance

Or replacements of components Frequency is high

Frequency comparatively much lower

A II 4 Risk if unmaintained( factor influencing safety)

More due to more play existing low due to lesser play

A II 5 Failure of component or missing of components High Low

A II 6 Replacement or wear & tear

Comparatively higher due to large number of

components

Comparatively lower due to lower

A II 7 Reconditioning worksNot so simple as fixed

type because of complexity in structure

Simple when compared to that of floating type

A II 8 Economy Initial coast is higher Cheaper than the floating type

A I 9 Design advantage

It easily guide though the pocket of container so that easy locking is

possible

It also guide through pocket but there is some

difficulty only where there is a problem in guiding base or subcomponents

etc..

A II 10 Alteration, assembling time taken

It involves comparatively complex

work in inspection, assembling, servicing & time taken is higher

Comparatively lower time for assembling, inspection & the time for the process

is lower

Comparison statement:These are just 10 points since it is a simple study and more & more parameters

can be studied if required depending on the case complexity.Out of these regarding fixed type, we found something useful from point 1 to 10

except point 9. But this can also be useful on the other side because whenever there is a small problem in guiding, the spreader find difficult to seat on the container, hence it can easily be rectified rather leading to an emergency when unnoticed.

As far as our concern is considered.

The same process while analyzing for the floating lock

1) The play generally is more as it is its nature 2) Maintenance should be of periodical check up for the system so as to rectify unlike present system.3) Even though maintenance can be done, it involves some complexity & time-consuming operation 4) Since we have more ups & downs on the surface the play will erratically increase & on inspection the outlook may find satisfactory, but result will deviate. Hence risk is more.5) There should be pucka maintenance each & every time for a single component missing, without which it may lead to the emergency condition. Since there is a time factor inclusion in replacement of each component for days together. This is to be noted. There is always a chance for the III rd level problem. I-inspection, II- rectification, III-emergency.

Conclusion statement Comparing all the above statement we can prefer fixed type of lock rather floating type.

II-DO This DOING OR, Implementation of any new concept or alteration requires some technique to be followed, unlike our site. Without these techniques & analysis if any alternations done, may lead to one or more of the following a

1. Erratic, unnoticed loss2. Emergency 3. Highly enhanced downtime, 4. Workload to employees, 5. Financial deployment, 6. To the extreme A crisis management, both by maintenance as well as operations

department.

Implementation Involves concurrent checking & immediate feedback & Analysis.

(1) There should be a proper periodical record for any equipment’s parts so as to

check

and to give any feedback for analysis. In simple, data maintenance.

(2) Inventory control (As there is any shortage of testing components, it can be

immediately replaced.

Since, this assembly is a simple one we can explain an effective inventory control as

follows.

INVENTORY CONTROL

SYNOPSISThe spare inventory in maintenance falls under 2 discrete viz., Revenue

spares and the Capital spares. Revenue spares are brought by unit purchase for

requirements where as Capital spares are ordered along with the machine.

1. From the view of finance:

It involves performing ABC ANALYSIS for the given regarding

equipment.

2. From the view of maintenance:

It involves doing VED ANALYSIS for spares maintenance stores.

ABC CLASSIFICATION METHOD

The main objective of inventory control is to minimize the Inventory

Carrying Cost. A small number of important items account for the dominant part

of total inventory investment while a large number of items constitute so small a

value that they have little effects on the results. Therefore much greater control is

required on the first type of items than on the others. The stocks of items, which

are expensive, have to be kept at minimum or nearly zero. These are classified as

“A” items. Item, which are voluminous but relatively inexpensive, are to be kept

in large stocks, as frequent ordering of such items is costlier. It is classified as “C”

items. The items falling midway between these two are put into “B” category.

Maximum attention is focused on items in category A as they constitute the most

important class of inventory, items in class B receive moderate attention as they

constitute an intermediate position. Items in class C have negligible importance

and, therefore, minimum attention is paid to them. This selective inventory control

is called ABC ANALYSIS.

ABC (or) Pareto analysis is a systematic & structured approach to distinguishing

between the “Vital” few & the “Trivial” many. In our concern materials account for

some percentage (x%) of annual Turnover in terms of Cost. Hence, maintaining optimum

level of inventory & thus reducing inventory cost is become inevitable.

ABC CLASSIFICATION

Class % Of items % Of total cost

A items

B items

C items

10

20

70

70

20

10

VED ALALYSIS

This analysis pertains to the classification of items denoting the degree of

essentiality for maintaining stock. “V” stands for vital items, which if not available

in stock, will bring the production to a halt. “E” stand for essential items, which if

not available might cause temporary losses in production. “D” denotes desirable

items which are necessary but do not cause any immediate effect on production in

case of stock out.

ANALYSIS OF CONSUMPTIONThe quantity consumed of different items is analyzed to identify non-

moving and slow moving items. Usually, slow moving items are those where stock

held is more than one year’s requirement. Non-moving items are those, which

have not moved for more than I year from the date of receipt. Statements of such

slow moving and non-moving items should be prepared and compiled in

descending order of value so that proper attention is focused on large value items

and decision taken to utilize such items or to declare them as surplus for initiating

disposal action.

CLASSIFICATION IN TERMS OF VALUE OF ITEMThe classification is done by or ABC analysis or Pareto

Analysis.

Total cost of an item depends upon the cost of the item and the number of that item. But

the cost of an item and the quantity of the item, both have great significance.

1. When the cost of the item is large & quantity used is less

i.e. Rs. 2,500 * 10

2. When the cost of the item is small & quantity used is more

i.e. Rs. 25 * 1000

Hence consideration must be taken when the total cost is determined using both by the

cost and the quantity issued. The term may be coined as usage value for the total cost.

CONCLUSION1. Materials are to be ordered only when the re-order level is reached and only ROQ

must be ordered.

2. Safety stock should be optimum for “A” and “B” value items.

3. Non-moving items should be modified and used for other purposes.

4. Identify the frequency of breakdown for “A” value spares.

5. TPM activities should be implemented.

Lead time should be reduced through proper communication

SUBTUITING THISCASE FOR INVENTORY CONTROL

Here, the following falls under the given classification

Class % of items % of Total

Base & pin

Bushes & spacers

twist lock Turning pin

keyways ,pins etc.,

A

B

C

10

20

70%

70%

20%

10%

Usage Value:

(1) When cost of item is large & quantity used is less.

(i.e.) Rs. 7,500 * 10 (for entire assembly)

(2) When the cost of items is small & quantity used in more.

(i.e.) Rs. 75 * 1000 (for smaller components)

This is a briefly classified usage value.

Checking & Acting:

(1) This process of checking always needs to be done to a satisfactory extent &

analyzing should be to an fully satisfactory level so that the end result must

always be nearly 100% correct.

This analysis should be done is such way that our alteration never fails easily &

this failure analysis may be done for any equipment as follows

Consider the following fig for

Failure Rate Analysis

Failure Rate Analysis

There are three distinct failure rate for any component during its work life as shown in figure.

Phase I : Higher initial failure rate, due to built in defects, installation errors etc.

Phase II : Lower mid life failure rate, where any failures may arise from occasional

overloads.

Phase III : Higher final failure rate due to wearing out, corrosion fatigue, etc.

So, it is always important for economical, safe & Highly work reducing efficient

operation to maintain the equipment between A & B. So as to minimize the failure rates.

We can always substitute the case of lock assembly of Indital for the above graph

& a brief view may be as follows.

Failure Rate

Time in service

Higher Initial Failure

Lower Final Failure

Higher Final Failure

Lock assembly Indital (or) Any equipment

From 0 To A

A to B

B – C

Small, pin, twist lock pins,

guides (or) any loose

packing assembly which

may be reduced by

inspection by appropriate

means.

Bushes which are the main

items preventing direct

damage to base & assembly

& pin so that increasing life

time of the assembly apart

from other smaller

components

Naturally when IInd point

is overlooked the victim is

the base assembly failure

which involve final failure

& ends up in full life ending

(or) maximum initial cost

settings

Small repairs such as newly

assembled inadequate

torque for any fasteners etc.

(setting of newly assembled

gears – correlation of

cylinder hoses etc.

Main pins holding

frames & booms,

chasses etc. & main

items like nylon pads,

bushes, oil seals, and

bearings etc which are

provided for protection

of metals from direct

contact so as to increase

the life time.

Simply replacing these items

the cost & the service Time

may be kept in A-B position.

Here initial cost when

failure rate is more is very

High that whatever the

concern may be (small or

cottage industry) the

investment cost is high that

even gives way for

comparing with new

equipment replacement.

Thus, after a satisfactory Analyzed result we may finally give a decision for the lock to

be altered may be fix type. Even a management or an Ordinary person with small IQ may

be possible to select after the analysis. However the obtained result also is a highly

précised, economic, safe & Tangible to our concern’s requirement nearly to 90%.

Implementing Cost-Benefit Analysis for practical cases:-

In practical, as far as this concern is considered there are certain principles &

practices followed in a view of value engineering (or) any of such practices which has

been totally practiced in a wrong way, which when even at least practiced in a logical

convention method would have been a better way in all aspects. (1) Safer, (2) Economic,

(3) Time management. Etc.

In the past record of 1 month ranging 30.10.2004 to 21.12.2004. There are certain

Typical cases, which when viewed closer will reveal this clearly.

Need for Implementation of Planned Maintenance

In a cycle of (i)Planning, Scheduling, Executing, recording, analysis and control or decision making. We may find on detailed analysis what may be the drawback we are undergoing etc. So that any changes can be done as required.

Here, on an overview, there are some new policies to be incultivated within the maintenance procedures, so as to follow a planned maintanance.

Though, all the steps are precently being followed, a truly planned maintanance can be over viewed only by analysing the data.For Example : Interpretation of data

Considering all the above cases :(i) In all the above cases, the continuation or frequency of

problem occuring often is obvious.(ii) For cost benefit, consider, the cost involved as

(1) Actual repair cost(2) Time consumed for every Breakdown (Productivity Lost)(3) Effective Time of Maintanence Personal

(3) Later when the same problem is continuing, the cost of repairing should be added to the Initial repair cost

Total Repair Cost – (Case I + IInd + IIIrd)

(4) When compared with the final & permanent repair, the total repair cost will be comparitively more, that even preventive maintenance would be suitable which will enchance

(a) Effective productivity Time (uninterrupted operation Time)(b) Effective service period of the Equipment(c) Effective usage of Maintanence staff(d) Higher reliability of Equipment(e) Safety(f) Usage of the maintenance team effectively(g) Worthfulness of repair(h) Controlled maintenance procedure etc.

INTRODUCTION PLANNING & CONTROL

1. Introduction - a. Brief b. Production

2. Basic objective - c. Planning d. Control

3. Need for PPC4. Effects of PPC5. Advantages of PPC6. Functions of PPC7. Computer Assisted PPC

INTRODUCTION : Industrial Giant Franklin G.Moore compares production planning & cobol

with “Brain in Human body” implying that PPC co-ordinates all activities of a firm.

In recent years, however, it has become more & more apparent that PPC systems are one of basic activities that determine the effective here of a production enterprise.

“The highest effeciency in production is obtained by manufacturing the required quantity of product, of required quality, at the required time, by best & cheapest method”. To attain this target, management employs PPC, the tool that co-ordinates all manufacturing activities.

The factors quantity, quality, time, space & price encompass the production system of which PPC is “Brain”.

Then in this Prod plan & control the word production is defined as

PRODUCTION :Production is any process or procedure to transform inputs into derived products.

INPUT PROCESS OUTPUT

Production System

PLANNING MEANS :Analysis of given data, on the basis of which a scheme for utilization of the firm’s

resources can be outlined. So as the desirable target may be most efficiently attained.

Example : Maruthi

The production plan sets sub-targets for the various departments in terms of predetermined time periods, and these sub-targets are so defined that in achieving then the over-all aim is realized.

This planning is based on scaler reports, market research & development, equipments, policy, new process & materials layout & workflow.

Finally simplification of products, materials & methods controll iritiates and supervises operations with the aid of a control mechanism that feed back information about the progress of work. This is also responsible for subsequently adjusting, modifying & redefining plans & targets, in order to ensure the attainment of goal.

1. Control Means1. Control of Inventories2. Control of Scraps3. Control of Transportation4. Analysis of work-in-program.

2. Basic Objective :1. PPC system should satisfy customer demand2. Economic one

3. Need for PPCIndia’s developing economy needs PPC :

The main intension behind industrial planning is to accelerate productivity so that our service may find suitable market with in the nation & also abroad.2. PPC is factory’s nervous system. It co-ordinates the activities of a plant.Meaning isIf suppose customer demands differ in quantities and delivery schedules, it will lead to large fluctuations in production level.Example : a. Procurement of Manufacturing Inputs

b. Skilled man power c. Over time requirement d. Building up inventories

4. Effects of PPC :

It is grouped under 2 main Factors2. Material Factor3. Human Factor

a) Material Factor :2. Quality of output3. Plant utilisation4. Use of Services – m/c5. Process Efficiency6. Standard of Safety7. Work Cleanliness

b)Human Factors : 1. Effectiveness of work2. Interest in work3. Waiting Time4. Need for supervision5. Ideas for new methods6. Team Spirit

5. Advantages of PPC :In terms of

1. Company’s point of view2. Share Holders point of view3. Employee’s point of view4. society point of view

From Company’s point of View :a. Cost per product reducesb. Company need more profitc. Administration & Management task

should go ahead smoothly & efficiently

This is acheived by :1. Production Control2. Quality Control & Waste Reduction3. Decreased Maintenance cost4. Decreased Replacement5. Having good marketing Management

From worker’s point of view :a. Reduced efforts of worker

b. Reduced number of handlingc. Reduced Fatiqued. Job Satisfactione. Reduced no of accidentsf. High earnings to raise standard of living

From Share Holder’s Point of View a. High Dividendsb. Reduced Speculation in Shares

From consumer’s point of Viewa. Reduced cost per pieceb. Excellent Quality

From society point of Viewa. Higher national income – Hyundai, Honda, Fordb. Unemployment problem – Youthc. National progress towards prospectus programmed. Stability & Security of Nation

Function of PPC :Main Functions of PPC are

1. Materials2. Methods3. Machines & Equipment4. Routing5. Estimating6. Loading & Scheduling7. Despatching8. Expediting9. Inspection10. Evaluating

Conclusion :

Crisis maintenance is important

Productivity based maintanence is more important.

Productivity and equipment life based maintanence is most important

This is a triangle showing the relationship between Productivity, Equipment life

and Maintanence.

If any one of the triangle side is found defective, the entire cycle will be affected.

Therefore from the management and maintenance point of view, maintenance is one,

which should be forming the bridge between the productivity and equipment / plant life.

And to maintain the consistency of the cycle, there should be some control over the cycle.

This theseis is an effort taken to create the awareness for a quality maintenance of the

concern and its necessity for the enhanced productivity through maintenance.

In simple words AWARENESS TOWARDS OPTIMIZATION OF

MAINTENANCE PROCEDURE AND HENCE THE PRODUCTIVITY.

“IF WE ARE FAILING TO PLAN

WE ARE PLANNING TO FAIL” is a famous saying

And this thesis by creating awareness, will surely intiate the planning attitude of the

Terminal activities.

PROJECT REPORT

ON

PLANNING AWARENESS TOWARDS OPTIMIZATION OF MAINTENANCE OF REACH STACKERS IN CONTAINER

TERMINAL OPERATIONS

SUBMITTEDTO THE BOARD OF DIRECTORS

SATTVA / BALAJI CONTAINER TERMINAL

Manali-Chennai

SUBMITTED By

Titopuvingadame Vijaikaladar.K