Gear Hobbing Machine Lab Report
3.2.5 Mechanical System of Gear Hobbing machine:
3.2.5.1 Schematic of mechanical system:
Front view of machine
Figure 20a: Front View
Back View of machine
Figure: 20b Back View
Description of Figures
Components of Mechanical System:
1. Gear train
2. Electric panel
3. Slides
4. Hob head
5. Cutter
6. Work piece holder
7. Column
8. Bed
9. Oil tank
10. Fluent tank
11. Motor (M1,M2,M3)
Sub- components of Mechanical System:
1. Gears
2. Pulley wheel
3. V-belt
4. Ball bearing
5. Lead screw
6. Sleeves
7. Worm wheel
8. Clutch
9. Shaft
10. Seal ring
Figure 20c Left Side View of Gear hobbing machine
3.2.5.2 Cause and effect diagrams of mechanical system
3.2.5.3 Cause and Effect Diagram of Induction Motor:
Figure 21: Cause and Effect …show more content…
This is done by analyzing how and why the causal factors occurred.
Tools which are used to map the failures and their root causes:
3.2.5 Recommendation generation and implementation
In the last step of the RCA recommendations on how to fix the identified root causes are made. It is also possible to already implement the recommendations and fix the root causes right away.
3.3 Approach:
After the basics of RCA have been described in the previous section the focus of this section is why and how RCA will be used to fix the failures and the most importantly the defects that causing the failures.
When we started working on the project there were numerous causes and failures identified through visual inspection and gap analysis. Instead of just dealing with the symptoms of the failures described in chapter 4, it would be better to fix the defects that caused them.
An even better approach would be to identify the root causes which led to the defects, because this could prevent similar defects in the future and would therefor increase the availability and stability of gear hobbing …show more content…
of Cases 1 cases in total
Net / Gross weight Kgs 3500-4200
Table 1 specifications of Gear Hobbing machine
3.5 Invitation Process/ Problems and Failures and Remedy Action
3.5.1 Visual Inspection & Gap analysis: During the session of visual inspection gap analysis on gear hobbing machine many details come on the stage like missing entities of machine and poor maintenance factors were common among them
• Machine was not working
• Mechanical jamming of machine components
• Clutch Lever is missing
• Hydraulic pump oil is not up to the level
• Poor lubricating oil properties
• Coolant oil is absent
• Lubricating oil leakages present
• Coolant oil filter is missing
• Filter oil’s tank is contaminated and out dated
• Standard operating procedure sheet is missing
• Improper maintenance or no maintenance
• Environmental factors like humidity, temperature, no cleanliness etc.
• 4Ms
Man Machine Method Material
Untrained workers Poor installation Standard operating procedure missing
Ethical behavior Power problems Equipment operational log file missing
No training session Machine manual is in Chinese language
Table 2:
3.2.5.1 Schematic of mechanical system:
Front view of machine
Figure 20a: Front View
Back View of machine
Figure: 20b Back View
Description of Figures
Components of Mechanical System:
1. Gear train
2. Electric panel
3. Slides
4. Hob head
5. Cutter
6. Work piece holder
7. Column
8. Bed
9. Oil tank
10. Fluent tank
11. Motor (M1,M2,M3)
Sub- components of Mechanical System:
1. Gears
2. Pulley wheel
3. V-belt
4. Ball bearing
5. Lead screw
6. Sleeves
7. Worm wheel
8. Clutch
9. Shaft
10. Seal ring
Figure 20c Left Side View of Gear hobbing machine
3.2.5.2 Cause and effect diagrams of mechanical system
3.2.5.3 Cause and Effect Diagram of Induction Motor:
Figure 21: Cause and Effect …show more content…
This is done by analyzing how and why the causal factors occurred.
Tools which are used to map the failures and their root causes:
3.2.5 Recommendation generation and implementation
In the last step of the RCA recommendations on how to fix the identified root causes are made. It is also possible to already implement the recommendations and fix the root causes right away.
3.3 Approach:
After the basics of RCA have been described in the previous section the focus of this section is why and how RCA will be used to fix the failures and the most importantly the defects that causing the failures.
When we started working on the project there were numerous causes and failures identified through visual inspection and gap analysis. Instead of just dealing with the symptoms of the failures described in chapter 4, it would be better to fix the defects that caused them.
An even better approach would be to identify the root causes which led to the defects, because this could prevent similar defects in the future and would therefor increase the availability and stability of gear hobbing …show more content…
of Cases 1 cases in total
Net / Gross weight Kgs 3500-4200
Table 1 specifications of Gear Hobbing machine
3.5 Invitation Process/ Problems and Failures and Remedy Action
3.5.1 Visual Inspection & Gap analysis: During the session of visual inspection gap analysis on gear hobbing machine many details come on the stage like missing entities of machine and poor maintenance factors were common among them
• Machine was not working
• Mechanical jamming of machine components
• Clutch Lever is missing
• Hydraulic pump oil is not up to the level
• Poor lubricating oil properties
• Coolant oil is absent
• Lubricating oil leakages present
• Coolant oil filter is missing
• Filter oil’s tank is contaminated and out dated
• Standard operating procedure sheet is missing
• Improper maintenance or no maintenance
• Environmental factors like humidity, temperature, no cleanliness etc.
• 4Ms
Man Machine Method Material
Untrained workers Poor installation Standard operating procedure missing
Ethical behavior Power problems Equipment operational log file missing
No training session Machine manual is in Chinese language
Table 2: