Establishment of autonomous maintenance programme to enhance efficiency of EDM machines

Tang, Lai Ee (2022) Establishment of autonomous maintenance programme to enhance efficiency of EDM machines. Project Report. Universiti Teknikal Malaysia Melaka, Melaka, Malaysia. (Submitted)

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Abstract

Electric Discharge Machining (EDM) is a broadly utilized machining method in the industry as it can cut complicated pieces and hard materials. It is a method of controlled material removal in which a high frequency electric spark is utilized to erode the work piece. Repetitive routines are often carried out on the EDM machines in the industry, but this project focuses on the EDM machines employed in the FTKMP laboratory where the machines are often use for different processes with different parameters and materials. This project studies and investigates the Fuguai or abnormalities found on the EDM machines and develop an ideal AM programme to enhance the functionality and safety of EDM machines. The implementation of AM is to eliminate fuguai on the machine by involving both operators and maintenance activities. AM improves overall machine efficiency and simulates higher consciousness on machine maintenance among machine operators. The process of identification of fuguai is applied by fuguai tagging using f-tags. The fuguai are divided into three categories which are physical, safety and function. 8 types of fuguai are identified in this project which are dust, dirt, leftover items, disorganized items, rusty parts, broken parts, missing components and loosen components. The results show the most critical machine area is the machine bed and the highest occurrence fuguai is rusty parts. 34 out of 42 identified fuguai are tagged in blue f-tags which indicates most of the fuguai can be resolve by operators. Almost all fuguai are eliminated, however, there are a few fuguai which are not eliminated as they require higher technical knowledge to resolve. Elimination of fuguai are presented through One Point Lesson (OPL) and the steps are layout in detail.

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