Maintenance Business Review
Monthly delay analysis and corrective action plan for the tyre building maintenance line.
Actual delay (358.5 min) came in just under target (360 min) — overall control is close to plan, but concentrated in a few machines. RB3-09 TBM is the single largest contributor at 1,197 min (15% of total), driven mainly by drum defective issues (861 min). Drum Defective is the top failure mode across all machines: 2,597 min (31% of total delay), spread across RB3-09, 265ASM-4, RB5-04 and RB3-11. 59J-04 and RB3 show the sharpest rise in the daily delay trend, climbing to 2,241 and 2,231 minutes respectively — both flagged for major overhauling. MTTR is highest on RB3 (135.4 min), nearly 2.3x that of HTBC (60.0 min) — a key repair-time improvement target.
Delay stays low and flat, then rises steeply from 265ASM onward
Shift-day delay minutes
59J-04 and RB3 alone account for over half the total delay minutes recorded across all ten machines — the clear priority for the action plan below.
Top 6 named machines vs the rest of the line
Minutes and share by machine, ranked
| Machine | Min | % |
|---|---|---|
| RB3-09 TBM | 1,197 | 15% |
| 59J-04 TBM | 513 | 6% |
| 265ASM-4 TBM | 398 | 5% |
| RB5-04 (Plant-1) | 385 | 5% |
| RB3-11 TBM | 372 | 4% |
| RB5-08 (Extn) | 300 | 4% |
| Other Machines | 4,400 | 53% |
Top 6 named machines = 47% of delay; the remaining 53% is spread across the rest of the line.
Minutes lost, all machines combined
31% of all delay minutes in June — more than 3x the next-largest failure mode.
Affected machines
RB3-09, 265ASM-4, RB5-04 (Plant-1), RB3-11
Action already in motion
16" and 28" drums repaired/replaced across four machines this month.
| Machine | Issue | Min | Action Plan |
|---|---|---|---|
| RB3-09 TBM | BPR Problem | 150 | To be planned |
| Drum Defective | 861 | 16" drum repaired | |
| 265ASM-4 TBM | Drum Defective | 278 | 28" drum replaced |
| 59J-04 Tyre Building M/C | T/Up & T/Down Problem | 160 | Major overhauling under progress |
| Wrinkle Problem | 220 | Major overhauling under progress | |
| RB5-04 (Plant-1) (BTP) | Bead Offset Problem | 152 | Drum repaired |
| Drum Defective | 150 | Drum repaired | |
| RB3-11 TBM | Drum Defective | 282 | 16" drum repaired |
RB3 stands out as the clear outlier
Highest MTTR on the line — 2.3x HTBC and 1.4x RB5(EXT).
Second-highest; watch alongside RB3 for spares availability and crew response time.
Currently unplanned — schedule root-cause review this week.
Address T/Up-T/Down and Wrinkle issues driving the steepest trend rise.
Monitor RB3-09, 265ASM-4, RB5-04 and RB3-11 for repeat drum defects post-repair.
Review spares stocking and repair crew allocation to bring MTTR toward the 60-90 min band.