Assignment - 1

Maintenance Management
Maintenance Schedule of Kansai Special Sewing Machine
Life Cycle Cost Of Kansai Special Sewing Machine

Chahak Nagpal | Deepali Pandit | Lovely Gupta | Rashmi Dhara | Shikhar Maurya
| BFT 6 |

ABSTRACT

In this document, we present a theoretical model, which grows together the elements of
Maintenance of machines in Apparel Industry. The data have been gathered from various
sources mainly from academic literature, and a qualitative analysis has been carried out.
The core category of the model is Maintaining the assets. The analysis and the model
answer the question of principles and practices should be considered in maintaining multi
needle kansai machine.
It is based on the philosophies that are linked to the categories: Life cycle of a machine,
types of maintenance used, timely treatments, production methods, saving resources and
etc.

LIST OF CONTENTS

Abstract
1. Working Methodology
2. Introduction to Multi needle Kansai
machine
3. Prepare an assets inventory record
4. Identify maintenance activity and tasks
5. Identify the frequency of the task
6. Estimate the time required to complete the
task
7. Develop an annual work Schedule
8. Prepare and issue a work order
9. Determine a Budget
10.Machine Lifecycle Cost
11.Conclusion

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WORKING METHODOLOGY

Maintenance Planning and Scheduling are key elements that influence the true success of
any organization.
In this Assignment, we act as a planner who is supposed to make maintenance for a multi
needle kansai machine for a year.
Preparing a maintenance plan and estimating the life cycle cost of a machine is quite a
complex process. So, we have break down the entire process in parts.
During the course of this assignment we will be analysing the types of maintenance required
and the suitable plan will be made. Also we will have to estimate the cost. For doing so we
will follow the following steps:
-

Prepare an assets inventory record.

Identify maintenance activity and tasks.
Identify the frequency of the task.
Estimate the time required to complete the task.
Develop an annual work Schedule.
Prepare and issue a work order.
Determine a Budget.

To make a plan it is important to understand the feature of machine

Prepare an assets
inventory record.

Identify
maintenance
activity and tasks.

Identify the
frequency of the
task.

Estimate the time

required to
complete the task.

Develop an annual
work schedule.

Prepare and issue a

work order.

Determine a
budget

INTRODUCTION TO MULTINEEDLE KANSAI MACHINE

DFB SERIES MULTI NEEDLES DOUBLE CHAIN STITCH

-

DFB series are flatbed, multi-needle double chain stitch machines.

This series is multi-purpose such as attaching elastic, attaching waistband, sewing the
front of shirts, attaching line tapes, smocking and shirring, etc., which are ideal for under
wear, sportswear, lady's wear, interior decorated goods (curtains, table cloths, etc.).
There are 2 up to 21 needles available due to vertical movement of the looper and also
many kinds of gauges which are selectable according to your needs.

DFB1404P

NB, BX SERIES - MULTI NEEDLES DOUBLE CHAIN STITCH

-

NBBX series are flatbed, multi-needle double chain stitch machines.

This series is multi-purpose such as attaching elastic, attaching waistband, sewing the
front of shirts, attaching line tapes, smocking and shirring, etc., which are ideal for under
wear, sportswear, lady's wear, interior decorated goods (curtains, table cloths, etc.).
There are 25, 33 needle available due to vertical movement of the looper and also many
kinds of gauges which are selectable according to your needs.
Just recently, KANSAI SPECIAL launched the "NB Series", the new model of BX Series.
This NB Series has a newly shaped, modern casting. The smocking models PSM & PSSM
are now equipped with 4 spreaders for the decorative threads. This innovation enables a
greater variety of different designs.

FX SERIES MULTI NEEDLE DOUBLE CHAIN STITCH

-

FX series is a versatile multi-needle, cylinder bed, double chain stitch machine with
vertical looper movement mechanism.
It can be used for attaching elastic and line tape to sweat pants, pajamas, trunks and
similar garments. Major features of this series are the wide range of available gauge size
(421 needle), cylinder bed (420mm in circumference), elastic guide rollers and KANSAI
SPECIAL's original rear puller mechanism. These features make this series popular for
attaching pre-closed elastic. KANSAI SPECIAL's unique automatic thread cutter (UTC)
increases productivity by trimming threads accurately and leaving less thread, which
curtail the production cost.

FX4404P

DX SERIES MULTI NEEDLES DOUBLE CHAIN STITCH MACHINE

-

DX series is cylinder bed (circumference 340mm), from 2 to 5 needle double chain stitch
machine with horizontal looper movement mechanism.
It can be used for attaching endless or pre-closed elastic. Major feature of this series is
the cylinder bed. This feature gives you benefits when you work with exercise wear,
pajamas, trunks, boxers and similar garments.

DX9900-4U
5

FBX SERIES - MULTI NEEDLES DOUBLE CHAIN STITCH MACHINE

-

FBX series is a cylinder bed, 2-6 needle double chain stitch machine with needle feed. It
is designed for sewing waistbands of medium heavy to heavy material such as jeans and
working pants.
As needle feed and lower feed are linked, both feeding amounts can be adjusted at the
same time by push button operation. An additional rear puller is available as option.
The needle feed solves any problems, such as twisting, puckering and slipping of the
material. FBX series has a wide range of applications as it can sew material up to a width
of 70mm, especially tubular goods such as waistbands, elastic attaching, sewing shirts
fronts and more.

FBX SERIES MACHINE

PREPARE AN ASSETS INVENTORY RECORD

Asset registers are typically used to help business owners keep track of all their fixed assets
and the details surrounding them. It assists in tracking the correct value of the assets, which
can be useful for tax purposes, as well as for managing and controlling the assets. A fixed
asset register provides a single location to quickly learn about any asset owned by the
business.

For example, assume a business owns a small fleet of trucks. The fixed asset register would
describe the trucks (indicate color, make, model), indicate their purchase date and price,
their amount of depreciation accumulated, and their estimated salvage value.

The asset register is important for keeping track of whether or not assets are still in
possession or are working, and is an important way of keeping track of the value of your
assets. It can be helpful not only for business management purposes, but should also be
provided to your accountant as it is an easy way for him or her to find information regarding
the assets and their values.

Following pattern is to be used to keep record of kansai machine

End of year

Depreciation

Average first cost if replaced at the

given year end

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2
3
4
5
6
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IDENTIFY MAINTENANCE ACTIVITY AND TASKS

Different components and materials respond to environment and use in different ways. A
planned maintenance approach should recognise and respond to anticipated failure
patterns and failure modes. Other factors include design, installation, quality of materials
and finishes. Planned maintenance activities are commonly a response to the external
environment.
The following maintenance schedule of Kansai Special machines is being developed
keeping in mind all the factors.

Scheduled
Preventive
Corrective
Breakdown maintenance.

SCHEDULED MAINTENANCE
In this type of maintenance work, the actual maintenance program is scheduled in
consultation with the production department, so that the relevant equipment is made for
maintenance work. The frequency of such maintenance work is pre-determined from
experience so as to utilize the idle time of the equipment effectively. In this way where and
when of the maintenance work can be approximated and most efficient use of the idle time
can be made.
This also helps the maintenance department to use their manpower effectively. If the
schedule of maintenance is known in advance, the specialist for the same can also be made
available during the maintenance period.
PREVENTIVE MAINTENANCE
Preventive maintenance is the utilization of planned and coordinated inspections,
adjustments, repairs and replacements in maintaining an equipment or plant. One of the
main objectives of preventive maintenance is to detect any condition that may cause
machine failure before such breakdown occurs. This makes it possible to plan and schedule
the maintenance work without interruption in production schedule and thus improves the
availability of equipment.
Under this type of maintenance, a systematic and extensive inspection of each item of
equipment is made at pre-determined intervals. The preventive maintenance is further
divided into the following main activities.
Routine attention: These activities are designed to preserve the assets of the organisation
at a given standard of maintenance which conforms to its financial an operating policies. It

carried out to identify dormant faults or items prone to failure. This helps to identify faults
well before they occur.
Preventive replacement: It involves preventive replacement of parts and components that
have a definite life. Such type of maintenance helps to avoid emergency situations and
measurements: It aims at identifying the degradation rate and such items are at
unacceptable service conditions. This type of testing atmosphere requires costly
equipments and laboratory testing facilities.
CORRECTIVE MAINTENANCE
The use of preventive maintenance brings out the nature of repetitive failures of a certain
part of the equipment. When such repetitive types of failures are observed, corrective
maintenance can be applied so that re-occurrence of such failures can be avoided. These
types of failures can be reported to the manufacturer to suggest modifications of the
equipment.
Corrective maintenance can be defined as the maintenance carried out to restore
equipment that has stopped working to acceptable standards. For example, an engine can
be in working condition, but does not take its full load because of worn out piston rings.
Thus if the piston rings are replaced, it will bring back the performance of the engine to the
specified level. The corrective maintenance, if properly carried out, will eventually bring
down the maintenance costs and there will also be a reduction in downtime of the
equipment.
BREAK-DOWN MAINTENANCE
The basic concept of this type of maintenance is not to do anything as long as everything is
going on well. Hence, no work is done until the component or the equipment fails or
becomes inoperable. In other words the work is called upon to be done in the case of an
emergency failure, when necessary repairs are carried out to bring back the equipment to
original working condition.
From the time machines came into existence, this type of maintenance is still in practice and
being followed in many organizations. The equipment is allowed to run till it stops working
and no efforts are being made in advance to prevent the failure of parts. Therefore,
breakdown maintenance occurs suddenly and all the repair and maintenance work
pertaining to it is only done when the equipment stops working. If this system is alone
followed, it will lead to poor operational availability of the equipment as spare [arts may not
be readily available. Even though it may appear to be an economical proposition, work
would greatly suffer if the machine is not restored to operational condition immediately. In
this type of maintenance during the repair time, no proper care is taken to know the real
cause of the breakdown, which in turn may lead to frequent failures of same kind.

IDENTIFY THE FREQUENCY OF THE TASK

It refers to determining how often the activities should be performed (frequency of service);
this is important particularly in preventive type of maintenance. Emergency or reactive
types of repairs are unpredictable, but with good preventive maintenance, the frequency of
emergency situations occurring may be reduced.
A task statement is a detailed list of the generic maintenance tasks to be performed for a
particular type of asset in conducting preventive or routine maintenance. Frequency refers
to how often the maintenance tasks are performed, for example, daily, weekly or every five
years. Task times indicate how long it will take to do such an amount of work.
Frequency of the maintenance depends on the type of maintenance.
Multi needle kansai machine works for 8hr a day
According to a research, a sophisticated machine like kansai machine is to be checked for
maintenance purpose fortnightly.
Predictive maintenance depends upon the feedback given by the operator and the
supervisor.
Breakdown maintenance is a kind of maintenance for which we need not to make schedule.
But it should be avoided as it results in greater loss of time and money.

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ESTIMATE THE TIME REQUIRED COMPLETING THE TASK

It indicates how long each task should take to complete.

Each task statement relates to a specific type of maintenance activity appropriate for an
asset. A component of an asset, such as a boiler in a building, may require maintenance
checks weekly, monthly, quarterly, and/or annually. Similarly, a road may have a single task
statement, such as grading, to be repeated a number of times during the year.
To prepare a set of tasks applicable to a particular asset, one should review the physical
features of an asset and/or the manufacturers operation and maintenance manual to
determine the maintenance tasks, task times and frequencies required. For emergency or
reactive type work orders, the maintenance tasks and estimated task times will have to be
assessed based upon the problem occurring.

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Develop an annual work schedule

The Checklist shown below must be filled daily by the operator whenever a particular
style on particular operation has been assigned to him.

These slip then must be collected by the supervisor to keep a track of which operator is
doing which job and on which machine.
PREVENTIVE/SCHEDULED MAINTENANCE:
Schedule maintenance (or Preventive Maintenance) is maintenance that is regularly
performed on a piece of equipment to lessen the likelihood of it failing. Preventative
maintenance is performed while the equipment is still working, so that it does not break
down unexpectedly. The machine should be checked on a regular basis and comprises of
most common checking and cleaning procedures.

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The preventive maintenance should be exercised on a weekly basis and should be done
under the supervision of the of the floor in-charge after the working hours. Daily when
operators are leaving, they must keep small piece of fabric under the needle, wipe and
put cover on machine.
PREDICTIVE MAINTENANCE SCHEDULE:
Predictive maintenance (PdM) techniques are designed to help determine the condition
of in-service equipment in order to predict when maintenance should be performed.
This approach promises cost savings over routine or time-based preventive
maintenance, because tasks are performed only when warranted.

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PREPARE AND ISSUE A WORK ORDER

Work orders provide information on what, where, when, how long and by whom
maintenance is to be carried out. Two sample work orders are shown in Figures 2 and 3.
Work orders are prepared from inventory data (physical features) and task statements. Each
work order lists tasks for the same frequency of work and for the same asset. For example,
one work order could contain tasks for weekly boiler maintenance for a school. Another
work order could contain different tasks for monthly maintenance of the same asset.
The general guidelines for preparing a work order are as follows:
- Starting with any asset on reserve, examine the inventory data and typical task
statements to determine the tasks appropriate for that specific asset.
- List the asset name, maintenance activity number and work order number, etc. on a
blank work order. Using the task statement or manufacturers operation and
maintenance manual as a reference (modify, if necessary, to suit specific situations), fill
in the appropriate tasks (i.e., Work to Be Performed) on the work order.
- Calculate or estimate the time needed to complete the individual tasks and enter the
total time for all tasks in the planned time block. The sum of work order planned times
for all assets in a reserve will determine the workforce requirement for planning and
scheduling personnel resources.

WORK ORDER SAMPLE

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DETERMINE A BUDGET
A maintenance budget is a cost projection based on the costs of labour, equipment,
material and other items (such as contracts) required to do all work identified in the Work
Schedule. A sample of an Annual Maintenance Budget - Worksheet is shown in Figure.
After the costs are calculated for one work order, the process is repeated for the remaining
work orders to get the total cost required to maintain the asset. The maintenance
supervisor is responsible for monitoring the actual expenditures against the budget for the
year. He or she is also responsible for its yearly update using forecast labour rates, and
material and service contract costs. The updated budget would be used for determining the
operation and maintenance costs of the First Nations physical assets. The Annual
Maintenance Budget - Summary, Figure 5, recaps total labour hours, labour cost, equipment
cost and material cost for the asset. At this point, all overhead costs, utility costs, and
maintenance management supervision costs are also entered. To determine the total
maintenance budget for a First Nation, simply prepare a similar summary for each asset in
the community and add up the totals of each asset in the community.

ANNUAL MAINTENANCE BUDGET WORKSHEET

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ANNUAL MAINTENANCE BUDGET SUMMARY

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MACHINE LIFECYCLE COST

The product life cycle can be divided into several stages characterized by the revenue
generated by the product or range of products, such as a brand. The life cycle can be very
short, as pertains to a product that is for an event, such as a Christmas toy, or very long such
as a watch or a car. For most products the beginning of the life cycle is the product
development stage. Companies develop new products all the time and a small percentage of
those reach the market.
INTRODUCTION STAGE
The introduction of a product into the market will not generate sales until the public is
aware of the product. The consumer is introduced to the product by the advertising that a
company uses to publicize the product. There are thousands of ways a company can
advertise their product and advertising costs usually are high during this stage in order to
quickly make consumers aware of the product. There may be additional costs associated
with product introduction such as packaging and distribution. The introduction stage of a
product generates few sales and the costs of introduction far outweigh the profits from the
small sales volume. During this introduction stage, a company is focused on making the
consumer aware of the product in the market and seeding a demand for future demand for
the product.
GROWTH STAGE
The growth stage in the product life cycle is a period of rapid revenue growth. As the
product awareness increases, customers are more likely to purchase the item and sales
increase. The success of a product in one area can lead to the product being introduced into
other market segments. Continuing increase in sales can lead to additional demand and
further sales. During the growth stage, competing products may be introduced by other
companies. This can lead to price competition and additional costs in advertising to maintain
the demand for the product at the expense of the competition.
MATURITY STAGE
A product becomes most profitable during the maturity stage. The sales for the product are
slower than in the growth stage but continues as the product becomes a market leader.
Continued advertising reinforces the product with the consumer, but generally advertising
costs are lower than for a new product. For example, companies such as Coca Cola and
Clorox advertise their mature products to reinforce the brand with the public. However,
competition from other companies or store brands may result in a decreased market share
and lower profits. A company may spend more with retailers to obtain more shelf space for
their products over competing products, which may differ only very slightly. During the
maturity stage, a companys focus is to maintain market share and extend the product life
cycle as much as possible. Many companies have been very successful in extending the life
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cycle of their product when new cheaper alternatives are introduced into the market such
as Clorox, Coca Cola, General Mills, Kraft and Pepsi.
THE DECLINE STAGE
In the decline stage the sales of a product declines, either due to a product becoming
obsolete, for example, a slide rule, or where the market becomes saturated. A company
does have a number of options when a product has reached the end of its life cycle. It can
remove the product from the market completely; reduce advertising and marketing to
maximize profits from the small
Sales volume or reduce costs in manufacturing the product allowing the product more time
for competing products to be withdrawn from the market.
ASSUMPTIONS
Costs Involved: Initial Cost (Cic) Delivery and Installation Costs (Cinst), Energy Cost (Ce),
Operational cost (Co), Maintenance Cost (Cm), Downtime Costs (Cs,
Decommissioning/disposal costs (Cd).
Lifecycle Costs: By Summation of all the above costs we get to know the whole lifecycle cost
of equipment.

Maintenance Cost Per year: Based on experience, it has been found that the
maintenance cost is zero during the first year is Zero and it is Rs. 10000 for the second
year. It increases by Rs. 3000 every year thereafter.
The maintenance cost will be including all the costs involved like equipments, spairs,
labor charges, delivery charges and miscellaneous costs excluding the initial price.
Machine Cost INR 2,49,000 (approx.).
End of the year

Maintenance cost at
the end of year

Summation of
maintenance cost

Average cost of
maintenance
through given year

1
2
3
4
5
6

0
10000
13000
16000
19000
22000

0
10000
23000
39000
58000
80000

0
5000
7667
9750
11600
13333

Total Life Cycle Cost Of Kansai Special = Initial Purchase Price of the Machine + Total
Maintenance Costs
= Rs. 2, 49,000 + Rs. 80,000 = Rs. 3, 29,000 /18

CONCLUSION
The above report has briefly focused on the various aspects of maintenance Schedule.
Maintenance is expected to play even much bigger role in years to follow, as industries
worldwide are going through an increasing and stiff competition and increased automation
of plants. The down time cost for such systems is expected to be very high. To meet these
challenges, maintenance has to use latest technology and management skills in all spheres
of activities to perform its effective role in profitability of the company.

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