CONCEPTS

OF
MAINTENANCE
Production and Quality in any Organisation
depends on
THE MAINTENANCE OF
THE MACHINERY AND
THEIR PARTS
Yarn Quality Level in Indian Mills
30s CH
Parameter
Local
Market
Export
Market
Count Cv%
Strength Cv%
Imperfections/km
Total Classimat
Faults/lakh m.
2.5% 1.5%
6.0 7.0% 4.5%
250 - 300 50 - 60
700 250
Importers main thrust is consistency in the
quality of product between lots
Of late ISO quality system is insisted only
to meet the above goal
Negligence of maintenance and timely
replacement of components will lead
to inconsistency
The machineries have seen a change in
their design to meet the global demands
Bale Openers
Blending Hoppers
Aeromix
Lap feed
S.H.P. Card
F.G. Cards like DK 740, LC 100
Crosrol Mark 7
O Bale Pluckers
O
O
O
O
Automixer
Unimix
Chute Feed Mechanism
H.P. Card O V.H.P. Card
O
S.S.D.
O
H.S.D.
O
D.FS with
Autolevellers
Innovations in drafting systems meant
for speed frame and ring frame
P.D.T.C./P.D.B.C. for preparatory
machines
Developments on Pneumafil
* Technological developments on overhead
cleaners, precisely set cop build by cop
masters
* Automatic Waste Extraction System for
machines up to comber to minimise
contaminations
SITRAS INTERFIRM COMPARISONS
TABLE OF DEVIATIONS
Low
Frequency
High
Frequency
General cleaning in
Ring Frames
Half setting in Cards
General cleaning of
Draw frames
12 days
90 days
20 days
5 days
10 days
4 days
REASONS FOR DEVIATIONS IN EXISTING
PRACTICES OF MAINTENANCE
s More concentration is on productivity
of the mills
s Absence of skilled labour
s Maintenance labour complement is not
worked out scientifically
s High level of absenteeism in the mills
s Adherence to break down maintenance
as a way of life
MAN POWER REQUIREMENT FOR
MAINTENANCE OPERATIONS
Dept. Operation
Category of
Personnel
Man House
Required to
Carry Out
The Operation
Cards
General cleaning
& half setting
1. Asst.
Fitter
2. Cleaner
2.66
2.66
Full Setting 1. Fitter
2. Cleaner
8.00
8.00
BENEFITS OF MAINTENANCE
1. Zero Breakdown
2. Improved life of machinery and
their spares
3. Consistent quality
4. Improved morale in the shop floor
5. Adherence to delivery schedules
ABSENCE OF MAINTENANCE LEADS TO
) Loss of customers confidence
) Frequent quality complaints and high
level of waste generation
) Chaos in shop floor
) Non-adherence to delivery schedules
DESIGN FEATURES OF THE MODERN
FOURTH GENERATION MACHINERY
Preheated and assembled bearings
Inverters and AC Servomotors to
control the speeds
Centralised system of lubrication
Automatic waste evacuation
DESIGN FEATURES OF THE MODERN
FOURTH GENERATION MACHINERY
Use of Microprocessor to
1. Set machinery parts
2. Change the speeds
3. Clear the yarn
4. Maintain humidity levels
5. Monitor the quality of output
S.M.P.
FOR THESE FOURTH GENERATION MACHINERY
Identification of Machinery
Collection & review of technical data
Training of personnel
Scheduling
Implementation & evaluation
TWO TYPES OF MAINTENANCE
MAINTENANCE
Breakdown Planned
BREAKDOWN MAINTENANCE
An unplanned system
Whenever a machine fails to run,
maintenance activity will be carried
upon to Restart the machine
DRAWBACKS
Sabotage to quality of the product
during the near breakdown period
Spoilt morale of the workforce
PLANNED MAINTENANCE
E A Scientific & Rational Principle
E Preservation of Machinery & Spares
E Economic use of machinery
SALIENT FEATURES OF PLANNED
MAINTENANCE
* Previously fixed workplan
* Attention is focused on controlling
the condition of machinery to
prescribed standards
* Primary emphasis is on the prevention
and retardation of wear and tear
AIMS OF MAINTENANCE
To maintain equipment at the maximum
operating speed and production
efficiency
To ensure the best possible level of
quality of the product
To minimise idle time
To reduce the cost of maintenance
THREE OBJECTIVES
IMMEDIATE : Perform standard tasks
at prescribed schedules
INTERMEDIATE : Effect replacements
ULTIMATE : Preservation of Capital
Equipment
CONCEPTS OF MAINTENANCE
1. Routine
2. Preventive
3. Predictive
4. Remedial
5. Restorative
6. Emergency
Maintenance
ROUTINE (RETENTIVE) MAINTENANCE
Bare minimum activities to ensure
efficient working of machines
They will be performed at
predetermined frequencies
Frequencies depend on technical &
quality considerations
(eg.) General cleaning & lubrication
PREVENTIVE MAINTENANCE
> Discover the defects before it
aggravates
> Rectify the defects
> Calls for systematic inspection
with planned schedules
PREDICTIVE MAINTENANCE
* To assess the effectiveness of routine
and preventive maintenance
* To know what has happened to different
parts of the equipment
* (e.g.) Bearing failure tests
REMEDIAL MAINTENANCE
Change of designs to increase the
capability of the machine
Study of failures & modifications
(e.g.) 1. Training of maintenance
personnel
2. Provision of positively
driven top clearer
RESTORATIVE MAINTENANCE
Replacement of major parts
Considerable expense of time & money
(e.g.) Re-erection/overhauling
Done when the machine Fails to run
EMERGENCY MAINTENANCE
PRE-REQUISITES FOR MAINTENANCE
PROGRAMME
= Establishing appropriate flow of
information and data on maintenance
= Ensuring timely supply of spares and
other materials
= Engaging personnel of varying skills
and competence
PRE-REQUISITES FOR MAINTENANCE
PROGRAMME
Well defined organisational
structure to plan and implement
Designing of proper Planning,
Scheduling and Controlling
activities
MAINTENANCE ORGANISATION
RESPONSIBILITY OF MAINTENANCE
O Separate from production staff
O Avoid mixed up responsibilities
O Production people are unwilling to
cooperate
EFFECTIVE MAINTENANCE PROGRAMME
CALLS FOR ADEQUATE FLOW OF
INFORMATION
4 Technical Information
4 Data on maintenance schedules and
backlogs
4 Performance analysis from production
records
4 Quality control reports
TIMELY SUPPLY OF SPARES & OTHER
MATERIALS
INVENTORY CONTROL BASED ON
ABC TECHNIQUE
A - Less No; More value/unit
(Differential Gear Box Assembly)
B - Slightly higher No; Medium
value/unit (Rings)
C - Large No; Less value/unit
TRAINING OF MAINTENANCE CREW
Recruitment
Policy
Education
Experience
Skill
Knowledge
TRAINING NEEDS TO BE IDENTIFIED
Provide
At mills site
At machinery
manufacturers site
SYSTEM
A network of related procedures
developed according to an
integrated scheme of performing
a major activity or function
PROCEDURE
Sequence of technical operations,
established to ensure uniform
accomplishment of a recurring task
NEEDS FOR SYSTEMS & PROCEDURES
Cyclic

Overlapping

Differential Frequency

Comprises one or
more other activities
Nature of Job
PATTERN OF MAINTENANCE IN A
SPINNING MILL
MAINTENANCE
Known Unknown
Repetitive Non-repetitive
Routine
Preventive
Major repair
Re-erection
Breakdowns
Change of
Layout
SYSTEM CAN BE BROUGHT ABOUT BY
# Planning
# Scheduling
# Controlling
PLANNING
Listing of all points to which
attention is to be paid
Establish frequencies of various
maintenance functions
To lay out the frequencies of
various operations over the plan
period with men & facilities
ANNUAL PLAN
EQUIPMENT HISTORY
MAINTENANCE RECORDS
CURRENT MAINTENANCE
PRACTICES
YEARLY PROGRAMME
WEEKLY WORK ORDERS
DAILY WORK
ALLOCATION
Spares List
Incomplete
Job reports
Request
from
SQC
Maintenance
Feed back from
Quality & Prodn.
Cost Estimates
FOR PLANNING MAINTENANCE
ACTIVITIES EQUIPMENT HISTORY
RECORDS WILL BE USEFUL
The equipment history record contains,
Name of machine
Serial No.
Date of commissioning
Major technical details
Major replacements/renovations
EQUIPMENT HISTORY RECORD
NAME OF MACHINE NO. DEPT.
MACHINE MODEL
LOCATION LENGTH WIDTH HEIGHT
SUPPLIER AGENT
DATE OF COMMISSIONING
TECHNICAL DETAILS
WELL DEVISED SCHEDULING
~ Minimise delays due to lack of
coordination
~ Reduce loss of man hours for
material procurement
~ Aim at minimum down time by
coordinating multi-skilled jobs
~ Reduce waiting time between jobs
~ Coordinate with SQC for effectiveness
COMPONENTS OF SCHEDULING
WORK UNIT
Minimum work unit to be taken as the
basis for work accomplishment (man
Hours)
SIZE OF JOB
Large or small, they pertain to a
single machine as a whole.
Cover all jobs
COMPONENTS OF SCHEDULING
PERCENT MAN HOURS
Few man hours as cushion for emergency
Follow widespread practice of doing
maintenance work in day shift only
LEAD TIME
Length of time to be covered by the
schedule
A 7 day week with a staggered holiday
THREE PARTS OF SCHEDULING
1. Preparation of work distribution
time table for the whole year
2. Convert to weekly work orders
3. Rescheduling to accommodate
backlogs
AIM OF MAINTENANCE CONTROL
_ Tool of the management to find out
deviations
_ Provide feed back information from
P.M.Checklists/review annual plans
_ Reports from Quality Control are
supplementary sources of feed back
MAINTENANCE RECORDS
MAINTENANCE LEDGER MACHINE CARDS
JOB INCOMPLETE REPORTS
BREAKDOWN RECORD
WEEKLY WORK ORDER
RECORD FOR THE CONSUMPTION OF
OVERTIME ENGAGEMENT RECORD
LUBRICANTS AND SPARES
MACHINE CARD FOR DRAWFRAME
MACHINE NO. :
MAKE & YEAR :
NEXT OVERHAULING
DUE ON :
1. Top Roller Cots
Buffing/Acid
treatment
DUE ON FREQ. DONE ON OPERATIONS
2. Replacement of
Top Roller Cots
3. Top Roller Bushes
Replacement
4. Pressure checking
5. Bottom roller trueing
6. Preventive
maintenance
checking
LUBRICATION
MAJOR ITEM OF EXPENDITURE IN
THE MAINTENANCE OF MACHINERY
PROTECTION OF MACHINERY FROM
i) Wear

ii) Corrosion

iii) Possible Breakdowns
WEAR
Undesired displacement (or)
removal of surface material
LEADS TO
Deterioration of product quality
Disproportionate effects
FACTORS CONTRIBUTING TO WEAR
U Contact with rough surface
U Eccentric movement of moving
bodies
U Absence of lubricating medium
WHAT IS LUBRICATION ?
1 Lubrication is done To make
slippery between two moving
bodies in order to avoid
i) Wear
ii) Heat generation
iii) Noise generation
1 Lubrication is done to
Separate two bodies

W
F
Frictional
Force
THE WEAR DEPENDS ON
i) Load applied
ii) Coefficient of friction of one material
with respect to the other
KINDS OF LUBRICANTS
Mineral Oils
Semi Solid Greases
Solids like graphite,
Molybdenum disulphide
Air and gas
Synthetic materials
HOW TO SELECT THE RIGHT TYPE
OF LUBRICANT?
ENVIRONMENT
i) Closed or open system
ii) Operating temperature
NATURE OF LOAD
INPUT HORSE POWER
LUBRICATION OF TEXTILE MACHINERY
Maintain low Power consumption
x W x V x 0.746
33,000
Power Loss =
KW
W = Load applied in pounds
V = Mean circumferential velocity
in feet / min.
LUBRICATION OF TEXTILE MACHINERY
O Protection against corrosion
(return of a material to its
natural state)
O Avoidance of staining of
yarn or fabric
METHODS OF LUBRICATION
Drip feed lubricators
Wick feed lubricators
Felt pad lubricators
Ring oil lubricators
Forced oil lubrication
Splash lubrication
Self lubrication system
WHY LUBRICANTS MUST BE TESTED?
i) Grade & quality can be
verified against standards
ii) Saving machinery from early
wear
iii)Selection of best lubricant
at competitive price
WHY LUBRICANTS MUST BE TESTED?
iv) Rationalisation towards
inventory control
v) Utility of service life of lubricant
vi) Near equivalent of imported oils
from indigenous manufacturers
can be identified
QUALITY CHARACTERISTICS
FOR OIL
1. Viscosity
2. Volatility
3. Flash Point
4. Acid Number
QUALITY CHARACTERISTICS
FOR GREASE
1. Dropping Point
2. Consistency
3. Penetration Number
STORAGE FACILITIES FOR LUBRICANTS
: Separate containers with
identification
: Containers must be non-corrosive
& should have liquids
: In the case of oils, trays must be
provided beneath the tap
: To be stored in a separate and
enclosed room
CONTROL ON CONSUMPTION OF
LUBRICANTS
s Possibility of mix up
s Confusion during supply from stores
s Purchase of oil through retailers
leads to quality problems
s High inventory / capital loss
LUBRICANTS IN A SPINNING MILL
c Heavy / light E.P. oil
(135 240 centistokes)
c Heavy / light spindle oil
(10 35 centistokes)
c Adhesive oil
(110 centistokes)
c Grease / E.P. Grease
(65 190 centistokes) - Oil base
c Dry lubricant
HOUSEKEEPING
BASIC REQUIREMENTS
s Proper lay out of building &
machinery
s Orderliness & Cleanliness
s Correct storage & materials
handling
LEVEL OF VARIATION BETWEEN MILLS
c Pillars between machines
c Narrow space between machines &
machine to wall
c No proper exhaust system
c No ventilation
LEVEL OF VARIATION BETWEEN MILLS
Fully humidified layout with
automation
Partially humidified mills
No proper storage facilities for
accessories / in-process materials
Low level of illumination
MACHINERY LAY OUT
Space between machines
Machine to wall
Machine to control panels
Guards for control panels
Alley ways
Re-layout of old mills suggested
ORDERLINESS
- Store the materials where it is to be
stored
- Windows and openings are not
storing place
- Any dust / fluff accumulation must be
cleaned at periodic intervals. Better
to curb at generation point
- Waste should be stored in waste bags/
baskets and not to be thrown on the
floor
CLEANLINESS
E Pressed seed coats over the calendar
rollers leads to unwinding problem
E Fly choking at card undercasings leads
to wire damage
E Fluff at arbor ends leads to higher level
of classimat faults
E Oily reserve disc in T.F.O. leads to
higher level of TPI CV
STORAGE AND MATERIALS HANDLING
Practices of good storage from cotton
godown to yarn godown
For transportation of materials, right
and convenient type of trolleys must
be used (tailor made)
RESPONSIBILITY OF GOOD HOUSEKEEPING
COLLECTIVE
EFFORTS
OF
ALL PERSONNEL IN THE ORGANISATION