Maintenance management

SHAHI EXPORTS - UNIT 12

MAINTENANCE MANAGEMENT

ACTIVITIES OF THE MAINTENANCE DEPARTMENT

• Planning of machinery well in advance as per the style

• Arranging machines for the batch setting well in advance

• Providing work aids/folders during setting batch to enhance productivity and quality

• Reducing of machine down time to meet timely shipment.

GENERAL PLANNING AND WORKING OF THE MAINTENANCE DEPARTMENT

• Maintain machines in peak condition by carrying out scheduled maintenance.

• Use genuine spare parts for longer life and also to avoid frequent failures

• Follow up with Planning and IED regarding the future styles and start preparing the attachments and planning the machines.

• In case of failures maintain sufficient spare and machine back up.

UP KEEPING THE MACHINE AND REGULAR MAINTENANCE TASKS

• Coordinating with the Planning and the I.E department regarding the type of style running in the batches (sewing lines). On the basis of the change of the product requirement, the new machines required are worked out by this section.

• On the basis of the change in the product specifications, the machinery requirements are bound to change. This section works out the changes to be brought in the batches.

DETAILED ACTIVITIES OF THE MAINTENANCE DEPARTMENT:

• Installation of the new machines whenever required in the plant

• Planning the type of machine to be positioned in the line on the basis of the line plan provided to them by the IE department.

• Verifies the data, check the availability of machines in any of other units.

• Receives the machine to be attended from the production floor with details of the problem faced and nature of breakdown and record same in breakdown register.

DETAILED ACTIVITIES OF THE MAINTENANCE DEPARTMENT:

• Keeps all the machines in particular bay for easy identification

• Responsible for keeping record of all inward/outward and serviced machines

• In case of folders or attachments IED gives the style bulletin at least a week in advance.

• The Maintenance store will keep Inventory of machine spares with proper record.

DETAILED ACTIVITIES OF THE MAINTENANCE DEPARTMENT:

• Inventory Management of the spare parts in the stores.

• Receive information for sampling section also, regarding the requirements of some machines which are not available with the company.

• Allot 1 mechanic for every 2 batches, who has to be present throughout the day for the production related problems with the machines.

• Arrange for the replacement of the machine in case of machine breakdown

DETAILED ACTIVITIES OF THE MAINTENANCE DEPARTMENT:

BASIC ACTIVITIES REQUIRED TO BE DONE FOR THE GENERAL PLANNING

AND WORKING OF THE MAINTENANCE DEPARTMENT

S.NO. ACTIVITY

1. Planning of machinery well in advance as per the PPC plan style wise.

2. Arranging machines for the batch setting well in

advance as per the IED bulletin for the styles,

indicating the machine requirements for the line.

3.Providing work aids/folders during setting batch to enhance productivity and quality

4.Reducing of machine down time to meet timely shipment

5.Standardization of spare parts (genuine) to obtain good quality seam and good performance of m/c

ACTIVITIES REQUIRED FOR THE UPKEEP OF THE MACHINES AND REGULAR

MAINTENANCE TASKS

S.NO. ACTIVITY

1. Maintain machines in peak condition by carrying

out AM (Autonomous Maintenance), PM

(Preventive Maintenance) and scheduled

maintenance. 2.

Use genuine spare parts for longer life and also to avoid frequent failures.

3.Follow up with PPC and IED regarding the future styles and start preparing the attachments and planning the machines.

4.

In case of failures maintain sufficient spare and machine back up.

ACTIVITIES DONE FOR THE CONTINUOUS IMPROVEMENT OF THE PROCESSES ON THE

SEWING LINE

S.NO. ACTIVITY

1.Reducing the batch setting time by proper planning of machines

2.Optimize the utility of UBT machines and avoid the usage of manual trimming by avoiding the thread wastage and time

3.Use only cone thread instead of tube thread to avoid loose stitch, frequent thread exhaustion and m/c stoppage for each thread changeover

4.Identify the machine running in lesser RPM and synchronize the speed

5.Train the mechanics to counter the tasks with out delay in reducing the m/c down time

ACTIVITIES REQUIRED FOR THE INTERACTION AND TRAINING OF THE

WORKERS AND ASSOCIATES

S.NO. ACTIVITY

1.Have one to one interaction with the associates and understand their problem and counsel.

2.Take the team for outing after each goal setting and upon achieving the same

3.Provide education and training to the associate according to the required skill

4.Recognize the work of the each and every associate and if he is found competitive promote him

5.A token of appreciation should be given for each developmental work or innovations

TOTAL PRODUCTIVE MAINTAINANCE

“TPM is a plant improvement methodology which enables continuous and rapid improvement of the

manufacturing process through use of employee involvement, employee empowerment and closed loop

measurement of results”

GOALS SET UP BY THE T.P.M. DEPARTMENT

• Reducing batch setting time from existing 8 hrs to 6 hrs.

• Conducting the skill test for all mechanics and electricians.

• Checking and synchronizing the m/.c speed and drives.

• Set up machine overhauling team and eliminate extra working of mechanics.

• Understand the problems of the associates and provide the solutions

SUB DEPARTMENTS AND DETAILED ACTIVITIES OF THE TPM DEPARTMENT

1. CENTRAL MAINTENANCE DEPARTMENT:

•Coordinating with the Central Planning and the Central I.E department regarding the type of style running in the batches (sewing lines). On the basis of the change of the product requirement, the new machines required are worked out by this section of the CMD.

•On the basis of the change in the product specifications, the machinery requirements are bound to change. This section works out the changes to be brought in the batches.

• Installation of the new machines whenever required in the plant

•Planning the type of machine to be positioned in the line on the basis of the line plan provided to them by the Central IE department.

•CMD will verify the data, check the availability of machines in any of other units or at the least on rental basis and then will confirm the same to IED.

•CMD will receive machine to be attended from the production floor with details of the problem faced and nature of breakdown and record same in breakdown register.

• CMD will consume time for breakdown maintenance according to the nature of breakdown. If it is minor technician will take Max. 15 to 20 Minutes. If it is major technician will take Max. 1 day.

• CMD will receive all the new machines ordered due to new requirements arising and on arrival of consignment, the department will call the franchise for installation and commissioning. After commissioning, it will obtain ID and Barcode Numbers from B.I (Business Intelligence).

• CMD will keep all the machines in particular bay for easy identification.

• CMD is responsible for keeping record of all inward/outward and serviced machines.

•CMD is having responsible for recruiting trainee mechanics by giving theoretical and practical test & decide to locate the recruited mechanic for production floor after judging his caliber.

•In case of folders or attachments IED gives the style bulletin at least a week in advance. This applies even for die sets.

•The Maintenance store will keep Inventory of machine spares with proper record. This store also comes under the CMD Head

•Inventory Management of the spare parts in the stores

•Receive information fro sampling section also, regarding the requirements of some machines which are not available with the company.

•Further the machine operators are trained to clean and check their machines daily under “Autonomous Maintenance Program.”

•An AM Clock is attached to all the machines. The activities are

Initial Cleaning, Implement Counter Measures, Preparation for Standardization [Cleaning,

Oiling and Tightening], General Inspection, Autonomous Inspection, Standardization and Autonomous Management

2. BATCH MAINTENANCE DEPARTMENT:

• Coordinating with the CMD in times of style change over.

• Allot 1 mechanic for every 2 batches, who has to be present throughout the day for the production related problems with the machines.

• Carrying out Autonomous Breakdown maintenance for the machines.

• Send the machine to the Central Maintenance Department in case the machine breakdown is not repaired on the floor itself. Side by side, arrange for the replacement of the machine by preparing an IOM (Indent of Materials) and sending it to the CMD.

• Training tailors and other operators for the Autonomous Maintenance and Preventive Maintenance.

• Machine settings changes according to the fabric type and the style running

• Inspect tools and cord periodically, and if damaged have it replaced by an authorized service agent.

• Ensure the oil tank cleaning, and check oil level and oil condition of the machine.

• The Spot Washing Machine is maintained daily by cleaning, Belt tension checking, and Oil level checked, Air leakage attended, loose connections rectified, Steam leakage attended and noise level maintained.

HIEARCHY OF MAINTENANCE DEPARTMENT

CONCLUSION

• This department is not just a maintenance department as its name suggests.

• The department in fact plans and makes the required machinery available on time.

• The company also boasts of its own unique Folders and Attachments fabrication unit wherein the required work aids are 100% fabricated from metal sheets. These attachments are a lot economical than those purchased from the specialized suppliers.

CONCLUSION

• Major area of focus for the department are:

plant improvement methodologycontinuous and rapid improvementemployee involvement

PLANT IMPROVEMENT METHODOLOGY:

TPM is a method for bringing about change. It is a set of structured activities that can lead to improved management of plant assets

when properly performed by individuals and team

CONCLUSION

• CONTINUOUS AND RAPID IMPROVEMENT:

• EMPLOYEE INVOLVEMENT

A critical aspect of TPM is that improvement should be rapid as well as continuous. To attain or maintain a leadership position

in industry, a company must continuously improve at a rate that is faster than that of its competition. Performance targets must

be dynamic, not static.

It is necessary part of TPM process. The goal is to tap into the expertise and creative capabilities of the entire plant or facility

through the use of small group activities. They have a heightened role in defining their job content, along with work

systems and procedures.

Thank you