Download - Maintenance Management in Garment Industry
-
8/12/2019 Maintenance Management in Garment Industry
1/22
Maintenance Managementin Garment IndustryKANSAI MULTI
NEEDLE MACHINE
-
8/12/2019 Maintenance Management in Garment Industry
2/22
Introduction
Garment industries use highly specialized machines andequipment on a daily basis, they face the daunting task of
continually managing these assets to ensure operationsrun smoothly.
Coordinating and scheduling preventive maintenance(PM), processing employee work requests and managingfacility repairs and modifications are just a few of thedaily tasks that need to be completed.
All of these tasks are complex and time-consuming, andpresent challenges that require an efficient maintenancedepartment in place to prevent productivity snags.
-
8/12/2019 Maintenance Management in Garment Industry
3/22
Importance of machine maintenance
Good machine maintenance is an investment inproductivity. Well maintained machines are more
reliable, safer and last longer. Basic maintenance is not expensive and can often be
done by workers.
Workers should be taught simple machine
maintenance skills such as machine cleaning,adjusting thread tension, changing broken needles,bobbin changes and emptying the dust filter
-
8/12/2019 Maintenance Management in Garment Industry
4/22
Maintenance
PlannedMaintenance
PreventiveMaintenance
Runningmaintenance
Shutdownmaintenance
Scheduledmaintenance
CorrectiveMaintenance
Breakdownmaintenance
PredictiveMaintenance
Unplannedmaintenance
Emergencymaintenance
-
8/12/2019 Maintenance Management in Garment Industry
5/22
Planned maintenance
In planned maintenance the maintenance action is carriedout with some fore thoughts, prior planning , record
keeping and control action. These can be further classifiedas :-
Preventive maintenance
Corrective maintenance
Predictive maintenance
-
8/12/2019 Maintenance Management in Garment Industry
6/22
Preventive maintenance
It is based upon the principle that prevention isbetter than cure.
It is a set of activities that are performed on plantequipment, machinery, and systems before theoccurrence of a failure in order to protect them andto prevent or eliminate any degradation in their
operating conditions The maintenance carried out at predetermined
intervals or according to prescribed criteria andintended to reduce the probability of failure or thedegradation of the functioning and the effectslimited.
-
8/12/2019 Maintenance Management in Garment Industry
7/22
Types of preventivemaintenance RUNNING MAINTENANCE
Running maintenance which includes those maintenanceactivities that are carried out while the machine or equipment is
running. Example lubrication, adjustment of nuts and screws,tightening of loose nut and bolts.
SCHEDULED MAINTENANCE
Scheduled Maintenanceis any variety of scheduled
maintenance to an object or item of equipment. SHUT DOWN MAINTENANCE
It is a set of preventive maintenance activities that are carriedout when the production line is in total stoppage situation. Theseare performed generally after three or six months.
-
8/12/2019 Maintenance Management in Garment Industry
8/22
Corrective maintenance
In this type, actions such as repair, replacement, orrestore will be carried out after the occurrence of a failure
in order to eliminate the source of this failure or reducethe frequency of its occurrence.
It also include the different types of actions like typicaladjustment of redesign equipment.
The difference between corrective maintenance andpreventive maintenance is that for the correctivemaintenance, the failure should occur before anycorrective action is taken.
-
8/12/2019 Maintenance Management in Garment Industry
9/22
Types of correctivemaintenanceBREAKDOWN MAINTENANCE
It is an emergency based policy in which the plant orequipment is operated until it fails and then it is broughtback into running condition by repair.
It is feasible for the small factories where
1. There are few types of equipment.
2. Machine and equipments are simple and does notrequire any specialist.
3. Where sudden failure does not cause any seriousfinancial loss.
-
8/12/2019 Maintenance Management in Garment Industry
10/22
Predictive maintenance
As the names implies it involves the prediction of thefailure before it occurs, identifying the root cause forthose failures symptoms and eliminating those causes
before they result in extensive damage of the equipment.
Type of maintenance performed continuously or atintervals according to the requirements to diagnose andmonitor a condition or system. Also called condition
based maintenance.
-
8/12/2019 Maintenance Management in Garment Industry
11/22
Unplanned Maintenance
Maintenance action which is carried out without anybefore thoughts or prior planning is called unplanned
maintenance. Emergency maintenance is one of the example of
unplanned maintenance.
In this type of maintenance the maintenance action is
executed with the help of all available maintenanceresources in least possible time, without any major timelag.
Examples are gas leakage in chemical plant, fire hazards,breakdown of boiler, turbine etc.
-
8/12/2019 Maintenance Management in Garment Industry
12/22
Kansai Multi-Needlemachines Kansai is a Japanese
company that
manufactures multi-needledouble chain stitchmachines for purposes likeattaching elastic, attachingwaist band, attaching line
tapes which is ideal forunderwear, sportswear,ladies clothes etc.
There are up to 2-33
needles available.
-
8/12/2019 Maintenance Management in Garment Industry
13/22
Maintenance of Kansai machine(BASED ON TIME SPAN)
DAILY MAINTENANCE
Machines should be blown off every day to
remove lint and trash. Remove lint and dust from the threadpassages.
To check whether needle is correctly setand not damaged.
Check to see that the machines are beinglubricated regularly. Oil levels should bechecked daily and additional oil added ifnecessary.
Using compressed air,which has a straw
(shown in red above) to
direct air to a desired
spot, blow out lint and
loose threads.
-
8/12/2019 Maintenance Management in Garment Industry
14/22
WEEKLY MAINTENANCE
If compressed air is used, make sure the airsystem is regulated properly and hashumidity dryers, filters and lubricator in theair lines.
Check Machines for wear on critical moving
parts Check for shake in needle bar due to worn needle
bar bushings
Check for excessive movement in stitch formingdevices, etc.
Check condition of critical screws Check for missing screws
Check for defective screws that are difficult totighten properly
-
8/12/2019 Maintenance Management in Garment Industry
15/22
Check the thread stands are in propercondition and the top eyelets areoriented properly.
Thread stand eyelets are smooth and notgrooved or damaged.
Cones are held in a vertical stationary
position Check to make sure the feed dog are not
broken or damaged
Check to see that the cutting knives are
sharp and are trimming properly. Thiscan be checked by placing a single end ofthread between the knives and observingif the thread is cut by the knives
-
8/12/2019 Maintenance Management in Garment Industry
16/22
MONTHLY MAINTENANCE Check for rusted areas due to excessive
moisture in production area. Machine eyelets and guides are smooth and
not grooved, rusted or damaged Check the condition of the tension disc, if
worn out, should be replaced. Check condition of mechanics tools to see
that they are being maintained properly.
Check the looper points for sharp surfacesor burrs. Observe excessive wear of looper. Check to make sure loopers are shaped
properly according to original factorycondition.
-
8/12/2019 Maintenance Management in Garment Industry
17/22
Lubrication of Kansai machine
Use Kansai special genuine oil
To extend machine life, be sure toreplace the oil after the first
250 hours of operation. Clean the filter element every sixmonths. If just a little or no oil flowsout from the nozzle with the properamount of oil in the machine, check
the filter element.
To clean the filter element, removeoil reservoir.
Before installing new cams, be sure
to grease the cam grooves.
-
8/12/2019 Maintenance Management in Garment Industry
18/22
Cleaning the machine At the end of each day, remove the presser foot and
the needle plate and then clean the slots of the needleplate and the area around the feed dogs.
-
8/12/2019 Maintenance Management in Garment Industry
19/22
Break down Maintenance Breakdown Maintenance activities are those works
associated with the repair and servicing of siteinfrastructure, buildings, plant or equipment within the
sites agreed building capacity allocation which havebecome inoperable or unusable because of the failure ofcomponent parts.
-
8/12/2019 Maintenance Management in Garment Industry
20/22
Storage of Partsand Equipment To ensure that spare parts and equipment remain ingood condition and last for a long time they should bestored properly. Stored tools and equipment will be easy
to find when needed. Some parts of the machine should always be kept in the
inventory incase of breakdown of machine like needles,bobbin cases, nuts and bolts, tension guides so that they
can be replaced easily. A record of all the spare parts should be maintained,
causes of machine breakdown due to which parts werereplaced.
-
8/12/2019 Maintenance Management in Garment Industry
21/22
Parts of Kansai Machine to
be kept as spare parts
Thread tension discs
Needle bar and needles
Feed dog
Pressure foot Motor
Looper
Pulley belt
Criticals nuts and screws
-
8/12/2019 Maintenance Management in Garment Industry
22/22
THANK YOU