maintenance management in garment industry

8/12/2019 Maintenance Management in Garment Industry

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Maintenance Managementin Garment IndustryKANSAI MULTI

NEEDLE MACHINE


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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.


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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


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Maintenance

PlannedMaintenance

PreventiveMaintenance

Runningmaintenance

Shutdownmaintenance

Scheduledmaintenance

CorrectiveMaintenance

Breakdownmaintenance

PredictiveMaintenance

Unplannedmaintenance

Emergencymaintenance


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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


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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.


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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.


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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.


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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.


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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.


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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.


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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.


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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.


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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


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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


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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.


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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.


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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.


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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.


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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.


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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


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THANK YOU

maintenance management in garment industry

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