Machine Maintenance and Management processes

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E,liminate numerical quotas, including Management b1t Objectiues.
-W. Edwards Deming
Machine Maintenance
Management
| 2014
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Solutions 4
Management
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Efectiue management alwa1s medlxs asking the right question.
- Robert Heller
Page 176 of20l
Solutions 4 Management International (S4Mi) Ltd.

Machine Maintenance Management
Introduction:
The work book is aimed at helping the trainees understand the key concepts of the subject
and carry out a self-study and activities that will reinforce the learning. The workbook will also
provide an opportunity to assess the understanding of the subject.
Learning Objective:
. Understand the basics about Maintenance & Maintenance Management
. Understand the Maintenance Policies
. Understand Maintenance Schedulingtechniques
. Understand calculation of Maintenance effectiveness
. Understand & explore common sewing machine problems using problem solving tools
Maintenance Management is an orderly and systematic approach to planning, organizing,
monitoring and evaluating maintenance activities and their costs
A good maintenance management system coupled with knowledgeable and capable
maintenance staff can prevent health and safety problems and environmental damage; yield
longer asset life with fewer breakdowns; and resulting lower operating costs and a higher
quality of Iife.
Natural life cycle of individual machine elements must be achieved
. col'f€ct set-up
. coFr€ct operation
. cleaning
. Iubrication
. €?s/ to maintain and reliable
. have quick set-up times
. operate at the lowest life cycle cost
Maintenance Objectives
. To increase functional reliability of production facilities.
. To enable product quality to be achieved through correctly adjusted, serviced and
operated equipment.
. To maximize the useful life of the equipment.
. To minimize the total production or operating costs directly attributed to equipment
service and repair.
. To minimize the frequency of interruptions to production by reducing breakdowns
. To maximize the production capacity from the given equipment resources.
. To enhance the safety of manpower.
lmpact of Machine Break-down
o p : Decrease of production amount and increase of wastes;
. Q : Defective production of or low quality product;
. C : lncrease of production cost and repairing cost;
o P : Delay in delivery time;
Solutions 4 Management International (S4Mi) Ltd. PagelTT of20l

: Occurrence of industrial accident or pollution; and
. M : Moral degradation due to frequent machine troubles.
Effect of Maintenance in these Areas
. Non-productive Time (NPT)
- The percentage of NPT causes for Machine maintenance problem?
- How severe the effect is?
. Style Changeover time
- Exactly how long it take to start the new style in production Iine after the last
style's last input ends?
. Productivity
- Can we use equipment in optimal condition? Is the machine performance
reducing Iine productivity?
. Quality
- Any particular effect on?
Mai ntenance Policies/Options
. Breakdown/UnplannedMaintenance
. Preventive/ScheduledMaintenance
a. Time based
b. Work based
c. Opportunity based
d. Condition based
Breakdown/Unplanned Maintenance
It is emergency based policy in which the equipment is operated until it fails and then it is
brought back into running condition by repair. The maintenance staff locates any mechanical,
electrical and any other fault to correct it immediately.
This strategy is suitable for equipment that is not critical and has spare capacity or
redundancy available.
Breakdown Maintenance Techn iques
. It arises out of the following:-
1. Breakdowns
2. Malfunctioning reported by Production
3. Abnormalities observed by Inspection
Breakdown Maintenance Procedure
. The operating personnel is asked to provide information about the nature of trouble
experienced by them.
. On-failure maintenance procedures took place by the mechanic.
. Reports of inspectors is indicating the part needing attention and the type of attention
required.
Solutions 4 Management Intemational (S4Mi) Ltd. Page 178 of201

Disadvantages of Breakdown Maintenance
. Breakdown generally occurs inappropriate times leading to poor and hurried
maintenance
. Excessive delay in production & reduces output
. Faster plant deterioration
. Increases chances of accidents and less safety for both workers and machines
. More spoilt materials
. Direct loss of profit
Preventive/Scheduled Maintenance
ln preventive Maintenance, maintenance actions such as inspection, Iubrication, cleaning,
adjustment and replacement are undertaken at fixed intervals of numbers of hours. An
effective PM program does help in avoidance of accidents.
a. Time based
It means doing maintenance at regular intervals. It is time dependent rather than usage
dependent.
b. Work based
Maintenance after a set of operating hours of volume of work produced.
c. Opportunity based
Where repair and replacement takes place when the equipment or system is available.
d. Condition based
Which often relies on planned inspection to reveal when maintenance is required. lt is
preferred for critical systems and for such systems breakdown maintenance is to be avoided.
A number of CM techniques such as vibration, temperature, oil analysis, etc. have been
developed.
Two Aspects of Preventive Maintenance
lnspection: lnspection of critical parts will indicate the need for replacement or repair well in
advance of probable breakdown. Regular inspection conducted is the most important direct
means of increasing equipment reliability.
Servicing: Routine cleaning, Iubrication and adjustment may significantly reduce wear and,
hence, prevent breakdowns. Frequently such duties are carried out by equipment operator or
may be carried out by maintenance department.
Advantages of PM
Reduces break down and thereby down time
Less odd-time repair and reduces over time of crews
Greater safety of workers
Lower maintenance and repair costs
Less stand-by equipment's and spare parts
Better product quality and fewer reworks and scraps
Increases ptant Iife
lncreases chances to get production incentive bonus
Solutions 4 Management International (S4Mi) Ltd. Page 779 of201

Machine Numbering
It is genuinely efficient to set a number with code against each and every machine of
yourfactory. Every unavoidable movement of machine from one line to another orfromm/c
storage to particular line should be tracked and recorded against each machine number.
Maintenance activities can be categorized as follows:
tr Preventive maintenance
tr Corrective maintenance
i. Preventive Maintenance Techniques:
It starts with creating:
' PM Main Lists
FactoryFloor Number
. Machine/Part of machine
. Time Interval
: :n';1{,Tlh[:-men/rype or work
. Maintenancelnstructions
: ffHilIffiffflI'3l,,..-,
' Routine Lists
[:iii:.#:[J [ffifl,,,$i::1ffiffi?,:,lf,,oroure arrectins the
production schedule for a group of equipment in a division or section.
AII such activities will be carried out during a specified week by a
designated category of worker. Each Routine List will be numbered and
scheduled over the year.
' PM cards
. pM card consists of all pM activities which require "special ptanning" or
"stoppage involving production loss" and whose frequencies are same.
Activities in each PM Card will be scheduled in a particular week of the
year with due consideration to the production plan.
. Maintenancelnstructions
. Maintenance Instructions give the detailed description of the
maintenance activity. This is to enable the worker carry outthe activity
as per the specified method.
ii. Corrective Maintenance Techniques
. Corrective Maintenance arises out of the following:-
. Breakdowns
. Malfunctioning reported by Production
. Abnormalities observed by Inspection
. The operating personnel should be asked to provide information about the nature of
trouble experienced by them.
Page 180 of201

. Reports of inspectors should indicate the part needing attention and the type of
attention required.
. Drawing of the machine should be used to determine the work required to be done to
reach, remove and replace the defective parts.
Maintenance Planning, Scheduling and Control
Consists of:
. Anticipating future work
. Visualization of the nature and details of the work
. Determination of the best method to perform the work
. Arranging for the required materials
. Scheduling of maintenance work to conform to production plans
. Allocation of work to individuals
. lnstructing the individuals about the schedules
. Instructing the individuals aboutthe methods
. Follow-up and monitoring the progress or work; and
. Evaluation of the work and performance.
Maintenance Scheduling
. Sources of Scheduling Data:
o 'Repair note' is the primary source of information for scheduling purpose
o Maintenance Methods and time estimates, evolved earlier for various maintenance
works, will give information regarding the various trades and the work-load
involved.
o Load schedule and the progress report of the various maintenance crews will give
information with respect to their availability.
o Special Material for maintenance and Spare Parts records in the stores will be the
source of information as to their availability.
o Master Production schedule is the source of information as to the time when the
equipment could be available for maintenance work and necessary servicing.
3 Principal classes of Schedules
1. The preventive maintenance Master Overhaul and lnspection schedule.
Many items of equipment which must be taken out of service at regular intervals
for inspection and overhaul. The frequency of such occurrences varies with the
equipment.
Experience (guided by statistics) permits establishing the frequency, so that the
lowest overall maintenance cost results.
After the frequencies have been determined, Iong-range master schedules are
prepared. These must be coordinated with Master production schedules.
The maintenance manager prepares detailed methods write-up which include
step-by-step descriptions of each inspection and/or overhaul. The work to be
done by each trade and shops is set forth in detail so that their activities can be
measured and scheduled accurately.

. The master schedules are integrated into the daily and weekly schedules so that
the regular preventive-maintenance work becomes a part of the overall plan-
maintenance programme. This ensures continuity and regularity of the preventive
phases of maintenance work.
2. The Daily Man Assignment Schedule.
Whether or not the daily schedule is written will depend on the size and
complexity of the organization. Cenerally, there is no need for aformal schedule.
The scheduling usually consists of the maintenance in-charge's handling the
mechanics, one or more work orders, or job plan with the sequence in which they
areto be done. Upon completion of the work, the foreman notifies the scheduling
group. Each day's progress is reflected in the next day's schedule. By 4th day
noon, sufficient data are available to prepare the weekly schedule for the next
week on a realistic basis.
3. The Area Maintenance Schedule.
. Many of the functions performed by the area maintenance personnel can be
scheduled on detailed weekly schedules.
. Such items as Lubrication, instrument inspection, machine inspection and
adjustment, and the like are of this nature. Usually these activities can be
scheduled with considerable accuracy.
. Periodic audits of these schedules are made by the scheduling group to determine
the validity of their time estimates.
Preventive Maintenance Program Check List (CALMO)
. Clean
. Adjust
. Lubricate
. Measure
. Observe
How well communicated we are
. We use:
*'
i"', lillli'*..r.u n i.,
. Mechanic is not aware of the machine trouble & the location of trouble.
. Mechanics are not concentrating if another section machine is in trouble.
How well communicated we can be
. Our current practice could be replaced by more advanced way with slight investment.
. Communicationindicator:
. Colored FIag: Arrangement of a flag which is different but attractive color.
When operator will face trouble in the machine she/he will hang this in his
machine so mechanic will easily understand where the problem is.

. Traffic Light: AIarm Iight system can be used. Each machine top there will be a
specific light of specific color and a switch near the operator hand, so when
machine will trouble operator will press the switch as alarm of machine
trouble.
. Light with AIarm: Alarming system can be used. An alarm bell can be fixed in
front of the Iine and connected switch will be available near of operator hand
when operator will face trouble in the machine helshe will press the switch
and bell will ring it for that mechanic will be aware of the machine trouble.
. Well-designed system against each 'indicator' can give us more effective solution for
maintenance problems.
Maintenance Decisions
. How much preventive & breakdown maintenance
. Who perflorms maintenance
Centr alized, decentra I i zed, oper ator etc.
Contract or in-house
. When to replace or repair
. How much to replace
Individual or group replacement
The OverallApproach
. Requires"systematic"approaches
. Utilize existing mechanisms where applicable
. Utirize ,nJ,nn{i!1,!ii{"";i,lr':::'#!:,y,;fffi::,operotion
Mechanism' etc
. Equipment optimization requires total employee involvement from top to bottom
. Leverages best practices so we can all get better in quicker fashion
. Optimize what we have before adding new equipment (Maximize ROIC)
. Ensure we are driving total organizational value
Time to think about:
Equipment and Process Improvement
. Maximizing efficiency by eliminating waste and manufacturing loss
. Manufacturing losses in the context of Maintenance are categorizedinto 12 bid losses:
o Equipment losses (6)
o Manpower losses (4)
o Material losses (2)

Equipment losses:
Equipment Six Big Losses
::::::; ;:i:!l i:,::::i,I: ,., i liill
1'"'== Bie;kdo*ni
2 Setup / adjustrnent
t.
. ldling / rninor
" stoppages
11161, , ..,-==,.=-1:i:: Llt :;!i;:=
4 speed " :':':'
iiil
5
ET lL! L ] ::::::]: . ::::i:::.:::::::;:;::i l| LL'
DefBcts irj$fotess
and rework
Reduction of Setup Time-(from Maintenance Dept. point of view)
. Working together with IE, production and planning department to ensure the minimal
time to set-up any line during style changeover time.
. Need to confirm the right type and right number of machine in right condition along
with right sets of guide, folders, needle, needle plate etc. during Line feeding.
. Need to calculate the efficiency of the machine during its loading time.
. Need to combine the availability and perflormance of your equipment with the quality
of parts made.
. Need to maintain a system for controlling the condition of equipment components
that affect variability in product quality.
Autonomous Maintenance
A system where machine operators leorn to:
Perform daily checks
Lubricate machine as needed
Replace simple components
Perform minor repairs on machines
Assist in problem solving
Operato[S become the early warning system for machine abnormalities.
Available time
Avai labl€: opeiatin$ ti me
'u:::t:ut t:
Actual opeiating
time
,r!l iil+ii:r r::::::::::': ::r:::::::::=
,= f,ffeEtiv€=
'operating
time
Solutions 4 Management International (S4Mi) Ltd. Page 184 of20l

5 Steps to Autonomous Maintenance
1. Perform basic cleaning
2. Eliminate sources of dirt and contamination
3. Establish cleaning and Iubrication standards
4. Teach general inspection of equipment and Perform autonomous equipment
inspection
5. Instill orderliness and organization
Roles of Operators
. Preventdeterioration:
Maintaining basic conditions
Operating equipment correctly
. Measuredeterioration:
Inspecting
Developing and adhering to standards
. Correctdeterioration:
Reporting problems
Assisting in repairs
Making minor adjustments (per local contract)
. Participate in teams:
Work center teams
Problem-solving teams
Roles of Maintenance Personnel
. Maintain Equipment
Inspect (disassembly)
Planned overhauls
Preventive maintenance
Teach selected maintenance tasks to operators
. Improve Equipment
Support R&M i mprovement
Implement predictive technologies
Correct design weaknesses
Partner with vendors

Problem Solving Techniques
Sewing machine Problem
Materials
Method Environrnent People
Common Sewing Machine problems:
FISH BONE diagram for Skip Stitch (Kansai M/C)
Garments construction
Wrong threading
Use ndl guard. proper size nd1
& handling
Mechanics at start
Feed dog & roller balance

Carments Construction
Thick fabric, elastic, draw cord etc
Feed dog alignment
Mechanics starti
Feed dog roller irnbalance
Mechanic at start
FISH BONE diagram for Uneven Stitch (Kansai M/C
FISH BONE diagram for lmproper Thread tension (Kansai M/C)
Page 187 of201
Obstruction in thread path
lmproper Thread tension
Retainer & needle misalignment
Mechanics dail

FISH BONE diagram for Thread break (Kansai M/C)
Needle bent
0perator daily
FISH BONE diagram for Roller Problem (Kansai MlC)
Onerator
Wronq Threadi
0perator daily
Thread break
Needle plate hole sharp
Mechanics dai
Tiaht tension
Roller problem
Spring life overl broken
Poor quality of roller
servicing check

How to calculate Maintenance Performance
. The following criteria can be used for measuring the effectiveness of maintenance
function:
Output (Product)
Maintenance cost (Product)
Downtime hours
2. Downtime index = x 100
Production hours
Total Maintenance costs
Total Man- hours worked
55 Examples- in Maintenance Area:
Fig: Arrangement of Cuide & Folders
Fig: Arranged Tool kit
Fig: nrranged Tool kit

Fig: Before 55
Fig: Ater 55 - Cleaned, organizedand drawers
labeled (less time and frustration hunting)
Page 190 of201
Fig: Guide and Folder storage
Fig: Report files storage

Maintenance Planning
Machine Maintenance Plan (MMP)
It is a document, in table format, that is used when developing the tasks needed to properly
maintain facility, plant or process equipment.
. The MMP helps developing the required maintenance tasks
. Ensuringthatthe development is done consistently for all equipment.
. Each MMP should include one or more maintenance tasks designed
. Ensure the continued operation and maintenance of an equipment item, process or
system.
Machine Maintenance Plan (MMP)
Each of these tasks has the following characteristics:
A descriptive title for each maintenance task to be performed
Afrequency assigned for performing of each task
Assignment of a specific workgroup and the number of each workgroup
required to perform the task
Equipment condition required for performance of the task (i.e. running or shut
down)
Type of Work - Preventive Maintenance (PM), Predictive Maintenance (PdM),
Corrective Maintenance (CM), etc.
Procedure number * Unique identifier for the task, or file name if linked to
another document that gives the individual task instructions
Estimoted time to perform the task
Specioltools, moteriols ond equipment required to perform the task
Maintenance Task Description
. ltem number - identifies each of the maintenance tasks listed on the MMP, giving each
a line item number
. Mointenonce tosk description - this area is where the very brief description of the work
to be performed is entered, i.e. Clean and lubricate m/ c, inspect and lubricate m/ c etc.
. Frequency - identifies the frequency at which the maintenance task is to be performed
Points to Remember:
Objective of a better Maintenance system is to maximize the useful life of the
equipment and minimize the total production or operating costs directly
attributed to equipment service and repair.
. 'Repair note' is the primary source of information for scheduling purpose

. High repair and maintenance cost of existing machines is the cost factor that
necessitate the replacement of machines.
Activities
Please write down existing Maintenance Procedures available in your factory? Please share
Machine 'Over Haul' Schedule and parameters for preventive maintenance machine wise. Do
you think existing maintenance is system a good system? Please make a note in which area
you can improve your maintenance system.
Assignments
. Identify the improvement area in the maintenance system of your factory.
Questions for Self-Assessment
. What types of maintenance policies are available?
. Which maintenance system is used in your factory?
o. Write down the demerits of your existing maintenance system.

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