Effect of Maintenance on Production & Quality

Southeast UniversitySchool of Science and Engineering

Department of Textile Engineering

Project on“Effect of Maintenance on Production and Quality”

Submitted by: ID No.

Ajaz-Ul Huq-Banna 2007200400041Gazi Abdul Kader Goni 2007000400051Ibrahim Kholil 2007200400068Emdadul Haque Joni 2007200400004Ariful Islam 2007200400081

Batch 6th


Supervisor:

Dr. Md. Abul Kalam Azad

Project Supervisor


Southeast University

Dhaka, 14, September, 2011

Brief Presentation

Industry Name: Standard Group Ltd.

&GMS Composite Knitting Ind. Ltd.

School: Science and Engineering

Course of Studies: B.Sc. in Textile Engineering

Supervising Teacher:

Dr. Md. Abul Kalam Azad

Project Supervisor

Department of Textile engineering.

Southeast University

Submitted by: ID No.

Ajaz-Ul Huq-Banna 2007200400041Gazi Abdul Kader Goni 2007000400051Ibrahim Kholil 2007200400068Emdadul Haque Joni 2007200400004Ariful Islam 2007200400081

Batch 6th


Date of Issues: 01 July, 2011

Date of submission: 09 September, 2011

TEXTILE ENGINEERING DEPARTMENT

Abstract

Textile technology education is based on industrial ground. Theoretical background is not

sufficient so, industrial training is an essential part of study to make a technologist techni-

cally sound in this field. Industrial training provides us that opportunity to gather practical

knowledge.

Standard Group Ltd & GMS Composite Knitting Ind. Ltd. is a truly integrated under-

taking. The textile division has the capability to offer a complete product range for the ex-

port & domestic textile markets. The goal of this textile factory is to become the preferred

partner for sourcing high quality fabrics & clothing from Bangladesh. With high advanced

technology & an emphasis on developing local human resources, the textile division has

the potential to make an important contribution to the nation’s growing readymade gar-

ments export sector.

The rationale behind the existing structure & future expansion of the textile division is to

capture value added at each stage of the textile manufacturing process. Despite

Bangladesh’s lack of indigenous cotton production capability, Standard Group Ltd. &

GMS Composite Knitting Ind. Ltd. has leveraged Bangladesh’s labor cost advantage &

export competitiveness to maximum level.

Standard Group Ltd. & GMS Composite Knitting Ind. Ltd. Page 1


Declaration

We hereby declare that the submitted work was completed using only the mentioned literature

and without any Unhallowed assistance.

Dhaka: 14 September, 2011

Thanks ,

Mahafuzur Rahman 2006100400029 (5nd Batch)Palash Saha 2006100400007 (5nd Batch)Md.Shahadat Hossain 2006100400038 (5nd Batch)Moazzem Hossain 2006100400005 (2nd Batch)A.K.M. Shariful Alam 2006200400007 (3rd Batch)



Acknowledgement

We take this opportunity to record my deep sense of gratitude and appreciation to our Project

Advisor “Dr.Md.Abul Kalam Azad” (Project Supervisor) Department of Textile engineering,

Southeast University for his constant encouragement and inspiring guidance with his

Wisdom.

We also take the opportunity to express our sincerest gratitude to the management,

administration & personnel of Standard Group & GMS Composite Knitting Ind. Ltd. for their

kind assistance.

We would like to express our depest appreciation, sincerest gratitude to our respected teacher

Professor Syed Fakhrul Hasan, Chairman, Department of textile Engineering, SEU, A.N.M.

Ahmed Ullah, Coordinator, Department ofTextile Enginering, SEU.Adnan Zaber Mahamud,

Assistant Professor, SEU and all other honourable teacher of Textile engineering

Department,SEU.

Cordial thanks goes to Engr.Liton General Manager(Dyeing) & Abu Jafor (AGM) GMS

Composite Knitting Ind. Ltd & Standard Group Ltd. for their excellent co-operation during

the period of our training. We would also like to thank Engr. Sumon (Dyeing Manager) knit

dyeing section and Engr. Saiful (Sr. Production Officer) of knit fabric section for their sincere

support.

Above all, we would like to acknowledge our deep debt to all teachers of our university &

particularly of Wet Processing Department for their kind inspiration & help, which remain as

the backdrop of all our efforts.

Finally, we would like to acknowledge that we remain responsible for the in-adequacies &

errors, which doubtless remain in the following report.



Contents

CHAPTER – I..........................................................................................................6

Introduction............................................................................................................6

Introduction............................................................................................................7

Factory description:..........................................................................................7

Standard Group........................................................................................7

GMS Composite Knitting Ind. Ltd.............................................................8

Factory Profile...................................................................................................8

Standard Group Ltd..................................................................................8

Management Organ gram...............................................................................12

Project Description..........................................................................................14

Maintenance Definition:..........................................................................14

Objectives of Maintenance.....................................................................14

Types of Maintenance............................................................................14

CHAPTER – II.......................................................................................................19

Background..........................................................................................................19

Background..........................................................................................................20

CHAPTER – III......................................................................................................21

Methodology........................................................................................................21

Methodology........................................................................................................22

Sections considered in the factory where maintenance is done:....................22

Machine’s of the different sections:.................................................................23

Sample section.......................................................................................23

CAD section....................................................................................................24

Spreading section...................................................................................24

Cutting section:.......................................................................................24

Fabric Cutting:........................................................................................25

Sewing section.......................................................................................26

Maintenance Schedule of Different parts of a sewing m/c[single needle]:......28

Different parts of sewing m/c[over lock]:.........................................................30

Practical Procedure:.......................................................................................31

To Maintain Machine Trouble Free:................................................................31

Maintenance of different m/c:..........................................................................32



For Plain Machine:.................................................................................32

Over Lock Machine:...............................................................................32

For Button Attaching Machine:...............................................................32

Button Holing Machine :.........................................................................33

Bartake Machine:...................................................................................33

Shortly Maintenance Schedule of m/c:...........................................................34

GENERAL CLEANING...................................................................................34

Unplug Your Machine.............................................................................36

Remove Lint...........................................................................................36

Sewing Machine Oil................................................................................36

Loose Screws.........................................................................................37

Wires 37

Breaking Needles...................................................................................37

Fabric Won't Feed Properly....................................................................37

Skipped Stitches.....................................................................................37

Thread Nest forms on the bottom...........................................................38

Maintenance system and Troubleshooting :.....................................................38

Maintenance:..................................................................................................38

Trouble Shooting:...........................................................................................38

Sample of a Preventive Maintenance Card:...................................................40

CHAPTER – IV......................................................................................................48

Result....................................................................................................................48

Result....................................................................................................................49

CHAPTER – V.......................................................................................................50

Conclusion...........................................................................................................50

Conclusion...........................................................................................................51

Remarks...............................................................................................................52



CHAPTER – I

Introduction

Introduction Factory description:



Standard GroupStandard Group is a readymade garments type. All kinds of woven products for man, women, boy s, girls & kids and all types of casual outerwear, bottoms & causal tops, printing, quilting, embroidery, washing, sand blasting.

It established at May 1984. Standard Group is one of the pioneer personalized and profes-sional skill garments manufacturing, construction, insurance, banking, trading, establishment. Standard trade area journey in 1969 in the field of construction and later in 1984 expression of business activities into Global linked garments manufacturing credits facilities emergent exposes of a giant complete garments manufacturing solution.

Manufacturer and exporter of all kinds of woven garments for man, women, boy s, girls & kids – spring and fall jacket, winter coat, shirts, shorts, trouser, skirt, down jacket & vest, short all, overall & dresses.

To maintain garments quality level foreign technician are engaged, 1.5-4.0 AQL system been followed, 100% garments inspected in finishing section and garments pass trough needle de-tector machine to metal free protective zone to ensure free from metal hazardous. High tech machinery for consistent quality and timely deliver, CAD and digitizing for design, pattern grading, marker making, computerized machine within sewing lines, GARBER machine to co-operation with modern technology and attend efficiency in quality.

Washing plant covering all kind of washing facility is like Enzyme wash, Silicon wash, En-zyme-silicon wash, Bleach wash, Stone wash, Sand blasting, Laser blasting along with tint-ing. Synchronous with growing business volume in our house facility been enriched with fa-cility in 1994 which covering up to 15 color beside, with the average factory growth rate 3.85 garments manufacturing unit strength reached at total of 14 no in 1990 and within the span of time of time by 2000 increasing customer demand against our reliable quality concern and ex-cellent service reputation put us to be a creatable factory strength of 25 no unit under standard family umbrella.

Over the years rolling growth rate helped accelerate building couple of our own factory premises at deferent location of the country’s capital mega city around 2 storied building at Tejgan 1991, 20 storied balding at Kalshi, 20 storied building at Mohakhali in 2003.

Standard sourcing office4 operating in Hong Kong to have a better grip and control on quality level in the far east region in addition to facilitate faster response from mills. In year 2003 in-clusion of new sweater factory with about 940 machines put Standard Group Garments divi-sion advancement entry to a new area sweater and knit garments field.

Nevertheless, Sandard Goup not only cares garments manufacturing but also keeping foot print in construction, Insurance, Banking and Trading sector.



In the name of civil engineering Ltd. a construction division made accredited achievement in capital mega city architectural multi storied high rise facilities, Convocation hall, Indoor sta-dium, 500 bed hospital, countries biggest power generation station, Bimen bhaban, TV sta-tion, national university, diabetic hospital.

GMS Composite Knitting Ind. Ltd.

GMS Composite Knitting Ind. Ltd. is a readymade Knit garments type. All kinds of knit prod-ucts for man, women, boy s, girls & kids and all types of casual outerwear, bottoms & causal tops, printing, quilting, embroidery, washing, sand blasting.

It incorporation in 1999 and successfully went for production in 2000. Manufacturer and ex-porter of all kinds of knit garments for man, women, boy s, girls & kids – spring and fall jacket, winter coat, shirts, shorts, trouser, skirt, down jacket & vest, short all, overall & dresses.

To maintain garments quality level foreign technician are engaged, 1.5-4.0 AQL system been followed, 100% garments inspected in finishing section and garments pass trough needle de-tector machine to metal free protective zone to ensure free from metal hazardous. High tech machinery for consistent quality and timely deliver, CAD and digitizing for design, pattern grading, marker making, computerized machine within sewing lines, GARBER machine to co-operation with modern technology and attend efficiency in quality.

Washing plant covering all kind of washing facility is like Enzyme wash, Silicon wash, En-zyme-silicon wash, Bleach wash, Stone wash, Sand blasting, Laser blasting along with tint-ing. Synchronous with growing business volume in our house facility been enriched with fa-cility in 2007 which covering up to 15 color.

Factory ProfileStandard Group Ltd.

Company Name : STANDARD GROUP TLD LTDStatus : Private Ltd. CompanyType & Business of the company : 100% Export oriented garments factory & Exporter.Factory Location : Kalshi, Mirpur-11,DhakaHead Office : Plot No. 389 Lane No:6,DOHS, Baridhara, DhakaSponsors : STANDARD GROUP TLD of company LTD…Year of Establishment : May 1984Project Investment : $ 2.00 MillionAnnual Turnover : $ 5.00 Million.Factory Floor Space : 126,000 sft



Factory Equipments : Different types of Cutting, Sewing, Finishing and Gen-erator machines supplied by mostly Japan, Taiwan, EU, USA, Singapore, China, etc.

Total Manpower : Total Cutting machine :Total Sewing machine :Total washing machine :Main Production : woven garments for man, women, boy s, girls & kids

– spring and fall jacket, winter coat, shirts, shorts, trouser, skirt, downjacket & vest, short all, overall & dresses.

Production Capacity : 4000 pcs/day (Average)Buyers : GAP, BIMTEX, ANAF, BHS, MILES, LOLL ,TOYS,

GEORGE, IVORYMain Market : EU, UK & Canada.Payment Terms : Confirmed Irrevocable Letter of Credit.Fax Number : + 880 – 2 – 934 –2368E–mail Address : [email protected]

GMS Composite Knitting Ind. Ltd.

Name of the Factory : GMS Composite Knitting Industry Limited

Motto : Striving For Excellence

Type : 100% Export Oriented Composite Knitting Industry

Year of Incorporation : 1999

Year of Starting Production: 2000

Status : Private Limited Company

Investor : Md. Golam Mostafa

Project Cost :

Annual Turnover :

Total Manpower : Around 8500

Address:

Corporate Office : House# 365 (1st Floor), Road# 28,


mailto:%[email protected]


New D.O.H.S., Mohakhali,

Dhaka-1207, Bangladesh

Telephone: +88-02-8837037-8

Fax: +88-02-8711095

E-mail: [email protected]

Factory Address : Shardaganj, Kasimpur, Gazipur

Telephone: +88-02-7788951-3

Fax: +88-02-7788934

Official Website : http://www.gmsbd.com

Production Capacity:

Knitting : Approximately 29 Tons/Day

Dyeing : Approximately 25 Tons/Day

Yarn Dyeing : Approximately 10 Tons/Day

Garments : Approximately 1,20,000 Pieces/Day.

Major Departments of the Factory:

Human Resource & Administration

Marketing & Merchandising

Knitting

Dyeing & Finishing

Yarn Dyeing

Garments

Quality Assurance

Technical Department

Printing

End Products: All kinds of Gents, Ladies & Kids Knitwear especially, T-shirt, Polo shirt,

Sweat shirt, Tank Top, Trousers etc.

Certificates & Awards:

Oeko-Tex

WRAP(Worldwide Responsible Apparel Production)


http://www.gmsbd.com/

Managing Director

Director. Admin, HR & MM

Admin, HR & Compliance Store


BSCI(Business Social Compliance Initiative)

Best Effluent Treatment Plant of the Year, 2010.

Other Facilities:

Full time Doctor & Nurse for emergency treatment & Preventive medical facility for

officials and workers.

Stuff canteen as in-house facility of lunch & snacks.

Complimentary bus service for the workers who are living 5 K.M. away of the fac-

tory.

Child care centre and mosque inside the factory.

Two times bonus and attendance award to increase workers diversity.

Committee of workers to maintain strong relationship with top management to full-fill

demands.

Project Area : 2,90,000 square foot.

Floor Plans:

Knitting : 40,000 square foot

Dyeing : 30,000 square foot

Finishing : 20,000 square foot

Garments : 90,000 square foot

Store : 60,000 square foot

Utility : 40,000 square foot

Office & Others : 10,000 square foot

Physical Infrastructure: Four seven stored building, 15 single stored building. All of them

are made of bricks.

Location: GMS Composite Knitting Ind. Ltd. is situated at Shardaganj, Kasimp ur, Gazipur.

It is located at the eastern side of the Dhaka-Tangail Highway. It is about 40 K.M. from

Dhaka.

Management Organ gram


Admin, HR & Compliance

Administration Human Resource Compliance

DGM

AGM

DGM

AGM

DGM

AGM

GM




Project Description

Maintenance Definition:British Standard Glossary of terms (3811:1993) defined maintenance as:



‘‘The combination of all technical and administrative actions, including supervi-sion actions, intended to retain an item in, or restore it to, a state in which it can perform a required function.’’ ‘‘Maintenance is a set of organized activities that are carried out in order to keep an item in its best operational condition with minimum cost acquired.’’

Objectives of Maintenance

Maintenance objectives should be consistent with and subordinate to production goals. The relation between maintenance objectives and production goals is reflected in the action of keeping production machines and facilities in the best possible condition.

Maximising production or increasing facilities availability at the lowest cost and at the highest quality and safety standards.

Reducing breakdowns and emergency shutdowns.

Optimising resources utilisation.

Reducing downtime.

Improving spares stock control.

Improving equipment efficiency and reducing scrap rate.

Minimising energy usage.

Optimising the useful life of equipment.

Providing reliable cost and budgetary control.

Identifying and implementing cost reductions.

Types of Maintenance

1. Run to Failure Maintenance (RTF)

2. Preventive Maintenance (PM)

3. Corrective Maintenance (CM)

4. Improvement Maintenance (IM)

5. Predictive Maintenance (PDM)

Run to Failure Maintenance (RTF)The required repair, replacement, or restore action performed on a machine or a facility after the occurrence of a failure in order to bring this machine or facility to at least its minimum ac-ceptable condition. It is the oldest type of maintenance. It is subdivided into two types:



Emergency maintenance: it is carried out as fast as possible in order to bring a failed ma-chine or facility to a safe and operationally efficient condition.

Breakdown maintenance: it is performed after the occurrence of an advanced considered failure for which advanced provision has been made in the form of repair method, spares, ma-terials, labor and equipment.

Disadvantages: Its activities are expensive in terms of both direct and indirect cost. Using this type of mainte-nance, the occurrence of a failure in a component can cause failures in other components in the same equipment, which leads to low production availability. Its activities are very difficult to plan and schedule in advance. This type of maintenance is useful in the following situa-tions:

The failure of a component in a system is unpredictable.

The cost of performing run to failure maintenance activities is lower than performing other activities of other types of maintenance.

The equipment failure priority is too low in order to include the activities of prevent-ing it within the planned maintenance budget.

Preventive Maintenance (PM)It is a set of activities that are performed on plant equipment, machinery, and systems before the occurrence of a failure in order to protect them and to prevent or eliminate any degrada-tion in their operating conditions. British Standard 3811:1993 Glossary of terms defined preventive maintenance as:‘‘The maintenance carried out at predetermined intervals or according to prescribed criteria and intended to reduce the probability of failure or the degradation of the functioning and the effects limited.’’Advantages:

The factors that affect the efficiency of this type of maintenance:

The need for an adequate number of staff in the maintenance department in order to perform this type of maintenance.

The right choice of production equipment and machinery that is suitable for the work-ing environment and that can tolerate the workload of this environment.

The required staff qualifications and skills, which can be gained through training.

The support and commitment from executive management to the PM programme.

The proper planning and scheduling of PM programme.

The ability to properly apply the PM programme.

It is good for those machines and facilities which their failure would cause serious production losses.



Its aim is to maintain machines and facilities in such a condition that breakdowns and emer-gency repairs are minimized. Its activities include replacements, adjustments, major over-hauls, inspections and lubrications.

1. Opportunity maintenance

which is a set of maintenance activities that are performed on a machine or a facility when an unplanned opportunity exists during the period of performing planned maintenance activities to other machines or facilities.

2. Window maintenance

which is a set of activities that are carried out when a machine or equipment is not required for a definite period of time.Corrective Maintenance (CM) In this type, actions such as repair, replacement, or restore will be carried out after the occur-rence of a failure in order to eliminate the source of this failure or reduce the frequency of its occurrence. In the British Standard 3811:1993 Glossary of terms, corrective maintenance is defined as:‘‘The maintenance carried out after recognition and intended to put an item into a state in which it can perform a required function.’’ This type of maintenance is subdivided into three types:

1. Remedial maintenance

which is a set of activities that are performed to eliminate the source of failure without inter-rupting the continuity of the production process.The way to carry out this type of corrective maintenance is by taking the item to be corrected out of the production line and replacing it with reconditioned item or transferring its workload to its redundancy.

2. Deferred maintenance

which is a set of corrective maintenance activities that are not immediately initiated after the occurrence of a failure but are delayed in such a way that will not affect the production process.

3. Shutdown corrective maintenance

which is a set of corrective maintenance activities that are performed when the production line is in total stoppage situation.

The main objectives of corrective maintenance are the maximization of the effectiveness of all critical plant systems, the elimination of breakdowns, the elimination of unnecessary re-pair, and the reduction of the deviations from optimum operating conditions. The difference between corrective maintenance and preventive maintenance is that for the corrective maintenance, the failure should occur before any corrective action is taken.



Corrective maintenance is different from run to failure maintenance in that its activities are planned and regularly taken out to keep plant’s machines and equipment in optimum operat-ing condition. Improvement Maintenance (IM)It aims at reducing or eliminating entirely the need for maintenance. This type of maintenance is subdivided into three types as follows:

1. Design-out maintenance

which is a set of activities that are used to eliminate the cause of maintenance, simplify main-tenance tasks, or raise machine performance from the maintenance point of view by redesign-ing those machines and facilities which are vulnerable to frequent occurrence of failure and their long term repair or replacement cost is very expensive.

2. Engineering services

which includes construction and construction modification, removal and installation, and re-arrangement of facilities.

3. Shutdown improvement maintenance

which is a set of improvement maintenance activities that are performed while the production line is in a complete stoppage situation.

Predictive Maintenance (PDM)Predictive maintenance is a set of activities that detect changes in the physical condition of equipment (signs of failure) in order to carry out the appropriate maintenance work for maxi-mizing the service life of equipment without increasing the risk of failure.It is classified into two kinds according to the methods of detecting the signs of failure:

1. Condition-based predictive maintenance

2. Statistical-based predictive maintenance

Condition-based predictive maintenance depends on continuous or periodic condition mon-itoring equipment to detect the signs of failure. Statistical-based predictive maintenance depends on statistical data from the meticulous recording of the stoppages of the in-plant items and components in order to develop models for predicting failures. The drawback of predictive maintenance is that it depends heavily on information and the correct interpretation of the information. Some researchers classified predictive maintenance as a type of preventive maintenance.The main difference between preventive maintenance and predictive maintenance is that predictive maintenance uses monitoring the condition of machines or equipment to determine the actual mean time to failure whereas preventive maintenance depends on industrial average life statistics.





CHAPTER – II

Background



Background In the period of pre-World War II, people thought of maintenance as an added cost to the plant which did not increase the value of finished product. Therefore, the maintenance at that era was restricted to fixing the unit when it breaks because it was the cheapest alternative. During and after World War II at the time when the advances of engineering and scientific technology developed, people developed other types of maintenance, which were much cheaper such as preventive maintenance.In addition, people in this era classified maintenance as a function of the production system. Nowadays, increased awareness of such issues as environment safety, quality of product and services makes maintenance one of the most important functions that contribute to the success of the industry. World-class companies are in Continuous need of a very well organized Maintenance pro-gram to compete world-wide. The subject textile engineering in recently developed Bangladesh. People are taking interest about the garments factory. Previously the higher educated persons are not interested in the garments to do their job. So people are not done thesis or any analytical object on that subject or in garments factory. We don’t get so much help on our topics, we find a thesis on ‘‘ Effect of Maintenance on Production’’ done by the faculty of BUET, and our senior student of our previous batch.From their thesis we get help, we get ideas to complete our project.



CHAPTER – III

Methodology



Methodology

Sections considered in the factory where maintenance is done:

A) Sample sectionB) CAD sectionC) Spreading sectionD) Cutting sectionE) Sewing sectionF) Finishing sectionG) Others

Above section maintenance are done by specific tools those tools are required to mainte-nance are give below:



1.1.1.1

No

1.1.1.2 E

q

u

i

p

m

e

n

t

N

a

m

e

Function

1.1.1.3

01

1.1.1.4 C

o

m

b

i

n

a

t

i

o

n

t

o

o

1.1.1.5 Tightening & loos-

ening of nuts &

bolts.



l

s

/

s

p

a

n

n

e

r



1.1.1.6

02

1.1.1.7 S

o

c

k

e

t

r

a

t

c

h

e

t

s

e

t

1.1.1.8 Tightening of nuts &

bolts.

1.1.1.9

03

1.1.1.10 S

l

i

d

e

r

a

n

g

e


ening of nuts &

bolts.



1.1.1.12

04

1.1.1.13 M

o

n

k

e

y

p

l

i

e

r

s


ening of nuts &

bolts.

1.1.1.15

05

1.1.1.16 P

i

p

e

t

h

r

e

a

t

c

u

t

t

1.1.1.17 To cut the threat in

pipe.



i

n

g

t

o

o

l

s



1.1.1.18

06

1.1.1.19 B

e

a

r

i

n

g

p

u

l

l

e

r

1.1.1.20 To assist the open-

ing of bearing from

shaft.

1.1.1.21

07

1.1.1.22 P

i

p

e

r

a

n

g

e


ening of pipe joint.

1.1.1.24

08

1.1.1.25 P

i

p

e

1.1.1.26 For pipe cutting



c

u

t

t

i

n

g

t

o

o

l

s



1.1.1.27

09

1.1.1.28 H

o

l

e

p

u

n

c

h

1.1.1.29 Punching the hole.

1.1.1.30

10

1.1.1.31 D

i

v

i

d

e

r

1.1.1.32 For circle marking

on metal & wood.

1.1.1.33

11

1.1.1.34 E

a

s

y

o

p

e

n

e

r

1.1.1.35 To open the broken

head bolt.

1.1.1.36 1.1.1.37 E 1.1.1.38 For external threat



12 x

t

e

r

n

a

l

t

h

r

e

a

t

d

i

e

cutting.

1.1.1.39

13

1.1.1.40 H

e

a

v

y

s

c

i

s

s

1.1.1.41 Cutting of gasket &

steel sheet.



o

r



1.1.1.42

14

1.1.1.43 O

i

l

c

a

n

1.1.1.44 Oiling of moving

parts.

1.1.1.45

15

1.1.1.46 D

r

i

l

l

m

a

c

h

i

n

e

a

n

d

d

r

i

l

1.1.1.47 For drilling.



l

b

i

t

.



1.1.1.48

16

1.1.1.49 G

r

e

a

s

e

g

u

n

1.1.1.50 For greasing of mov-

ing parts of m/c.

1.1.1.51

17

1.1.1.52 G

r

i

n

d

i

n

g

m

/

c

1.1.1.53 For grinding & cut-

ting of mild steel

1.1.1.54

18

1.1.1.55 W

e

l

d

i

n

g

1.1.1.56 For welding & cut-

ting.



m

/

c



1.1.1.57

19

1.1.1.58 S

p

i

r

i

t

l

e

v

e

l

e

r

1.1.1.59 For perfect leveling

1.1.1.60

20

1.1.1.61 F

i

l

e

1.1.1.62 For smoothing the

surface.

1.1.1.63

21

1.1.1.64 H

a

m

m

e

r

1.1.1.65 For scaling & right

angling.

1.1.1.66

22

1.1.1.67 C

i

r

c

l

Circlip opening & closing.



i

p

t

o

o

l

s

1.1.1.68

23

1.1.1.69 H

a

c

k

s

a

w

b

l

a

d

e

1.1.1.70 For metal cutting.

Table 01: Machine Maintenance require tools for garments section.

Machine’s of the different sections: Sample section

It is the first section of garment manufacturing process. This section is used in apparel indus-try for-

a)To make sample garment for approval.


http://textilestudy.com/what-is-textiles-do-you-know.html


b)To make pattern sets for bulk production when needed.

Section Type of machine Quantity

Sam

ple

Sec

tion

Single needle 150Double needle 25Over Lock 22Kansai 10Bar Tack 15Button Stitch 12Button Hole 12Eyelet Button Hole 10Button Hem 05Flat Lock 15Snap Button Attach 05Blind Stitch 07Cutter M/C 70Heat Cutter 2Over Lock Elastic Attaching 1Arm Hole Sewing M/C 1

Table 02: Machine description of Sample Section

CAD sectionSample section givens pattern and CAD section done Marker according to follow shrinkage percentage .Marker length should be bigger than fabric length.


CA

D S

ecti

on

Gerber CAD 15Gerber Plotter 02Gerber Digitizer 01

Table 03: Machine description of CAD Section

Spreading sectionA. Automatic Spreading Machine

To achieve tension free in spreading, stretch out the fabric smooth, regular and ship-shape. Machine Type : Cloth Cutting Machine Supplier : New Sheng Ling Industrial Co., LTD. Manufacturer: Taiwan

B. Semi Automatic Fabric Spreading Machine Semi automatic spreading machine with one way, zigzag or tubular Machine Type : Cloth Cutting Machine



Supplier : Serkon Textile Machinery Manufacturer : Turkey

A. Fully Automatic Spreader Machine Type : Cloth Cutting Machine Supplier : RICHPEACE GROUP CO LTD Manufacturer : Hong Kong


Spr

eadi

ng S

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Gerber auto Spreader 02Manual spreader table 09Manual spreading m/c 07Light box 09

Table 03: Machine description of Spreading Section.

Cutting section:

It is the second section of apparel manufacturing. In this section the following works are com-pleted-

a)Marker Makingb)Fabric Spreadingc)Fabric Cutting

Fabric Cutting:

The definition of cutting is very complex. In garments industries fabric is cut from lay & spreading with accuracy & properly which is termed as fabric cutting. Marker outline is used to cut the fabric. Fabric cutting is very important as if some thing is cut in wrong way, cannot be rectified.

Requirements of cutting:

Precision in cut

Clean edge

Infused edge

Consistency in cutting


http://textilestudy.com/what-is-textiles-do-you-know.html


Support of lay

Methods of fabric cutting:There are mainly three methods of cutting are as follows:

1. Manual:

Hand operated scissor

2. Manually operated power knife:

Straight knife

Band knife

Round knife

Die cutting

Notches

Drill

3. Computerized:

Knife

Laser

Water

Plasma torch




Cut

ting

Sec

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Fabric Inspection m/c 02Light box 09Gerber Cam 02Manual Cutter 09Manual cutting m/c 09

Table 01: Machine description of Cutting section

Parts NameMaintenance doneDaily Weekly Monthly Half yearly Yearly

Motor --- Done --- --- ---Knife Done --- --- --- ---Sharpener Done Done Done --- ---Knife Guard Done --- Done --- ---Handle Done --- --- --- ---Switch --- Done --- --- ---

Sewing section

Sewing is the craft of fastening or attaching objects using stitches made with a needle and thread. Sewing is one of the oldest of the textile arts, arising in the Paleolithic era. Before the discovery of spinning yarn or weaving fabric, archaeologists believe Stone Age people across Europe and Asia sewed fur and skin clothing using bone, antler or ivory needles and "thread" made of various animal body parts including sinew, catgut, and veins .

Most sewing in the industrial work is done by machine. Pieces of a garments are often first tack together. The Machine has a complex set of gears and arms that pierces thread through the layers of the cloth and semi-securely interlock the thread. Mainly Garment’s cut parts are assembled here.

Figure : Sewing Section


Sew

ing

Sec

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1-Needle Lock Stitch 4101-Needle China Stitch, Flatbed 18Vertical Trimmer 202-Needle Lock Stitch 82-Needle Chain Stitch, Flatbed 20


http://en.wikipedia.org/wiki/Vein

http://en.wikipedia.org/wiki/Catgut

http://en.wikipedia.org/wiki/Tendon

http://en.wikipedia.org/wiki/Ivory

http://en.wikipedia.org/wiki/Antler

http://en.wikipedia.org/wiki/Bone

http://en.wikipedia.org/wiki/Clothing

http://en.wikipedia.org/wiki/Leather

http://en.wikipedia.org/wiki/Fur

http://en.wikipedia.org/wiki/Archaeology

http://en.wikipedia.org/wiki/Textiles

http://en.wikipedia.org/wiki/Weaving

http://en.wikipedia.org/wiki/Spinning_(textiles)

http://en.wikipedia.org/wiki/Paleolithic

http://en.wikipedia.org/wiki/Textile_arts

http://en.wikipedia.org/wiki/Yarn

http://en.wikipedia.org/wiki/Sewing_needle

http://en.wikipedia.org/wiki/Stitch_(textile_arts)

http://en.wikipedia.org/wiki/Craft


Multi Needle Chain Stitch 124-Thread Over Lock 1802-Needle Piping 16Zig-Zag M/C[Computerized] 6Bartack M/C[Computerized] 24Button Hole M/C[Computerized] 24Button Sewing M/C[Computerized] 24Rib Cutting M/C 18Blind Stitch[Overlock] 6Heat Transfer M/C 18Snap Button 18Fusing M/C 18Rib Cutting M/C 18Blind Stitch[Overlock] 6Heat Transfer M/C 18Snap Button 18Fusing M/C 18

Table 01: Machine description of Sewing Section

Maintenance Schedule of Different parts of a sewing m/c[single needle]:

Parts Name PictureThread stand

Thread clamp

Thread retainer



Thread up-lever guide

Tension disk

Pressure screw

Pressure bar

Hand lifter

Needle clamp

Needle

Needle plant

Feed dog

SPI adjust

Reverse lever

Bobbin wilder



Pulley

Oil sight wilder

Pulley belt cover

Leg lifter

Foot

Safety guide

Motor

Different parts of sewing m/c[over lock]:

Parts Name

Thread stand

Thread retainer

Thread guide

Pressure screw



Pressure bar

Pressure spring

Upper & lower lopper

Needle clamp

Needle

Needle plant

Feed dog

Pulley

Oil sight wilder

Pulley belt cover

Leg lifter

Safety guide



Motor

All sewing machines need basic lubrication maintenance to keep them running over the months and years.

1. Oil your sewing machine after every 9-10 hours of stitching work. I do the same with my Singer machine and it keeps it in good working condition.

2. Remember that sewing machine oil is clear white and may be different for your particular brand. Use just a drop of oil in each location to lubricate the moving parts and prevent rust.

3. After oiling, run a few stitches on disposable fabric to let any excess oil run out and settle.

Practical Procedure:

Here standard system is to service a machine once per 15 days. But it is done once per month.Some machine needed to oil in oil tank. In that case. A pump once per two month changes oil.Machine that have rotary hook are oiled once per week. At first the service system of machine is written on the machine log card with machine remarks and next schedule.

To Maintain Machine Trouble Free:

The following instruction must be carried out to secure the utmost in production and to the prolong the life of your machine-Before morning starts,

To oil every moving parts with one or two drops of oil

To check whether needle is correctly set or not damage.

To check whether threading is correct.

To check whether chaining thread of approximately 10 mm long remain behind pres-

sure foot.

Maintenance of different m/c:

For Plain Machine:Changing over the specified voltage and changing the fuse be sure to turn off the power to the power to the machine before starting the procedure Insert a slotted screwdriver into the slot of change over the voltage and set the voltage to a desired voltage. Set the operation voltage to the position with mark.

Replacing the fuse:



Be sure to turn off the power to the machine before starting the procedure starting the proce-dure and remove the cap from the fuse holder. Then, take out the fuse and replace it with a new one.

Over Lock Machine:

To protect against possible personal injury due to abrupt start of the machines, be sure to start the work after turning the power off and ascertaining that the motor is at rest.

Position of the needle thread take up and the needle thread eyelet

The needle thread take up shall be positioned at the lower dead pt.

Position of the looper thread take up and the looper thread guide

Checking the cartridge filter and replacing it after a long period of usage, cartridge fil -

ter may become clogged with dust

Insert a cartridge

Remove first oil discharging screw.

Remove screw and lift top cover just above until it comes off .

Dimensions use to adjust the looper and the needle guard

LubricationRemoved the oil cap, Poor juki machine oil 18 into the oil reservoir, supply oil until the pointer bar almost reaches the upper red marker line when oil gauge is observed from the side.

For Button Attaching Machine:

Checking the needle :Always check that the tip of the needle is not broken and also the needle is not bent before starting sewing.Cleaning the rotary hook:The shuttle race cover toward you to open it and then remove the bobbin caseOpen the setting claw in the direction indicated by the arrow and then remove the shuttle race body and the shuttle hook.Clean all the dust and thread ends from around the driver, the top of the rotary hook thread guide and the shuttle race.

Lubrication:

Fill the arm side oil tank with oil, Fill the bed side oil tank with oil,Add oil to the felt of the shuttle race base.When setting up the sewing machine and when it hasn’t been used foe asn extended period of time, be sure to add 2-3 drop oil to the felt, If using the liquid cooling tank, fill it with silicon oil.

Button Holing Machine :

Turn off the power switch before carrying out cleaning; otherwise the machine may operate if the treadle is depressed by mistake, which could result in injury. Be sure to wear protective goggles and gloves when handling the lubricating oil and grease so that they do not get into



your eyes or onto your skin otherwise inflammation can result. Furthermore do not drink the oil or eat the grease under any circumstances as thy can cause vomiting and diarrhea, keep the oil our of the reach of children.

Cleaning:

Remove lint and dust from the thread passages

Remove lint and dust form around the work clamp

Remove the bobbin case and remove lint and dust from around the lower thread trim-

mer mechanism.

Bartake Machine:

Maintenance of bar take machine

Adjust the height of the needle bar

Adjusting the needle to shuttle relation

Adjusting the lift of the work clamp foot

Adjusting the rising amount of the thread tension dist

The moving knife and counter knife

Cleaning the filter

Draining waist oil

Replacing the fuse

Shortly Maintenance Schedule of m/c:

SectionMaintenance doneDaily Weekly Monthly Half yearly Yearly

Sample section --- Done --- --- ---CAD section --- --- Done --- ---Spreading section --- Done Done --- ---Cutting section Done --- --- --- ---Sewing section Done --- --- --- ---Finishing section --- Done --- --- ---

GENERAL CLEANING

As you clean the machine, it is best to clean one area at a time. Remove only the parts that are involved and be sure to note where each



part is from, its position, and which side is top.

Remove all the parts possible in order to clean the machine thoroughly. Keep the parts in order to make it easier to replace them.

Upper Thread Tension -- Pull a piece of cloth soaked in solvent back and forth between discs to clean


Bobbin Area -- If possible, remove the bobbin case to remove all lint and stray threads.


Don't forget to clean inside the bobbin case. Using compressed air, which has a straw (shown in red above) to direct air to a desired spot, blow out lint and loose threads.

Use a soft piece of muslin with a dot of sewing machine oil to clean the race hook. If the hook is removable, place a drop of oil on it before returning it to the machine.

Unplug Your Machine

For your own safety and to prevent damage to your machine always unplug the ma-chine before you start cleaning and oiling your machine.


Fold a piece of muslin in half, and use the folded edge to clean between tension disks.


Remove Lint

Fabric and thread are a combination that is going to produce lint. Lint can build up in unseen areas of your machine leading to wear and tear that is preventable.

Open all areas that you can and clean the lint out of the machine. Use the brush that came with your sewing machine to remove lint in cracks and crevices and from under the bobbin case.

Try to get in the habit of cleaning the lint out of your machine every time you finish a project. That way the machine will be ready to sew when you are!

Sewing Machine Oil

Sewing machine oil is not something you borrow from the garage. It is clear white oil. Be sure to use the proper oil. Refer to your owner’s manual for the proper spots to oil. Some of the older machines have these areas marked.

After oiling your machine run stitches on some scrap fabric before you tackle your project. This allows oil to escape on to the scraps, if it's going to, instead of the project you are working on.

Oiling the machine not only lubricates your moving parts, to prevent wear, it reduces the risk of rust. Rust forms rapidly with any dampness, even just the humidity in the air. Surface rust can act just like loose sand granule in your machine, and create ex-cess wear.

Loose Screws

As you clean and oil the machine you will find many screws and set-screws. As a gen-eral rule, tighten regular screws as you run across them. Set screws which usually re-quire hex key wrenches, should only be adjusted by a repair person unless you have a complete understanding of the timing of your sewing machine.

If the set screws are missing or loose, take the machine to a repair shop. It may seem easy to just replace the screw or tighten it, but all of these details go in to the timing of the machine. If the timing is off you can do great damage and the repair bill will be much more then a tune up.

Wires

You should always be watching for wear signs on wires but while you’re cleaning your machine, take the time to honestly inspect the wires.

Check the entire length of the wire for abrasions to the plastic coating or for damage a pet may have done.

Check that all the electrical prongs are tight and secure. Consult a repair person or electrician for any problems you may find.

Breaking Needles

Properly insert a new needle. Your needle may have broken because it was defective. Make sure the needle you are using is appropriate for the thickness and density of the

fabric you are sewing on. A dense, high thread count fabric like a batik or pima cotton calls for a Microtex Sharp needle.



Don't pull your fabric as you sew. It is common for new free motion quilters to pull on the fabric when they are learning to quilt. This bends the needle and it breaks when it hits the throat plate.

Check for a proper tension setting. Is your needle in the proper position. If you are using a single stitch throat plate the

needle must be in the center position. Is it? Don't sew over pins. If you hit a pin, change the needle. Make sure that the foot, the throat plate and the needle are inserted correctly and tight-

ened appropriately.

Fabric Won't Feed Properly

Make sure your feed dogs are in the “up’ position. Make sure your feed dogs are clean and free of lint and dirt. Check that you are using pressure foot pressure. Have you recently been machine

quilting and removed the pressure? Is your presser foot installed correctly so that it is making contact with the fabric? Is your stitch length set higher than 0? Again, with free motion machine quilting you

may have forgotten to reset your stitch length.

Skipped Stitches

First change to a new needle. Make sure the needle is correctly installed and in good shape – no burrs, not bent, no

nicks. Is there enough pressure on the presser foot? Have you recently reduced the pressure

foot pressure because you were quilting and forgotten to increase it again? Check your needle tension. A too tight tension can cause skipped stitches. Make sure the machine is properly threaded. Is the thread in the take up lever?

Thread Nest forms on the bottom

Re-thread your sewing machine making sure that the thread is in the tension guides, as well as in the take up lever.

Raise your feed dogs if you are piecing and not quilting. Hold the both the bobbin and needle thread tails in your fingers as you begin a line of

stitching. This will keep the tails from tangling on the underside.

Maintenance system and Troubleshooting :

Maintenance:From the above discussion we can write down the basic maintenance are given below:

1. Machine adjustments should only be performed by a qualified technician.2. Check the oil level weekly when the machine is used daily. Add sewing machine oil as re-quired to the high level marking.3. Clean the machine with a clean, damp cloth. Do not use solvents or thinners.4. When not in use, cover the machine and store in a clean and dry location.



Trouble Shooting:

This section contain trouble shooting which can be of help in determining and removing the causes of trouble that may develop in the machine .when the troubles cover by this section de-velop, they can be conveniently tracked down and readily corrected by consulting the follow-ing tabulation:

Symptom Causes Remedy FrequencyNeedle Breakage Needle is loose in needle clamp Tighten needle clamp. Daily or When need

Needle of incorrect class and style is being used.

Compare needle with one of correct type.

Daily or When need

Pressure foot is loose or out of line

Straighten and align presser foot; tighten se-

curely.

Daily or when need

Needle is too light for material being sewn.

Select the correct needle. As per material required.

Operator is pulling the material being sewn.

Do not assist machine in feeding of material.

Daily or When need

Thread Breakage(Needle)

Thread is too heavy for needle for used

Select and inset a thicker needle.

Daily or Weekly

Right twist thread is being used Only left twist thread is to be used.

Weekly

Damp and defective thread is be-ing used

Use new, dry and smooth thread of correct size.

Daily or Monthly

Machine is incorrectly threaded Follow threading dia-gram as shown.

Weekly or Monthly

Needle is incorrect set. Set the needle with the short groove closest to the loop taker (shuttle).

Weekly or Monthly

Upper tension is too tight Adjust for the correct stitch balance.

Daily or When need

Thread take up spring is out of adjustment

Adjust to proper position. Weekly or monthly

Needle is rubbing against pres-sure foot.

Re-align and tighten pressure foot.

Weekly or Monthly

Needle is defective, blunt or bent at point.

Replace with new needle. Weekly or Monthly

Sharp edge on the loop taker (shuttle), bobbin case or tension

controller.

Smooth with fine emery paper and polish with

rouge cloth.

Monthly or Half-yearly

Thread Breakage (Bobbin)

.

Damp o defective thread being used.

Use new, dry and smooth thread of correct size.

Daily or Monthly

Bobbin thread tension is too tight.

Adjust for correct stitch type.

Weekly or Monthly

Bobbin shuttle case is incorrectly threaded.

Follow threading instruc-tion as described.

Weekly or Monthly

Bobbin is wound too full to re-volve freely

Remove excess thread to the rim of the bobbin winder accordingly.

Daily or when need

Round of thread on the bobbin Unwind bobbin manually Monthly



Thread Breakage (Bobbin) Continue

are lapped over one another. and rewind evenly and uniformly.

Bobbin case is sticky with gummy oil and lint.

Clean bobbin case, shut-tle and shuttle race with

kerosene with a few drops of oil.

Daily

Shrap edge on shuttle, bobbin case, bobbin or needle.

Smooth with fine energy paper and polish with

rouge cloth.

Monthly

Skipping(Skip Stitches)

The needle thread fail to catch the bobbin

Reset the needle bar and needle as describe.

Monthly or Yearly

Drawing of seam The thread draw or pucker the seam.

Adjust tensions for cor-rect stitch balance.

Monthly or When Need

Stitches uneven and piled up

Stitch pile up in one place. Adjust stitch regulation for longer stitch.

Monthly or When Need

Sample of a Preventive Maintenance Card:

PREVENTIVE MAINTENANCE CARD

Name Of Machine- Mig Welding Machine Schedule

Machine No.- M.W. - 02 15 days/ Annual

PM to be taken up 1.Open cover &Remove dust by Blower

5.General check-up like bolts cable con-nection

2.Check forHeat-uo Connection6.Annual Maintenance Schedule on revese

3.Measure current in each Phase7.For annual maintenance Schedule on reserve

4.Check rotation ofblower for Smoothness 8

S. N. Due Date Status By Date Remarks

1

2

3

4

5

6

7

8



9

10

11

12 Firstly, all sections of the garments factory have been pointed out for assessment. It is ob-served that the goal of all factory improvement activity is to increase productivity by mini-mizing input and maximizing output. Equipment and machinery are the crucial factors in in-creasing output. Productivity, quality, cost and delivery, as well as safety, hygiene, environ-ment, and morale are all influenced significantly by equipment conditions. The goal of main-tenance management is to enhance equipment effectiveness and maximize output. It strives to attain and maintain optimal equipment conditions in order to event unexpected breakdowns, speed losses, and quality defects in process. Overall efficiency including economic efficiency is achieved by minimizing the cost of upkeep and maintaining optimal equipment conditions throughout the life of equipment. So the steps that were followed are:

Identification of major losses.

Identification of significant losses by Pareto analysis.

Calculation of Overall Equipment Efficiency (OEE).

Reduction of losses with analytical techniques.

Steps in introducing TPM in an organization

Stage A – Preparatory stageStep1: General announcement by management about TPM introductionStep2: Initial education and propaganda for TPMStep3: Setting up TPM and departmental committeesStep4: Establishing the TPM working system and targetStep5: A master plan for institutionalizing

Stage B – Introduction StageStage C – ImplementationStage D – Institutionalizing Stage.

5S(Sort, Systematic, Shine the workplace, Standardization, Self discipline)JISHU HOZEN(Autonomous Maintenance)KOBETSU KAIZEN(Focused Improvement)Planned MaintenanceQuality MaintenanceEducation and TrainingOffice TPMSafety, Health and Environment



Figure 1: Eight pillars of TPMTPM stands on 8 pillars as shown in figure 1. Among these, the third pillar KAIZEN is used in this study. This pillar is aimed at reducing losses in the workplace that affect the efficien-cies. It is possible to eliminate losses in a systematic method using various Kaizen tools such as: PM analysis, Why - Why analysis, Summary of losses, Kaizen register and Kaizen sum-mary sheet. As one of the pillars of TPM activities, Kaizen pursues efficient equipment, oper-ator and material and energy utilization. Kaizen activities try to thoroughly eliminate 16 ma-jor losses shown in Table 1.

Loss Category1. Failure losses-Breakdown loss2. Setup/adjustment loss3. Cutting blade loss4. Minor stoppage5. Speed loss6. Start up loss7. Defect/rework loss8. Scheduled down time loss

Losses that impede equipment efficiency

1. Management loss2. Operating motion loss3. Line organization loss4. Logistics loss5. Measurement loss

Loses that impede human work efficiency

1. Energy loss2. Die, jig and tool breakage loss3. Yield loss

Loses that impede effective use of production resources

Table 1: Sixteen major losses that occur in a factory

MAXIMIZING OVERALL EQUIPMENT EFFICIENCYAfter studying all the sections of the factory, the Sewing section was taken for the Project purpose. There are 4 lines in the Sewing section. The production rate of different lines in Sewing section is considered. Line 5B is considered for identifying and reducing equipment losses to maximize overall equipment efficiency (OEE) by TPM pillar 3- Kobetsu Kaizen (Focused Improvement).IDENTIFYING LOSSES: To identify losses and equipment efficiency, loss data is collected for several machines for 10 days during operation. These data are presented in Table 2. Table 2: loss data for several machines (Ten days)

Day MachineName

Losses Time(min)

01 SingleNeedle

Idling & Minor stoppage(Needle break & Bobbin case)

3+3=6

SingleNeedle

Reduced speed 4

Overlock Idling & Minor stoppage (Falsestitch)

8



Overlock Set up & adjustment 2002 Overlock Idling & Minor stoppage (False

stitch)10

SingleNeedle


3+7+4+4=18

SingleNeedle

Reduced yield 5

TwoNeedle

Breakdown 30

03 Overlock Set up & adjustment 20SingleNeedle

Idling & Minor stoppage(Needle break, Bobbin case &others)

13+4+3=20

04 SingleNeedle


6+4=10

TwoNeedle

Set up & adjustment 30

Overlock Reduced speed 4SingleNeedle

Defects in process 10

05 SingleNeedle


13

06 Overlock Set up & adjustment 20SingleNeedle

Idling & Minor stoppage(Needle break , Bobbin case &others)

12+5+3=20

07 Overlock Idling & Minor stoppage (Falsestitch)

10

SingleNeedle


7+3+4+4=18

SingleNeedle

Reduced yield 4

TwoNeedle

Breakdown 30

08 SingleNeedle


6+4=10

TwoNeedle

Set up & adjustment 35

Overlock Reduced speed 6SingleNeedle

Defects in process 10

09 SingleNeedle


8+5=13

10 Single Idling & Minor stoppage 3+4+3=10



NeedleOverlock Idling & Minor stoppage 8Overlock Set up & adjustment 25

Based on these data, the following 6 major equipment losses are identified in Line 5B: I. Breakdowns due to equipment failure2. Set up and adjustment3. Idling and minor stoppages4. Reduced speed5. Defects in process and rework6. Reduced yield between machine startup and stable production

Identifying Significant Losses:From these 6 major losses the most significant losses are then identified by PARETO analy-sis. The data of PARETO analysis is given in Table 3.

Table 3: Pareto Chart for six major losses

MajorLosses

Time(min)

Composition%

Cumulative%

Idling andminorstoppages

174 41 41

Set up andadjustment

150 35 76

Breakdown 60 14 90Defects inProcess

20 5 95

ReducedSpeed

14 3 68

ReducedYield

9 2 100

Total 427 100

It is seen that the most significant sources of OEE loss are Minor Stoppages and Set up and adjustment. Calculation of OEE: The calculations for Overall Equipment Efficiency (OEE) of the machines having losses are given in Table 4.

Table 4: Calculation for Overall Equipment Efficiency

A Running time per day=60 min*8hrs=480 min

B Down time per day= 20 min

C Loading time per day=A-B=480-20=460 min

D Stoppage losses per day= 174 min/10 days = 17.4min = 18 min



E Operating time per day=C-D= 460-18 = 442 min

F Out put per day=70 pcs/hr * 8 hrs = 560 pcs

G Rate of quality products=(Processed amounts – Defect amount)/Processedamount*100=(560-15)/560*100 = 97.32%

H Ideal cycle time = 30 sec = 0.5 min

I Actual cycle time = 35 sec = 0.58 min

J Actual processing time = I*F = 0.58*640 = 325Min

K Operating speed rate = H/I*100 = (30/35)*100 =85.71%

L Net operating rate = J/E*100 = (325/442) *100 =73.52 %

M Availability = (E/C)*100 = (442/460)*100 =96.08%

N Performance efficiency = K*L*100 = 0.8571 *.7352 * 100 = 63.01%

Now, the target is to increase the OEE from 59% by inimizing the losses. Minimizing the Losses: The basic analytical techniquesused in TPM for improvement are: WWBLA (Why Why Because Logical Analysis) P-M analysis Why-Why analysis Fault tree analysis Failure Mode Effect analysis Pareto analysis SPC etcTable 5: Major Causes of Idling and Minor stoppages

MajorCauses

Time(min)

%Composition

Cumulative%

Needle Break 81 47 47Bobbin Case 56 32 79False Stitch 28 16 95Others 9 5 100Total 174 100

Here, WWBLA is used. WWBLA technique is a worksheet which identifies the root causes of a problem. In this technique, each major problem is considered separately and a worksheet is prepared. For each major problem, a cause is identified and called it first factor for prob-



lem. Then it is verified whether it can be divided into further root causes. If it is possible, then it is marked as G. Here, G stands for Go. Then a second factor for problem is identified and verified. In this way, a third, fourth problems are identified. If it is not possible to identify fur-ther, then verification is marked as NG (Stand for No Go). Finally, countermeasures are iden-tified for each root causes of the problem. Now, from Pareto analysis, it is seen that the two significant losses (Idling &Minor Stoppages and Set up and adjustment) comprise of about 68% of total loss. So, it needs to eliminate these losses first to increase the OEE. The main cause of the most significant loss i.e. Idling & Minor Stoppages, is due to Needle breaking in the machines. It can be easily observed from the Pareto analysis given in Table 5. It is seen that the main cause of idling and minor stoppage is needle breaking. Now, WWBLA tech-nique is used for identifying the countermeasures to reduce the problem of needle breaking. The WWBLA worksheet is given in Table 6. Table 6: Why Why Because Logical Analysis (WWBLA) worksheet

Pro

blem

1st Factor forproblem

Ver

ific

a-ti

on

2nd Factor forproblem

Ver

ific

a-ti

on

3rd Factorfor problem

Ver

ific

a-ti

on

Countermeasures

N

eedl

e B

reak

ing

1. Needle nib hits theneedle plate

G 1.1 Needle platebecomes down

G 1.1.1 Needleplate is notpositionedproperly

NG 1.1.1 Needle plate shouldbe positioned properly atthe beginning ofoperation

2. Needle nib fallswithin the ro-tary hook

G 2.1 Rotary hook isdisplaced2.2 Needle-hooktiming is notmaintained properly

NG 2.1 Rotary hook shouldbe positioned by screwtightening2.2 Rotary hook shouldbe replaced by a new one

3. Pressure guide isDisplaced

G 3.1 Pressure guidebecomes loose

NG 3.1 Pressure guide shouldbe tightened properly

4. Needle safety guideis displaced

G 4.1 Needle safetyguide becomes loose

NG 4.1 Needle safety guideshould be tight-enedproperly

5. Needle quality islow

NG NG 5. Good quality of needleshould be bought andused



Due to the countermeasures found in the WWBLA, the stoppage loss per day reduced to 11 minutes from 18 minutes and consequently output per day increased to 600 pcs. Thus, the OEE is increased which is shown Table 7. Table 7: Revised Calculations for OEE After ReducingStoppage Loss.

A Running time per day=60 min*8hrs=480 min

B Down time per day= 20 min

C Loading time per day=A-B=480-20=460 min

D Stoppage losses per day = 110 min/10 days = 11 min(as the time losses for needle break is eliminated,the stoppage losses time becomes 174 min-64 minof needle break = 110 min )

E Operating time per day=C-D= 460-11=449 min

F Out put per day=75 pcs./hr * 8 hrs =600 pcs

G Rate of quality products=(Processed amounts – Defect amount)/Processedamount*100=(600-10)/600*100 = 98.33%

H Idle cycle time = 30 sec

I Actual cycle time = 34 sec = 0.57 min

J Actual processing time = I*F = 0.57 min *600 pcs= 342 min

K Operating speed rate = H/I*100 = (30/34)*100 =88.24%

L Net operating rate = J/E*100 = (342/449) *100 =76.17 %

M Availability = (E/C)*100 = (449/460)*100 =97.60%

N Performance efficiency = K*L*100 = .8824 * .7617* 100 = 67.21%

Overall Equipment Efficiency = M*N*G*100 =.9760 * .6721 * .9833 * 100 = 64.50% = 65 %



CHAPTER – IV

Result



Result The experiment has provided us wide idea regarding the repair. Maintenance, setting and re-placement of different components of textile machines, it has given us a basic knowledge on machine maintenance as a whole. It has also oriented me with different machine tools and their use those are required for the said job. The gathered knowledge will indeed help me in our practical life. I hope to important my learning in the days to come.Trough our experimental work we see that our production efficiency increased from 59% to 65%. so we can say that maintenance increases the overall equipment efficiency thus pro-duction quality, environment, machine life time, worker mind and keep us refresh.All mills have a strong maintenance fitter’s troop to fix up all types problem. Two groups of three shifts obey their duties responsibly and sincerely. With their different tools or equip-ments they perform their duties skillfully.


CHAPTER – V

Conclusion


Conclusion

‘‘Maintenance is a set of organized activities that are carried out in order to keep an item in its best operational condition with minimum cost acquired.’’ The main objectives of the maintenance are to keep the machine in best operational condition and thus increasing the production of any factory by minimizing the losses due to minimizing the ideal condition.

The purpose of our project is indentifying the effect of maintenance. By the project work we have gathered a lot o f knowledge about the maintenance procedure of garments indus-try and its importance.

We specially select the sewing section for our thesis purpose to make proper maintenance to increase the production of any factory thus increases the profit and also increases the ef-ficiency of the machine and worker.

In our thesis paper we have done a calculation of OEE (overall equipment efficiency) with-out maintenance and with proper maintenance. Through the maintenance calculation, we

see that the OEE increase from 59% to 65%.This makes clear concert that if we take proper attention to the maintenance our produc-tion will be raised.

We think further thesis is required as our project work and it will be helpful for the stu-dent and as well as factory people.



[Pick the date]

Remarks

1. M.A.Kashem,Garments and Technology.

2. BUET,Journals of Mechanical Engineering.

3. Phyllis G.Tortora,Textile Terms & Drfination.

4. http://www.google.com

5. http://www.plant-maintenance.com/article/tpm_intro .shtml

6. http://www.plant-maintenance.com/maintenance_article_tpm.stml

7. http://www.findarticles.com/p/article/mi_m3101/is_2_75/

ai_88760478/machinemitenancehistry .jpg

8. http://www.answer.com

GMS Composite Knitting Ind. Ltd. Page 67

http://www.answer.com/

http://www.findarticles.com/p/article/mi_m3101/is_2_75/ai_88760478/machinemitenancehistry.jpg

http://www.findarticles.com/p/article/mi_m3101/is_2_75/ai_88760478/machinemitenancehistry.jpg

http://www.plant-maintenance.com/maintenance_article_tpm.stml

http://www.plant-maintenance.com/article/tpm_intro.shtml

http://www.google.com/

Documents

Effect of Maintenance on Production & Quality