Maintenance Management

Maintenance management is a term used to describe the activities to ensure that the
assets operate at the required state and that maintenance is performed in order to
achieve continuous improvements in reliability, maintainability and availability.
Maintenance management as: all activities of the management that determine the
maintenance objectives, strategies and responsibilities, and implementation of them
by such means as maintenance planning, maintenance control, and the
improvement of maintenance activities and economics . Maintenance management
can be done in three different:

The first level is dealing with the formulation of the maintenance strategy so
that is consistent with the other business strategies within the company.
The second level is planning and schedule maintenance in order to ensure
efficient maintenance operations.
The third level is related to the execution and collection of data from the
maintenance actions. As maintenance has been an increasingly important
discipline the last decades, improvement of the maintenance management
have been the focus of attention.

Types of maintenance
Traditionally, 5 types of maintenance have been distinguished, which are
differentiated by the nature of the tasks that they include:

Corrective maintenance: The set of tasks is destined to correct the defects

to be found in the different equipment and that are communicated to the
maintenance department by users of the same equipment.

Preventive Maintenance: Its mission is to maintain a level of certain service

on equipment, programming the interventions of their vulnerabilities in the most
opportune time. It is used to be a systematic character, that is, the equipment is
inspected even if it has not given any symptoms of having a problem.

Predictive Maintenance: It pursues constantly know and report the status

and operational capacity of the installations by knowing the values of certain
variables,which represent such state and operational ability. To apply this
maintenance, it is necessary to identify physical variables (temperature, vibration,
power consumption, etc.). Which variation is indicative of problems that may be
appearing on the equipment. This maintenance it is the most technical, since it
requires advanced technical resources, and at times of strong mathematical,
physical and / or technical knowledge.

Zero Hours Maintenance (Overhaul): The set of tasks whose goal is to

review the equipment at scheduled intervals before appearing any failure, either
when the reliability of the equipment has decreased considerably so it is risky to
make forecasts of production capacity . This review is based on leaving the
equipment to zero hours of operation, that is, as if the equipment were new. These
reviews will replace or repair all items subject to wear. The aim is to ensure, with
high
probability,
a
good
working
time
fixed
in
advance.

Periodic maintenance (Time Based Maintenance TBM): the basic

maintenance of equipment made by the users of it. It consists of a series of
elementary tasks (data collections, visual inspections, cleaning, lubrication,
retightening screws) for which no extensive training is necessary, but perhaps only
a brief training. This type of maintenance is the based on TPM (Total Productive
Maintenance).

Productivity Improvement in a Garment Factory by Preventive

Maintenance
Abstract
The objective of this study was to improved the productivity of a machine unit
were operated in a garment factory. This research by using preventive maintenance
techniques to improve the machine efficient capacity. On the Thai garment factory
almost used weaving machine for traus from raw materials to be finished product for
export to the oversea market. This study focuses on weaving machine to produce
high quality of products. The previous working method obtained 77% of main
problems cause of machine breakdown. This work utilized the preventive
maintenance programs in three months to reduce the wasted time. The implement
was used the maintenance plan in daily, weekly, and monthly, and used the MTBF
index to eliminate the breakdown times. The results from this improvement showed
the increased 11.46% of productivity values or 7,475 yards/month to 8438.75
yards/month, and mean time between failure (MTBF) was increased to 73.99% or
from 62.89 hrs/month to 241.799 hrs/month. The mean time to repair (MTTR) was
decreased from 19.98 hrs/breakdown to 13.38 hrs/breakdown or 33.03% reduction.

Introduction
The competition of businesses and industries in the world markets, there are strong
competitions for survival of businesses, so many businesses and industries must
improve their activities for maintaining their businesses in the competitive world The
garment factory is one of the industries that must be planned to improve the working
process and environment for higher efficiency of production process. Some garment
companies invested in the new weaving machine which was controlled by computer
for increasing productivity and high quality of products. The new model of weaving
machine is one of the most important factors for producing the high quality of
product. New models of weaving machines were developed in weaving system by
developing cotton control system which has many types such as water-jet, air-jet,
gripper of rapier and so on: Moreover, it has high speed working process with
computer control. However, the new model of weaving machine is a complicated
working system if operator cannot keep it in good condition, it may be difficult to
control the weaving process because of some breakdown. From case study, there
were machine breakdowns during working period after two years of using new
machine that led to low productivity. From production data in October to December
2000, theTable 1 The production output from October to December, 2000.
Month

Net Fabric length (yard per machine)

October

7,581.6

November

7,394.4

December

7,450.6
Average

7,475.3

Table 2 Causes of inefficiency of production.

October
Frequency Loss
Causes

(Times)

(hrs.)

113.27

Wrap yam break

243

Weft yam break

November
% Frequency

Loss

December
%

Frequency

Loss

(Times)

(hrs.)

Average
%

Frequency

Loss

(Times)

(hrs.)

(Times)

(hrs.)

76

92.35

74

10

118.78

81

8.66

108.14

77.16

19.37

13

241

14.98

12

210

13.1

231.33

15.58

11.30

213

10.43

199

11.32

187

10.27

199.67

10.65

7.60

Set up new roll

4.47

3.7

4.40

4.19

2.99

Idle

1.49

2.5

1.6

11.33

0.95

Machine
breakdown

Total

466

149.03 100

453

124.76 100

410

146.64 100

433.93

140.16

100

Table 2 determined the volumes of machine breakdown leads to the serious

problems of low productivity. This information obtained from machine breakdown
caused of incorrect adjustment, incorrect lubrication, incorrect cleaning etc.
Moreover, there is no suitable preventive maintenance plans to protect machine
breakdown.

Methods
The improvement of mean time between failure (MTBF) and mean time to repair
(MTTR) were necessary to consider the data were shown in table 2. The main
problem of inefficiency is machine breakdown, which is about 77% of whole
problems. Recording data of machine breakdown has details of breakdown in
several causes, for example in driving system, control system, shedding system,
weft insertion system, let weft release system, tuck in system, and lenos system
were shown in table 3.
The main cause of breakdown is shedding system because it has the average
breakdown 29.79 hours/3 months and frequency of breakdown is 2 times/month.
Then, the cause effect diagram must be analyzed to correct the primary cause of
machine breakdown and plan to protect it was determined. By this method,
maintenance took very long times because of lacking history data in maintenance.
So, data in table 3 can be used to calculate performance of machine, on ready for
used of machine waste of working time, mean time between failures, and mean time
to repair. It is found that ready for use of machine is 82.89%, while waste of working
time is 17.11%. Mean time between failures is 62.89 hrs./time and mean time to
repair is 12.98 hrs./time while average breakdown of machine per month is 108.13
hours. With cause effect diagram, it was founded that main shaft of dobby broken is
the main problem of machine breakdown. The main shaft was divided from several
cases to be are unbalance cloth structure, improper speed, warp overload and
frequency stops. The unbalance cloth structure affects mostly on breakdown from
main shaft of dobby broken. The working system must be set the weaving process,
proper speed, and load of yarn in weaving machine for balance cloth structure.

Table 3 The causes of machine breakdown and the average of machine breakdown
in garment factory during October-December, 2000: (previous improvement
phase).
Cause of breakdown Frequency

Average of breakdown
(times per month)

(hrs per month)

Driving

system

1.33

22.0

Control

system

2.00

21.4

Shedding system

2.00

29.79

Weft

1.33

25.33

1.00

4.58

0.67

4.19

0.33

0.85

8.66

108.13

Let

insertion system
weft release

system
Tuck

in

Lenos system
Total

system

Table 4 Production output during January to March 2001.

Month

Net Fabric length (yards per machine)

January

8,126.26

February

8,750.99

March

8,439.00

Average

8,438.75

Results
After the information of machine breakdown was studied and analyzed with cause
effect diagram, the maintenance plan is set as daily, weekly, and monthly
maintenance [5]. Daily maintenance composes of cleaning, lubrication and
adjustment plans. Following the instruction handbook [4] did annual maintenance
program. By working with maintenance plan, the average production output during
January-March, 2001 was 8,438.75 yards/ machine was shown in Table 4 and Figure

3. It was found that the output increased up to nearly 85% to meet the target.
The results of comparing the machine performance before and after maintenance by
planning are as follow. It was found that the ready for use of machine was 94.75% or
increased by 14.30% while the percentage of machine breakdown was decreased to
72.15%. In contrast, mean time between failures: MTBF was increased to 241.79
hours/time while lost of machine breakdown was decreased 5.24%. Mean time to
repair: MTTR was decrease to 13.38 hours/time and average of machine
breakdown/month was decreased from 108.03 hours/month to 31.05 hours/month.
Then, the efficiency of production before and after maintenance by plan was
compared. Production was more effective as shown by the increase of average
efficiency to 963.45 yards/month/machine.

Conclusions
Preventive maintenance techniques were utilized to improve the performance
efficiency of machine in this study. As the information obtained from this work,
machine breakdown times were analyzed. The data presented above show many
causes of system breakdowns. Due to the productivity improvement, preventive
maintenance programs could be done for the higher machine capacity utilization and
save the factory cost.

Suggestions
According to the several problems, the solutions of this project improvement
were summarized as follow : (1) Instructors manual for setup the balance shedding
was necessary. (2) Daily maintenance inspection plans were set and used. (3) Welltrained operators for understanding the importance of the daily lubrication of parts
and cleaning machine. (4) Set the weekly changing spare parts plan for each
machine. (5) Planning the annual lubrication oil changing and check the lubrication
systems every 2 months. and (6) Inspection manual for setup the machine.

MAINTENANCE MANAGEMENT
ASSIGNMENT -2
TYPES OF MAINTENANCE USED IN APPAREL INDUSTRY

SUBMITTED BY:
ABHISHEK KUMAR
UJJAWAL PRAKASH