INTRODUCTION: Maintenance system plays a ional

EXPERIMENT NO: 02
EXPERIMENT NAME: Study on maintenance process and maintenance tools.

INTRODUCTION:
Maintenance system plays a key role in achieving organizational goals and objectives. It
contributes in reducing equipment downtime, improving quality and increasing productivity.
Selection of best maintenance policy is important as the maintenance management is complex
and the output of maintenance is hard to measure and quantify. Maintenance is the chronological
activities or as the process of systematic activities which is done to keep the factory plan
equipment machine tools etc. in an optimum working condition, minimize the breakdown of
machine's to improve Productivity of existing machine tools and avoid sinking of additional
capacity and to prolong the useful life of the factory plant & machinery.

DEFINITION:
Maintenance is a procedure by which we can maintain active functioning in operation according
to the behavior and utility of a particular element. Machine, buildings and other facilities are
subjected to deterioration due to their use and exposure to environmental condition. Process of
deterioration, if unchecked. culminates in rendering these service facilities unserviceable and
brings them to a standstill. In Industry, therefore has no choice but to attend them from time to
time to repair and recondition them so as to elongate their life to the extent it is economically and
physically possible to do so. In engineering, we use this terminology for maintaining smooth and
uninterrupted performance of machines, tools and metallurgical characteristics in practical uses.

OBJECTIVE:
 To know about maintenance.
 To know about different maintenance tools and their functions.
 To keep the factory plants, equipment, machine tools in an optimum working condition.
 To modify the machine tools to meet the needs for production
 Better or superior quality for the product.
 Higher productivity of machines
 Wastage reduces & control.
 Economization of the process.
 To keep the m/c running continuously up to the maximum production level.
 To make sure the best use of utilities.
 To prevent the undesirable failure of the m/c.
 Reducing break down and emergency shut down.
 Optimizing resources utilization.
 Minimizing energy usage.
 Improving equipment efficiency.
Classification of Maintenance System:
 Planned Maintenance
 Unplanned Maintenance

 Planned Maintenance system: There are three types of Planned Maintenance system, which
are given below:

1. Preventive maintenance: It is daily maintenance (Cleaning, inspection, oiling and re-

tightening), design to retain the healthy condition of Equipment and prevent failure through
the prevention of deterioration, periodic inspection or equipment condition diagnosis, to
measure deterioration. 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.

Studies indicate that this savings can amount to as much as 12% to 18% on the average.
Depending on the facilities current maintenance practices, present equipment reliability, and
facility downtime, there is little doubt that many facilities purely reliant on reactive maintenance
could save much more than 18% by instituting a proper preventive maintenance program.

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 working
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 Preventive Maintenance
program.
 The proper planning and scheduling of Preventive Maintenance program.
 The ability to properly apply the Preventive Maintenance program.
 It is good for those machines and facilities where their failure would cause serious production
losses.
 Its aim is to maintain machines and facilities in such a condition that breakdowns and
emergency repairs are minimized.
 Its activities include replacements, adjustments, major overhauls, inspections and
lubrications.

Types of Preventive Maintenance:
Researchers subdivided preventive maintenance into different kinds according to the nature of its
activities:
1. Running Maintenance: It includes those maintenance activities that are carried out while
the machine or equipment is running and they represent those activities that are performed
before the actual preventive maintenance activities take place.
2. Shutdown Maintenance: It is a set of preventive maintenance activities that are carried out
when the production line is in total stoppage situation.
3. Opportunity maintenance: It is a set of maintenance activities that are performed on a
machine Shutdown preventive maintenance or a facility when an unplanned opportunity
exists during the period of performing planned maintenance activities to other machines or
facilities.
4. Window maintenance: It is a set of activities that are carried out when a machine or
equipment is not required for a definite period of time.
5. Scheduled / Routine Maintenance: It includes those maintenance activities that are
repetitive and periodic in nature such as lubrication, cleaning, and small adjustment. Every
machine has a schedule of maintenance of 10 or 15 days. According to date, schedule
maintenance is taken on the machines. Operators are informed about the time of
maintenance. After pre estimated production, they hand over the machine to the fitters. Thus,
fitters assure all machines are ok. Maintenance of different machines are prepared by expert
engineer of maintenance department. Normally in case of dyeing machine maintenance after
30 days complete checking of different important parts are don.

Advantages:
 Cost effective in man capital-intensive processes.
 Flexibility allows for the adjustment of maintenance periodicity.
 Increased component life cycle.
 Energy savings.
 Reduced equipment or process failure.
 Estimated 12% to 18% cost savings over break down maintenance program.
 Increase the product quality.
 Improved worker and environmental safety.
 Improved worker morale.

Disadvantages:
 Includes performance of unneeded maintenance.
 Increased investment in diagnostic equipment.
 Increased investment in staff training.
 Savings potential not readily seen by management.

CORRECTIVE MAINTENANCE:
The task performed after the occurrence of a failure and intended to replace an item in a state
where it can perform properly its required, this is called corrective maintenance. Corrective
maintenance is one that performs urgent interventions when there is unforeseen machine
stoppage due to breaking or a defect in the material it produces. In this type, actions such as
repair, replacement, or restore will be carried out after the occurrence 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:

a) Remedial maintenance: It is a set of activities that are performed to eliminate the source of
failure without interrupting 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.

b) Deferred maintenance: It 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.

c) Shutdown corrective maintenance:  It is a set of corrective maintenance activities that are

performed when the production line is in total stoppage situation.

Advantage of Corrective Maintenance:

1) Corrective maintenance maximizes the effectiveness of all critical plant systems, eliminates
breakdowns, eliminates unnecessary repair, and reduces deviations from optimum operating
conditions.
2)   For the corrective maintenance, the break down should occur before any corrective action is
taken.

3) Corrective maintenance activities are planned and regularly taken out to keep plant’s
machines and equipment in optimum operating condition.

Disadvantages of Corrective Maintenance:

1) The way to perform corrective maintenance activities is by conducting four important steps: a.
Fault detection, b. Fault isolation, c. Fault elimination, d. Verification of fault elimination.  In the
fault elimination step several expensive actions could be taken such as adjusting, aligning,
calibrating, reworking, removing, replacing or renovation.

2) Accurate identification of incipient problems is the prerequisite of Corrective Maintenance.

3) Effective planning which depends on the skills of the planners, the availability of well
developed maintenance database about standard time to repair, a complete repair procedures, and
the required labor skills, specific tools, parts and equipment.

4) Verification of repair is required.

2. 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
maximising the service life of equipment without increasing the risk of failure.
It indicates the design of new equipment. Weakness of current machines are sufficiently studied
(on site information leading to failure prevention, easier maintenance and prevents defects, safety
and easy of manufacturing) and are incorporated before commissioning a new equipment.
It is classified into two kinds according to the methods of detecting the signs of failure:
a) Condition-based predictive maintenance: Condition based predictive maintenance depends on
continuous or periodic condition monitoring equipment to detect the signs of failure.
b) Statistical-based predictive maintenance: 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.
 Unplanned Maintenance (Run to Failure Maintenance): It means that people waits until
equipment fails and repair it. In other way we can say “run it till breaks”. Such a thing could
be used when the equipment failure does not significantly affect the operation or production
or generate any significant loss other than repair cost. Still it is predominant mode of
maintenance. A recent study in United States shows the following figure of different type of
maintenance.

It is subdivided into two types:

1. Emergency maintenance: it is carried out as fast as possible in order to bring a failed
machine or facility to a safe and operationally efficient condition.
2. 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,
materials, labor and equipment.

Advantages of unplanned maintenance:

 Low cost for the process.
 Less staff required.
Disadvantages unplanned maintenance:

 Increased cost due to unplanned downtime of equipment.

 Increased labor cost, especially if overtime is needed.
 Cost involved with repair or replacement of equipment.
 Possible secondary equipment or process damage from equipment failure.
 Inefficient use of staff resources.
 Equipment durability reduces.
 Quality of output degraded

Flow Chart of Maintenance:

Problem occurred
↓
Operator
↓
Supervisor
↓
Production officer
↓
Maintenance officer 
↓
Solution

Maintenance Procedure:
During Maintenance Procedure following Point should be checked:
 Maintenance: Mechanical
 Machine: Dyeing M/C
 Maintenance: Electrical
 Machine: Dyeing 

Procedure:
1. For effective maintenance a no. of pre-requirement site have to met
2. There must be a well defined organizational structure to & implement the program.
3. Proper planning, scheduling & controlling of maintenance must be designed.
4. An appropriate flow of information & data on maintenance must be devised.
5. Timely supply of the spare parts & also other materials needed must be ensured.
6. Personnel of varying skilled & competence must be engaged.

OPERATION INCLUDES in MAINTENANCE:

Setting: Setting is the activities to set or install the machine parts or required ancillaries.
Adjustment also complementary word to setting used f or appropriate setting.
Checking: Checking means investigation of machine condition. It is very important work in case
of maintenance. It is very skilled depends work as successful maintenance that depends on
correct fault detection.
Repairing: Repairing or altering of spares & equipment (if necessary) is to be detected &
necessary measures are taken (repairing\altering\setting\adjustment).
Overhauling: It is the work of maintenance, but not frequent or schedule work. It is done as per
as necessary.

FUNCTIONS of DIFFERENT MACHINE TOOLS:

Maintenance tools are that tools used in maintenance of a machine. Different types of
maintenance tools are used in Textile sector for different machines every day. Name of some
maintenance tools used in textile machine and their function are given below:
Tools Name Images & Function

Combination tools (Spanner)

 It is usually made of forged steel.
 The size of spanners denotes the size of
the bolt on which it can work.
Function: Tightening & Loosening of Nuts &
bolts  
 

Socket Ratchet set

Function: Tightening of Nuts & bolts

Slide Range
 They may consist of a slot, socket, pins,
or moveable jaw for grasping the nut, with
the rest of the tool serving as a handle
applying pressure.
Function: Tightening & Loosening of Nuts &
bolts  
Hammer

Function: Forging hot metal, riveting,

bending,
Straightening, peening, stretching and swaging.  

Screw driver
 Made of steel.
 The blade is shaped on flattened to fit
recesses in the head of screws on bolts.
Function: Is a hand tool, designed to turn or
release screws or bolts.  

L-Key
 Generally made of steel.
Function: For loosing & tighten the screw.  

Steel Tape

Function: To measure the length.  

Pliers
Function: To grip anything & cut metal wires.  

Hacksaw blade

Function: To cut any metal thing.  

 Punch

Function: Used to fit any worm out shaft.  

Oil Can & Grease Gun

Function: For Oiling & greasing of moving

Parts of M/C.  

Drill M/C and Drill bit.

Function: For Drilling.  

Toolbox:

Function: Generally all necessary maintenance

tools are kept in a box it is called tool box.
Generally it is made of steel.
 

DIFFERENT TYPES of WRENCHES:

Wrenches are also known as spanners in some parts of the world. A spanner or wrench is used
for turning a nut, bolt or similar fixing that is turned to tighten. The spanner is used to grip the
given fixing (whether it is a nut, bolt, concrete screw etc.) and turn it, allowing you to apply
torque and tighten the nut onto the bolt.
They are generally made from drop forged steel and coated in chrome to stop corrosion. Higher
quality spanners tend to be made from Chromium-Vanadium alloys and in some cases even
titanium

Now discuss about the different types of wrenches:

There are numerous types of wrenches, with the specialty and purpose of each differing.
Although, now you will know exactly what type of wrench you would require for a particular
task on

1. Open-ended: This type of wrench is open-ended at both its ends. The openings are U-
shaped. These openings are not of the same size. These wrenches are useful when dealing
with nuts and bolts that are difficult to access. They provide much more ease in turning such
nuts and bolts.

2. Box-ended: A box-ended wrench has a closed loop at both its ends. This loop is usually
designed to fit a hexagonal shape, and in some cases it may be designed to fit a square shape.
The loops at both the ends are of different sizes. These wrenches are used in cases where
open-ended wrenches are of no good. Box-ended -wrenches will avoid the rounding-off at
the edges that may occur on use of open-ended wrenches.
3. Combination: A combination wrench, as the name suggests, is a combination of both an
open-ended wrench as well as a box-ended wrench. This wrench has a closed loop at one
end, while it is open-ended at the other. These can be used to unfasten nuts and bolts with the
box-end, and then separate them quickly using the open-end. Combination wrenches are
generally put to use in this combination, and hence both the ends are of the same size.

4. Adjustable: This is an open-ended wrench. It can be used only from one end. The size of the
opening is not fixed. It can be varied based on the size of the nut and bolt. These can be used
on nuts and bolts of multiple sizes, as opposed to the earlier seen wrenches where one unit
can be used for a single or at the most two sizes. However, such types of wrenches are
difficult to use in remote or confined areas.

5. Allen: This wrench has a hexagonal end. It comes in either a T-shape or an L-shape. A
shaped wrench is similar to an L-shaped wrench (shown below), except for the handle it has,
which is made up of either metal or plastic, at the end that is absent in the L-shaped one.
These wrenches are used with heads that have hexagonal recesses in them. Allen wrenches
 are used to turn such screws or bolts. The way in which they operate is similar to that of
screwdrivers.

6. Socket: In case of a socket wrench, it fits completely over a nut or a bolt. Such a wrench also
requires a handle. Hence, most of them have an in-built joint. When socket wrenches are
used, they need not be removed completely from the head of nut or bolt after the completion
of the turn. The handle can be removed and re-inserted, while the socket remains on top of
the nut or bolt.

7. Line: A line wrench lies somewhere between an open-ended wrench and a box-ended
wrench. This wrench is open-ended at both its ends, unlike a box-ended wrench. On the other
hand, unlike an open-ended wrench, the openings are just wide enough to fit over the head of
a nut or bolt. These are used when the nuts or bolts are of softer metals. Line wrenches cover
the maximum area of the nut/bolt head and allows for maximum contact, thus minimizing the
damage to the softer metal heads.

8. Ratcheting: A ratcheting wrench is similar to a socket wrench. In this case, a metal handle is
attached to a ratcheting mechanism that is in turn attached to a socket. As it is attached to a
socket, there is no need for the wrench to detach itself from the head of the nut/bolt till the
job is done. These are used when there are restrictions on time and space. These wrenches get
the job done quickly. They can also function in a limited space.
9. Pipe: This is a type of an adjustable wrench. The jaws of the wrench are like a saw. It is
generally used on soft iron pipes and fittings that are round in shape. The saws are designed
in such a manner that when the handle is pulled forward, the jaws become tighter. Due to the
saw-like nature of the jaws of these wrenches, they are used mainly for plumbing purposes.

10. The serrated jaws, though, leave some scratches behind on the surfaces that they are used
on.

11. Torque: A torque wrench provides a specific amount of torque for fastening purposes. This
will help in avoiding over-tightening of the nut-bolt assembly. The required amount of torque
can be achieved by calibrating the wrench. In a few cases, like in the automobile industry, the
level of torque required for fastening is precise. They are used in the assembly of such
precision mechanisms, where excess torque is as dangerous as inadequate.

12. Alligator: This wrench, has serrated jaws on one side, while the other jaw is flat. The shape
of this wrench is like the mouth of an alligator, and hence the name. This kind was in vogue
when wrenches were designed for square heads, unlike today, where they are designed for
hexagonal heads. Alligator wrenches are not in much use today, as with time, the designs of
wrenches have been made friendlier for use on hexagonal heads. In its heyday, these were
used whenever regular wrenches failed in their job.
13. Drum Key: This is a type of square wrench. It is used for the tuning of percussion musical
instruments. This wrench is a specialty wrench, and cannot be used for any purpose other
than the intended one. uning can be achieved by using these wrenches for tightening the rods
or strings of instruments. As the name suggests, these can be used for tuning of drums as
well.

14. Spark Plug: A spark plug wrench is a type of

socket wrench. It is similar to a ratcheting wrench. It has openings at both the ends. This is
also a specialty wrench. These wrenches are used only with spark plugs. They help in the
removal and fitting of spark plugs that in general are inaccessible. These cannot be put to any
other use.

15. Fire-hydrant: A fire-hydrant wrench is a type of a box-ended wrench. The loop is

pentagonal shaped. The valve on the fire-hydrant is also pentagonal. The valves cannot be
opened with any other type of wrench. These are specialty wrenches with the above
mentioned purpose. The irregular shape makes the valves temper-resistant.

16. Lug: This wrench has sockets in four directions,

and the handles are larger than regular wrenches.
 This wrench is also known as a wheel brace. These are specialty wrenches that are used in
the automobile industry. They are used to tighten the nuts on the wheels of automobiles.

17. Plumber: A plumber wrench is an adjustable wrench. It is similar to a pipe wrench. It is

exclusively used for plumbing purposes. These are used to fasten or loosen the nuts used on
the pipes in a plumbing system. As these area adjustable wrenches, the same wrench can be
used for pipes of varied sizes. These are specialty wrenches.

18. Dumb-bell: This is a box-ended wrench. This is also known as a dog-bone wrench. The loop
sizes at both the ends are, in general, different. These are specialty wrenches. They are
designed to be specifically used on bicycles. These wrenches can be difficult to fit into tight
spaces.

19. Spoke: This is an open-ended wrench. The handle is at an offset to make it easy to grip,
despite its, in general, short size. The handle has to be short enough for the wrench to fiat in
between spokes. These are designed to be used on the spokes of a wheel. This spoke is
designed to manipulate the tension in the wheel.
20. Spud: A spud wrench is open-ended at one end and has a spike at the other. This kind is not
much in use today, owing to the plumber wrench. These were originally used to line up bolts
using the spiked end, and fasten using the wrenched end. Before the plumber wrench became
a preferred choice, spud wrenches were used for plumbing purposes.

21. Impact: This is also known as an air wrench or an air gun. This kind is either powered
electrically or through compressed air. It is designed to provide high torque for the fastening
or unfastening process. It is a type of socket wrench. These can be used in most processes.
These wrenches, however, cannot be used when precision is required in the torque delivered
during the process. They are, hence, not used in precision mechanism.

22. Die-stock: A Die stock wrench comes in two types; male and female. These are used on dies,
and hence, are known as die-stock wrenches. They are used for threading purposes, that is
making threads on a die. A die is used to give shape to molten metals in a manufacturing
process. When threads are cut using a die, then the process is termed as tapping. This is a
specialty wrench, and cannot be put to any other use.
23. Male Die-stock wrench: Is used for the threading on a nut.

24. Female Die-stock wrench: It is used for threading on bolts.

CONCLUTION:
By this experiment we learn about different necessary maintenance tools for an industry, their
function and so on. The tools should be handling with care & put it in the right place.