With today`s modern machinery it is essential to audit the machines at frequent intervals to get the best productivity and Yarn Quality in Spinning Mills.This has been practiced by WINSYS SMC at Spinning mills.

1. A.KANTHIMATHINATHAN
WINSYS LIMITED
winsyssmc@gmail.com
MACHINERY MAINTENANCE AUDIT
(MMA)

2.  What is an Audit
 Machinery maintenance System audit
 What we derive out of Systematic Machinery
Maintenance Audit
 Online and Offline audits
 Equipments that facilitate Online audits

3. Effective utilisation of resources
 Men
 Machine
 Material
 Finance

4. CRITICAL ASSESSMENT OF A
SYSTEM,PROCESS TO UNEARTH
 DEVIATIONS FROM THE EXISTING
PRACTICES
 DEVIATIONS FROM THE BENCHMARKED
PRACTICES

5. CRITICAL ASSESSMENT OF A SYSTEM/
PROCESS
TO IDENTIFY SCOPE FOR FURTHER
IMPROVEMENTS

7. PLAYS A VITAL ROLE TO
 Minimise ADD vs EDD variance
 Realise the best out of Machinery
 Attain Maximum Utilisation
 Achieve consistency in YQ
 Control/Reduce Manufacturing cost
 Train the Workforce

8. A Mill commits EDD for 20 feet container of 40S
CK to Korea by 6TH
July.One Unilap feeding to
the respective combers broke down for 14
Hours on July 1st
.
WHAT HAPPENS TO DELIVERY ADHERENCE?

9.  Trumac Cards are supposed to give 99%
Cleaning efficiency.
 Varioclean is supposed to give 40% cleaning
efficiency
 LC 300A Card 5m CV shd be below 2%
 RSB 851 shd run at 400 mpm conveniently for
combed counts with 1m CV below 0.6
HOW TO ACHIEVE THESE LEVELS ALWAYS?

10.  NEW RING FRAME SHOULD RUN AT 98.8 %
UTILISATION
 AUTOCONER SHOULD RUN AT 96%
UTILISATION
 MODERN CARDS (0.5 CRORE) SHOULD BE
RUN AT 96% UTILISATION
WHICH SYSTEM HELPS TO ATTAIN THESE
LEVELS……

11.  SPLICE STRENGTH SHOULD BE ABOVE 90%
 CV OF IMPERFECTIONS SHOULD NOT
EXCEED 7.5%
 CLEARER CUTS SHOULD NOT EXCEED +10
PER LAC METERS
WHAT IS TO BE DONE….???????

12.  3 % of Turn over is allotted for Repairs and
Maintenance
 0.5 % Deviation means 14.5 lacs for 25000
spindles on 100s CW
Can we exercise control thro any system for for strict
adherence to budgeted amount?

13.  COST OF THE SPARE
 COST OF PRODUCTION LOSS
 COST OF SUBSEQUENT MACHINERY
CHANGES
 BEYOND ABOVE,
LOSS OF A CUSTOMER FOREVER

14.  ROUTINE MAINTENANCE
ORGANISED MANUFACTURERS GIVE
RECOMMENDED SCHEDULES
MILLS HAVE TO DEVELOP FOR MACHINERY
FROM UNORGANISED SECTOR
 HAS IT BEEN DEVELOPED?
 HAS IT BEEN IN LINE WITH
REQUIREMENTS?

15.  REDUCES WEAR OF THE PARTS
 DEPENDS ON LOAD,HEAT,NATURE OF
ENVIRONMENT,TYPE OF DRIVE etc
 CARE ON STORAGE SYSTEMS
 RATIONALISATION OF LUBRICANTS
 SHELF LIFE OF LUBRICANTS

16.  PREVENTIVE MAINTENANCE CHECKS
 PREVENTIVE MAINTENANCE/CRITICAL
ITEMS REPALCEMENT SCHEDULES

17. CHECK MAINTENANCE SCHEDULES AND
LUBRICATION SHEDULE WHETHER,
 IT IS IN LINE WITH MANUFACTURERER`S
RECOMMENDATION?
 IT IS IN LINE WITH INDUSTRY`S BEST
PRACTICES?

18.  ADEQUACY(CHECKS FEW CRITICAL
PARTS)
 SCOPE FOR RATIONALISATION

19.  ONLINE AUDITS
 OFFLINE AUDITS

21.  Waste clogging in Undergrids
 Slow motion of Material in conveying ducts
 Synchronisation of Feeding lines
 Suction levels

22.  CV of Slivers
 Sheet thickness after chutes in cards
 Deposits in Flat tops

23.  LAP LICKING
 WEB UNIFORMITY

24.  Web Appearance
 Unicomb Cleanliness
 Sliver CV in Modern Combers

25.  1 M CV%
 Shift from central Values
 Deposits on Creel Guides and Use of Blowing
fans/Timing

26.  Performance of PDTC(Top/Bottom)
 Apron shift
 ROVING alignment
 Creel slackness/stretch

27.  Bobbin revolution
 Yarn Path
 Position of Underclearers
 Effectiveness of OHTC

28.  WAX DISC MOVEMENTS
 SPLICE APPEARANCE
 TENSION LEVELS

30.  BEATER QUALITY
 LATTICE PIN QUALITY
 LATTICE BOWL AND DRIVE SHAFT
 QUALITY OF UNDERGRID
 CRITICAL SETTINGS INSPECTIO
(MILLS STDS VS ACTUAL)

31.  CHECK CYLINDER AND DOFFER FOR
LAND
 CHECK FLAT TOPS /STATIONARY FLATS
FOR STRAIGHTENING OF WIRES
 CHECK LICKERIN FOR BENT /BROKEN
WIRES

32.  CHECK MOTE /TRASH KNIVES FOR
SHARPNESS
 CHECK BASIC SETTINGS FOR
AUTOLEVELERS
 CHECK CRITICAL SETTINGS

33.  TOP ROLLER WEIGHTING SYSTEMS
 TOP ROLLER SADDLE QUALITY
 LAP SELVEDGE QUALITY

34.  CONDITION OF UNICOMB AND TOP
COMBS
 CONDITION OF DET ROLL AND DRAFT
ROLL WEIGHTING SYSTEMS
 NIPPER BITE

35.  TOP ROLLER WEIGHTING/SADDLE
 LATERAL PLAY IN DRIVE
 BRAKING EFFICIENCY
 PRESSURE LEVELS
 CARBON IMPRESSION OF ROLLER
SETTINGS

36.  TOP ROLLER PRESSURE VARIATION
 BUILDER MOTION FUNCTION
 ALIGNMENT OF ROVING GUIDES
 APRON TENSION

37.  TRAVERSE MOVEMENT
 SPINDLE CENTERING
 RING RAIL LEVEL
 RING RAIL MOVEMENT
 TAPE TENSION
 BOBBIN HOLDER SPRINGS UNIFORMITY

38.  YARN PATH IN COMPACT ZONE
 SUCTION CONSISTENCY BETWEEN
SECTIONS
 COMPACTING SPARES CONDITION

39.  CONDITION OF DRUMS
 SPLICE CUTTERS
 SPLICER COMPONENTS
 BALCON SETTINGS/MOVEMENTS
 PACKAGE DENSITY CHECKS

40.  LEAF GAUGE
 MASTER Pr. GAUGE
 NILOMETER
ENSURE TIMELY CALIBRATION OF TOOLS
AND GAUGES

41.  NOT TO BE STEROTYPED
 CHECK LISTS-REVIEW PERIODICALLY
 CHANGE AUDITORS PERIODICALLY
 LINK CUSTOMER COMPLAINTS
 CHANGE OF M/CY NEEDS CHANGE OF
FORMAT
 HELPS IN SELECTING THE RIGHT TYPE OF
VENDORS

42.  EXTENT TO WHICH PLANNED ACTIVITIES
ARE REALISED AND THE PLANNED
ACTIVITIES ARE CARRIED OUT

43.  RELATIONSHIP BETWEEN THE RESULTS
AND RESOURCES USED

44.  INQUISITIVE – Should Probe
 PROFESSIONAL-Fair and report only based on
facts collected
 PRINCIPLED-Open and Transparent approach
 POSITIVE-Every discrepancy is an opportunity
for Improvement

45.  YARN CLEARERS OF TODAY HAVE ALARM
SETTINGS FEATURE
 ALARMS CAN BE SET FOR COPS HAVING
DEFECTS BEYOND SET LIMITS
 REJECTED COPS CAN BE ANALYSED FOR
HISTORY

46.  COPS FROM A RINGFRAME CAN BE FED
TO AUTOCONERS WITH PRESET ALARM
LIMITS
 COPS WILL BEAR THE SPINDLE NUMBER
OF THE RINGFRAME
 RUN THESE COPS WITH PRESET ALARM
LIMITS

47. ALARM LIMITS CAN BE SET FOR
 CV OF IMPERFECTIONS
 IMPERFECTIONS
 CLUSTER FAULTS(PEARL CHAIN)
 HAIRINESS/SFI

48.  Spindlewise defects can be identified and
Clearers help for thoro auditing of Prior
Machinery on a periodical basis
 DIFFICULTIES:Spindle numbering and
doffing.Can be practiced.Few Mills have
exclusive empties for this purpose.

49.  Auditing of Maintenance activity is essential
 To assess Buffing activity mills use Rogue
Soindle analysis immediately after Buffing.

50.  Next Level of MMA is TPM
TOTAL PRODUCTIVE MAINTENANCE

51. Thanks!