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Maintenance management


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Maintenance management

  2. 2. INTRODUCTION Maintenance- to keep the equipment in operational condition or repair it to its operational mode. Maintenance Management - orderly and systematic approach.  planning,  organizing,  monitoring and  evaluating maintenance activities and their costs.
  3. 3. OBJECTIVES SAFE ENVIRONMENT WASTAGE • Prevent Accidents • 0% wastage • 100% participation of employees EFFECIENCY • 100% OEE • 100% OPE
  4. 4. TYPES Routine Preventive Emergency
  6. 6. FUNCTIONS Maintenance of installed equipment and facilities Installations of new equipment and facilities PM tasks – Inspection and lubrication of existing equipment CM tasks – monitoring of faults and failures using appropriate techniques Modifications of already installed equipment and facilities Management of inventory Supervision of manpower Keeping records
  7. 7. ELEMENTS OF MANTAINANCE MANAGEMENT Maintenance Policy Control of materials Preventive Maintenance Condition Monitoring Work Order Job planning Priority and backlog control Data recording system Performance measurement measures or indices
  8. 8. General Functions 1.Attend to breakdown of machine. 2. Periodic machine maintenance. 3. Maintenance of needle breakdown report. 4. Providing new folders and attachments. 5. Development of templates and profiles. 6. Assisting the operator in knowing the machine 7. Inform the HOD for the requirement of any new machine. 8. To replace any broken parts of the machine.
  9. 9. General Functions 9. To collect the broken parts of the needle and maintain its record. 10.To carry out preventive maintenance of the machines as per schedule. 11.To contact the machine manufacturer in case of persistent problem. 12.To set up the line as instructed in the sewing room. 13.To carry out oiling and cleaning of the machines as per the schedule.
  10. 10. Maintenance Approaches The following maintenance approaches are followed at Arvind Ltd. A. Corrective or Breakdown maintenance Corrective maintenance can be defined as a maintenance task performed to identify, isolate, and rectify a fault so that the failed equipment, machine, or system can be restored to an operational condition within the tolerances or limits established for in-service operations. It is aimed at restoring an asset to a condition in which it can perform its intended function. Corrective maintenance can be subdivided into "immediate corrective maintenance” and "deferred corrective maintenance"
  11. 11. Maintenance Approaches B. Preventive maintenance 1.Condition MonitoringCM is the process that assesses the health of an equipment/system at regular intervals or continuously and exposes incipient failures a. Continuous Monitoring b. Periodic MonitoringAdvantages : Cost reduction in Maintenance. Reduction in No. of Failures. Etc. 2.Planned Maintenance Planned maintenance (PM) or Scheduled Maintenance is any variety of scheduled maintenance to an object or item of equipment. It is a scheduled service visit carried out by a suitable agent, to ensure that an item of equipment is operating correctly and to therefore avoid any unscheduled breakdown and downtime.
  12. 12. Maintenance Approaches C. Total Productive Maintenance TPM is a company-wide team-based effort to build quality into equipment and to improve overall equipment effectiveness Total  all employees are involved  it aims to eliminate all accidents, defects and breakdowns Productive  actions are performed while production goes on  troubles for production are minimized Maintenance  keep in good condition  repair, clean, lubricate The major difference between TPM and other concepts is that the operators are also made to involve in the maintenance process.
  13. 13. Sub- departments: The maintenance department is divided into four sub-divisions 1.CMD 2.BATCH MAINTENANCE: 3.FOLDERS AND FABRICATION 4. UTILITY AND SAFETY
  14. 14. Hierarchy  Arvind Ltd. Electronic city unit, which has a daily production capacity of 10,000pcs approx spread over 12 lines has in its maintenance dept. Head Maintenance manager Central Maintenance Manger 1 assistant manager 2 executives 1 data entry operator Folders And Batch Maintenance Utility And Safety Fabrication Manager: Manager : Manager : 1 assistant 1 assistant 2 assistants 4 mechanics 3 mechanics 3 + 4 mechanics 2 helpers
  15. 15. Maintenance Sub- departments:1. CENTRAL MAINTENANCE DEPARTMENT The central maintenance department is concerned with the issue of machines and preventing their breakdown. The main responsibilities are as follows: Installation and commissioning of new machines. Procurement and development of the required machinery. In addition the CMD department acts as a coordinator among the other maintenance departments. Maintenance approach : CBM; Planned Maintenance;
  16. 16. Maintenance Sub- departments:  2. BATCH MAINTENANCE:  This division is involved in maintaining the machines in all the batches.  One senior executive from TPM heads this branch . There are 4 mechanics who maintain 12 lines.  The mechanic is involved in planned maintenance i.e. servicing of machine from time to time.  Batch setting: setting the machines according to the style.  Over-hauling: repairing completely broken-down machines.  Maintenance approach: TPM,  breakdown maintenance
  17. 17. Maintenance Sub- departments:  3. FOLDERS AND FABRICATION:  Arvind ltd. has its own folder and templates making workplace at its electronic city unit, which helps in reducing a great deal of production cost.  The folders which are prepared are manually fabricated by using different tools and acrylic & leather sheets of varying thickness.  The folders & templates are maintained & graded according to size and style variations and stored in a systematic manner to be issued instantly as per requirements.  This helps in carrying out many operations at a single machine and increases the efficiency of the operators.
  18. 18. Maintenance sub-department 4.UTILITY AND SAFETY :UTILITY This subdivision basically takes care of generator, air conditioning, steam line for iron and airline for pneumatic machines. This department also fulfills the light requirements according to the nature of operations to be carried out as well as manages and maintains the electrical equipments Maintenance approach: CBM, Breakdown Maintenance.
  19. 19. Maintenance Department 4.UTILITY AND SAFETY :SAFETY There are three steps followed General safety, which consists of fire extinguishers and smoke detectors. Human safety, which consists of needle guard, eye guard etc. Product safety, which consists of needle detector machine and maintaining the broken needle policy. Maintenance approach: preventive maintenance.
  20. 20. ASSOCIATED DEPARTMENTS  IE department  This department notifies the central maintenance Maintenance department (CMD) the batch setting requirements according to changes in style. Production Industrial planning & engineering control  PPC Department  The production planning & control department does the assessment equipment availability & requirement in association with the maintenance department as per production requirements.  It sends the folder requirement chart according to design and style variations to the folders and fabrication department.
  21. 21. Thank you