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8/3/2019 Southern Range Nyanza Ltd
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Agaba, BSc. Textile Technology (Hons.)/KYU
SSOOUUTTHHEERRNN RRAANNGGEE NNYYAANNZZAA LLTTDD
SSppiinnnniinngg DDeeppaarrttmmeenntt
Introduction and Application a Computerized Maintenance
Management System (CMMS) Software for Better Management of
Maintenance activities in Spinning Department
Presented By:
Agaba Moses
(Graduate Management Trainee)
To:
The Production Manager
November, 2011
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Introduction
The term maintenance means to keep the equipment in operational condition or repair it to its
operational mode. Maintenance can also be defined as a set of organised activities that are
carried out in order to keep an item in its best operational condition with minimum cost acquired.
Main objective of the maintenance is to have increased availability of production systems, with
increased safety and minimized cost. Maintenance management involves managing the functions
of maintenance. Activities of maintenance function could be either repair or replacement
activities, which are necessary for an item to reach its acceptable productivity condition or these
activities, should be carried out with a minimum possible cost.
Maintaining equipment in the field has been a challenging task since the beginning of industrial
revolution. Since then, a significant of progress has been made to maintain equipment effectively
in the field. As the engineering equipment becomes sophisticated and expensive to produce and
maintain, maintenance management has to face even more challenging situations to maintaineffectively such equipments in industrial environment.
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. The objectives include
the following;
Maximising production or increasing facilities availability at the lowest cost and at thehighest 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.
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Types of maintenance
Run to Failure Maintenance (RTF) Preventive Maintenance (PM) Corrective Maintenance (CM) Improvement Maintenance (IM) Predictive Maintenance (PDM)
The above types can be explained as follows;
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
acceptable condition.
It is subdivided into two types:
y Emergency maintenance: it is carried out as fast as possible in order to bring a failedmachine or facility to a safe and operationally efficient condition.
y Breakdown maintenance: it is performed after the occurrence of an advanced consideredfailure for which advanced provision has been made in the form of repair method, spares,
materials, labour and equipment.
Disadvantages:
1. Its activities are expensive in terms of both direct and indirect cost.2. Using this type of maintenance, the occurrence of a failure in a component can cause
failures in other components in the same equipment, which leads to low production
availability.
3. Its activities are very difficult to plan and schedule in advanceHowever this type is advantageous in a sense that it helps to rectify a problem since
the
failure of a component in a system is unpredictable.
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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 degradation in
their operating conditions.
British Standard 3811:1993 Glossary of terms defined preventive maintenance asthemaintenance carried out at predetermined intervals or according to prescribed criteria and
intended to reduce the probability of failure or the degradation of the functioning component of a
facility.
The factors that affect the efficiency of this type of maintenance:
1. The need for an adequate number of staff in the maintenance department in order toperform this type of maintenance.
2. The right choice of production equipment and machinery that is suitable for the workingenvironment and that can tolerate the workload of this environment.
3. The required staff qualifications and skills, which can be gained through training.4. The support and commitment from executive management to the PM programme.5. The proper planning and scheduling of PM programme.6. The ability to properly apply the PM programme.
It is good for those machines and facilities whose failure would cause serious production losses.
Its aim is to maintain machines and facilities in such a condition that breakdowns and emergency
repairs are minimised.
Its activities include replacements, adjustments, major overhauls, inspections and
lubrications.
Preventive maintenance is subdivided into different kinds according to the nature of its activities:
Routine maintenance which includes those maintenance activities that are repetitive andperiodic in nature such as lubrication, cleaning, and small adjustment.
Running maintenance which includes those maintenance activities that are carried outwhile the machine or equipment is running and they represent those activities that are
performed before the actual preventive maintenance activities take place.
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Opportunity maintenance which is a set of maintenance activities that are performed ona machine or a facility when an unplanned opportunity exists during the period of
performing planned maintenance activities to other machines or facilities.
Window maintenance which is a set of activities that are carried out when a machine orequipment is not required for a definite period of time.
Shutdown preventive maintenance, which is a set of preventive maintenance activitiesthat are carried out when the production line is in total stoppage situation.
Corrective Maintenance (CM)
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.
Types of corrective maintenance
Remedial maintenance, which is a set of activities that are performed to eliminate thesource 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.
Deferred maintenance, which is a set of corrective maintenance activities that are notimmediately initiated after the occurrence of a failure but are delayed in such a way that
will not affect the production process.
Shutdown corrective maintenance, which is a set of corrective maintenance activitiesthat are performed when the production line is in total stoppage situation.
The main objectives of corrective maintenance are the maximisation of the effectiveness of all
critical plant systems, the elimination of breakdowns, the elimination of unnecessary repair, and
the reduction of the deviations from optimum operating conditions.
The difference between corrective maintenance and preventive maintenance is that forthe 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 plants machines and equipment in optimum operating
condition.
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The way to perform corrective maintenance activities is by conducting four important steps:
1. Fault detection.
2. Fault isolation.
3. Fault elimination.
4. Verification of fault elimination.
In the fault elimination step several actions could be taken such as adjusting, aligning,
calibrating, reworking, removing, replacing or renovation.
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:
y Design-out maintenance which is a set of activities that are used to eliminate the causeof maintenance, simplify maintenance tasks, or raise machine performance from the
maintenance point of view by redesigning those machines and facilities which are
vulnerable to frequent occurrence of failure and their long term repair or replacement cost
is very expensive
y Engineering services which include construction and construction modification, removaland installation, and rearrangement of facilities.
y Shutdown improvement maintenance, which is a set of improvement maintenanceactivities 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
maximising 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:
o Condition-based predictive maintenanceo Statistical-based predictive maintenance
y Condition-basedpredictive maintenance depends on continuous or periodic conditionmonitoring equipment to detect the signs of failure.
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y Statistical-basedpredictive maintenance depends on statistical data from recording ofthe stoppages of the in-plant items and components in order to develop models for
predicting failures.
MAINTENANCE TYPES
Having looked all the maintenance types, it can be observed that preventive maintenance is the
best for effective and efficient operation of machines
Preventive maintenance is a time-based maintenance strategy where on a predetermined periodic
basis, equipment is taken off-line, opened up and inspected. It is based on visual inspection,
repairs are made and the equipment is then put back on-line
MAINTENANANCE
PLANNED
MAINTENANCE
(PROACTIVE)
UNPLANNED
MAINTENANCE
REACTIVE
BREAKDOWEMERGENCY
PREDICTIVE PREVENTIVE INPROVEMENT CORRECTIVE
STATISTICAL
-BASED
CONDITION
-BASED
DESIGN-OUTENGINEERING
SERVICES
DEFERED REMED-
IAL
WINDOW RUNNING ROUTINE OPPORTU
-NITY
SHUT-
DOWN
SHUT-
DOWN
SHUT-
DOWN
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Objectives ofPreventive Maintenance
The objectives of preventive maintenance include the following:
y To avoid, as far as possible, failure or breakdown of equipment during normal operation.y
To maximize the operating efficiency of the equipment.y To ensure safety in operation.y To minimize the cost of production by maximizing the availability of equipment for
production.y To improve the product quality by maintaining the operating parameters of equipment
within control limits.
Preventive maintenance can best be applied using a computerized maintenance management
system (CMMS)
Proposal of a maintenance strategy
A computerized maintenance management system (CMMS) package contains a database of
information about an organizations maintenance operations.
Computerized Maintenance Management Systems (CMMS) enable the maintenance team to
track the status of maintenance work on their assets and the associated costs of that work.
CMMS are utilized by facilities maintenance organizations to record, manage and communicate
their day-to-day operations. The system can provide reports to use in managing theorganization's resources, preparing facilities key performance indicators (KPIs)/metrics to use in
evaluating the effectiveness of the current operations and for making organizational and
personnel decisions. In today's maintenance world the CMMS is an essential tool for the modern
facilities maintenance organization.
In spinning department paper records are maintained to track the work. With the dawn of the
computer age we should use software to record work requirements, track the status of the work
and analyze the recorded data for managing the work, produce reports and help control costs.
Good Computerized Maintenance Management Software (CMMS) that schedules preventive
maintenance work orders on the equipment is an integral component of any efficient
maintenance department. Preventive and scheduled maintenance, efficiently scheduled, will not
only reduce maintenance costs, but will minimize emergency repairs and downtime, resulting in
an increase in overall profitability.
It can also be called computerized maintenance management information system (CMMIS)
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The information is intended to help maintenance workers to do their job more effectively.For example determining which machines require maintenance and which store rooms
contain spare parts they need.
The information is also intended to help management make informed decisions (forexample, calculating the cost of machine breakdown repair versus preventive
maintenance for each machine, possibly leading to better allocation of resources.
Therefore, spinning department needs such a data base system to eliminate the current
maintenance problems which among others include, manual estimation of due dates for
preventive maintenance, delayed work order generation, unreliable keeping of maintenance
history and limited access to machine data.
CMMS software in spinning department can produce status reports and documents giving details
or summaries of maintenance activities.
Basic roles of a CMMS package in spinning department shall include among others thefollowing;
Managing Work Orders; This involves scheduling jobs, assigning personnel, reservingmaterials, recording costs and tracking relevant information such as cause of the problem.
Typically, the CMMS software schedules preventive maintenance automatically
depending on maintenance plans.
Asset Management; CMMS software will help in recording of data about machinesincluding maintenance activities, specifications, purchase date, year of manufacture,
expected life time, warranty information, service history, spare parts and anything elsethat might be helpful to management and maintenance workers.
Inventory Control; CMMS software will help in management of spare parts, tools andother materials including reservation of materials for particular jobs, recording where
materials are stored, determining when more materials shall be purchased, tracking
shipment receipts and tracking inventory.
CMMS software shall help me manage maintenance of spinning department perfectly as
compared with the manual maintenance management we are currently using.
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The preventive maintenance activities in spinning department shall include the following;
SPINNING DEPARTMENT PREVENTIVE MAINTENANCE ACTIVITIES
SECTION/MACHINE PM ACTIVITIES DURATION
BLOW ROOM 1. Scouring 25 days2. Gear oil change 6 months3. Replacement of beater
lags36 months
CARDS 1. Cleaning all suctionhoods, tuft feeder, flatstrip roll, revolving flat
area, doffing section,feed table and flats brush
25 days
2. Checking the tension ofall belts 2 months3. Cleaning main cylinder
covers3 months
4. Main cylinder bearinggreasing
6 months
5. Doffer bearing greasingand delivery rollergreasing
12 months
DRAW FRAMES 1. Cleaning and checkingbearings and top rollers
7 days
2. Greasing the can plate,drive pressure element,pressure bar coiler plate
and auto lever andcleaning sliver guides,
flexible horses and filternet
25 days
3. Cots buffingAll timing belt cleaning
and tightening
All nipple greasing andchecking oil level
3 months
4. Lubrication of top rollerbearingsLubrication of coiler
plate and can platebearings
6 months
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SECTION/MACHINE PM ACTIVITIES DURATION
UNILAP 1. Cleaning sliver guidesand guide rolls, feed
framesChecking chains and
beltsCleaning guide bushes
for the lap rollerOiling fringes
Lubricating sprocketchains
Lubricating gears andcylinders.
1 month
2. Cleaning inner chambersEmptying water
separatorssGrinding top rollers 3 months
3. Washing top rollerbearing bushes
Greasing bearings forclearer cloth drive
Greasing lap roller fringebearing and loading lever
Greasing lockerbearing,tube feed and
shafts
6 months
4. Immersing sprocketchains in oil bath 1 yearCOMBER 1. Cleaning longitudinal
part, coiler, v-belt main
drive, belt drive forbrush
7 days
2. Cleaning the circularcomb, top comb unit.
Adjusting brushes.Cleaning detaching
cylinder and top drum
roller
1 month
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3. Cleaning and lubricatingthe stripper detachingroll, drafting system
drive.Lubricating horse on
length ways shaft
3 months
COMBER CONTD 4. Lubricating the bottomdrafting roller and
bearingCleaning the can turn
table
6 months
5. Head stock gear box oilchange
1 year
SPEED FRAME 1. Lubricating the articulateshaft, compressed air
coilerCentral lubrication
Lubricating gear wheelsof the drafting system
Greasing cone drive
25 days
2. Lubricating guides inbuilder motion
Lubricating bottom rollerbearings and drive chains
of feed rollers
2.5 months
3. Bobbin rail oil changeFlyer table lubrication
5 months
4. Cots buffing 3 months5. Lubricating the head
stock drives10 months
RING FRAME 1. Motor variator settingPneumatic drum cleaning
Draw bar roller cleaning
1 months
2. Cots buffingLubricating pum
checking
3 months
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3. Ring rail and lappetheight settingSuction tube washing
Traveller cleaning andsetting
Electro valve cleaningInspection brake setting
6 months
4. Fluted roller eccentricitysetting
Roving traverse settingTop arm setting
Bottom roller setting
1 year
OPEN END/OUTOCORO
312
1. Servicing coromat 1Servicing coromat 2
1 months
2. Servicing twin discassembly
Inspecting the rotor belt,
opening roller belt, trash
conveyor belt, empty
tube conveyor belt
6 months
3. Suction end centrallubrication station 1, 6,
16, 19
Head stock central
lubrication station 1, 7,
17,19
2 months
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4. Head stock nipplegreasing in cams and
follower traverse motion
Suction end central
lubrication stn. 2,3,4,5
Head stock central
lubrication stn.
2,3,4,5,6,14,16,15
Head stock nipple
greasing in shaft of Z4
4 months
5. Yarn guide settingRotor brake setting
Spin box dial gauge
checking
1 year
WINDING/MURATA 1. Drum brushescleaningConveyor bearing
greasingTension motor
checkingCone cheese holder
checkingAir filter and pipe
cleaning
7 days
2. Cassette gear jointgreasing
Tension cuttercleaning
Cam shaft chaingreasing
1 months
3. Drum brake greasingCassette gear jointrolling
Reduction geargreasing
Coil holder bearinggreasing
6 months
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AUTOCONER 5 1. RS 400 spray onsplicer sensors andlower yarn shears
Checking dustextraction system
Inspecting blowerfilter
15 days
2. RH adaptor applysilicon oil
LH adaptor removeand clean hard waste
Suction motor- applyEP2 grease
Checking packageconveyor
3 months
3. Lapping cylinder oilleakage checkingLubricating thepackage doffer
lubricationCleaning and
checking the waxingdevice
Tension device; cleanand check lower end
yarnDust extraction; check
blades
6 months
TWO FOR ONE TWISTER
(TFO)
1. Checking nylonbushes in middlesupport
7 days
2. Check and clean camzone in cradle lifting
mechanismCheck brushes and
gear boxes
2 months
PRECISION PROPPELER
WINDER (PPW)
1. Check the tightness ofbelts
Yarn pass settingTraverse guide setting
7 days
2. All gear checkingPropeller settingChecking yarn tension
of all spindles
1 month
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All the above preventive maintenance activities can be done using a good maintenance plan
Preparing a Maintenance Plan
Depending on the application and design of a maintenance system, the format and steps of
preparing a maintenance plan can vary. The key steps in preparing a typical maintenance planare:
(1)Prepare an asset inventory - identifying the equipments which require maintenance;(2) Identify maintenance activity and tasks - defining the type of maintenance task
(activity) to be performed on each asset and what work should be done under each
activity, e.g.
Activity: preventive maintenance.
Work to be performed: greasing bearings, chains, etc.;
(3) Identify the frequency of the task- determining how often the activities should be
performed (frequency of service); this is important particularly in preventive type of
maintenance
(4) Estimate the time required to complete the task- indicating how long each task
should take to complete;
(5) Develop an annual work schedule - planning what time the maintenance work for
the entire year should take place;
(6) Prepare and issue a work order - identifying what, when, where and by whom
maintenance work is to be done; and
(7) Determine a Budget - determining the costs for all maintenance activities bycalculating labor hours, material, equipment, and contracting costs.
In this regard therefore, the following are the requirements for effective implementation of
the CMMS software in spinning department;
A computer system where the software is to be installed A CMMS software package which is to be installed and used Space/room where the computer system is to be situated Adequate maintenance manpower to answer to the requests of the software
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Conclusion
Maintenance is expected to play even much bigger role in years to follow, as industries
worldwide are going through an increasing and stiff competition and increased automation of
plants. The down time cost for such systems is expected to be very high. To meet these
challenges, maintenance has to use latest technology and management skills in all spheres of
activities to perform its effective role in profitability of the company.
cc. General Manager
cc. Logistics Manager
cc. Human Resource Manager