machinery maintenance audit by winsys smc

A.KANTHIMATHINATHANWINSYS LIMITED

winsyssmc@gmail.com

MACHINERY MAINTENANCE AUDIT(MMA)

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

Effective utilisation of resources

Men Machine Material Finance

CRITICAL ASSESSMENT OF A SYSTEM,PROCESS TO UNEARTH

DEVIATIONS FROM THE EXISTING

PRACTICES

DEVIATIONS FROM THE BENCHMARKED PRACTICES

CRITICAL ASSESSMENT OF A SYSTEM/PROCESS

TO IDENTIFY SCOPE FOR FURTHER IMPROVEMENTS

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

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?

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?

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……

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….???????

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?

COST OF THE SPARE COST OF PRODUCTION LOSS COST OF SUBSEQUENT MACHINERY

CHANGES BEYOND ABOVE,

LOSS OF A CUSTOMER FOREVER

ROUTINE MAINTENANCEORGANISED MANUFACTURERS GIVE

RECOMMENDED SCHEDULESMILLS HAVE TO DEVELOP FOR MACHINERY

FROM UNORGANISED SECTOR HAS IT BEEN DEVELOPED? HAS IT BEEN IN LINE WITH

REQUIREMENTS?

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

PREVENTIVE MAINTENANCE CHECKS

PREVENTIVE MAINTENANCE/CRITICAL ITEMS REPALCEMENT SCHEDULES

CHECK MAINTENANCE SCHEDULES AND LUBRICATION SHEDULE WHETHER,

IT IS IN LINE WITH MANUFACTURERER`S RECOMMENDATION?

IT IS IN LINE WITH INDUSTRY`S BEST PRACTICES?

ADEQUACY(CHECKS FEW CRITICAL PARTS)

SCOPE FOR RATIONALISATION

ONLINE AUDITS

OFFLINE AUDITS

Waste clogging in Undergrids Slow motion of Material in conveying

ducts Synchronisation of Feeding lines Suction levels

CV of Slivers

Sheet thickness after chutes in cards

Deposits in Flat tops

LAP LICKING

WEB UNIFORMITY

Web Appearance

Unicomb Cleanliness

Sliver CV in Modern Combers

1 M CV%

Shift from central Values

Deposits on Creel Guides and Use of Blowing fans/Timing

Performance of PDTC(Top/Bottom)

Apron shift

ROVING alignment

Creel slackness/stretch

Bobbin revolution

Yarn Path

Position of Underclearers

Effectiveness of OHTC

WAX DISC MOVEMENTS

SPLICE APPEARANCE

TENSION LEVELS

BEATER QUALITY LATTICE PIN QUALITY LATTICE BOWL AND DRIVE SHAFT QUALITY OF UNDERGRID CRITICAL SETTINGS INSPECTIO

(MILLS STDS VS ACTUAL)

CHECK CYLINDER AND DOFFER FOR LAND CHECK FLAT TOPS /STATIONARY FLATS

FOR STRAIGHTENING OF WIRES CHECK LICKERIN FOR BENT /BROKEN

WIRES

CHECK MOTE /TRASH KNIVES FOR SHARPNESS

CHECK BASIC SETTINGS FOR AUTOLEVELERS

CHECK CRITICAL SETTINGS

TOP ROLLER WEIGHTING SYSTEMS

TOP ROLLER SADDLE QUALITY

LAP SELVEDGE QUALITY

CONDITION OF UNICOMB AND TOP COMBS

CONDITION OF DET ROLL AND DRAFT ROLL WEIGHTING SYSTEMS

NIPPER BITE

TOP ROLLER WEIGHTING/SADDLE

LATERAL PLAY IN DRIVE

BRAKING EFFICIENCY

PRESSURE LEVELS CARBON IMPRESSION OF ROLLER

SETTINGS

TOP ROLLER PRESSURE VARIATION

BUILDER MOTION FUNCTION

ALIGNMENT OF ROVING GUIDES

APRON TENSION

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

YARN PATH IN COMPACT ZONE

SUCTION CONSISTENCY BETWEEN SECTIONS

COMPACTING SPARES CONDITION

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

LEAF GAUGE

MASTER Pr. GAUGE

NILOMETER

ENSURE TIMELY CALIBRATION OF TOOLS AND GAUGES

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

EXTENT TO WHICH PLANNED ACTIVITIES ARE REALISED AND THE PLANNED ACTIVITIES ARE CARRIED OUT

RELATIONSHIP BETWEEN THE RESULTS AND RESOURCES USED

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

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

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

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

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.

Auditing of Maintenance activity is essential

To assess Buffing activity mills use Rogue Soindle analysis immediately after Buffing.

Next Level of MMA is TPM

TOTAL PRODUCTIVE MAINTENANCE

Thanks!