southern range nyanza ltd

8/3/2019 Southern Range Nyanza Ltd

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Agaba, BSc. Textile Technology (Hons.)/KYU

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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

southern range nyanza ltd

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