MAINTENANCE

COMPILED BY: SHILPI M/BFT/09/28 SEM 6 B.F.Tech NIFT Mumbai

Maintenance Managements 1

INTRODUCTION
Maintenance management can be considered as the direction and organisation of resources to control the availability of equipment. The tasks associated with maintenance can be divided into three main areas; work management, plant condition control and cost control. Maintenance specifications give in details the procedures to be followed to ensure that the product receives correct maintenance at required intervals. Apart from having quality system and the best practices, machine maintenance is also a very important are to get quality products. Unacceptable quality of products often results ill-maintained machines.

Benefits of Maintenance in any Organization:

Reduce equipment downtime Improve equipment reliability Improve equipment output (OEE) Improve OSHA compliance/Reduce injury rates Reduce scrap rates Reduce maintenance costs Reduce energy consumption costs

Ideal Attendees:

Maintenance Managers Maintenance Supervisors Operations management Plant managers Continuous improvement leaders

Rating a maintenance department of any garment industry is a herculean task. These are some of the rounds on which we can rate the maintenance department of the garment production unit.

Maintenance Managements 2

PARAMETERS ON WHICH TO RATE A MAINTENANCE DEPARTMENT

Parameter Equipment Availability Schedule Compliance Emergency maintenance percentage Maintenance Overtime percentage Preventive Maintenance Completion Percentage Preventive Maintenance Budget Cost Predictive Maintenance budget/cost Calculations (Hours each unit is available to run at capacity/Total hours during the reporting time period) (Total hours worked on the scheduled jobs/ Total hours Scheduled) (Total hours worked on emergency jobs/Total hours worked) (Total maintenance overtime during period/Total regular maintenance hour during period) (Preventive maintenance actions completed/ Preventive Maintenance actions scheduled) (Preventive maintenance cost/ Total maintenance cost) (Preventive Maintenance cost/Total maintenance cost) Benchma rk >95% Point s 1

>90% <10% <5%

1 1 1

>90%

15%-18% 10%-12%

1 1

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PARAMETERS ON WHICH TO RATE A MAINTENANCE DEPARTMENT S.N o 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 Parameters Type Of Maintenance program followed Is there An SOP for the Maintenance department (Y/N) Time spent in various procedures before the machine can be catered to Time taken to repair a machine Maintaining of the log books, work orders etc., equipment record sheets Frequency of routine examination Type of inspection Frequency of re-occurrence of a failure Availability of Spare parts Availability of Back-up machine & equipments Man- Machine ratio in the maintenance department Automation degree of maintenance department Probability of restoration of the failed machine Frequency of Planned Maintenance Method of maintenance Frequency of breakdown Mean time between failure Machine Downtime Cost of maintenance
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Remar ks

20

No. of Casualties

ASSESSMENT CRITERIA FOR THE ABOVE SHEET S. No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 Assessment Preventive yes 5 -10Mins 10-20mins Regular Daily Indicator/Integr al monitoring Weekly Yes Yes 1/10 Automated 100% Weekly Complete Overhaul 2 in 6 months 6 months 1 hour Less Than 1/10th the cost of machine Point s 1 1 1 1 1 1 1 -1 1 1 1 1 1 1 1 1 1 1 1 Assessment Corrective No 10-15 mins 20-25 mins Improper Alternate Days Visual/sensor Monthly No No 1/20 Semi-Automated <100% Monthly Major Parts More than 2 Less Than That More than1 More than That but less than half the cost of machine
5

Points 0.5 0.0 0.5 0.5 0.0 0.5 0.5 -0.5 0.0 0.0 0.5 0.5 0.5 0.5 0.5 0.0 0.0 0.0 0.5

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20

1 in a year (depends on severity)

-1

Less Severe

-0.5

Assessment Of A Maintenance Department In A Garment Industry On The Aforesaid Parameters

Marks Scored Above 20 17- 20 15-17 10-15 Less Than 10 Less than 7 Meaning Excellent Very- Good Good Average Needs Improvement Poor

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