SOUTHERN RANGE NYANZA LTD Spinning Department

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

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

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 maintain effectively 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 the highest 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.

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

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 y Emergency maintenance: it is carried out as fast as possible in order to bring a failed machine or facility to a safe and operationally efficient condition. Breakdown maintenance: it is performed after the occurrence of an advanced considered failure 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 advance However 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.

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

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 as the maintenance 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 to perform this type of maintenance. 2. The right choice of production equipment and machinery that is suitable for the working environment 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 and periodic in nature such as lubrication, cleaning, and small adjustment. Running maintenance which includes those maintenance activities that are carried out while the machine or equipment is running and they represent those activities that are performed before the actual preventive maintenance activities take place.

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

Opportunity maintenance which is a set of maintenance activities that are performed on a 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 or equipment is not required for a definite period of time. Shutdown preventive maintenance, which is a set of preventive maintenance activities that 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 the source 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 not immediately 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 activities that 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 for the 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.

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

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 cause of 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 Engineering services which include construction and construction modification, removal and installation, and rearrangement of facilities. Shutdown improvement maintenance, which is a set of improvement maintenance activities that are performed while the production line is in a complete stoppage situation.

y y

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 maintenance o Statistical-based predictive maintenance y Condition-based predictive maintenance depends on continuous or periodic condition monitoring equipment to detect the signs of failure.

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

Statistical-based predictive maintenance depends on statistical data from recording of the stoppages of the in-plant items and components in order to develop models for predicting failures. MAINTENANCE TYPES

MAINTENANANCE

PLANNED MAINTENANCE (PROACTIVE) EMERGENCY

UNPLANNED MAINTENANCE (REACTIVE) BREAKDOW

PREDICTIVE

PREVENTIVE

INPROVEMENT

CORRECTIVE

STATISTICAL -BASED

CONDITION -BASED

ENGINEERING SERVICES

DESIGN-OUT

DEFERED

REMEDIAL

WINDOW

RUNNING

ROUTINE

OPPORTU -NITY

SHUTDOWN

SHUTDOWN

SHUTDOWN

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

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

Objectives of Preventive Maintenance The objectives of preventive maintenance include the following:
y y y y y

To avoid, as far as possible, failure or breakdown of equipment during normal operation. To maximize the operating efficiency of the equipment. To ensure safety in operation. To minimize the cost of production by maximizing the availability of equipment for production. 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 the organization'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)

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

 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 (for example, 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 the following;  Managing Work Orders; This involves scheduling jobs, assigning personnel, reserving materials, 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 machines including maintenance activities, specifications, purchase date, year of manufacture, expected life time, warranty information, service history, spare parts and anything else that might be helpful to management and maintenance workers.

 Inventory Control; CMMS software will help in management of spare parts, tools and other 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.

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

The preventive maintenance activities in spinning department shall include the following; SPINNING DEPARTMENT PREVENTIVE MAINTENANCE ACTIVITIES SECTION/MACHINE BLOW ROOM PM ACTIVITIES 1. Scouring 2. Gear oil change 3. Replacement of beater lags 1. Cleaning all suction hoods, tuft feeder, flat strip roll, revolving flat area, doffing section, feed table and flats brush 2. Checking the tension of all belts 3. Cleaning main cylinder covers 4. Main cylinder bearing greasing 5. Doffer bearing greasing and delivery roller greasing 1. Cleaning and checking bearings and top rollers 2. Greasing the can plate, drive pressure element, pressure bar coiler plate and auto lever and cleaning sliver guides, flexible horses and filter net 3. Cots buffing All timing belt cleaning and tightening All nipple greasing and checking oil level 4. Lubrication of top roller bearings Lubrication of coiler plate and can plate bearings DURATION 25 days 6 months 36 months

CARDS

25 days

2 months 3 months 6 months 12 months

DRAW FRAMES

7 days

25 days

3 months

6 months

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

SECTION/MACHINE UNILAP

PM ACTIVITIES 1. Cleaning sliver guides and guide rolls, feed frames Checking chains and belts Cleaning guide bushes for the lap roller Oiling fringes Lubricating sprocket chains Lubricating gears and cylinders.

DURATION

1 month

COMBER

2. Cleaning inner chambers Emptying water separatorss 3 months Grinding top rollers 3. Washing top roller bearing bushes Greasing bearings for clearer cloth drive Greasing lap roller fringe 6 months bearing and loading lever Greasing locker bearing,tube feed and shafts 4. Immersing sprocket 1 year chains in oil bath 1. Cleaning longitudinal 7 days part, coiler, v-belt main drive, belt drive for brush 2. Cleaning the circular comb, top comb unit. Adjusting brushes. Cleaning detaching 1 month cylinder and top drum roller

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

3. Cleaning and lubricating the stripper detaching roll, drafting system drive. Lubricating horse on length ways shaft COMBER CONTD 4. Lubricating the bottom drafting roller and bearing Cleaning the can turn table 5. Head stock gear box oil change

3 months

6 months

1 year

SPEED FRAME

RING FRAME

1. Lubricating the articulate shaft, compressed air coiler Central lubrication 25 days Lubricating gear wheels of the drafting system Greasing cone drive 2. Lubricating guides in builder motion Lubricating bottom roller 2.5 months bearings and drive chains of feed rollers 3. Bobbin rail oil change 5 months Flyer table lubrication 4. Cots buffing 3 months 5. Lubricating the head 10 months stock drives 1. Motor variator setting Pneumatic drum cleaning 1 months Draw bar roller cleaning 2. Cots buffing Lubricating pum 3 months checking

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

3. Ring rail and lappet height setting Suction tube washing Traveller cleaning and setting Electro valve cleaning Inspection brake setting 4. Fluted roller eccentricity setting Roving traverse setting Top arm setting Bottom roller setting

6 months

1 year

OPEN END/OUTOCORO 312

1. Servicing coromat 1 Servicing coromat 2 2. Servicing twin disc assembly Inspecting the rotor belt, opening roller belt, trash conveyor belt, empty tube conveyor belt 3. Suction end central lubrication station 1, 6, 16, 19 Head stock central lubrication station 1, 7, 17,19

1 months

6 months

2 months

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

4. Head stock nipple greasing 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 setting Rotor brake setting Spin box dial gauge checking

1 year

WINDING/MURATA

1. Drum brushes cleaning Conveyor bearing greasing Tension motor checking Cone cheese holder checking Air filter and pipe cleaning 2. Cassette gear joint greasing Tension cutter cleaning Cam shaft chain greasing 3. Drum brake greasing Cassette gear joint rolling Reduction gear greasing Coil holder bearing greasing

7 days

1 months

6 months

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

AUTOCONER 5

TWO FOR ONE TWISTER (TFO)

PRECISION PROPPELER WINDER (PPW)

1. RS 400 spray on splicer sensors and lower yarn shears Checking dust extraction system Inspecting blower filter 2. RH adaptor apply silicon oil LH adaptor remove and clean hard waste Suction motor- apply EP2 grease Checking package conveyor 3. Lapping cylinder oil leakage checking Lubricating the package doffer lubrication Cleaning and checking the waxing device Tension device; clean and check lower end yarn Dust extraction; check blades 1. Checking nylon bushes in middle support 2. Check and clean cam zone in cradle lifting mechanism Check brushes and gear boxes 1. Check the tightness of belts Yarn pass setting Traverse guide setting 2. All gear checking Propeller setting Checking yarn tension of all spindles

15 days

3 months

6 months

7 days

2 months

7 days

1 month

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

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 plan are: (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 by calculating 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

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

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

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