Effect of Maintenance On Production & Quality

Southeast University
School of Science and Engineering Department of Textile Engineering
Project on Effect of Maintenance on Production and Quality
Submitted by:
Ajaz-Ul Huq-Banna Gazi Abdul Kader Goni Ibrahim Kholil Emdadul Haque Joni Ariful Islam Batch 6th Department of Textile Engineering
ID No.
2007200400041 2007000400051 2007200400068 2007200400004 2007200400081
Supervisor:
Dr. Md. Abul Kalam Azad Project Supervisor Department of Textile Engineering Southeast University
Dhaka, 14, September, 2011
Brief Presentation
Industry Name: Standard Group Ltd. & GMS Composite Knitting Ind. Ltd.
School: Course of Studies:
Science and Engineering B.Sc. in Textile Engineering
Supervising Teacher: Dr. Md. Abul Kalam Azad Project Supervisor Department of Textile engineering. Southeast University
Submitted by:
Ajaz-Ul Huq-Banna Gazi Abdul Kader Goni Ibrahim Kholil Emdadul Haque Joni Ariful Islam
ID No.
2007200400041 2007000400051 2007200400068 2007200400004 2007200400081
Batch 6th Department of Textile Engineering
Date of Issues:
01 July, 2011
Date of submission: 09 September, 2011
TEXTILE ENGINEERING DEPARTMENT
Abstract
Textile technology education is based on industrial ground. Theoretical background is not sufficient so, industrial training is an essential part of study to make a technologist technically sound in this field. Industrial training provides us that opportunity to gather practical knowledge.
Standard Group Ltd & GMS Composite Knitting Ind. Ltd. is a truly integrated undertaking. The textile division has the capability to offer a complete product range for the export & domestic textile markets. The goal of this textile factory is to become the preferred partner for sourcing high quality fabrics & clothing from Bangladesh. With high advanced technology & an emphasis on developing local human resources, the textile division has the potential to make an important contribution to the nations growing readymade garments export sector.
The rationale behind the existing structure & future expansion of the textile division is to capture value added at each stage of the textile manufacturing process. Despite Bangladeshs lack of indigenous cotton production capability, Standard Group Ltd. & GMS Composite Knitting Ind. Ltd. has leveraged Bangladeshs labor cost advantage & export competitiveness to maximum level.
Standard Group Ltd. & GMS Composite Knitting Ind. Ltd.
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Declaration
We hereby declare that the submitted work was completed using only the mentioned literature and without any Unhallowed assistance.
Dhaka: 14 September, 2011
Thanks ,
Mahafuzur Rahman Palash Saha Md.Shahadat Hossain Moazzem Hossain A.K.M. Shariful Alam
2006100400029 (5nd Batch) 2006100400007 (5nd Batch) 2006100400038 (5nd Batch) 2006100400005 (2nd Batch) 2006200400007 (3rd Batch)
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Acknowledgement
We take this opportunity to record my deep sense of gratitude and appreciation to our Project Advisor Dr.Md.Abul Kalam Azad (Project Supervisor) Department of Textile engineering, Southeast University for his constant encouragement and inspiring guidance with his Wisdom. We also take the opportunity to express our sincerest gratitude to the management, administration & personnel of Standard Group & GMS Composite Knitting Ind. Ltd. for their kind assistance. We would like to express our depest appreciation, sincerest gratitude to our respected teacher Professor Syed Fakhrul Hasan, Chairman, Department of textile Engineering, SEU, A.N.M. Ahmed Ullah, Coordinator, Department ofTextile Enginering, SEU.Adnan Zaber Mahamud, Assistant Professor, SEU and all other honourable teacher of Textile engineering Department,SEU. Cordial thanks goes to Engr.Liton General Manager(Dyeing) & Abu Jafor (AGM) GMS Composite Knitting Ind. Ltd & Standard Group Ltd. for their excellent co-operation during the period of our training. We would also like to thank Engr. Sumon (Dyeing Manager) knit dyeing section and Engr. Saiful (Sr. Production Officer) of knit fabric section for their sincere support. Above all, we would like to acknowledge our deep debt to all teachers of our university & particularly of Wet Processing Department for their kind inspiration & help, which remain as the backdrop of all our efforts. Finally, we would like to acknowledge that we remain responsible for the in-adequacies & errors, which doubtless remain in the following report.
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Contents
CHAPTER I ..........................................................................................................6 Introduction ...........................................................................................................6 Introduction ...........................................................................................................7 Factory description: ..........................................................................................7 Standard Group .......................................................................................7 GMS Composite Knitting Ind. Ltd. ............................................................8 Factory Profile ..................................................................................................8 Standard Group Ltd..................................................................................8 Management Organ gram ..............................................................................12 Project Description .........................................................................................14 Maintenance Definition:..........................................................................14 Objectives of Maintenance .....................................................................14 Types of Maintenance ............................................................................14 CHAPTER II .......................................................................................................19 Background .........................................................................................................19 Background .........................................................................................................20 CHAPTER III ......................................................................................................21 Methodology ........................................................................................................21 Methodology ........................................................................................................22 Sections considered in the factory where maintenance is done: ....................22 Machines of the different sections: ................................................................23 Sample section ......................................................................................23 CAD section ...................................................................................................24 Spreading section ..................................................................................24 Cutting section: ......................................................................................24 Fabric Cutting: ........................................................................................25 Sewing section .......................................................................................26 Maintenance Schedule of Different parts of a sewing m/c[single needle]: ......28 Different parts of sewing m/c[over lock]: .........................................................30 Practical Procedure: .......................................................................................31 To Maintain Machine Trouble Free: ................................................................31 Maintenance of different m/c: .........................................................................32
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For Plain Machine: .................................................................................32 Over Lock Machine: ...............................................................................32 For Button Attaching Machine: ...............................................................32 Button Holing Machine : .........................................................................33 Bartake Machine: ...................................................................................33 Shortly Maintenance Schedule of m/c: ...........................................................34 GENERAL CLEANING ...................................................................................34 Unplug Your Machine.............................................................................36 Remove Lint ...........................................................................................36 Sewing Machine Oil ...............................................................................36 Loose Screws ........................................................................................37 Wires 37 Breaking Needles ...................................................................................37 Fabric Won't Feed Properly....................................................................37 Skipped Stitches ....................................................................................37 Thread Nest forms on the bottom ..........................................................38 Maintenance system and Troubleshooting : ....................................................38 Maintenance: ..................................................................................................38 Trouble Shooting: ...........................................................................................38 Sample of a Preventive Maintenance Card: ...................................................40 CHAPTER IV .....................................................................................................48 Result ...................................................................................................................48 Result ...................................................................................................................49 CHAPTER V ......................................................................................................50 Conclusion ...........................................................................................................50 Conclusion ...........................................................................................................51 Remarks ...............................................................................................................52
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CHAPTER I Introduction
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Introduction
Factory description:
Standard Group
Standard Group is a readymade garments type. All kinds of woven products for man, women, boy s, girls & kids and all types of casual outerwear, bottoms & causal tops, printing, quilting, embroidery, washing, sand blasting. It established at May 1984. Standard Group is one of the pioneer personalized and professional skill garments manufacturing, construction, insurance, banking, trading, establishment. Standard trade area journey in 1969 in the field of construction and later in 1984 expression of business activities into Global linked garments manufacturing credits facilities emergent exposes of a giant complete garments manufacturing solution. Manufacturer and exporter of all kinds of woven garments for man, women, boy s, girls & kids spring and fall jacket, winter coat, shirts, shorts, trouser, skirt, down jacket & vest, short all, overall & dresses. To maintain garments quality level foreign technician are engaged, 1.5-4.0 AQL system been followed, 100% garments inspected in finishing section and garments pass trough needle detector machine to metal free protective zone to ensure free from metal hazardous. High tech machinery for consistent quality and timely deliver, CAD and digitizing for design, pattern grading, marker making, computerized machine within sewing lines, GARBER machine to co-operation with modern technology and attend efficiency in quality. Washing plant covering all kind of washing facility is like Enzyme wash, Silicon wash, Enzyme-silicon wash, Bleach wash, Stone wash, Sand blasting, Laser blasting along with tinting. Synchronous with growing business volume in our house facility been enriched with facility in 1994 which covering up to 15 color beside, with the average factory growth rate 3.85 garments manufacturing unit strength reached at total of 14 no in 1990 and within the span of time of time by 2000 increasing customer demand against our reliable quality concern and excellent service reputation put us to be a creatable factory strength of 25 no unit under standard family umbrella. Over the years rolling growth rate helped accelerate building couple of our own factory premises at deferent location of the countrys capital mega city around 2 storied building at Tejgan 1991, 20 storied balding at Kalshi, 20 storied building at Mohakhali in 2003. Standard sourcing office4 operating in Hong Kong to have a better grip and control on quality level in the far east region in addition to facilitate faster response from mills. In year 2003 inclusion of new sweater factory with about 940 machines put Standard Group Garments division advancement entry to a new area sweater and knit garments field.
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Nevertheless, Sandard Goup not only cares garments manufacturing but also keeping foot print in construction, Insurance, Banking and Trading sector. In the name of civil engineering Ltd. a construction division made accredited achievement in capital mega city architectural multi storied high rise facilities, Convocation hall, Indoor stadium, 500 bed hospital, countries biggest power generation station, Bimen bhaban, TV station, national university, diabetic hospital.
GMS Composite Knitting Ind. Ltd.

GMS Composite Knitting Ind. Ltd. is a readymade Knit garments type. All kinds of knit products for man, women, boy s, girls & kids and all types of casual outerwear, bottoms & causal tops, printing, quilting, embroidery, washing, sand blasting. It incorporation in 1999 and successfully went for production in 2000. Manufacturer and exporter of all kinds of knit garments for man, women, boy s, girls & kids spring and fall jacket, winter coat, shirts, shorts, trouser, skirt, down jacket & vest, short all, overall & dresses. To maintain garments quality level foreign technician are engaged, 1.5-4.0 AQL system been followed, 100% garments inspected in finishing section and garments pass trough needle detector machine to metal free protective zone to ensure free from metal hazardous. High tech machinery for consistent quality and timely deliver, CAD and digitizing for design, pattern grading, marker making, computerized machine within sewing lines, GARBER machine to co-operation with modern technology and attend efficiency in quality. Washing plant covering all kind of washing facility is like Enzyme wash, Silicon wash, Enzyme-silicon wash, Bleach wash, Stone wash, Sand blasting, Laser blasting along with tinting. Synchronous with growing business volume in our house facility been enriched with facility in 2007 which covering up to 15 color.
Factory Profile
Standard Group Ltd.
Company Name Status Type & Business of the company Factory Location Head Office Sponsors Year of Establishment Project Investment : : : : : : : : STANDARD GROUP TLD LTD Private Ltd. Company 100% Export oriented garments factory & Exporter. Kalshi, Mirpur-11,Dhaka Plot No. 389 Lane No:6,DOHS, Baridhara, Dhaka STANDARD GROUP TLD of company LTD May 1984 $ 2.00 Million
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Annual Turnover Factory Floor Space Factory Equipments
Total Manpower Total Cutting machine Total Sewing machine Total washing machine Main Production
Production Capacity Buyers Main Market Payment Terms Fax Number Email Address
: $ 5.00 Million. : 126,000 sft : Different types of Cutting, Sewing, Finishing and Generator machines supplied by mostly Japan, Taiwan, EU, USA, Singapore, China, etc. : : : : : woven garments for man, women, boy s, girls & kids spring and fall jacket, winter coat, shirts, shorts, trouser, skirt, downjacket & vest, short all, overall & dresses. : 4000 pcs/day (Average) : GAP, BIMTEX, ANAF, BHS, MILES, LOLL ,TOYS, GEORGE, IVORY : EU, UK & Canada. : Confirmed Irrevocable Letter of Credit. : + 880 2 934 2368 : fashionbd@.com

Name of the Factory Motto Type Year of Incorporation : GMS Composite Knitting Industry Limited : Striving For Excellence : 100% Export Oriented Composite Knitting Industry : 1999
Year of Starting Production : 2000 Status Investor Project Cost Annual Turnover Total Manpower Address: Standard Group Ltd. & GMS Composite Knitting Ind. Ltd. Page 9 : Private Limited Company : Md. Golam Mostafa : : : Around 8500
Corporate Office
: House# 365 (1st Floor), Road# 28, New D.O.H.S., Mohakhali, Dhaka-1207, Bangladesh Telephone: +88-02-8837037-8 Fax: +88-02-8711095 E-mail: eti@gmsbd.com
Factory Address
: Shardaganj, Kasimpur, Gazipur Telephone: +88-02-7788951-3 Fax: +88-02-7788934
Official Website Production Capacity: Knitting Dyeing Yarn Dyeing Garments
: http://www.gmsbd.com
: Approximately 29 Tons/Day : Approximately 25 Tons/Day : Approximately 10 Tons/Day : Approximately 1,20,000 Pieces/Day.
Major Departments of the Factory: Human Resource & Administration Marketing & Merchandising Knitting Dyeing & Finishing Yarn Dyeing Garments Quality Assurance Technical Department Printing
End Products: All kinds of Gents, Ladies & Kids Knitwear especially, T-shirt, Polo shirt, Sweat shirt, Tank Top, Trousers etc. Certificates & Awards:
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Oeko-Tex WRAP(Worldwide Responsible Apparel Production) BSCI(Business Social Compliance Initiative) Best Effluent Treatment Plant of the Year, 2010.
Other Facilities: Full time Doctor & Nurse for emergency treatment & Preventive medical facility for officials and workers. Stuff canteen as in-house facility of lunch & snacks. Complimentary bus service for the workers who are living 5 K.M. away of the factory. Child care centre and mosque inside the factory. Two times bonus and attendance award to increase workers diversity. Committee of workers to maintain strong relationship with top management to full-fill demands.
Project Area Floor Plans: Knitting Dyeing Finishing Garments Store Utility Office & Others
: 2,90,000 square foot.
: 40,000 square foot : 30,000 square foot : 20,000 square foot : 90,000 square foot : 60,000 square foot : 40,000 square foot : 10,000 square foot
Physical Infrastructure: Four seven stored building, 15 single stored building. All of them are made of bricks. Location: GMS Composite Knitting Ind. Ltd. is situated at Shardaganj, Kasimp ur, Gazipur. It is located at the eastern side of the Dhaka-Tangail Highway. It is about 40 K.M. from Dhaka.
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Management Organ gram

Managing Director Director. Admin, HR & MM Admin, HR & Compliance Accounts & Finance Merchandising
Store Audit Work Study Garments Cutting Garments Quality Sample GPQ Monitoring Dyeing
Garments Sewing Garments Finishing Printing Embroidery Security Technical
Knitting
Maintenance
GMTS (Maintenance)
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Admin, HR & Compliance GM Administration DGM Human Resource

DGM
Compliance DGM
AGM
AGM
AGM
Manager
Manager
Manager
Asst. Manager
Asst. Manager
Asst. Manager
Sr.Executive
Sr.Executive
Sr.Executive
Executive
Executive
Executive
Jr.Executive
Jr.Executive
Jr.Executive
Sr.Officer
Sr.Officer
Sr.Officer
Officer
Officer
Officer
Jr.Officer
Jr.Officer
Jr.Officer
Staff
Staff
Staff
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Project Description
Maintenance Definition:
British Standard Glossary of terms (3811:1993) defined maintenance as:
The combination of all technical and administrative actions, including supervision actions, intended to retain an item in, or restore it to, a state in which it can perform a required function. Maintenance is a set of organized activities that are carried out in order to keep an item in its best operational condition with minimum cost acquired. 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. 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.
Types of Maintenance
1. Run to Failure Maintenance (RTF) 2. Preventive Maintenance (PM) 3. Corrective Maintenance (CM) 4. Improvement Maintenance (IM) 5. Predictive Maintenance (PDM)
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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 the oldest type of maintenance. It is subdivided into two types: 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, labor and equipment. Disadvantages: Its activities are expensive in terms of both direct and indirect cost. 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. Its activities are very difficult to plan and schedule in advance. This type of maintenance is useful in the following situations: The failure of a component in a system is unpredictable. The cost of performing run to failure maintenance activities is lower than performing other activities of other types of maintenance. The equipment failure priority is too low in order to include the activities of preventing it within the planned maintenance budget. 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 and the effects limited. Advantages: The factors that affect the efficiency of this type of maintenance: The need for an adequate number of staff in the maintenance department in order to perform this type of maintenance. The right choice of production equipment and machinery that is suitable for the working environment and that can tolerate the workload of this environment. The required staff qualifications and skills, which can be gained through training. The support and commitment from executive management to the PM programme. The proper planning and scheduling of PM programme.
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The ability to properly apply the PM programme. It is good for those machines and facilities which their failure would cause serious production losses. Its aim is to maintain machines and facilities in such a condition that breakdowns and emergency repairs are minimized. Its activities include replacements, adjustments, major overhauls, inspections and lubrications. 1. 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. 2. 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. 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. In the British Standard 3811:1993 Glossary of terms, corrective maintenance is defined as: The maintenance carried out after recognition and intended to put an item into a state in which it can perform a required function. This type of maintenance is subdivided into three types: 1. 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. 2. 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. 3. Shutdown corrective maintenance which is a set of corrective maintenance activities that are performed when the production line is in total stoppage situation.
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The main objectives of corrective maintenance are the maximization 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. 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: 1. 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. 2. Engineering services which includes construction and construction modification, removal and installation, and rearrangement of facilities. 3. Shutdown improvement maintenance which is a set of improvement maintenance activities 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 maximizing 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: 1. Condition-based predictive maintenance 2. Statistical-based predictive maintenance Condition-based predictive maintenance depends on continuous or periodic condition monitoring equipment to detect the signs of failure. Statistical-based predictive maintenance depends on statistical data from the meticulous recording of the stoppages of the in-plant items and components in order to develop models for predicting failures. The drawback of predictive maintenance is that it depends heavily on information and the correct interpretation of the information. Some researchers classified predictive maintenance as a type of preventive maintenance. The main difference between preventive maintenance and predictive maintenance is that predictive maintenance uses monitoring the condition of machines or equipment to determine Standard Group Ltd. & GMS Composite Knitting Ind. Ltd. Page 17
the actual mean time to failure whereas preventive maintenance depends on industrial average life statistics.
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CHAPTER II Background
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Background
In the period of pre-World War II, people thought of maintenance as an added cost to the plant which did not increase the value of finished product. Therefore, the maintenance at that era was restricted to fixing the unit when it breaks because it was the cheapest alternative. During and after World War II at the time when the advances of engineering and scientific technology developed, people developed other types of maintenance, which were much cheaper such as preventive maintenance. In addition, people in this era classified maintenance as a function of the production system. Nowadays, increased awareness of such issues as environment safety, quality of product and services makes maintenance one of the most important functions that contribute to the success of the industry. World-class companies are in Continuous need of a very well organized Maintenance program to compete world-wide. The subject textile engineering in recently developed Bangladesh. People are taking interest about the garments factory. Previously the higher educated persons are not interested in the garments to do their job. So people are not done thesis or any analytical object on that subject or in garments factory. We dont get so much help on our topics, we find a thesis on Effect of Maintenance on Production done by the faculty of BUET, and our senior student of our previous batch. From their thesis we get help, we get ideas to complete our project.
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CHAPTER III Methodology
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Methodology
Sections considered in the factory where maintenance is done:
A) Sample section B) CAD section C) Spreading section D) Cutting section E) Sewing section F) Finishing section G) Others
Above section maintenance are done by specific tools those tools are required to maintenance are give below: 1.1.1.1 1.1.1.2No 1.1.1.3 1.1.1.401
Equipment Name Combination tools / 1.1.1.5 spanner
Function Tightening & loosening of nuts & bolts.
1.1.1.6 1.1.1.702 1.1.1.9 1.1.1.10 03 1.1.1.12 1.1.1.13 04 1.1.1.15 1.1.1.16 05 1.1.1.18 1.1.1.19 06 1.1.1.21 1.1.1.22 07 1.1.1.24 1.1.1.25 08 1.1.1.27 1.1.1.28 09 1.1.1.30 1.1.1.31 10 1.1.1.33 1.1.1.34 11 1.1.1.36 1.1.1.37 12 1.1.1.39 1.1.1.40 13 1.1.1.42 1.1.1.43 14 1.1.1.45 1.1.1.46 15
Socket ratchet set 1.1.1.8 Slide range

1.1.1.11
Tightening of nuts & bolts. Tightening & loosening of nuts & bolts. Tightening & loosening of nuts & bolts. To cut the threat in pipe. To assist the opening of bearing from shaft. Tightening & loosening of pipe joint. For pipe cutting Punching the hole. For circle marking on metal & wood. To open the broken head bolt. For external threat cutting. Cutting of gasket & steel sheet. Oiling of moving parts. For drilling.
Monkey pliers 1.1.1.14 Pipe threat cutting tools 1.1.1.17 Bearing puller 1.1.1.20 Pipe range
1.1.1.23
Pipe cutting tools 1.1.1.26 Hole punch Divider Easy opener

1.1.1.29 1.1.1.32 1.1.1.35
External threat die 1.1.1.38 Heavy scissor 1.1.1.41 Oil can

1.1.1.44
Drill machine and drill 1.1.1.47 bit.
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1.1.1.48 1.1.1.49 16 1.1.1.51 1.1.1.52 17 1.1.1.54 1.1.1.55 18 1.1.1.57 1.1.1.58 19 1.1.1.60 1.1.1.61 20 1.1.1.63 1.1.1.64 21 1.1.1.66 1.1.1.67 22 1.1.1.68 1.1.1.69 23
Grease gun
1.1.1.50
For greasing of moving parts of m/c. For grinding & cutting of mild steel For welding & cutting. For perfect leveling For smoothing the surface. For scaling & right angling.
Circlip opening & closing.
Grinding m/c 1.1.1.53 Welding m/c 1.1.1.56 Spirit leveler 1.1.1.59 File Hammer Circlip tools Hacksaw blade 1.1.1.70
1.1.1.62 1.1.1.65
For metal cutting.
Table 01: Machine Maintenance require tools for garments section.
Machines of the different sections: Sample section

It is the first section of garment manufacturing process. This section is used in apparel industry fora)To make sample garment for approval. b)To make pattern sets for bulk production when needed. Section Type of machine Single needle Double needle Over Lock Kansai Bar Tack Button Stitch Button Hole Eyelet Button Hole Button Hem Flat Lock Snap Button Attach Blind Stitch Cutter M/C Heat Cutter Over Lock Elastic Attaching Arm Hole Sewing M/C Table 02: Machine description of Sample Section Standard Group Ltd. & GMS Composite Knitting Ind. Ltd. Sample Section Quantity 150 25 22 10 15 12 12 10 05 15 05 07 70 2 1 1
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CAD section
Sample section givens pattern and CAD section done Marker according to follow shrinkage percentage .Marker length should be bigger than fabric length. Section CAD Section Type of machine Gerber CAD Gerber Plotter Gerber Digitizer Quantity 15 02 01
Table 03: Machine description of CAD Section
Spreading section A. Automatic Spreading Machine

To achieve tension free in spreading, stretch out the fabric smooth, regular and ship-shape. Machine Type : Cloth Cutting Machine Supplier : New Sheng Ling Industrial Co., LTD. Manufacturer: Taiwan
B. Semi Automatic Fabric Spreading Machine

Semi automatic spreading machine with one way, zigzag or tubular Machine Type : Cloth Cutting Machine Supplier : Serkon Textile Machinery Manufacturer : Turkey A. Fully Automatic Spreader Machine Type : Cloth Cutting Machine Supplier : RICHPEACE GROUP CO LTD Manufacturer : Hong Kong Section Spreading Section Type of machine Gerber auto Spreader Manual spreader table Manual spreading m/c Light box Quantity 02 09 07 09
Table 03: Machine description of Spreading Section.
Cutting section:
It is the second section of apparel manufacturing. In this section the following works are completeda)Marker Making b)Fabric Spreading c)Fabric Cutting
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Fabric Cutting:
The definition of cutting is very complex. In garments industries fabric is cut from lay & spreading with accuracy & properly which is termed as fabric cutting. Marker outline is used to cut the fabric. Fabric cutting is very important as if some thing is cut in wrong way, cannot be rectified. Requirements of cutting: Precision in cut Clean edge Infused edge Consistency in cutting Support of lay Methods of fabric cutting: There are mainly three methods of cutting are as follows: 1. Manual: Hand operated scissor 2. Manually operated power knife: Straight knife Band knife Round knife Die cutting Notches Drill 3. Computerized: Knife Laser Water Plasma torch
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Section Cutting Section
Type of machine Fabric Inspection m/c Light box Gerber Cam Manual Cutter Manual cutting m/c
Quantity 02 09 02 09 09
Table 01: Machine description of Cutting section Maintenance done Daily Weekly --Done Done --Done Done Done --Done ----Done
Parts Name Motor Knife Sharpener Knife Guard Handle Switch
Monthly ----Done Done -----
Half yearly -------------
Yearly -------------
Sewing section
Sewing is the craft of fastening or attaching objects using stitches made with a needle and thread. Sewing is one of the oldest of the textile arts, arising in the Paleolithic era. Before the discovery of spinning yarn or weaving fabric, archaeologists believe Stone Age people across Europe and Asia sewed fur and skin clothing using bone, antler or ivory needles and "thread" made of various animal body parts including sinew, catgut, and veins . Most sewing in the industrial work is done by machine. Pieces of a garments are often first tack together. The Machine has a complex set of gears and arms that pierces thread through the layers of the cloth and semi-securely interlock the thread. Mainly Garments cut parts are assembled here. Standard Group Ltd. & GMS Composite Knitting Ind. Ltd. Page 26
Figure : Sewing Section Section Type of machine 1-Needle Lock Stitch 1-Needle China Stitch, Flatbed Vertical Trimmer 2-Needle Lock Stitch 2-Needle Chain Stitch, Flatbed Multi Needle Chain Stitch 4-Thread Over Lock 2-Needle Piping Zig-Zag M/C[Computerized] Bartack M/C[Computerized] Button Hole M/C[Computerized] Button Sewing M/C[Computerized] Rib Cutting M/C Blind Stitch[Overlock] Heat Transfer M/C Snap Button Fusing M/C Rib Cutting M/C Blind Stitch[Overlock] Heat Transfer M/C Snap Button Fusing M/C Quantity 410 18 20 8 20 12 180 16 6 24 24 24 18 6 18 18 18 18 6 18 18 18
Table 01: Machine description of Sewing Section
Sewing Section
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Maintenance Schedule of Different parts of a sewing m/c[single needle]:

Parts Name Thread stand
Picture
Thread clamp
Thread retainer
Thread up-lever guide
Tension disk
Pressure screw
Pressure bar
Hand lifter
Needle clamp
Needle
Needle plant
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Feed dog
SPI adjust
Reverse lever
Bobbin wilder
Pulley
Oil sight wilder
Pulley belt cover
Leg lifter
Foot
Safety guide
Motor
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Different parts of sewing m/c[over lock]:

Parts Name Thread stand
Thread retainer
Thread guide
Pressure screw
Pressure bar
Pressure spring
Upper & lower lopper
Needle clamp
Needle
Needle plant
Feed dog
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Pulley
Oil sight wilder
Pulley belt cover
Leg lifter
Safety guide Motor
All sewing machines need basic lubrication maintenance to keep them running over the months and years. 1. Oil your sewing machine after every 9-10 hours of stitching work. I do the same with my Singer machine and it keeps it in good working condition. 2. Remember that sewing machine oil is clear white and may be different for your particular brand. Use just a drop of oil in each location to lubricate the moving parts and prevent rust. 3. After oiling, run a few stitches on disposable fabric to let any excess oil run out and settle.
Practical Procedure:
Here standard system is to service a machine once per 15 days. But it is done once per month. Some machine needed to oil in oil tank. In that case. A pump once per two month changes oil. Machine that have rotary hook are oiled once per week. At first the service system of machine is written on the machine log card with machine remarks and next schedule.
To Maintain Machine Trouble Free:

The following instruction must be carried out to secure the utmost in production and to the prolong the life of your machine-
Page 31
Before morning starts, To oil every moving parts with one or two drops of oil To check whether needle is correctly set or not damage. To check whether threading is correct. To check whether chaining thread of approximately 10 mm long remain behind pressure foot.
Maintenance of different m/c:

For Plain Machine:
Changing over the specified voltage and changing the fuse be sure to turn off the power to the power to the machine before starting the procedure Insert a slotted screwdriver into the slot of change over the voltage and set the voltage to a desired voltage. Set the operation voltage to the position with mark. Replacing the fuse: Be sure to turn off the power to the machine before starting the procedure starting the procedure and remove the cap from the fuse holder. Then, take out the fuse and replace it with a new one.
Over Lock Machine:

To protect against possible personal injury due to abrupt start of the machines, be sure to start the work after turning the power off and ascertaining that the motor is at rest. Position of the needle thread take up and the needle thread eyelet The needle thread take up shall be positioned at the lower dead pt. Position of the looper thread take up and the looper thread guide Checking the cartridge filter and replacing it after a long period of usage, cartridge filter may become clogged with dust Insert a cartridge Remove first oil discharging screw. Remove screw and lift top cover just above until it comes off . Dimensions use to adjust the looper and the needle guard
Lubrication Removed the oil cap, Poor juki machine oil 18 into the oil reservoir, supply oil until the pointer bar almost reaches the upper red marker line when oil gauge is observed from the side.
For Button Attaching Machine:

Checking the needle : Always check that the tip of the needle is not broken and also the needle is not bent before starting sewing. Standard Group Ltd. & GMS Composite Knitting Ind. Ltd. Page 32
Cleaning the rotary hook: The shuttle race cover toward you to open it and then remove the bobbin case Open the setting claw in the direction indicated by the arrow and then remove the shuttle race body and the shuttle hook. Clean all the dust and thread ends from around the driver, the top of the rotary hook thread guide and the shuttle race. Lubrication: Fill the arm side oil tank with oil, Fill the bed side oil tank with oil,Add oil to the felt of the shuttle race base.When setting up the sewing machine and when it hasnt been used foe asn extended period of time, be sure to add 2-3 drop oil to the felt, If using the liquid cooling tank, fill it with silicon oil.
Button Holing Machine :

Turn off the power switch before carrying out cleaning; otherwise the machine may operate if the treadle is depressed by mistake, which could result in injury. Be sure to wear protective goggles and gloves when handling the lubricating oil and grease so that they do not get into your eyes or onto your skin otherwise inflammation can result. Furthermore do not drink the oil or eat the grease under any circumstances as thy can cause vomiting and diarrhea, keep the oil our of the reach of children. Cleaning: Remove lint and dust from the thread passages Remove lint and dust form around the work clamp Remove the bobbin case and remove lint and dust from around the lower thread trimmer mechanism.
Bartake Machine:
Maintenance of bar take machine Adjust the height of the needle bar Adjusting the needle to shuttle relation Adjusting the lift of the work clamp foot Adjusting the rising amount of the thread tension dist The moving knife and counter knife Cleaning the filter Draining waist oil Replacing the fuse
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Shortly Maintenance Schedule of m/c:

Section Sample section CAD section Spreading section Cutting section Sewing section Finishing section Maintenance done Daily Weekly --Done ------Done Done --Done ----Done Monthly --Done Done ------Half yearly ------------Yearly -------------
GENERAL CLEANING
As you clean the machine, it is best to clean one area at a time. Remove only the parts that are involved and be sure to note where each part is from, its position, and which side is top.
Remove all the parts possible in order to clean the machine thoroughly. Keep the parts in order to make it easier to replace them.
Bobbin Area -- If possible, remove the bobbin case to remove all lint and stray threads.
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Upper Thread Tension -- Pull a piece of cloth soaked in solvent back and forth between discs to clean
Fold a piece of muslin in half, and use the folded edge to clean between tension disks.
Page 35
Don't forget to clean inside the bobbin case. Using compressed air, which has a straw (shown in red above) to direct air to a desired spot, blow out lint and loose threads.
Use a soft piece of muslin with a dot of sewing machine oil to clean the race hook. If the hook is removable, place a drop of oil on it before returning it to the machine.
Unplug Your Machine
For your own safety and to prevent damage to your machine always unplug the machine before you start cleaning and oiling your machine.
Remove Lint

Fabric and thread are a combination that is going to produce lint. Lint can build up in unseen areas of your machine leading to wear and tear that is preventable. Open all areas that you can and clean the lint out of the machine. Use the brush that came with your sewing machine to remove lint in cracks and crevices and from under the bobbin case. Try to get in the habit of cleaning the lint out of your machine every time you finish a project. That way the machine will be ready to sew when you are!
Sewing Machine Oil
Sewing machine oil is not something you borrow from the garage. It is clear white oil. Be sure to use the proper oil. Refer to your owners manual for the proper spots to oil. Some of the older machines have these areas marked. After oiling your machine run stitches on some scrap fabric before you tackle your project. This allows oil to escape on to the scraps, if it's going to, instead of the project you are working on. Oiling the machine not only lubricates your moving parts, to prevent wear, it reduces the risk of rust. Rust forms rapidly with any dampness, even just the humidity in the air. Surface rust can act just like loose sand granule in your machine, and create excess wear.
Page 36
Loose Screws
As you clean and oil the machine you will find many screws and set-screws. As a general rule, tighten regular screws as you run across them. Set screws which usually require hex key wrenches, should only be adjusted by a repair person unless you have a complete understanding of the timing of your sewing machine. If the set screws are missing or loose, take the machine to a repair shop. It may seem easy to just replace the screw or tighten it, but all of these details go in to the timing of the machine. If the timing is off you can do great damage and the repair bill will be much more then a tune up.
Wires

You should always be watching for wear signs on wires but while youre cleaning your machine, take the time to honestly inspect the wires. Check the entire length of the wire for abrasions to the plastic coating or for damage a pet may have done. Check that all the electrical prongs are tight and secure. Consult a repair person or electrician for any problems you may find.
Breaking Needles

Properly insert a new needle. Your needle may have broken because it was defective. Make sure the needle you are using is appropriate for the thickness and density of the fabric you are sewing on. A dense, high thread count fabric like a batik or pima cotton calls for a Microtex Sharp needle. Don't pull your fabric as you sew. It is common for new free motion quilters to pull on the fabric when they are learning to quilt. This bends the needle and it breaks when it hits the throat plate. Check for a proper tension setting. Is your needle in the proper position. If you are using a single stitch throat plate the needle must be in the center position. Is it? Don't sew over pins. If you hit a pin, change the needle. Make sure that the foot, the throat plate and the needle are inserted correctly and tightened appropriately.
Fabric Won't Feed Properly

Make sure your feed dogs are in the up position. Make sure your feed dogs are clean and free of lint and dirt. Check that you are using pressure foot pressure. Have you recently been machine quilting and removed the pressure? Is your presser foot installed correctly so that it is making contact with the fabric? Is your stitch length set higher than 0? Again, with free motion machine quilting you may have forgotten to reset your stitch length.
Skipped Stitches
First change to a new needle.
Page 37
Make sure the needle is correctly installed and in good shape no burrs, not bent, no nicks. Is there enough pressure on the presser foot? Have you recently reduced the pressure foot pressure because you were quilting and forgotten to increase it again? Check your needle tension. A too tight tension can cause skipped stitches. Make sure the machine is properly threaded. Is the thread in the take up lever?
Thread Nest forms on the bottom

Re-thread your sewing machine making sure that the thread is in the tension guides, as well as in the take up lever. Raise your feed dogs if you are piecing and not quilting. Hold the both the bobbin and needle thread tails in your fingers as you begin a line of stitching. This will keep the tails from tangling on the underside.
Maintenance system and Troubleshooting :

Maintenance:
From the above discussion we can write down the basic maintenance are given below: 1. Machine adjustments should only be performed by a qualified technician. 2. Check the oil level weekly when the machine is used daily. Add sewing machine oil as required to the high level marking. 3. Clean the machine with a clean, damp cloth. Do not use solvents or thinners. 4. When not in use, cover the machine and store in a clean and dry location.
Trouble Shooting:
This section contain trouble shooting which can be of help in determining and removing the causes of trouble that may develop in the machine .when the troubles cover by this section develop, they can be conveniently tracked down and readily corrected by consulting the following tabulation:
Symptom Needle Breakage
Causes Remedy Needle is loose in needle Tighten needle clamp clamp. Needle of incorrect class Compare needle with and style is being used. one of correct type. Pressure foot is loose or out Straighten and align of line presser foot; tighten securely. Needle is too light for maSelect the correct terial being sewn. needle. Operator is pulling the maDo not assist material being sewn. chine in feeding of material.
Frequency Daily or When need Daily or When need Daily or when need
As per material required. Daily or When need
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Thread Breakage (Needle)
Thread Breakage (Bobbin)
Select and inset a thicker needle. Only left twist thread is to be used. Use new, dry and smooth thread of correct size. Machine is incorrectly Follow threading dithreaded agram as shown. Needle is incorrect set. Set the needle with the short groove closest to the loop taker (shuttle). Upper tension is too tight Adjust for the correct stitch balance. Thread take up spring is out Adjust to proper poof adjustment sition. Needle is rubbing against Re-align and tighten pressure foot. pressure foot. Needle is defective, blunt Replace with new or bent at point. needle. Sharp edge on the loop takSmooth with fine er (shuttle), bobbin case or emery paper and tension controller. polish with rouge cloth. Damp o defective thread Use new, dry and being used. smooth thread of correct size. Bobbin thread tension is Adjust for correct too tight. stitch type. Bobbin shuttle case is inFollow threading incorrectly threaded. struction as described.
Thread is too heavy for needle for used Right twist thread is being used Damp and defective thread is being used
Daily or Weekly Weekly Daily or Monthly
Weekly or Monthly Weekly or Monthly
Daily or When need Weekly or monthly Weekly or Monthly Weekly or Monthly Monthly or Halfyearly
Daily or Monthly
Weekly or Monthly Weekly or Monthly
Bobbin is wound too full to revolve freely
Round of thread on the bobbin are lapped over one another. Bobbin case is sticky with gummy oil and lint.
Shrap edge on shuttle, bob-
Remove excess thread to the rim of the bobbin winder accordingly. Unwind bobbin manually and rewind evenly and uniformly. Clean bobbin case, shuttle and shuttle race with kerosene with a few drops of oil. Smooth with fine
Daily or when need
Monthly
Daily
Monthly Page 39
Thread Breakage (Bobbin) Continue Skipping(Skip Stitches)
bin case, bobbin or needle.
The needle thread fail to catch the bobbin
energy paper and polish with rouge cloth. Reset the needle bar and needle as describe. Adjust tensions for correct stitch balance. Adjust stitch regulation for longer stitch.
Monthly or Yearly
Drawing of seam Stitches uneven and piled up
The thread draw or pucker the seam. Stitch pile up in one place.
Monthly or When Need Monthly or When Need
Sample of a Preventive Maintenance Card:

PREVENTIVE MAINTENANCE CARD
Name Of Machine-
Mig Welding Machine

M.W. - 02
1.Open cover &Remove dust by Blower 2.Check forHeat-uo Connection 3.Measure current in each Phase 4.Check rotation ofblower for Smoothness
Schedule 15 days/ Annual

5.General check-up like bolts cable connection 6.Annual Maintenance Schedule on revese 7.For annual maintenance Schedule on reserve 8
Machine No.PM to be taken up
S. N. 1 2 3 4 5 6 7 8 9 10 11 12
Due Date
Status
By
Date
Remarks
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Firstly, all sections of the garments factory have been pointed out for assessment. It is observed that the goal of all factory improvement activity is to increase productivity by minimizing input and maximizing output. Equipment and machinery are the crucial factors in increasing output. Productivity, quality, cost and delivery, as well as safety, hygiene, environment, and morale are all influenced significantly by equipment conditions. The goal of maintenance management is to enhance equipment effectiveness and maximize output. It strives to attain and maintain optimal equipment conditions in order to event unexpected breakdowns, speed losses, and quality defects in process. Overall efficiency including economic efficiency is achieved by minimizing the cost of upkeep and maintaining optimal equipment conditions throughout the life of equipment. So the steps that were followed are: Identification of major losses. Identification of significant losses by Pareto analysis. Calculation of Overall Equipment Efficiency (OEE). Reduction of losses with analytical techniques. Steps in introducing TPM in an organization
Stage A Preparatory stage Step1: General announcement by management about TPM introduction Step2: Initial education and propaganda for TPM Step3: Setting up TPM and departmental committees Step4: Establishing the TPM working system and target Step5: A master plan for institutionalizing Stage B Introduction Stage Stage C Implementation Stage D Institutionalizing Stage.
5S (Sort, Systematic, Shine the workplace, Standardization, Self discipline) JISHU HOZEN (Autonomous Maintenance) KOBETSU KAIZEN (Focused Improvement) Planned Maintenance Quality Maintenance Education and Training Office TPM Safety, Health and Environment Figure 1: Eight pillars of TPM TPM stands on 8 pillars as shown in figure 1. Among these, the third pillar KAIZEN is used in this study. This pillar is aimed at reducing losses in the workplace that affect the efficiencies. It is possible to eliminate losses in a systematic method using various Kaizen tools such
Page 41
as: PM analysis, Why - Why analysis, Summary of losses, Kaizen register and Kaizen summary sheet. As one of the pillars of TPM activities, Kaizen pursues efficient equipment, operator and material and energy utilization. Kaizen activities try to thoroughly eliminate 16 major losses shown in Table 1.
Loss 1. Failure losses-Breakdown loss 2. Setup/adjustment loss 3. Cutting blade loss 4. Minor stoppage 5. Speed loss 6. Start up loss 7. Defect/rework loss 8. Scheduled down time loss 1. Management loss 2. Operating motion loss 3. Line organization loss 4. Logistics loss 5. Measurement loss 1. Energy loss 2. Die, jig and tool breakage loss 3. Yield loss
Category
Losses that impede equipment efficiency
Loses that impede human work efficiency
Loses that impede effective use of production resources
Table 1: Sixteen major losses that occur in a factory MAXIMIZING OVERALL EQUIPMENT EFFICIENCY After studying all the sections of the factory, the Sewing section was taken for the Project purpose. There are 4 lines in the Sewing section. The production rate of different lines in Sewing section is considered. Line 5B is considered for identifying and reducing equipment losses to maximize overall equipment efficiency (OEE) by TPM pillar 3- Kobetsu Kaizen (Focused Improvement). IDENTIFYING LOSSES: To identify losses and equipment efficiency, loss data is collected for several machines for 10 days during operation. These data are presented in Table 2. Table 2: loss data for several machines (Ten days) Day Machine Losses Time Name (min) 01 Single Idling & Minor stoppage 3+3=6 Needle (Needle break & Bobbin case) Single Reduced speed 4 Needle Overlock Idling & Minor stoppage (False 8 stitch) Overlock Set up & adjustment 20 02 Overlock Idling & Minor stoppage (False 10 stitch) Single Idling & Minor stoppage 3+7+4+4=18
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03
Needle Single Needle Two Needle Overlock Single Needle Single Needle Two Needle Overlock Single Needle Single Needle Overlock Single Needle Overlock Single Needle Single Needle Two Needle Single Needle Two Needle Overlock Single Needle Single Needle
(Needle break & Bobbin case) Reduced yield Breakdown Set up & adjustment Idling & Minor stoppage (Needle break, Bobbin case & others) Idling & Minor stoppage (Needle break & Bobbin case) Set up & adjustment Reduced speed Defects in process Idling & Minor stoppage (Needle break & Bobbin case) Set up & adjustment Idling & Minor stoppage (Needle break , Bobbin case & others) Idling & Minor stoppage (False stitch) Idling & Minor stoppage (Needle break & Bobbin case) Reduced yield Breakdown Idling & Minor stoppage (Needle break & Bobbin case) Set up & adjustment Reduced speed Defects in process Idling & Minor stoppage (Needle break & Bobbin case)
5 30 20 13+4+3=20
04
6+4=10 30 4 10 13
05
06
20 12+5+3=20
07
10 7+3+4+4=18 4 30 6+4=10 35 6 10 8+5=13
08
09
10
Single Idling & Minor stoppage 3+4+3=10 Needle Overlock Idling & Minor stoppage 8 Overlock Set up & adjustment 25 Based on these data, the following 6 major equipment losses are identified in Line 5B: Standard Group Ltd. & GMS Composite Knitting Ind. Ltd. Page 43
I. Breakdowns due to equipment failure 2. Set up and adjustment 3. Idling and minor stoppages 4. Reduced speed 5. Defects in process and rework 6. Reduced yield between machine startup and stable production Identifying Significant Losses: From these 6 major losses the most significant losses are then identified by PARETO analysis. The data of PARETO analysis is given in Table 3. Table 3: Pareto Chart for six major losses Major Losses Idling and minor stoppages Set up and adjustment Breakdown Defects in Process Reduced Speed Reduced Yield Total Time (min) 174 Composition % 41 Cumulative % 41
150 60 20 14 9 427
35 14 5 3 2 100
76 90 95 68 100
It is seen that the most significant sources of OEE loss are Minor Stoppages and Set up and adjustment. Calculation of OEE: The calculations for Overall Equipment Efficiency (OEE) of the machines having losses are given in Table 4. Table 4: Calculation for Overall Equipment Efficiency A B C D E F Running time per day=60 min*8hrs=480 min Down time per day= 20 min Loading time per day=A-B=480-20=460 min Stoppage losses per day= 174 min/10 days = 17.4 min = 18 min Operating time per day=C-D= 460-18 = 442 min Out put per day=70 pcs/hr * 8 hrs = 560 pcs
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Rate of quality products= (Processed amounts Defect amount)/Processed amount*100= (560-15)/560*100 = 97.32% Ideal cycle time = 30 sec = 0.5 min Actual cycle time = 35 sec = 0.58 min Actual processing time = I*F = 0.58*640 = 325 Min Operating speed rate = H/I*100 = (30/35)*100 = 85.71% Net operating rate = J/E*100 = (325/442) *100 = 73.52 % Availability = (E/C)*100 = (442/460)*100 = 96.08% Performance efficiency = K*L*100 = 0.8571 * .7352 * 100 = 63.01%
H I J K L M N
Now, the target is to increase the OEE from 59% by inimizing the losses. Minimizing the Losses: The basic analytical techniques used in TPM for improvement are: WWBLA (Why Why Because Logical Analysis) P-M analysis Why-Why analysis Fault tree analysis Failure Mode Effect analysis Pareto analysis SPC etc Table 5: Major Causes of Idling and Minor stoppages Major Causes Needle Break Bobbin Case False Stitch Others Total Time (min) 81 56 28 9 174 % Composition 47 32 16 5 100 Cumulative % 47 79 95 100
Here, WWBLA is used. WWBLA technique is a worksheet which identifies the root causes of a problem. In this technique, each major problem is considered separately and a worksheet is prepared. For each major problem, a cause is identified and called it first factor for problem. Then it is verified whether it can be divided into further root causes. If it is possible, then it is marked as G. Here, G stands for Go. Then a second factor for problem is identified and Standard Group Ltd. & GMS Composite Knitting Ind. Ltd. Page 45
verified. In this way, a third, fourth problems are identified. If it is not possible to identify further, then verification is marked as NG (Stand for No Go). Finally, countermeasures are identified for each root causes of the problem. Now, from Pareto analysis, it is seen that the two significant losses (Idling &Minor Stoppages and Set up and adjustment) comprise of about 68% of total loss. So, it needs to eliminate these losses first to increase the OEE. The main cause of the most significant loss i.e. Idling & Minor Stoppages, is due to Needle breaking in the machines. It can be easily observed from the Pareto analysis given in Table 5. It is seen that the main cause of idling and minor stoppage is needle breaking. Now, WWBLA technique is used for identifying the countermeasures to reduce the problem of needle breaking. The WWBLA worksheet is given in Table 6. Table 6: Why Why Because Logical Analysis (WWBLA) worksheet Verification Verification Verification NG 1.1.1 Needle plate should be positioned properly at the beginning of operation 2.1 Rotary hook should be positioned by screw tightening 2.2 Rotary hook should be replaced by a new one 3.1 Pressure guide should be tightened properly 4.1 Needle safety guide should be tightened properly 5. Good quality of needle should be bought and used 1st Factor for problem 2nd Factor for problem 3rd Factor for problem Countermeasures
Problem
1. Needle nib hits the needle plate
1.1 Needle plate becomes down
1.1.1 Needle plate is not positioned properly
2. Needle nib falls within the rotary hook Needle Breaking
2.1 Rotary hook is displaced 2.2 Needlehook timing is not maintained properly 3.1 Pressure guide becomes loose 4.1 Needle safety guide becomes loose
NG
3. Pressure guide is Displaced 4. Needle safety guide is displaced
NG
NG
5. Needle quality is low
NG
NG
Due to the countermeasures found in the WWBLA, the stoppage loss per day reduced to 11 minutes from 18 minutes and consequently output per day increased to 600 pcs. Thus, the OEE is increased which is shown Table 7. Standard Group Ltd. & GMS Composite Knitting Ind. Ltd. Page 46
Table 7: Revised Calculations for OEE After Reducing Stoppage Loss. A B C D Running time per day=60 min*8hrs=480 min Down time per day= 20 min Loading time per day=A-B=480-20=460 min Stoppage losses per day = 110 min/10 days = 11 min (as the time losses for needle break is eliminated, the stoppage losses time becomes 174 min-64 min of needle break = 110 min ) Operating time per day=C-D= 460-11=449 min Out put per day=75 pcs./hr * 8 hrs =600 pcs Rate of quality products= (Processed amounts Defect amount)/Processed amount*100= (600-10)/600*100 = 98.33% Idle cycle time = 30 sec Actual cycle time = 34 sec = 0.57 min Actual processing time = I*F = 0.57 min *600 pcs = 342 min Operating speed rate = H/I*100 = (30/34)*100 = 88.24% Net operating rate = J/E*100 = (342/449) *100 = 76.17 % Availability = (E/C)*100 = (449/460)*100 = 97.60% Performance efficiency = K*L*100 = .8824 * .7617 * 100 = 67.21%
E F G
H I J K L M N
Overall Equipment Efficiency = M*N*G*100 = .9760 * .6721 * .9833 * 100 = 64.50% = 65 %
Page 47
CHAPTER IV Result
Page 48
Result
The experiment has provided us wide idea regarding the repair. Maintenance, setting and replacement of different components of textile machines, it has given us a basic knowledge on machine maintenance as a whole. It has also oriented me with different machine tools and their use those are required for the said job. The gathered knowledge will indeed help me in our practical life. I hope to important my learning in the days to come. Trough our experimental work we see that our production efficiency increased from 59% to 65%. so we can say that maintenance increases the overall equipment efficiency thus production quality, environment, machine life time, worker mind and keep us refresh. All mills have a strong maintenance fitters troop to fix up all types problem. Two groups of three shifts obey their duties responsibly and sincerely. With their different tools or equipments they perform their duties skillfully.
Page 49
CHAPTER V Conclusion
Page 50
Conclusion
Maintenance is a set of organized activities that are carried out in order to keep an item in its best operational condition with minimum cost acquired. The main objectives of the maintenance are to keep the machine in best operational condition and thus increasing the production of any factory by minimizing the losses due to minimizing the ideal condition. The purpose of our project is indentifying the effect of maintenance. By the project work we have gathered a lot o f knowledge about the maintenance procedure of garments industry and its importance. We specially select the sewing section for our thesis purpose to make proper maintenance to increase the production of any factory thus increases the profit and also increases the efficiency of the machine and worker. In our thesis paper we have done a calculation of OEE (overall equipment efficiency) without maintenance and with proper maintenance. Through the maintenance calculation, we see that the OEE increase from 59% to 65%. This makes clear concert that if we take proper attention to the maintenance our production will be raised. We think further thesis is required as our project work and it will be helpful for the student and as well as factory people.
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TEXTILE ENGINEERING DEPARTMENT [Pick the date]
Remarks
1. 2. 3. 4. 5. 6. 7. M.A.Kashem,Garments and Technology. BUET,Journals of Mechanical Engineering. Phyllis G.Tortora,Textile Terms & Drfination. http://www.google.com http://www.plant-maintenance.com/article/tpm_intro.shtml http://www.plant-maintenance.com/maintenance_article_tpm.stml http://www.findarticles.com/p/article/mi_m3101/is_2_75/ai_8876047 8/machinemitenancehistry.jpg 8. http://www.answer.com
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Effect of Maintenance On Production & Quality

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Southeast University

School of Science and Engineering Department of Textile Engineering

Project on Effect of Maintenance on Production and Quality

Dhaka, 14, September, 2011

School: Course of Studies:

Science and Engineering B.Sc. in Textile Engineering

Batch 6th Department of Textile Engineering

Date of submission: 09 September, 2011

TEXTILE ENGINEERING DEPARTMENT

Standard Group Ltd. & GMS Composite Knitting Ind. Ltd.

TEXTILE ENGINEERING DEPARTMENT

Dhaka: 14 September, 2011

Standard Group Ltd. & GMS Composite Knitting Ind. Ltd.

TEXTILE ENGINEERING DEPARTMENT

Standard Group Ltd. & GMS Composite Knitting Ind. Ltd.

TEXTILE ENGINEERING DEPARTMENT

Standard Group Ltd. & GMS Composite Knitting Ind. Ltd.

TEXTILE ENGINEERING DEPARTMENT

Standard Group Ltd. & GMS Composite Knitting Ind. Ltd.

TEXTILE ENGINEERING DEPARTMENT

Standard Group Ltd. & GMS Composite Knitting Ind. Ltd.

TEXTILE ENGINEERING DEPARTMENT

Standard Group Ltd. & GMS Composite Knitting Ind. Ltd.

TEXTILE ENGINEERING DEPARTMENT

GMS Composite Knitting Ind. Ltd.

Standard Group Ltd. & GMS Composite Knitting Ind. Ltd.

TEXTILE ENGINEERING DEPARTMENT

Annual Turnover Factory Floor Space Factory Equipments

GMS Composite Knitting Ind. Ltd.

TEXTILE ENGINEERING DEPARTMENT

: Shardaganj, Kasimpur, Gazipur Telephone: +88-02-7788951-3 Fax: +88-02-7788934

Official Website Production Capacity: Knitting Dyeing Yarn Dyeing Garments

: Approximately 29 Tons/Day : Approximately 25 Tons/Day : Approximately 10 Tons/Day : Approximately 1,20,000 Pieces/Day.

Standard Group Ltd. & GMS Composite Knitting Ind. Ltd.

TEXTILE ENGINEERING DEPARTMENT

: 2,90,000 square foot.

Standard Group Ltd. & GMS Composite Knitting Ind. Ltd.

TEXTILE ENGINEERING DEPARTMENT

Management Organ gram

Garments Sewing Garments Finishing Printing Embroidery Security Technical

Standard Group Ltd. & GMS Composite Knitting Ind. Ltd.

TEXTILE ENGINEERING DEPARTMENT

Admin, HR & Compliance GM Administration DGM Human Resource

Standard Group Ltd. & GMS Composite Knitting Ind. Ltd.

TEXTILE ENGINEERING DEPARTMENT

Standard Group Ltd. & GMS Composite Knitting Ind. Ltd.

TEXTILE ENGINEERING DEPARTMENT

Standard Group Ltd. & GMS Composite Knitting Ind. Ltd.

TEXTILE ENGINEERING DEPARTMENT

Standard Group Ltd. & GMS Composite Knitting Ind. Ltd.

TEXTILE ENGINEERING DEPARTMENT

TEXTILE ENGINEERING DEPARTMENT

Standard Group Ltd. & GMS Composite Knitting Ind. Ltd.

TEXTILE ENGINEERING DEPARTMENT

Standard Group Ltd. & GMS Composite Knitting Ind. Ltd.

TEXTILE ENGINEERING DEPARTMENT

Standard Group Ltd. & GMS Composite Knitting Ind. Ltd.

TEXTILE ENGINEERING DEPARTMENT

CHAPTER III Methodology

Standard Group Ltd. & GMS Composite Knitting Ind. Ltd.

TEXTILE ENGINEERING DEPARTMENT

Equipment Name Combination tools / 1.1.1.5 spanner