Maintenance Strategy and Activites of Textile Industry (Spinning Mill)

Name Danial Sohail Roll no. ME-089 Section A B.E Mechanical Engineering

i

TABLE OF CONTENTS

Table Of Figures ............................................................................................................................................ ii

Preface / Acknowledgement ......................................................................................................................... 1

Visit Information ........................................................................................................................................... 2

Visit Photograph ........................................................................................................................................... 3

Maintenance of Spinning Mill ....................................................................................................................... 4

1.1 Spinning ......................................................................................................................................... 4

1.2 Processes in Spinning Operation................................................................................................... 4

1.2.1 Mixing Section ....................................................................................................................... 5

1.2.2 Blow room ............................................................................................................................. 6

1.2.3 Carding .................................................................................................................................. 7

1.2.4 Drawing ................................................................................................................................. 7

1.2.5 Simplex .................................................................................................................................. 8

1.2.6 Ring ....................................................................................................................................... 9

1.2.7 Auto Cone ............................................................................................................................. 9

1.2.8 Packaging .............................................................................................................................. 9

1.3 Roles of Maintenance Department of Star Textile Mills Limited ................................................ 10

1.4 Cotton Quality Based Maintenance in Star Textile Mills Limited Spinning Mill ......................... 10

1.5 Condition Based Monitoring/Predictive Maintenance in Star Textile Mills Ltd Spinning Mill ... 11

1.6 Preventive Maintenance Plan of Star Textile Mills Limited Spinning Mill .................................. 12

1.6.1 Maintenance Plan for Blow Room ...................................................................................... 13

1.6.2 Maintenance Plan for Carding ............................................................................................ 13

1.6.3 Maintenance Plan for Drawing ........................................................................................... 14

1.6.4 Maintenance Plan for Combing Machine ........................................................................... 15

1.6.5 Maintenance Plan for Simplex ............................................................................................ 16

1.6.6 Maintenance Plan for Ring .................................................................................................. 17

2. Conclusion ........................................................................................................................................... 21

2.1 Views on Maintenance Plan of Star Textile Mills Ltd .................................................................. 21

2.2 Recommendations on Improvement of Maintenance Plan ........................................................ 21

2.3 Recommendation for use of CMMS ............................................................................................ 22

ii

TABLE OF FIGURES

Figure 1: Process flow in a Spinning mill ....................................................................................................... 5

Figure 2: Cotton mixing machine .................................................................................................................. 6

Figure 3: Blowing Machine in a Spinning Mill ............................................................................................... 6

Figure 4: Carding Machine Mechanism ........................................................................................................ 7

Figure 5: Drawing Machine in a Spinning Mill .............................................................................................. 8

Figure 6: Simplex machine in a spinning mill ................................................................................................ 8

Figure 7: Packaging and Conditioning Room in a Spinning Mill .................................................................... 9

Figure 8: Condition Based Monitoring Plan ................................................................................................ 12

Figure 9: Maintenance Plan for Blow room ................................................................................................ 13

Figure 10: Maintenance Plan for Carding ................................................................................................... 14

Figure 11: Maintenance Plan for Drawing .................................................................................................. 15

Figure 12: Maintenance Plan for Combing ................................................................................................. 16

Figure 13: Maintenance Plan for Simplex ................................................................................................... 17

Figure 14: Maintenance Plan for Ring ......................................................................................................... 18

Figure 15: Maintenance Plan for 1- 15th October 2014 ............................................................................. 19

Figure 16: Maintenance Plan for 15-30th October 2014 ............................................................................ 20

1 | P a g e

PREFACE / ACKNOWLEDGEMENT

Giving practical exposure to theoretical knowledge is important as it enhances one’s concepts

and that’s the reason, why engineering students are advised to visit industries and relate their

theoretical knowledge with industrial practices.

Instructed by our course teacher of “Plant Maintenance” we had to visit any textile industry

having its own Spinning mill, in a group of 14 students. In the visit we had to study mill’s predictive

maintenance program. And finally we had to present it in the form of detailed report. In this

regard our group managed to arrange a visit to Star Textile Mills Limited located in site area

Karachi.

This report covers following major topics,

1) Introduction to spinning operation

2) Machinery involved in execution of spinning operation

3) Detailed maintenance strategy of spinning mill machinery

This visit helped us a lot to boost our knowledge about Plant Maintenance, but it would have

never been possible without the help Mr. Shamshir (Former Manager Star Textiles Mills). We

would like to express our sincere thanks to him for arranging this informative visit and sharing

his valuable knowledge with us.

2 | P a g e

VISIT INFORMATION

Star Textile Mills Limited is a huge name in textile industry. Our group visited this industry on

Thursday, 29th October 2015. While organizing visit to Star Textile Mills through the reference

of Mr. Shamshir, we were informed that spinning unit in Star mills has been closed for the last

few months due to some financial and management issues but machinery is still there. Though

we tried our best to arrange a 2nd visit in some other Spinning Mill but due to unfavorable replies

and time consuming procedures, we had to make this report out of the knowledge that we gained

from Star Textile Mills visit. However in any way it does not mean that by visiting Star Textile

Mills, we were not able to fulfil the purpose for which we had to visit the industry. In fact we

were able to observer and study the spinning machinery in a much better way as it was not in

operation.

3 | P a g e

VISIT PHOTOGRAPH

4 | P a g e

MAINTENANCE OF SPINNING MILL

In a spinning mill, the performance of the plant depends on the reliability, availability and

maintainability of the plant, all of which are of primary importance for ensuring an excellent and

affordable product. The concept of maintenance has changed substantially over the years; its

main function now is to prevent mechanical and quality breakdowns. Quality breakdown does

not mean that the quality of whole lot is low; but it means the lot is rejected due to poor quality

of yarn on few bobbins or cones. Therefore to maintain excellent quality, plant engineers are

capable of judging spindle to spindle variations in ring frames, speed frames and winding, and

machine to machine variations in preparatory. But in order to discuss maintenance strategy of

Star Textile Mills Limited spinning mill, it is important to define the processes and equipments

involved in execution of spinning first. Therefore following section briefly defines spinning and

the processes involved in spinning:

1.1 Spinning

In textile product processing, fibers from bales of cotton are converted into finished clothes. First

process of textile product processing is spinning. Spinning is a process in which fibers from bales

of cotton are drawn out and are twisted to form yarn. However commercially process is defined

in 3 steps

Drawing out fibers.

Twisting fibers to form yarns.

Winding yarns onto bobbins.

1.2 Processes in Spinning Operation

A typical spinning process involves a number of operations in different sections. Therefore

process flow diagram of spinning mill with respect to sections is given below:

5 | P a g e

Figure 1: Process flow in a Spinning mill

1.2.1 Mixing Section

Mixing section is basically designed for the purpose of mixing different lots, because these lots

are purchased from different regions and areas and contain different colors, shades and

brightness ranges due to moisture, weather, packing condition and treatment during

Mixing hall

Blow Room

Carding

Drawing

Simplex Department

Ring Department

Auto Cone

Packing Department

6 | P a g e

transportation. Mixing hall serves as a cotton opener, cotton mixer and remover of any foreign

particle like jute and pieces of cloth from cotton.

Following picture is of mixing machine installed in a spinning mill:

Figure 2: Cotton mixing machine

1.2.2 Blow room

The cotton is received in blow room through condensers from the mixing section. In blow room

this cotton is stocked for 12 to 16 hours for conditioning according to the temperature of blow

room, in the form of layers horizontally and cut vertically which is very old method of mixing the

cotton of different regions and characteristics. Blow room mixes, open (tuft to tuft), cleans and

from laps of tuft for the next process.

Figure 3: Blowing Machine in a Spinning Mill

7 | P a g e

Above two machines are different setups that can be used for blowing cotton bales into tufts.

1.2.3 Carding

In carding section laps are converted into sliver. In carding machines laps are feed and slivers are

received as an end product. Carding machine opens laps from fibers to fibers, cleans fibers, forms

wires, drafts, eliminate short fibers. Carding is the most important process of spinning therefore

extensive care and maintenance is provided to Carding machine.

Figure 4: Carding Machine Mechanism

1.2.4 Drawing

Drawing is a process in which different wires from carding are combined together to produce

single wire. Normally 8 wires are fed behind one drawing machine and get an end product in form

of single wire in cans or boxes. The purpose of doing this is that to create uniformity.

Following is illustration of drawing in spinning mill.

8 | P a g e

Figure 5: Drawing Machine in a Spinning Mill

1.2.5 Simplex

Finished wire is input of simplex machine while "roving" is its end product. Roving is a big bobbin

having refined wire (in the form of package) but thin and slim than input wire. In this process,

twisting is done on roving. Here the twist per inch (TPI) is approximately 1.004. Roving is further

used in "Ring Department" for making of small bobbins after that making of cones. One package

normally contains 3,000 meters roving.

Figure 6: Simplex machine in a spinning mill

9 | P a g e

1.2.6 Ring

In ring section, final spinning process starts. Here in this section roving from simplex section is

turned into fine & sophisticated yarn of different counts. Pulling effect makes counts. Spindle is

a smaller tapering rod, the rotation of which gives the twist and around which the thread is

wound as it is twisted.

1.2.7 Auto Cone

In auto cone a winding machine converts ring bobbins into large cones with removing spinning

faults.

1.2.8 Packaging

Packaging area has a conditioning system, this conditioning system is especially designed by

textile engineers. Specially designed duct are used for conditioning of yarn. The yarn is

conditioned 24 hours before packing. Enhanced conditioning of yarn increases the strength of

yarn. The result is a product which is not only conditioned exceptionally but additionally it helps

to decrease the wastage as well.

Figure 7: Packaging and Conditioning Room in a Spinning Mill

10 | P a g e

1.3 Roles of Maintenance Department of Star Textile Mills Limited

Following are the roles that are served by maintenance department of Star Textile Mills Limited in spinning

mill

Preparation of policy statement for the maintenance department, which explains basic

objectives based on the organizational objectives, and preparation of standard

maintenance procedures, maintenance schedules, lubrication charts etc.

Preparation of maintenance charts for individual equipment and to train the maintenance

personnel for their implementation.

Coordination with the production department staff to ensure that a regular maintenance

will be implemented without affecting important production schedules.

Maintenance department carry out the scheduled preventive maintenance programs and

ensure that plant is available for production for the maximum duration.

Carry out the overhauling of the machinery at the scheduled time without fail.

Calibration of various instruments installed at various points in the plants.

Record keeping of maintenance activities.

Keeping a watch on critical parts in inventory that could be required for any breakdown.

To prepare maintenance budget in the start of each fiscal year.

To adjust the different machines in the process according to the fiber processed.

1.4 Cotton Quality Based Maintenance in Star Textile Mills Limited

Spinning Mill

Maintenance plan of Star Textile Mills Limited spinning mill also includes setting and adjustment

of the machine depending upon the fiber to be processed. A cotton fiber is a peculiar object and

has not truly fixed length, width, thickness, shape and cross-section. Such variations exist because

of the large number of varieties in cultivation which not only differ widely in several key

properties but also grown under divergent agro-climatic conditions. Besides inter-seasonal

variations, the same variety displays variation at different locations and even in the same season.

This is due to the fact that, apart from the genetic constitution of variety, the quality of cotton is

11 | P a g e

influenced by various factors such as soil, climate, moisture levels of soil and atmosphere during

crop growth, nutrient supply, pests, disease infestation, picking time and method, post-harvest

handling. Hence, it is a known fact that cotton fiber characteristics vary from bale to bale. In order

to process the cotton fiber in a spinning mill, the machines need adjustments like roller settings,

gauge and speed settings in draw frames, speed frames and cards from time to time in order to

optimize the process with respect to fiber.

1.5 Condition Based Monitoring/Predictive Maintenance in Star Textile

Mills Ltd Spinning Mill

Condition-based monitoring is the right way to optimize maintenance interval for inspection and

also for replacement of parts. However not all operations in a spinning mill are monitored for

condition, instead operations like general cleaning of cards in carding machine, greasing, belt

cleaning and tension checking etc. are done using preventive maintenance techniques.

Star Textile Mills Limited spinning mill currently applying condition based monitoring on some

equipment as follows

Component Condition Based

Assessment

Schedule (tons)

Blow Room

Beater Wire Replacement Visual Inspection / Machine

Performance

2500

Combing Segment

Replacement

Visual Inspection / Machine

Performance

2500

Carding

Cylinder Wire Replacement Visual Inspection / Machine

Performance

600

Doffer Wire Replacement Visual Inspection / Machine

Performance

600

12 | P a g e

Flat Tops Replacement Visual Inspection / Machine

Performance

600

Cylinder and Doffer Grinding Visual Inspection / Machine

Performance

200

Flat Grinding Visual Inspection / Machine

Performance

100

Comber

Uni Comb Nep Removal Efficiency and

Combine Efficiency

1500

Nipper Physical Checking 10 years

Ring Frame

Rings Replacement Visual Inspection /End

breakages /hairiness

3

Bottom and Top Apron Visual Inspection / Uster

Imperfection and evenness

trends

1.5

Figure 8: Condition Based Monitoring Plan

Predictive maintenance in Star Textile Mills Limited spinning mill is only limited to above

mentioned components and majority of maintenance is Preventive maintenance where

equipment is maintained after regular time interval.

1.6 Preventive Maintenance Plan of Star Textile Mills Limited Spinning

Mill

Preventive maintenance plan of Star Textile Mills Limited defines type of maintenance,

maintenance interval and expected down time for maintenance in form of charts for each

department and machine. Following are department wise plans of preventive maintenance of

Star Textile Mills Limited spinning mill extracted from an internship report.

13 | P a g e

1.6.1 Maintenance Plan for Blow Room

Blow Room is stopped after a 12 hours a day shift for maintenance, Maintenance is done by

opening the covers and doors; a high velocity compressed air is blown into the machines. Air is

blown in the waste zones and delivery zones like

In bale opener/ plucker - take up zone, fan zone, and ducts

In mild opener - inlet zone, outlet zone and grid bar sections.

In mixing machine - all cages for compartments, photocell regions, inlet zone, beater

and grid bar zone, outlet zone.

In fine cleaner - feed zone, beating zone, spikes of beater, photocell regions.

For good preventive maintenance, proper planning is developed, optimized plan for Star Textile

Mills Limited spinning mill is:

Maintenance Type Maintenance Frequency Maintenance Time

Daily Compressed Air Cleaning Daily Half hour

Exhaust checking, repair and

cleaning

15 days 5 hours

Figure 9: Maintenance Plan for Blow room

1.6.2 Maintenance Plan for Carding

After the blow room in sequence is carding operation, following maintenance plan is followed for

maintenance of equipment in carding department.

Maintenance Activity Maintenance Frequency

General Cleaning of Card 15 days

Blow Room General Cleaning 15 days

Doffer Hand Stripping Every day

Front Stationary Flat 150 tons

Back Stationary Flat 150 tons

Cleaning Fillet 1 year

Licker In Segment 150 tons

14 | P a g e

Resetting of Cards 4 months

Licker-in Wire Re sharpening 4 months

Gear Box Oil Change 3 months

Coiler Over hauling 8 months

Web Doffing Cleaning and Greasing 3 months

Main motor Clutch Pulley Greasing 3 months

Side Shaft Gearbox Cleaning and Bearing

Checking

6 months

Figure 10: Maintenance Plan for Carding

1.6.3 Maintenance Plan for Drawing

The major areas of maintenance that are considered in draw frame machines are time to time oil

change of the gear box, greasing activity of bearings at various drives in machine, setting points

and calibrations. Following is maintenance plan for drawing:

Maintenance Activity Frequency

General Cleaning and Greasing 11 days

Bottom Plate Cleaning and Greasing 1 month

Can changer Assembly Cleaning and Greasing 1 month

Pneumatic Connection and Roller Membrane

checking

1 month

Bottom Roller Gauge checking 1 month

Top Roller Buffing and Greasing 1 month

All belt cleaning and Tension checking During Cleaning

All stop motion checking During Cleaning

Flat Belt and Timer belt cleaning and

checking

During Cleaning

Creel cleaning, checking and Greasing During Cleaning

RSB: Scanning roller gauge checking During Cleaning

Bottom Roller Bearing Cleaning and Checking 3 months

15 | P a g e

Gearbox oil Change and Coiler Cleaning and

Greasing

3 months

Scanning Roller Gauge checking 6 months

Bottom roller bearing Cleaning and Greasing 3 months

Figure 11: Maintenance Plan for Drawing

1.6.4 Maintenance Plan for Combing Machine

Important areas in combing preparatory and comber are drafting zone, combing zone, lap

formation zone, delivery zone and waste extraction zone. Following show maintenance plan for

combing machine at Star Textile Mills Limited spinning mill.


Full Cleaning and Greasing

Greasing of All bearing and Needle

Bearings

Greasing of top detaching roll, draw

box roll bush.

Checking of oil level in gearbox

Coiler Assembly cleaning and greasing

Bush shaft bearing checking and

greasing

Aspirator Cleaning

11 days

Draw Box gauge checking 1 month

Top Comb and Uni Comb checking 11 days

Noil suction wire mesh/ cage washing 11 days

Main Gearbox Oil Change 3 months

Asperiator Bush setting 6 months

Full setting (All points) 3 months

Coiler Over hauling, Cleaning and Greasing 6 months

16 | P a g e

Detaching Roller, draw box roller S.L.R.L, top

roller buffing.

6 months

Nipper Setting 6 months

Figure 12: Maintenance Plan for Combing

1.6.5 Maintenance Plan for Simplex

Important areas in Speed frame are creel zone, drafting zone and building zone


General Cleaning, Oiling and Greasing

Bottom roller needle bearing

greasing.

Bottom fluted needle cleaning with

petrol

Top roller (cots) cleaning with C.T.C

Top and bottom cone drum cleaning

and belt setting of full doff stop

motion checking

Greasing of Jack shaft, Lifter shaft,

Bobbin and Spindle shaft, Bobbin rail

lifting shaft

Spindle and spindle collar oiling with

CKS 600T Oil

Flyer Cleaning

11 days

Creel Greasing 3 months

Differential Gearbox Oil Change 3 months

Clutch Cleaning and Position Checking 3 months

Top roller buffing 6 months

Spindle Collar cleaning and foot step oil

change

3 months

17 | P a g e

Bottom Roller setting and saddle Gauge 6 months

Top and Bottom apron washing 3 months

Flyer Cleaning with graphite powder 6 months

Roller Eccentricity checking 6 months

Trough Leveling 6 months

Top roller arbor greasing 6 months

Spindle and Spindle Collar truing 6 months

Top Roller Greasing 6 months

Figure 13: Maintenance Plan for Simplex

1.6.6 Maintenance Plan for Ring

Important zones are creel, drafting zone, winding zone and building zone.


General Cleaning head stock greasing and

traveler change

15 days

1st bottom roller needle bearing greasing 15 days

2nd and 3rd bottom roller needle bearing

greasing

1 month

Front and Back cots buffing 1 month

Bottom Apron Centering 15 days

Fan Cleaning 2 months

New bottom Apron fitting 15 months

New spindle tape fitting 2 years

New front/back cots fitting When under size

Variation Overhauling 3 months

Suction tube washing 3 months

Main shaft greasing 3 months

Gearbox load checking 3 months

Additional drive and gearbox oil change 4 months

18 | P a g e

Jockey Pulley Greasing 4 months

Spindle Oiling 5 months

Ring Rail, Lappet Rail, height gauge 9 months

2nd top roll greasing 6 months

Top apron washing 6 months

Head stock overhauling 6 months

Creel and U bar checking 9 months

O.H.T.C overhauling and greasing 9 months

Drafting checking 6 months

Lappet joint collar checking 9 months

Top arm centering 12 months

Pneumatic connection checking 12 months

Traveler clearance setting 12 months

Figure 14: Maintenance Plan for Ring

While above charts show the type of maintenance and their frequency in general, below is the

maintenance plan which Star Textiles Mills Limited developed last year for its spinning department for the

month of October. These charts specifies department wise machinery and their sub components which

Star Textile Mills maintenance department planned to maintain on specific dates of October.

19 | P a g e

Star Textile Mills

Department - All Departs Preventive Maintenance Schedule For the Month Of OCTOBER -2014 Day Wednesday Thursday Friday Saturday Sunday Monday Tuesday Wednesday Thursday Friday Saturday Sunday Monday Tuesday Wednesday

Date & Day 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15

Department OH OH OH OH W.R OH OH OH OH OH OH W.R OH OH OH

Blow Room Mixing Auto Plucker# 01

Mixing Auto

Plucker# 02

General Cleaning

Mixing Auto Plucker# 03

Weekly Rest

Mixing Condensor

# 01

Mixing Condensor

# 02

Mixing Condensor

# 03 B-11

General Cleaning

B - 70 Weekly Rest

A-21 # 1, 2 B - 60 # 1 B - 60 # 2

Carding Carding #

12 Carding #

13 General Cleaning

Carding # 14 Weekly Rest

Carding # 15 Carding #

16 Carding #

17 Carding #

18 General Cleaning

Carding # 19

Weekly Rest

Carding # 20

Carding # 21 Card

Machine # 01

D/Simplex Toyota

DYH-500 C # 03

Drawing DYH-500 C

# 04

General Cleaning

Toyoda FL-16 Simplex # 2

Weekly Rest

Toyoda FL-16 Simplex # 08

DX 7A # 04 Toyoda FL-

16 Simplex# 01

Drawing DYH-500 C

# 01

General Cleaning

Drawing Toyoda FL-

16 # 01

Weekly Rest

Toyoda FL-16

Simplex# 02

Drawing Toyoda FL-

16 # 02 DX 7A # 03

Ring 14, 17 15, 36 26 34 Weekly Rest

1, 12 33 3, 18 4, 40 32 22 Weekly Rest

5, 10 31 6, 38

Auto Cone M/C # 08

SP # 01 ~ 10

M/C # 08 SP # 11 ~

20

General Cleaning

M/C # 08 SP # 21 ~ 30

Weekly Rest

M/C # 08 SP # 31 ~ 40

M/C # 08 SP # 41 ~

50

M/C # 08 SP # 51 ~ 60

M/C # 04 SP # 01 ~

10

General Cleaning

M/C # 04 SP # 11 ~

20

Weekly Rest

M/C # 04 SP # 21 ~

30

M/C # 04 SP # 31 ~ 40

M/C # 04 SP # 41 ~ 50

Air Condition

Auto Cone & Ring # 1

ElementPlats, Supply,Return

Air Trunch Cleaning &

water change


Element Plats, Supply,

Return Air Trunch

Cleaning & water change

General Cleaning

D/Simplex & Ring # 3 Element

Plats& Air Rotory Cleaning & water

change

Weekly Rest

Carding & Ring # 1 Element Plats


All depart defusel &

Befall Plats Cleaning




water change


Element Plats, Supply,

Return Air Trunch


General Cleaning


Plats& Air Rotory


Weekly Rest

Carding & Ring # 1

Element Plats Cleaning &

water change

All depart defusel & Befall Plats Cleaning




water change

Figure 15: Maintenance Plan for 1- 15th October 2014

20 | P a g e

Star Textile Mills

Department - All Departs Preventive Maintenance Schedule For the Month Of OCTOBER -2014 Day Thursday Friday Saturday Sunday Monday Tuesday Wednesday Thursday Friday Saturday Sunday Monday Tuesday Wednesday Thursday Friday

Date 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31

Department OH OH OH W.R OH OH OH OH OH OH W.R OH OH OH OH OH

Blow Room D-X # 1 General Cleaning

MCM # 1 Weekly Rest

B - 11 China

clc1 & condensor

Looptex Filter

cleaning General Cleaning

Roving machine,

Press machine

Weekly Rest

Auto Plucker

# 01

Auto Plucker

# 02

Auto Plucker #

03

General Cleaning

General Cleaning

Carding Card

Machine # 02

General Cleaning

Card Machine #

03

Weekly Rest

Card Machine #

04

Card Machine # 05

Card Machine #

06

Filter (C-60)

General Cleaning

Can Wheel Checking

C-60

Weekly Rest

Done O.H if Remaning Any M/C

Can Wheel Checking Carding


General Cleaning

General Cleaning

D/Simplex Drawing

DYH-500 C # 02

General Cleaning

Toyoda FL-16

Simplex# 03

Weekly Rest

Drawing DYH-500 C

# 03

Drawing Toyoda FL-16

# 05

Drawing #

02

Drawing Toyoda FL-

16 # 04

General Cleaning

Toyoda FL-16

Simplex # 05

Weekly Rest

Toyoda FL-16

Simplex # 03

Toyoda FL-16

Simplex # 02

Toyoda FL-16

Simplex # 09

Drawing DYH-500 C

# 06

Drawing DYH-500 C #

05

Ring 9, 16 30 27 Weekly Rest

7, 16 23 8, 39 19 28 11, 13 Weekly Rest

28 2, 37 24 20 26

Auto Cone M/C # 04

SP # 51 ~ 60 General Cleaning

M/C # 05 SP # 01 ~

10

Weekly Rest

M/C # 05 SP # 11 ~

20

M/C # 05 SP # 21 ~ 30

M/C # 05 SP # 31 ~

40

M/C # 05 SP # 51 ~ 60

General Cleaning

Done O.H if Remaning Any M/C spindles

Weekly Rest

General checking

Done O.H if Remaning Any M/C spindles

General checking

General Cleaning

General Cleaning

Air Condition

Auto Cone & Ring

# 2 Element Plats, Supply,

Return Air Trunch


General Cleaning


Plats& Air Rotory


Weekly Rest

Carding & Ring # 1


water change

All depart defusel & Befall Plats

Cleaning




water change

D/Simplex & Ring # 3

Element Plats& Air Rotory Cleaning &

water change

General Cleaning

Carding & Ring # 1


water change

Weekly Rest

All depart defusel &

Befall Plats Cleaning



General Cleaning

General Cleaning

Figure 16: Maintenance Plan for 15-30th October 2014

21 | P a g e

2. Conclusion

In previous section we have discussed the maintenance program and maintenance related

activities adapted by Star textile Mills Limited and this section comprises of my personal views

about this visit and some recommendations as a Mechanical engineering student on

maintenance program of Star Textile Mills Limited. These recommendations may help to increase

machine availability and overall equipment effectiveness of equipment in different departments

of Star Textile Mills Limited.

2.1 Views on Maintenance Plan of Star Textile Mills Ltd

Star Textile Mills have a well-defined maintenance plan and maintenance activities associated

with each component of each machinery and it helped us a lot to boost our practical knowledge

of maintenance programs that are adapted by industries rather than just keeping our knowledge

to books.

2.2 Recommendations on Improvement of Maintenance Plan

From the previous section it can be noticed that Star Textile Mills Limited has preventive

maintenance program for maintenance of most of its component and a few components which

are checked through predictive maintenance have very poor condition based monitoring system

which is based on visual inspection and machine efficiency rather than a real time monitoring

system which could monitor the thicknesses of wires and apron using cutting edge laser

technologies. Moreover no vibration signatures of machinery was developed to compare with

distorted vibrations when machine encounters a problem in a rotating and reciprocating

component, for easy detection of area of maintenance.

If the previously define preventive maintenance program is combined and optimized with new

predictive maintenance schemes it’ll not only increase machine availability, overall equipment

effectiveness and productivity of employed staff but will also decrease the power requirement

of plant as less energy will be consumed by well-maintained machinery.

22 | P a g e

2.3 Recommendation for use of CMMS

By looking at the attached maintenance plan of Star Textile Mills which was developed for month

of October 2014, it can be presumed that they have manual way of planning and executing

maintenance activities, by using Microsoft Excel, despite of availability of advanced maintenance

dedicated software knows as Computer-Managed Maintenance System (CMMS).

Without CMMS, maintenance manager faces lots of problems regarding the analysis of feedback

received from the maintenance department, and too much computer work burdens the

maintenance manager and he gets little time to provide attention to the equipment and to the

ongoing maintenance work. Likewise without an adequate information base, the manager is

likely to take a wrong or a non-optimum decision, which may cost more to the company.

The primary objective of the maintenance management is to achieve the optimum balance

between the plant availability and maintenance resource utilization. The effective matching of

labor and material resources for maintenance planning and control is essential for industry to

increase labor productivity, machine availability and overall equipment efficiency.

If Star Textile Mills limited shifts their maintenance management to CMMS they’ll have the

following benefits:

Improved maintenance planning

Clear maintenance reports and ease of access to historical information for maintenance

audit

Reduced management overhead

Fewer breakdowns

Less stock-outs

Adapting the following recommendation can increase machine availability and overall equipment

effectiveness.

Maintenance Strategy and Activites of Textile Industry (Spinning Mill)

Engineering

Transcript of Maintenance Strategy and Activites of Textile Industry (Spinning Mill)