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Maintenance analysis

Name: Bilal Ahmed Roll no: am552469 Course: business Production Operation and Management Level: m.com Assignment submitted to: Prof Khalid farooq Couse code: 8509

ALLAMA IQBAL OPEN UNIVERISITY

ACKNOWLEDGEMENT
First of all we thank to ALLAH ALMIGHTY gave us this beautiful life and blessing us throughout the working on these papers or pages. We are indebted to our respected teacher whos in dispensable and intricate comments on various aspects conjoined with motivation made us come forth holding such as assignment.

Introduction of Maintenance analysis


The definition of maintenance analysis: o The care and serving by personnel for the purpose of maintaining equipment and facilities in satisfactory operating condition by providing for systematic inspection, detection, and correction of incipient failures either before they occur or before they develop into major defects. o Maintenance, including tests, measurements, adjustments, and parts replacement, performed specifically to prevent faults from occurring.

Introduction to subheading: Preventive maintenance can be described as maintenance of equipment or systems before fault occurs. It can be divided into two subgroups: o Planned maintenance and o Condition based maintenance The main difference of subgroups is determination of maintenance time, or determination of moment when maintenance should be performed. While preventive maintenance is generally considered to be worthwhile, there are risks such as equipment failure or human error involved when performing preventive maintenance, just as in any maintenance operation. Preventive maintenance as scheduled overhaul or scheduled replacement provides two of the three proactive failure management policies available to the maintenance engineer. Common methods of determining what preventive failure management Policies should be applied are; OEM recommendations, requirements of codes and legislation within a jurisdiction, what an expert thinks ought to be done, or the maintenance thats already done to similar equipment, and most important measured values and performing indications.

To make it simple: Preventive maintenance is conducted to keep equipment working and extend the life of the equipment. Corrective maintenance, sometimes called repair is conducted to get equipment working again. The primary goal of maintenance is to avoid or mitigate the consequences of failure of equipment. This may be by preventing the failure before it actually occurs which planned maintenance help to achieve. It is designed to preserve and restore equipment reliability by replacing worn components before them actual fail. A preventive maintenance activity includes partial or complete overhauls at specific periods, oil changes lubrication and so on. In addition, workers can record equipment deterioration so they know to replace or repair worn parts before they cause system failure. The ideal preventive maintenance program would prevent all equipment failure before it occurs.

INTRODUCTION OF CRESCENT TEXTILE MILLS: Crescent Textile Mills is a Faisalabad based textile unit. The company was listed at stock exchange in 1951. Crescent Textile Mills is engaged in the business of textile manufacturing of spinning, weaving, dyeing, bleaching, printing, made ups and otherwise dealing in yarn and fabrics. Flagship of large crescent group, CTMs main area of business is in textile. As a composite unit having ISO-9002 certification on 1997, which is engaged in spinning, weaving, processing and is one of the largest exporters of cotton yarn in Pakistan. The pioneer of Crescent Textile Mills was Mian Muhammad Shafi, who belonged to Chinyot. Crescent Textile Mills started as a weaving unit with 500 semi auto looms. Now the present picture of Crescent Textile Mills is that it is the one of the largest textile units in Pakistan. Now Crescent Textile Mills has seven independent complete units of spinning, 184 weaving sulzer looms, one separate unit of towel & one complete unit of garments. Crescent Textile Mills has one of the largest textile-processing units with a capacity of 2.5 million meters fabric monthly. The electricity consumed by Crescent Textile Mills is produced by its own power station located within the boundary of Crescent Textile Mills. All spinning, weaving, towel, processing and garment units are located within the same boundary. The total no of employees are more than 5000 from which 2000 employees are staff and on permanent basis. Factory runs complete 24 hrs. a day and employees work in three-day and night shifts of 8 hours. Crescent Textile Mills was established in 1951 as a private limited company. Crescent Textile Mills was converted into a public limited company in 1958. The crescent group effectively controls the company. In the context of Pakistan, Crescent Textile Mills stands out for the composite nature of its activities. Superior quality standards with ISO 9002 certificate management is committed to expand into the higher value added areas of industry. Crescent Textile Mills is playing a vital role in the development of Pakistan specially by earning a huge foreign exchange through exports. Crescent Textile Mills sells more than 80% of its products to the foreign market. In 1992-93 &

1994, the Crescent Textile Mills was awarded the President of Pakistan Trophy for export, given to the largest exporter from Pakistan in any category. Historical Perspective: The Crescent Textile Mills Ltd was incorporated and set up in FSD as a public limited company. It is one of the first few textile mills to be established in the country, and also the first unit of the crescent group. The Crescent Textile Mills Ltd is situated on Sargodha Road, at an area spread on 115 acres of land; and from the very inception, it had been designed as an integrated unit. It commenced its business operations in 1951 with 50316 spindles, 500 auto looms and finishing capacity of nearly 4000 meters per day. In the mid 50s sponsor of the company decided to divert its production exclusively towards exports and became the pioneer company to have commenced export of cloths from Pakistan in 1956. With the passage of time, the company grew in stature and its sponsors became to be known as crescent family. The period up to mid-60s was also the period of growth of the family businesses as the sponsors/ crescent family diversified their investments to more textile companies, sugar mills, jute mills, larger trading houses, shipping etc. and so the crescent family came to be known as the crescent group. As years road on, the Crescent Textile Mills Ltd continued to expand its exports and earned the reputation of being the leading exporter of yarn, fabric and various products in the home textile sector. The companys prosperity broad about a better quality of life for those who worked for it. The company provides accommodation for its employees, staff and executives as well as plays grounds, parks shops, community centers, and industrial homes for their welfare. It insures that its work force is happy and their families are well cared of. In its desired to forge ahead in the competitive field of the home textile sector, the company has made investments for updating and modernizing its machinery and equipment and insures training of its employees by hiring and contracting its experts in textile for its workers for its staff.

As well as sending executives to recognized institutes in the country and abroad for specialized training in management, accounting, IT and technical training. It was the first textile company to introduce quality circles even at the workers level and by mid-80s had graduated to total quality management and Demings 14 points. It was also the first composite company in Pakistan to obtain ISO 9002 certification and has recently been certified for OekotexStandard 100. The main architect of the sales in the marketing of the Crescent Textile Mills Ltd has been its Chief Executive, Mr. Muhammad Anwer, who has led the company for the front. Besides been awarded every year its highest sales in yarn and cloth, the C.E has also been recognized as the business man of the year twice in the year 1993,1994 and 1994,1995 by the Pakistan federation of Chamber of Commerce and industry. The company has also been awarded the president of Pakistan export trophy for three consecutive years in the mid 90s. For the year ending in September 2002, the company had generated export sales revenue of $60.94 million, of which clothe (beached , dyed or printed) accounted for nearly US $ 33.95 million; made ups in the textile sector accounted for US $ 14.16 million; yarn sales accounted for :Us $ 10.31 million and towel sales accounted for US $ 2.52 million. The Crescent Textile Mills Ltd has been introduced as a public limited company under the companys ordinance on 1 May 1951 and has quoted on the stock exchange. Crescent energy and SAC are fully owned subsidies of the Crescent Textile Mills Ltd.

MISSION STATEMENT:
Mission of Crescent Textile Mills Mission of Crescent Textile Mills is To produce superior quality products to face competition in the international market and to train the staff at the worldclass level to enhance the maximum shareholders value

CORPORATE OBJECTIVES:
Following are some main objectives of Crescent Textile Mills: To arrange timely production and maintain quality goods for entire satisfaction of the customers To make Crescent Textile Mills a first choice for the foreign customers by improving its quality and services. To extend exports all over the world through better services. To establish and develop excellent working environment in the departments. Computerization Incline a sense of civic responsibility in the staff members To achieve companys objectives Implementation of ISO-9002 standards To provide the employees a friendly atmosphere to increase their commitment and loyalty towards their organization.

Practical study of crescent textile mills


Maintain record of machines: PPC also maintain report that shows daily record or orders, which are being processed on all available machines in spinning, weaving, garments department and also records of machines which are busy and which needs orders. Training and development: Training is mean through which a man learns how to do work and how one can increase ones efficiency. In Crescent Textile Mills training opportunities are available. They give training of maintenance also. Day to day check: Engineer from CTM check the fault of the textile machinery. If there is any fault they are trying to remove the fault of that machine or replaced the new part of that machine. Record of factory over head: CTM also record of the factory over head like oil changes of machine, lubricants changes, repair charges, change of burnt part of machine etc. Health and safety: Health facilities are available in Crescent Textile Mills for the employee whose salary is below RS.3000 However following health and safety measures are taken in at the factory 1) Fire extinguishers have been hanged on the walls to be more prominent. 2) In case of industrial injury, first aid is provided to the injured at the spot. 3) The cotton is stocked in go down to prevent from fire moisture etc. 4) No much woodwork has been carried inside the factory building.

Engineer from CTM are trying to maintain the safety of machine and workers from undue incident. They properly check the fire extinguishers and electricity main circuit time to time. Purchase of new technology: CTM purchase new technology for the maintenance of machines and imposed new quality standard timely. They also check the engineer for checking the machines on regularly bases. Regular check on employees: CTM check on employees, how they are used the machine regularly. If employees used machine brutally machines cost of industry is high automatically. Spare parts of machine: CTM maintain the record of spare parts of machine regularly by production department. Maintenance of machine includes oil, lubricants, threads etc. Compensation of employees: In case of any undue happen due to burnt machine or short circuit. CTM pay some compensation to employees after proper investigation.

Review of theoretical and practical situations


Almost there is same practical and theoretical maintenance analysis according to the definition and crescent textile mills. Training in not given to the employees properly for the maintenance of machines and facilities according to its standards of crescent textile mills. CTM imposed managerial strategies for maintenance of machines and facilities of industry. CTM purchase new technology for the maintenance of machines and imposed new quality standard timely. They also check the engineer for checking the machines on regularly bases. CTM maintain the record of spare parts of machine regularly by production department. Maintenance of machine includes oil, lubricants, threads etc. Engineer from CTM check the fault of the textile machinery. If there is any fault they are trying to remove the fault of that machine or replaced the new part of that machine. PPC also maintain report that shows daily record or orders, which are being processed on all available machines in spinning, weaving, garments department and also records of machines which are busy and which needs orders. In case of any undue happen due to burnt machine or short circuit. CTM pay some compensation to employees after proper investigation. Mangers hire good people in the organization for the maintenance of overhauls, facilities and machines.

Swot analysis:
Strengths: Crescent Textile Mills is using imported machinery It has high financial resources It has competent staff working for the progress of the company It has certificate of ISO 9002 It always sets new standards for quality Its design studio is equipped with latest technology. Weaknesses: There is lack of proper training programs especially for workers. They learn through experience and from seniors thats the reason of high rate of wastage during production. Wastage is very high especially in spinning sector because of burnt of parts. Opportunities: As Crescent Textile Mills is ISO-9002 certified company so it has a chance to increase maintenance analysis for expand business all over the world. Long term loans are easily available for maintenance of facilities and machines. Threats: Foreign investment in textile sector in Sri Lanka, Bangladesh and India is a danger in future for Crescent Textile Mills It has been seen that many other groups in Pakistan have entered in competition with Crescent Textile Mills. If they will not be competed well, there is a chance that they can get share of export from foreign buyers.

Recommendation: A proper training should be given to the employees and the workers to enhance their skills to increase their productivity and ultimately of the company. All the duties and responsibilities of the employees and the workers should be clearly defined. The management should hire multi-skilled workers to maintenance of machines or facilities. Conclusion: We got a lot of experience from Crescent Textile Mills. During our research we came to know that how the different activities take place, what are the procedures? The Crescent Textile Mills is on the way of progress. It has been earning profit for the last five years. The management is professionally qualified and experienced. The Crescent Textile Mills should motivate their employees by providing different incentives. Their salary package is also not attractive. The performance of the Human Resource department is also not satisfactory. Crescent Textile Mills look at maintenance on facilities, machines and so on. Crescent textile mills must look on machines maintenance timely; change the oil or other lubricants on time which can increase productivity and save wastage of time.