Maintenance Management

Maintenance management is a term used to describe the activities to ensure that the
assets operate at the required state and that maintenance is performed in order to
achieve continuous improvements in reliability, maintainability and availability.
Maintenance management as: ―all activities of the management that determine the
maintenance objectives, strategies and responsibilities, and implementation of them
by such means as maintenance planning, maintenance control, and the
improvement of maintenance activities and economics ‖. Maintenance management
can be done in three different:

The first level is dealing with the formulation of the maintenance strategy so
that is consistent with the other business strategies within the company.
The second level is planning and schedule maintenance in order to ensure
efficient maintenance operations.
The third level is related to the execution and collection of data from the
maintenance actions. As maintenance has been an increasingly important
discipline the last decades, improvement of the maintenance management
have been the focus of attention.

Types of maintenance
Traditionally, 5 types of maintenance have been distinguished, which are
differentiated by the nature of the tasks that they include:

Corrective maintenance: The set of tasks is destined to correct the defects
to be found in the different equipment and that are communicated to the
maintenance department by users of the same equipment.

Preventive Maintenance: Its mission is to maintain a level of certain service
on equipment, programming the interventions of their vulnerabilities in the most
opportune time. It is used to be a systematic character, that is, the equipment is
inspected even if it has not given any symptoms of having a problem.

Predictive Maintenance: It pursues constantly know and report the status
and operational capacity of the installations by knowing the values of certain
variables,which represent such state and operational ability. To apply this
maintenance, it is necessary to identify physical variables (temperature, vibration,
power consumption, etc.). Which variation is indicative of problems that may be
appearing on the equipment. This maintenance it is the most technical, since it
requires advanced technical resources, and at times of strong mathematical,
physical and / or technical knowledge.

The previous working method obtained 77% of main problems cause of machine breakdown. and monthly. This research by using preventive maintenance techniques to improve the machine efficient capacity. that is.799 hrs/month. This study focuses on weaving machine to produce high quality of products. The implement was used the maintenance plan in daily. lubrication. The mean time to repair (MTTR) was decreased from 19. Zero Hours Maintenance (Overhaul): The set of tasks whose goal is to review the equipment at scheduled intervals before appearing any failure. but perhaps only a brief training. either when the reliability of the equipment has decreased considerably so it is risky to make forecasts of production capacity . The results from this improvement showed the increased 11.99% or from 62. The aim is to ensure.75 yards/month. These reviews will replace or repair all items subject to wear. and mean time between failure (MTBF) was increased to 73. with high probability.03% reduction. visual inspections. This review is based on leaving the equipment to zero hours of operation. This work utilized the preventive maintenance programs in three months to reduce the wasted time.46% of productivity values or 7. On the Thai garment factory almost used weaving machine for traus from raw materials to be finished product for export to the oversea market. . cleaning. Productivity Improvement in a Garment Factory by Preventive Maintenance Abstract The objective of this study was to improved the productivity of a machine unit were operated in a garment factory.  Periodic maintenance (Time Based Maintenance TBM): the basic maintenance of equipment made by the users of it.475 yards/month to 8438. and used the MTBF index to eliminate the breakdown times. This type of maintenance is the based on TPM (Total Productive Maintenance). weekly. retightening screws) for which no extensive training is necessary. as if the equipment were new.38 hrs/breakdown or 33.89 hrs/month to 241. a good working time fixed in advance. It consists of a series of elementary tasks (data collections.98 hrs/breakdown to 13.

49 1 3 2.7 3 3 4.40 3 3 4. air-jet.5 2 - - - 1.475.394.6 Average 7.581.95 Machine breakdown . the new model of weaving machine is a complicated working system if operator cannot keep it in good condition.32 9 187 10.16 19. there are strong competitions for survival of businesses.3 Table 2 Causes of inefficiency of production.) 8 113.27 Wrap yam break 243 Weft yam break November % Frequency Loss December % Frequency Loss (Times) (hrs.Introduction The competition of businesses and industries in the world markets. From production data in October to December 2000. 2000.67 10.1 9 231.27 7 199. New models of weaving machines were developed in weaving system by developing cotton control system which has many types such as water-jet. October Frequency Loss Causes (Times) (hrs. theTable 1 The production output from October to December.99 Idle 2 1.14 77.33 15. Some garment companies invested in the new weaving machine which was controlled by computer for increasing productivity and high quality of products.98 12 210 13.) % (Times) (hrs.35 74 10 118.66 108.6 November 7. From case study. The new model of weaving machine is one of the most important factors for producing the high quality of product.43 7 199 11.78 81 8. Month Net Fabric length (yard per machine) October 7.65 7.450. it has high speed working process with computer control. it may be difficult to control the weaving process because of some breakdown.30 213 10.19 2.) 76 7 92.4 December 7.6 11. there were machine breakdowns during working period after two years of using new machine that led to low productivity.60 Set up new roll 3 4. gripper of rapier and so on: Moreover. so many businesses and industries must improve their activities for maintaining their businesses in the competitive world The garment factory is one of the industries that must be planned to improve the working process and environment for higher efficiency of production process. However.58 11.) Average % Frequency Loss (Times) (hrs.33 0.47 3 3 3.37 13 241 14.

data in table 3 can be used to calculate performance of machine.13 hours. By this method.03 100 453 124. for example in driving system. maintenance took very long times because of lacking history data in maintenance.64 100 433.79 hours/3 months and frequency of breakdown is 2 times/month.76 100 410 146. control system. The unbalance cloth structure affects mostly on breakdown from main shaft of dobby broken. and mean time to repair. let weft release system. warp overload and frequency stops. proper speed. which is about 77% of whole problems. The main problem of inefficiency is machine breakdown. there is no suitable preventive maintenance plans to protect machine breakdown.16 100 Table 2 determined the volumes of machine breakdown leads to the serious problems of low productivity.93 140. mean time between failures./time and mean time to repair is 12. it was founded that main shaft of dobby broken is the main problem of machine breakdown.98 hrs.11%.Total 466 149. shedding system. Mean time between failures is 62. . the cause effect diagram must be analyzed to correct the primary cause of machine breakdown and plan to protect it was determined. weft insertion system. and lenos system were shown in table 3. tuck in system. Then.89%. This information obtained from machine breakdown caused of incorrect adjustment. The working system must be set the weaving process. The main shaft was divided from several cases to be are unbalance cloth structure. Methods The improvement of mean time between failure (MTBF) and mean time to repair (MTTR) were necessary to consider the data were shown in table 2.89 hrs. on ready for used of machine waste of working time. improper speed. incorrect lubrication. and load of yarn in weaving machine for balance cloth structure. It is found that ready for use of machine is 82. incorrect cleaning etc. So. Moreover. while waste of working time is 17. Recording data of machine breakdown has details of breakdown in several causes./time while average breakdown of machine per month is 108. With cause effect diagram. The main cause of breakdown is shedding system because it has the average breakdown 29.

67 4. Cause of breakdown Frequency Average of breakdown (times per month) (hrs per month) Driving system 1.33 22.126. Month Net Fabric length (yards per machine) January 8.75 Results After the information of machine breakdown was studied and analyzed with cause effect diagram.33 1.4 Shedding system 2.00 4.58 0.99 March 8. By working with maintenance plan.00 29.75 yards/ machine was shown in Table 4 and Figure . weekly.750.66 108. the average production output during January-March.Table 3 The causes of machine breakdown and the average of machine breakdown in garment factory during October-December.439.00 Average 8.26 February 8. and monthly maintenance [5].33 25.00 21.438.33 0. 2001 was 8. the maintenance plan is set as daily. Following the instruction handbook [4] did annual maintenance program.13 Let insertion system weft release system Tuck in Lenos system Total system Table 4 Production output during January to March 2001.0 Control system 2.19 0.79 Weft 1. lubrication and adjustment plans.438.85 8. 2000: (previous improvement phase). Daily maintenance composes of cleaning.

the efficiency of production before and after maintenance by plan was compared. Conclusions Preventive maintenance techniques were utilized to improve the performance efficiency of machine in this study.45 yards/month/machine. the solutions of this project improvement were summarized as follow : (1) Instructor’s manual for setup the balance shedding was necessary. Production was more effective as shown by the increase of average efficiency to 963.79 hours/time while lost of machine breakdown was decreased 5. and (6) Inspection manual for setup the machine. Due to the productivity improvement. (4) Set the weekly changing spare parts plan for each machine. In contrast. .3. mean time between failures: MTBF was increased to 241. The data presented above show many causes of system breakdowns. Mean time to repair: MTTR was decrease to 13.30% while the percentage of machine breakdown was decreased to 72. Then. machine breakdown times were analyzed.75% or increased by 14. The results of comparing the machine performance before and after maintenance by planning are as follow. preventive maintenance programs could be done for the higher machine capacity utilization and save the factory cost. (3) Welltrained operators for understanding the importance of the daily lubrication of parts and cleaning machine. (2) Daily maintenance inspection plans were set and used.15%.38 hours/time and average of machine breakdown/month was decreased from 108. It was found that the output increased up to nearly 85% to meet the target. It was found that the ready for use of machine was 94.24%. (5) Planning the annual lubrication oil changing and check the lubrication systems every 2 months.05 hours/month. As the information obtained from this work.03 hours/month to 31. Suggestions According to the several problems.