Q1. Define maintenance engineering. What are maintenance objectives? Explain different maintenance approaches.

Maintenance Engineering is the discipline and profession of applying engineering concepts to the optimization of equipment, procedures, and departmental budgets to achieve better maintainability, reliability, and availability of equipment. Maintenance, and hence maintenance engineering, is increasing important due to rising amounts of equipment, systems, machineries and infrastructures. Since the Industrial Revolution devices, equipment, machinery and structures have grown increasingly complex, requiring a host of personnel, vocations and related systems needed to maintain them and hence maintenance engg. evolved as a disciple. A person practicing Maintenance Engineering is known as a Maintenance Engineer. Maintenance engineering plays a vital role in the efficiency, development and progress of manufacturing and processing industries. Maintenance engineers work with other professionals in order to improve production facilities, reduce the incidence of costly breakdowns and develop strategies to improve overall reliability and safety of plant, personnel and production processes.

The Objectives of Maintenance Management Maintenance management can increase plant availability and reduce overall maintenance costs.. Maintenance management can be considered as the direction and organization of resources to control the availability of equipment. The tasks associated with maintenance can be divided into three main areas; • work management, • plant condition control and • cost control. Work Management Work management is concerned with the logistics of organising maintenance and has the following objectives: To identify, control and co-ordinate the resources (labour, spare parts, materials and tools) that are required to completer the maintenance tasks; To ensure that job priorities are correctly allocated; To locate plant failures or potential failures and provide an appropriate response. Plant Condition Control Close monitoring and control of the overall plant condition is necessary to achieve a

the maintenance manager must make use of all of the available management tools. Computerised Maintenance Management System A computerised maintenance management system will contain a number of integrated programs or modules to improve the efficiency and effectiveness of the maintenance engineering function. albeit highly complex and difficult to produce. diagnosing causes and providing effective solutions. To adapt maintenance policy as production requirements change. The basic modules or component part of the maintenance systems are as follows: Preventive maintenance Asset register Maintenance stores system Purchasing MAINTENANCE APPROACHES Two main approaches to maintenance are 1. This should not be restricted to changes in preventive maintenance but should encompass re-design and the application of condition monitoring techniques where appropriate. Equipment is allowed to run till it stops working and no efforts made in advance to prevent the failure of parts. cost control. Breakdown maintenance 2. Cost Control The third activity. To achieve the improvements in maintenance effectiveness and efficiency. In this sense the system is like a set of tools. . is normally operated as part of a company’s budgetary and expenditure control system. Planned maintenance Breakdown maintenance It means that people waits until equipment fails and repair it. Such a thing could be used when the equipment failure does not significantly affect the operation or production or generate any significant loss other than repair cost. But with the correct design the system should be easy to use and provide the engineer with all of the information that is required to make better decisions. primarily for job costing. Its long-term objectives are: To highlight maintenance engineering problems by monitoring plant performance.high level of plant availability.

Types of Maintenance Planned maintenance 1. design to retain the healthy condition of equipment and prevent failure through the prevention of deterioration. designed to monitor conditions through an on-line system. Periodic maintenance ( Time based maintenance . no initial costs for instruments for supervision of equipment. 3. It is further divided into periodic maintenance and predictive maintenance.Preventive maintenance ( 1951 ) It is a daily maintenance ( cleaning. Planned Maintenance is a scheduled service visit carried out by a competent and suitable agent. costs are distributed more evenly. periodic inspection or equipment condition diagnosis. It manages trend values. in order to use the parts to the limit of their service life. servicing and cleaning equipment and replacing parts to prevent sudden failure and process problems. Equipment with design weakness must be redesigned to improve reliability or improving maintainability . Compared to periodic maintenance. 2. Just like human life is extended by preventive medicine. Predictive maintenance This is a method in which the service life of important part is predicted based on inspection or diagnosis. oiling and re-tightening ).TBM) Time based maintenance consists of periodically inspecting. by measuring and analyzing data about deterioration and employs a surveillance system. to measure deterioration. the equipment service life can be prolonged by doing preventive maintenance. to ensure that an item of equipment is operating correctly and to therefore avoid any unscheduled breakdown and downtime.Planned maintenance: Planned Preventative Maintenance ('PPM') or more usual just simple Planned Maintenance (PM) or Scheduled Maintenance is any variety of scheduled maintenance to an object or item of equipment. Specifically. Advantages of planned maintenance:    easier planning of maintenance and ordering spares. Corrective maintenance ( 1957 ) It improves equipment and its components so that preventive maintenance can be carried out reliably. inspection. 4. predictive maintenance is condition based maintenance.

Condition-based maintenance was introduced to try to maintain the correct equipment at the right time. shortly described. Total Productive Maintenance (TPM) is a maintenance program which involves a newly defined concept for maintaining plants and equipment. in some cases. The goal is to hold emergency and unscheduled maintenance to a minimum. It is no longer regarded as a non-profit activity. minimizing spare parts cost.Condition-based maintenance (CBM). and act only when maintenance is actually necessary. Down time for maintenance is scheduled as a part of the manufacturing day and. 2. increasing employee morale and job satisfaction. Ideally condition-based maintenance will allow the maintenance personnel to do only the right things. Such a system will determine the equipment's health. This maintenance is performed after one or more indicators show that equipment is going to fail or that equipment performance is deteriorating.5. and together with better tools for analyzing condition data. The goal of the TPM program is to markedly increase production while. Developments in recent years have allowed extensive instrumentation of equipment. . Maintenance prevention ( 1960 ) It indicates the design of a new equipment. system downtime and time spent on maintenance. safety and ease of manufacturing ) and are incorporated before commissioning a new equipment. In addition to the above some modern forms of maintenance management are 1. TPM brings maintenance into focus as a necessary and virtually important part of the business. Weakness of current machines are sufficiently studied ( on site information leading to failure prevention. at the same time. easier maintenance and prevents of defects. Observing the state of the system is known as condition monitoring. CBM is based on using real-time data to prioritize and optimize maintenance resources. as an integral part of the manufacturing process. is maintenance when need arises. the maintenance personnel of today are more than ever able to decide what is the right time to perform maintenance on some piece of equipment.

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and a greater understanding of the level of risk that the organization is presently managing.Reliability Centered Maintenance.3. changes to operating procedures and strategies and the establishment of capital maintenance regimes and plans. Successful implementation of RCM will lead to increase in cost effectiveness. often known as RCM. RCM – identifies the maintenance requirements of equipments -. It is generally used to achieve improvements in fields such as the establishment of safe minimum levels of maintenance. is a process to ensure that assets continue to do what their users require in their present operating context.establishes functional requirements and the desired performance standards of equipments and then relates to design and inherent reliability parameters of machines. . machine uptime.

All work carried out is either preventative or emergency maintenance Maintenance engineers work in manufacturing. production or transport and may use computerised systems to schedule the work. The Maintenance Engineer is a leader-manager. planning and scheduling planned and unplanned work. Maintenance engineers plan the routine maintenance of equipment and machinery. carrying out quality inspections on jobs. Other types of work include mechanical. diagnosing breakdown problems. . electrical. procedures and methods. They work on-site or remotely diagnose faults and oversee time-critical repairs. hydraulic or pneumatic work. Typical work activities Responsibilities and tasks may vary from role to role but typical work activities include: • • • • designing maintenance strategies. teaching and ensuring others to do this as part of his duty to develop and implement maintenance systems to do ever better maintenance.what are the tasks and responsibilities of a maintenance engineer in the garment industry.Q2.

arranging specialist procurement of fixtures. 6. Development of templates and profiles.To carry out preventive maintenance of the machines as per schedule. fittings or components. To replace any broken parts of the machine. 5. . 13. Maintenance of needle breakdown report. Attend to breakdown of machine. 9. To collect the broken parts of the needle and maintain its record. Periodic machine maintenance. 3. Providing new folders and attachments.• • • • • liaising with client departments and customers. stores and equipment. Assisting the operator in knowing the machine 7. Function 1. 8. 12. 2. writing maintenance strategies to help with installation and commissioning guidelines. Inform the HOD for the requirement of any new machine.To contact the machine manufacturer in case of persistent problem.To carry out oiling and cleaning of the machines as per the schedule.To set up the line as instructed in the sewing room. monitoring and controlling maintenance costs. controlling maintenance tools. 11. 4. 10.

MANAGER FINISHING ASST.Q4. AUDITING MANAGER HR EXECUTIVE QUALITY EXECUTIVE STORES EXECUTIVE’S ADMIN ASST. FACTORY MANAGER PRODUCTION MANAGER ASST. MANAGER QUALITY MANAGER STORES CHIEF MANAGER HR ASST. MANAGER QA. MANAGER QUALITY ASST. Organizational structure of garment industry with an emphasis on the maintenance dept. MANAGER EXECUTIVE PPC EXECUTIVE CUTTING EXECUTIVE MAINTAINS EXECUTIVE SEWING . MANAGER IED ASST. CEO HEAD OPERATIONS CHIEF MANAGER TECHNICAL Sr.

EXECUTIVE MAINTAINS LINE SUPERVISOR ELECTRICIAN 1 electrician for 3-4 sewing lines MECHANIC 1 mechanic for each sewing lines .

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