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

different maintenance approaches.

Maintenance Engineering is the discipline and profession of applying engineeringconcepts to the optimization of equipment, procedures, and departmental budgets toachieve bettermaintainability, 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 increasinglycomplex, 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 ofmanufacturing 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 directionand 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 appropriateresponse.

Plant Condition Control

Close monitoring and control of the overall plant condition is necessary to achieve a

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high level of plant availability. Its long-term objectives are:To highlight maintenance engineering problems by monitoring plant

performance, diagnosing causes and providing effective solutions;

To adapt maintenance policy as production requirements change. This shouldnot be restricted to changes in preventive maintenance but should encompass

re-design and the application of condition monitoring techniques whereappropriate.

Cost Control

The third activity, cost control, is normally operated as part of a companys budgetary

and expenditure control system, primarily for job costing. To achieve the

improvements in maintenance effectiveness and efficiency, the maintenance managermust make use of all of the available management tools.

Computerised Maintenance Management SystemA computerised maintenance management system will contain a number of integrated

programs or modules to improve the efficiency and effectiveness of the maintenance

engineering function. In this sense the system is like a set of tools, albeit highlycomplex and difficult to produce. 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.

The basic modules or component part of the maintenance systems are as follows:

Preventive maintenanceAsset register

Maintenance stores system

Purchasing

MAINTENANCE APPROACHES

Two main approaches to maintenance are

1. Breakdown maintenance

2. Planned maintenance

Breakdown maintenance

It means that people waits until equipment fails and repair it. Such a thing could be usedwhen the equipment failure does not significantly affect the operation or production or

generate any significant loss other than repair cost.Equipment is allowed to run till it stops working and no efforts made in advance toprevent the failure of parts.

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Planned maintenance:

Planned Preventative Maintenance ('PPM') or more usual just simple PlannedMaintenance (PM) orScheduled Maintenance is any variety of scheduled maintenanceto an object or item of equipment. Specifically, Planned Maintenance is a scheduled

service visit carried out by a competent and suitable agent, to ensure that an item ofequipment is operating correctly and to therefore avoid any unscheduled breakdown and

downtime.

Advantages of planned maintenance:

easier planning of maintenance and ordering spares,

costs are distributed more evenly,

no initial costs for instruments for supervision of equipment.

Types of Maintenance Planned maintenance

1.Preventive maintenance ( 1951 )It is a daily maintenance ( cleaning, inspection, oiling and re-tightening ), design to retain

the healthy condition of equipment and prevent failure through the prevention of

deterioration, periodic inspection or equipment condition diagnosis, to measuredeterioration. It is further divided into periodic maintenance and predictive maintenance.

Just like human life is extended by preventive medicine, the equipment service life can

be prolonged by doing preventive maintenance.

2. Periodic maintenance ( Time based maintenance - TBM)Time based maintenance consists of periodically inspecting, servicing and cleaning

equipment and replacing parts to prevent sudden failure and process problems.

3. Predictive maintenance

This is a method in which the service life of important part is predicted based oninspection or diagnosis, in order to use the parts to the limit of their service life.

Compared to periodic maintenance, predictive maintenance is condition based

maintenance. It manages trend values, by measuring and analyzing data aboutdeterioration and employs a surveillance system, designed to monitor conditions through

an on-line system.

4. Corrective maintenance ( 1957 )

It improves equipment and its components so that preventive maintenance can be carried

out reliably. Equipment with design weakness must be redesigned to improve reliabilityor improving maintainability

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5. Maintenance prevention ( 1960 )

It indicates the design of a new equipment. Weakness of current machines are

sufficiently studied ( on site information leading to failure prevention, easier maintenanceand prevents of defects, 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. Total Productive Maintenance (TPM) is a maintenance program which involves a

newly defined concept for maintaining plants and equipment. The goal of the TPMprogram is to markedly increase production while, at the same time, increasing employee

morale and job satisfaction.

TPM brings maintenance into focus as a necessary and virtually important part of the

business. It is no longer regarded as a non-profit activity. Down time for maintenance isscheduled as a part of the manufacturing day and, in some cases, as an integral part of the

manufacturing process. The goal is to hold emergency and unscheduled maintenance to a

minimum.

2.Condition-based maintenance (CBM), shortly described, is maintenance when need

arises. This maintenance is performed after one or more indicators show that equipment

is going to fail or that equipment performance is deteriorating.

Condition-based maintenance was introduced to try to maintain the correct equipment atthe right time. CBM is based on using real-time data to prioritize and optimize

maintenance resources. Observing the state of the system is known as condition

monitoring. Such a system will determine the equipment's health, and act only when

maintenance is actually necessary. Developments in recent years have allowed extensiveinstrumentation of equipment, and together with better tools for analyzing condition data,

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. Ideally condition-basedmaintenance will allow the maintenance personnel to do only the right things,

minimizing spare parts cost, system downtime and time spent on maintenance.

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3.Reliability Centered Maintenance, often known as RCM, is a process to ensure thatassets continue to do what their users require in their present operating context.

It is generally used to achieve improvements in fields such as the establishment of safe

minimum levels of maintenance, changes to operating procedures and strategies and the

establishment of capital maintenance regimes and plans. Successful implementation ofRCM will lead to increase in cost effectiveness, machine uptime, and a greater

understanding of the level of risk that the organization is presently managing.

RCM identifies the maintenance requirements of equipments

-- establishes functional requirements and the desired performance standards of

equipments and then relates to design and inherent reliability parameters of machines.

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Q2.what are the tasks and responsibilities of a maintenance engineer in the garment

industry.

Maintenance engineers plan the routine maintenance of equipment and machinery. Theywork on-site or remotely diagnose faults and oversee time-critical repairs. 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. Other types of work include mechanical,electrical, hydraulic or pneumatic work.

The Maintenance Engineer is a leader-manager, teaching and ensuring others to do this

as part of his duty to develop and implement maintenance systems to do ever better

maintenance.

Typical work activities

Responsibilities and tasks may vary from role to role but typical work activities include:

designing maintenance strategies, procedures and methods;

planning and scheduling planned and unplanned work;

diagnosing breakdown problems;

carrying out quality inspections on jobs;

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liaising with client departments and customers;

arranging specialist procurement of fixtures, fittings or components;

controlling maintenance tools, stores and equipment;

monitoring and controlling maintenance costs;

writing maintenance strategies to help with installation and commissioning

guidelines.

Function

1. Attend to breakdown of machine.2. Periodic machine maintenance.

3. Maintenance of needle breakdown report.

4. Providing new folders and attachments.5. Development of templates and profiles.

6. Assisting the operator in knowing the machine7. Inform the HOD for the requirement of any new machine.

8. To replace any broken parts of the machine.9. To collect the broken parts of the needle and maintain its record.

10.To carry out preventive maintenance of the machines as per schedule.

11.To contact the machine manufacturer in case of persistent problem.12.To set up the line as instructed in the sewing room.

13.To carry out oiling and cleaning of the machines as per the schedule.

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Q4. Organizational structure of garment industry with an emphasis on the

maintenance dept.

CEO

HEAD OPERATIONS

CHIEF MANAGER

TECHNICAL

Sr. MANAGER

QUALITY

MANAGER

STORES

CHIEF

MANAGER HR

ASST. MANAGER

QUALITY

ASST. MANAGER

QA. AUDITING

MANAGER HR

EXECUTIVESADMIN

EXECUTIVE

QUALITY

EXECUTIVESTORES

ASST.

FACTORY

MANAGER

PRODUCTION

MANAGER

ASST.

MANAGER

IED

ASST.

MANAGER

FINISHING

ASST.

MANAGER

EXECUTIVE

PPC

EXECUTIVE

CUTTING

EXECUTIVE

MAINTAINS

EXECUTIVE

SEWING

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EXECUTIVE

MAINTAINS

LINE SUPERVISOR

ELECTRICIAN

1 electrician for 3-4 sewing lines

MECHANIC

1 mechanic for each sewing lines