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What is an Audit Machinery maintenance System audit What we derive out of Systematic
Machinery Maintenance Audit Online and Offline audits Equipments that facilitate Online audits
Effective utilisation of resources
Men Machine Material Finance
CRITICAL ASSESSMENT OF A SYSTEM,PROCESS TO UNEARTH
DEVIATIONS FROM THE EXISTING
PRACTICES
DEVIATIONS FROM THE BENCHMARKED PRACTICES
CRITICAL ASSESSMENT OF A SYSTEM/PROCESS
TO IDENTIFY SCOPE FOR FURTHER IMPROVEMENTS
PLAYS A VITAL ROLE TO Minimise ADD vs EDD variance Realise the best out of Machinery Attain Maximum Utilisation Achieve consistency in YQ Control/Reduce Manufacturing cost Train the Workforce
A Mill commits EDD for 20 feet container of 40S CK to Korea by 6TH July.One Unilap feeding to the respective combers broke down for 14 Hours on July 1st.
WHAT HAPPENS TO DELIVERY ADHERENCE?
Trumac Cards are supposed to give 99% Cleaning efficiency.
Varioclean is supposed to give 40% cleaning efficiency
LC 300A Card 5m CV shd be below 2% RSB 851 shd run at 400 mpm
conveniently for combed counts with 1m CV below 0.6
HOW TO ACHIEVE THESE LEVELS ALWAYS?
NEW RING FRAME SHOULD RUN AT 98.8 % UTILISATION
AUTOCONER SHOULD RUN AT 96% UTILISATION
MODERN CARDS (0.5 CRORE) SHOULD BE RUN AT 96% UTILISATION
WHICH SYSTEM HELPS TO ATTAIN THESE LEVELS……
SPLICE STRENGTH SHOULD BE ABOVE 90%
CV OF IMPERFECTIONS SHOULD NOT EXCEED 7.5%
CLEARER CUTS SHOULD NOT EXCEED +10 PER LAC METERS
WHAT IS TO BE DONE….???????
3 % of Turn over is allotted for Repairs and Maintenance
0.5 % Deviation means 14.5 lacs for 25000 spindles on 100s CW
Can we exercise control thro any system for for strict adherence to budgeted amount?
COST OF THE SPARE COST OF PRODUCTION LOSS COST OF SUBSEQUENT MACHINERY
CHANGES BEYOND ABOVE,
LOSS OF A CUSTOMER FOREVER
ROUTINE MAINTENANCEORGANISED MANUFACTURERS GIVE
RECOMMENDED SCHEDULESMILLS HAVE TO DEVELOP FOR MACHINERY
FROM UNORGANISED SECTOR HAS IT BEEN DEVELOPED? HAS IT BEEN IN LINE WITH
REQUIREMENTS?
REDUCES WEAR OF THE PARTS DEPENDS ON LOAD,HEAT,NATURE OF
ENVIRONMENT,TYPE OF DRIVE etc CARE ON STORAGE SYSTEMS RATIONALISATION OF LUBRICANTS SHELF LIFE OF LUBRICANTS
PREVENTIVE MAINTENANCE CHECKS
PREVENTIVE MAINTENANCE/CRITICAL ITEMS REPALCEMENT SCHEDULES
CHECK MAINTENANCE SCHEDULES AND LUBRICATION SHEDULE WHETHER,
IT IS IN LINE WITH MANUFACTURERER`S RECOMMENDATION?
IT IS IN LINE WITH INDUSTRY`S BEST PRACTICES?
ADEQUACY(CHECKS FEW CRITICAL PARTS)
SCOPE FOR RATIONALISATION
ONLINE AUDITS
OFFLINE AUDITS
Waste clogging in Undergrids Slow motion of Material in conveying
ducts Synchronisation of Feeding lines Suction levels
CV of Slivers
Sheet thickness after chutes in cards
Deposits in Flat tops
LAP LICKING
WEB UNIFORMITY
Web Appearance
Unicomb Cleanliness
Sliver CV in Modern Combers
1 M CV%
Shift from central Values
Deposits on Creel Guides and Use of Blowing fans/Timing
Performance of PDTC(Top/Bottom)
Apron shift
ROVING alignment
Creel slackness/stretch
Bobbin revolution
Yarn Path
Position of Underclearers
Effectiveness of OHTC
WAX DISC MOVEMENTS
SPLICE APPEARANCE
TENSION LEVELS
BEATER QUALITY LATTICE PIN QUALITY LATTICE BOWL AND DRIVE SHAFT QUALITY OF UNDERGRID CRITICAL SETTINGS INSPECTIO
(MILLS STDS VS ACTUAL)
CHECK CYLINDER AND DOFFER FOR LAND CHECK FLAT TOPS /STATIONARY FLATS
FOR STRAIGHTENING OF WIRES CHECK LICKERIN FOR BENT /BROKEN
WIRES
CHECK MOTE /TRASH KNIVES FOR SHARPNESS
CHECK BASIC SETTINGS FOR AUTOLEVELERS
CHECK CRITICAL SETTINGS
TOP ROLLER WEIGHTING SYSTEMS
TOP ROLLER SADDLE QUALITY
LAP SELVEDGE QUALITY
CONDITION OF UNICOMB AND TOP COMBS
CONDITION OF DET ROLL AND DRAFT ROLL WEIGHTING SYSTEMS
NIPPER BITE
TOP ROLLER WEIGHTING/SADDLE
LATERAL PLAY IN DRIVE
BRAKING EFFICIENCY
PRESSURE LEVELS CARBON IMPRESSION OF ROLLER
SETTINGS
TOP ROLLER PRESSURE VARIATION
BUILDER MOTION FUNCTION
ALIGNMENT OF ROVING GUIDES
APRON TENSION
TRAVERSE MOVEMENT SPINDLE CENTERING RING RAIL LEVEL RING RAIL MOVEMENT TAPE TENSION BOBBIN HOLDER SPRINGS UNIFORMITY
YARN PATH IN COMPACT ZONE
SUCTION CONSISTENCY BETWEEN SECTIONS
COMPACTING SPARES CONDITION
CONDITION OF DRUMS SPLICE CUTTERS SPLICER COMPONENTS BALCON SETTINGS/MOVEMENTS PACKAGE DENSITY CHECKS
LEAF GAUGE
MASTER Pr. GAUGE
NILOMETER
ENSURE TIMELY CALIBRATION OF TOOLS AND GAUGES
NOT TO BE STEROTYPED CHECK LISTS-REVIEW PERIODICALLY CHANGE AUDITORS PERIODICALLY LINK CUSTOMER COMPLAINTS CHANGE OF M/CY NEEDS CHANGE OF
FORMAT HELPS IN SELECTING THE RIGHT TYPE OF
VENDORS
EXTENT TO WHICH PLANNED ACTIVITIES ARE REALISED AND THE PLANNED ACTIVITIES ARE CARRIED OUT
RELATIONSHIP BETWEEN THE RESULTS AND RESOURCES USED
INQUISITIVE – Should Probe PROFESSIONAL-Fair and report only
based on facts collected PRINCIPLED-Open and Transparent
approach POSITIVE-Every discrepancy is an
opportunity for Improvement
YARN CLEARERS OF TODAY HAVE ALARM SETTINGS FEATURE
ALARMS CAN BE SET FOR COPS HAVING DEFECTS BEYOND SET LIMITS
REJECTED COPS CAN BE ANALYSED FOR HISTORY
COPS FROM A RINGFRAME CAN BE FED TO AUTOCONERS WITH PRESET ALARM LIMITS
COPS WILL BEAR THE SPINDLE NUMBER OF THE RINGFRAME
RUN THESE COPS WITH PRESET ALARM LIMITS
ALARM LIMITS CAN BE SET FOR CV OF IMPERFECTIONS IMPERFECTIONS CLUSTER FAULTS(PEARL CHAIN) HAIRINESS/SFI
Spindlewise defects can be identified and Clearers help for thoro auditing of Prior Machinery on a periodical basis
DIFFICULTIES:Spindle numbering and doffing.Can be practiced.Few Mills have exclusive empties for this purpose.
Auditing of Maintenance activity is essential
To assess Buffing activity mills use Rogue Soindle analysis immediately after Buffing.
Next Level of MMA is TPM
TOTAL PRODUCTIVE MAINTENANCE
Thanks!
