Maintenance:
Maintenance is the actions taken to prevent a device or component from failing or torepair nor- mal equipment degradation experienced with the operation of the device to keep it in proper working order. Types of maintenance: Reactive maintenance Preventive maintenance Predictive maintenance Capital replacement
Beximco Denims Ltd. follows all types of maintenance those described above.
Preventive Maintenance:
Preventive Maintenance refers to only a part of a good maintenance programmed. It consists of routine actions taken in a planned manner to prevent break-down and to ensure operation accura- cy to the extent it is economically and practically possible to do so. Lubrication and inspection are the two constituents of preventive maintenance. Lubrication insures long life and safe work- ing of equipment without mishaps. Inspection tries to detect faults in a equipment and facility so that repairs and replacement may be undertaken before the faults assume the proportion and shape of a break down.
Reactive/Break-down maintenance:
Breakdown maintenance practice allows a machine or facility to run without much of routine at- tention, till it actually, breaks down to be then put back into commission. Type: gravity, place and time of breakdown are of a random nature. This practice, therefore, leads to disruption of production plans. It also makes it impossible to plan the workload and distribution of mainten- ance work force for a balanced attention of all equipment. It increases over time payment and involves prolonged down time due to non- availability of requisite man-power and spares. This practice, consequently, accepts a lower level of organizational efficiency, and cannot be recom- mended as general practice for all types of equipment.
It is, however, an economical way of maintaining certain non-critical items whose repair and down time costs are less this way than with any other system of maintenance.
Predictive/Planned Maintenance:
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riods on the basis of priority and after ascertaining production requirements; and arranges for availability of material tools and man-power and for release of machines in time. Planned main- tenance also provides for a system of feedback of information for necessary changes in the origi- nal plan.
Capital Replacement:
A replacement may have to be affected when -
a) An equipment ages to the extent that the costs of maintaining in the required condition provide gain that is less than those realizable from investments in a new unit.
b) Changes in quality and quality of the product and / or emergence better machine in the market render the original unit obsolete. Process of discarding old equipment and installing a new one in its place is a continuous feature of an industry because of its dynamic nature that is reflected through the improvements in product quality, increase in the volume of sales, general technolo- gical development and deterioration of the existing equipment. Maintenance department of a company has therefore, to assume the responsibility for evolving a long-range replacement poli- cy commensurate with the company‟s objectives and growth.
Maintenance activities for their optimum performances at their following points:
1. Routes of different utilities like water, stem, gas, electricity, compressed air, etc. 2. Dyestuff & chemical dosing system.
3. Drainage system of waste water, color & chemical. 4. Driving arrangement of different machineries. 5. Power transmission to different machineries. 6. Fabric guiding system through the machineries. 7. Cleanliness of machine parts.
Manpower of maintenance:
Table 20: Manpower for maitenance
Position No. of Person Department
B.Sc. Engr. 1 Elect. & Mechanical.
Foreman 2 Elect. & Mechanical
Fitter 2 Elect. & Mechanical
Assistant Fitter 2 Elect. & Mechanical
Welder 2 Elect. & Mechanical
Maintenance tools & equipments:
1. Pliers
2. Inside Calipers 3. Outside Calipers 4. Digital Multi Meter 5. Heating Shoulder 6. Hammer
7. Philes etc.
Maintenance Schedule for dyeing section:
Inspection Action Frequency
Pump/Dosing pump
Inspect & check oil
Weekly Plaiter & plaitor
motor
Inspect & check noise level. Everyday
Water level indica- tor
Inspect & check its function Everyday
Loading/Unloading winch
Inspect & check gears condition & noise level etc.
Everyday
Heat exchanger actuator & valve
Inspect & check heating & cooling system inspect for change as necessary with compressed air/vacuum
weekly
Filter screen Inspect & check as necessary Every 8 hours Safety guards Inspect all location to aware that Daily
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guards are in place
Fans & Drives Clean screens at motor suctions check lubricants
weekly
Belts & Blankets Check for wear Damage trucking alignment &Tension impact.
Connecting seem to be sure Edges are in line.
weekly
Sensors limit switches gauge
Impact for correct operation weekly
Gear boxes Check oil level, noise small operation weekly
Control cabinet Inspect & clean next filters.
Checks that all lights are operational make sure cabinet in clean inside , check A/C unit to clean
weekly
Table 21: maintenance schedule of dyeing section
Weaving section is always under air suction for fluff. Thus here break down maintenance is fol- lowed. As the looms were installed a few days ago & comparatively new, maintenance is less required here than the dyeing section.