textile machines maintenance

Textile Machines Maintenance
OBJECTIVES OF MAINTENANCE:
Safety of the machine
To maintain the machine in working condition.
To give high production at low cost.
To repair the machine.
To restore the original condition of the machine.
To reduce the machine damages and faults.
Look after(care) the machine.
To make machine life longer
To increase quality.
To enhance efficiency of the machine.
Total time = down time + running time
Availability of time = Running time / Total time

MECHANICAL MAINTENANCE

Ø Maintenance of all mechanical parts of the machine is very important. Every mechanical part has its own job without which machine can not run.
Ø Maintenance of mechanical parts result in the increase of efficiency of the machine by keeping the machine in working condition for longer time. In this way production can be increased.
Ø Oiling and cleaning has also a good effect on maintenance. It is very important because in this way machine can work faster and for longer time.
Ø By proper mechanical maintenance parts of the machine are changed or repaired on time which doesn’t cause machine damages frequently. In this way we reduced the machine down time and increase production.
Ø Efficiency of the machine also increased by mechanical maintenance as working time of the machine increases. Efficiency=running time/D.T+R.T
BUILDING MAINENANCE
Ø Maintenance of the building where they are installed is very important because it gives the machine protection from weather affects.
Ø Poor or old building demands more cleaning. In some cases sand and dust falls from the roof on the machine in working condition. it may effect the quality of the product.
Ø If building material continued to falling on the machine, it can be a cause for machine jamming.
Ø If the floor is not maintained properly there will be cracks on it. This may disturb the balance of the machine due to which quality and production affected.
IMPORTANT FACTORS FOR EFFECTIVE MAINTENANCE
Following factors are very important for the effective maintenance of textile machinery.
MACHINE DESIGN
It should be simple and according to the requirements. Design of the machine effects the working time and treatment of the material. machine should be so designed that less cleaning and oiling is required and machine can run at high speed to give high production. It should be easy to operate and of low price.
REPAIRING TOOLS
Tools for the repairing of the machine should be available every time and in working condition and according to the machine parts or design. Tools of one machine may not fit for the other machine.
QUALITY OF MACHINE
Machine should be of better quality i.e. high speed and high production rate. High quality mean it requires less maintenance and give high production.
MANAGEMENT OF MANTENANCE WORK
Maintenance work should be planned so that maintenance time can be reduced. Planned maintenance is more effective then unplanned.
MANPOWER
Use of manpower properly is very effective. We can employ individual worker for every work i.e. for mechanical faults mechanical engineer, for electric fault electric engineer. But demand is that one man should be able to maintain the whole machine whether it is mechanical or electronic fault.
OILING AND CLEANING
Machine should be cleaned regularly. After cleaning, if oiling and lubrication is done then it will make the machine life longer.
SKILLED LABOUR
Maintenance worker should be skilled and of sufficient experience.
MACHINE SPEED
Machine speed should be according to the manufacturer suggestions. Appropriate machine speed require less maintenance as it cause less damaging of machine parts.
EXCHANGE OF PARTS
machine parts should be repaired or exchanged on time otherwise it will cause damaging of other adjacent machine parts.
MACHINE TIME
Maintenance time should be less than 2-3% of the total down time.
MACHINE SETTING
If machine setting is not according to the design of the machine then some parts of the machine may not work properly..
SYSTEM FOR MAINTENANCE
Maintenance should be according to a proper system of maintenance. Preventive maintenance system is best in this regard.
CAUSES OF MACHINE DEFECTS

Ø DUSTING causes machine jamming and more resistance between the working parts of the machine. Dust may damage the quality of the material(cotton) which results in bad quality yarn. It may affect color, strength or evenness of the yarn.
Ø OILING should be proper i.e. according to the requirement of the machine. More oiling can damage other machine parts by flowing out from the required place to the material or other machine parts. In this way material quality can be affected.
Ø MANUAL TREATMENT also causes machine damages. Skilled operators should control all the machine working to avoid this problem. Untrained worker may damage the machine or material by improper handling.
Ø QUANTITY OF THE FEEDED MATERIA should be according to the capacity of the machine. More feed causes breakage of working parts that handling the material. In other case machine stoppage can occur or the production is of bad quality.
Ø MACHINE SPEED should be within working limits. Machine running over speed can cause breaking of some parts of the machine.
Ø HEAVY IMPURITIES like motes, leaves etc. can disturb the working of the machine.
MANGEMENT FUNCTIONS:
Managing the work.
Scheduling
Implementation
Controlling
For better maintenance one should know
Machine functions
Machine segments
Machine specifications
None repeated functions of maintenance are :
§ Overhauling
Major replacements etc.
Machine segments are made for inspection.
Machine specification e.g
Ring machine specifications,
ü No. of spindles
ü Speed of machine
ü Size of machine
ü Working mechanism
ü Rate of production
ü Efficiency etc.
MAINTENANCE FUNCTIONS
1. Inspection
Cleaning
Lubrication
History(faults history)
Adjustments
Repairs & replacements
Overhauling
Fixing
Calibration
Testing & rectification e.g. gauging
Pre requests for maintenance are,
ü Tools
ü Parts
ü Manpower
COSTING SEGMENTS:
· Production cost
Maintenance cost
Management cost
Marketing cost
Sale & purchase technique

MAINTENANCE SCHEDULING

For better understanding of maintenance scheduling we must understand the relation between maintenance functions & objectives.

REQUIREMENTS:
For making proper maintenance schedule one must know
ü Machine specifications
ü Machine design
ü Machine functions
ü Machine system
ü Machine speed
ü Working mechanism of machine
ü Data
ü Planning

Scheduling can be on daily, weakly, monthly or yearly basis.
History factors for better understanding of maintenance scheduling are,
· Quality report
Production chart/report
Defects/problem report
Causes of damages
QUESTION:
Why we need rescheduling?
ANSWER:
We need rescheduling to get high quality and production. For the removal of faults. Rescheduling is very important when we are going to do preventive maintenance.

Preventive
Emergency
Emergency
Corrective

Routine
Predictive
Restorative
Routine
MAINTENANCE FACILITIES
Maintenance facilities can broadly divided into two types as;
1. Stores
2. Workshops
1. STORES
Stores are used to keep tools and material such as spares parts, lubricants etc. Stores can be use for different machines in a department or for different machines of different departments. Stores can be further classified into two departments;
a) Main store
In main store we usually made sections of rooms, e.g. spinning section, weaving section, processing section etc.
b) Sub stores
Sub stores are usually made within the department for limited stock keeping e.g. for 15, 20, or 30 days.
BENEFITS OF STORES.
ü Easy to trace equipments.
ü Safety problems decreases
ü Easy presentation of tools
ü Easy documentation and record keeping
ü Security achieved
ü Easy to manage
ü Easy to use
ü Prevention from weather effects
ü Prevention from harmful chemicals
ü Moisture control
ü Long run storage
2. WORKSHOPS
Workshop is very important facility for repairing and manufacturing the machine parts. workshops can be,
· Mechanical
· Electrical
· Electronics
a) MECHANICAL WORKSHOP
REQUIREMENTS:
ü Welding plant
ü Grinder
ü Fitter
ü Drill
ü Lath machine
In mechanical workshop instrument should be neat and clean. Working conditions should also be checked.