(B) ELECTRICAL MAINTENANCE DEPARTMENT

• ELECTRICAL MAINTENANCE
DEPARTMENT MAINLY TAKES CARE OF
DAY TODAY MAINTENANCE ACTIVITIES
IN THE DIFFERENT SHOPS IN THE PLANT

1. MACHINE SHOP
2. INJECTION MOULDING SHOP
3. FABRICATION SHOP
4. POWDER COATING SHOP/ PAINT SHOP
5. UITLITY MAINTENANCE ACTIVITIES( DIESEL
GENSETS, COMPRESSORS AND OTHER
ELECTRICAL APPLIANCES)
1. MACHINE SHOP

• MACHINE SHOP IS THE DEPARTMENT WHERE MACHINING OF

METAL JOBS ARE DONE WHICH ARE USED WHILE THE ASSEMBLY
OF LOOMS.

• MACHINE SHOP INCLUDES BOTH CONVENTIONAL AND MODERN

CNC MACHINES SOME OF WHICH ARE AS UNDER:

i. VERTICAL TURNING LATHES: A TOTAL OF 7 MACHINES. OUT OF WHICH TWO

ARE OLD CONVENTIONAL MACHINES AND FIVE ARE CNCs. FOUR CNC MACHINES
ARE YOUJI TAIWAN MAKE WITH FANUC CONTROLLER AND ONE IS
RETROFITTED BY PNC WITH FANUC CONTROLLER.
ii. VERTICAL MACHINING CENTERS: THERE WERE 3 VMCS. ALL THREE HAD FANUC
CONTROLLER 0I-MC.
iii. HORIZONTAL MACHINING CENTERS: THERE WERE TWO HMCS. ONE WAS
YAMAZAKI MAZAK MAKE FH4000 WITH MAZATROL CONTROLLER AND ONE
WAS PREMIER AUTO MAKE HC-500 WITH FANUC CONTROL.
iv. HORIZONTAL LATHES: FOUR LATHES WERE THERE. TWO WERE CONVENTIONAL
WITH THREE JAW CHUCK. AND TWO WERE CNCS, ONE YAMAZAKI MAZAK MAKE
QT-6T WITH MAZATROL CONTROL AND ONE FAIR FRIEND TAIWAN MAKE WITH
FANUC 0I-TC CONTROL.
v. CAM MILLING MACHINES: THERE WERE THREE CAM MILLING MACHINES(CMM).
TWO WERE CNCS WITH SIEMENS SINUMERIC 840D CONTROLLER AND ONE WAS
PLC CONTROLLED.
vi. SOME OTHER WERE VERTICAL GRINDING MACHINE, CO-ORDINATE DRILLING
AND TAPPING MACHINE, SURFACE GRINDING MACHINE ETC.
2. INJECTION MOULDING SHOP
• THE PROCESS OF INJECTION MOULDING CAN BE UNDERSTOOD
WITH FOLLOWING BLOCK DIAGRAM:

GRANUALS HOPPER HOPPER BARREL WITH

(HDPE, LDPE, PP, SCREW AND
DELRINE, LOADER
HEATER.
NYLON6 ETC)

CLAMPING OF MOULD
WASTE IS CUT IN WITH HYDRAULIC
GRANULATOR PRESSURE

FAST COOLING
OF DIE WITH MOVEMENT OF
FINAL OIL OR WATER INJECTION MATERIAL WITH
PRODUCT INTO DIE OR ROTATION OF
MOULD SCREW

• THE MACHINES FOR INJECTION MOULDING WERE CLASSIFIED AS:

I. VERTICAL MOULDING MACHINES: MULTIPLAS TAIWAN MAKE WITH
85TON CLAMP PRESSURE.
II. HORIZONTAL MOULDING MACHINES: VICTOR TAICHUNG TAIWAN
MAKE WITH CLAMP PRESSURE 80TON, 130TON, 180TON, 250TON.
3. FABRICATION SHOP/ SHEET METAL SHOP

• THE PROCESS OF JOINING TWO COMPONENTS WITH ANY METHOD IS

KNOWN AS FABRICATION.

 IN FABRICATION I SAW DIFFERENT TYPES OF WELDING MACHINES LIKE

SINGLE PHASE, DOUBLE PHASE AND THREE PHASE MACHINES,
THYRISTORIZED WELDING MACHINES, ROBO WELD MACHINE WITH
FANUC CONTROLER ETC.

• SHEET METAL WORK IS THE SHAPING OPERATION OF METAL SHEETS VIA

BENDING, PUNCHING, SHEARING ETC. THESE PROCESSES WERE DONE WITH
FOLLOWING TYPES OF MACHINES;

i. AMADA LESER CUTTING MACHINE

ii. AMADA OCTO PUNCHING MACHINE
iii. HYNDUSTAN HYDRAULIC SHEARING PRESS
iv. HINDUSTAN HYDRAULIC BENDING PRESS
v. KAUSHICO POWER PRESS 250T.
4. POWDER COATING/ PAINT SHOP
• POWDER COATING/PAINTING IS THE PROCESS TO PREVENT THE METAL
SURFACE FROM DIRECT CONTACT OF ATMOSPHERE CAUSING RUSTING AND
DEGRADING ITS QUALITY.
• THE PROCESS OF SURFACE COATING CAN BE UNDERSTOD BY FOLLOWING
BLOCK DIAGRAM:

CLEANING OF CHEMICAL WASHING AND

METAL PIECE BY PROCESSING OF DRYING OF METAL
EITHER SHOT METAL PIECE BY PIECE BEFORE
BLASTING OR PRE-TREATMENT SURFACE COATING
THINNER PROCESS

CONDITIONING OF
FINAL PRODUCT METAL PIECE FOR SURFACE COATING
AFTER SURFACE FINALISING (HEAT OF METAL PIECE
COAT TREATMENT IN OVEN (EITHER BY POWDER
AND DRYING FOR COATING OR
POWDER COATING AND LEQUIDE PAINT)
DIRECT AIR DRYING FOR
LEQUIDE PAINT )
5. UTILITY MAINTENANCE WORK

• THIS FIELD OF WORK OF MAINTENANCE DEPARTMENT COMPRISES OF:

 MAINTAINING CONTINOUS ELECTRIC SUPPLY IN THE PLANT

a. THE PLANT WAS PROVIDED WITH 11KV SEPARATE HT POWER LINE FROM
KESCO WITH OVER AND UNDER VOLTAGE PROTECTION CIRCUIT PANEL.
b. THIS SUPPLY WAS STEPPED DOWN TO 3PHASE 440VOLT SUPPLY FROM
AUTO TAPPING CHANGE TRANSFORMER.
c. THIS SUPPLY IS THEN DISTRIBUTED TO DIFFERENT SHOPS FROM
DISTRIBUTION BOXES EACH WITH OVER CURRENT PROTECTION
SWITCHES AND POWER MONITORING CIRCUITS.
d. CAPACITOR BANKS ARE PROVIDED FOR POWER FACTOR IMPROVEMENT
OF ELECTRIC SUPPLY AS THE PLANT LOAD IS GENERALY INDUCTIVE IN
NATURE DUE TO DIFFERENT MOTORS OTHER TYPE OF COILS. THESE
BANKS ARE PROVIDED WITH SEVERAL CAPACITY CAPACITORS THAT
TURN ON AND OFF AUTOMATICALLY BY POWER FACTOR MONITORING
DEVICE.
e. WHEN KESCO SUPPLY GETS FAIL THE PLANT HAD A BANK OF THREE
380KVA DEISEL GENSETS. BY THE USE OF PLC, THESE GENSETS WERE
DESIGNED TO TURN ON AUTOMATICALLY AND GET SYNCRONIZED
AUTOMATICALLY AT THE TIME OF POWER FAILURE ONE BY ONE ON THE
REQUIREMENT OF LOAD.
 MAINTENANCE OF AIR COMPRESSORS FOR COMPRESSED AIR
a. THE NEED OF CONTINOUS SUPPLY OF COMPRESSED AIR IS A MUST IN ANY
PLANT.
b. FOR THIS NEED THE PLANT HAD THREE DIFFERENT CAPACITY
COMPRESSORS: ATLAS COPCO GA75 SCREW TYPE, ATLAS COPCO GA55 SCREW
TYPE AND INGERSOL 719CFM PISTON CYLINDER TYPE COMPRESSOR.

 TAKING CARE OF ELECTRICAL APPLIANCES LIKE AC S , FAN, LIGHTING

ETC IN THE PLANT.