MAINTENANCE

MANAGEMENT
Assignment 2

BY AKANKSHYA SAHOO
AKSHAT NARA
BINSHITA KAYAL
 CONTENTS
INTRODUCTION

COMPANY INTRODUCTION

OBJECTIVE

STRUCTURE OF MAINTENANCE DEPARTMENT

CHALLENGES

APPROACH AND MONITORING

MAINTENANCE BUDGET

MAINTENANCE POLICY

CONCLUSION

REFERENCE
 OBJECTIVE BRIEF

To come up with an ideal maintenance department Design an ideal layout for a maintenance
of a company. department of a garment industry.
To understand the responsibilities of the
department.
To check equipment breakdowns.
To provide suggestions and scope for
improvement.
Machines and other facilities should be maintained
so that they can be used at their fullest (profit-
making) potential without any hiccups or obstacles.
To check there's no loss of time in production.
To ensure safety of life and limbs of the workmen.
WHAT IS
MAINTENANCE?
Maintenance management is defined as the process of
maintaining the assets and resources of a company,
which has as main objective to control and reduce
costs, times, and resources.

Maintenance management allows managers to control

all processes so that everything flows as intended and
without unexpected failures.
 OBJECTIVES OF
MAINTENANCE

One of the main objectives of maintenance

management is to plan and schedule work
correctly. Therefore, it is necessary to define the
most appropriate maintenance strategies for
equipment and facilities, such as Preventive and
Corrective Maintenance.

Through these strategies, it is possible to eliminate

technical failures and maintain the operation and
availability of equipment, machines, and plants.
 TYPES OF
MAINTENANCE

The main types of industrial maintenance are:

Corrective Maintenance
Preventive Maintenance
Predictive Maintenance
Systematic Preventive Maintenance
Conditional Preventive Maintenance.
 IMPORTANCE OF
MAINTENANCE
It aids in determining the reason of failure, such as
whether the issue is a result of a wear-out failure or
a design flaw.
Additionally, it aids in making maintenance
decisions like replacement and repair.
It offers the crucial details about the equipment's
durability and dependability.
Machines idled by breakdowns cannot produce,
thus the capacity of the system is reduced.
It minimizes accidents through regular inspection
and repair of safety devices.
It improves the quality of products and improves
productivity.
It maximizes efficiency and economy in production
through optimum use of facilities.
COMPANY
INTRODUCTION
The company A &B manufactures men's formal shirts.
It is ISO certified.
There are 6 production lines with each line producing
approximately 1000 shirts per day.
There are around 800-1000 machines helping with the
production of the shirts.
There are around 900 operators working per day in the
industry.

The objective of the A&B Group are to meet or surpass the

expectations of our customers and to guarantee, via
effective quality systems and management procedures, the
consistency, performance, dependability, safety, and value
of our goods and services.
STRUCTURE
MAINTENANCE
CAPACITY PLANNING
Maintenance capacity planning determines the required
resources for maintenance including the required crafts,
administration, equipment, tools and space to execute
the maintenance load efficiently and meet the objectives
of the maintenance department.
MAINTENANCE DEPARTMENT LAYOUT
 CUTTING

Takes care of cutting and spreading machines.

Uses straight knife, band knife and Gerber cutters
along with fusing machines and spreading
machines.
2 people take care of this section:
1 senior technician
1 junior technician
 SEWING

Larger area, since it has more machines.

Total 8 members in the section with 1 head
technician.
The sewing department is sub-divided into two
parts:
Components section - 2 senior and 2 junior
technicians.
Assembly section - 1 senior and 1 junior
technician.
 FINISHING

Mainly pressing and washing machines in this

section, works properly almost all the time.
Requires annual and bi-annual maintenance
checks.
1 senior and 1 junior electrician.
 UTILITY

Machines include 1 boiler, 1 compressor and

generators.
3 members - 1 senior technician and 2 junior
technicians.
CHALLENGES AND
APPROACHES
 MAINTENANCE BUDGET
One of the aspects of your asset management that is
most frequently overlooked is your maintenance
budget. It outlines the projected costs associated
with achieving your annual maintenance goals. The
estimated expenses for each form of maintenance
and how they relate to various assets or asset groups
should be included.
The maintenance budget needs to include:
salaries of maintenance managers and
technicians
costs of hiring new staff, if necessary
costs for training and workshops throughout
the year
an estimate for the price of materials, tools,
and parts
contracts agreed with external suppliers
an estimate for energy costs (especially in
FM)
other expenses, such as periodic inspections,
insurance, etc
 MAINTENANCE POLICIES

The policies that are used are :

Dividend Distribution Policy

Risk Management Policy
Information Security Policy
Code of conduct
Policy for determination of materiality of information or event.
Human Rights policy
Policy for determining "material" subsidiaries.
Policy for archival of documents
Policy on board diversity
Policy for the preservation of documents.
Policy on related party transactions.
Corporate tax Policy
Privacy policy
CSR Policy
Stakeholder Engagement Policy
Suppliers' Code of conduct
 INTERVENTIONS
Application of lean tools such as 5S
Implementation of TPM - Total Productive Maintenance
Incorporation of AI and IOT to help in advancement of maintenance of the unit.
Tool kits and tool boards in every section
Digital dashboards with employee performance and skill matrix
Dashboards with production on display
Visual tools such as traffic lights and floor markings
Machine and equipment check sheets and regular maintenance being done
annually, bi-annually, quarterly, monthly, weekly or daily according to the machines
requirements.
Spare parts inventory which is well organized and sorted to save time.
 CONCLUSION
The above report has briefly focused on various aspects of maintenance management. Maintenance is expected to play even
much bigger role in years to follow, as industries worldwide are going through an increasing and stiff competition and
increased automation of plants. The downtime cost for such systems is expected to be very high. To meet these challenges,
maintenance has to use latest technology and management skills in all spheres of activities to perform its effective rolein
profitability of the company.
THANK YOU