Predictive

Maintenance in
Garment Industry
Made By: Atlanta Priyansh

Mehak Ritika

Nupur Soumyadeep

Priyanka Swati
Predictive Maintenance
• Predictive maintenance (PdM) techniques are designed to help
determine the condition of in-service equipment in order to estimate
when maintenance should be performed. This approach promises
cost savings over routine or time-based preventive maintenance,
because tasks are performed only when warranted. Thus, it is
regarded as condition-based maintenance carried out as suggested by
estimations of the degradation state of an item.

• Predictive maintenance uses condition-monitoring equipment to

evaluate an asset’s performance in real-time.
Predictive
Technologies
Insulation Multimeter:
Insulation Multimeter is a high-performance
wireless digital insulation tester plus full-featured
true-RMS digital multimeter (DMM) combined into
one versatile hand-held tool. It also provides
enhanced versatility for both troubleshooting and
preventive maintenance applications.
Integrated Condition Monitoring System:
Softwares are able to perform condition monitoring hardware
includes both offline and online monitoring of vibration and
other signals. The software integrates the data and makes is
accessible throughout a single facility or across multiple
locations.
Process Modeling Software:
The process modelling software, helps industrial manufacturers increase their
engineering effectiveness and optimize their process designs. Process modelling
allows engineers to create a number of steady-state and dynamic models for
plant and control design and optimization, hazard and operability and safety
system studies, performance monitoring, troubleshooting, operational
improvement, business planning and asset management.
Global Remote Equipment Monitoring System:
The devices are able to offers satellite wireless hour, alarm and location
metering for remote locations. Machinery is heavily used in remote locations
like mines, logging sites, drilling rigs, off shore oil rigs and international
ships. These applications typically don’t have cellular or WiFi connectivity and
monitoring their usage is expensive and troublesome. Tackling these
dilemmas, this provides equipment monitoring from anywhere in the world,
without the need for a SIM card or local wireless plan.
Compressed Air System Control with IIoT Capabilities:
The device brings the Internet of Things to industrial plants with its adaptive
control, data storage, analysis, and predictive maintenance capabilities, all while
ensuring a reliable, consistent supply of compressed air. It optimizes pressure values,
automatically adjusts system air delivery to accommodate fluctuating air demand,
and optimizes system efficiency by constantly analyzing the relationship between
control losses, switching losses, and pressure flexibility.
Connected Machine System:
Connected Machines delivers a complete solution to securely connect devices,
transform machine data into real-time insight, and grow recurring business
when working with machine builders and manufacturers. By implementing
the Connected Machines solution, manufacturers can benefit from the
domain expertise of machine builders to drive machine process improvements
through real-time corrective action and continuous, predictive maintenance.
Fully Scalable Condition Monitoring System:
Industrial remote monitoring with the first system of portable sensors, a
gateway, and software that you can access data anywhere, anytime. Each
wireless sensor sends measurements as frequently as every second, giving you a
history of equipment performance before, during and after an event. Data
logging allows you to make preventive maintenance decisions with the complete
information, as events are happening.
PdM in Garment
Industry
Selection Of Machines

Factors Requirement
Cost of Machine High
Criticality of Machine(based on how much High
that machine is used and how important
the operation is)
Frequency of failure Low

Downtime High

Ease of MRO Easy to Implement

Machine Selected
• Compressor
• Fusing Machine
• Band Knife Cutting Machine
• Sleeve attaching Machine
• Feed of the Arm
• Waistband Attaching Machine
• Button Hole Machine
Continuous Flat Bed
Fusing Machine
Requirement of Maintainance
• The belt is the most important part of a continuous Fusing
machine.
• Continuous heating and cooling of the machine result in the
change in the dimension of the belt since they are made of
Polytetrafluoroethylene (PTFE) or Teflon
• Improper adjustment or looseness in the belt will result in
fusing defects like air pockets and uneven fusing.
Capacitive Displacement sensor
• Capacitive sensors are designed for non-
contact measurement of displacement,
distance and position, as well as for
thickness measurement. Due to their
high signal stability and resolution,
capacitive displacement sensors are
applied in laboratories and industrial
measurement tasks.
• In production control, for example,
capacitive sensors measure film
thickness and application of the
adhesive. Installed in machines, they
monitor displacement and tool positions.
 IMPLEMENTATION

Sensor

Fig: Continuous Fusing

Machine

Sensor

Sensor

Fig: Bird’s eye view(Fusing

machine)
Compressor
Values to Monitor

I. Motor temperature
II. Vibration
III. Motor current
 Module used
 The SNAP-AITM provides two channels
of analog-to-digital conversion.
 Each channel can be configured for -150
to +150 mV DC or -75 to +75 mV DC, or
for type E, J, or K thermocouple
operation.

SNAP-AITM
25
 Temperature
 A Thermocouple is a sensor used to measure temperature.
Thermocouples consist of two wire legs made from different
metals. The wires legs are welded together at one end, creating a
junction. This junction is where the temperature is measured.
 When the junction experiences a change in temperature, a
voltage is created. The voltage can then be interpreted using
thermocouple reference tables to calculate the temperature.
 Type J or K thermocouple could be mounted on the motor
housing.
 This would be wired to a SNAP-AITM thermocouple input
module.

26
 Vibration
 Accelerometers are small devices that are installed directly
on the surface the vibrating object.
 When the accelerometer is moved, the small mass will
deflect proportionally to the rate of acceleration.
 Accelerometers can provide acceleration information in one
or more axes with a 4-20 mA output.
 These sensors are widely available, inexpensive, and could
be mounted on the motor and other areas.
 We would need 12-30 VDC to power the loop, and the 4-20
mA signal would be wired to a SNAP-AIMA module.

27
 Motor current
 Measure the motor's 3-phase current by using three split-core
current transformers installed at the compressor disconnect switch.
 The motor is rated at about 90 amps, select appropriate Current
Transformers with an adequate inner diameter to accommodate the
feed wire.
Benefits of doing predictive
maintenance
◉ Avoiding Downtime
◉ Saving money by avoiding costly emergency repairs.
◉ Lower Energy Costs
◉ Increased air compressor life and efficiency.
Band Knife Cutting
Machine
What is Band Knife Cutting
Machine..??
 Band knife cutting machine is an endless
and looks like a loop.
 This cutting machine works automatically
according to the height of the relevant
material.
 This machine is with special blower
decreases resistance between fabrics and
table, which enables the fabrics be moved
easily and be cut precisely.
 It could adjustable speed to fit different
fabrics.
Parts Of A Band Knife Machine
1. Bodywork
2. Band knife,
3. Motor,
4. Work surface,
5. Knife sharpener
Band Knife & Knife Sharpener
Parts where predictive maintenance can be applied :-
 There is a series of three or more pulleys, which provide the continuous
rotating motion of the knife
 Automatic grinder is used to sharpen the knife.
Band Knife & Knife Sharpener
Tool of Predictive maintenance applied:-
 Vibrations:-This is achieved through recordkeeping
of a machine’s vibration history and over time predict
problems before serious issues arise. A critical
component of vibration analysis involves sensors. That
means obtaining a full-spectrum vibration signature
in three axes (horizontal, vertical and axial).
 Sensors are used to quantify the magnitude of
vibration known as vibration amplitude. It will reports
how smooth or rough the machine is running. A
vibrations’ magnitude is expressed as:
Displacement
Velocity
Acceleration
Vibration Analysis
Predictive maintenance of following parts can be done:-
 Power Source :-Sensors can be applied to check fluctuation in power supply.
 Rotating equipment:-Vibration are checked by obtaining a full-spectrum vibration
signature in three axes (horizontal, vertical, and axial) on both ends of the motor and
the driven equipment.
Frequency analysis plays an important part in the detection and diagnosis of machine
faults. In the time domain, the individual contributions such as unbalance, bearings,
gears etc. to the overall machine vibration are difficult to identify. In the frequency
domain, they become much easier to identify and can therefore be much more easily
related to individual sources of vibration

By measuring and analyzing

the vibration, it is possible
to determine both the
nature and severity of the
defect.
Tests For Motors
Different tests can also be done on motors to prevent failure of motors
few of them are:-
• Resistance Testing
• Megger Testing
• Impedance testing
Work Surface
 The work surface of the machine is smooth and may
be equipped with a special air blowing system. This
creates an airspace under the cut fabric which
facilitates its maneuverability. The air pressure is
adjustable. The surface may have also a special air
filter to remove the dust created during cutting.
 Sensors can be used as Automatic safety top in case
of knife breakage.
 Surface temperature of the machine, sharpener and
the sharpener lever sharpener belt. rust in the blade
& blade change can be controlled using sensors.
 Sensors can also be used to check the electrical wiring.
Tribology
 Oil level sensors can be used.
I. sensors can be used which involves the
opening or closing of a mechanical switch
through direct contact with the switch.
II. (Switching occurs when a permanent
magnet sealed inside a float rises or falls to
the actuation level)
Visual Inspection
 Right thickness of the blade
 Remove the knife and clean the knife slides with the slot cleaner
included with machine.
 Fabric height controller
 Oil level check and refill.
 Clean all the grease and dirty from the Sharpening Assembly, with
compressed air
 Double-checking parameter settings.
 Nuts and bolts.
Sewing Machines
SPECTROMETRIC OIL
ANALYSIS
• SOA is a tool of Visual Inspection.
• SOA process is useful for any mechanical moving device that uses oil
for lubrication.
• It tests for presence of metals, water, glycol, fuel dilution, viscosity,
and solid particles.
• It evaluate when oil is no longer lubricating properly and should be
replaced
• identifies and measures small quantities of metals that are wearing
from the moving surfaces.
• Automotive engines, compressors, and turbines all benefit from oil
analysis.
• In Garment Industry, oil analysis is done in almost all machines,
from sewing, cutting to heat compressors and washing turbines.
• Eg. Button hole machines, feed of the arm, sleeve attaching
machines, waistband machines, fabric cutting machines, etc..
OIL ANALYSIS IN SEWING
MACHINES
• Sewing machines generally require basic
maintenance of cleaning, oiling, and lubricating.
• In the holes designated, and on all parts that rub
against or within one another, squirt a little oil.
• Run the machine by hand to distribute the oil
into all the bearings. Use oil freely because all oil
has been removed in the cleaning process. If
there are any wool or felt pads that feed oil to
parts, be sure they are well oiled.
• Needle bar and presser bar in face plate area is
cleaned of gummy grease and lubricated properly.
• For areas like bobbin and hook area, first a dry
brush is used to clean the lint and dust, and then
lubricate it after cleaning.
• Needle bar and pressure foot area need to be
checked if they are gummy.
PRECAUTION
• Do not oil the tension discs, the hand wheel release, or the
belts and rubber rings on any machine.
• It is a good practice to oil the machine after each day’s work or after
8 to 10 hours of use.
• Even if you do not use your machine often, oil it occasionally to keep
the oil from drying and gumming.
IOT based PdM
Architecture
Architecture
IOT based Predictive Maintenance Architecture.
Sensor data cannot pass directly to the cloud – it goes through
gateways.
• Field Gateways are physical devices that filter and preprocess the
data.
• A Cloud Gateway ensures safe data transmission and provides
connectivity to various field gateways.
• Streaming data processor is to allow continuous flow of data and
quickly and efficiently transmit data streams to a data storage – a
data lake.
• A data lake stores the data gathered by sensors. It is still raw, so it
may be inaccurate, erroneous or contain irrelevant item
• The big data warehouse stores cleansed structured data.
• Once the data is prepared, it is analyzed with machine learning
(ML) algorithms. ML algorithms are applied to reveal hidden
correlations in data sets and detect abnormal data patterns.
Thank you !
Role discription
Name Slides/Role
Swati • 48-51
• Guided the Execution of project
• 16-17
Priyansh • 2
• 16-17
• Merged and combined all work
Ritika/ Priyanka • 24-31
Nupur • 42-47
Atlanta/Mehak • 32-41
Soumyadeep • 18-23
• 3-14

* Machine Selection Table (Excel Sheet) Made by Swati and Priyansh