Maintenance Management

Assignment - 1

4 Thread Overlock Machine

Submitted By:
Anushka Khandelwal - 09
Simran Arora - 28
Basil Basheer - 10
 4 Thread Overlock Machine

Machine are subjected to deterioration due to their use and exposure to

environment condition.
Process of deterioration if unchecked culminate in rendering these facilities
unserviceable and brings them to standstill. Industry therefore has a choice but to
attend to them from time to time, to repair to maintain and to recondition them so
as to elongate their life to the extent it is economically and physically possible to do
so. Thus repair, maintenance, accurate setting and replacement of components
assure importance as an engineering function.
 Four thread overlock:
• It will stitch a chain stitch or a safety stitch as it stitches and overcasts seams.
• Two needles and two loopers.
• Can be converted to both two and three thread overlock
• All 4 threads are necessary to sew a serged seam.
• Suitable for sewing blouses, shirts, skirts, dresses, pants, lingerie, action wear,
swimwear, and even sleepwear.
Needle spec - DC × 27 (12 to 16 size)

Three types of maintenance need to done:

1. Regular Routine Maintenance:
Check machine condition. The problem is identified at the spot and it's repaired.

2. Periodic Maintenance:
Check machine condition
Lubricants (once a week)
Once in three months check every part and replace the wore out (damaged) parts.

3. Preventive Maintenance:
Once a month machine is taken out from the place and service to find out problems in
the machine and replace it before the machine breaks down

Spare parts: Overlock machine:

Brand: Juki
Needless Cost - 48 - 55 k
Loopers
Threads
Cutters
Needle bar
Daily Maintenance:
Done by : Operators

Supervised by: Maintenance Personnel

Needle Replacement: Check whether the needle is bent or blunt or not. If it is bent or blunt change the needle
and install it under the supervision of maintenance personnel.

Looper:Clean the tail of thread, dust and lint in the looper.

Lubrication:Lubricate the machine parts where necessary.

Time required: 10 minutes.

Cleaning the looper case and other possible parts:Clean the lint, loose thread and other dirt from the shuttle of
looper and looper case. Besides the table and other parts which cannot effect the setting must be cleaned.

Required time: 10 minute.

Weekly Maintenance:
Done by : Maintenance Personnel

Needle – Looper timing:Check whether the needle – looper timing is correct or not. If
there lies miss-timing then adjust it.

The checkpoints are

1. Needle – looper clearance

2. The height of needle from its lowest position of upward stroke when the looper
reach at the center line of needle
● At the same time the distance between the looper and the top end of the needle
eye.

Required time: 10 minute.

The clearance between looper holder and looper case holder bracket: Check the clearance between the
looper & looper case holder bracket (1-1.5mm). Make sure that the looper will not touch loooper case
holder bracket.

Required time: 5 minute.

Presser foot pressure: Check whether the pressure of presser foot is proper or not. If not adjust it by
adjusting the distance between the bottom washer and top of pressure bar guide bracket. And the bottom
of work clamp must be kept parallel to the top of the work.

Required time: 5 minute.

Thread take-up amount: Check the amount of the thread take-up stroke, clearance between needle thread
and thread take-up lever guide (0.5-1mm). Make sure that it is not more than necessary.

Required time: 5 minute.

Needle & looper thread tension adjustment: Check whether the standard operating range of thread take-up spring is
accurate or not (6-8 mm). The tension at appropriate operating range must be checked.

Required time: 5 minute.

Needle installation: It must be remembered during needle installation that the long groove of the needle is on the left and
tightened with the needle clamping screw. Adjust the needle clearance and lift amount.

Required time: 2 or 3 minute.

Stitch Length: Check whether the stitch length is appropriate or not. If not , slowly turn the hand wheel as you keep
depressing push button and a point is found at which the push button goes further. With this condition, align the desired
scale on the hand wheel with mark on the belt and reset the push button.

Required time: 5 minute.

Needle Bar height: It is remembered that when the needle bar is in its lowest position the reference line on the must be at
the lower end of the containing the needle bar. If it is not so, remove the needle plate, loosen the needle bar connecting stud
clamping screw and adjust by raising or lowering the needle bar.

Required time: 5 minute.

Presser foot height: The standard height of the presser foot is 6 mm when the presser foot is raised with presser foot
lifter lever. To adjust the presser foot height, loosen the nut of the adjustment screw and then the presser foot
adjustment screw so that no pressure will be applied to the presser foot, then loosen the set screw and adjust the
presser foot height by raising or lowering the presser bar.

Required time: 5 minute.

Lubrication: Change oil when it contains contaminants. If the pointer bar of the oil gauge comes down under the
lower marker line when the observing the sideward, supply oil. Change oil when one month has passed after the first
set-up of machine. Apply two or three drops of oil to the needle bar and upper looper guide when operating the
machine for the first time after set-up of after along time of disuse.

Caution: Be careful not to exceed the upper red marker line, or else troubles due to excessive lubrication may result.

Required time:5 minute.

Height of the lower knife: Loosening the set screw adjust the height of lower knife so that its
edge is flush with the throat plate surface.

Height of the upper knife: Loosening the set screw perform the adjustment so that upper knife
overlaps the lower knife 0.5-1 mm when the upper knife is at its lowest position.

Caution:

● Be sure to tighten screw before operating machine.

● After completion of adjustment, make the knives cut a thread to check sharpness of the
knives.

Required time: 10 minute.

Sharpening the lower knife: When the lower knife has become dull, sharpen it.

Required time: 15 minute.

Monthly Maintenance:
Oil replacement and other interrelated checks:

1. Check lubricant or oil whether that is to replace.

2. Check bush leakage, oil seal leakage or age, vibration of oil and the flow of oil pump more or less than
setting.
● Check rubber cushion seats, four corners of machine tool groove on which oil pan stands.

Required time: 10 minute.

Rotary hook: Check rotary hook wear whether it is need to replace.

Required time: 10 minute.

Presser foot canal: Check its canal wear. If necessary replace it.

Required time: 5 minute.

• Quarterly Maintenance:
• Cleaning the filter and pump-net: Clean the filter and pump net to lengthen the machine life. If these are
clogged with dust, the machine components may be seized or worn out extraordinarily.
Half yearly Maintenance:
Lubrication: Change oil of the machine every six month.

Adjustment Overlocker Knives for Fabric Cutting:

Different types of overlocker knives are described below shortly-

Lover Knife : The blade of Lover Knife (A) must be even with the top face of Stitch Plate or a little
lower (0-‘-‘0.3 mm). To make this adjustment, loosen Screw(B).

Flat Upper Knife : As for the height of Flat Upper Knife, when this Knife reaches the bottom of its
movement, make the engagement with Lower Knife be 0.5~1.0min. To make this adjustment, loosen
Screw(C).
Angled Upper Knife: Height of Angled Upper Knife is impossible to adjust as it is decided by
Stopper(D) naturally. To set this Knife, loosen Screw(E) and insert the Knife to Upper Knife
Holder until it will touch with Stopper(D), then tighten Screw(E) again.

Overlocking Angled Upper Knife

Sharpness of Knives: Turning the Pulley manually, after adjusting width of overedge seam,
check the sharpness of Knives with a thread put between both Knives.
Re Sharpening Overlocker Knives: It is unnecessary to re sharpen Upper Knife for about one
year as this Knife is made of Super Hard Alloy. During this period, if the cutting becomes
blunt, Lower Knife must be sharpened as the sketch shows. As stated above, the Upper
Knife cannot be re-sharpened by the ordinary grinder, the provisional one must be prepared
always. For overlocker sewing machine repair and adjustment of parameters, please contact
us directly or the dealer who sold the machine to you.

Repair :
Repair work is carried out when a component requires slight modification. To carry out such
job the machine needs to be switched off first. The component under repair is then screwed
off by suitable apparatus. After repairing the part is fixed to its designed place and hence its
correctness I measured by running the machine. In an over edge stitch machine looper,
presser foot, tensioner, check spring, motor belt etc can undergo repair job.
PREVENTATIVE MAINTENANCE

1. Check to see if the machines are being kept clean

2. Machines should be blown off every day to remove lint and trash
3. On lockstitch machines, the hook should be blown off regularly during the
day to prevent lint or dirt from building up in the oil ports in the race of the
Hook.
4. Check to see that the machines are being lubricated regularly Oil levels
should be checked daily and additional oil added if necessary %.
5. Randomly check the oil levels in the machines
6. A high quality white machine oil should be used that will not stain
7. Check availability of proper machine oil in the factory
8. Check to make sure the oil is not contaminated
9. Check to see that oil reservoir pump filters are cleaned regularly
● If compressed air is used, make sure the air system is regulated properly
and has humidity dryers, filters and lubricator in the air lines.
● Check for rusted areas due to excessive moisture in production area
● Check Machines for wear on critical moving parts
● Check for shake in needle bar due to worn needle bar bushings
● Check for excessive movement in stitch forming devices, etc.
● Check condition of critical screws
● Check for missing screws
● Check for defective screws that are difficult to tighten properly
● Check condition of mechanics tools to see that they are being maintained
properly.
Replacement :
The replacement is revealed when the relation of equipment is no
more remains an economical proposition. A replacement is
affected when the equipment is subjected to complete breakage
which can not used even after repair or the components has
become so obsolete that affects production or it has crossed its
expiry date.
THANK YOU