Maintenance Management in Garment Industry

KANSAI MULTI
NEEDLE MACHINE
Introduction

• Garment industries use highly specialized machines and

equipment on a daily basis, they face the daunting task of
continually managing these assets to ensure operations
run smoothly.
• Coordinating and scheduling preventive maintenance
(PM), processing employee work requests and managing
facility repairs and modifications are just a few of the
daily tasks that need to be completed.
• All of these tasks are complex and time-consuming, and
present challenges that require an efficient maintenance
department in place to prevent productivity snags.
Importance of machine maintenance
• Good machine maintenance is an investment in
productivity. Well maintained machines are more
reliable, safer and last longer.
• Basic maintenance is not expensive and can often be
done by workers.
• Workers should be taught simple machine
maintenance skills such as machine cleaning,
adjusting thread tension, changing broken needles,
bobbin changes and emptying the dust filter
 Running
maintenance
Preventive Shutdown
Maintenance maintenance
Scheduled
Planned maintenance
Maintenance
Maintenance

Corrective Breakdown
Maintenance maintenance
Predictive
Maintenance
Unplanned Emergency
maintenance maintenance
Planned maintenance
In planned maintenance the maintenance action is carried
out with some fore thoughts, prior planning , record
keeping and control action. These can be further classified
as :-
Preventive maintenance
Corrective maintenance
Predictive maintenance
Preventive maintenance

 It is based upon the principle that ‘prevention is

better than cure’.
 It is a set of activities that are performed on plant
equipment, machinery, and systems before the
occurrence of a failure in order to protect them and
to prevent or eliminate any degradation in their
operating conditions
 The maintenance carried out at predetermined
intervals or according to prescribed criteria and
intended to reduce the probability of failure or the
degradation of the functioning and the effects
limited.
Types of preventive
maintenance
• RUNNING MAINTENANCE
Running maintenance which includes those maintenance
activities that are carried out while the machine or equipment
is running. Example – lubrication, adjustment of nuts and
screws, tightening of loose nut and bolts.
• SCHEDULED MAINTENANCE
Scheduled Maintenance is any variety of scheduled
maintenance to an object or item of equipment.
• SHUT DOWN MAINTENANCE
It is a set of preventive maintenance activities that are carried
out when the production line is in total stoppage situation.
These are performed generally after three or six months.
 Corrective maintenance

In this type, actions such as repair, replacement, or

restore will be carried out after the occurrence of a failure
in order to eliminate the source of this failure or reduce
the frequency of its occurrence.
It also include the different types of actions like typical
adjustment of redesign equipment.
The difference between corrective maintenance and
preventive maintenance is that for the corrective
maintenance, the failure should occur before any
corrective action is taken.
Types of corrective
maintenance
BREAKDOWN MAINTENANCE
It is an emergency based policy in which the plant or
equipment is operated until it fails and then it is brought
back into running condition by repair.
It is feasible for the small factories where
1. There are few types of equipment.
2. Machine and equipments are simple and does not
require any specialist.
3. Where sudden failure does not cause any serious
financial loss.
 Predictive maintenance

• As the names implies it involves the prediction of the

failure before it occurs, identifying the root cause for
those failures symptoms and eliminating those causes
before they result in extensive damage of the equipment.
• Type of maintenance performed continuously or at
intervals according to the requirements to diagnose and
monitor a condition or system. Also called condition
based maintenance.
Unplanned Maintenance

• Maintenance action which is carried out without any

before thoughts or prior planning is called unplanned
maintenance.
• Emergency maintenance is one of the example of
unplanned maintenance.
• In this type of maintenance the maintenance action is
executed with the help of all available maintenance
resources in least possible time, without any major time
lag.
• Examples are gas leakage in chemical plant, fire hazards,
breakdown of boiler, turbine etc.
Kansai Multi-Needle
machines
• Kansai is a Japanese
company that
manufactures multi-needle
double chain stitch
machines for purposes like
attaching elastic, attaching
waist band, attaching line
tapes which is ideal for
underwear, sportswear,
ladies clothes etc.
• There are up to 2-33
needles available.
 Maintenance of Kansai machine
(BASED ON TIME SPAN)

DAILY MAINTENANCE
• Machines should be blown off every day to
remove lint and trash.
• Remove lint and dust from the thread
passages.
• To check whether needle is correctly set
and not damaged.
Using compressed air,
• Check to see that the machines are being which has a straw (shown
lubricated regularly. Oil levels should be in red above) to direct air
checked daily and additional oil added if to a desired spot, blow out
lint and loose threads.
necessary.
WEEKLY MAINTENANCE
• 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 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 the thread stands are in proper
condition and the top eyelets are
oriented properly.
• Thread stand eyelets are smooth and not
grooved or damaged.
• Cones are held in a vertical stationary
position
• Check to make sure the feed dog are not
broken or damaged
• Check to see that the cutting knives are
sharp and are trimming properly. This
can be checked by placing a single end of
thread between the knives and observing
if the thread is cut by the knives
MONTHLY MAINTENANCE
• Check for rusted areas due to excessive moisture
in production area.
• Machine eyelets and guides are smooth and not
grooved, rusted or damaged
• Check the condition of the tension disc, if worn
out, should be replaced.
• Check condition of mechanics tools to see that
they are being maintained properly.
• Check the looper points for sharp surfaces or
burrs.
• Observe excessive wear of looper.
• Check to make sure loopers are shaped properly
according to original factory condition.
Lubrication of Kansai machine
• Use Kansai special genuine oil
• To extend machine life, be sure to
replace the oil after the first
250 hours of operation.
• Clean the filter element every six
months. If just a little or no oil flows
out from the nozzle with the proper
amount of oil in the machine, check
the filter element.
• To clean the filter element, remove
oil reservoir.
• Before installing new cams, be sure
to grease the cam grooves.
Cleaning the machine
• At the end of each day, remove the presser foot and
the needle plate and then clean the slots of the needle
plate and the area around the feed dogs.
Break down Maintenance
• Breakdown Maintenance activities are those works
associated with the repair and servicing of site
infrastructure, buildings, plant or equipment within the
site’s agreed building capacity allocation which have
become inoperable or unusable because of the failure of
component parts.
Storage of Parts
and Equipment
• To ensure that spare parts and equipment remain in
good condition and last for a long time they should be
stored properly. Stored tools and equipment will be easy
to find when needed.
• Some parts of the machine should always be kept in the
inventory incase of breakdown of machine like needles,
bobbin cases, nuts and bolts, tension guides so that they
can be replaced easily.
• A record of all the spare parts should be maintained,
causes of machine breakdown due to which parts were
replaced.
Parts of Kansai Machine to
be kept as spare parts
• Thread tension discs
• Needle bar and needles
• Feed dog
• Pressure foot
• Motor
• Looper
• Pulley belt
• Criticals nuts and screws
THANK YOU