Preventive maintenance system of Garments Manufacturing

Breakdown and Preventive maintenance Policy of Sewing machine in Garments Manufacturing

Machine Maintenance

The machine is an important resource that is constantly used for adding value to a product. So it is necessary to keep in the best operating condition. Otherwise, there will be excessive downtime and also interruption of production if is used in the mass production line. Poor working of machinery and equipment will lead to quality-related problems, it's necessary to maintain the machine in good operating conditions with economical cost. The machine maintenance system is the key factor for Garments Manufacturing. The factory’s work efficiency depends on machine fitness too.
Maintenance is the action to retain or to fix or to restore an item in a state in which it can perform its required function by the combination of all technical administrative, managerial, and supervision actions. In general words, maintenance is the process by which equipment is looked after in such a way so that it runs trouble-free. Service and increased machine life can be ensured and specific product quality required by the customer is sustained.

Types of Maintenance

Generally, there are two types of maintenance systems found in the apparel industry:

1.      Breakdown Maintenance

2.      Preventive Maintenance/Routine maintenance

Breakdown Maintenance
Breakdown Maintenance is the repair generally done after equipment has attained downstate. Online mechanics set for breakdown maintenance sewing line for immediate support or quick information system can be set to call mechanic, can set traffic lighting system in every sewing line. Breakdown time should be recorded and tracked to see a mechanic's performance. Machine breakdown time considers a loss of time in garments manufacturing. These are unpredictable or reactive types of maintenance and are more difficult to schedule than the above categories. There are no routine maintenance tasks to perform and equipment is repaired or replaced only when obvious problems occur. Breakdown maintenance works well if equipment shutdowns don’t affect product quality or revenue generation.

Preventive maintenance/Routine maintenance

Preventive maintenance is periodical inspection (daily, weekly, monthly basis cleaning, inspection, oiling, and re-tightening) and service activities that are aimed to detect potential failures and perform minor adjustments and repairs which will present major operating problems in the future. The sewing maintenance team does preventive maintenance as per their maintenance schedule or calendar. It’s the preventive maintenance to retain the healthy condition of equipment and prevent major breakdowns of failure by a deterioration of facilities. It ranges from such simple tasks as cleaning, inspection, equipment condition diagnosis checking, changing oil, water, air, alignment, re-tightening, etc.  Routine maintenance consists of periodically inspecting, servicing, lubricating, and cleaning equipment and replacing parts to prevent sudden failure and process problems to ensure continuous working conditions.

Sewing Machine Maintenance equipment:

•             Flat screwdriver (Small/ Medium/ Large)

•             Star screwdriver (Small/ Large)

•             Nose pliers (Large/ Small)

•             Sly- Wrench

•             Forceps (chimta)

•             L- Key Needle

•             Needle driver

•             L- Keyset

•             Daly set

•             Lock Pliers

•             Hammer (Small/ Large)

•             File set

•             Tester

•             Welding machine

•             Air gun

•             Vacuum cleaner 

Preventive Maintenance Checklist for Single Needle Lockstitch machine

1.            Clean Oil Filter

2.            Needle Condition/ Position

3.            Thread Sequence

4.            Oil Level

5.            Check Spring Operation

6.            Treadle Looseness/ Operation

7.            Brake Position

8.            Belt Tension + Condition.

9.            Oil Flow to Rotary Hook.

10.          Thread Stand Tight + Straight.

11.          Oil Condition.

12.          Rotary Hook Condition.

13.          Hook Timing.

14.          Bobbin Case Thread Tension.

15.          Feed Dog Height/Condition

16.          Presser Foot Sole Condition.

17.          Position Finger Condition

Preventive Maintenance Checklist for OverLock Machine:

1.            Needle

2.            Thread Sequence

3.            Machine Clean

4.            Oil Level

5.            Knife Sharpness

6.            Treadle Looseness/ operation

7.            Brake Position

8.            Stitching part check

9.            Feed dog height

10.          Oil Condition

11.          Oil Filter clean

12.          Check all screws complete clean and test

13.          Thread stands Straight + Tight 

Preventive Maintenance Checklist for Button Attach Machines:

1.            Needle Position/Condition

2.            Thread Sequence

3.            Oil all parts indicated in manual

4.            Drive belt tension

5.            Grease gears + clutch

6.            Clean Machine thoroughly Needle to buttonhole position

7.            Treadle operation smooth

8.            Stitching parts timing

 Preventive Maintenance Checklist for Bartacking Machine:

1.            Needle Condition/Position

2.            Thread Sequence

3.            Check spring Operation

4.            Bobbin case threads tension

5.            Bobbin winder operation

6.            Throat plate Condition (hole)

7.            Drive belt Condition/tension

8.            Oil Machine (as per manual)

9.            Clean Machine thoroughly 

Preventive Maintenance Checklist for Lockstitch Button Hole Machine:

1.            Thread Stand Straight – Tight

2.            Needle Condition / Position

3.            Thread Sequence

4.            Cutting knife Condition

5.            Oil Level

6.            Clean Machine Thoroughly

7.            Check Oil flow to Rotary Hook

8.            Check Half-Speed Operation

9.            Check Upper Trimmer operation

10.          Bobbin Winder Operation

11.          Oil Condition

12.          Drive Belts (3) Condition + Tensional

13.          Treadle Operations (2)

14.          Presser Foot Rubber Condition

Sewing machine maintenance & safety policy practice

Best & regular maintenance of plants machinery increase not only machine life but also with quality garments stitching, less consumption of spare parts & reduce the tendency of machine problem results increase total productivity. In view of the above the machinery maintenance policy & procedure are being given below.

1.            Daily maintenance: while the sewing floor is running if any machine creates a problem, initially floor mechanics try to fix that machine within the line. If it is not possible in a short time, the machine will be shifted to the maintenance room replaced by another machine & necessary measure will be taken to fix that Machine. The daily records of maintenance works have been kept in a format.

2.            Monthly maintenance: It is preventive maintenance to reduce machinery problems & increase machine life, execute by predetermining a schedule fixed at the starting of the year on a regular basis. This maintenance program covers total servicing of all machines, oil change, oil filter change, or any defective parts change. Records of monthly maintenance work havebeen kept in a format.

Sewing machine preventive maintenance

Responsibilities of Sewing machine Operator

1.      Check threading of the machine→ daily

2.      Complete cleaning of the machine→ daily

3.      Keep the Clean paper under the foot→ daily

4.      Check for oil leaks → Every Four hour

5.      Clean needle/foot/t. feed bars        → Every Four hour

6.      Clean machine head with → Every Four hour

7.      Clean machine tabletop→ Every Four hour

8.      Un-usual noise of the machine→ all-day

Responsibilities of Sewing machine Mechanic

Daily Basis work of Sewing machine Mechanic

1.      Check Machine Setting Correct or Not→   all-day

2.      Check Oil Level and Oil Leaks of the Machine→ Day starting

3.      Check un-usual noise of the machine →All-day

4.      Check Oil-paper → Day starting

5.      Check safety Equipment→ Day starting

6.      Check Machine allocation (According to M/C Layout) → Day starting

7.      Check Production Plan → Day starting

Monthly basis work Sewing machine Mechanic

1.      Whole machine clean opening parts

2.      Back/ Front cover

3.      Hook/ Looper timing and Needle

4.      Needle plate

5.      Feed dog

6.      Oil lubrication change

7.      Checking machine fitness to run continuously.

Daily Sewing Machine Check Points

1. Tension spring

2. Take up spring

3. Bobbin case spring

4. Thread wiper

5. Oil level/ oil leak

6.  Threading

7. Needle plate/ fee dog

8. Machine washer

9. Laser light

10. Needle plate/ fee dog

Monthly Sewing machine maintenance/servicing checklist

1. Air device
2. Trimmer device
3. Super tension post take up spring
4. Needle bar, bush and clam condition
5. Needle plate condition
6. Feed dog condition
7. Winder condition
8. Rottery hook or loopers
9. Oil level/ oil filter condition
10. Machine table in good condition
11. Cleaning and blowing
12. The lubricant in equipment (oil and grease cut)
13. Main shaft, connecting rod, bearing condition
14. Machine head has to be balanced with base plate
15. Knife slide
16. Power on/ off switch
17. Motor and control box condition
18. Abnormal sound Connecting rod and crosshead