maintenance shahi

Maintenance Management Case study : Shahi Exports

Study By:Gokulraj V

Shashank TrivediSaurabh Singh Rajput

Faculty:Mr. Arivoli N(Asst Prof.) - DFT

NIFT Bangalore, BFT(2011 - 15)


Introduction

• A systematic approach to planning, organizing, monitoring and evaluating maintenance activities and their costs

• Various strategies applied in plant are :• Breakdown• Preventive or Scheduled• Predictive or CBM• Design out


CMD at Shahi Exports

• Has set objectives and sub objectives to work in co-ordination with all the departments

• Accordingly CMD has to perform various functions of maintenance in respective departments



• The central maintenance department is concerned with the issue of machines and preventing their breakdown.

• Divisions of CMD are-• Production support- This division plans and meet the

requirements of machine and machineries as per the product.

• Utilities- Maintenance of supporting machineries like diesel generators, compressors, boilers, ETP/STP plants.

• Fabrication of folders- The folders required for production are made available and maintained by this division.



• Electrical department- Maintenance of all electrical equipment and devices like fittings, motors, boards etc.

• Maintenance store- this is a centralized spare parts store for all the all the departments.

• Fabrication of working aids- the working aids like chair, table etc. are made in-house by this dept.



• Overtime1.Overtime is governed by company policy.2.Overtime must be authorized by the employees

immediate supervisor.Salary for overtime: Above than Rs.7000 – single pay

Less than Rs.7000 – double pay

• Appraisal1.Maintenance employees are appraised by the

Maintenance Manager on an annual basis.2.Each employee has a running evaluation of work habits,

strengths and skill levels.



• Vacation / Time off

• Employee vacations are scheduled so that the ability to service

the company’s requirements is not unduly degraded.

• A blank vacation form shall be posted in the shop so employees

may indicate their desired vacation time. In case of conflicts,

the Maintenance Supervisor will attempt to mediate a solution

that meets company needs and satisfies the affected employees.


Objectives of CMD

• To Direct and coordinate the operations and activities of the physical plant maintenance, including but not limited to: Facilities engineering administration Layout, design, and construction; Equipment maintenance; utilities operations and maintenance; Building and grounds maintenance; Facilities protection and security; Departmental safety; and environmental compliance.

• To ensure compliance with applicable federal, state, and local laws,

regulations, statutes, and codes; securing required permits; and coordinating with appropriate local authorities.


Functions of CMD

• Work order generation, prioritization, and tracking by equipment/component.

• Historical tracking of all work orders generated which become sortable by equipment, date, person responding, etc.

• Tracking of scheduled and unscheduled maintenance activities.

• Storing of maintenance procedures as well as all warranty information by component.


Functions of CMD

• Real-time reports of ongoing work activity.

• Calendar- or run-time-based preventive maintenance work order generation.

• Capital and labor cost tracking by component as well as shortest, median, and longest times to close a work order by component.

• Complete parts and materials inventory control with automated reorder capability.


Hierarchy of Maintenance Dept.

MAINTAINENCE MANAGER

PURCHASING TECHNICIAN

SECRATORY

TECHNICAL SUPERVISOR

SAFETY INCHARGE

EXECUTIVE MANAGER

PLUMBERS

ELECTRONIC TECHNICIAN

ELECTRICIAN

PARTS INVENTOY TECHNICIAN

LOCKSMITHS

PREVENTIVE TEAM

CORRECTIVE TEAM


TPM at Shahi Exports

• The maintenance approach followed in Shahi Exports Pvt.

Ltd is Total Protective Maintenance (TPM) and the Quality

policy is 5s.



• The subdivisions of the TPM department are:• CMD• Batch maintenance• Folders and fabrication• Utility and Project• Safety



CMD

The central maintenance department is concerned with the issue of machines and preventing their breakdown.

The main responsibilities are as follows:• Installation and commissioning of new machines.• Research and development in the field of machinery.• Implementing Planned and Autonomous maintenance.• Batch setting and over-hauling.



BATCH MAINTENANCE• This division is involved in maintaining the machines in all the

batches.• There is one supervisor for 120 machines. • The mechanic is involved in planned maintenance i.e.

servicing of machine from time to time.

FOLDERS AND FABRICATION• They have their own folder making workplace.• The folders which are prepared are manually fabricated by

using different tools and sheets of varying thickness.• This helps in carrying out many operations at a single machine


• UTILITY AND PROJECT:• This subdivision basically takes care of generator, air

conditioning, and steam line for iron and airline for pneumatic machines.

• It is also responsible for providing different projects from time to time.

• SAFETY:There are three steps followed:• General safety, which consists of fire extinguishers and

smoke detectors.• Human safety, which consists of needle guard, eye guard etc.• Product safety, which consists of needle detector machine.


Outsourcing

• For some critical and huge time consuming maintenance, outsourcing is carried.

• And also for building and construction outsourcing is done.

• No Annual Maintenance Contract with any other organisation is there.


Snapshots of CMMS


Breakdown Times


Machine history record


Machine inward details


Master list of M/c’s


Material Requistion


Breakdown Percentage


Preventive Maintenance schedule


Training

• Original Equipment Maintenance (OEM).

• Maintenance training programmes are organised by the company in every three or six months, in which they call machine’s company’s personnel (eg. Juki trainers) for training Shahi’s workers in maintenance areas.


Cost of Maintenance

• Total employees for maintenance- 150 • Expenditure on electrical and sewing machine per month is

Rs.3.6 lacs.• Expenditure on washing and printing is Rs.1.35 lacs per

month.• Expenditure on embroidery machines is Rs. 75000 per

month.• Other than the above expenditures, salaries of maintenance

personnel also add up to the cost of maintenance.• The downtime cost or the penalty is close to zero because 5

to 10 minutes of tolerance is given on the production floor which is single piece floor.

maintenance shahi

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