Development of Maintenance Plan (Case study : Eastern Jute mills Ltd, Khulna.)

Abstract

Maintenance acts like the heart of the machine. Due to running, every machine Undergoes wear and tear due to friction. Maintenance of a machine consists of all the Various activities required to keep machine in standard working condition, so that, Production operations will not be interrupted by machine failure. In Eastern Jute mill, there are various types of maintenance such as break-down, Preventive and overhauling maintenance. Breakdown maintenance may be minor or Major. Preventive maintenances are routine and periodic. Routine maintenance means day to day cleaning and greasing. In the factory, periodic maintenance is done strictly in every week. As a result, all machines run smoothly for the rest six days. There are different types of machines. The breaker and finisher card machine play an Important role in the production system of the jute mill. The breaker and finisher card Machines consist of 7 and 13 repining rollers respectively. Among these, the cylinder roller is the biggest. At present, at every 3 months interval, the cylinder roller is repined by dismantling its 150 staves. At that time, the breaker card machine is stopped completely. The rest of Rollers are repined when they are broken. For this reason, the machine has to be Stopped frequently. The finisher card machine is stopped every 5 months; the cylinder roller is repined by dismantling its 189 staves. As a result, the machine becomes idle and the production system is hampered severely. About four and half lac taka is lost, if production is hampered for a single day. So, it is found that the jute mill has been facing a huge amount of loss, if machines are stopped for repair frequently. The objective of the present study is to investigate the possibility of repining all the rollers at a time. For this purpose, the break-down data of the above mentioned machines were collected from the log book from 2005 to 2010. Breakdown interval is obtained by deducting the two consecutive break-down. Frequency chart of 3-12 months were made for 1 month interval as shown in tables 3, 5, 7, 9, 12, 14, 16. Total maintenance cost was calculated for different time intervals. Total cost curve is shown in figures 1, 2, 3, 4, 5, 6, 7 which are U-shaped graphs. The lowest point of U-shaped graph gives breakdown interval at which the total maintenance cost is minimum. It is found that production loss can be minimized by repining all the rollers Including the cylinder at an interval of 6 months for breaker card and for finisher card machine, the same is 7 months. So, the develop model tells us that, if the maintenance of the breaker card and finisher card is done at an interval of 6 and 7 months respectively, the no. of sudden breakdown of machines will be reduced and at the same time production loss will also be minimum.