Introduction to Maintenance 

 Maintenance and its types 

Maintenance is a set of organised activities that are carried out in order to keep an equipment (or) machine in its best operational condition with minimum cost acquired. 

 There are four types of Maintenance,  

1. Corrective or Breakdown maintenance  

2. Scheduled  maintenance  

 3. Preventive maintenance 

 4. Predictive maintenance  

Objectives of maintenance 

Maintenance objectives should be consistent with and subordinate to production goals. Maximising production at the lowest cost and at the highest quality and safety Standards. Reducing breakdowns and Optimising resources utilisation. Improving equipment efficiency and reducing down time. Minimising energy usage and optimising the useful life of equipment.  

 Scheduled maintenance 

Scheduled maintenance is a stitch-in-time procedure and incorporates inspection, lubrication repair and overhaul of equipment's. Scheduled maintenance is a service carried out by a competent person, to ensure that an item of machine is operating correctly and to therefore avoid any unscheduled breakdown and down time.  

Maintenance planning  

Maintenance planning is the process by which the elements required to perform a task are determined in advance of the job start. The maintenance Planning is to improve work force productivity and work quality by planning and coordination of labor, parts and material, and equipment access. 

Predictive  maintenance  

The predictive maintenance is first to predict when machinery failure might occur, and secondly, to prevent the occurrence of the failure by performing the maintenance. Predictive maintenance allows the maintenance frequency to be as low as possible to prevent Break down maintenance. 

Importance of  preventive maintenance 

Preventive maintenance is performed while the equipment is still working; so that it does not break down unexpectedly. Preventive maintenance is planned so that any required resources are available. The importance of preventive maintenance is as follows. 

 – Reduces break down time. Less odd-time repair and reduces over time of crews 

– Lower maintenance and repair costs and Less stand-by equipment's and spare parts  

– Better product quality and fewer reworks and scraps. Increases plant life  

 Break down Maintenance and  losses happening  

Breakdown maintenance implies that repairs are made after the equipment is failed and cannot perform its normal function anymore.  Breakdown generally occurs inappropriate times leading to poor and hurried maintenance, excessive delay in production & reduces output. Faster plant deterioration and direct loss of profit.  

Different types of Maintenance Schedule 

 The different types of Maintenance Schedule are 

 Daily  Schedule  

 Weekly Schedule  

 Long range schedule 

 Weekly Schedule – 

 Covering 1 week. Generated from the master maintenance schedule. 

 Takes into account current operations schedules and economic considerations. 

   Allow 10% to 15% of the workforce to be available for emergency work. 

 The schedule prepared for the current week and the following one in order to consider the available backlog. 

  The maintenance work orders scheduled in this week are sequenced based in priority.  

Confirming leveling for Injection Molding machine 

 Injection molding machine has larger bases, leveling and alignment may become a problem, thus necessitating the use of Leveling mounts.  Proper leveling and alignment of machinery and process equipment is essential for long-term performance, calibration and accuracy. Floor/foundation mounted larger moulding machines can be easily leveled and aligned using anti vibration pads/ Mounts. The Leveling mounts used to protect heavy production machinery from shock and vibration. 

Term leveling 

Levelling is important factor of Installation and commissioning of machine. Floor should be even and rigid base foundation for placing the machine. Levelling of machine is required to prevent uneven self-weight loading. It may cause the machine to undergo forced wearing. Levelling of machine helps in its optimum performance. Normally machines are levelled with reference to their XYZ axis. Tubular Spirit Level and digital level indicates digital readout and inclinometer. The digital level proved to be faster to settle than the old spirit models.            

   

Term Installation & Commissioning 

 Machine installation and commissioning is a key part of putting the machine into service.     If installation and commissioning is carried out carefully using the correct procedures, it is an investment in the machine´s serviceability and reliability for its entire service life. Commissioning is the process of planning, documenting, scheduling, testing, adjusting,        verifying, and training, to provide a facility that operates as a fully functional system per the requirements.  

 Installation means to build and/or put the machine in to service. To 'commission' a plant means to carry out all necessary tests and procedures required by industry standards to show that the plant is able to deliver the purpose for which it was installed. 

Factors considered for installation & Commissioning 

Main factors carried out for Installation procedures: 

  Visual inspection of the machine 

  Inspection of the parts & spares 

 Proper machine axial alignment checking and correction 

  Checking the main and auxiliary electric circuit connection, cooling circuit connection and lubricating circuit connection  

 Commissioning factors are Mechanical and electrical installations are inspected first to check whether the required parameters are kept. Subsequently, all auxiliary and supervisory circuits required for machine starting and operation are checked. 

Term alignment 

 Machine set-up most often starts with the foundation. If the foundation is level and flat you will have less problems with the rest of the installation and alignment of the machine.          Features for the alignment of the machine, 

 Measure the flatness of the foundation 

  Check plane parallelism for several surfaces on large machines  

 Align the foundation level and plumb 

 Align pipes straight and square 

 The measuring units align the shafts of rotating machinery.  

Safety precautions to be followed in plastics processing shop floor 

The following safety procedure, which should be maintained to assure a safe working            Environment. First aid kits should be available. Never make any Adjustments to a Machine When it is in Operation. Before Making Adjustments Always Talk to Your Supervisor for  permission. 

  Floor and machine should be kept free of oil, pellets.

  Never reach over or under machine guards. 

  Never climb between the bars when pumps are running. 

 Retract injection unit before entering the bar space. 

Importance of safety in the Production shop floor 

 Workplace safety is important because it: protects employees and the employer from death or injury. Teaches workers how to work in a safe environment. Helps everyone feel safe and happy.  A safe and healthy workplace not only protects workers from injury and illness, it can also lower injury/illness costs, reduce absenteeism and turnover, increase productivity and quality, and raise employee morale. In other words, safety is good for business.

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