Table of Contents

Preface Need of maintenance Introduction Modes of failure Role of maintenance Role of maintenance Introduction Maintenance Planned maintenance Unplanned maintenance Quality-based maintenance Role of maintenance department in spinning mill Proactive maintenance Introduction Preventive maintenance Condition-based monitoring Benefits of condition-based monitoring Implementation of condition-based maintenance Planning and scheduling Introduction General principles of planning Procedure of planning Scheduling Principle of standardization of frequencies and jobs Principle of cyclic schedule for the maintenance team Principle of interlinking spare part planning with maintenance plan and schedule Operators must act as machine keepers Maintenance schedule Maintenance audit Introduction Methodology Preparation of maintenance audit report Presenting the report to management Role of manpower in maintenance Introduction Factors affecting manpower planning Manpower norms Maintenance organization structure Concept of common gang Responsibilities at various positions Human error in maintenance Crew size required for various activities in maintenance department Maintenance repair inventory and its control Inventory Types of inventory Inventory carrying cost Material and repair inventory Different methods for controlling the inventory How to implement the spare parts management? Maintenance information systems Computer-managed maintenance system Benefits of CMMS Components of CMMS Safety while maintenance Accident Effects of an accident Accidents and its related losses Cause of accidents How to prevent accidents? Electrical safety House keeping Workshop/workplace Machine guarding Methods and procedure Safety in shifting material Safety while unpacking and cleaning Precautions for handling machine under maintenance Precautions during spinning operation Safety tags Lubricants Types of lubricants Functions of lubricant Liquid lubricants Semisolid lubricants Solid lubricants Lubricant used in spinning mill Lubricants handling and storage Conservation of lubricants Summary Belt drive and its maintenance Introduction Flat belt drives Spindle tape Flat pulley V belts V pulleys Timing belts Steel wire and chain Steel wire rope Construction Design of wire Classification of steel wire ropes Measuring wire rope Wire pulley or sheave Lubrication Reason for failure of wire Chains Construction of chain Designation of chain Chain lubrication Chain installation Maintenance of chains British standard roller chain American standard roller chain Leaf chain Silent chain Temporary fasteners Introduction Screwed joint Different types of bolt/screw Washer Nut Locking device Key Tension element Pins Retaining rings Taper lock Universal joint Screw hose clamps Oil seal and gasket Introduction Material selection Why garter spring is needed? Shelf life Procedure for installation Reasons for seal failure Gasket Effecting a seal Installation of gasket Gears Introduction Spur gear Helical gears Worm gears Bevel gears Gear trains Black lash Lubrication Reasons for the failure of gear teeth Compressed air Introduction Compression of air Free air or atmospheric air Analyzing compressed air needs Production of compressed air How to specify the right compressor type, capacity and pressure? Receiver or tank size for air compressor Moisture Quality of water required for compressor What is oil free compressed air? Air distribution systems Pneumatic cylinder Regulator Lubricator Moisture separator Minimum pressure switch Filters Safety valves Non-return valve Quick release valve Micro valve Speed control device Time delay valve Port flow control valve Silencer Piping Pressure hoses Push-type fitting Threaded connector Barbed-type connectors Solenoid valve Dial indicator Compressed air system leaks Leak detection Pressure drop and controlling system pressure Compressor air system economics Maintenance of pneumatic system Bearing and its maintenance Introduction Bearing Types of bearing Roller bearings Bearing designation Internal clearance Withdrawal sleeves with nut and locking washer Bearing characteristics Lubrication of bearing Mounting of different bearings Dismounting method of different bearing Reason for failure of bearings Examinations of bearing in service Tools Open-ended spanner Ring spanner Sockets and accessories Torque wrench sockets Allen key Try square Steel rule Feeler gauge Hammers Soft hammers Dial gauge Spirit level Vernier calliper Digital vernier calliper File Chisels Screw driver Vices Punch Hacksaw Taps Die and die stock Grinding wheels Pliers Stud extractor Kit for mounting of bearing Pullers Micrometer Drill Step ladder Oil cans Grease gun Chalk line Knife Plumb bob Requirement of tool for erection, installation and maintenance Tips to fine tune the spinning machinery Introduction Blow room Card Drawframe Comber Speedframe Ringframe Automatic cone winder Two-for-one twister Tips to improve energy saving in spinning mills Energy Textile production process Energy consumption in spinning mill Maximum cost effectiveness in energy use Energy conservation measures Index.

About the Author

Neeraj Nijhawan is an industrial engineer with extensive hands-on, meticulous, bottom line-oriented experience of over 17 years in managing and delivering high quality spun yarn products. Presently, he is working as an Astt. General Manager (Technical) in a textile mill in Indonesia.