Maintenance

Management
Case study : Shahi Exports
Study By:
Gokulraj V
Shashank Trivedi
Saurabh 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
NIFT Bangalore, BFT(2011 - 15)
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
NIFT Bangalore, BFT(2011 - 15)
CMD at Shahi Exports
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.

NIFT Bangalore, BFT(2011 - 15)
CMD at Shahi Exports
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.

NIFT Bangalore, BFT(2011 - 15)
CMD at Shahi Exports
Overtime
1.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

Appraisal
1.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.

NIFT Bangalore, BFT(2011 - 15)
CMD at Shahi Exports
Vacation / Time off
Employee vacations are scheduled so that the ability to service the
companys 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.

NIFT Bangalore, BFT(2011 - 15)
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.

NIFT Bangalore, BFT(2011 - 15)
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.

NIFT Bangalore, BFT(2011 - 15)
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.



NIFT Bangalore, BFT(2011 - 15)
Hierarchy of Maintenance Dept.
NIFT Bangalore, BFT(2011 - 15)
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
NIFT Bangalore, BFT(2011 - 15)
The maintenance approach followed in Shahi Exports Pvt.
Ltd is Total Protective Maintenance (TPM) and the Quality
policy is 5s.

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

NIFT Bangalore, BFT(2011 - 15)
TPM at Shahi Exports
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.

NIFT Bangalore, BFT(2011 - 15)
TPM at Shahi Exports
BATCH MAI NTENANCE
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

NIFT Bangalore, BFT(2011 - 15)
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.

NIFT Bangalore, BFT(2011 - 15)
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.

NIFT Bangalore, BFT(2011 - 15)
Snapshots of CMMS

NIFT Bangalore, BFT(2011 - 15)
Breakdown Times

NIFT Bangalore, BFT(2011 - 15)
Machine history record

NIFT Bangalore, BFT(2011 - 15)
Machine inward details

NIFT Bangalore, BFT(2011 - 15)
Master list of M/cs

NIFT Bangalore, BFT(2011 - 15)
Material Requistion

NIFT Bangalore, BFT(2011 - 15)
Breakdown Percentage

NIFT Bangalore, BFT(2011 - 15)
Preventive Maintenance
schedule

NIFT Bangalore, BFT(2011 - 15)
Training
Original Equipment Maintenance (OEM).

Maintenance training programmes are organised by the
company in every three or six months, in which they call
machines companys personnel (eg. Juki trainers) for
training Shahis workers in maintenance areas.

NIFT Bangalore, BFT(2011 - 15)
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.

NIFT Bangalore, BFT(2011 - 15)
NIFT Bangalore, BFT(2011 - 15)