The document provides information about the maintenance plan of the spinning mill of Star Textile Mills Limited. It discusses the various processes involved in spinning like mixing, blowing, carding, drawing, simplex, ring frame, auto cone and packaging. It then outlines the roles of the maintenance department and discusses cotton quality based maintenance and condition based monitoring practices. Finally, it presents the preventive maintenance plan for various departments like blow room, carding, drawing etc. in the form of charts specifying maintenance activities, their frequency and expected downtime. The maintenance plan aims to minimize breakdowns and ensure high plant availability through scheduled preventive maintenance.

1. Name Danial Sohail
Roll no. ME-089
Section A
B.E
Mechanical Engineering

2. i
TABLE OF CONTENTS
Table Of Figures ............................................................................................................................................ ii
Preface / Acknowledgement.........................................................................................................................1
Visit Information ...........................................................................................................................................2
Visit Photograph ...........................................................................................................................................3
Maintenance of Spinning Mill.......................................................................................................................4
1.1 Spinning.........................................................................................................................................4
1.2 Processes in Spinning Operation...................................................................................................4
1.2.1 Mixing Section.......................................................................................................................5
1.2.2 Blow room.............................................................................................................................6
1.2.3 Carding..................................................................................................................................7
1.2.4 Drawing.................................................................................................................................7
1.2.5 Simplex..................................................................................................................................8
1.2.6 Ring .......................................................................................................................................9
1.2.7 Auto Cone .............................................................................................................................9
1.2.8 Packaging ..............................................................................................................................9
1.3 Roles of Maintenance Department of Star Textile Mills Limited................................................10
1.4 Cotton Quality Based Maintenance in Star Textile Mills Limited Spinning Mill .........................10
1.5 Condition Based Monitoring/Predictive Maintenance in Star Textile Mills Ltd Spinning Mill ...11
1.6 Preventive Maintenance Plan of Star Textile Mills Limited Spinning Mill ..................................12
1.6.1 Maintenance Plan for Blow Room ......................................................................................13
1.6.2 Maintenance Plan for Carding ............................................................................................13
1.6.3 Maintenance Plan for Drawing ...........................................................................................14
1.6.4 Maintenance Plan for Combing Machine ...........................................................................15
1.6.5 Maintenance Plan for Simplex............................................................................................16
1.6.6 Maintenance Plan for Ring..................................................................................................17
2. Conclusion...........................................................................................................................................21
2.1 Views on Maintenance Plan of Star Textile Mills Ltd..................................................................21
2.2 Recommendations on Improvement of Maintenance Plan........................................................21
2.3 Recommendation for use of CMMS............................................................................................22

3. ii
TABLE OF FIGURES
Figure 1: Process flow in a Spinning mill.......................................................................................................5
Figure 2: Cotton mixing machine..................................................................................................................6
Figure 3: Blowing Machine in a Spinning Mill...............................................................................................6
Figure 4: Carding Machine Mechanism ........................................................................................................7
Figure 5: Drawing Machine in a Spinning Mill ..............................................................................................8
Figure 6: Simplex machine in a spinning mill................................................................................................8
Figure 7: Packaging and Conditioning Room in a Spinning Mill....................................................................9
Figure 8: Condition Based Monitoring Plan................................................................................................12
Figure 9: Maintenance Plan for Blow room................................................................................................13
Figure 10: Maintenance Plan for Carding ...................................................................................................14
Figure 11: Maintenance Plan for Drawing ..................................................................................................15
Figure 12: Maintenance Plan for Combing .................................................................................................16
Figure 13: Maintenance Plan for Simplex...................................................................................................17
Figure 14: Maintenance Plan for Ring.........................................................................................................18
Figure 15: Maintenance Plan for 1- 15th October 2014.............................................................................19
Figure 16: Maintenance Plan for 15-30th October 2014............................................................................20

4. 1 | P a g e
PREFACE / ACKNOWLEDGEMENT
Giving practical exposure to theoretical knowledge is important as it enhances one’s concepts
and that’s the reason, why engineering students are advised to visit industries and relate their
theoretical knowledge with industrial practices.
Instructed by our course teacher of “Plant Maintenance” we had to visit any textile industry
having its own Spinning mill, in a group of 14 students. In the visit we had to study mill’s predictive
maintenance program. And finally we had to present it in the form of detailed report. In this
regard our group managed to arrange a visit to Star Textile Mills Limited located in site area
Karachi.
This report covers following major topics,
1) Introduction to spinning operation
2) Machinery involved in execution of spinning operation
3) Detailed maintenance strategy of spinning mill machinery
This visit helped us a lot to boost our knowledge about Plant Maintenance, but it would have
never been possible without the help Mr. Shamshir (Former Manager Star Textiles Mills). We
would like to express our sincere thanks to him for arranging this informative visit and sharing
his valuable knowledge with us.

5. 2 | P a g e
VISIT INFORMATION
Star Textile Mills Limited is a huge name in textile industry. Our group visited this industry on
Thursday, 29th October 2015. While organizing visit to Star Textile Mills through the reference
of Mr. Shamshir, we were informed that spinning unit in Star mills has been closed for the last
few months due to some financial and management issues but machinery is still there. Though
we tried our best to arrange a 2nd visit in some other Spinning Mill but due to unfavorable replies
and time consuming procedures, we had to make this report out of the knowledge that we gained
from Star Textile Mills visit. However in any way it does not mean that by visiting Star Textile
Mills, we were not able to fulfil the purpose for which we had to visit the industry. In fact we
were able to observer and study the spinning machinery in a much better way as it was not in
operation.

6. 3 | P a g e
VISIT PHOTOGRAPH

7. 4 | P a g e
MAINTENANCE OF SPINNING MILL
In a spinning mill, the performance of the plant depends on the reliability, availability and
maintainability of the plant, all of which are of primary importance for ensuring an excellent and
affordable product. The concept of maintenance has changed substantially over the years; its
main function now is to prevent mechanical and quality breakdowns. Quality breakdown does
not mean that the quality of whole lot is low; but it means the lot is rejected due to poor quality
of yarn on few bobbins or cones. Therefore to maintain excellent quality, plant engineers are
capable of judging spindle to spindle variations in ring frames, speed frames and winding, and
machine to machine variations in preparatory. But in order to discuss maintenance strategy of
Star Textile Mills Limited spinning mill, it is important to define the processes and equipments
involved in execution of spinning first. Therefore following section briefly defines spinning and
the processes involved in spinning:
1.1 Spinning
In textile product processing, fibers from bales of cotton are converted into finished clothes. First
process of textile product processing is spinning. Spinning is a process in which fibers from bales
of cotton are drawn out and are twisted to form yarn. However commercially process is defined
in 3 steps
 Drawing out fibers.
 Twisting fibers to form yarns.
 Winding yarns onto bobbins.
1.2 Processes in Spinning Operation
A typical spinning process involves a number of operations in different sections. Therefore
process flow diagram of spinning mill with respect to sections is given below:

8. 5 | P a g e
Figure 1: Process flow in a Spinning mill
1.2.1 Mixing Section
Mixing section is basically designed for the purpose of mixing different lots, because these lots
are purchased from different regions and areas and contain different colors, shades and
brightness ranges due to moisture, weather, packing condition and treatment during
Mixing hall
Blow Room
Carding
Drawing
Simplex Department
Ring Department
Auto Cone
Packing Department

9. 6 | P a g e
transportation. Mixing hall serves as a cotton opener, cotton mixer and remover of any foreign
particle like jute and pieces of cloth from cotton.
Following picture is of mixing machine installed in a spinning mill:
Figure 2: Cotton mixing machine
1.2.2 Blow room
The cotton is received in blow room through condensers from the mixing section. In blow room
this cotton is stocked for 12 to 16 hours for conditioning according to the temperature of blow
room, in the form of layers horizontally and cut vertically which is very old method of mixing the
cotton of different regions and characteristics. Blow room mixes, open (tuft to tuft), cleans and
from laps of tuft for the next process.
Figure 3: Blowing Machine in a Spinning Mill

10. 7 | P a g e
Above two machines are different setups that can be used for blowing cotton bales into tufts.
1.2.3 Carding
In carding section laps are converted into sliver. In carding machines laps are feed and slivers are
received as an end product. Carding machine opens laps from fibers to fibers, cleans fibers, forms
wires, drafts, eliminate short fibers. Carding is the most important process of spinning therefore
extensive care and maintenance is provided to Carding machine.
Figure 4: Carding Machine Mechanism
1.2.4 Drawing
Drawing is a process in which different wires from carding are combined together to produce
single wire. Normally 8 wires are fed behind one drawing machine and get an end product in form
of single wire in cans or boxes. The purpose of doing this is that to create uniformity.
Following is illustration of drawing in spinning mill.

11. 8 | P a g e
Figure 5: Drawing Machine in a Spinning Mill
1.2.5 Simplex
Finished wire is input of simplex machine while "roving" is its end product. Roving is a big bobbin
having refined wire (in the form of package) but thin and slim than input wire. In this process,
twisting is done on roving. Here the twist per inch (TPI) is approximately 1.004. Roving is further
used in "Ring Department" for making of small bobbins after that making of cones. One package
normally contains 3,000 meters roving.
Figure 6: Simplex machine in a spinning mill

12. 9 | P a g e
1.2.6 Ring
In ring section, final spinning process starts. Here in this section roving from simplex section is
turned into fine & sophisticated yarn of different counts. Pulling effect makes counts. Spindle is
a smaller tapering rod, the rotation of which gives the twist and around which the thread is
wound as it is twisted.
1.2.7 Auto Cone
In auto cone a winding machine converts ring bobbins into large cones with removing spinning
faults.
1.2.8 Packaging
Packaging area has a conditioning system, this conditioning system is especially designed by
textile engineers. Specially designed duct are used for conditioning of yarn. The yarn is
conditioned 24 hours before packing. Enhanced conditioning of yarn increases the strength of
yarn. The result is a product which is not only conditioned exceptionally but additionally it helps
to decrease the wastage as well.
Figure 7: Packaging and Conditioning Room in a Spinning Mill

13. 10 | P a g e
1.3 Roles of Maintenance Department of Star Textile Mills Limited
Following are the roles that are served by maintenance department of Star Textile Mills Limited in spinning
mill
 Preparation of policy statement for the maintenance department, which explains basic
objectives based on the organizational objectives, and preparation of standard
maintenance procedures, maintenance schedules, lubrication charts etc.
 Preparation of maintenance charts for individual equipment and to train the maintenance
personnel for their implementation.
 Coordination with the production department staff to ensure that a regular maintenance
will be implemented without affecting important production schedules.
 Maintenance department carry out the scheduled preventive maintenance programs and
ensure that plant is available for production for the maximum duration.
 Carry out the overhauling of the machinery at the scheduled time without fail.
 Calibration of various instruments installed at various points in the plants.
 Record keeping of maintenance activities.
 Keeping a watch on critical parts in inventory that could be required for any breakdown.
 To prepare maintenance budget in the start of each fiscal year.
 To adjust the different machines in the process according to the fiber processed.
1.4 Cotton Quality Based Maintenance in Star Textile Mills Limited
Spinning Mill
Maintenance plan of Star Textile Mills Limited spinning mill also includes setting and adjustment
of the machine depending upon the fiber to be processed. A cotton fiber is a peculiar object and
has not truly fixed length, width, thickness, shape and cross-section. Such variations exist because
of the large number of varieties in cultivation which not only differ widely in several key
properties but also grown under divergent agro-climatic conditions. Besides inter-seasonal
variations, the same variety displays variation at different locations and even in the same season.
This is due to the fact that, apart from the genetic constitution of variety, the quality of cotton is

14. 11 | P a g e
influenced by various factors such as soil, climate, moisture levels of soil and atmosphere during
crop growth, nutrient supply, pests, disease infestation, picking time and method, post-harvest
handling. Hence, it is a known fact that cotton fiber characteristics vary from bale to bale. In order
to process the cotton fiber in a spinning mill, the machines need adjustments like roller settings,
gauge and speed settings in draw frames, speed frames and cards from time to time in order to
optimize the process with respect to fiber.
1.5 Condition Based Monitoring/Predictive Maintenance in Star Textile
Mills Ltd Spinning Mill
Condition-based monitoring is the right way to optimize maintenance interval for inspection and
also for replacement of parts. However not all operations in a spinning mill are monitored for
condition, instead operations like general cleaning of cards in carding machine, greasing, belt
cleaning and tension checking etc. are done using preventive maintenance techniques.
Star Textile Mills Limited spinning mill currently applying condition based monitoring on some
equipment as follows
Component Condition Based
Assessment
Schedule (tons)
Blow Room
Beater Wire Replacement Visual Inspection / Machine
Performance
2500
Combing Segment
Replacement
Visual Inspection / Machine
Performance
2500
Carding
Cylinder Wire Replacement Visual Inspection / Machine
Performance
600
Doffer Wire Replacement Visual Inspection / Machine
Performance
600

15. 12 | P a g e
Flat Tops Replacement Visual Inspection / Machine
Performance
600
Cylinder and Doffer Grinding Visual Inspection / Machine
Performance
200
Flat Grinding Visual Inspection / Machine
Performance
100
Comber
Uni Comb Nep Removal Efficiency and
Combine Efficiency
1500
Nipper Physical Checking 10 years
Ring Frame
Rings Replacement Visual Inspection /End
breakages /hairiness
3
Bottom and Top Apron Visual Inspection / Uster
Imperfection and evenness
trends
1.5
Figure 8: Condition Based Monitoring Plan
Predictive maintenance in Star Textile Mills Limited spinning mill is only limited to above
mentioned components and majority of maintenance is Preventive maintenance where
equipment is maintained after regular time interval.
1.6 Preventive Maintenance Plan of Star Textile Mills Limited Spinning
Mill
Preventive maintenance plan of Star Textile Mills Limited defines type of maintenance,
maintenance interval and expected down time for maintenance in form of charts for each
department and machine. Following are department wise plans of preventive maintenance of
Star Textile Mills Limited spinning mill extracted from an internship report.

16. 13 | P a g e
1.6.1 Maintenance Plan for Blow Room
Blow Room is stopped after a 12 hours a day shift for maintenance, Maintenance is done by
opening the covers and doors; a high velocity compressed air is blown into the machines. Air is
blown in the waste zones and delivery zones like
 In bale opener/ plucker - take up zone, fan zone, and ducts
 In mild opener - inlet zone, outlet zone and grid bar sections.
 In mixing machine - all cages for compartments, photocell regions, inlet zone, beater
and grid bar zone, outlet zone.
 In fine cleaner - feed zone, beating zone, spikes of beater, photocell regions.
For good preventive maintenance, proper planning is developed, optimized plan for Star Textile
Mills Limited spinning mill is:
Maintenance Type Maintenance Frequency Maintenance Time
Daily Compressed Air Cleaning Daily Half hour
Exhaust checking, repair and
cleaning
15 days 5 hours
Figure 9: Maintenance Plan for Blow room
1.6.2 Maintenance Plan for Carding
After the blow room in sequence is carding operation, following maintenance plan is followed for
maintenance of equipment in carding department.
Maintenance Activity Maintenance Frequency
General Cleaning of Card 15 days
Blow Room General Cleaning 15 days
Doffer Hand Stripping Every day
Front Stationary Flat 150 tons
Back Stationary Flat 150 tons
Cleaning Fillet 1 year
Licker In Segment 150 tons

17. 14 | P a g e
Resetting of Cards 4 months
Licker-in Wire Re sharpening 4 months
Gear Box Oil Change 3 months
Coiler Over hauling 8 months
Web Doffing Cleaning and Greasing 3 months
Main motor Clutch Pulley Greasing 3 months
Side Shaft Gearbox Cleaning and Bearing
Checking
6 months
Figure 10: Maintenance Plan for Carding
1.6.3 Maintenance Plan for Drawing
The major areas of maintenance that are considered in draw frame machines are time to time oil
change of the gear box, greasing activity of bearings at various drives in machine, setting points
and calibrations. Following is maintenance plan for drawing:
Maintenance Activity Frequency
General Cleaning and Greasing 11 days
Bottom Plate Cleaning and Greasing 1 month
Can changer Assembly Cleaning and Greasing 1 month
Pneumatic Connection and Roller Membrane
checking
1 month
Bottom Roller Gauge checking 1 month
Top Roller Buffing and Greasing 1 month
All belt cleaning and Tension checking During Cleaning
All stop motion checking During Cleaning
Flat Belt and Timer belt cleaning and
checking
During Cleaning
Creel cleaning, checking and Greasing During Cleaning
RSB: Scanning roller gauge checking During Cleaning
Bottom Roller Bearing Cleaning and Checking 3 months

18. 15 | P a g e
Gearbox oil Change and Coiler Cleaning and
Greasing
3 months
Scanning Roller Gauge checking 6 months
Bottom roller bearing Cleaning and Greasing 3 months
Figure 11: Maintenance Plan for Drawing
1.6.4 Maintenance Plan for Combing Machine
Important areas in combing preparatory and comber are drafting zone, combing zone, lap
formation zone, delivery zone and waste extraction zone. Following show maintenance plan for
combing machine at Star Textile Mills Limited spinning mill.
Maintenance Activity Frequency
Full Cleaning and Greasing
 Greasing of All bearing and Needle
Bearings
 Greasing of top detaching roll, draw
box roll bush.
 Checking of oil level in gearbox
 Coiler Assembly cleaning and greasing
 Bush shaft bearing checking and
greasing
 Aspirator Cleaning
11 days
Draw Box gauge checking 1 month
Top Comb and Uni Comb checking 11 days
Noil suction wire mesh/ cage washing 11 days
Main Gearbox Oil Change 3 months
Asperiator Bush setting 6 months
Full setting (All points) 3 months
Coiler Over hauling, Cleaning and Greasing 6 months

19. 16 | P a g e
Detaching Roller, draw box roller S.L.R.L, top
roller buffing.
6 months
Nipper Setting 6 months
Figure 12: Maintenance Plan for Combing
1.6.5 Maintenance Plan for Simplex
Important areas in Speed frame are creel zone, drafting zone and building zone
Maintenance Activity Frequency
General Cleaning, Oiling and Greasing
 Bottom roller needle bearing
greasing.
 Bottom fluted needle cleaning with
petrol
 Top roller (cots) cleaning with C.T.C
 Top and bottom cone drum cleaning
and belt setting of full doff stop
motion checking
 Greasing of Jack shaft, Lifter shaft,
Bobbin and Spindle shaft, Bobbin rail
lifting shaft
 Spindle and spindle collar oiling with
CKS 600T Oil
 Flyer Cleaning
11 days
Creel Greasing 3 months
Differential Gearbox Oil Change 3 months
Clutch Cleaning and Position Checking 3 months
Top roller buffing 6 months
Spindle Collar cleaning and foot step oil
change
3 months

20. 17 | P a g e
Bottom Roller setting and saddle Gauge 6 months
Top and Bottom apron washing 3 months
Flyer Cleaning with graphite powder 6 months
Roller Eccentricity checking 6 months
Trough Leveling 6 months
Top roller arbor greasing 6 months
Spindle and Spindle Collar truing 6 months
Top Roller Greasing 6 months
Figure 13: Maintenance Plan for Simplex
1.6.6 Maintenance Plan for Ring
Important zones are creel, drafting zone, winding zone and building zone.
Maintenance Activity Frequency
General Cleaning head stock greasing and
traveler change
15 days
1st bottom roller needle bearing greasing 15 days
2nd and 3rd bottom roller needle bearing
greasing
1 month
Front and Back cots buffing 1 month
Bottom Apron Centering 15 days
Fan Cleaning 2 months
New bottom Apron fitting 15 months
New spindle tape fitting 2 years
New front/back cots fitting When under size
Variation Overhauling 3 months
Suction tube washing 3 months
Main shaft greasing 3 months
Gearbox load checking 3 months
Additional drive and gearbox oil change 4 months

21. 18 | P a g e
Jockey Pulley Greasing 4 months
Spindle Oiling 5 months
Ring Rail, Lappet Rail, height gauge 9 months
2nd top roll greasing 6 months
Top apron washing 6 months
Head stock overhauling 6 months
Creel and U bar checking 9 months
O.H.T.C overhauling and greasing 9 months
Drafting checking 6 months
Lappet joint collar checking 9 months
Top arm centering 12 months
Pneumatic connection checking 12 months
Traveler clearance setting 12 months
Figure 14: Maintenance Plan for Ring
While above charts show the type of maintenance and their frequency in general, below is the
maintenance plan which Star Textiles Mills Limited developed last year for its spinning department for the
month of October. These charts specifies department wise machinery and their sub components which
Star Textile Mills maintenance department planned to maintain on specific dates of October.

22. 19 | P a g e
Star Textile Mills
Department - All Departs Preventive Maintenance Schedule For the Month Of OCTOBER -2014
Day Wednesday Thursday Friday Saturday Sunday Monday Tuesday Wednesday Thursday Friday Saturday Sunday Monday Tuesday Wednesday
Date & Day 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15
Department OH OH OH OH W.R OH OH OH OH OH OH W.R OH OH OH
Blow Room
Mixing Auto
Plucker# 01
Mixing
Auto
Plucker#
02
General
Cleaning
Mixing Auto
Plucker# 03
Weekly
Rest
Mixing
Condensor
# 01
Mixing
Condensor
# 02
Mixing
Condensor
# 03
B-11
General
Cleaning
B - 70
Weekly
Rest
A-21 # 1, 2 B - 60 # 1 B - 60 # 2
Carding
Carding #
12
Carding #
13
General
Cleaning
Carding # 14
Weekly
Rest
Carding # 15
Carding #
16
Carding #
17
Carding #
18
General
Cleaning
Carding #
19
Weekly
Rest
Carding #
20
Carding # 21
Card
Machine #
01
D/Simplex
Toyota
DYH-500 C #
03
Drawing
DYH-500 C
# 04
General
Cleaning
Toyoda FL-16
Simplex # 2
Weekly
Rest
Toyoda FL-16
Simplex # 08
DX 7A # 04
Toyoda FL-
16
Simplex# 01
Drawing
DYH-500 C
# 01
General
Cleaning
Drawing
Toyoda FL-
16 # 01
Weekly
Rest
Toyoda FL-
16
Simplex#
02
Drawing
Toyoda FL-
16 # 02
DX 7A # 03
Ring 14, 17 15, 36 26 34
Weekly
Rest
1, 12 33 3, 18 4, 40 32 22
Weekly
Rest
5, 10 31 6, 38
Auto Cone
M/C # 08
SP # 01 ~ 10
M/C # 08
SP # 11 ~
20
General
Cleaning
M/C # 08
SP # 21 ~ 30
Weekly
Rest
M/C # 08
SP # 31 ~ 40
M/C # 08
SP # 41 ~
50
M/C # 08
SP # 51 ~ 60
M/C # 04
SP # 01 ~
10
General
Cleaning
M/C # 04
SP # 11 ~
20
Weekly
Rest
M/C # 04
SP # 21 ~
30
M/C # 04
SP # 31 ~ 40
M/C # 04
SP # 41 ~ 50
Air
Condition
Auto Cone & Ring
# 1
ElementPlats,
Supply,Return
Air Trunch
Cleaning &
water change
Auto Cone &
Ring # 2
Element
Plats, Supply,
Return Air
Trunch
Cleaning &
water change
General
Cleaning
D/Simplex & Ring
# 3 Element
Plats& Air Rotory
Cleaning & water
change
Weekly
Rest
Carding & Ring #
1 Element Plats
Cleaning & water
change
All depart
defusel &
Befall Plats
Cleaning
Auto Cone &
Ring # 1
ElementPlats,
Supply,Return
Air Trunch
Cleaning &
water change
Auto Cone &
Ring # 2
Element Plats,
Supply,
Return Air
Trunch
Cleaning &
water change
General
Cleaning
D/Simplex &
Ring # 3
Element
Plats& Air
Rotory
Cleaning &
water change
Weekly
Rest
Carding &
Ring # 1
Element Plats
Cleaning &
water change
All depart
defusel & Befall
Plats Cleaning
Auto Cone &
Ring # 1
ElementPlats,
Supply,Return
Air Trunch
Cleaning &
water change
Figure 15: Maintenance Plan for 1- 15th October 2014

23. 20 | P a g e
Star Textile Mills
Department - All Departs Preventive Maintenance Schedule For the Month Of OCTOBER -2014
Day Thursday Friday Saturday Sunday Monday Tuesday Wednesday Thursday Friday Saturday Sunday Monday Tuesday Wednesday Thursday Friday
Date 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31
Department OH OH OH W.R OH OH OH OH OH OH W.R OH OH OH OH OH
Blow Room D-X # 1
General
Cleaning
MCM # 1
Weekly
Rest
B - 11
China
clc1 &
condensor
Looptex
Filter
cleaning
General
Cleaning
Roving
machine,
Press
machine
Weekly
Rest
Auto
Plucker
# 01
Auto
Plucker
# 02
Auto
Plucker #
03
General
Cleaning
General
Cleaning
Carding
Card
Machine #
02
General
Cleaning
Card
Machine #
03
Weekly
Rest
Card
Machine #
04
Card Machine
# 05
Card
Machine #
06
Filter
(C-60)
General
Cleaning
Can Wheel
Checking
C-60
Weekly
Rest
Done O.H if
Remaning
Any M/C
Can Wheel
Checking
Carding
Done O.H if
Remaning
Any M/C
General
Cleaning
General
Cleaning
D/Simplex
Drawing
DYH-500 C #
02
General
Cleaning
Toyoda FL-
16
Simplex#
03
Weekly
Rest
Drawing
DYH-500 C
# 03
Drawing
Toyoda FL-16
# 05
Drawing #
02
Drawing
Toyoda FL-
16 # 04
General
Cleaning
Toyoda FL-
16
Simplex #
05
Weekly
Rest
Toyoda FL-
16
Simplex #
03
Toyoda FL-
16
Simplex #
02
Toyoda FL-
16
Simplex # 09
Drawing
DYH-500 C
# 06
Drawing
DYH-500 C #
05
Ring 9, 16 30 27
Weekly
Rest
7, 16 23 8, 39 19 28 11, 13
Weekly
Rest
28 2, 37 24 20 26
Auto Cone
M/C # 04
SP # 51 ~ 60
General
Cleaning
M/C # 05
SP # 01 ~
10
Weekly
Rest
M/C # 05
SP # 11 ~
20
M/C # 05
SP # 21 ~ 30
M/C # 05
SP # 31 ~
40
M/C # 05
SP # 51 ~ 60
General
Cleaning
Done O.H if
Remaning
Any M/C
spindles
Weekly
Rest
General
checking
Done O.H if
Remaning
Any M/C
spindles
General
checking
General
Cleaning
General
Cleaning
Air
Condition
Auto Cone & Ring
# 2 Element
Plats, Supply,
Return Air
Trunch
Cleaning &
water change
General
Cleaning
D/Simplex &
Ring # 3
Element
Plats& Air
Rotory
Cleaning &
water change
Weekly
Rest
Carding &
Ring # 1
Element Plats
Cleaning &
water change
All depart defusel
& Befall Plats
Cleaning
Auto Cone &
Ring # 1
ElementPlats,
Supply,Return
Air Trunch
Cleaning &
water change
D/Simplex &
Ring # 3
Element Plats&
Air Rotory
Cleaning &
water change
General
Cleaning
Carding &
Ring # 1
Element Plats
Cleaning &
water change
Weekly
Rest
All depart
defusel &
Befall Plats
Cleaning
Done O.H if
Remaning
Any M/C
Done O.H if
Remaning
Any M/C
General
Cleaning
General
Cleaning
Figure 16: Maintenance Plan for 15-30th October 2014

24. 21 | P a g e
2. Conclusion
In previous section we have discussed the maintenance program and maintenance related
activities adapted by Star textile Mills Limited and this section comprises of my personal views
about this visit and some recommendations as a Mechanical engineering student on
maintenance program of Star Textile Mills Limited. These recommendations may help to increase
machine availability and overall equipment effectiveness of equipment in different departments
of Star Textile Mills Limited.
2.1 Views on Maintenance Plan of Star Textile Mills Ltd
Star Textile Mills have a well-defined maintenance plan and maintenance activities associated
with each component of each machinery and it helped us a lot to boost our practical knowledge
of maintenance programs that are adapted by industries rather than just keeping our knowledge
to books.
2.2 Recommendations on Improvement of Maintenance Plan
From the previous section it can be noticed that Star Textile Mills Limited has preventive
maintenance program for maintenance of most of its component and a few components which
are checked through predictive maintenance have very poor condition based monitoring system
which is based on visual inspection and machine efficiency rather than a real time monitoring
system which could monitor the thicknesses of wires and apron using cutting edge laser
technologies. Moreover no vibration signatures of machinery was developed to compare with
distorted vibrations when machine encounters a problem in a rotating and reciprocating
component, for easy detection of area of maintenance.
If the previously define preventive maintenance program is combined and optimized with new
predictive maintenance schemes it’ll not only increase machine availability, overall equipment
effectiveness and productivity of employed staff but will also decrease the power requirement
of plant as less energy will be consumed by well-maintained machinery.

25. 22 | P a g e
2.3 Recommendation for use of CMMS
By looking at the attached maintenance plan of Star Textile Mills which was developed for month
of October 2014, it can be presumed that they have manual way of planning and executing
maintenance activities, by using Microsoft Excel, despite of availability of advanced maintenance
dedicated software knows as Computer-Managed Maintenance System (CMMS).
Without CMMS, maintenance manager faces lots of problems regarding the analysis of feedback
received from the maintenance department, and too much computer work burdens the
maintenance manager and he gets little time to provide attention to the equipment and to the
ongoing maintenance work. Likewise without an adequate information base, the manager is
likely to take a wrong or a non-optimum decision, which may cost more to the company.
The primary objective of the maintenance management is to achieve the optimum balance
between the plant availability and maintenance resource utilization. The effective matching of
labor and material resources for maintenance planning and control is essential for industry to
increase labor productivity, machine availability and overall equipment efficiency.
If Star Textile Mills limited shifts their maintenance management to CMMS they’ll have the
following benefits:
 Improved maintenance planning
 Clear maintenance reports and ease of access to historical information for maintenance
audit
 Reduced management overhead
 Fewer breakdowns
 Less stock-outs
Adapting the following recommendation can increase machine availability and overall equipment
effectiveness.