*Overall
equipment efficiency” is used as an indicator of how well equipment is used in
batch/lot production.
The overall equipment efficiency is obtained in relation to losses that can impede equipment efficiency. The magnitude of stoppage loss is expressed as availability, that of performance loss as performance rate, and that of defect loss as quality products rate ratio. The product of the three ratios is called “overall equipment efficiency.” Overall equipment efficiency = Availability Í performance rate Í quality products rate.
Empirically,
the targets have been 90% or higher in the case of availability, 95% or higher
in the case of performance rate, and 99% or higher in the case of quality
products rate. The overall equipment efficiency has been targeted at 85% or
higher.
Generally
the overall equipment efficiency of a plant before introduction of TPM ranges
between 40% – 60%.When this ratio is raised to 85% or more. A 1.5 – 2-fold
production increase can be attained with the existing facilities. Or if, output
is kept constant, production is possible with only 1/2 -2/3 of the present
equipment
Seven major losses that can equipment effectiveness
In
TPM, 16 major losses are addressed as problems hampering production system
effectiveness. Of these, the following seven losses are addressed as the ones
that impede equipment effectiveness:
Failure losses
Set-up/adjustment losses
Cutting blade change losses
Start-up losses
Minor stoppage/idling losses
Speed loss
Defect and rework losses
Reference →16 major losses
Sixteen major losses
In TPM, every effort is made to maximize production system effective and explore to keep all losses hampering such effectiveness to zero. These are 16 losses that hamper production system effectiveness hence they are called “16 major losses that hamper effectiveness.
Seven major losses that can hamper equipment effectiveness
Failure losses
Set-up/adjustment losses
Cutting blade change losses
Start-up losses
Minor stoppage/idling losses
Speed losses
Defect and rework losses
Losses than can impede machine operability:
SD (Shutdown) losses
Five major losses than can impede man’s efficiency:
INCLUDED : A) Hanger mold for laundry bag 2 set (according buyer choice) B) Double lined perforated bottom sealing knife 1 set C) MIDDLE PERFORATION WHEEL. D) BOTTOM SEALING KNIFE WITH SEALING BAR. E) FLAT IRON TABLE FOR PICES BAG COLLECTION. F) E.P.C. (EDGE POSITION CONTROLLER) HEAVY DUTY. G) MAGNETIC POWDER BRAKE IN UNWIND SECTION. H) ONE PAIR LONG NECK AIR HOLE PUNCHER. I) Bottom sealing machine Hot-needle device for laundry bag collection. J) Bottom sealing machine AIR SHAFT K) TOUCH SCREEN CONTROLLER. Price : CFR Chittagong ………………………….US$ 18,500.00
Payment : By irrevocable L/C at sight in favor of Chinese Manufacture. Bottom sealing machine Delivery : Within 45 days after receipt the clean L/C.
Maintenance
Department
Instant information given for line layout. We need at least one (01) hour)
Regarding critical process, supervisor not interested to work in alternative M/C
Floor Manager / Executive giving decision without going to place.
Before solving any problem production people inform to higher authority of maintenance.
If we engage any task of repair and maintenance but production will call for another job as well as not accept Jr. Mechanic if we provide.
Auto Clave Machine Preventive Maintenance Procedure
Auto Clave Machine Preventive Maintenance Procedure
Purpose of Auto Clave Machine
To establish a standard preventive maintenance procedure of Auto Clave machine aaa
Scope
To ensure safe and standard preventive maintenance procedure of Auto Clave machine to meet the required smooth operation in cephalosporin production area.
Responsibility
Engineering Personnel
Abbreviations and Definitions
None
Health and Safety Considerations
None
Procedure
Inspection or Auto Clave for voltage fluctuation
Proper earthling condition of machine
Inspection the supply air pressure must be 4 kg/cm2
Check the any leakage of compressed air line
Visual inspection of the chamber with silicone spray
Check there are no leaks in the doors cylinders: Movement should be continuous during all the length
Check the locking cylinders work properly
Clean doors guides
Empty the steam generator
Clean the generator
Passivate the generator
Clean the photoelectric cell and the reflector
Leak inspection of main pipes
Dismantle and clean condensates traps
Visual inspection of safety relief valves
Dismantle and clean check valves. Replace if necessary
Dismantle and clean needle valves
Dismantle and clean pneumatic valves, replace PTFE seals.
Dismantle and clean solenoid valves. Replace spare parts kit
Dismantle and clean manual valves. Replace if necessary
Dismantle and clean the strainers
Clean the compressed air filter and empty water of the recipient
Check the absence of leaks in all pneumatic wires & connections
Check the absence of leaks in the cylinders & valves
Check and adjust steam supply pressure switch: 3 bar.
Check and adjust water supply pressure switch: 1.5 bar.
Check and adjust desmineralized water supply pressure switbar.
Check and adjust compressed air pressure switch: 6 bar
Check and adjust jacket safety pressure switches: 3 bar
Dismantle and calibrate temperature sensors (pt100)
Clean the electrical panel use compressed air of Auto Clave
Check all the contactors, power wires & control wires,
Check all ventilation outlets. Clean Touch-screen and the main panel.
Check all wiring connections.
After completion of maintenance record of Auto Clave
Autoclave Machine Check Points
Inspection for voltage fluctuation
Proper earthing condition of machine
Inspection the supply pressure must be 4 kg/cm2
Check the any leakage of compressed air
Visual inspection of the chamber with silicone spray
Check there are no leaks in the doors cylinders: Movement should be continuous during all the length
Check the locking cylinders work properly
Clean doors guides
Empty the steam generator
Clean the generator
Passivate the generator
Clean the photoelectric cell and the reflector
Leak inspection of main pipes
Dismantle and clean condensates traps
Visual inspection of safety relief valves
Dismantle and clean check valves. Replace if necessary
Dismantle and clean needle valves
Dismantle and clean pneumatic valves, replace PTFE seals.
Dismantle and clean solenoid valves. Replace spare parts kit
Dismantle and clean manual valves. Replace if necessary
Dismantle and clean the strainers
Clean the compressed air filter and empty water of the recipient
Check the absence of leaks in all pneumatic wires & connections
Check the absence of leaks in the cylinders & valves
Check and adjust steam supply pressure switch: 3 bar.
Check and adjust water supply pressure switch: 1.5 bar.
Check and adjust desmineralized water supply pressure switch: 2 bar.
Check and adjust compressed air pressure switch: 6 bar
Check and adjust jacket safety pressure switches: 3 bar
Dismantle and calibrate temperature sensors (pt100)
Clean the electrical panel use compressed air
Check all the contactors, power wires & control wires,
Check all ventilation outlets. Clean Touch-screen and the main panel.
Heavy Equipment Leasing Companies- An Agreement Format
Heavy Equipment Leasing Companies- An Agreement Format
Date: …May,2009
Heavy Equipment Leasing Companies
Deed of agreement between
1st and 2nd parties.
Condition between First party i.e. Heavy Equipment Leasing Companies ,B, Tejgaon Industrial Area and Second party i.e. MMM………Board Bazar….regarding loan of Snap button machine &Security deposit (refundable) money.
First party Heavy Equipment Leasing Companies will provide snap button machine as loan, in good condition to 2nd party MMM……
No. of machine: 2 (seven) snap button machines to be provided by 1st party to 2nd party in good condition.
2nd party will make a security deposit of Tk 25,000×2=Tk50,000/–(in total).
2nd party will return those seven machines in good condition to 1st party, within maximum 45 days of receipt. In case of further requirement of 2nd party,agreement can be renewed.
1st party may ask to return the machines , in case they need it for their own use,within the loan period.In that case 2nd party will be informed by the 1st party, 7 days in advance.
Rent of the machine would be Tk 500/DAY /per machine.
Upon return of machine,security deposit will be returned, after deducting rent amount.
Refundable money will be returned against money receipt only.
(Authorized signature)
(Authorized signature)
Heavy Equipment Leasing Companies MMM….
1st party 2nd party
Machine Rent
Date:
8th November -2003
To,
General
Manager (Production)
Subject:
Over Lock Machine.
Dear
Sir,
With due respect I like to inform you that I have arranged
3 (Three) Over Lock Machine on rent.
3 (Three) Machine will keep on work 8th Nov ’03
to 20th Nov ’03 = 13 days. Rent per Machine per day TK- 200/=
Total Rent 3 x 200 x 13 = 7800/= (Seven Thousand Eight
Hundred Only).
You are requested to approve.
With thanks & best regards
Date:
6th Octorber-2003
To,
The
Honorable Director
Attention:
General Manager (Production)
Subject:
Over Lock Machine.
Dear
Sir,
With due respect I like request for 4(Four) Over Lock
Machine on rent or Loan for the following reasons.
At present we are working Order no 74887800 Order Quantity 298,310 PCs.
We have 20 (Twenty) Over Lock Machine 5 (Five) in
each line. But for this order we need 4 (Four) Over Lock Machine.
Installing Overhead Moving Rail -Provision of overhead moving rail with stirrer in colour kitchen so as to avoid print paste spillages, which is commonly encountered in situations when the stirrer is stationery and filled drums are moved for paste preparation. Reduced spillage (about 5-7 kg print paste per day is spilled while shifting drums). Ease of operation and reduced fatigue to workers. Reduced pollution load. Improved shop floor environment. iii aaa
This measure could be implemented in colour kitchens, where print paste is prepared. Space availability above the drums for installation of the overhead cranes has to be ensured before implementing this measure.
Reusing
dye liquor
The spent dyeing bath, depending on type of dye used, contains residual dyes, auxiliary chemicals, thermal energy and water. Besides, the mentioned resources, discharged spent dye baths cost significant amounts in their treatment, before they get discharged. In practice, direct VAT, disperse and sulphur dyes spent bath can be recycled several times with proper filtration and storage. However, for recycling of spent bath, it is desirable to have circuit collection tanks with proper colour codes for pipings, preferably for different shades to avoid interference of colour mixing for synthetic and blended fibres. Where dyeing is done at higher temperatures, the spent liquor can be transported to storage tanks using the available pressure. Normally dyeing is done at 113°C having 2 Kg pressure, which is sufficient in transportation to storage tank without using additional energy. However, in case of reactive dyes, recycling is possible only after adsorption of residual hydrolysed dyes, using a suitable adsorption media like activated carbon or membranes to remove high molecular dye stuffs. The spent dye bath of reactive dyes contributes high inorganic emission load due to electrolyte and alkali. Moreover, reactive dyes are applied at low temperature which requires additional energy for transportation of spent bath to the storage tank in practice. Reuse of reactive dye spent bath is generally not acceptable. Therefore, care should be taken before practicing this.
In reusing and recycling of spent bath, one can prevent a major portion of the auxiliary chemicals from going down the drain, which also contributes to a high TDS and which hampers the biological activity for removal of organic pollutants. Reuse of spent dye bath, not only reduces the organic and inorganic pollution load, but also Reuse of spent dye bath is very much feasible for synthetic and blended fibres using direct, VAT, disperse and sulphur dyes. The light shade and medium shade spent bath can also be used for dark shade application by optimising the make-up chemical requirement. For reactive dyes, the application is still techno-economically not feasible but environmentally desirable. The investment for proper collection filtration and reuse of dye bath will vary from unit to unit, depending upon the type of shades mostly used and the space available for additional storage tanks and pipings. etc.
Investment for additional installation of 1 to 10 tanks, piping and control This option is feasible and suitable, particularly for large orders for same shade or darker shades without affecting the product quality, provided proper elaboration of spent bath and addition of make-up chemicals are strictly controlled. In developed countries, it has been reported that spent dye baths are re-used up to 25 times, before being discharged to the wastewater treatment plant.
