A simple machine is any device that only requires the application of a single force to work. Simple machines include: the inclined plane, wheel and axle, lever, pulley, wedge (single and double) and the Archimedes' screw. A machine is a mechanical device with moving parts, often powered by electricity, used to perform a task, especially one that would otherwise be done by hand. Machinery refers to the aggregate parts that make up a machine or group of machines to produce a particular result.
Every industry, field and profession today employs the use of machinery in some way, shape or form. The computer industry, farming and agriculture, the automotive industry, the medical field, engineering, mining, manufacturing, packaging and construction are just a few of the industries and fields that are dependent on machinery. The major machinery factoring countries include: the United Kingdom, Germany, France and Italy.
INTRODUCTION OF THE COMPANY:
Company Visited: Parle Products Private Limited, V.S.Khandekar Marg Vile Parle (East), Mumbai- 400057.
Production Management: Mr. Rajesh Rahul; Plant Engineering : Mr. D.B.Jha; Chief Engineering : Mr.Gadiwala.
Machines and Machine Maintenance: The machines in the factory are SPM i.e. they are special purpose machines. These machines are prepared by the machine manufacturing company depending on the specifications given by the company. There are nearly 18 machines in the factory each of them operated by one OR two worker. These machines require special maintenance, therefore; there is special department for maintenance. Apart from this it has also other department for maintenance. The only regular maintenance that takes place is the oiling in the machine daily. If there is any kind breakdown then the machine is replaced as these are SPM. If the machine asks for any repairing then it is done only if it is a minor repair. If it’s a major one then the machine is replaced. In many cases the repairing is done by the Mechanical engineer who is specially appointed for this purpose. Preventive Maintenance is adopted in this factory as it is a large scale industry. In some cases, the machines have to be replaced even though they are in good condition. This is due to the changes in technology and demand.
The following are the different types of machines used in this factory: 1. Stephen Mixer 2. Nagema Single Twist Machine 3. Nagema Double Twist Machine 4. Euro Sigma Machine 5. Euro Sigma Bar Wrapping Machine 6. Kneding Roller 7. Multipacking Machine 8. Rottary Brush $ Rottary Cutter.
[pic]
The company has its own unique method of maintenance which comprises of different types of tags for maintenance of the different departments:- ▪ Green Tag is for Maintenance Department. ▪ Red Tag is for Electrical Department. ▪ White Tag is for Cleaning Department.
Preventive Maintenance:
It means to maintain the maintenance operation performed prior to breakdown and may be either minor or major. It is carried out on scheduled basis for retaining equipment in a satisfactory operating condition.
Preventive maintenance is done on every Sundays.
Preventive maintenance takes place in four ways:- 1. Time based: 2. Work based: 3. Opportunity based: 4. Condition based:
MAINTAINING MACHINES: Maintaining our plant and equipment in good order not only increases its life, but makes it safer to use and also quieter.
How wear and tear affects noise output?
We can understand this by looking at the "bathtub" curve. This shows what happens to the noise output of a machine over its working life.
[pic]
Servicing needs to be carried out at Point C, before the wear and tear becomes serious. By doing this, we may not achieve a large noise reduction, as the noise level will drop back to the level at Point A or Point B. But what we will do is to avoid the period of high noise exposure up to Point D.
Not only this, but repairs carried out at Point D are going to be much more expensive.
Inspection: After the assembling is done, the Inspector and his inspecting team come and inspect. The inspection is done to check the pressure resistance of the machines with the help of pressure gauges. Then various tests are conducted as per inspection rules. The inspection report is prepared and then the packaging takes place. Inspection also takes place after the packaging. The Administration – in - charge inspects the production when it is being prepared. He inspects them from the cabin which is above the gate near the place where packaging takes place. This cabin has glass windows through which he can have a continuous check.
How can you tell when your machine needs servicing?
Obviously you won't want to wait till Point D on the curve before you realise the need for servicing. There are three simple ways you can check whether any of the nine problems above are starting to appear. 1. Look - can you see signs of wear? Is the machine's performance down? Remember, however, that only qualified people may take an electrical machine apart. 2. Feel - some of the problems will show up as looseness or increased vibration, which you can learn to recognize by feel, especially in hand-held machines. Again, only touch the machine where you can do so safely. 3. Listen - your ears are a good fault detector - even with hearing protectors on. Listen for new noises, especially tonal ("whining") sounds, repeated impacts, or high frequency ("screech") sounds. Also, slipping belts will cause a screech at start-up, while a damaged bearing may appear as a "clunk" during run-down.
Ideally, your workplace should have in place a system for checking and servicing the various machines and power tools. If you don't have the expertise in your workplace, then use a qualified service centre in your area.
Safety and Machinery:
Machinery-related hazards are present in virtually every industry but they are more common in manufacturing, farming and construction. Because these industries employ the use of numerous types of machinery, the chances of work-related injuries increases greatly. However, many machinery-related accidents result from human error. The operator either ignored a warning, didn't follow safety rules, decided to take a shortcut or the operator could be distracted or even sleep-deprived. In some cases, guards removed for maintenance often aren't replaced. For overall risk and loss management, machinery should be tested and assessed prior to use. The following guidelines should give you an idea of common assessment procedures.
• Machinery should be checked against OSHA, ANSI, NFTA and EEC requirements to determine compliance with the current regulatory standards.
• Safety circuits should be verified and checked.
• Check warning labels against current standards.
• Test control systems for control reliability.
• Check for actual use versus design specifications.
• Evaluate other safety components for appropriateness.
• Check guarding for appropriateness.
Observations:-
About the machines: The machines are arranged as per process layout. Process layout refers to the arrangement of machines performing similar processes together. In this factory, the machines are arranged on the middle of the walls of the factory and the assembling takes place in the centre on a table with the special toolbox. Next to that the packing takes place. This is the layout of the machines inside the factory:
Biscuits Manufacturing Flow Chart:-
Raw Material
Mixing
Moulding
Baking
Cooling
Packing
CONCLUSION
PARLE-G the world’s largest selling biscuits have won many NATIONAL & INTERNATIONAL AWARDS for its excellence. They take pride in saying that they have goodwill in the market because of their quality and fast service.
It was a lovely experience interviewing Mr. Pereira and his staff and it has made a contribution to our knowledge.
