Breakdown Maintenance in Plants: All You Need To Know

What is breakdown maintenance? It is a type of maintenance carried out on equipment that is out of order. This type of maintenance is unplanned and performed on malfunctioning equipment. A few assets don’t need preventive maintenance because their failure is manageable. These assets are less valuable, and the company doesn’t want to spend extra on them, whereas high-value assets are constantly under preventive maintenance to safeguard them from sudden failure. Although breakdown maintenance is conducted after equipment fails to function, it can be performed strategically. Category of breakdown maintenance To effectively manage a breakdown program, it  can be classified into two types. 1. Run-to-failure maintenance   In run-to-failure maintenance, the organization is ready to handle a machine that will stop functioning soon. The assets under this maintenance are easy to replace and won’t disturb the operational system. The cost of repairing these assets under run-to-failure maintenance is less than the preventive maintenance costs. Inexpensive or unimportant parts and machinery can be repaired under run-to-failure maintenance. 2. Emergency maintenance Emergency maintenance is needed when an essential piece of equipment goes out of order unexpectedly. The organization must repair it promptly before the system completely halts. However, this type of sudden

The Imperative of Preventive Maintenance in Indian Manufacturing Industries

In Indian manufacturing industries, the heartbeat of productivity lies in well-oiled machinery and seamless equipment maintenance. The Indian industrial landscape, marked by its diverse sectors and burgeoning growth, necessitates a robust approach to maintenance. Preventive maintenance ensures machinery’s longevity and optimal performance & efficiency in manufacturing industries. In this article delves into the significance of preventative care, its challenges, and the potential transformative impact it can have on the Indian manufacturing sector. Understanding Scheduled maintenance Routine maintenance involves regular inspection, detection, and correction of potential failures in equipment before they lead to downtime or disastrous breakdowns. Unlike reactive supervision, where repairs are conducted after machinery failure, preventive care aims to identify and rectify issues proactively. This approach reduces typically unexpected breakdowns, extends the lifespan of equipment, enhances safety, and improves the overall operational efficiency of machinery in the plant. The Current Landscape in Indian Manufacturing: India’s manufacturing sector is undergoing a paradigm shift, with a push towards Industry 4.0 and automation. However, this technological advancement also introduces a higher level of complexity in machinery, making it more susceptible to wear and tear. The traditional mindset of many industries, often characterized by a “run-to-failure” approach, poses challenges to adopting preventive maintenance

Predictive Maintenance in Indian Automobile Manufacturing Industries: A Double-Edged Sword

The Indian automobile manufacturing industry has witnessed remarkable growth in recent years. However, this surge in production comes with a host of challenges, particularly regarding maintenance. One revolutionary solution that has gained prominence is predictive maintenance. This article explores the importance, advantages, and disadvantages of predictive maintenance in the context of Indian automobile manufacturing. Importance of Fault prediction and diagnosis Minimizing Downtime: Downtime in an automobile manufacturing plant can lead to significant financial losses. Predictive maintenance helps in identifying potential equipment failures before they happen, allowing timely repairs and minimizing production downtime. Cost Savings: By accurately predicting maintenance needs, companies can reduce unnecessary maintenance tasks and lower overall maintenance costs. This optimization of resources can significantly impact the bottom line. Extended Equipment Lifespan: Predictive maintenance allows manufacturers to address issues before they become severe, thus extending the lifespan of expensive machinery. This reduces the need for frequent replacements, saving both money and resources. Improved Safety: Ensuring that machinery is in good working condition enhances workplace safety. Predictive maintenance helps identify potential safety hazards and allows for timely corrective actions. Advantages of Predictive asset management Cost Efficiency: Predictive maintenance optimizes maintenance schedules, reducing both labor and material costs. Companies only perform maintenance when

Contract Manufacturing: The Key to Profitability

Contract manufacturing is a business model where a company hires a third-party manufacturer, also known as a contract manufacturer, to produce goods on its behalf. It means that the company does not own and employ manufacturing personnel. Instead, it outsources the manufacturing to a specialized company with the required expertise and personnel.   In this arrangement, the company provides the contract manufacturer with product designs, specifications, and other relevant information necessary for production. The contract manufacturer is responsible for sourcing the raw materials, production, assembly, and testing of the finished products based on the specifications provided by the client company.   Various industries, like electronics, pharmaceuticals, food and beverage, consumer goods, etc., can use contract manufacturing. It can help companies to reduce capital investment, increase efficiency, and streamline their supply chain operations by outsourcing non-core activities to specialized manufacturers.   Contract manufacturing in the automobile industry refers to outsourcing the production of automotive components or entire vehicles to a third-party manufacturer. In India, contract manufacturing in the automobile industry has gained significant momentum in recent years, with many domestic and international companies opting for this business model.   One of the main reasons for the growth of contract manufacturing in

Unlock New Possibilities with FWF Model in Your Manufacturing Unit

Maximize Efficiency & Profitability with the Factory Within Factory Manufacturing Concept At SGK India Engineering Pvt Ltd, we specialize in Factory Within Factory (FWF) model in manufacturing units, providing innovative solutions tailored to our customer’s needs.  With years of experience in in-house and outsourced manufacturing strategies, we know how to maximize efficiency using the FWF model in the Production, Quality Control, and Maintenance fields.  Our Engineering team understands customers’ unique requirements and creates custom solutions that perfectly fit their business needs, ensuring quality.  At SGK India, we are passionate about Engineering to provide end-to-end solutions with value-added manufacturing technology. Our ‘Factory within Factory’ model offers a revolutionary concept for OEMs and Ancillaries Industries.    In this model, our customer uploads various activities with Process knowledge; our Team’s responsibility is to deliver output effectively with proper supervision with its expert team within client Premises using their Shop Floor with maintaining the SOP guidelines.  Let us Schedule an appointment to discuss how the FWF model will more effectively support your Industries.

Why Timely Maintenance Is More Important in Industrial Plants?

Timely maintenance of equipment is one of the best practices to improve the efficiency of the equipment in industrial plants. It reduces downtime and ensures production is lined up. It ensures that your employees are safe and that your products are in good condition for the customer. Let’s gather some knowledge about the types of plant maintenance, how to assess as well as implement plant maintenance, and finally what are its benefits. Types of Plant Maintenance Reactive Maintenance Reactive maintenance refers to repairing equipment when it has already broken down. That means, if it is not broken, don’t repair it in any way. This type of maintenance is suitable. It will save money and cost in the short run. However, it will cost you more in terms of efficiency loss and premature failure in the long run. Preventative Maintenance Preventive maintenance means carrying out regular maintenance activities to stop unexpected failures in the future. In other words, monitoring and fixing equipment before they break completely. Predictive Maintenance Predictive maintenance refers to a strategy that uses data analysis tools and techniques to detect the current operating condition of your equipment. And as per the equipment condition, a particular maintenance schedule is

How outsourced maintenance KPIs deliver in-house success

𝐊𝐏𝐈’𝐬 or “key performance indicators” form the basis of benchmarking the performance of Industrial assets like 𝐦𝐚𝐧𝐩𝐨𝐰𝐞𝐫, 𝐦𝐚𝐜𝐡𝐢𝐧𝐞𝐫𝐲, 𝐩𝐫𝐨𝐣𝐞𝐜𝐭𝐬 𝐚𝐧𝐝 𝐩𝐫𝐨𝐜𝐞𝐬𝐬𝐞𝐬 to achieve desired results within a stipulated time-frame. 𝐌𝐚𝐢𝐧𝐭𝐞𝐧𝐚𝐧𝐜𝐞 KPI’s are the key elements that lay down a structure for periodic quantitative evaluation and smooth functioning of these assets by eliminating or curtailing down-times and improving the overall performance. It is an integral part of the monitoring system which if not followed holistically then it may lead to untimely loss of such assets thereby hampering the revenue generation of any industry. Hence, it is always advisable to appoint a highly experienced and dedicated 𝐦𝐚𝐢𝐧𝐭𝐞𝐧𝐚𝐧𝐜𝐞 team for analyzing, structuring and monitoring the total compliance of maintenance processes across all types of Industrial assets for ensuring optimum productivity of these assets at all times. In this regard, 𝐦𝐚𝐢𝐧𝐭𝐞𝐧𝐚𝐧𝐜𝐞 𝐨𝐮𝐭𝐬𝐨𝐮𝐫𝐜𝐢𝐧𝐠 companies can be the most effective resource for entrusting such tasks as they carry both experience and expertise under one roof with total responsibility and accountability onus.

Why Should Companies More Prefer to SGK INDIA to Outsource Manufacturing Activities in the Automotive Industry nowadays?

Outsourcing is a kind of Business Practice of hiring a party outside a company to perform Services and Produce goods that primarily were performed by the In-House Staff. According to Larry Elder, ”Outsourcing and Globalization allow Companies to Minimize Costs, benefit consumers with Lower- Cost Goods and Services, Cause Economic expansion that Reduces Unemployment, and Increases Productivity and Job creation.” Outsourced Manufacturing Unit by SGK INDIA! What is it? Outsourced Manufacturing means, hiring SGK INDIA, will Take Care of Production Target, Maintain Rejection ratio & Quality of Products of your Business’. In this practice, the SGK INDIA takes the Entire Responsibility of the Operations & Maintenance Activities. Many companies in India from the Automotive Industries nowadays are planning to adopt this Practice for future Strategy to save time, energy, labour & finally costing. Presence of Outsourcing in the Automotive Industry Outsourcing has been with the automotive industry for a long time in foreign countries. Henry Ford, an American automobile manufacturer, was determined to present a simple, reliable, and affordable car to the average American worker. His dedication and determination finally brought the Model T and assembly line. These two innovations revolutionized the automotive industry. Henry Ford once said,” if there

Importance and Advantages of Hiring Manpower Agency

If you are suffering from manpower related problem or if you are thinking about cutting labour cost, then you should consider outsourcing a manpower agency so as to save your labour cost.Have you ever wondered why such a lot of organizations have already started outsourcing manpower agency? What are the advantages they are really obtaining from it? Do not go anywhere trying to find answers; we help you to gain insight on hiring manpower agency. Read On!  Here you will find the importance and advantages of hiring a manpower agency: Helps in hiring highly experienced and skilled employeesHiring a professional manpower agency gives direct access to skilled, dedicated and competent experts who can help your business grow drastically. Hire manpower agency to lessen cost on manpower:It is cheaper to hire offshore employees on local workers; it is so because on doing these employers don’t need to pay for insurance, health benefits, and various other bonuses. Hiring manpower agency help you reduce your burden associated with manpower supply. Manpower agency offers flexibility to focus on your business:Outsourcing manpower agency allows you to give more attention to other operations of your business thus rendering boost your workflow, lead time as well as

Monitoring maintenance quantitatively maintaining KPI’s

KPI’s or “key performance indicators” form the basis of benchmarking the performance of Industrial resources like manpower, machinery, projects and processes to achieve desired results within a stipulated time frame. Maintenance KPI’s are the key elements that lay down a structure for periodic quantitative evaluation and smooth functioning of critical mechanical resources by eliminating or curtailing downtimes and improving the overall performance. It is an integral part of the monitoring system which if not followed holistically, may lead to the untimely deterioration of such resources thereby hampering the production process of any industry. Hence, it is always advisable to appoint a highly experienced and dedicated maintenance team for analyzing, structuring and monitoring the total maintenance schedules across all types of mechanical assets for ensuring optimum productivity at all times. In this regard, outsourcing agencies can be the most effective resource for entrusting such tasks as they carry both experience and expertise under one roof with total responsibility and accountability to keep the machineries up and running in their optimum capacities.