BAKERY PLANT MAINTENANCE MANAGEMENT SYSTEM
Bakery operations need a very good maintenance management system for efficient running of plant .
Maintenance activity needs regular monitoring and records to evaluate problems and their solution . Bakery
maintenance has its own features which need attention apart from regular maintenance practices .Break down
s lower production out put and have to be reduced to minimum .To achieve lower down time a robust
maintenance system with skilled manpower are required .
Major equipments in bakery are Mixers , Ovens , Packing machines , Air Compressors , Material Handling
equipments ,Fire Hydrant Systems , Bulk Handling systems ,Grinders ,Motors ,Gear Boxes , Fans , Screw
Conveyors , Gears and Chain, Burners and Sprockets .
A good maintenance system would have following elements of maintenance system in place
Manpower
A bakery plant would have an engineering head / plant manager / maintenance manager who is responsible
for all activity related to plant and machinery . Depending upon the size and hours of operation, factory
needs to have skilled technicians who would perform maintenance jobs . Planning and scheduling is done with
machine history .Idle time available for maintenance and requirement of machinery in accordance with
production planning .
Manpower requirement varies as per size of the plant . We can have
Three shift coverage - 8 hr Shift
Two shift coverage - 12 hr Shift
General shift coverage - 8/12 hrs
Each shift coverage needs to have Foreman , Fitters/technician( Elect/Mech ) and Helper s . Now days
concept of outsourcing of maintenance part are being implemented but this concept is yet to take ground as
factories still prefer to have their own maintenance personnel.
Tools
Maintenance work force requires all basic to advance tools to perform their job efficiently . I has been
observed few task which could have been done are executed by people from outside as the maintenance
team lack latest or basic tools to perform . Training for maintenance personnel by the machine manufacturers /
tool manufacturer should be included in factory hr programs .
Critical Spare Inventory
A small store to cater all critical and regular spares with a person responsible for monitoring
/inspection/liaising for stock out material /indent with purchase deptt is must for any medium to big bakery
plants .Concept of making spare available at work station or production hall are popular in many factories.
Predictive Maintenance
This methods utilises prior diagnosis of any aberration from ideal operations with help of sensing equipments
through Inspection .
Heat
Noise
Smell
Equipment used are Multimeter , Ultrasonic equipments , Vibration analyser , Decibel Meters ,Infra red
equipments .Now days PLC based systems are common hence system health can be checked through
various software .
Preventive Maintenance
This is the most common practice for plant maintenance as this is based on equipments life preventive
maintenance can be scheduled by number of hours or days such as weekly /monthly/half yearly/annually
Preventive maintenance is done with schedules in hand and could be planned and required spares could be
ordered as per plan .Preventive maintenance main activity can be divided into C-O-T
C -Cleaning of equipments .Very Important as majority of break downs happens due to lack of proper cleaning
O - Oiling or topping for gearboxes , chain and sprockets , moving parts , lubricating systems .
T -Tightening of all fastener which have loosened in operations or which could not be done in course of
production .
Normally for bakeries a day is fixed in a week for preventive maintenance . Maintenance jobs are listed in the
course of the week and all critical repair , replacement and modifications are done on preventive maintenance
alongwith regualr maintenance job ( COT )
Break Down Maintenance
Break Down maintenance requires immediate actions as to run the production with quick fix solution or what
ever best in that circumstances . Break down maintenance would need to be- re done when we take
preventive maintenance of the equipment. This may require certain by pass , modification and alternation from
basic set up.For such type of maintenance skill and level of experience of the technician comes into role
.Therefore training and seminars must be conducted to improve the analytical and trouble shooting skills of the
technicians .
Records or Log books
Maintenance log book should be filled or written by shift technicians on observations during break downs such
as action taken ,material repalced or repaired and job to be done by the next shift personnel . The log book
should be the basis of any major overhaul during preventive maintenance . Other important documents and
records which are to be maintained are
Checklist for equipments
Layout Diagram of Machinery
Operations and Maintenance Book from Manufacturers
Circuit Diagram
Cross Section Diagrams
Safety Precautions during maintenance
These also helps in root cause analysis of the problem
Circuits //layout / cross section diagrams along with Operation and Maintenance manual to be kept handy
and to ensure that they are available for study . This is very important for maintenance activity.
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