ACKNOWLEDGEMENT

Assalamualaikum Warahmatullahhiwabarakatuh. First of all, i would like to thank to Allah S.W.T. most Gracious and most Merciful, for giving me strength and ability to prepare and finished this assignment. I would also like to thank to my course lecturer, Madam Mastura Bin Omar who help me to understand about this assignment. Besides that, i would also like to deliver my gratitude to my beloved classmates that were also try the best in helping me in certain things. The information and knowledge regarding to this course that they had given us was really helped and useful. Last but not least to those people who were helping us either directly or indirectly in fulfilled the particular task. Their useful information and experiences in the printing field had showing us the right way to do job in printing industry. On the 31th may 2011, Madam Mastura have given a different assignment to each student in the class AD1206A / B. The assignment that i get is about maintenance in management. I need to explain about the importance of maintenance and the mechanisms that been used in the process.

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1. MANAGEMENT
Management can be defined as a work of art to implement the planned and implemented in a systematic, organized have certain guidelines. The verb manage comes from the Italian maneggiare (to handle: especially tools), which in turn derives from the Latin manus (hand). The French word mesnagement (later mnagement) influenced the development in meaning of the English word management in the 17th and 18th centuries. Referring from the Wikipedia Free Encyclopedias, management consists of directing and controlling a group of one persons or more persons or entities for the purpose of coordinating and harmonizing the group to achieve a goal. It also includes resources-human resources, finance, technology and natural resources as well. Management can also refer to a person or group of persons who exercise managerial functions.

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2. MAINTENANCE MANAGEMENT
Maintenance management is a business concept that describes the successful and efficient management of maintenance issues involved in the upkeep, operation and productivity of a factory, manufacturing facility or plant. A maintenance manager's goal is to increase productivity and profits through improved operations. The major areas of maintenance management focus include fleet or vehicle maintenance, production operations, ecological concerns, inventory control, quality assurance and outsourcing options.

Maintaining a company on a prescribed schedule is important. Following preventive maintenance guidelines and keeping warranties up to date are generally good practices. Adhering to these schedules can save a company money in repair costs and improve the overall safety of the fleet crew.

Production operations can frequently be improved and become more profitable if they are outsourced. Fair and careful review of material and labor costs can be advantageous. Determining if labor can be more efficiently allocated to different departments can often eliminate the need for increased staffing.

Maintenance managers often are involved in regular reviews and discussions of ecological and environmental topics regulated by governing agencies. As guidelines change, it is generally more profitable to be prepared for what the next level of rules will likely require for compliance. Maintaining a safe, clean and healthy work environment normally facilitates the implementation of environmental improvements.

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2.1 IMPORTANCE OF MAINTENANCE

Maintenance is an important factor in quality assurance, which is another basis for the successful competitive edge. Inconsistencies in equipments lead to variability in product characteristics and result in defective parts that fail to meet the established specifications. Beyond just preventing break downs, it is necessary to keep equipments operating within specifications (i.e. process capability) that will produce high level of quality.

Good maintenance management is important for the company cost control. As companies go in for automation to become more competitive, they increasingly rely on equipments to produce a greater percentage of their output. It becomes more important that, equipments operate reliably within specifications. The cost of idle time is higher as equipment becomes more high-tech and expensive e.g. NC/CNC machines and robots.

Dependability of service is one of the performance measures by which a company can distinguish itself from others. To establish a competitive edge and to provide good customer service, companies must have reliable equipments that will respond to customer demands when needed. Equipments must be kept in reliable condition without costly work stoppage and down time due to repairs, if the company is to remain productive and competitive.

Many manufacturing organizations, particularly those with JIT (Just-In-Time) programs are operating with inventories so low that, they offer no protection in the event of a lengthy equipment failure. Beyond the cost of idle equipment, idle labor, and lost ales that can result from a breakdown, there is a danger of permanently losing market shares to companies that are more reliable. Maintenance function can help prevent such as occurrence.

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2.1.1 Impact of Poor Maintenance Maintenance operations include all efforts to keep production facilities and equipments in an acceptable operating condition. Failure or ml-functioning of machines and equipments in manufacturing and service industries have a direct impact on the following:

Production capacity:

Machines idled by breakdowns cannot produce, thus the capacity of the system is reduced.

2.1.2 Production costs: Labor costs per unit rise because of idle labor due to machine breakdowns. When machine malfunctions result in scrap, unit labor and material costs increase. Besides, cost of maintenance which includes such costs as costs of providing repair facilities, repair crews, preventive maintenance inspections, spare parts and stand by machines will increase as machines break down frequently.

2.1.3 Product and service quality: Poorly maintained equipments produce low quality products. Equipments that have not been properly maintained have frequent break downs and cannot provide adequate service to customers.

2.1.4 Employee or customer safety: Worn-out equipment is likely to fail at any moment and these failures can cause injuries to the workers, working on those equipments. Products such as two wheelers and automobiles, if not serviced periodically, can break down suddenly and cause injuries to the stress.

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2.1.5 Customer satisfaction: When production equipments break own, products often can not be produced according to the master production schedules, due to work stoppages. This will lead to delayed deliveries of products to the customers.

2.1.6 OBJECTIVE OF MAINTENANCE MANAGEMENT The following are some of the objectives of maintenance management:

I. Minimizing the loss of productive time because of equipment failure (i.e. minimizing idle time of equipment due to break down). II. Minimizing the repair time and repair cost.

III. Minimizing the loss due to production stoppages.

IV. Efficient use of maintenance personnel and equipments.

V. Prolonging the life of capital assets by minimizing the rate of wear and tear.

VI. To keep all productive assets in good working conditions.

VII. To maximize efficiency and economy in production through optimum use of facilities.

VIII. To minimize accidents through regular inspection and repair of safety devices.

IX. To minimize the total maintenance cost which includes the cost of repair, cost of preventive maintenance and inventory carrying costs, due to spare parts inventory.

X. To improve the quality of products and to improve productivity.

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3. MAINTENANCE ON PRESS
Everyone have to choose one machine. We have to tell all about the machine maintenance. I choose Speedmaster SM 74. I will tell all about: 3.1 Maintenance on Printing Unit 3.2 Maintenance on The Entire Press 3.3 Maintenance by Service Technicians

Maintenance In Management

3.1 Maintenance on Printing Unit

3.1.1 Printing unit - safety instructions a. To be observed when working at the press 1. Warning - Risk of injury! When you perform maintenance work, observe all notes on safety contained in the operating manual. 2. Warning - Risk of injury from rotating rollers and cylinders! When cleaning the rollers and cylinders, the ball of your hand must face the in feed nip, and your fingers must be directed toward the outlet nip. Select the corresponding direction of rotation. 3. Warning - Risk of explosion and fire due to dust deposits! Dust, such as powder or paper dust, can pose a risk of fire or explosion. You should therefore clean the areas affected by dust regularly, at least once a week, using a vacuum cleaner. Only use suitable and approved industrial vacuum cleaners and avoid working with compressed air, as this could swirl up the dust.

b.

Washing fluid container 1. Warning - Risk of explosion from evaporating solvent! Fill the washing fluid container carefully and only with approved cleaning agents. Do not overfill the washing fluid container. Keep sources of heat away from the washing fluid container. Dispose of any leaked substances immediately and in the correct manner.

Maintenance In Management

2. Warning - Risk of injury from cleaning agents escaping! The washing fluid container is under pressure. This pressure can lead to washing fluid being sprayed out of the container. Close the compressed air supply hose and deaerate the washing fluid container before opening the lid.

c.

Blanket cylinder and plate cylinder 1. Warning - Risk of injury from rotating rollers and cylinders! Use the gap cover of the blanket cylinder and/or plate cylinder to avoid injuries.

d.

Inking unit 1. Warning - Risk of injury from rotating ink fountain roller! Be careful with the rotating ink fountain roller when working on the ink fountain when it is engaged or swung down. Clean the swung-down ink fountain only when the ink fountain roller is at standstill.

e.

Numbering device 1. Warning - Risk of injury from rotating rollers and cylinders! Only operate the numbering inking unit with the wash up tray in place. The wash up tray prevents access to the rollers.

Maintenance In Management

3.1.2 Maintenance points on the printing unit

Maintenance point on printing unit List of maintenance point :1. 2. 3. 4. 5. 6. 7. 8. 9. Maintenance points on the sheet alignment system Maintenance points on the transfer gripper Maintenance points on the feed cylinder Maintenance points on the impression control mechanism Maintenance points on the impression cylinder Maintenance points on the plate cylinder Maintenance points on the plate clamping device Maintenance points on the dampening system Maintenance points on the transfer cylinder I

10. Maintenance points on the transfer drum 11. Maintenance points on the transfer cylinder III 12. Maintenance points on the storage drum 13. Maintenance points on the reversing drum 14. Maintenance points on the impression cylinder(P) 15. Maintenance points on the perfector 10 Maintenance In Management

3.2 Maintenance on The Entire Press

Maintenance point on entire press

1. 2. 3. 4. 5.

Maintenance points on the central oil lubrication system Maintenance points on the control cabinet of the SinuSynchro main driving motor Maintenance points on the Prinect Press Center Maintenance points on the Prinect Axis Control Maintenance points on the Wall screen

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3.3 Maintenance by Service Technicians 3.3.1 Maintenance activities on the feeder with service support

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3.3.2 Maintenance work on the printing unit with service support

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3.3.3 Maintenance work on the coating unit with service support

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3.3.4 Maintenance activities on the standard delivery with service support

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3.3.5 Maintenance activities on the high-pile delivery with service support

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3.3.6 Maintenance work on the entire press with service support

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CONCLUSION
Based on this assignment, i had known how important maintenance management in printing industry. Not only to prevent breakdown, it is necessary to keep equipments operating within specifications (i.e. process capability) that will produce high level of quality. Good maintenance
management is important for the company cost control. As companies go in for automation to become more competitive, they increasingly rely on equipments to produce a greater percentage of their output.

The importance of an effective maintenance program cannot be overlooked because it plays such an important role in the effectiveness of Lean manufacturing. As in personal health care insurance, maintenance may be considered the heath care of our manufacturing machines and equipment. It is required to effectively reduce waste and run an efficient, continuous manufacturing operation, business, or service operation. The cost of regular maintenance is very small when it is compared to the cost of a major breakdown at which time there is no production.

REFERENCES
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Website: 1. http://www.citeman.com/1137-importance-and-objective-of-maintenance-management/
(6.00pm, 5.6.2011). 2. http://lnu.diva-portal.org/smash/record.jsf?pid=diva2:205726 (6.30 pm, 5.6.2011) 3. http://www.wisegeek.com/what-is-maintenance-management.htm (4.30 am, 10.6.2011)

Book: 1. Speedmaster SM 74 : Maintenance and cleaning manual book, HEIDELBERG. 2. Maintenance impact on companys profitability and competitiveness by Hamid Al-najjar,

2007. 3. PRT 369 notes.

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