I. General Provisions
1.1 Objective
Based on GB 17953-2013 Textile Machinery Safety Standards, these standards address loom breakdown issues causing daily downtime exceeding 2 hours, fabric quality fluctuations with defect rate increases of 1.2%, and excessive repair costs exceeding 3% of annual revenue. The target is to reduce failure rate below 5% and improve OEE to 85%.
1.2 Scope
Covers all production workshops including Weaving Workshop I and II, Equipment Management Department, and Quality Management Department. Applies to all shuttle looms and shuttleless looms (rapier, air-jet types). Special process equipment such as jacquard looms should reference these standards with additional specific provisions.
1.3 Core Principles
Prevention first, individual accountability, standardized specifications, continuous improvement.
II. Daily Maintenance Procedures
2.1 Pre-Shift Inspection (15 minutes before startup)
- Check environment around loom: floor free of oil stains and debris, passages clear, electrical wiring without exposure or damage
- Inspect critical areas: shuttle box free of accumulated lint and debris, heald frame movement smooth without jamming, warp tension adjuster pointer within standard range (±2mm)
- Check safety devices: emergency stop button sensitive and reliable, protective guards not loose or missing
2.2 In-Shift Patrol (hourly during operation)
- Monitor loom operational sounds: no abnormal knocking or friction sounds, main shaft bearing temperature not exceeding 70°C
- Check fabric quality: no regular defects such as thin/thick picks or broken weft, weft yarn supply continuous
- Record abnormalities: immediately stop machine upon finding faults, press emergency stop button, notify maintenance, document fault phenomenon and time of occurrence
2.3 Post-Shift Cleaning (30 minutes before end of shift)
- Clean loom surfaces: use soft brush to remove lint from machine top and sides, wipe oil stains with dry cloth
- Organize work area: return tools and parts to designated positions, sort waste materials into recycling bins
- Handover records: document equipment status, fault handling, and pending issues in handover logbook; successor operator signs confirmation
III. Periodic Maintenance
3.1 Weekly Maintenance (Friday afternoon, 2-hour shutdown)
- Mechanical: Check picking mechanism leather buffers and picking stick wear; replace if wear exceeds 5mm; check sley frame bolt tightness
- Lubrication: Apply lithium-based grease per Loom Lubrication Chart to 8 points including crank bearings and connecting rod bolts at 10-15g per point
- Electrical: Test main motor insulation resistance, minimum 10 MΩ; check limit switch contacts for oxidation or burning
3.2 Monthly Maintenance (last working day, 4-hour shutdown)
- Key component disassembly: Open shuttle box cover to check shuttle guide wear (replace if exceeding 1mm); check heald wire straightness (straighten or replace if error exceeds 0.5mm)
- Parameter calibration: Calibrate warp tension with tensiometer to 280-320 cN per end; adjust weft cutter position for consistent cutting length (±2mm)
- Deep cleaning: Clean internal dust accumulation, especially electrical control cabinets using compressed air; verify cooling fan operation
3.3 Quarterly Maintenance (end of quarter, 1-day shutdown)
- Comprehensive inspection: Measure main shaft radial runout (max 0.1mm); check clutch wear (replace friction plates if slipping)
- Wear parts replacement: Replace all drive V-belts if elongation exceeds 10%; replace weft detection sensors if sensitivity reduced
- Performance testing: Run loom unloaded for 30 minutes; verify coordinated mechanism movement; load test with standard fabric to confirm stable process parameters
IV. Fault Response
4.1 Minor Faults (downtime under 2 hours)
Maintenance staff process within 4 hours using Equipment Abnormality Feedback Form.
4.2 Major Faults (downtime 2 hours or more)
Activate green channel — workshop supervisor immediately reports, Equipment Department supervisor coordinates resources. Target 24-hour restoration.
4.3 Post-Repair Verification
Operator confirms equipment functionality is normal after repair. Maintenance staff complete Fault Repair Report including fault phenomenon, cause analysis, and recommended measures.
V. Performance Metrics
- Monthly Failure Rate: Not exceeding 5% of total operating hours
- OEE: Not below 85% (time utilization ≥ 90%, performance ≥ 95%, quality rate ≥ 98%)
- Maintenance Plan Completion: Monthly 100%, Weekly ≥ 98%
- Emergency Response: Within 10 minutes
- Annual Maintenance Cost: Not exceeding 8000 RMB per loom
