SM-034
Sewing Machine - Overlock (4-Thread)
Line: Line C
Floor: Floor 2
Status: Maintenance
Commissioned: Mar 2019
🚨
CRITICAL DOWNTIME RISK
This machine requires immediate attention. Thread tension spring is critically low. Estimated 2-3 days until potential failure. Production Line C will be impacted.
Machine Criticality
âš  HIGH
Core production machine
Downtime Impact
🔴 HIGH IMPACT
8 workers affected, ~250 units/day loss
Total Maintenance Cost
৳512,300
Lifetime (since Mar 2019)
Spare Parts Cost (YTD)
৳84,600
+18% vs last year
11,892
Operational Hours
94.2%
Uptime (Last 90 Days)
42
Maintenance Jobs (Total)

Machine Specifications

Manufacturer Juki Corporation
Model Number MO-6804S
Serial Number JK-2019-034-SM
Purchase Date March 15, 2019
Warranty Expiry March 14, 2022 (Expired)
Last Preventive Maintenance December 28, 2025
Next Scheduled PM February 28, 2026

Complete Maintenance History

Job ID Date Job Type Description Technician Duration Cost Status
WO-2026-0157 Jan 26, 2026 Corrective Thread tension issue, intermittent skip stitch Kamal Hossain Ongoing ৳3,200 In Progress
WO-2025-1243 Dec 28, 2025 Preventive Bi-monthly service - oil change, timing adjustment Rahim Khan 2.5 hrs ৳4,800 Completed
WO-2025-1156 Nov 14, 2025 Corrective Looper timing adjustment, thread breakage Kamal Hossain 3.2 hrs ৳5,600 Completed
WO-2025-0987 Oct 29, 2025 Preventive Bi-monthly service - cleaning, lubrication Rahim Khan 2.0 hrs ৳4,200 Completed
WO-2025-0823 Sep 18, 2025 Emergency Needle bar assembly replacement (broken) Sumon Das 4.5 hrs ৳18,400 Completed
WO-2025-0745 Aug 31, 2025 Preventive Bi-monthly service - general inspection Rahim Khan 1.8 hrs ৳3,900 Completed
WO-2025-0612 Jul 22, 2025 Corrective Feed dog mechanism adjustment Kamal Hossain 2.8 hrs ৳6,200 Completed
WO-2025-0534 Jun 28, 2025 Preventive Bi-monthly service - belt tension check Rahim Khan 2.2 hrs ৳4,500 Completed

Spare Parts Consumption History

Date Used Spare Part Name Part Code Quantity Batch Number Unit Cost Total Cost Job ID
Jan 26, 2026 Thread Tension Spring SP-TTS-JK 1 pc BTH-2026-0034 ৳850 ৳850 WO-2026-0157
Dec 28, 2025 Machine Oil (5L) SP-OIL-5L 2 ltr BTH-2025-1287 ৳450 ৳900 WO-2025-1243
Nov 14, 2025 Upper Looper SP-ULP-MO 1 pc BTH-2025-1089 ৳3,200 ৳3,200 WO-2025-1156
Nov 14, 2025 Thread Guide Assembly SP-TGA-JK 1 pc BTH-2025-1090 ৱ1,600 ৳1,600 WO-2025-1156
Oct 29, 2025 Cleaning Solution (500ml) SP-CLN-500 1 btl BTH-2025-0956 ৳180 ৳180 WO-2025-0987
Sep 18, 2025 Needle Bar Assembly SP-NBA-MO 1 pc BTH-2025-0823 ৳14,500 ৳14,500 WO-2025-0823
Sep 18, 2025 Needle Set (Size 14) SP-NDL-14 5 pcs BTH-2025-0824 ৳12 ৳60 WO-2025-0823
Aug 31, 2025 Machine Oil (5L) SP-OIL-5L 1.5 ltr BTH-2025-0745 ৳450 ৳675 WO-2025-0745
Jul 22, 2025 Feed Dog Mechanism SP-FDM-JK 1 pc BTH-2025-0612 ৳4,800 ৳4,800 WO-2025-0612
Jun 28, 2025 Drive Belt SP-DBT-MO 1 pc BTH-2025-0534 ৳2,400 ৳2,400 WO-2025-0534
âš 
IMMEDIATE ACTION REQUIRED
2 critical spare parts are below minimum stock levels. Machine downtime is imminent. Recommend emergency procurement and temporary production reallocation.

Critical Spare Parts Inventory Status

Spare Part Part Code Current Stock Minimum Required Stock Status Est. Days to Stockout Priority Action
Thread Tension Spring SP-TTS-JK 4 pcs 15 pcs
27% (Critical)
11 days HIGH Order Now →
Rotary Hook Assembly SP-RHA-MO 1 pc 5 pcs
20% (Critical)
18 days HIGH Order Now →
Upper Looper SP-ULP-MO 3 pcs 8 pcs
38% (Low)
35 days MEDIUM Schedule Order →
Needle Bar Assembly SP-NBA-MO 4 pcs 6 pcs
67% (Low)
56 days MEDIUM Schedule Order →
Feed Dog Mechanism SP-FDM-JK 7 pcs 10 pcs
70% (Monitor)
78 days LOW Monitor →
Thread Guide Assembly SP-TGA-JK 12 pcs 15 pcs
80% (Normal)
124 days LOW Monitor →
Drive Belt SP-DBT-MO 8 pcs 8 pcs
100% (Normal)
146 days LOW Monitor →
Needle Set (Size 14) SP-NDL-14 145 pcs 100 pcs
145% (Normal)
180+ days LOW Monitor →

Risk Mitigation Recommendations

Immediate Actions (Next 48 Hours):
  • Initiate emergency purchase order for Thread Tension Spring (SP-TTS-JK)
  • Initiate emergency purchase order for Rotary Hook Assembly (SP-RHA-MO)
  • Transfer production load from Line C to backup capacity on Line A/B
  • Schedule backup machine SM-002 for activation if SM-034 fails
Short-term Planning (Next 7-14 Days):
  • Schedule regular purchase order for Upper Looper and Needle Bar Assembly
  • Review spare parts consumption pattern for this machine type
  • Adjust reorder points based on recent consumption trends (+18% YoY)
  • Consider preventive replacement of high-wear components during next PM