Equipment Maintenance and Repairs

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Questions and Answers

What are the initial actions to take after an equipment breakdown?

Only fast repair of the malfunctioning equipment.

Fast repair and program development to eliminate causes of breakdowns. (correct)

Immediate replacement of the equipment with new machinery.

Development of a long-term replacement plan.

What is one disadvantage of allowing workers to perform their own machine repairs?

Improved machine care through operator training.

Increased flexibility in operations.

Possibility of inconsistent repair quality. (correct)

Faster minor repairs.

Why are predictive maintenance programs valuable?

They help extend the useful life of equipment. (correct)

They increase the chance of machinery breakdowns.

They eliminate the need for repairs entirely.

They decrease safety in the workplace.

What is included in the PM data base requirements for maintenance?

A detailed ongoing history of malfunctions and repair costs. Signup and view all the answers

What is a significant responsibility of workers in modern approaches to preventive maintenance?

Listening for indications of potential equipment malfunction. Signup and view all the answers

Which of the following is NOT an advantage of a preventive maintenance program?

Completely eliminating maintenance needs. Signup and view all the answers

What is a key decision in planning maintenance activities?

Determining the number of spare parts to carry. Signup and view all the answers

What approach should be taken when repairing malfunctioning equipment?

Perform thorough repairs and consider parts replacements. Signup and view all the answers

What is one of the primary objectives of maintenance management?

To minimize repair time and repair cost Signup and view all the answers

Which of the following impacts can result from poor maintenance management?

Decreased production capacity Signup and view all the answers

What is a key step in effective maintenance planning?

Establishing priorities Signup and view all the answers

What is one function of a maintenance department?

Developing effective communication strategies regarding maintenance activities Signup and view all the answers

Centralized maintenance departments operate from:

A separate office location Signup and view all the answers

Which of the following is NOT part of the objectives of maintenance management?

Maximizing inventory costs Signup and view all the answers

Which activity is essential for the preventive maintenance process?

Developing a schedule for regular maintenance tasks Signup and view all the answers

What is an outcome of effective maintenance management?

Increased operational efficiency Signup and view all the answers

What is one of the main advantages of centralized maintenance compared to decentralized maintenance?

Requires fewer maintenance personnel Signup and view all the answers

Which of the following is a disadvantage of centralized maintenance?

Requires more time to reach work areas Signup and view all the answers

During the maintenance management improvement process, what is the first step?

Identify existing deficiencies Signup and view all the answers

What should be included in the short-range maintenance plan?

Focus on high priority goals within a one-year period Signup and view all the answers

What is a key principle in establishing performance measurement parameters?

Develop a quantifiable measurement for each set goal Signup and view all the answers

What is a necessary action to take after implementing the maintenance plan?

Examine progress annually Signup and view all the answers

Which of the following reflects a common misconception about decentralized maintenance?

It is more efficient than centralized maintenance. Signup and view all the answers

What should the maintenance management team do periodically to communicate progress effectively?

Prepare a brief report semi-annually Signup and view all the answers

Study Notes

Breakdown Trigger Repairs and Corrective Actions

Equipment breakdowns should activate two actions:
- Fast repair of malfunctioning equipment
- Development of a program to eliminate the cause of the malfunction and prevent future repairs

Extent of Repairs

Perform just enough repairs to get equipment running again
Repair the malfunction and replace worn parts
Replace old equipment with new equipment

Advantages of Worker-Performed Machine Repairs

Increased flexibility
Faster minor repairs
Prevention of minor repairs through cleaning, lubrication, adjustments, and servicing machines
More careful operation of machines

Reasons for Preventive Maintenance (PM) Programs

Reduce frequency and severity of equipment malfunctions
Extend the useful life of equipment
Reduce total maintenance costs by substituting PM costs for repair costs
Ensure a safe working environment
Improve product quality by maintaining proper equipment adjustment

PM Database Requirements

Detailed records or ongoing history must be maintained for each machine
- Dates and frequency of breakdowns
- Descriptions of malfunctions
- Costs of repairs
Machine specifications/checklists for PM inspection
Computerized records can be kept in a plastic pocket on a machine

Modern Approaches to PM

Workers are responsible for preventing breakdowns by performing PM on their own machines
Workers should listen for indications of potential equipment malfunction
Workers should maintain maintenance-related records

Decision Analysis in PM

Determining the number of spare parts to carry for repairs
Determining how often to perform PM on groups of machines
Planning and controlling large-scale PM projects

Maintenance Management and Control

Maintenance management encompasses the control of maintenance activities and the establishment of maintenance policies
The importance of maintenance management increases with the size of the maintenance activity and group
Traditionally, maintenance groups comprise 5-10% of the operating force, but their proportion has increased significantly.

Maintenance and Maintenance Management Differences

Maintenance is the daily function of keeping industrial plants in working order, managed by production management
Maintenance management is concerned with planning, organizing, and directing maintenance efforts to control plant availability

Objectives of Maintenance Management

Minimize production downtime
Minimize time spent on repairs and associated costs
Minimize production downtime due to stoppages
Maintain effective use of maintenance personnel and equipment

Impact of Poor Maintenance Management

Reduced production capacity
Increased production costs
Reduced product and service quality
Diminished customer satisfaction

Maintenance Department Function and Organization

Maintenance departments plan and implement repairs to equipment/facilities that meet established standards
They develop preventive maintenance programs, perform work associated with repair operations, and maintain financial records to track material/personnel costs
Maintenance staff should be kept up to date with maintenance activities and procedures.
Staff should also be trained in safety and other related practices.

Types of Scheduling

Fixed scheduling: Problems of backlogs are common
Dynamic scheduling: Accounts for all practical constraints in all situations

Cost Reduction Through Maintenance Planning and Scheduling

Utilizing shutdown time for work repairs
Finalizing shutdown work plans well in advance
Planning work procedures for optimal effectiveness during shutdowns

Work Executed During Breakdowns

Minor maintenance tasks, such as cleaning and repair, are prioritized to minimize shutdown time
During major shutdowns, maximum maintenance tasks are performed so that they are completed

Minor Downtime Importance

Minor downtime periods can be used to perform tasks that cannot be done during normal operation; these are included in long-term plans to keep maintenance up to date with the equipment.

Importance of Maintenance Scheduling History

Reviewing repair histories for accurately estimating time, material, and expenses
Avoid using past budget figures during budget creation

Planning Shutdown Work

Thorough planning enables more work to be completed by fewer personnel

Maintenance Reliability and Probability

Reliability is the probability an item performs its intended function under specified conditions.
Reliability = Probability
Methods to improve reliability include better component design, improved production techniques, and improved testing procedures.

Non-Destructive Testing (NDT) Methods

A variety of NDT methods are used to inspect and diagnose issues without damaging the inspected object/item
- Acoustic Emission Testing (AET)
- Acoustic Resonance Testing (ART)
- Electromagnetic Testing (ET)
- Infrared Testing (IRT)
- Leak Testing (LT)
- Magnetic particle testing (MT)
- Dye penetrant testing (PT)
- Radiographic Testing (RT)
- Ultrasonic testing (UT)
- Visual testing (VT)

Common NDT Methods

Visual inspection
Dye penetrant inspection (DPI)
Magnetic particle inspection (MPI)
Ultrasonic testing (UT)
Radiography testing

Storage Tank Inspection

Robotics crawlers and cameras are used for wall and interior inspection, respectively

Aircraft Inspection

NDT is used throughout aircraft design and operation phases for routine maintenance and diagnostics

Jet Engine Inspection

Aircraft engines undergo periodic overhaul inspection and repair
Fluorescent penetrant inspection checks for cracks

Pressure Vessel Inspection

Radiography and ultrasonic tests are used to maintain pressure vessels for safety
NDT is critical in ensuring the integrity of pressure vessels

Rail Inspection

Specialized cars equipped with NDT equipment check for track cracks and ensure safety

Bridge Inspection

Visual inspections and NDT are performed on bridges every few years to detect and prevent potential safety issues

Pipeline Inspection

NDT helps prevent environment-damaging leaks in various pipeline infrastructure

Maintenance of Pumps

Friction is reduced through lubrication
Lubrication mechanisms such as hydrodynamic and boundary lubrication techniques are used to reduce friction costs.

Types of Lubricants

Liquid, solid, or gases

Typical Lubricants-Applications

Rust preventives
Heat transfer
Refrigeration
Rubber process oils
Ink process oils

Function of Lubricants

Lubricate- Reduces friction
Cooling- Heat transfer
Cleaning- Detergency
Noise Reduction- Preventing metal-to-metal contact
Sealing- Prevents high-pressure gas leakage
Protection- Against wear and tear

Additive Properties of Engine Oils

Corrosion/rust inhibitor
Anti-wear additives
Detergents
Dispersants
Friction modifiers

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Description

This quiz explores the importance of equipment maintenance practices, including breakdown repairs, preventive maintenance programs, and worker-performed machine repairs. Test your knowledge on how these strategies can enhance safety, reduce costs, and improve equipment efficiency.