Maintenance Concepts
196 Questions
0 Views

Choose a study mode

Play Quiz
Study Flashcards
Spaced Repetition
Chat to lesson

Podcast

Play an AI-generated podcast conversation about this lesson

Questions and Answers

What is the primary goal of Preventive Maintenance (PM)?

  • To increase machinery production
  • To minimize the occurrence of unexpected failures (correct)
  • To reduce maintenance personnel
  • To repair broken machinery

    • What is an example of a Planned maintenance activity?

  • Implementing regular inspections to machinery (correct)
  • Reducing maintenance personnel
  • Repairing a broken machine
  • Increasing machinery production

    • What is Predictive Maintenance (PDM) used for?

  • To plan for maintenance operations during regular shut-downs (correct)
  • To increase machinery production
  • To reduce maintenance costs
  • To predict when a machine will break down

    • What is a benefit of maintaining a well-organised history of machinery performance?

    <p>To improve maintenance scheduling</p> Signup and view all the answers

    Why is it important to collect oil samples from machinery?

    <p>To identify when the next oil change is due</p> Signup and view all the answers

    What is the purpose of vibration condition monitoring systems?

    <p>To raise alarms of imminent part failure</p> Signup and view all the answers

    What is an example of an ongoing service in Preventive Maintenance?

    <p>Lubrication</p> Signup and view all the answers

    How often should blades be inspected for integrity according to the maintenance crew?

    <p>Every three months</p> Signup and view all the answers

    What is a characteristic of Corrective Maintenance (CM)?

    <p>It involves repairs after the event of failure.</p> Signup and view all the answers

    What is a benefit of implementing Preventive Maintenance (PM) and Predictive Maintenance (PDM)?

    <p>It reduces the number of corrective maintenance operations needed.</p> Signup and view all the answers

    What is an example of a Preventive Maintenance (PM) schedule?

    <p>Scheduling a routine sump oil and filter change every 6 months.</p> Signup and view all the answers

    What is a goal of maintenance planning?

    <p>Avoid interruptions to machinery or processes.</p> Signup and view all the answers

    What is a benefit of planned maintenance?

    <p>It minimizes damage to infrastructure/equipment.</p> Signup and view all the answers

    What is a characteristic of a Preventive Maintenance (PM) approach?

    <p>It applies maintenance at a scheduled interval.</p> Signup and view all the answers

    Why is planned maintenance important?

    <p>All of the above.</p> Signup and view all the answers

    What is a benefit of scheduling maintenance during regular shut-down periods?

    <p>It avoids interruptions to machinery or processes.</p> Signup and view all the answers

    What is the definition of failure in maintenance?

    <p>Any deviation or change in a product or system from its satisfactory working condition to a condition that is below the acceptable or set operating standards for the system</p> Signup and view all the answers

    What are the two cost components of maintenance?

    <p>Labour and material costs, and lost production capacity</p> Signup and view all the answers

    What is the goal of an effective maintenance programme?

    <p>To eliminate or minimise failures</p> Signup and view all the answers

    What is a consequence of automation and increases in system complexity in maintenance?

    <p>An increase in the need for advanced maintenance techniques</p> Signup and view all the answers

    What can the consequences of system or piece of equipment failing provide?

    <p>Valuable insights into what type and level of maintenance activities should be applied</p> Signup and view all the answers

    What is the primary goal of maintenance planning?

    <p>To ensure that maintenance activities are performed at the right time</p> Signup and view all the answers

    What is the purpose of computerized maintenance management systems?

    <p>To make maintenance planning and scheduling more efficient</p> Signup and view all the answers

    What is the benefit of real-time/online monitoring in maintenance?

    <p>It allows for quick response to failures and minimizes downtime</p> Signup and view all the answers

    What is an example of a minor preventive maintenance activity?

    <p>Bolt tightening</p> Signup and view all the answers

    Which of the following is NOT a major preventive maintenance activity?

    <p>Routine inspections</p> Signup and view all the answers

    What is a benefit of performing routine preventive maintenance?

    <p>Reducing equipment downtime</p> Signup and view all the answers

    What is an example of a major overhaul preventive maintenance activity?

    <p>Machine overhauls</p> Signup and view all the answers

    Why is equipment modification/upgrade considered a major preventive maintenance activity?

    <p>It may involve equipment maker/supplier</p> Signup and view all the answers

    What is the primary focus of preventive maintenance planning?

    <p>Preventing equipment failures</p> Signup and view all the answers

    What is essential for establishing routine cycles of PM activities?

    <p>Historical data of equipment maintenance</p> Signup and view all the answers

    What is an example of a routine inspection in Preventive Maintenance?

    <p>Monitoring equipment condition using sensors</p> Signup and view all the answers

    What is a minor repair in Preventive Maintenance?

    <p>Replacing a faulty machine part</p> Signup and view all the answers

    What is the purpose of collecting historical data of equipment maintenance?

    <p>To establish routine cycles of PM activities</p> Signup and view all the answers

    What is an example of a major overhaul in Preventive Maintenance?

    <p>Making major changes to equipment design</p> Signup and view all the answers

    Why is equipment modification necessary in Preventive Maintenance?

    <p>To improve equipment functionality</p> Signup and view all the answers

    What is a primary focus of routine maintenance activities?

    <p>Cleaning, degreasing, and debris removal</p> Signup and view all the answers

    What is a typical example of a routine PM activity?

    <p>Inspections and sensing of faulty parts</p> Signup and view all the answers

    What may be included in minor repairs and adjustments?

    <p>An array of activities not already listed</p> Signup and view all the answers

    What is a benefit of cleaning and lubrication in routine maintenance?

    <p>Reducing mechanical wear and tear</p> Signup and view all the answers

    What is an indirect benefit of cleaning and lubrication in routine maintenance?

    <p>More familiarity with equipment function</p> Signup and view all the answers

    What is a typical outcome of routine maintenance activities?

    <p>Reduced mechanical wear and tear</p> Signup and view all the answers

    What is the primary purpose of pH monitoring in predictive maintenance?

    <p>To establish acidity or alkalinity levels in machine oils and lubricants</p> Signup and view all the answers

    What is the focus of tribological analyses in predictive maintenance?

    <p>To analyze the effects of friction on material degradation</p> Signup and view all the answers

    Why is periodic pH monitoring important in predictive maintenance?

    <p>To identify potential lubricant deterioration</p> Signup and view all the answers

    What is the benefit of using pH monitoring in predictive maintenance?

    <p>To identify potential issues with machine oils and lubricants</p> Signup and view all the answers

    What is the role of OEM specifications in pH monitoring?

    <p>To specify pH levels for machine oils and lubricants</p> Signup and view all the answers

    What is the consequence of ignoring changes in pH levels in machine oils and lubricants?

    <p>Broken machine gaskets, seals, and lubricant deterioration</p> Signup and view all the answers

    What is the primary goal of tribological analyses in predictive maintenance?

    <p>To clarify the effects of surface friction on material degradation</p> Signup and view all the answers

    Why is pH monitoring essential in predictive maintenance?

    <p>To detect potential issues with machine oils and lubricants</p> Signup and view all the answers

    What is the primary difference between Predictive Maintenance and other maintenance approaches?

    <p>It is a forecasting approach</p> Signup and view all the answers

    What is a major cost associated with implementing Predictive Maintenance?

    <p>Higher cost of instrumentation and data analysis</p> Signup and view all the answers

    What is the term used to describe Predictive Maintenance?

    <p>Condition-Based Maintenance</p> Signup and view all the answers

    What is the goal of Predictive Maintenance?

    <p>To predict when maintenance is required</p> Signup and view all the answers

    What is a key characteristic of Predictive Maintenance?

    <p>It is a proactive approach</p> Signup and view all the answers

    What is a benefit of using Predictive Maintenance?

    <p>It reduces the cost of maintenance</p> Signup and view all the answers

    What is the primary objective of Predictive Maintenance?

    <p>To predict system or component failures</p> Signup and view all the answers

    What is a characteristic of Predictive Maintenance?

    <p>It is a complex approach to maintenance</p> Signup and view all the answers

    Which of the following is a fundamental approach to industrial maintenance?

    <p>All of the above</p> Signup and view all the answers

    What is a key aspect of Predictive Maintenance?

    <p>Measuring and monitoring system and component operating characteristics</p> Signup and view all the answers

    What is the relationship between the level of complexity and direct cost of the three fundamental approaches to industrial maintenance?

    <p>Higher complexity leads to higher direct cost</p> Signup and view all the answers

    Which of the following is NOT a characteristic of Predictive Maintenance?

    <p>It is a reactive approach to maintenance</p> Signup and view all the answers

    What is the formula to calculate R, the length of operating hours?

    <p>R = 1 - λ</p> Signup and view all the answers

    What is MTTF short for?

    <p>Mean Time To Failure</p> Signup and view all the answers

    What is the approximate MTBF in hours?

    <p>142.85 hrs</p> Signup and view all the answers

    What is the definition of λ?

    <p>Failure rate</p> Signup and view all the answers

    What is the purpose of MTTF?

    <p>To determine the reliability of disposable items</p> Signup and view all the answers

    What is the formula to calculate λ, the failure rate?

    <p>λ = 3 / (15 + 35 + 60 + 4 × 80)</p> Signup and view all the answers

    What is the importance of considering wear-out failures when calculating Mean Time Between Failures (MTBF)?

    <p>It avoids inaccurate oversimplification of MTBF</p> Signup and view all the answers

    What is a characteristic of Mean Time Between Failures (MTBF) when wear-out failures occur?

    <p>It varies with time</p> Signup and view all the answers

    In the example of the 10 batteries applied to generator sets, what happened during the first 24 months?

    <p>No batteries failed</p> Signup and view all the answers

    What does the example of the 10 batteries applied to generator sets illustrate?

    <p>No failure during a certain period</p> Signup and view all the answers

    Why is it important to consider the time dependence of failure rates?

    <p>To calculate MTBF accurately</p> Signup and view all the answers

    What is the implication of not considering wear-out failures when calculating MTBF?

    <p>MTBF values become less accurate</p> Signup and view all the answers

    What is the consequence of calculating MTBF during a period of wear-out failures?

    <p>MTBF becomes less accurate</p> Signup and view all the answers

    What is the importance of considering the time dependence of failure rates in maintenance?

    <p>To ensure accurate MTBF calculation</p> Signup and view all the answers

    What does Mean Down Time (MDT) equate to for non-repairable items?

    <p>Life expectancy of the equipment</p> Signup and view all the answers

    What is the formula for Availability?

    <p>MTBF / (MTBF + MDT)</p> Signup and view all the answers

    What is the typical trend of failure rate during the lifetime of equipment?

    <p>Bath-tub curve</p> Signup and view all the answers

    What contributes to the length of Mean Down Time (MDT)?

    <p>Time needed to issue the work order and arrival of maintenance crew</p> Signup and view all the answers

    What is the purpose of tracking equipment life time?

    <p>To schedule maintenance activities</p> Signup and view all the answers

    What is a key aspect of maintenance operational time management?

    <p>Minimizing equipment downtime</p> Signup and view all the answers

    What is the purpose of Failure Mode and Effect Analysis (FMEA)?

    <p>To identify potential failures in equipment or a process.</p> Signup and view all the answers

    What is a key principle of Implementing Total Productive Maintenance (TPM)?

    <p>Reducing breakdowns and improving productivity.</p> Signup and view all the answers

    What is the focus of the 'Autonomous Maintenance' pillar of TPM?

    <p>Operator-led maintenance activities.</p> Signup and view all the answers

    Which of the following is a benefit of implementing Total Productive Maintenance (TPM)?

    <p>Improved equipment reliability and productivity.</p> Signup and view all the answers

    What is the primary goal of Root Cause Analysis (RCA) in maintenance?

    <p>To identify and eliminate the underlying causes of failure.</p> Signup and view all the answers

    What is a key aspect of the 'Focused Improvement' pillar of TPM?

    <p>Implementing continuous improvement initiatives.</p> Signup and view all the answers

    What is the purpose of assessing current equipment conditions in Total Productive Maintenance (TPM)?

    <p>To determine equipment effectiveness</p> Signup and view all the answers

    What is the primary focus of equipment improvement in TPM?

    <p>To enhance equipment capabilities</p> Signup and view all the answers

    What is a characteristic of equipment in excellent condition in TPM?

    <p>Perfect condition, excellent capabilities, and no breakdowns</p> Signup and view all the answers

    What is the primary goal of implementing TPM?

    <p>To improve overall equipment effectiveness</p> Signup and view all the answers

    What is the purpose of implementing a maintenance program in TPM?

    <p>To improve equipment reliability</p> Signup and view all the answers

    What is a key aspect of the 'Good' category in TPM equipment assessment?

    <p>Very little scrap and all PM done</p> Signup and view all the answers

    What is the primary benefit of implementing TPM?

    <p>Increased equipment effectiveness</p> Signup and view all the answers

    What is a characteristic of equipment in 'Not' category in TPM equipment assessment?

    <p>Limited capability and average scrap rate</p> Signup and view all the answers

    What is the purpose of the Occurrence (OCC) ranking in a Service FMEA?

    <p>To provide information about the expected frequency of each failure</p> Signup and view all the answers

    What is calculated by multiplying the Occurrence, Severity, and Detection rankings in a Service FMEA?

    <p>Risk Priority Number (RPN)</p> Signup and view all the answers

    What is the purpose of the recommended action(s) in a Service FMEA?

    <p>To reduce or eliminate potential failures and consequences</p> Signup and view all the answers

    What information is provided in the 'Action taken' section of a Service FMEA?

    <p>The date of action taken to eliminate/reduce potential failures</p> Signup and view all the answers

    What is the primary goal of Implementing TPM?

    <p>To reduce maintenance costs and increase equipment availability</p> Signup and view all the answers

    What is a key aspect of the 'Operator Involvement' pillar of TPM?

    <p>Autonomous maintenance by operators</p> Signup and view all the answers

    What is the primary focus of the 'Maintenance Process Improvement' pillar of TPM?

    <p>Improving equipment reliability and reducing downtime</p> Signup and view all the answers

    What is the purpose of the Five Pillars of TPM?

    <p>To provide a framework for implementing Total Productive Maintenance (TPM)</p> Signup and view all the answers

    What is the frequency of PM activities required to achieve a reliability level of 95%?

    <p>Every 8 hours</p> Signup and view all the answers

    What is the annual cost of the PM program if each activity costs $120?

    <p>$36,000</p> Signup and view all the answers

    What is the purpose of calculating the cost of the PM program?

    <p>To justify the investment in the PM program</p> Signup and view all the answers

    What is the outcome of not achieving the desired reliability level of 95%?

    <p>Increased equipment downtime</p> Signup and view all the answers

    What is the goal of optimizing a maintenance program?

    <p>To improve equipment reliability</p> Signup and view all the answers

    What is the relationship between the frequency of PM activities and the desired reliability level?

    <p>As the frequency of PM activities increases, the desired reliability level increases</p> Signup and view all the answers

    What is the purpose of calculating the number of PM activities per year?

    <p>To determine the cost of the PM program</p> Signup and view all the answers

    What is the consequence of not performing PM activities frequently enough?

    <p>Increased equipment downtime</p> Signup and view all the answers

    What is the primary goal of reducing equipment breakdowns through effective PM activity?

    <p>To reduce the cost of corrective maintenance</p> Signup and view all the answers

    What is a potential benefit of justifying the costs associated with a PM programme?

    <p>Optimizing the maintenance programme</p> Signup and view all the answers

    What is the total cost incurred by the company if a breakdown occurs despite the PM program?

    <p>$750</p> Signup and view all the answers

    What is an example of a cost that can be reduced through effective PM activity?

    <p>The cost of corrective maintenance</p> Signup and view all the answers

    What is the monthly cost associated with the new PM program?

    <p>$900</p> Signup and view all the answers

    What is the primary objective of the PM program?

    <p>To reduce the probability of having breakdowns</p> Signup and view all the answers

    What is a characteristic of a well-organized maintenance programme?

    <p>Well-documented service history</p> Signup and view all the answers

    What is a potential outcome of reducing equipment downtime through effective PM activity?

    <p>Optimized maintenance programme</p> Signup and view all the answers

    What can be inferred about the effectiveness of the PM program?

    <p>It has significantly reduced the occurrence of breakdowns</p> Signup and view all the answers

    What is a benefit of implementing a PM programme?

    <p>Reduced equipment downtime</p> Signup and view all the answers

    What additional information is required to decide whether to continue the PM program?

    <p>The total cost of breakdowns over 12 months</p> Signup and view all the answers

    What is the benefit of continuing the PM program despite the occasional breakdown?

    <p>It reduces the total maintenance cost</p> Signup and view all the answers

    What is a potential benefit of optimizing the maintenance programme?

    <p>Reduced equipment downtime</p> Signup and view all the answers

    What is a cost justification method for a PM programme?

    <p>Comparing the cost of PM activities to the cost of corrective maintenance</p> Signup and view all the answers

    What is a precaution to take when working with lubricants and other substances like machining/cutting oils?

    <p>Minimise skin contact through appropriate work methods and equipment</p> Signup and view all the answers

    What should be avoided when handling lubricants?

    <p>Skin contact with concentrates</p> Signup and view all the answers

    What is a consideration when disposing of lubricants?

    <p>Disposal should be governed by relevant industry practice and local regulations</p> Signup and view all the answers

    Why is it important to minimising skin contact when working with lubricants?

    <p>Most petroleum products are natural skin degreasing agents</p> Signup and view all the answers

    What is a recommended practice when handling oily substances?

    <p>Dispose of wipes after application</p> Signup and view all the answers

    What should be applied as per recommended dilutions?

    <p>Both soluble oils and synthetic fluids</p> Signup and view all the answers

    Why is it important to follow recommended dilutions when applying lubricants?

    <p>To ensure the lubricant is effective</p> Signup and view all the answers

    What is a consequence of prolonged and repeated contact with petroleum products in poor conditions of personal hygiene?

    <p>Various skin disorders</p> Signup and view all the answers

    What happens to mineral oils at high temperatures?

    <p>They thin out</p> Signup and view all the answers

    What is the role of additives in lubricating systems?

    <p>To form a protective layer on ferrous surfaces</p> Signup and view all the answers

    What is the result of oils undergoing chemical degradation when exposed to oxygen?

    <p>They react with oxygen to form bubbles</p> Signup and view all the answers

    What is the primary reason why lubricating systems are more likely to experience problems during start-ups?

    <p>Air and moisture accumulation</p> Signup and view all the answers

    What is the result of sludge forming in combustion engines?

    <p>Increased corrosion</p> Signup and view all the answers

    What is the purpose of additives in hydraulic oils?

    <p>To form a protective layer on surfaces</p> Signup and view all the answers

    What is the primary benefit of using additives in lubricating systems?

    <p>Improved corrosion protection</p> Signup and view all the answers

    What is the result of temperature changes on the viscosity of lubricating oils?

    <p>The viscosity decreases with temperature</p> Signup and view all the answers

    What is the primary function of viscosity in a lubricant?

    <p>To reduce friction</p> Signup and view all the answers

    What is the purpose of additives in lubricants?

    <p>To meet special functions</p> Signup and view all the answers

    What is a characteristic of a lubricant that is physically and chemically stable?

    <p>It won't break down under normal operating conditions</p> Signup and view all the answers

    What is a consequence of localized welding at points on a lubricated joint?

    <p>Joint seizure and cessation of motion</p> Signup and view all the answers

    What is the primary function of lubrication in reducing wear?

    <p>To reduce friction and prevent localized welding</p> Signup and view all the answers

    What is a characteristic of a lubricant that is non-toxic?

    <p>It is safe for human exposure and handling</p> Signup and view all the answers

    What is the primary benefit of using a lubricant with the correct viscosity?

    <p>It reduces friction and wear on moving components</p> Signup and view all the answers

    What is a consequence of inadequate lubrication leading to adhesive wear?

    <p>Joint seizure and cessation of motion</p> Signup and view all the answers

    What is the primary responsibility of Maintenance Supervisors, Foreman or Coaches?

    <p>To direct the maintenance work force and provide on-site expertise</p> Signup and view all the answers

    What is one of the key aspects of Maintenance Supervisors, Foreman or Coaches' role in terms of Health and Safety?

    <p>Ensuring that work is accomplished in a safe and efficient manner</p> Signup and view all the answers

    What is the focus of Maintenance Supervisors, Foreman or Coaches in terms of Environmental Compliance?

    <p>Enforcing environmental regulations</p> Signup and view all the answers

    What is the role of Maintenance Supervisors, Foreman or Coaches in terms of Maintenance Organization?

    <p>To manage crew work (crafts)</p> Signup and view all the answers

    What is one of the key responsibilities of Maintenance Supervisors, Foreman or Coaches in terms of Energy Efficiency?

    <p>Ensuring equipment availability is adequate to meet the profit plan</p> Signup and view all the answers

    What is the primary focus of Maintenance Supervisors, Foreman or Coaches in terms of Predictive Maintenance?

    <p>To champion proactive maintenance vs. reactive maintenance</p> Signup and view all the answers

    What is one of the responsibilities of Maintenance Supervisors, Foreman or Coaches in terms of Health and Safety?

    <p>To verify the qualifications of hourly personnel and recommend training as needed</p> Signup and view all the answers

    What is one of the key aspects of Maintenance Supervisors, Foreman or Coaches' role in terms of Maintenance Organization?

    <p>To focus downward and be highly visible in the field</p> Signup and view all the answers

    What is the main purpose of collecting accurate records for equipment maintenance?

    <p>To determine the mean time between failure</p> Signup and view all the answers

    What is a key characteristic of larger organisations in terms of maintenance operations?

    <p>Greater need for Computerised Maintenance Management Systems (CMMS)</p> Signup and view all the answers

    What is the primary role of work orders in the maintenance process?

    <p>To generate reports from collected data</p> Signup and view all the answers

    What is a significant consequence of system or equipment failure?

    <p>Increased maintenance costs</p> Signup and view all the answers

    What is a key objective of a maintenance organisation?

    <p>To obtain accurate records for equipment maintenance</p> Signup and view all the answers

    What is a primary function of a Computerised Maintenance Management System (CMMS)?

    <p>To collect and analyse maintenance data</p> Signup and view all the answers

    What is a primary benefit of collecting equipment maintenance data?

    <p>Enhanced predictive maintenance capabilities</p> Signup and view all the answers

    What is a key consideration in the development of a maintenance organisation?

    <p>Gaining management support for maintenance operations</p> Signup and view all the answers

    What is a key responsibility of a maintenance planner?

    <p>Providing logistical support for maintenance supervisors</p> Signup and view all the answers

    What is a task associated with the role of a maintenance planner?

    <p>Scheduling and coordinating maintenance activities</p> Signup and view all the answers

    What is an important aspect of a maintenance planner's role?

    <p>Maintaining accurate CMMS software data</p> Signup and view all the answers

    What is a benefit of having a well-organised maintenance organisation?

    <p>More efficient maintenance processes</p> Signup and view all the answers

    What is a key consideration in developing a maintenance organisation?

    <p>Executing the business plan</p> Signup and view all the answers

    What is a task associated with a maintenance planner's role in relation to equipment maintenance?

    <p>Identifying, analysing, and reviewing equipment maintenance problems</p> Signup and view all the answers

    What percentage of reported occurrences were attributable to systems operated unsafely during maintenance?

    <p>13%</p> Signup and view all the answers

    What was the single highest reason used to explain why maintenance errors took place?

    <p>Pressure</p> Signup and view all the answers

    What percentage of reported occurrences were due to contact between maintenance workers and hazards?

    <p>7%</p> Signup and view all the answers

    What was the percentage of reported occurrences due to incorrect assembly processes or locations?

    <p>7%</p> Signup and view all the answers

    What was the percentage of occurrences contributed by memory lapses?

    <p>20.1%</p> Signup and view all the answers

    What was the percentage of occurrences contributed by violations?

    <p>17.2%</p> Signup and view all the answers

    What was the primary factor contributing to maintenance errors?

    <p>Pressure</p> Signup and view all the answers

    What percentage of reported occurrences were due to towing events?

    <p>7%</p> Signup and view all the answers

    What was the primary focus of the Inquiry regarding the occupational hazards?

    <p>Exposure to toxic chemicals</p> Signup and view all the answers

    What was the issue with the personal protective equipment used by the Air Force?

    <p>It was not appropriate for the tasks at hand</p> Signup and view all the answers

    What was the second pathway of investigation utilised in the study by Lind & Nenonen (2008)?

    <p>Risk assessment surveys</p> Signup and view all the answers

    What was the total number of severe accident reports from 1994-2004 in the study by Lind & Nenonen (2008)?

    <p>90</p> Signup and view all the answers

    What was a fundamental failure identified in the Inquiry?

    <p>Chain of command failure</p> Signup and view all the answers

    What was the purpose of the risk assessment surveys in the study by Lind & Nenonen (2008)?

    <p>To identify hazards and estimate their likelihood of occurrence</p> Signup and view all the answers

    What was the consequence of the failure of some workers to wear personal protective equipment?

    <p>Increased risk of accidents</p> Signup and view all the answers

    What is one of the main causes of accidents in maintenance crew personnel?

    <p>Lack of relevant safety related information</p> Signup and view all the answers

    What was the focus of the study by Lind & Nenonen (2008)?

    <p>Occupational hazards during industrial maintenance</p> Signup and view all the answers

    What is essential to promote working in a safe manner in the maintenance crew?

    <p>Taking into account work conditions and planning work accordingly</p> Signup and view all the answers

    What is the primary goal of a study on aircraft maintenance errors?

    <p>To identify the causes of maintenance errors</p> Signup and view all the answers

    What should maintenance crew personnel do to minimize the risk of accidents?

    <p>Identify potential hazards and take corrective action</p> Signup and view all the answers

    What is a crucial aspect of accident investigation in maintenance?

    <p>Identifying the root cause of the accident</p> Signup and view all the answers

    What is a key factor in promoting safety in maintenance work?

    <p>Flexible safety management systems</p> Signup and view all the answers

    What is a critical step in hazard detection in maintenance work?

    <p>Identifying potential hazards and taking corrective action</p> Signup and view all the answers

    What is essential for effective risk assessment in maintenance?

    <p>Identifying and evaluating potential hazards</p> Signup and view all the answers

    Study Notes

    Defining Maintenance

    • The cost components of maintenance include labour and material costs, as well as lost production capacity due to ineffective or absent maintenance.
    • Failure is defined as any deviation or change in a product or system from its satisfactory working condition to a condition that is below the acceptable or set operating standards for the system.

    Corrective Maintenance (CM)

    • Corrective maintenance is a passive maintenance approach that applies repairs after failure has been detected.
    • It can lead to unplanned maintenance activities, interruptions to machinery or processes, and potential hazards.
    • It may also result in higher costs associated with maintenance, particularly if breakdowns lead to outsourcing maintenance work.

    Preventive Maintenance (PM)

    • Preventive maintenance involves ongoing routine maintenance activities to avoid failures before they occur.
    • Examples of preventive maintenance include:
      • Scheduling routine maintenance tasks, such as oil and filter changes, on a regular basis.
      • Regularly inspecting machinery, such as sheet metal guillotines, to maintain their integrity.
    • Preventive maintenance activities may also include design and installation of machinery, maintaining a history of repairs, and implementing regular inspections.

    Predictive Maintenance (PDM)

    • Predictive maintenance involves collecting data to identify when maintenance is required.
    • Examples of predictive maintenance include:
      • Collecting oil samples to analyse viscosity and chemical constituents, and identifying when the next oil change is due.
      • Implementing condition monitoring systems to acquire data from critical gearboxes and plan maintenance during regular shutdowns.

    Preventive Maintenance Activities

    • Major PM activities include: equipment dismantling, machine overhauls, worn parts replacement, equipment modification/upgrade, equipment installation, equipment recalibration, and test runs.
    • These activities may involve equipment makers/suppliers.

    Routine PM Activities

    • Typical examples of routine PM activity include: inspections, minor repairs/adjustments, lubrication, and cleaning.
    • Inspections involve sensing faulty parts or operation using all senses and instruments, such as:
      • Visible observation (e.g., low coolant/oil levels)
      • Tactile/hearing (e.g., loose parts vibrating)
      • Faulty gauges, safety interlocks, faulty lights/indicators, and leak checking (gas, hydraulic)

    Importance of Equipment History

    • Documented equipment history is essential for establishing routine cycles of PM activities.
    • It helps in determining how often PM activities should be applied and what resources are needed.
    • Documented equipment history includes:
      • When the machine was last serviced
      • Causes of failure or state of condition
      • Ongoing maintenance costs

    Additional Notes

    • Cleaning is an important part of maintenance, providing benefits such as aesthetics, friction reduction, and wear prevention.
    • Lubrication is a routine maintenance activity that can help reduce mechanical wear when done regularly.
    • Minor equipment adjustments include tasks such as bolt tightening.

    Predictive Maintenance

    • Applies various technologies and analytical tools to measure, monitor, and compare system and component operating characteristics with established standards and specifications to predict system or component failures.

    Types of Maintenance

    • There are three fundamental approaches to industrial maintenance: Predictive, Preventive, and Corrective.
    • Predictive Maintenance is considered the most complex of the three approaches.

    Levels of Complexity and Cost

    • Different levels of complexity and associated cost lead to varying extents for applying these three fundamental approaches.
    • Predictive Maintenance has the highest level of complexity and direct cost.

    Predictive Maintenance Methods

    • Chemical Analysis: pH Monitoring
      • Establishes acidity or alkalinity levels with a numerical value from 0 to 14.
      • Machine oils and lubricants have OEM specified pH levels, and periodic monitoring can help avert more serious damage.
    • Tribological Analyses
      • Helps clarify the effects of surface friction on material degradation (wear).

    Predictive Maintenance vs. Other Approaches

    • CM (Corrective Maintenance) is remedial, focusing on returning equipment/systems to their original operating state after failure has occurred.
    • PM (Preventive Maintenance) is precautionary, attempting to minimize the occurrence of CM through ongoing service.
    • PDM (Predictive Maintenance) is forecasting, measuring a condition, and extrapolating data into the future to predict future events.

    Characteristics of Predictive Maintenance

    • Requires collecting data, analyzing it, and using it to predict future events.
    • Associated with high costs, including more time, higher skill levels, dedicated instrumentation, and greater commitment from management.

    Mean Down Time (MDT)

    • Total time needed to bring failed equipment back into an acceptable operational state
    • Comprised of:
      • Time needed to issue the maintenance work order
      • Time for arrival of maintenance crew at the failed equipment
      • Time for completing all maintenance tasks and checks needed to ensure the equipment is operational

    Availability

    • Proportion of time over which equipment is available for use
    • Calculated as: Availabili ty = MTBF / (MTBF + MDT)

    Component Life Time

    • Failure rate largely changes during lifetime and follows a "bath-tub" trend
    • Failure rate can be calculated using the formula: λ = Number of Failures / Length of Operating Hours
    • Example: λ = 3 / (15 + 35 + 60 + (4 x 80)) hr ≈ 0.007, MTBF ≈ 142.85 hrs

    Mean Time To Failure (MTTF)

    • Applicable to components that cannot be brought back into an acceptable operational condition (i.e., disposable items)
    • Different from MTBF

    Mean Time Between Failures (MTBF)

    • Caution: MTBF calculation can be inaccurate if done during wear-out failures (i.e., changing failure rate)
    • MTBF can vary with time if calculated during wear-out failures
    • Example: MTBF calculation during wear-out failures can be an oversimplification of use

    Total Productive Maintenance (TPM)

    • Implementing TPM involves performing a Service FMEA (Failure Mode and Effect Analysis)

    Service FMEA

    • Occurrence (OCC): provides numerical ranking about the expected frequency of each failure
    • Severity (SEV): provides numerical ranking about the effects and criticality of each failure
    • Detection (DET): provides numerical ranking about the likelihood of determining a failure
    • Risk Priority Number (RPN): calculated by multiplying OCC, SEV, and DET to prioritize potential failures

    Performing Service FMEA

    • Provides recommendation(s)/action(s) to reduce or completely eliminate potential failures and consequences
    • Action taken: provides follow-up information to ensure recommended actions were taken to eliminate/reduce potential failures

    Benefits of Implementing TPM

    • Reduces breakdowns

    Failure Mode and Effect Analysis (FMEA)

    • Purpose: identify potential failures, determine their effects on the overall operation, and propose solutions to eliminate them

    FMEA Classification

    • Not in good condition: Limited capability, Average OEE, Average scrap rate
    • Good: Reliable machine, Nice appearance, Very little scrap, All PM done, Some improvements done, Good (low) OEE, Meet all standards
    • Excellent: Perfect condition, Looks brand new, Excellent capabilities, No scrap, Equipment improved, No breakdowns, Perfect PM done, Excellent (very low) OEE

    Assessing Current Equipment Conditions

    • Overall equipment effectiveness (OEE) is a reliable approach to evaluate the current equipment conditions

    Maintenance Costing

    • Corrective Maintenance (CM) costs can be reduced through effective Preventive Maintenance (PM) activity
    • PM activities require cost justification, and there are simplified methods to help justify the costs associated with a PM programme

    Calculating PM Program Cost

    • The number of PM activities (annual) can be calculated by dividing the available work hours (annual) by the frequency of PM activities
    • Example: with 2400 available work hours and a frequency of 8 hours (for 95% reliability), there are 300 PM activities per year
    • The PM Program Cost (annual) is calculated by multiplying the number of PM activities (annual) by the Cost per single PM activity
    • Example: 300 PM activities/year * 120/PMactivity=120/PM activity = 120/PMactivity=36,000/year

    Reliability and Maintenance Costs

    • The cost of running a PM program (at 95% reliability) occurs on top of the CM activity costs (for the expected 5% failure rate)
    • The total cost of an ongoing PM program includes the costs of the PM program and the occasional CM remedial activity

    Preventive Maintenance Costs

    • The costs associated with a new PM program can be established, including the costs of the PM program and the occasional CM activity
    • Example: the costs of the new PM program were found to be $900/month
    • The feasibility of continuing the PM program depends on the reduction in breakdowns and the associated CM costs

    Health and Safety Considerations

    • Minimise skin contact with lubricants and machining/cutting oils through appropriate work methods and equipment.
    • Dispose of wipes after application to prevent skin contact.
    • Soluble oils and synthetic fluids should only be applied as per recommended dilutions.
    • Avoid skin contact with concentrates.
    • Considerations may also need to be taken where oil mists, vapours or sprays exist.

    Lubricant Application and Environmental Considerations

    • Lubricants will eventually need to be replaced and disposed of.
    • Disposal should be governed by relevant industry practice and local regulations and standards.
    • Lubricants should never be discharged into streams or sewage systems.

    Lubrication and Reaction with Oxygen

    • When exposed to oxygen, lubricants can undergo chemical degradation.
    • Accumulated air and moisture in lubricating systems can be detrimental to ferrous surfaces.
    • The presence of air and moisture can cause additives to react with oils.
    • This reaction can lead to combustion products and sludge formation.

    Importance of Temperature in Lubrication

    • Temperature is a key factor in lubrication, particularly in high-temperature conditions.
    • Additives help reduce the degradation of lubricants at high temperatures.

    Adhesive Wear and Lubrication

    • Adhesive wear arises from localised bonding across small surface features.
    • Effective lubrication reduces wear by preventing localised welding at points.
    • Lack of lubrication or overheating can lead to joint seizure and cessation of motion.

    Functions and Properties of Lubricants

    • A lubricant can serve multiple functions, including removal of heat, attaining correct alignment and joint separation, providing corrosion resistance, and reducing friction.
    • A lubricant needs to have certain qualities, such as the correct viscosity, containing additives for special functions, being physically and chemically stable, and being non-toxic.

    The Maintenance Organisation

    • Maintenance planners provide logistical support for supervisors, enabling efficient task execution and effective maintenance processes.

    Roles and Responsibilities

    • Maintenance planners' tasks include:

      • Planning, scheduling, and coordinating corrective and preventive maintenance activities
      • Developing weekly schedules and assisting supervisors in determining job priorities
      • Ensuring CMMS software data files are complete and current
      • Assisting with stores and purchasing functions
      • Identifying, analysing, and reviewing equipment maintenance problems with maintenance engineering

    • Maintenance supervisors', foremen, or coaches' tasks include:

      • Directing the maintenance workforce and providing on-site expertise
      • Ensuring work is accomplished safely and efficiently
      • Reviewing work planning and scheduling with planners
      • Ensuring quality of work
      • Ensuring equipment availability meets the profit plan
      • Working with plant or production supervision to ensure first-line maintenance is performed by operators
      • Verifying hourly personnel qualifications and recommending training as needed
      • Enforcing environmental regulations
      • Focusing on proactive maintenance vs. reactive maintenance
      • Administering union collective bargaining agreements
      • Monitoring CMMS

    Goals and Objectives

    • Goals and objectives of a maintenance organisation include:
      • Obtaining accurate records for equipment maintenance
      • Tracking equipment failure data (e.g., Mean Time Between Failure, Mean Time To Repair)
      • Collecting information such as repair durations and time between successive maintenance operations

    Maintenance Organisation Structure

    • Maintenance engineers identify, analyse, and review equipment maintenance problems with maintenance planners.

    Maintenance Management

    • Maintenance managers oversee maintenance planners and supervisors.

    Computerised Maintenance Management Systems (CMMS)

    • CMMS becomes necessary in larger organisations to facilitate maintenance operations and data collection.

    Occupational Hazards during Industrial Maintenance

    • Exposure to toxic chemicals was the main focus of the inquiry, and it was possible due to the reliance on personal protective equipment (PPE) to protect workers from hazards in confined spaces.

    Failures in Safety Protocols

    • Problems arose with the appropriateness of protective equipment, availability and control of equipment through the supply network, and failure of some workers to wear the equipment.
    • Inadequate compliance system and failure of the chain of command to operate optimally were also identified as significant failures.

    Case Study: Occupational Hazards during On-Site Industrial Maintenance

    • 90 persons were severely injured and 37 persons were fatally injured in Finland between 1994 and 2004 due to maintenance incidents.
    • Risk assessment surveys were conducted in companies to identify hazards, estimate their likelihood of occurrence, and evaluate the expected consequences.

    Case Study: Aircraft Maintenance Errors and Contributing Factors

    • Aircraft maintenance errors were attributed to maintenance personnel errors, including:
      • Systems operated unsafely during maintenance (13%)
      • Incomplete installations (8%)
      • Contact between maintenance workers and hazards (7%)
      • Incorrect assembly processes or locations (7%)
      • Towing events (7%)
    • Contributing factors to occurrences included:
      • Memory lapses (20.1%)
      • Violations (17.2%)
      • Pressure (23.5%)
    • Recommendations for promoting safety include:
      • Providing relevant safety-related information to maintenance crew personnel
      • Instructing workers on safe work methods before working independently
      • Appropriately planning work and conducting independent identifications of potential hazards
      • Considering work conditions to promote safe working practices

    Studying That Suits You

    Use AI to generate personalized quizzes and flashcards to suit your learning preferences.

    Quiz Team

    Related Documents

    Principles of Industrial Maintenance PDF
    Principles of Industrial Maintenance PDF
    Principles Of Industrial Maintenance PDF
    Component Life Time - PDF
    Principles of Industrial Maintenance PDF
    Principles Of Industrial Maintenance PDF
    Principles Of Industrial Maintenance PDF
    Principles of Industrial Maintenance PDF
    Principles of Industrial Maintenance PDF

    Description

    Quiz on maintenance concepts, including cost components, failure definition, and corrective maintenance approach.

    More Like This

    Use Quizgecko on...
    Browser
    Open
    Browser
    Browser