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Chapter 1 Maintenance Principle and Procedures

This document discusses maintenance principles and procedures. It defines maintenance as activities that preserve equipment function, including repair, scheduled upkeep, and preventative maintenance. The document outlines categories of maintenance like closed-loop systems. It then discusses maintenance principles such as minimizing costs and downtime. Different types of maintenance are defined, like emergency, preventative, and predictive maintenance. Workplace safety procedures like lockout/tagout and personal protective equipment are also explained. Finally, common hand tools and power tools used in maintenance are identified.

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Hafizuddin Senawi
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3K views10 pages

Chapter 1 Maintenance Principle and Procedures

This document discusses maintenance principles and procedures. It defines maintenance as activities that preserve equipment function, including repair, scheduled upkeep, and preventative maintenance. The document outlines categories of maintenance like closed-loop systems. It then discusses maintenance principles such as minimizing costs and downtime. Different types of maintenance are defined, like emergency, preventative, and predictive maintenance. Workplace safety procedures like lockout/tagout and personal protective equipment are also explained. Finally, common hand tools and power tools used in maintenance are identified.

Uploaded by

Hafizuddin Senawi
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
Available Formats
Download as DOCX, PDF, TXT or read online on Scribd
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JJ615 : Mechanical Component and Maintenance

Chapter 1 : Maintenance Principle And Procedure

Maintenance

In general, Maintenance means to hold, keep, sustain or preserve.


Maintenance, repair and operations (MRO) or maintenance, repair, and
overhaul involves fixing any sort of mechanical, plumbing or electrical
device should it become out of order or broken (known as repair,
unscheduled, or casualty maintenance). It also includes performing
routine actions which keep the device in working order (known as
scheduled maintenance) or prevent trouble from arising (preventive
maintenance). MRO may be defined as, "All actions which have the
objective of retaining or restoring an item in or to a state in which it can
perform its required function. The actions include the combination of all
technical and corresponding administrative, managerial, and supervision
actions."

MRO operations can be categorised by whether the product


remains the property of the customer, i.e. a service is being offered, or
whether the product is bought by the reprocessing organisation and sold
to any customer wishing to make the purchase (Guadette, 2002). In the
former case it may be a backshop operation within a larger organization
or smaller operation.

The former of these represents a closed loop supply chain and


usually has the scope of maintenance, repair or overhaul of the product.
The latter of the categorisations is an open loop supply chain and is
typified by refurbishment and remanufacture. The main characteristic of
the closed loop system is that the demand for a product is matched with
the supply of a used product. Neglecting asset write-offs and exceptional

activities the total population of the product between the customer and
the service provider remains constant.

Principle Of Maintenance

Minimizing the repair time and repair cost.


Minimizing the loss due to production stoppages.
Efficient use of maintenance personnel and equipments.
Prolonging the life of capital assets by minimizing the rate of wear
and tear.
To keep all productive assets in good working conditions.
To maximize efficiency and economy in production through
optimum use of facilities.
To minimize accidents through regular inspection and repair of
safety devices.
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.
To improve the quality of products and to improve productivity.

Advantages of Implement Maintenance

1. Reduced inventory
Reducing stores and buffer stock.
2. Continuous improvement
On going effort to improve product services or process.
3. Higher productivity

Is high ratio of output to input of production.

4.Improved capacity
Improve the capacity of product.
5. Improved quality
Achieve a step change in quality through contracting out the
service with the new service level agreement.
6. Lower operating cost
Expenses which are related to the operation of a organization in a
lower cost.

Type Of Cost Maintenance

1. Emergency @ breakdown maintenance


It means that people waits until equipment fails and repair it.
2. Periodic maintenance
It means periodically inspecting, servicing and cleaning equipment
and replacing parts to prevent sudden failure and process
problems.
3. Corrective maintenance
It improves equipment and its components so that preventive
maintenance can be carried out reliably

4. Routine maintenance
It is a daily maintenance ( cleaning, inspection, oiling and retightening )
5. Preventive maintenance
It design to retain the healthy condition of equipment and prevent
failure
6. Predictive maintenance
It is a method in which the service life of important part is
predicted based on inspection or diagnosis, in order to use the
parts to the limit of their service life.

Workplace Safety

Benefits Of Clean And Working Environment

1. Reduced Accidents
reduce accidents that can result in employees injuring their backs,
legs, shoulders or other body parts because of broken equipment,
and also wet areas where people can slip.
2. Air Quality
Employees will literally breathe easier in safe workplaces free from
chemical pollution, asbestos, dust, cigarette smoke or other
allergens.
3. Reduced stress
Unsafe workplaces may cause unhealthy stress levels among
employees fearful of threats from co-workers, dramatic altercations

with management or persistent problems related to parking lot theft


and other challenges.

Personal Protective Equipment (PPE)

Personal protective equipment (PPE) refers to protective clothing,


helmets, goggles, or other garments or equipment designed to protect
the wearer's body from injury.The hazards addressed by protective
equipment include physical, electrical, heat, chemicals, biohazards, and
airborne particulate matter.

Examples :

Hearing protection
Gloves
Protective clothing
Safety helmet
Goggles
Safety boots
Respirator

Important Of Personal Protective Equipment

To reduce employee exposure to hazards when engineering and


administrative controls are not feasible or effective in reducing these
exposures to acceptable level.PPE is needed when there are hazards
present.PPE has the serious limitation that it does not eliminate the
hazard at source and may result in employees being exposed to the
hazard if the equipment fails.

Lockout and Tagout

Lockout/Tagout refers to the procedures established for Control of


Hazardous Energy as described by the Occupational Safety and Health
Administration (OSHA) under Federal Registry 29 CFR1910.147.
Lockout/Tagout ensures employee safety during inspection,
maintenance, or service of equipment by controlling all energy flow to
and from the equipment.

To achieve system lockout, all energy sources are turned off or


disconnected, and stored energy is released, restrained, or dissipated. A
lock or lockout device applied to each energy source prevents accidental
startup.

Tag out is a labelling process that is always used when lockout is


required.The process of tagging out a system involves attaching or using
an indicator.

Lock out/tag out program

Lockout/Tagout specification includes the following:

Plant or company-wide safety policies.


Machine-specific lockout procedures.
Lock and key and tag control.
Program review and certification.
Outside contractor rules and regulations.

All companies whose employees service or maintain equipment with


potentially hazardous energy sources must have an OSHA-compliant
Lockout/Tagout program.

Purpose of lock out/tag out

A lockout/tag out program will help prevent:


Contact with a hazard while performing tasks that require the
removal, by-passing, or deactivation of safe guarding devices.
The unintended release of hazardous energy (stored energy).
The unintended start-up or motion of machinery, equipment or
processes.

When lock out/tag out is required?

Lockout/Tagout is required whenever employees are exposed to


hazardous energy. It is also a procedures that are required whenever
you must remove or bypass a machine guard or other safety device, and
place any part of your body where you could be caught by moving
machinery.

Hazardous materials

Hazardous materials or Hazmat, are solids, gases, and liquids that


can hard people, animals property, and the environment. Throughout the
U.S.hazardous materials are moved by marine vessels, air, rail, and
truck.
During the servicing and maintenance of machines and equipment,
the unexpected startup or release of stored energy could cause injury to
employees.

Organizations that given safety at Hazardous materials

The Occupational Safety and Health Act (OSH Act) gives OSHA
authority to promulgate the hazardous materials regulations. EPA
Hazoardous materials organization has primary responsibility for
regulating the transport of hazardous materials across all modes except
pipelines.

Hand Tools

Chisel
Remove unwanted timber or to carve it out
Clamps
to create inward pressure to secure objects or materials together
to prevent movement or separation.
Hammer
To deliver an impact or force such as pounding or striking to an
object.
Hand saw
used to cut materials with its blade.
Screwdrivers
Screwdrivers are used for driving screws into materials or for
securing or loosening parts on machinery.

Planer
A planer is used to shape or thin out a piece of timber by removing
small amounts of wood.

Wrench
It s used to for gripping, fastening,rotating ,loosing or turning
bolts,nuts and screw.
Pliers
These are used to hold objects firmly for bending or physical
compression.

Power Tools

Circular saw
Circular saws are similar to jigsaws only the blade is round and
much larger which means it is better for straight cuts.
Drill
Used for drilling holes or inserting and removing screws from a
material.
Jigsaw
used for cutting curves much like a coping saw as it uses a similar
sized blade only it cuts much quicker.
Electric Planer

Electric planers are the same as hand planers only they work
automatically which makes planning much faster and easier.
Router
create curved edges and mill out timber making them very useful.
Belt sander
creates scratches if it is used against the woods grain but it
removes more material.
Air Compressor
An air compressor is a device that converts power (usually from an
electric motor, a diesel engine or a gasoline engine)
4 Angle Grinder
also known as a side grinder or disc grinder, is a handheld power
tool used for cutting,grinding and polishing.

Important of inspecting a hand tools & power tools

The purpose of the inspection is to ensure a well-functioning tools

Identify tools that are not broken

Keep the tool to be used does not pose a high risk

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