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KYAMBOGO UNIVERSITY

FACULTY OF ENGINEERING

DEPARTMENT OF ELECTRICAL AND ELECTRONICS ENGINEERING

BACHELOR OF ENGINEERING IN TELECOMMUNICATIONS ENGINEERING

TETE 4106
PRINCIPLES OF MAINTENANCE ENGINEERING
TAKE HOME TEST
NAME: NDAGIRE OLIVER
REGISTRATION NUMBER: 19/U/ETD/295/GV
Question Three

a) Describe maintenance planning and scheduling and how it can be implemented. (10
marks)

Maintenance planning: This is the process of determining which assets or facilities need to be
maintained, when they need to be maintained and how often. The process also involves
identifying resources required for maintenance. It should define the what, the why and the how.

The purpose of maintenance planning is to determine the correct maintenance jobs and get them
ready for scheduling. To do this, a designated planner develops a work plan (sometimes called a
job plan) for each work request. These work plans detail everything a technician must do and use
to accomplish the task.

Maintenance scheduling: This refers to the timing of planned work, when work should be done
and who should perform the work. Scheduling is meant to:

i. Schedule according to the highest priority work orders.


ii. Schedule the maximum number of preventive maintenance jobs when necessary.
iii. Minimize the use of contract and outside resources by effectively using internal labor.

Maintenance schedule can be prepared at three levels which include; Long range schedule,
weekly schedule and a daily schedule.

How Maintenance Planning and Scheduling can be implemented

Start-to-finish implementation of Maintenance Planning and Scheduling can be viewed in six


phases.

Phase 1: Set-up

The setup phase is all about ensuring you are setup for success. Ensure your organization is
onboard with implementing maintenance planning and scheduling, that you have leadership
support and resources are in place. That you have built a clear case for change. That you
identified key stakeholders and put an initial communications plan in place.
Phase 2: Define and analyze the situation.

Phase two involves your team looking at your current situation and identifying problems
currently faced in maintenance execution. During this phase, you should have representation
from all levels of the maintenance process — technicians, key managers, or supervisors, and
even representatives from procurement, finance and the warehouse.

Ask questions, such as: How are work orders initiated? How do you prioritize work? Where
do you access documents like technical drawings and equipment manuals? How are materials

acquired? Do you run a weekly schedule? How are planners getting feedback on their job
plans?

If you currently use planning and scheduling software, ask questions like: Is your CMMS set
up to meet your needs? Can you tag work orders by their priority level? Can you track
performance metrics like schedule compliance?

Phase 3 - Develop and prepare for Delivery: Phase three involves planners and supervisors

working to establish supporting documentation and process maps as well as defining in detail
new processes, roles, and responsibilities. Make any necessary changes to your computerized

maintenance management system (CMMS) and develop training and coaching programs.

Phase 4 - Implement: Once everything is in place, it's time to roll out the new maintenance

planning and scheduling processes. The goal here is to embed the new standards and
procedures into the daily routines of all those involved until they become the new normal.

Phase 5 - Review: This is sometimes called the "close-out" phase. Here, you want to ensure
the new maintenance planning and scheduling process won't disintegrate when the training
and one on-one time is over. Celebrate successes and make sure people are aware of how
their hard work is paying off. Review what is going well and what could be better, and
document these for the next meeting with the planning department.

Phase 6 - Sustain: This phase is considered "evergreen," as processes and procedures should

always be improving. Be sure you have:


All performance metrics in place and review them in meetings, verifying that they are
meeting long-term trends.

b) Maintenance Engineers are responsible for the development and implementation of


a decision support system including the Maintenance Master Schedule.
i. What is maintenance Master Scheduling? (3 marls)

Maintenance Master Scheduling can be defined as a strategic process that involves the creation
of a comprehensive, well-structured schedule that outlines all planned maintenance activities,
tasks, and resources within a defined timeframe. It serves as a centralized blueprint for
coordinating and optimizing maintenance operations, ensuring the efficient allocation of
resources, minimizing downtime, and maximizing equipment reliability. By integrating
preventive maintenance, inspections, repairs, and other necessary maintenance actions into a
single schedule, Maintenance Master Scheduling enables organizations to proactively plan,
execute, and track maintenance activities, leading to improved operational efficiency, cost
optimization, enhanced safety, and long-term asset management.

ii. Mention 10 items expected on the maintenance Master Schedule performance


checklist. (10 marks)
1. Maintenance Task Description: Clearly define each maintenance task to be
performed, including the scope of work and specific instructions.
2. Scheduled Date and Time: Assign a specific date and time for each maintenance
task to ensure proper planning and resource allocation.
3. Equipment/Asset Identification: Identify the equipment or assets that require
maintenance, including their unique identifiers, such as serial numbers or location
codes.
4. Assigned Personnel: Assign the responsible individuals or teams for each
maintenance task, ensuring clarity of roles and responsibilities.
5. Resource Allocation: Determine the necessary resources, such as tools, spare parts,
or specialized equipment, required for each maintenance task.
6. Duration and Estimated Time: Estimate the expected duration or time required to
complete each maintenance task accurately.
7. Priority Level: Assign a priority level to each maintenance task based on factors like
criticality, safety, and operational impact.
8. Maintenance Frequency: Specify the frequency at which recurring maintenance
tasks should be performed, such as daily, weekly, monthly, or annually.
9. Documentation and Reporting: Include requirements for documentation, such as
work orders, checklists, or inspection reports, to ensure proper record-keeping and
performance tracking.
10. Follow-up Actions: Note any follow-up actions that may be necessary after
completing the maintenance task, such as retesting, further inspections, or additional
repairs.

iii. Discuss the key benefits of Maintenance Master scheduling. (5 marks)


1. Improved Planning and Organization: By developing a comprehensive maintenance
master schedule, organizations can effectively plan and organize maintenance activities
in a structured manner.
2. Optimal Resource Utilization: The scheduling process allows for efficient allocation of
resources, including personnel, tools, and materials. It ensures that the right resources are
available at the right time, avoiding unnecessary delays or shortages, and maximizing
productivity.
3. Increased Equipment Reliability: Maintenance Master Scheduling facilitates proactive
maintenance planning by including preventive maintenance tasks. Regular inspections
and preventive actions help identify and address potential issues before they lead to
equipment failures, thus improving reliability and reducing unexpected breakdowns.
4. Minimized Downtime: By having a well-defined schedule that outlines maintenance
activities, organizations can minimize equipment downtime. Planned maintenance tasks
can be scheduled during planned production downtime, reducing the impact on
operations and avoiding costly unplanned shutdowns.
5. Enhanced Safety: Regular maintenance plays a crucial role in ensuring the safety of
equipment and facilities. A maintenance master schedule ensures that safety-related
inspections and maintenance tasks are properly scheduled and performed, reducing the
risk of accidents and promoting a safe working environment.
6. Improved Compliance: Maintenance Master Scheduling helps organizations meet
regulatory and compliance requirements by ensuring that maintenance activities, such as
inspections or audits, are scheduled and documented according to relevant standards and
regulations.
7. Better Communication and Coordination: The maintenance master schedule serves as a
central document that provides a clear overview of maintenance activities to all
stakeholders. It facilitates effective communication and coordination among maintenance
teams, operations personnel, and management, ensuring everyone is aware of scheduled
maintenance activities and can plan accordingly.
8. Data-Driven Decision Making: The scheduling process generates valuable data on
maintenance activities, task durations, and resource utilization. This data can be analyzed
to identify patterns, optimize maintenance strategies, and make data-driven decisions to
improve efficiency and reduce costs.
9. Long-Term Asset Management: Maintenance Master Scheduling enables organizations to
take a proactive approach to asset management. By scheduling routine maintenance tasks,
organizations can extend the lifespan of their assets, improve performance, and avoid
premature failures.
10. Cost Optimization: Effective maintenance planning and scheduling help organizations
optimize costs by reducing unplanned breakdowns, minimizing equipment downtime,
and maximizing the utilization of resources. It leads to improved operational efficiency,
reduced repair costs, and enhanced overall profitability.

Question Four

a) Describe the term maintainability and mention 8 design features that must
be in place for good asset maintainability (10 Marks)

Maintainability refers to the inherent design characteristics and features of an asset or system that
contribute to its ease of maintenance and repair. It focuses on ensuring that maintenance
activities can be performed efficiently, effectively, and with minimal disruption to operations.

Here are eight design features that are essential for good asset maintainability:
1. Accessibility: Assets should be designed with easy access to critical components,
subsystems, and maintenance points. This includes providing clear pathways, sufficient
space, and removable panels or covers to facilitate inspection, servicing, and replacement
of parts.

2. Modularity: Designing assets in a modular manner allows for the separation of


components or subsystems, enabling easier maintenance and repair. Modular designs
facilitate quick replacement of faulty parts without needing to dismantle or disrupt the
entire asset.

3. Standardization: Standardization of components, interfaces, and maintenance


procedures simplifies maintenance activities. Using standardized parts and tools enhances
efficiency by reducing the time required for training, troubleshooting, and procurement.

4. Simplicity: Assets with simpler designs and fewer complex features tend to have better
maintainability. Minimizing unnecessary complexities, intricate arrangements, and
intricate wiring reduces the chances of errors during maintenance and improves ease of
troubleshooting.

5. Error-proofing: Incorporating error-proofing mechanisms into the design helps prevent


or detect potential errors or mistakes during maintenance. This can include color-coded
wiring, clear labeling, or foolproof connectors that guide maintenance personnel and
minimize the risk of incorrect reassembly.

6. Testability: Designing assets with built-in test points, diagnostic capabilities, or self-
checking features simplifies maintenance and troubleshooting processes. Testability
features enable quick and accurate identification of faults or malfunctions, reducing
diagnostic time and improving repair efficiency.

7. Serviceability: Consideration of serviceability factors in the design phase allows for


easier and more efficient maintenance. This can include features like easily accessible
service ports, removable panels, and quick-connect/disconnect mechanisms for utilities
such as power, fluids, or data connections.
8. Documentation and Information Availability: Providing comprehensive and up-to-
date documentation, including maintenance manuals, schematics, and repair guides,
ensures that maintenance personnel have the necessary information to carry out their
tasks effectively. Clear and detailed documentation reduces ambiguity and supports
efficient troubleshooting and repair processes.

b) Describe the term ergonomics and state its relevance in maintenance


engineering. (3 marks)

Ergonomics is the scientific discipline that focuses on designing and arranging work
environments, tools, equipment, and tasks in a way that optimizes human performance, safety,
and well-being. It considers the capabilities, limitations, and needs of individuals to ensure that
they can interact with their work environment efficiently and comfortably.

In the context of maintenance engineering, ergonomics is highly relevant. Here's why:

1. Worker Safety: Ergonomics plays a critical role in ensuring the safety of maintenance
personnel. By designing workstations, tools, and equipment with ergonomic principles in
mind, the risk of work-related injuries and musculoskeletal disorders can be minimized.
Proper ergonomics reduces strain, fatigue, and the potential for accidents, leading to a
safer work environment.

2. Efficiency and Productivity: Good ergonomic design in maintenance engineering can


enhance efficiency and productivity. Ergonomic workstations and tools enable
maintenance personnel to carry out their tasks with less physical effort, reduced repetitive
motions, and improved comfort. This can lead to increased work speed, accuracy, and
overall productivity.

3. User Experience and Satisfaction: Ergonomics focuses on improving the user


experience by considering the physical and cognitive needs of maintenance personnel.
Ergonomic designs that prioritize user comfort and usability contribute to higher job
satisfaction, motivation, and overall well-being. This, in turn, can positively impact
employee retention, morale, and performance.
c) Discuss the six elements of ergonomics. (6 marks)

The elements below have been discussed in relation to maintenance.

1. Physical Ergonomics. This element focuses on designing maintenance workstations,


tools, and equipment to accommodate the physical capabilities and limitations of
maintenance personnel. It involves considerations such as proper workstation layout,
adjustable heights, ergonomic tool design, and minimizing physical strain or fatigue
during maintenance tasks.
2. Cognitive Ergonomics. Cognitive ergonomics is relevant in maintenance
engineering to optimize human cognition, decision-making, and problem-solving. It
involves designing maintenance procedures, instructions, and displays to facilitate
efficient information processing, reduce mental workload, and enhance situational
awareness during maintenance activities.
3. Organizational Ergonomics. Organizational ergonomics considers the broader
context of maintenance operations. It focuses on work design, team dynamics,
communication patterns, and organizational policies to create a supportive and
productive maintenance work environment. It includes factors such as workload
distribution, task allocation, shift scheduling, and effective communication channels
within the maintenance team.
4. Environmental Ergonomics: Environmental ergonomics addresses the impact of the
physical environment on maintenance performance and well-being. It includes
designing maintenance work areas with proper lighting, temperature control, noise
reduction measures, ventilation, and other environmental factors that can affect
maintenance personnel's comfort and efficiency.
5. Macro-ergonomics: Macro-ergonomics examines the overall work system and
interactions between maintenance processes, technology, and the organizational
context. In maintenance engineering, it involves optimizing the coordination of
maintenance activities, resource allocation, workflow management, and integrating
maintenance practices with other departments or functions within the organization.
6. Anthropometry and Biomechanics: Anthropometry and biomechanics consider the
physical characteristics and movements of maintenance personnel. In maintenance
engineering, understanding anthropometric measurements and biomechanical
principles helps in designing equipment, workstations, and tools that suit the body
sizes, proportions, and strength capabilities of maintenance workers, ensuring
ergonomic compatibility.
d) Mention six factors that signal the need for a full-time health and safety
professional in an organization. (6 marks)

The decision to hire a full-time health and safety professional in an organization depends on
various factors that indicate the need for dedicated expertise and focus on occupational health
and safety. Here are six factors that may signal the need for a full-time health and safety
professional:

1. Regulatory Compliance: An organization operating in an industry or jurisdiction with


complex and stringent health and safety regulations, may require a full-time professional
to ensure compliance. A dedicated expert can navigate the legal requirements, develop
and implement safety programs, and monitor ongoing compliance.
2. Size and Complexity: As organizations grow in size and complexity, the risks and
challenges associated with health and safety also increase. If the organization has
multiple locations, diverse operations, or high-risk activities, a full-time health and safety
professional can effectively address and manage these complexities.
3. Industry Hazards: Certain industries inherently have higher levels of occupational
hazards, such as manufacturing, construction, mining, or chemical industries. If an
organization operates in such industries, a full-time health and safety professional is
essential to identify, assess, and mitigate the specific risks associated with those sectors.
4. History of Incidents: Organizations that have a history of workplace accidents, injuries,
or near-misses may benefit from having a dedicated health and safety professional. Their
expertise can help investigate incidents, identify root causes, implement corrective
actions, and develop preventive measures to mitigate future incidents.
5. Employee Health and Well-being: If there is a focus on employee health and well-being
within the organization, a full-time health and safety professional can help develop and
manage comprehensive wellness programs. They can address physical and mental health
concerns, conduct risk assessments, and provide guidance on promoting a healthy and
safe work environment.
6. Cultural Emphasis on Safety: Organizations that prioritize safety as a core value and
strive for a strong safety culture may find value in having a full-time health and safety
professional. This professional can drive safety initiatives, provide ongoing training,
promote employee engagement, and foster a proactive safety culture throughout the
organization.

References

Maintenance-Engineering-Handbook-7th-Edition.pdf

Ben-Daya, Mohamed, Salih O. Duffuaa, Abdul Raouf, Jezdimir Knezevic, and Daoud Ait-Kadi,
eds. Handbook of maintenance management and engineering. Vol. 7. London: Springer London,
2009.

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