MACHINING -LEVEL II

Based on Version 2 February 2017

Occupational Standard (OS)
Training Module –Learning Guide 17-
20
Unit of Competence: - Maintain Tools and
Equipment
Module Title: Maintaining Tools and Equipment
TTLM Code: IND MAC2 TTLM06 1019v1

October 2019
Module Title: Maintaining Tools and Equipment
TTLM Code: IND MAC2 TTLM06 1019v1
LG 17: Undertake program safety and
maintenance checks.
LG Code:IND MAC2 M06 LO1 LG-17
LG 18: : Undertake basic program maintenance
LG Code:IND MAC2 M06 LO2 LG-18
LG 19: Perform basic preventive maintenance of
tools.
LG Code:IND MAC2 M06 LO3 LG-19
LG 20: Inventory tools and equipment
LG Code:IND MAC2 M06 LO4 LG-20

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 Instruction Sheet Learning Guide #17

This learning guide is developed to provide you the necessary information regarding the
following content coverage and topics –
 Inspecting and checking tools and machines/equipment.
 Undertake checks to prescribing operational procedures
 Checking and calibrating Measuring instruments.
 Segregate (separate) and label Non-functional tools, instruments and equipment
 Recording or reporting status/report on pro-forma or orally

This guide will also assist you to attain the learning outcome stated in the cover page.
Specifically, upon completion of this Learning Guide, you will be able to –
 Inspect/check tools and machines/equipment according to workplace routine
 Undertake checks safely to prescribe operational procedures.
 Check and calibrate measuring instruments in accordance with manufacturer‘s
instructions
 Segregate and label non-functional tools, instruments and equipment according
to classification
 Record on pro-forma or report orally Status/reports based on operational
processes

Learning Instructions:
1. Read the specific objectives of this Learning Guide.
2. Follow the instructions described below.
3. Read the information written in the ―Information Sheets‖. Try to understand what are
being discussed. Ask your trainer for assistance if you have hard time understanding
them.
4. Accomplish the ―Self-checks‖ which are placed following all information sheets.
5. Ask from your trainer the key to correction (key answers) or you can request your
trainer to correct your work. (You are to get the key answer only after you finished
answering the Self-checks).
6. If you earned a satisfactory evaluation proceed to ―Operation sheets
7. Perform ―the Learning activity performance test‖ which is placed following ―Operation
sheets‖ ,
8. If your performance is satisfactory proceed to the next learning guide,
9. If your performance is unsatisfactory, see your trainer for further instructions or go
back to ―Operation sheets‖.

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 Information Sheet-1 Inspecting and checking tools and
machines/equipment

1.1. Introduction
According to the classic view, the role of maintenance is to fi broken items. Taking
such a narrow perspective, maintenance activities will be confied to the reactive
tasks of repair actions or item replacement triggered by failures. Thus, this approach
is known as reactive maintenance, breakdown maintenance, or corrective
maintenance.

1.1.1 Maintenance Definition

Maintenance is a set of organised activities that are carried out in order to keep an item
in its best operational condition with minimum cost acquired (British Standard Glossary
of terms3811:1993)
All actions necessary for retaining an item, or restoring to it, a serviceable condition,
include servicing, repair, modification, overhaul, inspection and condition verification
 Increase availability of a system
 Keep system‘s equipment in working order

1.1.2 Terms of maintenance

Many terms and definitions are used in maintenance engineering work. The section
presents some of the frequently used terms and definitions in these areas taken from
various sources:
Maintainability: The probability that a failed item will be restored to its satisfactory
operational state
Maintenance: All actions necessary for retaining an item or equipment in, or restoring it
to, a specified condition
Reliability: The probability that an item will perform its assigned mission satisfactorily for
the stated time period when used according to the specified conditions
Availability: The probability that an item is available for use when required
Mission time: The time during which the item is carrying out its assigned mission
Downtime: The total time during which the item is not in satisfactory operating state
Logistic time: The portion of downtime occupied by the wait for a required part or tool
Failure: The inability of an item to operate within the defined guidelines

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Serviceability: The degree of ease or difficulty with which an item can be restored to its
working condition
Redundancy: The existence of more than one means for accomplishing a stated
function
Failure mode: The abnormality of an item‘s performance that causes the item to be
considered to have failed
Human reliability: The probability of accomplishing a task successfully by humans at
any required stage in the system operation with a given minimum time limit (if the time
requirement is stated)
Useful life: The length of time a product operates within a tolerable level of failure rate
Maintenance concept: A statement of the overall concept of the product specification or
policy that controls the type of maintenance action to be taken for the product under
consideration.
Corrective maintenance: The repair or unscheduled maintenance to return items or
equipment to a specified state, performed because maintenance personnel or others
perceived deficiencies or failures
Continuous task: A task that involves some kind of tracking activity (e.g., monitoring a
changing situation)
Human performance: A measure of human functions and actions under some specified
conditions
Active redundancy: A type of redundancy in which all redundant units are functioning
simultaneously
Human error: The failure to carry out a specified task (or the performance of a forbidden
action) that could result in disruption of scheduled operations or damage to property or
equipment
Active repair time: The period of downtime when repair personnel are active to affect a
repair
Inspection: The qualitative observation of an item‘s condition or performance
Overhaul: A comprehensive inspection and restoration of a piece of equipment or an
item to an acceptable level at a durability time or usage limit

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1.2. Types of maintenance
British Standard 3811 classified maintenance as the followings:

Types of maintenance

Planned
Unplanned

Preventive Corrective
Emergency
Breakdown
maintenance
Maintenance

Scheduled Condition
based

 Unplanned Maintenance: ―The maintenance carried out to no predetermined plan.‖

 Emergency maintenance: it is carried out as fast as possible in order to bring a
failed machine or facility to a safe and operationally efficient condition. ―The
maintenance which it is necessary to put in hand immediately to avoid serious
consequences‖
 Breakdown maintenance: it is performed after the occurrence of an
advanced considered failure for which advanced provision has been made in the
form of repair method, spares, materials, labour and equipment. Repair is
undertaken only after failure of system. Equipment is allowed to run till it fails.
Lubricating and minor adjustments are done during the period. Small factories
where equipment is very small and doesn‘t use special tools Isn‘t suitable for big
industries

 Planned Maintenance: ―The maintenance organized and carried out with

forethought, control and the use of records to a predetermined plan.‖
 Preventive Maintenance (PM) Condition-based (Predictive) Maintenance: ―The
preventive maintenance initiated as a result of knowledge of the condition of an
item from routine or continuous monitoring.‖ In predictive maintenance, machinery
conditions are periodically monitored and this enables the maintenance team to
take timely actions, such as machine adjustment, repair or overhaul.

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  Scheduled Maintenance: ―The preventive maintenance carried out to a
predetermined interval of time, number of operations, etc.
 Corrective Maintenance (CM) Corrective Maintenance: ―The maintenance
carried out after a failure has occurred and intended to restore an item to a state in
which it can perform its required function.‖In this type, actions such as repair,
replacement, or restore will be carried out after the occurrence of a failure in order
to eliminate the source of this failure or reduce the frequency of its occurrence.

E.g Shutdown corrective maintenance, which is a set of corrective maintenance activities

that are performed when the production line is in total stoppage situation
The main objectives of corrective maintenance are the maximisation of the effectiveness
of all critical plant systems, the elimination of breakdowns, the elimination of
unnecessary repair, and the reduction of the deviations from optimum operating
conditions.
The difference between corrective maintenance and preventive maintenance is that for
the corrective maintenance, the failure should occur before any corrective action is
taken. The way to perform corrective maintenance activities is by conducting four
important steps:
 Fault detection/finding
 Fault isolation./separation
 Fault elimination./removing
 Verification/proof of fault elimination.
In the fault elimination step several actions could be taken such as adjusting, aligning,
calibrating, reworking, removing, and replacing

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 Types of Maintenance Strategies

1.3. Purpose and objective of maintenance

The main purpose of maintenance in all industrial perspective is to reduce the
business risks. In general, operation and maintenance is synonymous with high
level of availability, reliability and assets operability linking directly with production
capacity, productivity and business profit.

 The main objectives of maintenance are:

 Improve and ensure maximum utilization of maintenance facilities
 To obtain plants and equipments at its maximum operating efficiency,
reducing downtimes and ensuring operational safety.
 To safeguard instruments by minimizing rate of deterioration and
achieving this at optimum cost through budgeting and controls.
 To help management in taking decisions on replacements or new
investments and actively participate in specification preparation,
equipment selection, its correction commissioning etc.
 Help in implementation of suitable procedures for procurement, storage
and consumption of spares, tools and consumables etc.
 Standardization of spares and consumables, in conformity with plant,
national and international standards and help in adoption of this
standard by all users in the plant.
 Running of centralized sciences like steam generation and distribution,
water supply, air supply and fuel supply etc.

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  Running of captive workshops for repairs and conditioning and also for
making some new spares.
 Reduce the amount and frequency of maintenance
 Improve maintenance operation

1.4. Advantage of preventive maintenance

List of different maintenance work is already given in which preventive
maintenance is an important function with which, an efficient plant maintenance
programmed, good per work system, work planning and scheduling, training, work
measurement, control report and good shop tools, may be achieved. There are so
many advantages followed by adoption of well preventive maintenance
programmed.
 Avoid major break downs
 Increased production
 Less down time of plant
 Increase life of plant
 Fewer number of spares maintaining
 Better man power control
 Less overhaul maintenance cost
 Prevention of accidents-grater safety
 Less damage of machine

1.5 OHS hazards and PPE

 Personal safety
 Always wear appropriate closes
 Stop machine before making maintenance activity
 Do not attempt to dismantle the machine unless you switch off the electric
power
 Remove your watch, rings etc before performing maintenance activity.
 Machine safety
 Never attempt to dismantle the machine until you have been instructed
properly.
 switch off the electric power before dismantling the machine.
 use proper hand tools to dismantle the machine.
 clean the machine parts before and after dismantling .

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  place the dismantled machine parts in proper sequence and easy for
assembly
 never attempt to carry heavy machine parts alone.
 Workplace safety
 keep all tools clear of a work table .
 change coolant fluid before it become contaminated.
 Wipe up all spilled coolants from the floor around the machine right away.

1.5.1 Personal protective equipment

The hazards and risks already present on maintenance shape , such as slips, trips, falls,
noise, moving vehicles, and the specific risks related to the maintenance of portable
tools frequently require the use of personal protective equipment. For example, safety
helmets must be worn in areas where overhead hazards exist. Hand protection and
gloves must be worn where workers have to work with sharp tools. Use of e.g.
lubricants, hydraulic fluids or cleaning agents (solvents) may cause eye or skin injuries
and requires protection. Ear protection may be necessary when working with or near
noisy machines or equipment.

1.5.2 Identifying Maintenance Hazards

The hazards associated with maintenance activities can be classified as follows:
 Safety Hazards
 Mechanical-equipment, tools
 Electrical-– live equipment
 Pneumatic ,Hydraulic & Thermal
 Health Hazards
 Chemical Agents -Process chemicals, Cleaning solvents, Unexpected reaction
products
 Physical Agents- noise, vibration
 Ergonomic Hazards
 Biomechanical- lifting, pushing, pulling (manual handling), stretching, ending
(to reach hard to access areas)
 Work/process design- poorly designed tools, hard to access work locations,
complex procedures, poorly fitting personal protective equipment

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  Many of these hazards are interrelated. Examine your process, the layout of your
process area, and the process equipment used, to determine the exact nature of
the hazards likely to be encountered during your maintenance activities.
 For example, maintenance work carried out in confined spaces carries a greater
risk of critical injuries and acute exposures to chemical and physical agents.
These risks are associated with equipment and materials in the space itself and
from nearby operations. Fatalities (wounded) are quite common.

1. 6 Tool/ Equipment Inspection Schedule

All equipment is to be inspected and maintained according to the following Equipment
Inspection Schedule as a minimum. Records of all inspections and maintenance are
completed and maintained for review and approval. Maintenance of equipment, release
of lubrication fluids, etc., is performed only in approved areas. Spills and leaks from
equipment are cleaned up promptly.

 Sample :

Type of tool Type of Inspection Schedule

Complete inspection and Before put to work and

certification annually
Cutting tool
Critical items, controls, overall
Boring tool Daily
functioning
Holding tool
Treading tool Safety device, electrical Monthly

Measuring tool Complete inspection Every 3 months

Repair When failure occurs

Hand tools
Manufacturer‘s
Preventative maintenance
recommendation

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  Sample of checking machine/equipment in the case of lathe

1.7 Preventive maintenance inspection

1.7.1. Daly inspection
Inspection of lathe is carried out on basis of each shift. The inspection work
accords to the following item 1-1.

1-1 Check before start the motor.

 Clean-up of machine: Dust, chips and other atticles should be removed from
sliding surface of machine to make the rotating or sliding parts performing easy
and smoothly. All other static parts are often also cleaned to avoid the corrosion.
 Gearing and oiling: Regular oiling should be done every day (see lubrication plan
sheet) to keep the machine properly lubricated.
 Check all the running parts not too tight, or loose. Bearings of headstock,
longitudinal and cross feed, tool holders etc would be examined and adjusted by
hand to proper fitness.
 Check the sensitivity & reliability of all manual control levers: To try the speed
change rate function of headstock feeds and apron in gear box and inspect their
starting, stopping and forward & reverse action whether they are sensitive at1d
reliable or not.
 Fixture and fig of headstock, tailstock and tool holder Tight clamping between
tailstock and bed surface, close running fit of spindle in tailstock, clamp bolts of
tool holder, and figs on headstock.

1-2 Check after start the motor

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  To check electrical control system: Try to put "on" and "off' button and examine
the sensitiveness of starting, stopping and pilot lamp strictly.
 The sensitivity and reliability of mechanical control device: Control levers for
forward and reverse main spindle, automatic feeds and threads change should be
sensitive and reliable. Automatic control devices for longitudinal and cross feed,
gear change threads change, carriage, and spindle direction change should be
accurate also.
 Limitation of noise and vibration: When starting max speed of headstock spindle
on no loading basis, check the noise and vibration whether they are over
specified limit or not
 Coolant system: Check the quantity of coolant oil and start the oil pump for
inspecting its function and leakage.
 Lubricating system: Examine all Lubricating system carefully and ensure all
flowing line without obstacle.

1. 3Caution during operation

 Temperature of bearings.
Touch the main bearing by hand and feel the temperature is nom1ally or
not.
 Temperature of motor:
Feel the temperature of motor bearing at the case of full load.
 Noise and vibration: If you find the noise and vibration of the machine are
abnormal or irregular. Stop the machine immediately for inspection and
adjustment.
 Quality of products:
If you discover the quality of products is out of limit. stop the machine at once for
finding the causes of defects.
 Safety affairs:
a. Must stop operation when you leave the machine.
b. When changing main spindle speed or feeding speed stop running first.
c. All tools and products are strictly not allowing to be left on sliding surface of
bed.

1-4 check after operation

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  Cleaning and collection of all tools:
All tools should be kept clean first then put back to original position (tool cabinet).
 Proper position of tailstock, carriage & tool holder:
Tailstock, carriage & tool holder should be placed to proper position.
 Clean-up of machine:
All of the oily matters, chips etc, on the machine should be removed completely
and
put a thin lubricating oil on the sliding surface of machine to prevent the corrosion.

1.4.1 Weakly inspection

 Lubricating system:
Clean up the whole lubricating system and replenish with fresh lubricating oil.
 Cooling system:
Clean up the whole cooling system and replenish with new cooling oil.
 Transmission system:
Check the damage of rubber V-belt and readjust the tensile strength of V-belt.

1.4.2 Monthly inspection

 Dismantle and clean all the dust, chips and foreign matter from moving parts.
 Electrical system:
Carefully examine the connection of all electrical wires, terminals and switches,
which occasionally have been damaged by chips or other.

1.4.3 Semi Yearly inspection

 Change oil in gearbox:
Remove the used oil from gearbox of headstock, feed and replenish with fresh oil.
 Check the wear and tear of all gears and packing:
Inspect the damage of all gears in various box. spindle and bearings, and
packing.
Repair or replace it if necessary.
 Check the clearance fit of complicated feed mechanism:
Check the clearance fit between feeding screw lever and nut and main screw
spindle
and nut whether they are right or not.

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  The stability of machine body:
Tighten up the foundation bolts of machine body to the ground and make the
body
stable.

1.4.4 Yearly inspection

 Positioning and leveling:
According to the inspection regulation, recheck the positioning and leveling after a
year service.
 Inspection for accuracy:
According to the regulation. Inspection work for accuracy should be rechecked. If
the accuracy is over specified limit, the adjustment or alignment will be done
accordingly.
 Bearing inspection:
Reexamine the insulating materials and clearance fit & lubrication of all bearings.
 Inspection for appearance:
a. If paints are peeled off, repaint it with the same color.
b. Check the exposed parts whether they have been damaged, corroded, or
deformed. repair or replace them if necessary.

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 Self-Check -1 Written Test

Directions: Answer all the questions listed below. Use the Answer sheet provided in
the next page:
1. Which one of the following is not an action of maintenance
A. Servicing & Repair
B. Modification& Overhaul
C. Inspection and Condition verification
D. None
2. Which one of the following is not Unplanned Maintenance
A. Emergency maintenance
B. Breakdown maintenance
C. Preventive maintenance
D. All
3. Which one of the following is not Planned Maintenance
A. Preventive Maintenance (PM)
B. Corrective Maintenance (CM)
C. Breakdown maintenance
D. All
4. Which one of the following is not preventive Maintenance activity
A. Inspection
B. lubrication
C. Repair
D. Overhaul of equipments
E. All
5. The main objectives of maintenance is
A. Improve and ensure maximum utilization of maintenance facilities
B. Reduce the amount and frequency of maintenance
C. Improve maintenance operation
D. All

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6. Which one of the following is not Advantage of preventive maintenance
A. Avoid major break downs
B. Increased production
C. Less down time of plant
D. Increase life of plant
E. None
Part II
Say True or False
1. All actions necessary for retaining an item or equipment in, or restoring it to, a
specified condition is called Maintenance.
2. The qualitative observation of an item‘s condition or performance is called
Inspection.
3. Most accidents are caused by ignorance and carelessness and lack of skill.
4. Prevention of accidents-grater safety is one of Advantage of preventive
maintenance.
5. The main purpose of maintenance is to reduce the business risks.

Note: Satisfactory rating 6 points Unsatisfactory - below 6 points

You can ask you teacher for the copy of the correct answers.
Answer Sheet
Score = ___________

Rating: ____________

Name: _________________________ Date: _______________

Short Answer Questions

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 Undertake Checks to prescribe operational
Information Sheet-2
procedures.

2.1 Introduction
2.1 Maintenance and inspection programmers
The key to safe maintenance is putting in place a maintenance programme,
integrating safety and health aspects of maintenance and including inspection,
reporting and record keeping procedures. Records must be kept to provide
information for planning maintenance and replacement activities so that they occur at
the proper time. Proper maintenance management of equipment requires a detailed
inventory of all major items, including among other things information on
manufacturer, model, year and number, and a list of the parts required for normal
service and major repairs respectively. An important part of the maintenance
programme is the inspection programme setting out the frequency of formal
inspections to be carried out by competent and trained maintenance technicians.
in the process

 Factors to consider when making the maintenance plan

 Type of tool and power source
 Manufacturer‘s instructions and recommendations
 Age of the tool
 Frequency of use and the work cycle of the tool
 Working environment in which the tool is used (e.g. wet or dusty), or likelihood
of mechanical damage
 Foreseeable misuse of the tool
 Effects of any modifications or repairs to the tool
 Analysis of previous records of maintenance.

2.1.2 Maintenance inspection Checklists

 Checklists
A checklist can help you identify the hazards related to maintenance of
tools/equipment and take the necessary preventive measures. Depending on the
power source, different checklists may be necessary:

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  Sample 1

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  Sample 2

 NB
 Different parts of equipment must be checked by the manufacturer Manual
Example: Adjustments of safety guards, stops, wear pads , tool holders, nipping up
glands , scrapers and aprons must be checked

 Tools must be checked

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  Before the tool is put into use for the first time
 After servicing and changing parts
 At regular intervals appropriate for each tool.
The period between inspections can vary, depending on the type of tool, the
conditions of use and the environment. portable equipment, including inspection
intervals.

2.1.3 Final check

When maintenance is complete workers have to check if the maintenance has left
the portable tools in a safe and functioning condition:
 Test the functionality of the tool
 Replace all guards and safety devices
 Record your inspection and actions, sign out and pass the tool to the worker
or store it safely.

 Scheduled Inspections and Maintenance check
All equipment is to be inspected and maintained according to the following Equipment
Inspection Schedule as a minimum. Records of all inspections and maintenance are
completed and maintained for review and approval. Maintenance of equipment, release
of lubrication fluids, etc., is performed only in approved areas. Spills and leaks from
equipment are cleaned up promptly.

 Maintenance Service Checks

Date Equipment Service Performed Performed By

2.2 Prescribing operational procedures

When servicing equipment, hazards not related to your process operation are likely
to be introduced. For this reason, it is important to prepare written servicing
procedures that include the following:

Operational procedure

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 A clear, step-by-step procedure, in checklist form, for controlling hazardous energy:
 Preparing for shutdown
 Shutting down machine, process or equipment
 Isolating energy to the machine, process or equipment
 Applying lockout devices
 Controlling stored energy (de-energization)
 Verification of isolation
 Release from lockout control
 Hazards identification
 Selection and specification of personal protective equipment:

 appropriate for the hazard

 proper fit
 Selection and specification of tools to be used:
 right tool for the job
 In good condition
 Appropriate for the environment (e.g., non-sparking tools in flammable
atmospheres)
 Ergonomic design
 Step-by-step procedure for disassembly
 Step-by-step checklist for inspection of components (to establish a baseline for
reliability)
 Identification of hazards associated with sub-procedures:
 entering and working in confined spaces
 welding in open and confined spaces
 removing insulation
 cleaning
 handling and using solvents
 erecting temporary structures
 using portable equipment
 using ladders
 abrasive blasting
 painting
 Disassembly of small-scale equipment
 Reassembly of small-scale equipment
 Support and disassembly of large scale equipment

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  Support and reassembly of components of large scale equipment
 Use of hoists and mobile working platforms

Training
Maintenance personnel are often involved in a complex and changing set of
problems. Therefore, they need more thorough training in accident prevention than
regular workers.

Serious consequences to maintenance and other workers can result from not
following established maintenance procedures (e.g., use of work permits, lockout
procedures, confined space entry procedures). Ensure that your maintenance
personnel are well trained in, and can demonstrate that they understand, all relevant
procedures.

Also provide training in: Hazard identification, Selection, use, and care of equipment,
machine tools, personal protective clothing/equipment, etc., required to be used
,First-aid and life-saving techniques It is a good practice to call the maintenance crew
(team) together at the start of each job, in order to discuss the hazards involved and
the method of doing it safely.In the course of their daily work, members of the
maintenance crew travel throughout the plant, becoming familiar with every machine
and process. If properly selected and trained, they can do much to identify and
correct unsafe conditions.

Self-Check -2 Written Test

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Directions: Answer all the questions listed below. Use the Answer sheet provided in
the next page:
Say True or False
1. A checklist can help you identify the hazards related to maintenance
2..A checklist can help you to take necessary preventive measures
3.. Analysis of previous records of maintenance is one of the factor to consider in
maintenance planning
4..Inspection program setting is an important part of the maintenance.
5.. "What to look at" and " what to look for" is the two categories of inspection

6.It is a good practice to call the maintenance crew (team) together at the start of

each

7. When servicing equipment, hazards not related to your process operation are

likely to be introduced.

8. maintenance work carried out in confined spaces carries a greater risk of

critical injuries

9. Selection and specification of tools to be used is one method to prescribing

procedure

Note: Satisfactory rating - 5 points Unsatisfactory - below 5 points

You can ask you teacher for the copy of the correct answers.

Answer Sheet
Score = ___________

Rating: ____________

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 Information Sheet-3 Checking and calibrating Measuring instruments.

3.1. What is calibration?

There are as many definitions of calibration as there are methods. According to ISA‘s
The Automation, Systems, and Instrumentation Dictionary, the word calibration is
defined as ―a test during which known values of measured are applied to the transducer
and corresponding outputreadings are recorded under specified conditions.‖ The
definition includes the capability to adjust the instrument to zero and to set the desired
span. An interpretation of the definition would say that a calibration is a comparison of
measuring equipment against a standard instrument of higher accuracy to detect,
correlate, adjust, rectify and document the accuracy of the instrument being compared.
Typically, calibration of an instrument is checked at several points throughout the
calibration range of the instrument. The calibration range is defined as ―the region
between the limits within which a quantity is measured, received or transmitted,
expressed by stating the lower andn upper range values.‖ The limits are defined by the
zero and span values. The zero value is the lower end of the range. Span is defined as
the algebraic difference between the upper and lower range values. The calibration
range may differ from the instrument range, which refers to the capability of the
instrument. For example, an electronic pressure transmitter may have a nameplate
instrument range of 0–750 pounds per square inch, gauge (psig) and output of 4-to-20
milliamps (mA). However, the engineer has determined the instrument will be calibrated
for 0-to-300 psig = 4-to-20 mA. Therefore, the calibration range would be specified as 0-
to-300 psig = 4-to-20 mA. In this example, the zero input value is 0 psig and zero output
value is 4 mA. The input span is 300 psig and the output span is 16 mA. Different terms
may be used at your facility. Just be careful not to confuse the range the instrument is
capable of with the range for which the instrument has been calibrated.

3.2 what are the characteristics of a calibration?

 Calibration Tolerance: Every calibration should be performed to a
specifiedtolerance. The terms tolerance and accuracy are often used incorrectly.
In ISA‘s The Automation, Systems, and Instrumentation Dictionary, the definitions
for each are as follows:

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  Accuracy: The ratio of the error to the full scale output or the ratio of the error to
the output, expressed in percent span or percent reading, respectively.
 Tolerance: Permissible deviation from a specified value; may be expressed in
measurement units, percent of span, or percent of reading. As you can see from
the definitions, there are subtle differences between the terms. It is recommended
that the tolerance, specified in measurement units, is used for the calibration
requirements performed at your facility. By specifying an actual value, mistakes
caused by calculating percentages of span or reading are eliminated. Also,
tolerances should be
specified in the units measured for the calibration.

For example, you are assigned to perform the calibration of the previously
mentioned 0-to-300 psig pressure transmitter with a specified calibration
tolerance of ±2 psig. The output tolerance would be:

The calculated tolerance is rounded down to 0.10 mA, because rounding to 0.11
mA would exceed the calculated tolerance. It is recommended that both ±2 psig
and ±0.10 mA tolerances appear on the calibration data sheet if the remote
indications and output milliamp signal are recorded.
Note the manufacturer‘s specified accuracy for this instrument may be 0.25% full
scale (FS). Calibration tolerances should not be assigned based on the
manufacturer‘s specification only.
Calibration tolerances should be determined from a combination of factors. These
factors include:
 Requirements of the process
 Capability of available test equipment
 Consistency with similar instruments at your facility
 Manufacturer‘s specified tolerance

E x a mp l e : The process requires ±5°C; available test equipment is

capable of ±0.25°C; and manufacturer‘s stated accuracy is ±0.25°C. The

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 specified
calibration tolerance must be between the process requirement and
manufacturer‘s specified tolerance. Additionally the test equipment must
be capable of the tolerance needed. A calibration tolerance of ±1°C might
be assigned for consistency with similar instruments and to meet the
recommended accuracy ratio of 4:1.
 Accuracy Ratio: This term was used in the past to describe the relationship
between the accuracy of the test standard and the accuracy of the instrument under
test. The term is still used by those that do not understand uncertainty calculations
(uncertainty is described below). A good rule of thumb is to ensure an accuracy
ratio of 4:1 when performing calibrations. This means the instrument or standard
used should be four times more accurate than the instrument being checked.
Therefore, the test equipment (such as a field standard) used to calibrate the
process instrument should be four times more accurate than the process
instrument, the laboratory standard used to calibrate the field standard should be
four times more accurate than the field standard, and so on. With today's
technology, an accuracy ratio of 4:1 is becoming more difficult to achieve. Why is a
4:1 ratio recommended? Ensuring a 4:1 ratio will minimize the effect of the accuracy
of the standard on the overall calibration accuracy. If a higher level standard is
found to be out of
tolerance by a factor of two, for example, the calibrations performed using
that standard are less likely to be compromised.
Suppose we use our previous example of the test equipment with a tolerance of
±0.25°C and it is found to be 0.5°C out of tolerance during a scheduled calibration.
Since we took into consideration an accuracy ratio of 4:1 and assigned a calibration
tolerance of ±1°C to the process instrument, it is less likely that our calibration
performed using that standard is compromised. The out-of-tolerance standard still
needs to be investigated by reverse traceability of all calibrations performed using
the test standard. However, our assurance is high that the process instrument is
within tolerance. If we had arbitrarily assigned a calibration tolerance of ±0.25°C
to the process instrument, or used test equipment with a calibration tolerance of
±1°C, we would not have the assurance that our process instrument is within
calibration tolerance. This leads us to traceability.

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 Traceability: All calibrations should be performed traceable to a nationally
or internationally recognized standard. For example, in the United States, the
National Institute of Standards and Technology (NIST), formerly National Bureau of
Standards (NBS), maintains the nationally recognized standards. Traceability is
defined by ANSI/NCSL Z540-1-1994 (which replaced MIL-STD-45662A) as ―the
property of a result of a measurement whereby it can be related to appropriate
standards, generally national or international standards, through an unbroken chain
of comparisons.‖ Note this does not mean a calibration shop needs to have its
standards calibrated with a primary standard. It means that the calibrations
performed are traceable to NIST through all the standards used to calibrate the
standards, no matter how many levels exist between the shop and NIST.

 Traceability is accomplished by ensuring the test standards we use are

routinely calibrated by ―higher level‖ reference standards. Typically the
standards we use from the shop are sent out periodically to a standards lab
which has more accurate test equipment. The standards from the calibration
lab are periodically checked for calibration by ―higher level‖ standards, and
so on until eventually the standards are tested against Primary Standards
maintained by NIST or another internationally recognized standard.

 The calibration technician‘s role in maintaining traceability is to ensure the

test standard is within its calibration interval and the unique identifier is
recorded on the applicable calibration data sheet when the instrument
calibration is performed. Additionally, when test standards are calibrated, the
calibration documentation must be reviewed for accuracy and to ensure it
was performed using NIST traceable equipment

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 Uncertainty: Parameter, associated with the result of a measurement that
characterizes the dispersion of the values that could reasonably be attributed to
the measurand. Uncertainty analysis is required for calibration labs conforming
to ISO 17025 requirements. Uncertainty analysis is performed to evaluate and
identify factors associated with the calibration equipment and process
instrument that affect the calibration accuracy. Calibration technicians should be
aware of basic uncertainty analysis factors, such as environmental effects and
how to combine multiple calibration equipment accuracies to arrive at a single
calibration equipment accuracy. Combining multiple calibration equipment or
process instrument accuracies is done by calculating the square root of the sum
of the squares, illustrated below:

3.3 Requirement of calibration

It makes sense that calibration is required for a new instrument. We want to make sure
the instrument is providing accurate indication or output signal when it is installed. But
why can‘t we just leave it alone as long as the instrument is operating properly and
continues to provide the indication we expect?

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Instrument error can occur due to a variety of factors: drift, environment, electrical
supply, addition of components to the output loop, process changes, etc. Since a
calibration is performed by comparing or applying a known signal to the instrument
under test, errors are detected by performing a calibration. An error is the algebraic
difference between the indication and the actual value of the measured variable

3.4 purpose of calibrating Measuring instruments

 To ensure the products designed are within the process and measuring
instruments capabilities available in the plant.
 To minimize the cost of inspection by effective use of available facilities, and to
reduce the cost of rejects and rework through application of Statistical Process
Control techniques.
 .Standardization of measuring methods. This is achieved by laying down the
inspection methods for any product right at the time when the production
technology is prepared.
 Maintenance of the measuring instruments used in the plant.
 to ensure that the part to be measured conforms to the established standard.
 to meet the interchangeability of manufacture.
 to provide customer satisfaction by ensuring that no faulty product reaches the
customers.
 to coordinate the functions of quality control, production, procurement & other
departments of the organization.
 to judge the possibility of making some of the defective parts acceptable after
minor repairs.

3.5 Rules to follow checking and calibrating Measuring instruments

 Establish realistic calibration intervals;
 List all measurement standards
 List all environmental conditions for calibration;
 Ensure the use of calibration procedures for all equipment and standards;
 Coordinate the calibration system with all users
 Assure that equipment is frequently checked by periodic system or cross-
checks in order to detect damage, inoperative instruments, erratic readings,
and other
performance degrading factors that cannot be anticipated or provided for by

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 calibration intervals;
 . Provide for timely and positive correction action;
 Establish decals, reject tags, and records for calibration labeling;
 Maintain formal records to assure proper controls.

Any equipment that does not have specific calibration intervals should be
 examined at least every six months, and
 calibrated at intervals of no longer than one year. Adjustments or
assignment of calibration intervals should be done in such a way that a
minimum of 95% of equipment, or standards of the same type, is within
tolerance when submitted for regularly scheduled recalibration. In other
words, ifmore than 5% of a particular type of equipment is out of tolerance at
the
end of its interval, then the interval should be reduced until less than 5% is
defective when checked.

3.6 Calibration record system

 A record system should be kept on every instrument, including:
 History of use;
 Accuracy;
 Present location; 4 Calibration interval and when due;
 Calibration procedures and necessary controls;
 Actual values of latest calibration;
 History of maintenance and repairs.

Test equipment and measurement standards should be labeled to indicate the

date of last calibration, by whom it was calibrated, and when the next calibration is
due. When the size of the equipment limits the application of labels, an identifying
code should be applied to reflect the serviceability and due date for the next
calibration. This provides a visual indication of the calibration serviceability status.
Both the headquarters calibration organization and the instrument user should
maintain a two-way check on calibration. A simple means of doing this is to have a
small form for each instrument with a calendar of weeks or months (depending on
the interval required) across the top, which can be punched and noticed to indicate
the calibration due date.

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  Common Measuring instrument for inspection are
 Visual inspection
 Audio gage
 Vibration analyzer
 Amplitude meter
 Pressure gage
 Strain gage


Defects Errors / Details Calibrated Place of Next Calibration Remarks

found(if Defects of by use calibration lab in
any) After repairs due on charge
repairs carried
(if any) out

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 3.7 Calibration labeling

Typical calibration labeling

Typical calibration labeling card

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 Self-Check -3 Written Test

Directions: Answer all the questions listed below. Use the Answer sheet provided in
the next page:

1. Which one of the following is not characteristics of a calibration

A. Tolerance
B. Accuracy
C. A and B
D. None

2. Which one of the following is not purpose of calibrating Measuring instruments

A. Maintenance of the measuring instruments used in the plant
B. Standardization of measuring methods
C. To minimize the cost of inspection
D. None
3 . A record system should be kept on every instrument all of the following except ---
-----
A. History of use
B. Accuracy
C. Calibration interval and when due.
D. None
4. One of the following is Measuring instrument for inspection
A. Visual inspection
B. Audio gage
C. Vibration analyzer
D. All
5. Measuring of test equipment and standards description should cover
A. Establish realistic calibration intervals
B. List all measurement standards
C. List all environmental conditions for calibration
D. Al

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Part II
Say rue or False
1. Measuring instruments are measuring devices that transform the measured
quantity into an indication or information.
2. Calibration is a comparison of measuring equipment against a standard
3. In the Direct method of measurement the value of a quantity is obtained
directly by comparing the unknown with the standard..
4. In the Deflection method the value of the quantity is directly indicated by
deflection of a pointer on a calibrated scale.
5. The calibration range may differ from the instrument range, which refers to the
capability of the instrument

Note: Satisfactory rating - 6 points Unsatisfactory - below 6 points

You can ask you teacher for the copy of the correct answers.

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 Segregate (separate) and label Non-functional
Information Sheet-4
tools, instruments and equipment

4.1 Classify non-Functional and functional tools

Tools are very useful to us in our homes especially to our job. But tools that are no
longer functional may cause harm.
A. Make an inventory of functional and non-functional tools in your shop.
B. Classify your tools according to there function.
4.1.1 Method of identifying non-functional tools and equipment
 Visual inspection. It refers to the visual observation of an expert on the
appearance of the tools and equipment.
 Functionality. Vibration or extra noise from the operation means
problems on parts and accessories started to develop.
 Performance. When there is something wrong with the performance of
either hand tools or equipment they need an immediate repair or
maintenance.
 Power supply (for electrically operated only). Failure to meet the
required power supply, malfunction will occurs in the part of hand tools
or equipment.
 Person‘s involved. It refers to the technical person who has the
knowledge and skills about the technology.
 Classifications of tools and equipment according to their uses:
 Measuring tools
 Holding tools
 Cutting tools
 Driving tools
 Boring tools
 Electrical equipment
 Miscellaneous tools/instrument/equipment
 Non-functional tools and equipment are those that are notable to perform its
regular function because of impaired and damage part. Examples of these are the
following:

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Hammer with a broken handle Screw driver with a broken handle Long Nose Pliers with
damage jaw

 Functional tools and equipment are those that are in good condition and can
perform its regular functions. Examples of these are the following:
Standard screw driver Philips Screw Driver Combination pliers

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 .

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 Self-Check -4 Written Test

Directions: Answer all the questions listed below. Use the Answer sheet provided in
the next page:

1. Which one of the following is not method of identifying non-functional tools and
equipment
A. Visual inspection.
B. Functionality
C. Performance
D. None

2. Which one of the following is Classifications of tools

A. Measuring tools
B. Holding tools
C. Cutting tools
D. All
3 . A ------------------ is refers to the technical person who has the knowledge and skills
about the technology.
A. Person‘s involved.
B. Electrical equipment
C. Miscellaneous tools
D. None
4. One of the following is Measuring instrument for inspection
A. Visual inspection
B. Audio gage
C. Vibration analyzer
D. All
5. Measuring of test equipment and standards description should cover
A. Establish realistic calibration intervals
B. List all measurement standards
C. List all environmental conditions for calibration
D. All

Part II

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Say True or False
1. Functional tools and equipment are those that are in good condition and can perform
its regular functions
2. Functional tools and equipment are those that are in good condition and can perform
its regular functions.
3. Tools are very useful to us in our homes especially to our job. But tools that are no
longer functional may cause harm.
4. Visual inspection is refers to the visual observation of an expert on the appearance of
the tools and equipment.

Note: Satisfactory rating - 9points Unsatisfactory - below 9 points

You can ask you teacher for the copy of the correct answers.

Answer Sheet
Score = ___________

Rating: ____________

Name: _________________________ Date: _______________

Short Answer Questions

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 Recording or reporting status/report on
Information Sheet-5
pro-forma or orally

5.1 Introduction
 It will be necessary to record any unsafe actions or conditions observed during
your inspection tour.
 A well-written inspection report will establish the location of the condition or action
observed.
 Give it a hazard rating.
 Provide some guidelines regarding action taken by the inspection team.
 Recommend corrective action and assign accountability for ensuring corrective
action by a certain date.
 Well-written inspection reports communicate to management, supervision and the
safety committee. They will be used to make records, plot trends and develop
statistics on the hazards found in the workplace.

5.2 Hazard Ratings

Classify each item that you observe and record during your inspection tour. This
hazard rating establishes priorities for corrective action and also highlights the
level of severity or seriousness of the hazards.

How does the ABC rating system work?

The A, B, C rating method is used to rate items observed during a safety
inspection. The reason for this system is to highlight the degree of severity of
those hazards and to assist both the inspectors and the employer in carrying out
corrective actions. The following examples can be used as guidelines.
 "A" Hazard

 Any condition or practice that has potential for causing loss of life, body part
and/or extensive loss of structure, equipment or material.

 Generally this means that immediate corrective action is required. Activity

should be discontinued until the hazard is corrected, e.g.
A window washer is seen working on the third floor level without any safety
belt, hanging on with one hand and leaning out to work.

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 Workers are seen in a ditch, about six feet in depth, vertical sides, no
shoring, sloping or other means of protection.
Bricklayers are observed up on scaffolding, 15 ft. high, without handrails or
safety belts.

 "B" Hazard

 Any condition or practice with the potential for causing a serious injury,
illness or property damage.

 Urgent situation. Requires attention as soon as possible, e.g.

Forklift trucks are rounding a blind corner into a loading area without
stopping.
Someone has spilled lube oil on the main floor, leading to the areas where
workers must gain access.
Workers observed smoking in a flammable storage area.

 "C" Hazard

 Any condition or practice with a probable potential for causing a non-

disabling injury or non-disruptive property damage.

 These types of hazards should be eliminated without delay, but the situation
is not an emergency, e.g.
Worker using a hammer with a loose head, in use on a daily basis for odd
jobs. Worker using a heavy file without file handle.
Oxygen and acetylene cylinders stored together, caps on, good ventilation,
fireproof surroundings.

Hazard Rating Lists

It may be helpful if the people involved in doing inspections (e.g. employer
representatives, worker representatives, health and safety committee
members) develop a hazard rating list to use during workplace inspections. If
this list is used for all inspections, then hazards will be rated consistently on
inspection reports no matter who is inspecting or when inspections are done.

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5.3 Note all items observed
Record any items that are not up to your predetermined checklist standards. Do not
eliminate any condition or action because you had it corrected during the inspection.
Remember that you are developing a record of what you found during that inspection.
Any items from previous inspections should be noted as "repeat" items.

Copies of inspection reports must be sent to:

Management
Joint health and safety committees
Worker health and safety representatives
Supervisors
Safety coordinator
Maintenance
Others?

5.4 Record keeping

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5.4.1. Reports
Keeping inspection records is important. Past inspection records show what has been
previously identified. They also show what an earlier inspection team concentrated on
and what areas it did not inspect. Do not simply repeat or copy previous inspection
results. Use the older inspection reports to help look for issues, and then determine
whether recommendations were implemented. Note if the changes have been effective.

5.4.2 Types of inspection reports

The following describes three other types of inspection reports:
 ongoing inspections as part of their job responsibilities. Such inspections identify
hazardous conditions and either correct them immediately or report them for
corrective action. The frequency of these inspections varies with the amount and
conditions of equipment use. Daily checks by users assure that the equipment meets
minimum acceptable safety requirements.
 Pre-operation checks involve inspections of new or modified equipment or
processes. Often these are done after workplace shutdowns.
 Periodic inspections are regular, planned inspections of the critical components of
equipment or systems that have a high potential for causing serious injury or illness.
The inspections are often part of preventive maintenance procedures or hazard
control programs. Laws and regulations may specify that qualified or competent
persons must inspect certain types of equipment, such as elevators, boilers, pressure
vessels, scaffolding, and fire extinguishers at determined points in the work process
and at regular intervals.

5.4.3. Final report

To make a report, first copy all unfinished items from the previous report on the new
report. Then write down the observed unsafe condition and recommended methods of
control. Enter the department or area inspected, the date and the inspection team's
names and titles on top of the page. Number each item consecutively, followed by a
hazard classification of items according to the chosen scheme.
State exactly what has been detected and accurately identify its location. Instead of
stating "machine unguarded," state "guard missing on upper pulley #6 lathe in North
Building." Assign a priority level to the hazards observed to indicate the urgency of the
corrective action required. For example:

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A = Major - requires immediate action
B = Serious - requires short-term action
C = Minor - requires long-term action
Report issues in a concise, factual way. Management should be able to understand and
evaluate the problems, assign priorities and quickly reach decisions.
After each listed hazard, specify the recommended corrective action and establish a
definite correction date if possible and appropriate. Each inspection team member
should review for accuracy, clarity and thoroughness.

Example of Workplace Inspection Report

Inspection Location: __________________ Date of Inspection: __________________
Department/Areas Covered: __________ Time of Inspection: _____________
Observations
Item and Hazard( Repea Priorit Recommen Responsi Action Date
Location s) t Item y ded Action ble Taken
Observe Y / N A/B/C Person
d

Copies to: _________________ Inspected by: ___________________

5.4.4 Daily Coolant Report Card

Here is a sample machine check sheet which can be used to track the
condition of a particular machine or system in regards to evaporation rates
over time, deterioration based on pH, and record of cleanouts. Other
fields may be added, including bacterial and fungal levels, water hardness,
conductivity and TDS.

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 5.4.5 Preventive Maintenance Recording Form
Records

Maintenance Recording Form

Maintenance Schedule Matrix
Approval signature: [signature]
Document to be posted? [Yes/No]
Distribution to: [distribution]

Important Reminder: It is a requirement that this information is documented for all

equipment in the workplace, examples include (but not limited to) production,
maintenance, and transportation equipment. Preventive Maintenance Recording Form
The assigned maintenance personnel must complete this form. The original submitted to
the Head of Maintenance at the end of every week. A copy will kept in the maintenance
files.
Item Information
List of items (parts to
be inspected)
Description of work
performed
Reporting any
deficiencies
Recommendations for
correcting deficiencies
identified

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Action taken(who,
what, when)
Inspector name
Inspector signature
Date of inspection

Maintenance Schedule Matrix

Vehicle license Schedule
Year/Model Who does maintenance
Number Number

Schedule number
1 Daily, 2. Weekly, 3.As per manufacturer‘s requirements.

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 Self-Check - 5 Written Test

Directions: Answer all the questions listed below. Use the Answer sheet provided in
the next page:
1. Copies of inspection reports must be sent to:
A. Management
B. Joint health and safety committees
C. Worker health and safety representatives
D. All
2. Which one of the following is not Samples for Preventive Maintenance Recording
Form
A. Maintenance Recording Form
B. Maintenance Schedule Matrix Cutting tools
C. A & B
D. None
3 . A ------------------ is refers to the technical person who has the knowledge and skills
about the technology.
A. Person‘s involved.
B. Electrical equipment
C. Miscellaneous tools
D. None
4. One of the following is Measuring instrument for inspection
A. Visual inspection
B. Audio gage
C. Vibration analyzer
D. All
5. Measuring of test equipment and standards description should cover
E. Establish realistic calibration intervals
F. List all measurement standards
G. List all environmental conditions for calibration
H. All

Part II

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Say True or False
6. Well-written inspection reports communicate to management, supervision and the
safety
committee. Calibration is a comparison of measuring equipment against a
standard
7. It will be necessary to record any unsafe actions or conditions observed during
your
inspection tour
8. A well-written inspection report will establish the location of the condition or action
observed
9. Recording Provide some guidelines regarding action taken by the inspection team
10.The A, B, C rating method is used to rate items observed during a safety
inspection.

Note: Satisfactory rating - 6 points Unsatisfactory - below 6 points

You can ask you teacher for the copy of the correct answers.
Answer Sheet
Score = ___________

Rating: ____________

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 Prescribing operational procedures
Operation Sheet-1

Procedures for Prescribing operation

Step 1- A clear, step-by-step procedure, in checklist form, for controlling hazardous
energy:
Step 2- Hazards identification
Step 3- Selection and specification of personal protective equipment:
Step 4- Selection and specification of tools to be used:
Step 5- Step-by-step procedure for disassembly
Step 6- Step-by-step checklist for inspection of components (to establish a baseline
for reliability)
Step 7- Identification of hazards associated with sub-procedures:
Step 8- Erection and disassembly of scaffolding and other temporary platforms
Step 9- Disassembly of small-scale equipment
Step 10- Reassembly of small-scale equipment
Step 11- Support and disassembly of large scale equipment
Step 12-Support and reassembly of components of large scale equipment
Step 13- Use of hoists and mobile working platforms
Step 14- Safe use of ladders especially near live electrical equipment

Operation Sheet 2 Segregating and labeling nonfunctional tool and

equipment

Procedures for Segregating and labeling nonfunctional tool and equipment

Step 1- Conduct an inventory of tool and equipment.
Step 2-Record the number of nonfunctional tool and equipment
Step 3-Segregate tool that are serviceable or unserviceable.
Step 4-Report the number of tool and equipment that are nonfunctional but
subject for repair.
Step 5-Label tool and equipment which are condemnable.
Step 6-Return tools and equipment in the tool cabinet as per operating
procedures.

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 LAP Test Practical Demonstration

Name: _____________________________ Date: ________________

Time started: ________________________ Time finished: ________________
Instructions: Given necessary templates, tools and materials you are required to
perform the following tasks within --- hour.

Task 1. Prescribe operational procedures

Task 2. Segregate and label nonfunctional tool and equipment

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 Instruction Sheet Learning Guide #18

This learning guide is developed to provide you the necessary information regarding the
following content coverage and topics –
 Cleaning and lubricating Machines / equipment
 Removing/replacing consumable components
 Replacing and/or topping up Fluids and lubricants.
 Performing minor machine repairs.
 Adjusting machine moving parts

This guide will also assist you to attain the learning outcome stated in the cover page.
Specifically, upon completion of this Learning Guide, you will be able to –
 clean and lubricate machines/equipment using appropriate lubricant, according to
preventive maintenance schedule or manufacturer‘s specifications/instructions
following standard procedures
 undertake removal/replacement of consumable components to prescribed
procedure and instructions
 Replace and/or top up Fluids and lubricants to prescribed schedule and
according to manufacturer‘s instructions
 perform Minor machine repairs according to manual instruction or workplace
procedures
 Adjusted Machine moving parts to manufacturer‘s specifications

Learning Instructions:
1. Read the specific objectives of this Learning Guide.
2. Follow the instructions described below.
3. Read the information written in the ―Information Sheets‖. Try to understand what are
being discussed. Ask your trainer for assistance if you have hard time understanding
them.
4. Accomplish the ―Self-checks‖ which are placed following all information sheets.
5. Ask from your trainer the key to correction (key answers) or you can request your
trainer to correct your work. (You are to get the key answer only after you finished
answering the Self-checks).
6. If you earned a satisfactory evaluation proceed to ―Operation sheets
7. Perform ―the Learning activity performance test‖ which is placed following ―Operation
sheets‖ ,
8. If your performance is satisfactory proceed to the next learning guide,
9. If your performance is unsatisfactory, see your trainer for further instructions or go
back to ―Operation sheets‖.

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 Cleaning and lubricating Machines / equipment by
Information Sheet 1
preventive maintenance schedule

1.1. Introduction
1.1.1 Cleaning and Lubrication
Cleaning of equipments, components, working tools, hands or working gloves and
workplace etc, before taking repairs, during and after repairs is of prime importance,
but is often not given due consideration. Cleaning is often considered ―donkey‘s job‖
and is left to some unskilled worker to decide and do. But the type and extent of
cleaning is purely a technical requirement, depending on the subsequent jobs to be
done. Cleaning of components is, normally, assisted by kerosene, petrol, carbon-
tetra-chloride (CTC) and many other solvents.

In hydraulic system, dirt and dust are the biggest enemy for sophisticated valves,
pumps and control equipments/ items, which calls for proper covering and sealing of
tanks, use of suitable filters during oil changing and repair of components to be done
in dust-free room/ enclosure. For cleaning of rust, sediments and deposits from
water-cooled components (furnace doors, heat shields), heat exchangers and tube-
nests etc, suitable chemicals and solvents are used which soften and loosen the
deposits so that the deposits come out by water or air force. Very often, high
pressure water jets (pressure over 160 bar) are used for descaling of big tube-nests,
heat-exchangers and condensers etc. Steam cleaning is also used often for many
components.

Magnetizers have been developed (using permanent magnets or electromagnets),

which can be clamped on the pipelines. The rust in water line or sludge in fuel lines
get ionized and detached from the inner surface of the pipe lines and remain
suspended or floating! moving as long as magnetic field exists. By placing number of
such magnetizers on the pipe length, the rust and slizdge can be taken to the tank
and removed. Scrubbing, etching, skinning, burnishing, vacuum cleaning, extractors
and many other such techniques are used for cleaning as per need. Many
customized cleaning equipments are available and also many brands and types of

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 cleaning fluids are available in market. You have to select the fluid, techniques and
cleaning equipments as per specific requirement for job.
 Cleaning the Machine proper procedures for care and feeding
The entire machine must be cleaned after every use. If another user needs
the machine, immediately after you, make sure you discuss who will leave
the machine clean. The process is simple and should not take more than
10 minutes. Make sure you are aware of clock to leave enough time to
finish clean-up.

Lubrication can be considered as vital part of a machine as any of the working

parts. Of course the various bearings, gears and cams which make up any machine
today must be carefully designed and precision made of the best materials to meet
the demands of modern high speed production. But without proper lubrication, these
same working parts would soon develop rapid wear and eventual failure. Then the
machine would be useless as a production tool. All of us in the plant have an
important role to play in an effective lubrication program. The foreman and machine
operator can be sure of 'getting out the goods' only if the lubrication service man has
properly lubricated the machine. In turn, the lubrication service man can lubricate his
machines properly only if the engineer has properly designed the machine and
specified the right lubricant for it. And in turn, the maintenance mechanic depends
upon proper lubrication to keep the machines running. It is a programme in which all
of us have an important role to play.

1.1.2 Kinds of friction

Friction can be classified into two types; solid friction which may be either sliding or
rolling, and fluid friction. Sliding friction occurs when two surfaces slide over each other
without lubrication as in a plain bearing or between a piston and a cylinder. Rolling
friction occurs when a cylindrical or spherical body rolls over another surface without
lubrication as in the modern ball and roller bearings. We require less force to overcome
rolling friction than sliding friction. Hence solid friction essentially occurs when there is no
lubrication. Now to compare fluid friction with solid friction, if a film of oil is introduced
between the same two surfaces, the peaks and valleys are filled up by the particles of
oil. When a sufficient number of these particles of oil are placed between the two
surfaces to produce a thick strong film, then the peaks and valleys slide by each other
without inter-loading.

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When such surfaces either flat, curved or spherical, are kept apart by a fluid film, we
have what we call fluid friction and these surfaces are said to be lubricated.

Therefore, in lubrication we actually reduce friction to a minimum by substituting fluid

friction for solid friction.
Friction is governed by following two laws:
 The frictional force is proportional to normal loads.
 Friction is independent of the size of bodies.

 Wear
Wear can be defined as undesired removal of material due to mechanical action. It is
poorly understood in the scientific sense. By a conventional method wear is divided into
following main types:
 Adhesive
 Abrasive
 Corrosive
 Fatigue
Adhesive wear means damage resulting when two metallic bodies rub together without
the deliberate presence of an abrasive agent.
Abrasive wear is characterized by damage to a surface by harder material introduced
between two rubbing surfaces from outside. The severity of abrasive wear depends on
size and angularity of abrasive particles and also the ratio between hardness of metal
and the abrasive particles, more the tendency to wear.
Fatigue wear occurs due to cyclic stresses in rolling and sliding contacts as in gears
and rolling bearings.
Corrosive wear occurs due to corrosion. Rusting is a well known example. The
presence of moisture, oxygen availability and dusty conditions accelerate corrosive
wear.

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1.1.3 VISCOSITY
Viscosity is defined as the internal frictional resistance offered by a fluid to change its
shape or relative motion of its parts. An oil film placed between two parallel plates is
shown in Fig. The lower plate is stationary while the upper plate is moved with a velocity
v by means of a force P. The molecules of oil are visualized as small balls which roll in
layers between two plates.
The oil will stick to both the surfaces, and therefore the layer of molecules in contact with

the stationary plate has zero velocity. Similarly, the layer of molecules in contact with the
upper plate will move with a velocity v. The intermediate layers will move with velocities
which are proportional to their distance from the Stationary plate.

Note
 A low viscosity oil is thin and flows easily
 A high viscosity oil is thick and flows slowly.
 As oil heats up it becomes more viscous (Becomes thin)
 If the oil is too thin(has very low viscosity) it will be forced out from between the
moving parts, resulting in rapid wear.
 If the oil is too thick(has very high viscosity) it will flow very slowly to engine
parts, especially when the engine and the oil are cold, resulting in rapid wear.

1.1.4 lubricant properties

Properties of a good lubricant are:
 It should give rise to low friction.
 It should adhere to the surface and reduce the wear.
 It should protect the system from corrosion.
 It should have good cleaning effect on the surface.
 It should carry away as much heat from the surface as possible.

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  It should have thermal and oxidative stability.
 It should have good thermal durability.
 It should have antifoaming ability.
 It should be compatible with seal materials.
 It should be cheap and available in plenty.

1.1.5 lubricant application methods

The methods for lubricating tools/machine can be divided into following categories.
 Manual Devices
Lubricating methods may require human action in one form or another. The term manual
lubrication applies to methods in which the operator is directly responsible for quantity of
lubricant and interval of lubrication. Although the initial cost of manual lubrication is low,
the maintenance costs can be high. Reliability may be owing to considerable
dependence on human action. The lubricant is quite prone in contamination.
Generally speaking, manual lubrication is satisfactory only for lightly loaded or low speed
bearings, typical applications include open gears, chains, wire rope, etc.
 Drop-feed Devices :
Drop feed devices are gravity-flow lubricators. They are employed to deliver lubricant
drop-by-drop to individual bearings and other machine elements. They give the best
advantage when lubricant points are readily accessible.
Their cost is relatively low. Maintenance cost depends on type of service and location.
Depending on the lubricator, lubricant flow may or may not be stopped and started
automatically. Automatic operation increase reliability.
Typical service applications include journal and roller bearings, gears, chains, engine
guides, pumps and compressors.
 Splash or Bath Lubrication :
This type of lubrication is commonly used for machinery having high speed moving
parts. These dip into oil and splash it on to the bearings or other machine elements. The
splash system requires enclosing the mechanism to be lubricated.
Initial cost of splash system depends on the expense incurred in enclosing the
mechanism. Maintenance costs are low. A splash system is reliable, prevents
contamination. Typical applications include internal-combustion engines, chain drives
and enclosed gear sets.
 Ring, Chain, Oilers :

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These lubricators are applicable to horizontal rotating shafts. The ring or chain oiler
encircles the shaft and turns freely on it. Each provides an automatic oiling system by
bringing oil to the bearing clearance from the oil reservoir.
Initial cost depends on housing for the bearing that must be built to contain these
lubricators. Maintenance cost is usually low.
Typical applications include electric motors, fans, blowers, compressors, and line shaft
bearings.
 Pad-and Waste-type Devices :
These lubricators use the oil-retaining properties of felt pads and waste packing to
provide the lubricant to a bearing. Oil is lifted from the reservoir by capillary action in the
wicking material. This system requires an appropriate housing, which accounts for a
large initial cost. Maintenance cost generally depends on the environment in which they
are used. They are generally low. This is often used for rail, road and traction motor
bearings.
 Positive Force feed Lubricators :
It consists of one or more plunger-type adjustable-stroke pumps mounted on a common
reservoir. The pumps are driven from a rotating shaft through a mechanical linkage. It
may have a separate drive motor.
Initial cost is high, but maintenance cost is low. The lubricant is free from contamination.
Typical applications include steam cylinders, bearings for diesel and gas engines, oil-
drilling rigs, etc.
 Air-oil Devices :
Air-oil devices operate by injecting or pumping oil drop-by-drop into an air stream. The
oil is drawn by the aspiratory action of compressed air passing through an orifice or
control valve.
The initial-cost is very high. However, maintenance costs are low and efficiency of the
devices is high. These are well suited for high speed bearings, enclosed gears, slides
and table ways.

 Pressure Circulating Systems :

Pressure circulating systems employ either gravity or pumps to develop the operating
pressures necessary. Generally these are designed to lubricate a number of parts on the
machine. Since oil is recirculated maximum economy is possible. Pressure circulating
systems are built into the machine. Therefore initial cost is high. Maintenance costs are
very low.

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Typical applications include steam-turbine bearings, reduction gears, steel-mill gear
drives, mill bearings, paper-machine bearings and gears and internal-combustion
engines.

 Centralized Lubrication Systems :

Centralized Systems can be designed for oil or grease. A typical centralized system
requires centrally located reservoir and pump, and permanently installed piping and
distribution valves. These deliver measures quantities of lubricant at desired points. It
can be either operated manually or automatically.
The piping and intricate dispensing valves make initial cost very high, but maintenance
costs are very low. Initial cost is offset by dependability, durability, safety and resistance
of system to contamination.
Centralized Systems are ideally suited for steel and paper mills, machine tools etc.
 Built-in-Lubrication :
Built-in lubrication refers to materials or components that do not require any external
lubricating device. Materials such as oil saturated porous metals, graphite materials,
poly-tetra-fluoro-ethylene(PTFE), nylon can rub together without a lubricant. These
materials may be used for sleeve bearings, gears etc.

1.2 Classification of lubricants

All lubricants are classified into the following three groups:
 Liquid lubricants are usually used in bearings are mineral oils and synthetic oils.
The mineral oils are most commonly used because of their cheapness and
stability. The liquid lubricants are usually preferred where they may be retained.
 Semi-liquid (or grease) lubricant is a lubricant with higher viscosity than oils.
The greases are employed where slow speed and heavy pressure exist and
where oil drip from the bearing is undesirable.
 Solid lubricants are useful in reducing friction where oil films cannot be
maintained because of pressures or temperatures. They should be softer than
materials being lubricated. A graphite is the most common of the solid lubricants
either alone or mixed with oil or grease.

1.3 Functions of lubricant

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  Separate moving materials from each other in order to prevent wear,
scoring, and seizure;
 Reduce heat;
 Keep out contaminants;
 Protect against corrosion;
 Wash away worn materials.
Good lubrication requires two conditions: sound technical design for
lubrication and a management program to assure that every item of
equipment is properly lubricated.

1.4 Best Maintenance Lubrication Practices

 When using a grease hand gun: always clean the end of the grease gun
and the grease fitting with a clean rag or towel.
 When using a grease hand gun: always know the amount of grease
required and the frequency. Ask a vendor‘s lubrication engineer to assist
in this area. Check and mark your grease gun to ensure the amount of
grease is known and can be visualized for each type of grease gun one
uses.
 Always take oil samples when changing oil in a gearbox.
 When installing a new gearbox, replace the oil 24 hours after installation
to remove any contamination that may have been washed from the
gearbox cavity and gears.
 Always add hydraulic fluid into a reservoir using a filter cart
 Never touch a hydraulic filter with your hand during installation. By
touching the filter you will introduce contamination to the hydraulic
system.
 Never accept leaks on any type of lubrication line or bearing. Identify the
true problem and make a permanent repair.
 Ensure maintenance personnel performing lubrication practices score at
least a 90% on the lubrication assessment
 ALWAYS read and follow lubrication instructions from an equipment
manufacturer. If you must change the instructions, contact the
manufacturer first for comments.
In conclusion, lubrication can cause up to 80% of your equipment problems
if not performed in a disciplined manner.

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1.5 Lubrication Program Development
Information for developing lubrication specifications can come from four main sources:
 Equipment manufacturers
 Lubricant vendors
 Other equipment users
 Individuals‘ own experience.

 Like most other preventive maintenance elements, initial guidance on lubrication

should come from manufacturers. They should have extensive experience with their
own equipment both in their test laboratories and in customer locations. They should
know what parts wear and are frequently replaced. Therein lies a caution: a
manufacturer could, in fact, make short-term profits by selling large numbers of spare
parts to replace worn ones. Over the long term, however, that strategy will backfire,
and other vendors, whose equipment is less prone to wear and failure, will replace
them. Lubricant suppliers can be a valuable source of information. Most major oil
companies will invest considerable time and effort in evaluating their customers‘
equipment to select the best lubricants and intervals for change. Naturally, these
vendors hope that the consumer will purchase their lubricants, but the total result can
be beneficial to everyone. Lubricant vendors perform a valuable service of
communicating and applying knowledge gained from many users to their customers‘
specific problems and opportunities. Experience gained under similar operating
conditions by other users or in your own facilities can be one of the best teachers.
Personnel, including operators and mechanics, have a major impact on lubrication
programs. A major step in developing the lubrication program is to assign specific
responsibility and authority for the lubrication program to a competent maintainability
or maintenance engineer.

 The primary functions and steps involved in developing the program are to:
 Identify every piece of equipment that requires lubrication;
 Assure that all major equipment is uniquely identified, preferably with a
prominently displayed number
 Assure that equipment records are complete for manufacturer and
physical location

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  Determine locations on each piece of equipment that needs to be
lubricated
 Identify lubricant to be used
 Determine the best method of application
 Establish the frequency or interval of lubrication
 Determine if the equipment can be safely lubricated while operating, or if it
must be shut down
 Decide who should be responsible for any human involvement
 Standardize lubrication methods
 Package the above elements into a lubrication program
 Establish storage and handling procedures
 Evaluate new lubricants to take advantage of state of the art
 Analyze any failures involving lubrication and initiate necessary corrective
actions

1.6 preventive maintenance schedule

It is important to have a schedule for preventative maintenance of each item of
equipment. This consists of a timetable stating when (and how frequently) maintenance
should be done, and a list of maintenance activities for each item. These schedules
should provide simple guidelines for all types of equipment, covering the tasks to be
undertaken in the following areas:
 Care and cleaning
 Safety checks
 Functional and performance checks
 Maintenance tasks (changing bulbs, lubricating moving parts, etc.)
The best source of this information is usually the manufacturer's user and/or service
manual. Schedules need to be developed separately for both users and maintainers. For
example, users can perform checks and basic maintenance tasks on a daily basis,
whereas the maintenance team can set aside a specific day of the week or month to
carry out regular maintenance tasks. More sophisticated maintenance tasks, such as
those which need to be carried out by service agents, should be scheduled for a specific
day or week in the year.
It is helpful to display maintenance schedules for users on or near the equipment they
refer to; this can serve as a useful daily reminder of the tasks that should be performed.

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All Moving parts which subjected to sliding or rolling friction in all case Cleaning and
lubrication is must
 Lubrication – is generally considered to be the heart of P.M of a machine
 Regular planned preventive maintenance consists of
 Miner repair
 Lubrication
 Medium repair
 Major repair

1.6.1 A proper P.M schedule should be followed by

 Daily check P.M
The following duties should be performed by the operator
 To clean the machine
 To check lubrication oil level
 check the coolant level
 Lubricate all moving parts
 Inform to maintenance department even minor defect noted in the
Performance of a machine

 Weekly check P.M

The following check should be carried out by maintenance department:-
 Check all lubrication
 Check coolant
 Check all filters
 Check hydraulic & pneumatic lines

 Monthly check P.M
Monthly check should be carried out by maintenance department
 Check spindle drive belt for wear
 check hydraulic pumps & hydraulic oil
 Check movement of oil

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  Six monthly checks
Six monthly should be carried out by maintained department
 check machine alignmen
 To replace oil and filters

1.6.2 Activities of P.M

All P.M has some of the basic activates
 Planning
 What to do?
 How to do?
 . Schedule
 When to do?

1.6.3 P.M planning

 Program of P.M of a machine include
 Cleaning of all machine parts
 Lubrication
 Application of protective coating
 Repair of crack & other repairable damages
 Adjustment
 Inspection of state of component
 Replacement of worn out component
 Cost calculation
 Machine may stopped due to the following reason
 Break down maintenance
 Preventive maintenance

1.6.4 Use of preventive maintenance

 To prolong the life of the machine
 To reduce an expected break down
 To improve accuracy of the machine
 To insure quality &continuity of production

1.7 Lubrication practices in different lathe machine parts

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  Point on the machine to be lubricate

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  Lubrication in Headstock
An oil-splash feed is utilized in the lubrication system of Headstock. On top of
the Headstock there grooves surrounded providing lubricant flow into the
spindle bearing along the groove, then finally flow down on the bottom of the
box. When supplying the lubricant, remove the cap of oil sight glass. To drain
the waste oils away, a drainer hole located in the right side downward of the
Headstock. Please take good care of checking whether the Headstock has
been filled up with lubricant or not when you purchase the machine. If
negative. use as show in the figure (6-4) lubricating oil. We request you to
change the lubricant at first month and then do once every two months so to
assure the gears are working in the best conditions

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  Lubrication in Gear Box and Apron
 Gear Box is oil-bath lubricated to insure the lifetime of gears and bearing. It
is recommended the lubricant to be changed every six months.
 Apron is also oil-bathed. If the oil quantity in Apron is lower than center
level of oil sightglass. then it is time to add up some oil to standard level.

 Useful reference lubricating table for other mechanism

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  Headstock
 Prevent from oil leakage from top cover of Headstock:
Before covering the top cover of Headstock, whenever it is removed, please
wipe to clean the contact surface and apply some grease on it. Make sure it
is tightly securing by setscrews.

 Prevent from blocking up the oil circuit:

The leakage of front headstock cover mostly caused by over-filling the oil or a
block-up of oil circuit. In this moment, remove the Headstock cover first, then
blow
the air jet into two oil circuit hole, which is on up side and dovm side of front
Spindle bearing, in the same time to rotate the Spindle and it will work again.

 Apron and saddle

 Filler hole location of Apron: On the right plat form of Saddle. The filler
hole has oil plug indicates "OIL".
 Drainer Hole location of Apron: On the bottom cover of Apron, as illustrated
left, position "A" (also can be seen in front side of Apron downward)
 Model No of Apron lubricant & change period Model No is way oil. ISO UG
68, suggestion changing period is every half a year

 Gear box
 Filler hole location of Gear Box:
1)Under the top cover of gearbox. remove the top cover there is an oil plug
indicates, "OIL" where filler hole is in. as per illustration "A".
2) Drainer hole location of Gear Box: On the left side of the ten-step speed
change the disc downward. The drainer hole is in the screws with hexagon
socket nut as illustrated "B" where an arrow point.
3) Oil brand and oil exchange time: We suggest as show in the figure 6-4
and please change it every half-year.

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 Self-Check -1 Written Test

Directions: Answer all the questions listed below. Use the Answer sheet provided in
the next page:

1. Which one of the following is Properties of a good lubricant

A. It should give rise to low friction.
B. It should adhere to the surface and reduce the wear.
C. It should protect the system from corrosion.
D. It should have good cleaning effect on the surface.
E. All
2. Which one of the following is Properties of a good viscosity
A. A low viscosity oil is thin and flows easily
B. A high viscosity oil is thick and flows slowly.
C. As oil heats up it becomes more viscous (Becomes thin) If the oil is too thin(has
very low viscosity)
D. All
3. One of the following is a category of wear.
A. Adhesive
B. Abrasive
C. Corrosive
D. All

4. One of the following is not the methods for lubricating tools/machine

A. Manual Devices
B. Drop-feed Devices
C. Splash or Bath Lubrication
D. Ring, Chain, Oilers
E. None

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Part II
Say True or False
6. Cleaning is often considered ―donkey‘s job‖ and is left to some unskilled worker to
decide and do.
7. Lubrication can be considered as vital part of a machine as any of the working
parts.
8. Tribology which helps in better visualizing conceptually the problems of friction,
wear and lubrication involved in relative motion between surfaces.
9. Friction can be defined as resistance to movement between any two surfaces in
contact with each other.
10. Always take oil samples when changing oil in a gearbox

Note: Satisfactory rating - 9 points Unsatisfactory - below 9 points

You can ask you teacher for the copy of the correct answers.
Answer Sheet
Score = ___________

Rating: ____________

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 Information Sheet-2 Removing/replacing consumable
components

2.1 Introduction
For the purpose of describing maintenance operations, it is convenient to think of
equipment as a collection of interrelated parts. Maintenance operations consist largely
(but not solely) in replacing parts of equipment. Maintenance strategies determine when
parts or equipment need to be replaced or maintained. Throughout this subsection, we
focus on the decision to maintain/replace a part, but our discussion also applies to the
decision to maintain/replace equipment. gives an overview of maintenance strategies. In
this subsection, in discussing different maintenance strategies. Modificative maintenance
concerns interchanging a part with a technically more advanced part in order to make
the equipment perform better9. This form of maintenance is usually project based and
non-recurring. The maintenance strategies that occur most often are preventive and
breakdown corrective maintenance. Under a breakdown corrective maintenance
strategy, a part is not replaced until it has failed, while under a preventive maintenance
strategy, the aim is to replace parts before failure occurs. (Off course, this aim may not
always be achieved: A part can break down before its replacement occurs.) Breakdown
corrective maintenance is an

attractive option for parts that do not wear, such as electronics. For parts that do wear, it
can be beneficial to follow a preventive maintenance strategy. Preventive maintenance
strategies can be further divided into usage and condition
based maintenance. Under usage based maintenance, the total usage of a part is
measured and maintenance is conducted when a certain threshold level has been

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reached. The usage of parts can be measured in many ways depending on the nature of
the equipment. Time in the field is perhaps the most common mean to measure usage.
For vehicles (e.g., rolling stock), mileage is a common measure of usage. The number of
on-off cycles is a measure of usage for equipment that is mainly loaded at the end or
beginning of on-off cycles. For example, the number of landings is a measure of usage
for the landing gear of an aircraft. Since the usage of equipment is usually scheduled,
the moment that maintenance is performed can also be scheduled. If there is a large set-
up cost associated with maintenance, it can be beneficial to interchange several parts
simultaneously (Block replacement and/or overhaul). Otherwise, maintenance
can be performed on a single component (Component replacement and/or overhaul). In
condition based maintenance, the actual condition of a part is gauged and maintenance
is conducted based on this. The condition of a part can be measured either periodically
during inspections (Periodic inspections) or continuously through a sensor (Condition
monitoring).

 The condition of equipment can be measured:

 The condition of ball-bearings can be measured via the amplitude of vibrations
around the bearing (Elwany and Gebraeel, 2008).
 The condition of a metal part can be determined by visually inspecting the
number and length of cracks.
 For metal systems with moving parts, the concentration of ferrous parts in the
lubrication fluid is measured as an indication of the wear and need for lubrication.
 The condition of a car engine is monitored continuously while driving by the
engine-oil temperature gauge. The need for maintenance can be ascertained
periodically during an inspection or at any time in case of condition monitoring.
Which types of maintenance are prevalent for a given piece of equipment depend
very much on the technical nature of the equipment involved. For electronics and
high-tech equipment, breakdown corrective maintenance is prevalent. For aircraft,
rolling stock and other heavy machinery with moving parts, the prevalent
maintenance strategies are preventive (both usage and condition based).

2.2 Types of consumable components maintenance (Spare parts)

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  Rotables - These are items that constitute a sufficiently large subsystem of the
original equipment to warrant a separate usage based maintenance strategy.
Rotables are individually tracked and traced so that the correct usage can be
ascribed to each rotable individually. Usually, there are dedicated resources for
the maintenance and overhaul of rotables. Examples include aircraft engines,
rolling stock bogies (see Figure 1.2a), and elaborate weapon or radar systems
on frigates.

 Repairables - These are items that are repaired after replacement after which
they are ready-for-use (RFU) again. Contrary to rotables, repairables do

not have their own usage based maintenance strategy, and are not usually individually
tracked and traced. A repair shop handles the repair of many different types of
repairables. Examples of repairables include compressors (see
Figure 1.2b) and pumps.

 Consumables - These are items that are discarded after replacement and bought
new from a supplier. Generally these are relatively cheap items such as gaskets
(see Figure 1.2c). These different part types generally are also connected to
different maintenance strategies as shown in Table 1.2. Demand for spare parts
inherits the uncertainty characteristics of the type of maintenance for which they
are used; see Table 1.1.
For example, there is almost no demand uncertainty for rotables, while demand
uncertainty for consumables subject to breakdown corrective maintenance is
high.

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 The role of different part types in maintenance operations

2.3 Removing/replacing practice of different consumable components

2.3.1 Removing /replacing practice of gaskets
 There are a number of general factors that should be considered when removing
or installing gaskets.
 It is advisable to have the new gasket cut or fabricated and ready to install before
breaking a joint.
 Do not, if possible, make the gasket by hammering on the flange face. This can
damage both the material and the flange.
 Use a thin gasket as possible for the joint conditions.
 For full face gaskets the bolt holes should be the same size as the holes in the
flange.
 The gasket inner diameter should be larger than the inside bore of the joint face
to prevent the gasket interfering with the fluids contained. The amount will
depend on the material. For example, rubber will swell more than CAF and hence
greater clearance will be required.
 If a joint has to be broken regularly then a coating of graphite or similar dry
lubricant on one or both surfaces may make the gasket easier to remove. If a
lubricant is used then a check should be made to make sure it is compatible with
the contents of the machine, vessel or pipeline.
 Gaskets on doors and lids that have to be opened frequently can be cemented
on one side and smeared with lubricant on the other. The cement chosen must
be able to stand up to the operating conditions

 Disassembling a joint
 Before starting make sure the joint is isolated and that all valves are closed. Drain
any residual liquid from the joint and purge any gas if necessary.
 For piping flanges, loosen and remove all bolts if the gasket is full-faced. For ring
type gaskets, loosen all bolts but only remove enough to remove the gasket.

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  In equipment flanges it is recommended that all bolts be removed.
 Where necessary, spring flanges apart using flange spreaders. If wedges are
used care must be taken not to damage the flanges.
 When the gasket has been removed, clean the joint faces and remove all traces
of the old gasket and any jointing compound used.
 Examine the joint faces for any evidence of scratching, corrosion, erosion or
distortion of any kind.

 Installing the gasket and assembling a joint

 Ensure that joint facings are clean and free from burrs.
 Bolt or stud threads should be clean and lubricated and spot facings on the back
of flanges should also be clean.
 Insert enough bolts in one flange to locate the gasket and make sure it lines up
evenly all the way around the inside.
 With the gasket in place on one flange, bring up the mating flange. Every effort
should be made to ensure the flanges remain parallel as they are brought
together.
 Vertical heavy flanges such as those on vessels and heat exchangers should be
jockeyed into position using a crane or hoist. These should be positioned on four
bolts at an angle of 90° to each other that can be pulled up evenly to allow the
flange to find its seat.
 Insert the remaining bolts and pull them up in the correct sequence as shown in
Do not snug up bolts on the first go round as this can tilt flanges out of parallel. If
using an impact wrench, set for about half final torque on the first go round.
Ensure that final tightening is uniform.
 For the best performance in high temperature service make sure that bolts are
retightened after 24 hours and then again after one week.

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 Fig. Sequence for tightening bolts.

2.3.2 considerations of O-ring replacement

 The most important concern when handling O-rings is to protect them from
damage and to ensure that the correct loading is applied. The following general
considerations should be taken into account.
 Ensure that the correct size of seal ring is used in relation to the size of
groove.
 Make sure that grooves and recesses are clean and free from sharp edges
and burrs.
 Care should be taken to ensure that the ring sits correctly in the groove
and cannot get pinched between the flange faces.
 Flange faces should be pulled down evenly and to the correct pre-load
recommended by the manufacturer.
 Failure patterns
The condition of an O-ring after disassembly may provide evidence of the cause of
failure.
A ring that has been extruded will show the effects of nibbling along the i.d. as shown in
Fig.

Fig. . Evidence of extrusion.

Damage caused to O-rings during assembly will usually be evident as nicks or cuts or
possibly as twisting.

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 Fig. evidence of damage during assembly.

2.3.3 Replacing practice of V-belt drive

 Check if the V-belt will fit to the pulley. Only a fitting belt can transform the full
transmission load.

 Align the two pulleys carefully using a straightedge. Misaligned drives can
damage the bearing and the belt itself. Especially when installing multiple belt
drives it is extremely important to align properly, because otherwise not all of the
belts will carry the same load. The vertical misalignment should not exceed 0.5
degree.

Self-Check -2 Written Test

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Directions: Answer all the questions listed below. Use the Answer sheet provided in
the next page:

1. One of the following is true about disassembling a joint

A. Before starting make sure the joint is isolated
B. All valves are closed.
C. Drain any residual liquid from the joint
D. purge any gas if necessary.
E. All

2. One of the following is a factors that should be considered when removing

gaskets
A. Do not, if possible, make the gasket by hammering on the flange face
B. This can damage both the material and the flange.
C. Use a thin gasket as possible for the joint conditions.
D. All
3. One of the following is discarded after replacement and bought new from a supplier.
A. Rotables
B. Repairables
C. Consumables
D. All

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Part II
Say True or False
4. The condition of ball-bearings can be measured via the amplitude of vibrations
around
the bearing
5. The condition of a metal part can be determined by visually inspecting the number
and
length of cracks.
6. For metal systems with moving parts, the concentration of ferrous parts in the
7. Rotables are items that constitute a sufficiently large subsystem of the original
equipment to warrant a separate usage based maintenance strategy.
8. Repairables are items that are repaired after replacement after which they are
ready-for-use

Note: Satisfactory rating - 8 points Unsatisfactory - below 8 points

You can ask you teacher for the copy of the correct answers.

Answer Sheet
Score = ___________

Rating: ____________

Name: _________________________ Date: _______________

Short Answer Questions

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 Information Sheet-3 Replacing and/or topping up Fluids and lubricants

3.1 Introduction
Fluids are used in metal machining for a variety of reasons such as improving tool
life, reducing work piece thermal deformation, improving surface finish and flushing
away chips from the cutting zone. Different applications and/or materials require
slightly different cutting fluids. These fluids are designed to provide the correct
amount of lubrication, cooling, better surface finish, increased tool life and more. All
cutting fluids (especially WS11) should be thoroughly cleaned / removed from the
machine when finished! The machine should be dry and a light ―misting‖ of WD40
applied to the entire vice, tables and machine ways to prevent corrosion.

 Functions of metalworking fluids

Metalworking fluids or coolants play a critical role in most machining processes.
The main functions of a metalworking fluid are:
 Cooling: To reduce and remove heat build-up in the cutting zone and in
the work piece.
 Lubricate: and thereby reduce friction between the tool and the chips
being removed.
 Chip removal: Flush chips away from cutting zone, carrying them back to
the sump.
 Protect against corrosion: of machine work piece and tools

 Cooling vs. Lubrication

Every operation has its own specific requirements for cooling versus lubrication.
By varying the mixing ratio or concentration of a water extendible coolant, you
can alter the balance of cooling and lubrication.
In general, the more water (leaner mix), the better the cooling; the more
concentrate (richer mix), the better the lubrication provided. When machining, the
requirements for lubrication are generally greater than for cooling; hence a richer
concentration is used. When grinding, the requirements for cooling are greater;
hence a more lean concentration is used (but not so lean as to cause rust).

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 There are exceptions to every rule and this one is no different. Some high-speed
machining can be performed well with rather lean mixes, and some grinding
applications, such as form or creep-feed grinding require a rich mixture for high
lubricity. Each operation should be evaluated on its own to determine proper
concentration.

3.2 Classifications of Metalworking Lubricants

 Neat or Straight Oils
 Neat oils are made up primarily of naphthenic or paraffinic base
oils with extreme pressure additives such as chlorine, sulfur and fats.
Neat oils will not emulsify with water nor do they contain any water.
 Soluble Oils
 Greater than 30% mineral oil and no water in concentrate. Dilution
appears milky and not translucent.
 Semi-Synthetics
 Less than 30% mineral oil content in concentrate and the concentrate
contains water. Dilution appears translucent.
 Synthetics
 Zero mineral oil content. Dilution looks transparent and is a true solution
with no droplet formation like semi-synthetics and soluble oils.

3.3 Advantages and disadvantage of different type of oil ( Fluid & lubrication)
 Soluble Oil Advantages
 More economical than straight or neat oils; dilution with water lowers cost
without sacrificing a great deal of tooling effectiveness.
 Soluble oils cool 2 to 3 times better than straight oils.
 Emulsions of soluble oils are very versatile and can be used in most
machining and grinding applications on a wide variety of materials.
 Soluble oils have better health and safety aspects with respect to the shop
environment vs. straight oils; no fire hazard, reduced oil misting and
fogging.
 Of all the water extendible metal removal fluids soluble oils are the most
forgiving of concentration fluctuations and poor management
 Residues created by soluble oils are generally oily and not sticky.

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 Soluble Oil Disadvantages
 Higher disposal costs due to high percentage of oil versus synthetics or
semi-synthetics.
 Emulsions are milky; therefore the workpiece is not visible through fluid.
 Less cooling in high-speed applications vs. synthetics or semisynthetics.
 May tend to pick up tramp oils due to partial mechanical emulsification from
circulation through the coolant pump.

 Semi-Synthetic Advantages
 Leaves oily film on machine and parts for protection.
 Tend to reject tramp oils.
 Very stable emulsion, long lasting.
 Better cooling allows higher cutting speeds.
 Semi-synthetics offer the best of both technologies; soluble oils and
synthetics.
 Semi-synthetics emulsions offer micro size oil droplets that have
advantages in single point turning applications where optimal cooling
and less lubrication is required.
 Our semi-synthetics are ideal for powdered metals, cast iron and metals that
when cut don't create chips but rather sand-like swarf that can
clog filters and form sump clinkers. Monroe‘s semi-synthetics are great
for cast iron machining and grinding applications.
 Semi-synthetic coolants are great for cleanliness and workpiece
visibility.

 Semi-Synthetic Disadvantages
 Low oil content reduces the physical corrosion film that is needed in
some applications.
 Mists, smoke or disposal may be a problem due to oil.
 Semi-synthetics are not very forgiving when it comes to concentration
control and rust and corrosion could be the results of poor fluid
management.

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  Synthetics Advantages
 Rapid heat dissipation.
 Excellent workpiece visibility.
 Total rejection of tramp oils possible.
 Usually easy to measure and control concentration.
 Bacterial attack may be easier to control.
 Usually stable and potentially long-lasting.
 No oil mist problem; no oil disposal concerns.
 Easily filtered.
 Recycling or reclaiming is usually highly effective.
 Low consumption due to the fact that synthetics are true
solutions with no droplet formation adding to carry off issues.

 Synthetics Disadvantages
 High performance products can be expensive.
 Residual films may be tacky or sticky, which may cause
gumming in the moving parts of the machine.
 Compared to oils, they have significantly reduced corrosion protection.
 Less forgiving in poor fluid management scenarios and require tighter
control of concentration ratios to protect against rust and corrosion.

3.4 Coolant maintenance

Good coolant maintenance programs will include regular laboratory tests of the
coolant, either in-house or by the coolant manufacturer. This section contains
suggestions for proper maintenance and control of coolant that the customer can
perform. Implementing these suggestions is not as straightforward as it seems.
Particularly in small systems or individual sumps, control and maintenance of coolant
can be challenging.
 Frequent testing and adjustment of coolant is feasible on large central systems
where the cost of these procedures is easily justified in the control of 10,000
gallons of coolant. It is not as easy to justify detailed analysis of a 100 gallon
sump. Unfortunately small systems are subject to much more rapid changes and
greater fluctuations and therefore actually should be checked more frequently than
large tanks to maintain good control. These factors make the choice of coolant
particularly critical for small sumps.

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  Small coolant systems normally use less effective equipment for filtration and oil
separation than those found on central systems. This requires that the coolant in
small systems be more tolerant of contamination from metal fines, tramp oils and
other materials or contaminants.

3.4.1 coolant life

 Many factors are involved in the success or failure of a metalworking coolant. This
brochure will attempt to address the most frequently encountered factors, and also
offer tips and techniques for maximizing the performance of your fluid.

These guidelines should be strictly adhered to for optimal results:

 Preparing the machine
 The most important step in maximizing coolant life is to start with a
clean sump.
 Any bacteria, fungus, dirt and/or sludge left from the previous coolant
can decrease the life of the new fluid.
 Thoroughly cleaning with a good machine cleaner is recommended
before the introduction of any new coolant.
 Astro-clean a is a low-foam alkaline cleaner designed to remove
process oils, gummy deposits of oil, grease, swarf and normal shop soils from
machine tools, floors, and other hard surfaces. Astro-Clean A combines organic
and mineral alkalinity builders, detergents, water conditioners and deodorizer for
optimum sanitizing performance.
 Astro-Clean A also contains special additives designed to penetrate deep into
compacted chips and swarf, and render the machine neutral of bacteria and
fungus. Astro-Clean A is mild enough on the operator‘s skin that there is no
concern for operator discomfort during the 24 hour cleaning cycle.

3.5 Replace or cleanout machine Fluid sump procedure

 If the system is severely contaminated or rancid, an appropriate amount of
conditioner approved for use in coolants should be added and allowed to circulate
per manufacturer's instructions before initiating cleanout procedure.
 Drain sump or system as far as possible.
 Remove any solids from sump or system.

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  Add 1 gallon of ASTRO-CLEAN A machine cleaner for each 20 gallons of coolant
capacity.
 Fill the sump with tap water up to the normal operating level and allow the fluid to
circulate for at least 4 hours.
 While the fluid is circulating, use a rag or brush to remove stubborn deposits on
machine surfaces and troughs. Allow the fluid to wash the material into the
machine sump.
 Remove the fluid from the sump.
 Remove any further solids from the sump.
 Fill the sump to normal operating level with water, add 1 gallon of ASTRO-
CLEAN A to each 100 gallons of water and allow the fluid to circulate for at least
1/2 hour as a final rinse.
 Drain this solution from the machine sump.

3.6 Top up or charging machine Fluid sump procedure

For best coolant life and successful coolant management program follow these
methods to recharge a freshly cleaned machine with Monroe metalworking fluid:
 When mixing coolant, it is best to use an automatic proportioned which
accurately and thoroughly mixes coolant.
 Always replenish the coolant with a mixture of coolant and water, not just
coolant or water. Never add coolant concentrate directly to the sump.
 Add the mix to the sump to the proper level.
 Start the pump and allow the fluid to circulate for at least 1/2 hour.
 Check concentration with refractometer and make necessary corrections
before machining.

Note: Due to the detergency of fresh emulsions they will continue to clean
a sump and system after the initial charge. This may result in:
 A temporary flush of odors from loosened deposits
 A temporary spike in bacteria levels Don‘t be alarmed if the appearance of
floating masses of sludge which have been dislodged from the inaccessible
areas of the sump and or system. These are considered normal and will
usually occur within the first two weeks of use of a fresh charge. Once
removed these floating masses
should not reappear.

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3.7 concentration control
Once a new coolant is in, concentration control is the most important parameter
for a coolant user to monitor. It is imperative for long coolant and tool life.
As a rule of thumb:
 Concentration consistency can be achieved by never adding straight water or
adding straight concentrate to the machine sump; always add a weak dilution half
of the goal concentration. If the goal concentration is 7% always add 3.5%
concentration. The reason for this is that the water evaporation rate versus
additive and component depletions correspond to this formula.
 Low concentration is the most common cause of coolant problems that
customers experience. Our coolants have been designed to operate at a
minimum concentration of 4% (25:1). A lower concentration than this, even for a
short period, could lead to problems such as machine and work piece corrosion,
poor tool life and rancidity of the in-service coolant

 Refractometers: designed for measuring the concentration of an aqueous

solution, can be used for checking cutting and grinding fluid concentrations. Hand
refractometers are useful for day-to-day control of concentration and are much
faster than the laboratory procedure. To use a refractometer, you simply place one
or two drops of the coolant solution onto the prism surface, close the cover plate,
look through the eyepiece (facing the light) and read the scale. Compare this
reading with
the Brix chart for your coolant to get actual concentration. It is important to ensure
that your refractometer reads zero on water alone. This is accomplished by

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 placing a drop of water on the prism and reading the results normally. If the
reading is not zero, an adjustment screw must be turned to calibrate the unit.

4.8 contamination
 Tramp oils
 An important factor in coolant life is control of tramp oils. This term refers to any
oils which are not part of the original coolant formulation, including way lubes,
hydraulic oil, tapping fluids, gear lubes, etc. which find their way into the
coolant.
 These tramp oils carry their own contaminants, such as sulfur, phosphorous or
solvents, which can be detrimental to the coolant, either by destabilizing the
emulsion or by providing food for bacteria. If tramp oil is allowed to cover and
"seal off" the surface of the sump, bacteria will grow and multiply rapidly,
producing the "rotten egg" odor familiar to many machinists. Keeping the level
of floating oils to a minimum will prevent this.
 Another problem with tramp oils is the potential for dermatitis caused by skin
contact with these oils, which may contain irritating components. Monroe‘s
metalworking fluids are designed to reject rather than emulsify these oils,
causing them to float to the surface, making removal a simple job. They can be
skimmed from the surface of the sump by any
of a variety of methods, such as oil wheels, rope-type skimmers, absorbent
pads or even shop vacuums.

 Solids contamination
 An area for concern that is so often overlooked is the level of chips, fines or swarf
in the sump. Quantities of these small particles can provide an enormous

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 surface area for bacteria to attach themselves to while at the same time
creating "dead areas" where coolant cannot circulate. There are many methods
available for removal of these particulates such as magnetic wheels, conveyors
or indexable filters. In general, the less solid material in the sump or system, the
better.
 Due to the nature of manufacturing facilities today, it is rare that only one type of
material would be machined. Because of the numerous types of metal chips
that conglomerate at the bottom of the sump, there is a potential to create
galvanic reactions, which could harm the coolant emulsion and result in
shortening the coolant life span. Corrosion is
also possible.

4.9 Daily coolant upkeep

 Daily In-service Coolant Management
 Run oil skimmers to remove excess tramp oil from coolant. These are
generally more efficient if run during down time, when the coolant is still and
the oils can float to the surface. A wet/dry vacuum can also be used to remove
floating oils. Dispose of as waste oil.
 Circulate coolant and check concentration with a refractometer. Maintain fluid
level. Add rich or lean pre-mixture of coolant and water where needed.
 Check pH. (If pH starts to fall, add coolant to bring up concentration. If pH
does not stabilize, it is time to replace coolant. If coolant needs to be replaced,
dump old coolant, clean machine and charge with fresh coolant.)
 Record data on a machine check sheet (See example). This can be used to
follow trends of a particular machine.

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  Check all filters, chip strainers and canister filters.Provide aeration of coolant
during extended periods of idle time. An air lance with 5 psi pressure allowed
to bubble gently in an idle sump is often sufficient to prevent excessive
anaerobic bacteria formation.

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 Self-Check -3 Written Test

Directions: Answer all the questions listed below. Use the Answer sheet provided in
the next page:
1. One of the following is not a source of Information to develop lubricate specifications
E. Equipment manufacturers
F. Lubricant vendors
G. Other equipment users
H. Individuals‘ own experience.
I. None
2. One of the following is not steps involved in lubrication developing program .
A. Identify lubricant to be used
B. Determine the best method of application
C. Establish the frequency or interval of lubrication
D. Identify every piece of equipment that requires lubrication;

Part II Say True or False

1. Most other preventive maintenance elements, initial guidance on lubrication
should come from manufacturers.
2. Lubricant suppliers can be a valuable source of information

Note: Satisfactory rating - 4 points Unsatisfactory - below 4 points

You can ask you teacher for the copy of the correct answers.

Answer Sheet
Score = ___________

Rating: ____________

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 Information Sheet- 4 Performing minor machine repairs

4.1 Introduction to Repair

Repair means responding to the breakdown of equipment and undertaking work to
correct the problem in order to return the equipment to a working condition.
Before equipment can be repaired, you need to be aware that there is a problem!
Therefore, there should be a clearly understood system for reporting faults and
breakdowns and equipment users should be encouraged to report faults and
breakdowns as soon as possible. If there is no back-up equipment, a breakdown will
mean that the service the equipment was providing will come to a halt.
 Simple repairs can be done by the in-house or external maintenance and repair
team. If the equipment is repaired where it is used, it is important that the team is
trained to work safely and that they don't create hazards for patients or staff.
 More complex repairs will be carried out by specialised maintenance personnel;
they might come to the eye care unit or you may have to send the equipment to
them for repairs.
In all these situations, it is important to keep equipment users informed of how long their
equipment will be unavailable.
Some items of equipment will be found to be damaged beyond repair. For others, spare
parts may no longer be available as the equipment has become outdated. These will
have reached the end of their lives and must be taken out of service (decommissioned
or retired) and be replaced if the service they provide is to continue. Equipment that is
being decommissioned should be disposed of safely and according to proper disposal
procedures. Remember to update your records accordingly.
‘Plan for maintenance when you purchase the equipment’

4.2 Record-keeping for repair

 Record-keeping
In order for an eye care unit to manage its equipment effectively, it needs good
maintenance and repair records. It is very difficult to manage the unknown!
A central maintenance and repair record will help you to keep track of the
maintenance and repair work done. Ideally, this system should correspond to the eye
unit's equipment inventory (mentioned on page 34); this means that you will have
maintenance and repair records for each of the items listed in the inventory.

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  Record-keeping for maintenance
The preventative maintenance schedule for users can be accompanied by a weekly or
monthly ‗tick sheet‘ near the item of equipment, with a space for each day so that users
can date and sign it, thereby showing that they have carried out the required tasks. This
may include a space for users to indicate what spare parts, such as bulbs, were used.
On a regular basis, the list of spare parts used should be noted in the central
maintenance and repair record so that more spare parts can be ordered.
The central maintenance and repair record can be used to keep track of all other
maintenance, including maintenance done by the in-house team, by vendors, or by
service agents. The information captured should include the date, the equipment
reference number, what was done, who did the work, and when next maintenance is
due.
 Record-keeping for repair
Table shows what information about repairs should be recorded in the central
maintenance and repair record, and what useful information this can provide.

Table 1
Record-keeping for repair
What should be recorded This provides information about…

The details of repair work done on

each machine (including  The history of each machine
cause/suspected cause, and who  Common problems
carried out the repair)
 The parts most frequently used
The spare parts and materials used
 What needs to be re-ordered
 What still needs to be repaired (which allows
The date equipment has broken you to prioritise the next week's tasks)
down, and the date it is repaired.  The duration equipment is not in use (down-
time)
 What the most common causes of delays are
(skill, labour, spare parts, transport,
The causes of any delays
bureaucratic delays, money) and what
additional resources may be needed to

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 What should be recorded This provides information about…
complete work on time
In addition to the practical benefits of a central maintenance and repair system, it also
provides eye care unit administrators and the equipment maintenance team with
valuable information and proof that they can use to ask for more resources.

4.3 Repairing machine parts

During service a component tends to degrade due to different reasons While some
cases the damage might have progressed to such an extent that nothing could be don
salvage the component, in many cases the extent of damage is within limit of being
repairable. repair limit depends upon the type of component, the operating environment
and risk it is subject to and the remaining life in it.
 For satisfactory repair, the following two main criteria have to be fulfilled—
 The repair should not affect the continuous serviceability of the component
 The cost benefit of doing the repair must be clearly demonstrated. The repair to
near i condition should, normally, cost less than 60% of cost of new part.

4.3.1 Dismantling & assembling

These are the basic functional job of maintenance, when a failed equipment or working
equipment (during shutdown etc) is opened partially or completely) necessary repairs,
adjustment or changing of elements and components are done and the equipment is
fitted back in position, using common or special tools. However, enough importance is
not given to these simple jobs! actions, which, often, result in faulty repairs.
 Some of the common cares to be taken prior to and during dismantling and
assembling are given below—
 Check drawing before dismantling and mark on the drawing. Estimate the weight
(if Not given in the drawing),
 Check the job manual! instruction and remember or list down the sequence of
dismantling and assembling.
 Put legible match mark, tags and labels on the two sides of couplings, flanges,
pipe/ hose joints and electrical joints etc before dismantling and record if needed.
If necessary, proper pipe schedule and electrical cable schedule may be made
before dismantling as those may not be correctly reflected in drawings because
of site modification etc.

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  Look for bench mark or level pads if base or foundation is to be repaired. This
would help in maintaining the level during erection after repair. If no level bench
mark is available, fresh bench mark is to be made by theodolite etc, before
dismantling.
 Use of proper tools is very essential, but often neglected. Torque wrenches
should be used for uniform tightening of critical boltings. Use of slide wrench or
pipe wrench should, normally, be banned for bolt joints.
 Prepare joints and surfaces properly, by filing, machining, cutting and threading
etc. Hand grinding and chipping of surfaces should, normally, be avoided as
these may produce uneven surface.
 Proper clamps and supports should be fitted, after assembling, to reduce
vibration of pipes, tubes and hoses etc. Avoid twisting and undue bending of
hoses. Use vibration absorbing pads with base of components or frames prone to
some vibration.
 Cover (or plug) all dismantled pipe end connections, hydraulic, pneumatic,
electrical or other such items to prevent ingress of dust and moisture etc.
 Proper depressurization of hydraulic and oil systems and putting oil collection
trays before opening any such joints.
 Proper alignment and balancing are to be checked after assembling, with the
help of proper tools/ gadgets, etc.

4.4 Rules to follow

 P.M interval are decided by
 Complexity of the machine tool
 Load condition
 Concept of repair complexity of a machine tool is used to determine
 Maintenance
 Spares and parts needed for maintenance
 Maintenance cost
 Percentage breakdown

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 4.4.1 P.M Repair cycle
Repair cycle of P.M consists of four stages as indicated bellow
 Inspection
 To inspect various mechanism at all speed &feed
 To adjust spindle bearing , clutches, bearing , coupling , clamping
device etc
 To tighten nut & bolt ,to replace once
 Change oil , clean oil& coolant filters and lubricating distributors
 Small repair
Disassemble some unit (e.g. 2 to 3) which expected to worn out
To check the working of guide surface
 Medium repair
 .To disassemble more unit of machine
 To grind or scrap the guide surface
 To check as pre standard accuracy test check
 Complete Overhaul
 To disassemble every part to clean the various parts
 To check foundation condition to repair it, if required

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 Self-Check 4 Written Test

Directions: Answer all the questions listed below. Use the Answer sheet provided in
the next page

Answer Sheet
Score = ___________

Rating: ____________

Name: _________________________ Date: _______________

Short Answer Questions

Note: Satisfactory rating - 5 points Unsatisfactory - below 5 points

You can ask you teacher for the copy of the correct answers.

Information Sheet-5 Adjusting machine moving parts

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5.1 Adjustment of different machine moving parts
 Adjustment on Spindle Bearing:
The front and the intel111ediatesection of spindle roller bearing. For high accuracy
and to meet the request of operation function, you may be asked to adjust the
appropriate pressure on bearing. After a long period of operation. nut "G" probably
will get loose and result the "wave trace" on cutting surface. You need to adjust it
at this moment. Use a hexagon socket wrench to remove the setscrew and install
back with the fixing nut again properly. Only an appropriate pressure is enough.
Never have it too tight. as it will lead to the bearing to O\"er-heated or damage the
rolling surface of bearing and lessen its dynamics. Make sure to fix the setscrew
completely after adjustment ad illustrated.

 Adjustment on Spindle Alignment

 Adjustment for the loosely Half Nut Engaged Lever

After long period of operation. the Half Nut Engaged Lever will get loose. please
adjust as per following steps:
 Remover Thread Dial Indicator, there is four adjustment screws can be
seen.
 Adjust those four screws to proper pressure as soon as to push the lever.
 Install Thread Dial Indicator back.

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  Feed load adjustment (cross feed & longitudinal feed):
There is a conical clutch "0" in the middle of Apron, which is an overload protector
. The capacity of safety load is about 12 kg. A hexagon socket screw in the
middle of apron can adjust appropriate load. Turn clockwise to increase load:
anti-c1ockv,:ise it decrease. A proper load capacity can be tested by pressing
hand wheel handle while auto feed operates to see if it will automatically cut-ofT
v,hen load is oyer 12 kg.

 Adjustment of tailstock centering

 To adjust the accuracy of Tailstock. get loose two hexagon socket screws
connect the Tailstock body and Bottom Plate, adjustment to be done depends
on what you expect it to which direction; if you need it to be in cline front. you
must let loose the adjustment screws then correct it to required accuracy
minutely. then install the hexagon socket screws and the adjustment screws.
Never have it too tight or the Clamping Lever will become heavier, as per
illustrated "A".
 If you feel the Release Hand wheel is still too heavy although the Tailstock quill
has been fixed. This is because the Clamping Block cannot be released freely.
You have to push forward thc Clamping lever a bit and it recover in good order
again.

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  Belt tension adjustment
After long period of working. belts will get slacked. so you need to adjust it for
some times. It is as:
1) Open the cover on rear left side of the lathe.
2) Release adjustment Nut "A", lower the motor to proper height and bring the
helt to certain tension.
3) Install the Nut tightly.

 Foot brake belt adjustment

A brake pad fading may caused the slack of brake hell. Adjust Nut "H \" on
Brake belt Open side rear cover remove top nut push bottom nut to
appropriate position.
then install two nuts to complete adjustment. Install the side rear .

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  Brake and micro switch Adjustment
Foot brake is linked to Micro Switch. It needs to maintain a backlash of 3-5mm
from Brake Cam to the touching head of the Micro Switch. Always disconnect
the power to break the machine or it will cause the fading of brake pad. After
stepping the foot brake, needs to reiterate the spindle control lever to make
the spindle revolute again.

 Adjustment of the back lash lead screw

Which it happens to some pole-up threads during processing. it is caused by
the backlash on Lead screw. Adjust the packing nut appropriately on rear side
of the Lead screw. Open the cover on rear side of Lead screw Bracket. turn
nut "A" very tight with no backlash left behind. (To check the result by pushing
down Half Nut Handle. turn Apron Hand wheel to rotate. clasp the contact

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 point between Gear Box and Lead screw . Make sure there is no backlash
created). Install "A" nut and side cover.

5.2 Trouble shooting portion of machine

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Page 103 of 157 Federal TVET Agency Version -1
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 Self-Check -5 Written Test

Directions: Answer all the questions listed below. Use the Answer sheet provided in
the next page:

Note: Satisfactory rating - 5 points Unsatisfactory - below 5 points

You can ask you teacher for the copy of the correct answers.

Answer Sheet
Score = ___________

Rating: ____________

Name: _________________________ Date: _______________

Short Answer Questions

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 Operation Sheet-1 Cleaning the Machine

procedure to Cleaning the Machine

Step 1- Turn off the machine and remove the tool holder. Brush, blow or wipe it
clean.
Step 2 -Put away all your hand, set-up and cutting tools. If not sure where they
go, ask a supervisor.
Step 3-Use a brush or light blasts of air to remove the chips from the vice, table
and ways.
Step 4-Do not blast the chips and fluids across the shop, only use enough force
to get the chips to the ground.
Step 5-. Brush or vacuum the difficult to reach spots. Wipe the spindle, slides,
ways, tool post, chuck, etc.
Step 6-Wipe off ALL cutting fluids and oils from the ENTIRE machine. Top to
bottom, machine must be dry.
Step 7-Gently mist the slides, ways, chuck(s) with WD40. Move the carriage
and slides to mist all surfaces.
Step 8-Sweep the floor and surrounding areas. Chips are to be placed in chip
buckets, not regular trash cans.
Step 9 -There should be NO visible chips of any size on the machine. Leave it
cleaner than when you found it.

Operation Sheet 2 Lubricating a bearing

procedure to Lubricating a bearing

1. . Prepare all tools, materials and equipment‘s needed
2. Check if there is a grease nipple on both side end of the motor..
3. If there is grease nipple, insert the grease gun and pump grease inside the motor
bearing
4. If there is no grease nipple, open the motor at both end by a screw driver and
spanner.
5. Remove the bearing [ use the gear puller if needed]

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 6. Open the side cover of the bearing, check if presence of foreign objects are seen,
clean the bearing with kerosene or the like if needed.
7. Repack the bearing with grease then close the cover.
8. Return the bearing and close the motor.
9. Commission the motor

Operation Sheet 3 Replace or cleanout machine Fluid sump procedure

Procedures for Replacing or cleanout machine Fluid sump

Step 1- Drain sump or system as completely as possible.

Step 2• Remove any solids from sump or system.
Step 3• Add 1 gallon of Astro-Clean A for each 20 gallons of coolant capacity.
Step 4• Fill sump with water to normal operating level and allow to circulate for a
period of at least 4 hours.
Step 5• While cleaner is circulating, use a rag or brush to remove stubborn
deposits on machine surfaces and in coolant troughs. Allow fluid to wash
material into the sump.
Step 6• Remove cleaner and all solids from the sump.
Step 8• Fill sump to normal operating level with water and add 1 gallon of Astro-
Clean A for each 100 gallons of water and allow to circulate for at least 1/2
hour.
Step 10• Remove fluid from the sump.

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 Top up or charging machine Fluid sump procedure
Operation Sheet 4

Procedures for Top up or charging machine Fluid sump procedure

Step 1- 1. When mixing coolant, it is best to use an automatic proportional which
accurately and thoroughly mixes coolant.
Step 2. Always replenish the coolant with a mixture of coolant and water, not just
coolant or water. Never add coolant concentrate directly to the sump.
Step 3. Add the mix to the sump to the proper level.
Step 4. Start the pump and allow the fluid to circulate for at least 1/2 hour.
Step 5. Check concentration with refractometer and make necessary corrections before
machining.

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 LAP Test Practical Demonstration

Name: _____________________________ Date: ________________

Time started: ________________________ Time finished: ________________
Instructions: Given necessary templates, tools and materials you are required to
perform the following tasks within --- hour.

Task 1. Clean the Machine

Task 2. Lubricate a bearing
Task 3 .Replace or cleanout machine Fluid sump
Task 4. Top up or charging machine Fluid sump

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 Instruction Sheet Learning Guide # 19

This learning guide is developed to provide you the necessary information regarding the
following content coverage and topics –
 Checking defects/functionality of tools
 Reporting defective hand tools.
 Types of cleaning materials.
 Lubricating and storing tools.
 Accomplishing necessary reports

This guide will also assist you to attain the learning outcome stated in the cover page.
Specifically, upon completion of this Learning Guide, you will be able to –
 Check tools for defects / functionality based on specifications
 Report defective hand tools for repair or replacement due to standard procedures
 Clean tools using appropriate cleaning materials and according to standard
procedures
 Lubricate and store tools according to prescribed procedures
 Accomplish necessary reports in accordance with workplace procedures

Learning Instructions:
1. Read the specific objectives of this Learning Guide.
2. Follow the instructions described below.
3. Read the information written in the ―Information Sheets‖. Try to understand what are
being discussed. Ask your trainer for assistance if you have hard time understanding
them.
4. Accomplish the ―Self-checks‖ which are placed following all information sheets.
5. Ask from your trainer the key to correction (key answers) or you can request your
trainer to correct your work. (You are to get the key answer only after you finished
answering the Self-checks).
6. If you earned a satisfactory evaluation proceed to ―Operation sheets
7. Perform ―the Learning activity performance test‖ which is placed following ―Operation
sheets‖ ,
8. If your performance is satisfactory proceed to the next learning guide,
9. If your performance is unsatisfactory, see your trainer for further instructions or go
back to ―Operation sheets‖.

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 Information Sheet-1 Checking defects/functionality of tools

1.1. Introduction
All tools and equipment used for maintenance should be checked for their proper
function which is appropriate for maintenance of the particular machine or parts.
There are many ways of identifying hand tools. One of these is to identify them
according to their function. However, awareness of defective and non-defective hand
tools is a primordial concern of workers/welders to be effective in their jobs.

1.2 Practices to identify defective and non-defective hand tools

 Visual inspection:
Defective tools can easily be distinguished from the functional ones
through visual inspection. The physical appearance of tools will describe
such characteristics as dullness, sharpness, dismantled parts, and
unevenness of the teeth of the cutting tools.

 Functionality
 Another way is to check the quality of the manufactured tools. Is it already
susceptible to wear and tear? Has it already exceeded its service life?
Has it passed the manufacturer‘s quality control test?
 A few pieces of the hand tools issued in the shop can be subjected for
Condemnation they are no longer serviceable. Some hand tools issued
for years in shops and few pieces of these can be subjected for
condemnation.

 Performance:
Performance of hand tools is determined not only during the actual use but also
after use to find out whether the hand tools are still worth using.

 Service span
 Hand tools are issued to shop teacher at one time. However, this must be
recorded to determine when it was received and how long the tools
have been kept in the shop. A hand tool which is too old is unsafe for

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 both the students and workers. Such tool should be marked defective
and segregated from the good ones.
 Defective tools can cause serious and painful injuries.
 If a tool is defective in some way, DON'T USE IT.

Be aware of problems like

 Chisels and wedges with mushroomed heads
 Split or cracked handles
 Chipped or broken drill bits
 Wrenches with worn out jaws
 Tools which are not complete, such as files without handles

To ensure safe use of hand tools, remember:

 Never use a defective tool
 Double check all tools prior to use 
 Ensure defective tools are repaired 
 Air, gasoline or electric power tools, require skill and complete attention on the
part of the user even when they are in good condition. Don't use power tools
when they are defective in any way.

Watch for problems like:

 Broken or inoperative guards
 Insufficient or improper grounding due to damage on double insulated tools
 No ground wire (on plug) or cords of standard tools
 The on/off switch not in good working order
 Tool blade is cracked
 The wrong grinder wheel is being used
 The guard has been wedged back on a power saw

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 Self-Check -1 Written Test

Directions: Choose the letter of the word/s that best complete each statement below.
Use the Answer sheet provided in the next page:
1. Defective hand tools are kept and ___________.
A. Marked as defective
B. Mixed together with non-defective tools
C. Put anywhere in the shop
D. Sold in the junk shop
2. One way of checking whether hand tools are defective or non-defective
the___________.
I. length of service
II. Trade mark of the manufacturer
III. Physical appearance
A. I only
B. II only
C. III only
D. I, II, and III
3. Which is determined after the operation of a hand tool is tested?
A. Service span
B. Performance
C. Physical appearance
D. Repair Maintenance
4. All defective hand tools with major defects are subject to _________.
I. Repair
II. Condemnation
III. Display/sample
A. I only
B. II only
C. III only
D. I, II, and III
5. Service span of a tool pertains to _________.
A. Maintenance schedule

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 B. Determining when the tool is acquired
C. Functionality of a tool
D. Defectiveness of a tool

Note: Satisfactory rating - 3 points Unsatisfactory - below 3 points

You can ask you teacher for the copy of the correct answers.
Answer Sheet
Score = ___________

Rating: ____________

Name: _________________________ Date: _______________

Short Answer Questions

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 Information Sheet-2 Reporting defective hand tools

2.1 Introduction
Detective tools can cause serious and painful injuries. If a tool is defective in some way,
DO NOT USE IT.
Be aware of problems like:
 chisels and wedges with mushroomed heads;
 split or cracked handles;
 chipped or broken drill bits;
 wrenches with worn out jaws; and
 tools which are not complete, such as files without handles.
To ensure safe use of hand tools, remember:
1. never use a defective tool;
2. double check all tools prior to use; and
3. ensure defective tools are repaired.
Air, gasoline or electric power tools, require skill and the operators‘ complete attention,
even when they are in good condition. Don‘t use power tools when they are defective in
any way.
Watch for problems like:
 broken or inoperative guards;
 insufficient or improper grounding due to damage on double insulated tools;
 no ground wire (on plug) or cords of standard tools;
 the on/off switch not in good working order;
 tool blade is cracked; and
 the wrong grinder wheel is being used, or the guard has been wedged back on
a power saw.

2.2 Reporting
 Any hand tools controlled by DIT found defective should be removed from
service and a label attached stating its defect.
 The condition / defect of the defective tool should be entered into the Tool Log
record.

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  The tools should be repaired in compliance with the manufacturer‘s or scraped
and a replacement tool if required be purchased.
 If the tool is repaired a retest / inspection must be carrie

2.3 Documentation
 The Technical staff member in charge of the laboratory /workshop should
maintain a Tool Log to record defective tools, their repair or disposal and their
replacement.

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 Self-Check -2 Written Test

Directions: Answer all the questions listed below. Use the Answer sheet provided in
the next page:

1. Fill workplace Inspection Report

Observations
Item and Location Hazard(s) Repeat Priority Recommende Responsibl Action Taken Date
Observed Item A/B/C d Action e Person
Y/N

Note: Satisfactory rating - 3 points Unsatisfactory - below 3 points

You can ask you teacher for the copy of the correct answers.
Answer Sheet
Score = ___________

Rating: ____________

Name: _________________________ Date: _______________

Short Answer Question

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 Cleaning tools by appropriate cleaning
Information Sheet-3 materials

3.1. Types and Kinds of Cleaning Solvents

Solvent is a component of a solution that dissolves solute and is usually present in large
proportion or amount. It can be classified as polar and nonpolar. Polar solvents are
solvents which dissolve/are soluble in water; while nonpolar solvents are solvents which
do not dissolve/are insoluble in water. Solvents are usually used for cleaning in
workshops. They are water, gasoline, kerosene, thinner and detergent soap.
Kinds of cleaning solvent based on their solubility in water:
Cleaning Solubility in polar Non
solvent water polar
a. water soluble x
b. gasoline insoluble x
c. kerosene insoluble x
d. thinner insoluble x
e. detergent soluble x
soap

3.2. Use of cleaning solvents:

Cleaning solvent uses
gasoline Wash greasy tool/equipment
kerosene Remove dust, grease oil, paint, etc
thinner Remove spilled paint on the floor, wall and
tool
water Wash dust in the floor, wall, etc
detergent soap Wash/clean benches, table, cabinet, etc

3.3. Cleaning Hand-Held Workshop Tools (Hammers, wrenches, screw drivers, etc.)
Whether gardening, fixing a broken pipe, or building a deck, using the proper tools to
complete your job is essential. Consequently, it is important to maintain your tools and
keep them clean so that they will last and be in good shape for any job you have in mind.
These simple tips will help you get the most out of your tools.

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What You Will Need:
 Wire scrub brush
 Commercial cleaner (Pine-Sol, Spic ‗n Span, Lest oil, etc)
 Large bucket
 Hot water
 Several old towels
 Heavy duty rubber gloves
 Steel wool
 Household oil
 Soft rag

The Cleaning Process:

1. Fill a large bucket with a measured amount of hot water (usually about a gallon or
two, depending on the number of tools you are washing) and add the amount of
commercial cleaner indicated on the product instructions for the amount of water.
2. Place tools in the bucket of cleaning solution, and let soak for at least 30 minutes.
3. While wearing rubber gloves, use the wire brush to scrub the tools, removing dirt
and grease.
4. Remove the tools from the cleaning solution and dry each one thoroughly.
5. If any of your tools have rust on them, use the steel wool to rub the rust off.
6. Many of today‘s hand tools are rust resistant, but if any of your tools are
susceptible to rust, it is recommended that about once every 6 months, you coat
them with a thin coat of household oil (such as WD-40® or 3-in-1® Household
Oil, available at most home improvement and hardware stores) by pouring some
on a soft rag and wiping

3.4. Cleaning Power Tools (Jigsaws, drills, chain saws, etc.)

What You Will Need:
 Heavy duty working gloves
 Can of compressed air (available at most home improvement stores)
 Cleaning rags
 Bucket
 Hot water
 Commercial cleaner (Pine-Sol, Spic ‗n Span, Lestoil, etc)
 Old towels

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  Steel wool
 Toothbrush

The Cleaning Process:

1. Make sure you wear heavy duty gloves when handling power tools, especially
power tools with sharp cutting edges.
2. ALWAYS check the manufacturer‘s directions and recommendations for proper
cleaning and maintenance of your power tool(s), and follow any such instructions
carefully.
3. DISCONNECT all power cords from the tool being cleaned.
4. If you are cleaning a chainsaw, jigsaw, or any other such type of power tool that
tends to collect sawdust, using the compressed air, spray out any sawdust and
dirt accumulated within the grooves and crevices.
5. Fill a large bucket with a measured amount of hot water (usually about a gallon or
two, depending on the number of tools you are washing) and add the amount of
commercial cleaner indicated on the product instructions for the amount of water.
6. Wet a cleaning rag with the cleaning solution and wring out thoroughly so that it is
just damp, not wet or dripping. Wipe down the surface of the tool. Avoid getting
water in or around the power cables or motor casings.
7. Dry thoroughly with an old towel.
8. With a toothbrush, clean around any switches or toggles, making sure to remove
any debris or dust that may interfere with the proper operation of any of those
switches.
9. With a DRY rag, wipe down the power cord, checking it carefully for any nicks,
cuts, fraying or damage. If you do find the cord to be damaged in any way, it
should be REPLACED before using the power tool again.
10. Check any exposed metal parts of the tool for rust. If there is any rust, remove it
by rubbing briskly with the steel wool.

3.5. Additional Tips and Advice

 NEVER submerge a power tool in water.
 NEVER attempt to clean a power tool while it is plugged in or operational! You will
risk serious injury!
 Avoid oiling power tools unless specifically recommended by the manufacturer.

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  Cleaning dirt, dust and debris from your tools after each use will make your job
much easier when it comes down to more substantial cleaning.
 Always make sure to dry your tools thoroughly after cleaning. If you store your
tools while they are wet, they stand a greater chance of developing rust, which
will eventually eat away at the metal.

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 Self-Check -3 Written Test

Directions: Answer all the questions listed below. Use the Answer sheet provided in
the next page:

1. Write use of cleaning solvent

2. Write three type of cleaning solvent

Note: Satisfactory rating - 5 points Unsatisfactory – below-3 points

You can ask you teacher for the copy of the correct answers.
Answer Sheet
Score = ___________

Rating: ____________

Name: _________________________ Date: _______________

Short Answer Questions

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 Lubricating and storing tools
Information Sheet-4

4.1 Introduction
 Lubricants are identified according to types of equipment.
 Tools and equipment are lubricated according to preventive maintenance
schedule or manufacturer‘s specifications.
 Measuring instruments are checked and calibrated in accordance with
manufacturer‘s instructions.
 Tools are cleaned and lubricated according to standard procedures.
 Defective equipment and tools are inspected and replaced according to
manufacturer‘s specification.
 Work place is cleaned and kept in safe state in line with OSHC regulations.
A lubricant is a substance introduced to lessen friction between moving surfaces. It
may also transport external particles. The property of reducing friction is known as
lubricity.

4.2 Types and Uses of lubricants

 Anti-rust lubricant spray:
 loosen rusted part
 cleans and protect
 drives out moisture
 stops squeaks
 free sticky mechanisms
 Wire Pulling Lubricant:
 does not damage insulation
 cling to wire and dries to a slippery film
 suitable for use with wire or cable covered with rubber (t, thw, thhn, etc)
 All Purpose Anti Rust Lubricant:
 anti-rust
 lubricating
 rust removal
 decontamination
 conductance
 Lubricant Oil and Engine Oil

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  lubricating the gear
 cleans and protect
 drives out moisture

 Silicon Lubricant:
 heat stable
 lubricates
 protects
 reduces friction
 water repellent

Reminders: A good lubricant possesses the following characteristics:

 High boiling point.
 Low freezing point.
 High viscosity index.
 Thermal stability.
 Corrosion prevention.
 High resistance to oxidation.

4.3 Lubricating and storing tools

Lubricant is a substance that reduces friction, heat, and wear when introduced as a
film between solid surfaces. Using the correct lubricant helps maximize the life of
your bearings and machinery, therefore saving money, time, and manpower, thus
making operations more efficient and more reliable.

 Lubricating and storing vice

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Lubrication
Lubricate slide and worm lightly with preservative lubricating oil (special) or engine oil
(SAE 10). Lubricate sparingly; excessive amounts help cause a messy shop.

Storage
Wash lubricants from vise with dry cleaning solvent. Dry vise thoroughly. Coat all
surfaces of vise with rust preventive compound (thin film) and store in a dry place. Upon
removal from storage, wash off the rust preventive compound with dry cleaning solvent.

 Lubricating and storing taps and dies

Storage
Coat all parts with rust preventive compound (thin film) and store in a dry place. Store in
racks or divided boxes to protect cutting edges from contact with metal. Upon removing
from storage wash with dry cleaning solvent to remove rust preventive compound

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  Lubricating and storing saws

Lubrication
Always oil blade with a clean cloth dampened with preservative lubricating oil (special)
after using saw. Do not permit blade to rust. Clean off all signs of rust from blade with
crocus cloth. Apply oil to blade after cleaning off rust

Storage
Apply rust preventive compound (thin film) to blades to prevent rust, and store so teeth
will not be dulled by contact with other tools. Upon removal from storage, wash metal
parts with dry cleaning. Solvent to remove compound.
 Lubricating and storing clamp

Lubrication
Keep screws lubricated with small quantity of preventive lubricating oil (special) or
engine oil (SAE 10). Excessive lubricant interferes with use of tool. Keep metal surfaces
free of rust. Scour off rust or corrosion with crocus cloth or aluminum oxide abrasive
cloth. Coat surfaces with preservative lubricating oil (special) or engine oil (SAE 10).
Storage (All Clamps)

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Coat clamps with rust preventive compound (thin film) and store in a dry place. After
removal from storage, wash metal parts with dry cleaning solvent to remove rust
preventive compound.

 Lubricating and storing calipers

Lubrication
Oil threaded and moving parts and friction surfaces (firm joint calipers) with preservative
lubricating oil (special). Coat non-operating surfaces with a film of preservative
lubricating oil (special).

Storage
Wrap in greaseproof wrapping and enclose in a covered box. Store roughly and apply a
film of preservative lubricating oil (medium). Wrap in greaseproof wrapping and enclose
in a covered box. Store in a dry place

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 Self-Check -1 Written Test

Directions: Answer all the questions listed below. Use the Answer sheet provided in
the next page:

I. Say true or false

1. Lubricant is a substance that increase friction
2. Saws teeth will not be dulled by contact with other tools.
3. Lubricant helps to maximize the life of tool.
4. Store taps and dies in racks or divided boxes to protect cutting edges from
contact with metal.
5. Engine oil (SAE 10) is not good for lubricating.

Note: Satisfactory rating - 5 points Unsatisfactory - below 5 points

You can ask you teacher for the copy of the correct answers.

Answer Sheet
Score = ___________

Rating: ____________

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 Information Sheet-5 Accomplishing necessary reports

5.1 Introduction
Accomplishing report
To make a report, first copy all unfinished items from the previous report on the new
report. Then write down the observed unsafe condition and recommended methods of
control. Enter the department or area inspected, the date and the inspection team's
names and titles on top of the page. Number each item consecutively, followed by a
hazard classification of items according to the chosen scheme.
State exactly what has been detected and accurately identify its location. Instead of
stating "machine unguarded," state "guard missing on upper pulley #6 lathe in North
Building."
Assign a priority level to the hazards observed to indicate the urgency of the corrective
action required. For example:
A = Major - requires immediate action
B = Serious - requires short-term action
C = Minor - requires long-term action
Report issues in a concise, factual way. Management should be able to understand and
evaluate the problems, assign priorities and quickly reach decisions.
After each listed hazard, specify the recommended corrective action and establish a
definite correction date if possible and appropriate. Each inspection team member
should review for accuracy, clarity and thoroughness.

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Example of Workplace Inspection Report
Inspection Location: __________________ Date of Inspection: __________________
Department/Areas Covered: __________ Time of Inspection: _____________
Observations
Item and Hazard( Repea Priorit Recommen Responsi Action Date
Location s) t Item y ded Action ble Taken
Observe Y / N A/B/C Person
d

Copies to: _________________ Inspected by: ___________________

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 Self-Check -2 Written Test

Directions: Answer all the questions listed below. Use the Answer sheet provided in
the next page:

Note: Satisfactory rating - 5 points Unsatisfactory - below 5 points

You can ask you teacher for the copy of the correct answers.

Answer Sheet
Score = ___________

Rating: ____________

Name: _________________________ Date: _______________

Short Answer Questions

Operation Sheet 1 Cleaning Hand-Held Workshop Tools

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Method of cleaning hand held workshop tool

Step 1- Fill a large bucket with a measured amount of hot water

Step 2- Place tools in the bucket of cleaning solution, and at least 30 minutes.
Step 4-Remove the tools from the cleaning solution and dry each one thoroughly
Step 4- While wearing rubber gloves, use the wire brush to scrub the tools
Step 5- if any of your tools have rust on them, use the steel wool to rub the rust off

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 LAP Test Practical Demonstration

Name: _____________________________ Date: ________________

Time started: ________________________ Time finished: ________________
Instructions: Given necessary templates, tools and materials you are required to
perform the following tasks within --- hour.

Task 1 . Clean hand held workshop tool

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 Instruction Sheet Learning Guide #20

This learning guide is developed to provide you the necessary information regarding the
following content coverage and topics –
 Performing Inventory of tools, instruments and equipment‘s.
 Documenting/recording Inventory results.
 Storing tools and equipments

This guide will also assist you to attain the learning outcome stated in the cover page.
Specifically, upon completion of this Learning Guide, you will be able to –
 perform Inventory of tools, instruments and equipment in accordance with
workplace procedures
 Document/record Inventory results in appropriate forms as per company
regulations
 Store tools and equipment safely in appropriate locations in accordance with
manufacturer‘s specifications or company policy

Learning Instructions:
1. Read the specific objectives of this Learning Guide.
2. Follow the instructions described below.
3. Read the information written in the ―Information Sheets‖. Try to understand what are
being discussed. Ask your trainer for assistance if you have hard time understanding
them.
4. Accomplish the ―Self-checks‖ which are placed following all information sheets.
5. Ask from your trainer the key to correction (key answers) or you can request your
trainer to correct your work. (You are to get the key answer only after you finished
answering the Self-checks).
6. If you earned a satisfactory evaluation proceed to ―Operation sheets
7. Perform ―the Learning activity performance test‖ which is placed following ―Operation
sheets‖ ,
8. If your performance is satisfactory proceed to the next learning guide,
9. If your performance is unsatisfactory, see your trainer for further instructions or go
back to ―Operation sheets‖.

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 Performing Inventory of tools, instruments and
Information Sheet-1
equipment’s

1.1 Introduction to Inventory

The word inventory simply means the goods and services that businesses hold in stock.
There are, however, several different categories or types of inventory.
The first is called materials and components. This usually consists of the essential items
needed to create or make a finished product, such as gears for a bicycle, microchips for
a computer, or screens and tubes for a television set.

The second type of inventory is called WIP, or work in progress inventory. This refers to
items that are partially completed, but are not the entire finished product. They are on
their way to becoming whole items but are not quite their yet. The third and most
common form of inventory is called finished goods. These are the final products that are
ready to be purchased by customers and consumers. Finished goods can range from
cakes to furniture to vehicles. Most people think of the finished goods as being part of an
inventory stock, but the parts that create them are held accountable in inventory as well.

1.2 Classification of inventory

 Rotable Inventory
Rotable inventory is defined as an inventory that can be economically restored to
a serviceable condition and, in the normal course of operations, can be
repeatedly rehabilitated to a fully serviceable condition over a period
approximating the life of the flight equipment to which it is related. Of course there
are scrap rates as with all inventory, however, with Rotable inventory the scrap
rate is assumed to be very low, perhaps only a few percentage points or even a
fraction of a point.

Examples of Rotables are flaps, transmissions, fuel pumps, hydraulic pumps, etc.
Because of their generally high cost, Rotables are economical to repair rather
than replace with new purchase upon failure. Rotables are also generally systems
made up of series of Repairable and Expendable subcomponents. Rotables are

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 unusual in that the repair cycle causes them to depart from mainstream notions
regarding
inventory. For example, inventory is typically considered consumed upon
installation, sale or other activity. In the case of a Rotable, the inventory is
generally tracked, both financially and from a compliance aspect for its entire life.
Rotables are typically held on a firm‘s books, and depreciated on a schedule that
may range from 5-7 years
to 20-25 years, depending on the firm‘s goals and mode of business.

 Repairable Inventory
Repairable Inventory generally follows the same conventions of Rotable inventory
with one important distinction: Repairable inventory has a higher scrap rate than
Rotable inventory. For example, a part may be of the same asset value and
lifespan as a comparable Rotable; however the repair process may have a 25%
scrap rate.

 Expendable Inventory
Expendable inventory is by definition, inventory with 100% scrap rate and
therefore 100% replacement for every use. Expendable inventory often meets the
criteria most laymen and financial professionals think of when they consider
inventory. Expendables range from common fasteners to filters to items which are
scrapped upon use and removal. Cost-wise, Expendables can be as expensive or
more expensive than inventory assets in the Rotable or Repairable class. Their
main distinction is the 100% scrap rate. Financially, Expendables are usually
expensed at the time of use or issue, depending on the financial dictums of the
operator. Bulk items are often expensed at the time of issue to a station or
maintenance base, and this practice can induce problems that mask the true
inventory levels in the operation, particularly if there are not robust systems for
inventory tracking and audit. If station visibility is lost, often planners are induced
to over order their Expendable levels, driving up Expendable balances due to the
lost visibility at stations.

 Recoverable Inventory
Recoverable inventory may be a classification not commonly known or utilized.
Sometimes they are referred to as Recoverable-Expendables or similar name. An

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 example may be a filter that has a 100% scrap rate, but there may be a simple
shop procedure which will restore the filter to serviceability on 4 in 10 filters. The
logical line between Recoverables and Expendables is generally an individual
airline designation. Recoverables can offset new purchase of Expendable items
substantially via the shop reconditioning processes, however the results can be
highly variable. Recoverables can be controversial since generally shop
production of a recoverable can result in a net credit to shop operations. It is
recommended that each operator make individual Recoverable classification
decisions based on sound economic analysis.

 Raw Material Inventory:

Raw materials are the basic materials that a manufacturing company buys from its
suppliers and that are used by the former to convert them into the final products by
applying a set of manufacturing processes. For example, aluminum scrap is the raw
material for a company that produces aluminum ingots. Flour is the raw material for a
company that produces bread or pizza. Similarly, metal parts and ingots are the raw
materials bought by a company that manufactures cars and crude oil is the raw material
for an oil refinery.

 Work in Progress (WIP) Inventory

Work in progress inventory can also be called semi-finished goods. They are the raw
materials that have been taken out of the raw materials store and are now undergoing
the process of their conversion into the final products. These are the partly processed
raw materials lying on the production floor. And they have also not reached the stage
where they have been converted into the final product.

 Finished Goods Inventory

Finished goods are indeed the final products obtained after the application of the
manufacturing processes on the raw materials and the semi-finished goods discussed
above in the article. They are saleable and their sale contributes fully to the revenue
from the core operations of the company.

1.3 PROCEDURE OF INVENTORY

1. District personnel whose position requires tool and equipment assignment will
complete at "Tool and Equipment Inventory Form" (attached) for these assigned

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 tools and equipment. The inventory list will identify all assigned storage area
related tools and equipment for which the individual is responsible.
2. Tool inventories will be standardized wherever possible so that inventory
equipment can be easily and readily assessed and accessed by all appropriate or
authorized users. No additional stock shall be maintained in the appropriate tool
and temporary materials or equipment to be utilized for a specific job or project.
3. Department Managers will assign to first line supervisors the responsibility for
review and approval of completed inventory lists or changes to inventory items or
quantities for all employees assigned district tools and equipment.
4. All District personnel assigned or utilizing District tools and equipment will be
responsible for assuring their safe and proper use and will closely monitor their
own assigned District tools and equipment on an on-going basis, making sure all
lost or stolen equipment is reported to their supervisor for replacement.
5. Employees will submit to Supervisors a District "Tool Replacement Form" prior to
requisitioning for replacement of worn, damaged, lost or stolen tools and
equipment Worn or damaged tools and equipment will be sent to Stores for
replacement.
6. The employee and their supervisor will conduct a full physical inventory twice a
year. A full inventory requires that all tools and equipment be counted and verified
and inventory forms completed and submitted for department head review.
Department heads will submit a copy of inventory reports and a departmental
inventory summary to the Purchasing Officer within 30 days of completion of bi-
annual inventory.
7. Those items, which meet the District's capitalization criteria will be verified with
the District's fixed asset records.
8. The purchasing officer will submit copies of bi-annual inventory reports to the
General Manager twice a year.
9. Supervisors shall maintain inventory information for a minimum of two years. After
this period, departments at their discretion may dispose of inventory records.
10. Upon termination of employment, all District tools and equipment will be
accounted for and returned prior to receiving the final wage payment.

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1.4 Benefits of inventory control
It is an established fact that through the practice of scientific inventory control,
following are the benefit of inventory control:
1. Improvement in customer‘s relationship because of timely delivery of good and
service.
2. Smooth and uninterrupted production and hence no stock out.
3. Efficiency utilization of working capital. Helps in minimizing loss due to
deterioration, obsolescence damage and pilferage.
4. Economy in purchasing.
5. Eliminates the possibility of duplicate ordering.

1.5 Responsibility
It is the responsibility of each department head, or designee, to conduct and document
an accurate inventory of all appropriate tools and equipment and maintain an inventory
list or file by employee, location or appropriate identifiable storage area or cabinet.

1.6 Equipment Labeling and Marking

Prior to being placed into the equipment inventory, all equipment covered under this
procedure will be inventoried and labeled with a unique SESD identification number. The
identification number will be assigned only to the identified equipment and will not be
reused if the meter is excised or disposed. Equipment that is no longer used or cannot
be repaired will be removed from the inventory. Equipment received after the effective
date of this procedure will be assigned a number that includes the date the equipment
was received followed by a sequential number starting at 01 (e.g., 031407-01, 031407-
02, etc.). BFEMS will ensure that duplicate SESD ID Numbers are not assigned to
equipment. Equipment received before the effective date of this operating procedure will
be assigned a number that will incorporate all or part of the serial number or other
manufacturer number as the unique SESD ID number.

1.7 Real Property Inventory

 Real Property Inventory is conducted through use of a standardized database that
collects basic information on all fixed assets with a replacement cost of $5,000 or
more.
 These fixed assets include such items as buildings, roads, bridges, levees, water
management structures, raceways, boardwalks, fences, and other structures and

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 facilities. Data is collected annually and reported to the General Services
Administration.
 A key feature of this data collection effort is the estimating of the replacement cost
of each individual property item.
 The Real Property Inventory (RPI) database is posted to the Service‘s intranet,
and authorized personnel may update records throughout the year.
 However, a comprehensive review is required followed by update during preset
time (say September of each year). The Director annually provides guidance for
conducting the required inventory update in a memorandum to all Regional
Directors.

1.8 purpose of inventory

To establish a formal method of strengthening controls and safeguarding tools and
equipment most vulnerable to theft and loss by identifying inventory units, assigning
responsibility for and frequency of verification and documenting loss.

Objectives: to ensure that controls are in place for safeguarding District tools and
equipment inventory. An inventory of tools and equipment will be maintained and
updated on a regular basis. These inventories will include hand tools, power tools,
pneumatic and hydraulic tools and equipment, measuring and testing equipment,
portable generators, compressors, electric and electronic tools and equipment and TV,
video and camera equipment.

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 Self-Check -1 Written Test

Directions: Answer all the questions listed below. Use the Answer sheet provided in
the next page:

1. What is inventory
2. Which one of the following raw material inventor?
a. Aluminum scarp c. Pizza
b. Bread d. Refined oil
3. Work in progress inventory
a. Raw material
b. Final product
c. Semi-finished product
d. All
4. Which of the following is benefits of inventory control
a. Economy in purchasing.
b. Eliminates the possibility of duplicate ordering
c. Improvement in customer‘s relationship
d. all
5. which one is false about procedure of inventory
a. Tool inventories will be standardized
b. The inventory list will identify all assigned storage area related tools and
equipment
c. The employee and their supervisor will conduct a full physical inventory twice
a year.
d. Supervisors shall maintain inventory information for a minimum of one years

Note: Satisfactory rating - 3 points Unsatisfactory - below 3 points

You can ask you teacher for the copy of the correct answers.
Answer Sheet
Score = ___________

Rating: ____________

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 Information Sheet-2 Documenting/recording Inventory results.

1.1. Introduction to Maintenance Documentation

Maintenance documentation is a small, but very important, part of the total capital
equipment procurement effort. In order to avoid the problems caused by inadequate
documentation, it is important to understand the end user needs and what information is
contained in an effective documentation package.
This article provides an overview of the needs of the operators and maintenance
technicians, and a checklist of specific information that should be covered in an effective
documentation package.
A maintenance technician needs to:
 Understand the nuts and bolts of how each machine operates,

 Understand the control system that ties the machines together,

 Know how to effectively troubleshoot the process,

 Know how to effectively troubleshoot and repair the individual machines,

 Perform routine maintenance, and

 Perform setups and changeovers.

1.2 Operator Level Documentation Checklist

The ten most important features of an effective operator level documentation
package are listed.
 Accurate safety information - should provide a list of all the hazards associated
with the process, identify e-stop locations and zones, identify electrical
disconnects, and identify air shutoffs.
 Basic process flow descriptions - should provide a process overview flow diagram
that identifies the function of each component.
 Plant specific component operation descriptions - should provide descriptions of
each component at the level that supports the understanding of task specific
information provided in the SOPs (Standard Operating Procedures) and
changeover instructions.

 Clear and concise descriptions of all operator controls - should locate each
control panel and describe the controls. Where touch screens panels are used, it

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 is useful to have screen hierarchy diagrams and a description of the functions that
are performed at each screen.
 Symptom-based troubleshooting and tips - should locate and describe the
process alarm annunciates. It should also provide tables listing possible alarm
messages with guidance for responding to each alarm.
 Quality task list - should identify the quality tasks and reference the documents
needed to perform each task.
 Operator maintenance SOPs and job aides
 Critical process control settings SOPs and job aides
 Line cleaning SOPs and job aides
 Changeover SOPs and job aides

1.3 Maintenance Level Documentation

Maintenance documentation builds on the operator documentation.
The ten most important features of an effective maintenance level documentation
package are listed.
 Detailed component operation descriptions - should identify the major
components for each machine, and describe the function and operation of each
component at a level that supports troubleshooting.
 Clear and concise descriptions of all maintenance controls - should locate each
control panel and describe the controls.
 Process control information, such as:
 Control program sequence and architecture
 Control device identification and function
 Detailed electrical, pneumatic, and hydraulic circuits
 Process level symptom-based troubleshooting and tips - should include basic
troubleshooting approaches, information on what triggers annunciated faults, and
guidance for responding to each alarm.
 Preventive maintenance activities and intervals
 Recommended lubricants and lubrication frequencies
 Recommended spare parts and quantities
 Changeover instructions and settings
 An OEM documentation library and index
Applied Performance Strategies supports OEMs and customers in the design and
development of user documentation and training courses. We can assist you with OEM

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documentation specifications, job task analysis, plant specific training manuals, SOP
and job aide development, training course design and presentation

1.4 Record maintenance

 Identify purpose(s) of records to be maintained in relation to customer
requirements, quality system or production requirements.
 Identify requirements for completion of workplace records in accordance with
workplace procedures.
 Record and collate information ensuring appropriate information and any samples
are included in an appropriate manner.
 Orally reporting routine information

The 4 basic rules for record keeping are:

 Useful — don‘t waste your time keeping records you will never use.
 Easy to use — Simple and neat to encourage you to use the system.
 Accurate — Bad records can lead to poor decisions.
 Compulsory – These are the records you are required to keep by law e.g.
financial records for tax returns.

1.5 Sample project report

It is a general problem that ‗How the maintenance record may be maintained? Most
of the persons follow their own system. Here one project report with details is
mainly applicable.
SI. Machine No Name of the Manufacture‘ Stor Person
No .given by machine/parts s machine e holding the
maintenance No. make & DS change of
section type/No. R machine/equi
No. p.
1 2 3 4 5 6

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 Instruction for form
Column No.1:-
Serial number as usual 1, 2, 3…should be noted. Start these entries from drilling
machine, bench grinder, lathe, milling .planer…etc.
Column No.2:-
This column is more important for the purpose of maintenance activity. Here
maintenance section has to denote the code number of the machine which will be
used as further reference number. This code should be given in following forms.
i. writes abbreviation (letter symbol)of the machine
ii. Next the serial No. (In continuation) of the particular category of the machine
Example: - LAC/12
Here LA is an abbreviation for lathe. Then letter C stands for center lathe.12
are the serial No. for the lathe.
Column No.3:- Write the name of the machine or equipment with its sub category.

Column No.4:-
i. name of the manufacturer of that machine
ii. Their machine No.
iii. Type of the machine/Equipment or code used by manufacturer
Column No.5:- Write the store DSR No. with date

Column No.6:-
Keep more space for this column. Write the name (initial) of the person (Instructor)
who holds the physical charge of that machine. At the beginning the first person
name should be written in ink. Subsequently, the charge may be changed. Write
these names by pencil.

1.5 Stock Records

Stock records provide a very useful way of monitoring stock in your store. Like other
inventory management tools there are many systems being used. The aim is to
provide up to date information about each product within the store. A typical stock
record system includes the product:
 name
 number
 size

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In addition the stock record would include:
 amount on hand
 minimum stock level
 amount on order
 retail price
 cost price
These systems can be manual or electronic. The more sophisticated electronic systems
may also include an automatic reorder function. Like any documentation accuracy and
regularly updating information is the key to its usefulness.

Sample stock record sheet

. Documentation
Your inventory control system and the outcomes of the stock take provide a range of
useful and up to date information. These documents help you to identify the current state
of the store's inventory with regard to:
 fast and slow moving stock
 stock turn
 damaged stock

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 Self-Check -2 Written Test

Directions: Answer all the questions listed below. Use the Answer sheet provided in
the next page:

1. Write 4 basic rules for record keeping?

2. What is the aim of Stock Records?

Note: Satisfactory rating - 3 points Unsatisfactory - below 3 points

You can ask you teacher for the copy of the correct answers.
Answer Sheet
Score = ___________

Rating: ____________

Name: _________________________ Date: _______________

Short Answer Questions

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TVET program title- Machining Level -2
Author/Copyright October 2019
 Information Sheet-3 Storing tools and equipments.

3.1 Introduction
If you‘re like most people, you probably have a wide variety of tools stored in
various places around the house. Maybe you have random screwdrivers and
hammers stored in the basement, garden tools like rakes and hoes in the garage,
and power tools stuffed in the tops of closets. If you aren‘t storing these tools
properly, it‘s possible they could get damaged and break- or even just simply lost!
What‘s worse than not being able to find a screwdriver when you need one?
You have to work with the space you have. Maybe you hang tool on pegboards, maybe
you store them in boxes, bags, or chests, or maybe you keep them in drawers or on
shelves in your shop. Whatever works for you is best.

3.2. Functions of stores

The functions of stores can be classified as follows:
1. To receive raw materials, components, tools, equipment‘s and other items
and account for them.
2. To provide adequate and proper storage and preservation to the various
items.
3. To meet the demands of the consuming departments by proper issues and
account for the consumption.
4. To minimize obsolescence, surplus and scrap through proper codification,
preservation and handling.
5. To highlight stock accumulation, discrepancies and abnormal consumption
and effect control measures.
6. To ensure good housekeeping so that material handling, material
preservation, stocking, receipt and issue can be done adequately.
7. To assist in verification and provide supporting information for effective
purchase action.
3.3. Tool Storage Ideas and Tips
By taking proper care of your tools, you‘ll ensure that they‘ll remain in good working
order and will be ready for use when you need them. No matter what kind of tools
currently in your possession, it‘s important to take some time organizing your collection
so you‘re protecting your investment. You‘ll want them in good condition when it‘s time to
start that next DIY project!

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Regardless of where you choose to store your tools, there are a few basic tool storage
ideas and tips to keep in mind before you put them away.
 Follow the instructions. Some manufacturers will have specific instructions for
how to store tools, so consult your manual first and foremost. It‘s important to
follow these instructions, especially for larger power tools like saws or drills, so
they remain in good working condition.
 Clean them off. Tools should be cleaned each time you use them. Wipe them
down with a damp rag or towel to get rid of any dirt, dust, grease or debris. Make
sure garden tools are free of mud and grime. Everything should be completely dry
before placing it in storage to avoid rust developing.
 Use original cases. Power tools usually come in hard, plastic cases, and it‘s
recommended to keep these cases for storage whenever possible. These cases
will keep your power tools in storage safe from extreme conditions, plus all the
parts can be stored right alongside them in the case. No more lost power cords or
chargers!
 Invest in sturdy storage containers. If you don‘t have the original container, or
you‘re storing smaller hand tools, invest in some sturdy containers. This will not
only keep your tools organized, but also allows them to be easily transportable to
your next project area.
 Store in a safe, dry place. Along with having the right containers, another way to
protect your tools is to ensure that area you‘re storing them in is safe and dry.
Water or humidity can cause damage to tools, especially power tools.
 Go vertical. Tools should never be stored on the ground. Invest in some shelving
for smaller tools, or hang pegboard along your workbench or on a wall in your
garage. You‘ll be able to hang things like wrenches, hammers, box cutters,
garden equipment and many other tools so they‘ll be easy to access at any time.

How to Store Tools & Equipment

 Zip those home projects out in no time with well-organized and properly stored
tools and other home maintenance equipment. Garden supplies, vehicle
implements and liquids and home tools such as hammers, saws, nails and power
equipment all benefit from proper care and storage. These items organized
efficiently make home projects easy, and make clean up even easier.
 You have to work with the space you have. Maybe you hang them on pegboards,
maybe you store them in boxes, bags, or chests, or maybe you keep them in

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 drawers or on shelves in your shop. Whatever works for you is best. Pegboards
make a great storage system for tools. They let you see all your tools at a glance
and they can make use of wall space in a pretty efficient way. If you don't have
enough wall space, though, you can still take advantage of pegboards by building
a hinged system, a rolling pegboard, or even a portable pegboard storage
system.
 The most important purpose served by the stores is to provide uninterrupted
service to the maintenance and repair divisions. Further, stores are often equated
directly with money, as money is locked up in the stores.

How to Prepare and Store Tools

1. To keep tools tidy, it should be cleaned after use and wiped down with a rag
or towel to be sure that they are free of dirt, grease and debris.
2. After cleaning, damage or defects should be checked. If the tool cannot be
repaired, it should be thrown to away.
3. Any soil and dirt should be scraped away from the metal surfaces with an
approved solution. Before placing in storage it should be dried with a towel or
rag.
4. The metal parts of the tools should be coated with a lubricant protector spray.
5. Tools is does not directly stored on the ground both small hand and power
tools should be Placed on shelving.
6. Short-handled tools should be stored in a plastic bin or box. All surfaces of
Power tools should be cleaned and completely dry before storage and
Spraying lubricants

Page 149 of 157 Federal TVET Agency Version -1

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3.2 Functions of stores
The functions of stores can be classified as follows:
 To receive raw materials, components, tools, equipment‘s and other items and
account for them.
 To provide adequate and proper storage and preservation to the various items.
 To meet the demands of the consuming departments by proper issues and
account for the consumption.
Page 150 of 157 Federal TVET Agency Version -1
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  To minimize obsolescence, surplus and scrap through proper codification,
preservation and handling.
 To highlight stock accumulation, discrepancies and abnormal consumption and
effect control measures.
 To ensure good housekeeping so that material handling, material
preservation, stocking, receipt and issue can be done adequately.
 To assist in verification and provide supporting information for
effective purchase action.

Page 151 of 157 Federal TVET Agency Version -1

TVET program title- Machining Level -2
Author/Copyright October 2019
 Self-Check -3 Written Test

Directions: Answer all the questions listed below. Use the Answer sheet provided in
the next page:
1. Which one of the following is not maintenance of plate compactor? (2 points)
A. Changing oil
B. Changing grease
C. Changing blade
D. Al
3. If you aren‘t storing tools properly
a. they could get damaged and break
b. it became to non-function
c. take time to find
d. all
4. All are functions of stores except
a. To ensure good housekeeping
b. To maximize obsolescence, surplus and scrap
c. To assist in verification and provide supporting information
d. To provide adequate and proper storage and preservation
5. Write few basic tool storage ideas and tips to keep in mind before you put them
away.

Say true or false

1. To receive raw materials, components, tools, equipment‘s and other items and
account for them is not the functions of stores
2. Provide adequate and proper storage is preserve various items.
3. Keeping tools properly storing, cleaning, and maintaining is not saves time
and money.
4. Minimize obsolescence, surplus and scrap through proper codification,
preservation and handling.

Note: Satisfactory rating - 3 points Unsatisfactory - below 3 points

You can ask you teacher for the copy of the correct answers.

Page 152 of 157 Federal TVET Agency Version -1

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Author/Copyright October 2019
 Techniques for Store Tools Properly
Operation Sheet-1

Step 1- Follow the instructions

Step 2- Clean them off
Step 3- Use original cases.
Step 4-Invest in sturdy storage containers
Step 5-Invest in sturdy storage containers
Step 6-Store in a safe, dry place.
Step 7-Go vertic

Page 153 of 157 Federal TVET Agency Version -1

TVET program title- Machining Level -2
Author/Copyright October 2019
 LAP Test Practical Demonstration

Name: _____________________________ Date: ________________

Time started: ________________________ Time finished: ________________
Instructions: Given necessary templates, tools and materials you are required to
perform the following tasks within --- hour.

Task 1. Store hand tool in in workshop

Page 154 of 157 Federal TVET Agency Version -1

TVET program title- Machining Level -2
Author/Copyright October 2019
 List of Reference Materials

 B.S Dhillon (maintainability, maintenance, and Reliability for Engineers)

 Ricky Smith and Keith Mobley (Industrial machinery Repair: Best maintenance
practices pocket guide)
 Lindley R.Higgins, P.E, R.Keith Mobley (Maintenance Engineering Hand Book)
Mc Graw-Hill standard Hand Book
 Introduction to Maintenance engineering, Modelling,
optimization,and Management,
 Mohammed Ben‐ daya,King Fahd University of Petroleum & Minerals, Dhahran,
Saudi Arabia
 Operation and maintenance manual - Fervi https://www.fervi.com › download ›
t999_user_manual
 . https://www.ihsa.ca/resources/safe_practices_procedures.aspx
 . Operation and maintenance manual - Fervi www.fervi.com › cgi-bin › download ›
0708_user_manual
 Download PDF Assembly and Instruction Guide - Sherline .. https://sherline.com
› 2015/01 › 5326_instructions_v8_web
 Mechanical services pdf - ILO https://www.ilo.org › ---asia › documents ›
publication › wcms_495715
 Coolant Management Assistance Guide [email protected] ●
www.monroefluid.com
 Maintenance, Replacement, and Reliability,Theory and Applications, S e c o n d e
dition Andrew K.S. Jardine,Albert H.c. Tsang
 Maintenance engineering handbook, Lindley R. Higgins, P.E, Sixth Edition, New
York Chicago San Francisco Lisbon London.
 Ricky Smith and Keith Mobley (Industrial machinery Repair: Best maintenance
practices pocket guide)
 European Agency for Safety and Health at Work - http://osha.europa

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 The trainers who developed the learning guide

NO Name Qualification Region E-mail

1 Gurmu Mulatu A /MSc/ Adis Ababa [email protected]
2 Mohammed Abdela A /MSc/ Dire Dewa [email protected]
3 Waliyi Bena A /MSc/ Oromia [email protected]
4 Elias Zemenu A /MSc/ Somali [email protected]
5 Muluneh Negussie A /BSc/ Amhara [email protected]
6 Teshome A /MSc/ Debub [email protected]
W/Yuhanis
7 Solomon Aderaw A /BSc/ Amhara [email protected]
8 Wakweya Tolera A /MSc/ Oromiya [email protected]

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Author/Copyright October 2019