DEPARTMENT OF ROBOTICS AND AUTOMATION

INTERNAL - 1 EXAM
(2024-25-EVEN SEM)
Name of Subject: RAT82 / MAINTENANCE & SAFETY ENGG

ANSWER KEY

PART-A

1. Define maintenance
Maintenance is the process of keeping equipment, machinery, or systems in good working
condition through regular inspection, repair, and servicing to prevent breakdowns and ensure
optimal performance.

2. What are the types of maintenance?

The main types of maintenance are:

 Corrective Maintenance: Repairs or adjustments made after a failure occurs.

 Preventive Maintenance: Scheduled maintenance to prevent failures before they occur.
 Predictive Maintenance: Using data and analysis to predict when maintenance should
be performed.
 Breakdown Maintenance: Maintenance carried out when a machine or system has
already failed.
 Autonomous Maintenance: Operators perform basic maintenance tasks on equipment to
prevent failures.

3. Which kind of maintenance will you prefer for aircrafts and state the reason.
Predictive Maintenance is preferred for aircraft because it allows for scheduled repairs based
on the analysis of equipment condition, reducing the risk of unexpected breakdowns and
improving safety.

4. Define breakdown maintenance

Breakdown maintenance is the reactive repair of equipment or machinery after it fails or stops
working, often leading to production delays or operational disruptions.

5.Define predictive maintenance

Predictive maintenance involves using sensors, data analysis, and technology to predict when
equipment is likely to fail, allowing maintenance to be performed just before the failure occurs to
avoid unexpected breakdowns.

6.Define TPM
TPM (Total Productive Maintenance) is a comprehensive approach to maintenance that involves
all employees in maintaining and improving equipment, focusing on preventing breakdowns and
maximizing the efficiency of machinery.
7. What are the elements of preventive maintenance?
The key elements of preventive maintenance are:

• Inspection
• Cleaning
• Lubrication
• Adjustment
• Replacement
• Testing
• Documentation and Scheduling

8. Define autonomous maintenance

Autonomous maintenance refers to the practice where operators or workers are trained to
perform basic maintenance tasks, such as cleaning, lubricating, and inspecting equipment, to
ensure it operates at peak performance.

9. Name the 5s Principle

The 5S Principle consists of:

 Sort (Seiri): Eliminate unnecessary items.

 Set in Order (Seiton): Organize items for easy access.
 Shine (Seiso): Clean and maintain the work area.
 Standardize (Seiketsu): Create consistent practices and procedures.
 Sustain (Shitsuke): Maintain and improve standards.

10. Define the term CLIT

CLIT refers to cleaning, lubrication, inspection and tightening in the autonomous maintenance.

PART-B

1. Describe the objectives & procedure for Predictive Maintenance

Objectives of Predictive Maintenance

 Increase Equipment Reliability: By monitoring the condition of equipment

continuously, predictive maintenance helps identify potential failures before they occur,
increasing the reliability of machinery.
 Reduce Unplanned Downtime: Predictive maintenance reduces the risk of unexpected
breakdowns by predicting when equipment will need maintenance, minimizing
unscheduled downtimes.
 Extend Equipment Lifespan: By performing maintenance only when necessary,
predictive maintenance ensures that equipment lasts longer, reducing the frequency of
over-maintenance.
 Optimize Maintenance Costs: It allows for maintenance to be done at the right time,
avoiding unnecessary repairs, thus optimizing the overall maintenance budget.
  Improve Safety: Early detection of equipment issues reduces the likelihood of accidents
and ensures safety in operations.

Procedure for Predictive Maintenance

1. Data Collection:
Gather data from sensors, gauges, and other monitoring equipment attached to machinery
to track performance indicators like temperature, vibration, pressure, and noise levels.
2. Data Analysis:
Analyze the collected data using predictive analytics, machine learning, or AI models to
identify patterns and trends that might indicate an impending failure.
3. Condition Monitoring:
Continuously monitor the machine's health by assessing key performance indicators
(KPIs) like wear, vibration levels, and thermal behavior.
4. Failure Prediction:
Use advanced algorithms to forecast when a machine is likely to fail, based on current
trends and data analysis, to determine the ideal time for maintenance.
5. Schedule Maintenance:
Perform maintenance only when required, based on predictive insights. This minimizes
downtime and ensures maintenance is carried out at the most optimal time.
6. Post-Maintenance Review:
After maintenance, assess the machine’s performance to ensure it operates as expected,
and analyze any discrepancies to refine future predictions.

2. Describe the objectives & procedure for Preventive Maintenance

Objectives of Preventive Maintenance

 Minimize Equipment Failure: By scheduling regular maintenance, preventive

maintenance aims to reduce the likelihood of equipment failure and unplanned downtime.
 Increase Equipment Lifespan: Regular inspection and servicing help keep machinery in
good working condition, extending its operational lifespan.
 Enhance Efficiency: Preventive maintenance ensures that equipment is always
functioning at its optimal efficiency, reducing energy waste and improving productivity.
 Lower Overall Maintenance Costs: By addressing minor issues before they escalate
into major problems, preventive maintenance reduces the cost of large repairs and
replacements.
 Improve Safety: Routine checks help identify potential safety hazards, ensuring the
work environment remains safe for operators.
Procedure for Preventive Maintenance

1. Identify Maintenance Needs:

Evaluate all equipment and machinery to identify maintenance needs based on
manufacturer recommendations, historical data, and performance monitoring.
2. Develop a Maintenance Schedule:
Create a detailed maintenance calendar outlining when specific tasks (such as cleaning,
lubrication, part replacement) should be performed based on the equipment's usage,
operating conditions, and lifecycle.
3. Routine Inspections and Servicing:
Regularly inspect and service equipment as per the established schedule to check for
wear and tear, lubricate moving parts, clean components, and perform minor repairs.
4. Replace Worn Components:
Replace components that have a limited lifespan (e.g., filters, seals, bearings) during
scheduled maintenance to avoid failure.
5. Document and Track Maintenance Activities:
Keep detailed records of each maintenance activity, including what was checked,
repaired, or replaced, and any anomalies found during the process.
6. Review and Adjust the Schedule:
Continuously evaluate the effectiveness of the preventive maintenance schedule and
make adjustments as needed based on equipment performance and changing operational
conditions.

3. Discuss Total Productive Maintenance (TPM) in Detail

Overview of Total Productive Maintenance (TPM)

Total Productive Maintenance (TPM) is a maintenance strategy that aims to achieve maximum
equipment efficiency by involving everyone in the organization, from operators to management.
TPM focuses on preventing breakdowns, improving equipment effectiveness, and enhancing
overall productivity.

Objectives of TPM

 Maximize Equipment Effectiveness (OEE): TPM aims to improve the Overall

Equipment Effectiveness (OEE), which is a measure of how effectively equipment is
utilized during production.
 Reduce Unscheduled Downtime: By proactively addressing potential issues and
involving all employees in maintaining equipment, TPM reduces unplanned downtime
and ensures continuous production.
 Empower Employees: TPM fosters a culture where employees are directly involved in
the maintenance process, from operators to maintenance technicians, creating a sense of
ownership.
  Improve Safety and Work Environment: TPM seeks to create a safe and clean work
environment by reducing hazards associated with malfunctioning equipment.

Key Pillars of TPM

TPM consists of 8 key pillars, each focusing on different aspects of maintenance and operational
excellence:

1. Autonomous Maintenance:
Operators are trained to carry out basic maintenance tasks, such as cleaning, lubricating,
and inspecting their equipment, to ensure that it operates optimally.
2. Planned Maintenance:
Maintenance activities are planned and scheduled to avoid unplanned downtimes. This
includes regular inspections, servicing, and replacement of parts before they wear out.
3. Quality Maintenance:
Equipment is maintained to ensure that it produces consistent, high-quality output. This
involves detecting and eliminating factors that could lead to product defects due to
equipment malfunction.
4. Focused Improvement:
Continuous improvement is a core concept of TPM, where teams are tasked with
identifying and eliminating inefficiencies or waste within the maintenance process.
5. Early Equipment Management:
Equipment is designed and maintained with reliability and ease of maintenance in mind,
preventing issues before they arise.
6. Training and Education:
Employees are trained on the principles of TPM and provided with the knowledge to
carry out basic maintenance tasks and contribute to equipment care.
7. Safety, Health, and Environment:
TPM promotes a safe and healthy work environment by addressing potential hazards and
ensuring that equipment operates safely for both employees and the environment.
8. Office TPM:
TPM extends beyond the shop floor to administrative functions, ensuring that processes
such as inventory management and scheduling are aligned with TPM goals.

Implementation of TPM

1. Commitment from Top Management:

Successful implementation of TPM requires strong support from top management to
create a culture of total involvement.
2. Develop TPM Strategies:
Create a roadmap for TPM implementation, focusing on equipment effectiveness,
employee training, and structured problem-solving methodologies.
3. Establish Maintenance Teams:
Form cross-functional teams that include operators, maintenance personnel, and
management to oversee TPM activities and track progress.
 4. Conduct Regular Audits:
Perform regular audits to evaluate the effectiveness of TPM initiatives, identify gaps, and
ensure continuous improvement.
5. Use Data and Metrics:
Track and analyze performance metrics such as OEE, downtime frequency, and
maintenance costs to assess the success of TPM and adjust strategies as necessary.

Benefits of TPM

 Increased Equipment Uptime: TPM leads to fewer breakdowns and extended

equipment life, resulting in improved operational efficiency.
 Improved Productivity: With fewer disruptions, production runs smoothly, leading to
increased productivity.
 Enhanced Employee Morale: Employees feel more involved and empowered, which
boosts morale and job satisfaction.
 Cost Reduction: TPM helps reduce maintenance costs and increases the return on
investment for equipment.