JJ615-MECHANICAL COMPONENTS & MAINTENANCE

CHAPTER 1 :MAINTENANCE PRINCIPLE &PROCEDURES

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Maintenance

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

• Maintenance is an activity involved in keeping something in good working order, and actions performed to keep systems functioning or in service.

Principle Of Maintenance

• To achieve product quality and customer satisfaction through adjusted and serviced equipment

• Maximize useful life of equipment• Keep equipment safe and prevent safety

hazards• Minimize frequency and severity of

interruptions

Objectives

• Must be consistent with the goals of production (cost, quality, delivery, safety)

• Must be comprehensive and include specific responsibilities

ADVANTAGES OF IMPLEMENT

MAINTENANCE

Reduced inventory

Continuous improvement

Improved capacity

Higher productivity

Faster and more dependable troughput Improved

quality

Lower operating

cost

• Reduced inventory-Reducing stores and buffer stock.

• Continuous improvement-Is on going effort to improve product

services or process.• Higher productivity

-Is high ratio of output to input of production.

• Improved capacity-Improve the capacity of product.

• Improved quality-Achieve a step change in quality

through contracting out the service with the new service level agreement.

• Lower operating cost-Expenses which are related to the

operation of a organization in a lower cost.

TYPE OF COST MAINTENANCECOST

MAINTENANCEUNPLANNED

MAINTENANCEPLANNED

MAINTENANCE

EMERGENCY @BREAKDOWN

MAINTENANCE

CORRECTIVE MAINTENANCE

OPPORTUNITIE MAINTENANCE

CORRECTIVE MAINTENANCE

ROUTINE MAINTENANCE

PREDECTIVE MAINTENANCE

SCHEDULE MAINTENANCE

CONDITION BASE

MAINTENANCE

DESIGN OUT MAINTENANCE

PERVENTIVE MAINTENANCE

VARIOUS TYPE OF COST MAINTENANCE AND RELATED

• Emergency @ breakdown maintenanceIt means that people waits until equipment fails and

repair it.• Periodic maintenance

It means periodically inspecting, servicing and cleaning equipment and replacing parts to prevent sudden failure and process problems.

• Corrective maintenanceIt improves equipment and its components so that preventive maintenance can be carried out reliably.

VARIOUS TYPE OF COST MAINTENANCE AND RELATED

• Routine maintenance -It is a daily maintenance ( cleaning, inspection, oiling

and re-tightening ),• Preventive maintenance

-It design to retain the healthy condition of equipment and prevent failure

• Predictive maintenance -It is a method in which the service life of important

part is predicted based on inspection or diagnosis, in order to use the parts to the limit of their service life.

WORKPLACE SAFETY

Benefits Of Clean and Working Environment

• Reduced Accidents– reduce accidents that can result in employees

injuring their backs, legs, shoulders or other body parts because of broken equipment, and also wet areas where people can slip.

• Air Quality– Employees will literally breathe easier in safe

workplaces free from chemical pollution, asbestos, dust, cigarette smoke or other allergens.

• Reduced stress– Unsafe workplaces may cause unhealthy stress

levels among employees fearful of threats from co-workers, dramatic altercations with management or persistent problems related to parking lot theft and other challenges.

Personal Protective Equipment (PPE)

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

Examples Gloves

Protective clothing

Safety helemt

Goggles

Safety boots

respirator

Hearing protection

Important Of Personal Protective Equipment

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

Lockout and Tagout

• Lockout/Tagout refers to the procedures established for Control of Hazardous Energy as described by the Occupational Safety and Health Administration (OSHA) under Federal Registry 29 CFR1910.147.

• Lockout/Tagout ensures employee safety during inspection, maintenance, or service of equipment by controlling all energy flow to and from the equipment.

• To achieve system lockout, all energy sources are turned off or disconnected, and stored energy is released, restrained, or dissipated. A lock or lockout device applied to each energy source prevents accidental startup.

• Tag out is a labelling process that is always used when lockout is required.The process of tagging out a system involves attaching or using an indicator.

Lock out/tag out sign

Tag out label Lock out

Lock out/tag out program

• Lockout/Tagout specification includes the following:– Plant or company-wide safety policies.– Machine-specific lockout procedures.– Lock and key and tag control.– Program review and certification.– Outside contractor rules and regulations.

• All companies whose employees service or maintain equipment with potentially hazardous energy sources must have an OSHA-compliant Lockout/Tagout program.

Purpose of lock out/tag out

• A lockout/tag out program will help prevent:– Contact with a hazard while performing tasks that

require the removal, by-passing, or deactivation of safe guarding devices.

– The unintended release of hazardous energy (stored energy).

– The unintended start-up or motion of machinery, equipment or processes.

When lock out/tag out is required?

• Lockout/Tagout is required whenever employees are exposed to hazardous energy

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

Hazardous materials

• Hazardous materials or Hazmat, are solids, gases, and liquids that can hard people, animals property, and the environment. Throughout the U.S.hazardous materials are moved by marine vessels, air, rail, and truck.

• During the servicing and maintenance of machines and equipment, the unexpected startup or release of stored energy could cause injury to employees.

Hazardous Energy

Hazardous energy

Electrical hydraulic

pnuematic thermalchemical

mechanical

Hazardous materials sign

Organizations that given safety at Hazardous materials

• The Occupational Safety and Health Act (OSH Act) gives OSHA authority to promulgate the hazardous materials regulations.

• EPA Hazoardous materials organization has primary responsibility for regulating the transport of hazardous materials across all modes except pipelines

Hand Tools

Chisel• Remove unwanted timber

or to carve it out

Clamps• to create inward pressure to

secure objects or materials together to prevent movement or separation.

Hammer• To deliver an impact or

force such as pounding or striking to an object.

Hand saw• used to cut materials with

its blade.

Screwdrivers• Screwdrivers are used for

driving screws into materials or for securing or loosening parts on machinery.

Planer• A planer is used to shape or

thin out a piece of timber by removing small amounts of wood.

Wrench• It s used to for gripping,

fastening,rotating ,loosing or turning bolts,nuts and screw.

Pliers• These are used to hold

objects firmly for bending or physical compression.

Power Tools

Circular saw• Circular saws are similar to

jigsaws only the blade is round and much larger which means it is better for straight cuts.

Drill• Used for drilling holes or

inserting and removing screws from a material.

Jigsaw• used for cutting curves

much like a coping saw as it uses a similar sized blade only it cuts much quicker.

Electric Planer• Electric planers are the

same as hand planers only they work automatically which makes planning much faster and easier.

Router• create curved edges and

mill out timber making them very useful.

Belt sander• creates scratches if it is used

against the woods grain but it removes more material.

Air Compressor • An air compressor is a

device that converts power (usually from an electric motor, a diesel engine or a gasoline engine)

4″ Angle Grinder• also known as a side

grinder or disc grinder, is a handheld power tool used for cutting,grinding and polishing.

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

• Identify tools that are not broken

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

Important of inspecting a hand tools & power tools