chapter 1 maintenance

8/12/2019 Chapter 1 Maintenance

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TOPIC 1 :

MAINTENANCE PRINCIPLES ANDPROCEDURES



SUB TOPICS

1. INTRODUCTION TO MAINTENANCE2. COST CONSIDERATION IN MAINTENANCE3. WORKPLACE SAFETY4. HAND TOOLS, POWER TOOLS AND

MAINTENANCE EQUIPMENTS



WHAT IS MAINTENANCE?

• “THE ACTION OF PRESERVING” (OXFORD) • In engineering : Actions necessary for

retaining or restoring a piece of equipment,machine, or system to the specified operablecondition to achieve its maximum useful life. Itincludes corrective maintenance and

preventive maintenance .



OBJECTIVES OF MAINTENANCE

1. Minimizing the loss of productive timebecause of equipment failure ( i.e.minimizing idle time of equipment due to

breakdown)2. Minimizing the repair time and repair cost3. Minimizing the loss due to production

stoppage4. Prolonging the life of capital assets byminimizing the rate of wear and tear



OBJECTIVES OF MAINTENANCE

5. To keep all productive assets in goodworking conditions

6. To eliminate / minimize accidents throughregular inspection and repair of safetydevices

7. To minimize the total maintenance cost



ADVANTAGES OF IMPLEMENTINGMAINTENANCE

1. Production capacity – Machines idled bybreakdowns cannot produce, thus thecapacity of the system reduced

2. Production costs – Labor costs per unit risebecause of idle labor due to machinebreakdowns. When machine malfunctionsresult in scrap, unit labor and material costsincrease



ADVANTAGES OF IMPLEMENTINGMAINTENANCE

3. Product and service quality – Poorly maintainedequipments produce low quality products.

4. Employee or customer safety – Worn-outequipment is likely to fail at any moments andthese failure can cause injuries to the workers

5. Customer satisfaction – When production

equipment break-down, product often cannotbe produced according to the master productionschedules



COST OF MAINTENANCE

• Breakdown (B/D) cost = labour + downtime• Preventive Maintenance (PM) cost = labour +

downtime due to planned shutdown• Cost of sub-standard performance = loss in

process material + scrapping of material +wastage

• Cost of spares = cost of spares + othermaterials



Cost related to Maintenance

1. Lubrication

2. Cleaning3. Adjustments - Return or slowdown the process ofdeterioration or wear4. Application of protective coating5. Examination of the state of the components

6. Analysis of history of behaviour of the machineand its components7. Replacement of worn out component



Cost related to Maintenance

8. Repair of cracks or other repairable damages

9. Modification of design of the components or locationof the equipment

10. Capital replacement - Replacement of the machinewhen the age of the existing machine requirements ofquality and quantity of output and emergence of bettermachines make it economical to dislodge the presentand install a new machine



WORKPLACE SAFETY

Benefits of clean and safe working environment:1. Prevent accidental slips with or around

dangerous tools and machine2. OSHA (Act 514, 1994) compliance3. Prevent Chemical hazards – mists, vapour,

gases, dusts and fumes

4. Prevent Physical hazards –noise, vibration,extremes of temperature and excessiveradiation



WORKPLACE SAFETY

5. Prevent Biological hazards – mould , fungi,bacteria and insects

6. Prevent ergonomics hazard – related to design

and condition of the workplace7. Reduce operation and production cost including

accident cost and other cost due to accident8. Reduce downtime and shutdown including lost

work hours, medical costs, insurance premiumand administration, property damage, firelosses and other indirect costs



WORKPLACE SAFETY

Important of Personal Protective Equipment (PPE)• PPE – Includes devices and clothing designed to be

worn or used for the protection of safety of anindividual while in potentially hazardous areas orperforming potentially hazardous operations.

• PPE most commonly used for protection of the head,including eyes and ears and the torso, arms, hands andfeet.

• Head protection – Prevent head injuries caused by

falling or flying objects, such as working below otheremployees who are using tools and materials that couldfall, or by bumping the head against a fixed object.(PPE- safety hats)



WORKPLACE SAFETY • Safety glasses, chemical goggles, face

shields, welding goggles, welding faceshield)

• Ear protection – Prevent from excessivenoise exposure to avoid hearing damage.(PPE- ear plug, ear muffs)

• Respiratory Protection – Appropriaterespirators should be worn to preventatmospheric contamination caused byarticulates (dust/mist/fumes) orgases/vapors



WORKPLACE SAFETY •

Torso Protection – Protect torso treated by heat,splashes from hot metals and liquids, impacts, cuts,and acids. (PPE- vest, jackets, aprons, coveralls, fullbody suits, kevlars)

•

Arm and Hand protection- Protect arm and againstvarious hazardous situation. (PPE-gloves, handpads, sleeves, wristlets

• Foot and Leg Protection – For protection of feetand legs from falling or rolling objects, sharpobjects, molten metal, hot surfaces, and wetslippery surfaces. (PPE – Foot guard, safetyshoes/boots, legging)



WORKPLACE SAFETY

Organization that governs the safety of hazardous material:1. Department of Occupational Safety and Health, DOSH2. (Occupational Safety and Health Act (Use and standards of

exposure of hazardous To Health – Regulation 2000))

3. Lembaga Pelesenan Tenaga Atom (AELB)Akta Perlesenan Tenaga Atom, 1984 StandardPerlindungan sinaran (standard asas Keselamatan)Peraturan-peraturan 1988 Act 304.

1. Chemical Industry Safety and Health Council2. Chemical Industries Association Limited



WORKPLACE SAFETY

Lockout/ Tag out System• The purpose of these instructions is to ensure that

before any employees performs any servicing ormaintenance on machinery or equipment, where the

unexpected energizing, start up, or release of any typeof energy could occur and cause injury, the machineryor equipment will be rendered safe to work on bybeing locked out or tagged out.

• When an employee performs work on machines,equipment, or systems is exposed or causes otheremployees to be exposed to the hazards of unexpectedenergization, these procedures must be followed.



WORKPLACE SAFETY • OSHA Regulations (Standards - 29 CFR)(USA)• The control of hazardous energy (lockout/tagout). - 1910.147• Standard Number: 1910.147• Standard Title: The control of hazardous energy (lockout/tagout).• SubPart Number: J•

SubPart Title: General Environmental Controls• This standard covers the servicing and maintenance of machines

and equipment in which the "unexpected" energization or start upof the machines or equipment, or release of stored energy couldcause injury to employees. This standard establishes minimum performance requirements for the control of such hazardousenergy

• This standard applies to the control of energy during servicingand/or maintenance of machines and equipment.



WORKPLACE SAFETY

• Example of a tag out/lock outsystem



WORKPLACE SAFETY • Each person places their lockout keys in the box which is

padlocked by one controlling person. During a lockout, anyperson joining the work team places their keys through theopen slot without exposing the keys inside. Only when the jobis checked and finished will the controlling person unlock thebox and re-issue the keys.



WORKPLACE SAFETY

Heavy duty steel constructed grouplockout box with yellow powdercoated finish has a standard 40hook key capacity. Clear Perspex

door allows contents to be easilychecked. Lockable with up to 6padlocks, ideal for larger grouplockout applications

450mm high x 380mm wide x80mm deep



TYPES OF HANDTOOLS, POWER TOOLS

AND MAINTENANCE EQUIPMENTS

GROUP ASSIGNMENT 1 (GROUP A & B) :- LIST THE TYPES OF HAND TOOLS D

- DEMONSTRATE THE PROPER USE OF HANDTOOLS

- DETERMINE THE IMPORTANCE OF INSPECTINGHAND TOOLS

DUE : WEEK 8 (31ST JAN 2013)



TYPES OF HANDTOOLS, POWER TOOLSAND MAINTENANCE EQUIPMENTS

GROUP ASSIGNMENT 1 (GROUP C & D) :- LIST THE TYPES OF POWER TOOLS

- DEMONSTRATE THE PROPER USE POWERTOOLS

- DETERMINE THE IMPORTANCE OF INSPECTING

POWER TOOLSDUE : WEEK 8 (31ST JAN 2013)



PRACTICAL TASK GROUPINGBIL KUMPULAN A BIL KUMPULAN B

1. 02DKM10F1060 MOHAMAD NAQIUDDEN BINMOHAMAD NAZRI 1. 02DKM10F1090 MUHAMMAD FAHYADH FAHMI BIN ABDUL

MALIK

2. 02DKM10F1056 MOHAMAD JAMALUDIN B SUHAIMI 2. 02DKM10F1048 AMIMZA BIN AHMAD

3. 02DKM10F1083 MUHAMAD SYAFAIZ BIN ZULKIFLI 3. 02DKM10F1084 MOHAMAD HUSNI BIN ASBUDI

4. 02DKM10F1092 AHMAD FARIS BIN MOHD IMARAM @MOHD IMRAN 4. 02DKM10F1070 MOHAMAD AFIQ BIN MAT ROZALI

5. 02DKM10F1047 SYED MUHAMMAD YUSUF BIN SYEDHASHIM 5. 02DKM10F1087 MOHAMAD AMIRUL SHAFIQ B. ABDUL RAZAK

6. 02DKM10F1116 MOHD NOR FAIZAN BIN ABD JALIL 6. 02DKM10F1065 MUHAMMAD FARIS BIN AZANAN

7. 02DKM10F1055 MUHAMMAD FAIZAL BIN MD ZOR 7. 02DKM10F1069 SHARUL NIZAM BIN YAAKOP

BIL KUMPULAN C BIL KUMPULAN D

1. 02DKM10F1079 NURUL SYUHADA BTE ALIAS 1. 02DKM10F1075 MUHAMAD NUR FAIZ BIN HAMIDON

2. 02DKM10F1049 NUR ATIKAH BINTI ABDUL RAZAK 2. 02DKM10F1062 MOHAMAD HAZIQ IZHAM BIN NAZAR

3. 02DKM10F1063 MOHAMAD HAFIZ IZMER BIN NAZAR 3. 02DKM10F1051 MOHD SAFWAN BIN MD NOR

4. 02DKM10F1080 NASHRUL AQIM BIN JAAFAR 4. 02DKM10F1086 MOHAMAD AZMI BIN MOHAMED NAZARI

5. 02DKM10F1057 MUHAMAD YUSRIZAL BIN OTHMAN 5. 02DKM10F1082 MOHAMMAD HASRUL BIN JALALUDIN

6. 02DKM10F1088 MOHAMAD SYAHAQIL BIN ABD TALIB 6. 02DKM10F1076 MUHAMAD AZRI BIN AZIZ

7. 02DKM10F1072 HASAN BIN SAPARUDDIN 7. 02DKM10F1188 MEGAVARNAN A/L THANGGASELVAM

8. 02DKM10F1077 PAVITHRAN A/L PARAMSIVAN

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