jj616_chapter_3.1

JJ616 MAINTENANCE MANAGEMENT

SYSTEM APPROACH TO MAINTENANCE

PART II

Instructor: MOHD ZULFADLI BIN AHMAD

• Upon completion of this chapter, students should be able to:-

Define instruction manual and operating manual.

Apply standard operating practices and work instruction.

Understand maintenance manual and department manual.

Information required from manuals

technical communication written to assist people with learning or using a particular program or device

may be the only contact between user and company.

INSTRUCTION MANUAL AND OPERATING MANUAL

Type of manual

instruction manual

operating manual

Instruction manual

is a manual usually accompanying a technical device and explaining how to install or operate it.

something tangible that records communication or facts with the help of marks, words, or symbols.

The information required from instruction manual is technical description about machine, Technical data of the machine, and maintenance of the system.


Operating manual

is a document that describes in detail the processes and systems that a company uses to produce its goods and provide its services.

For bigger or special equipment, separate operating manual are supplied.

only focus the guide on how to operates the machine and equipment with the right procedure.


Operating manual vs Operating Procedure special preparation the user needs before operation, such

as:-

i. Hand washing or device warm-up procedures.

ii. Any warnings or safety instructions specifically related to operation, placed immediately before the corresponding task or instruction.

iii. Results of incorrect operation.

iv. Operating steps in logical order, with the expected results.

v. Space for user-specific instructions.

vi. Who to call if there is a problem.


Operating manual vs Operating Procedure

Basically included in operating manual

providing information on equipment and system operating procedures

i. Startup procedures.

ii. Equipment or system break-in.

iii. Routine and normal operating instructions.

iv. Regulation and control procedures.

v. Instructions on stopping.

vi. Shutdown and emergency instructions.

vii. Summer and winter operating instructions.

viii.Required sequences for electric or electronic systems.

ix. Special operating instructions.


important component of consumer electronics, software and programs, household items and major appliances

provide a step-by-step approach to the user guide on how to handle the equipment.

SECTIONS OF INSTRUCTION MANUAL

Safety regulation

Machine brief introduction

(technical data)

Maintenance and cleaning

Installation and

handling

Transportation

components inside instruction manual

Safety Regulation

is defined as the condition of being free from or protected against failure, damage, error, accidents, or harm or any other event, which could be considered undesirable.

The safety regulation can be in the form of list of safety tips and hazard alerts.

The purpose of safety regulation is to protect customer, avoid equipment damage and also avoid lawsuits.


Safety Regulation

example symbol of safety which is as guided to user.


Machine Brief Introduction

consist of Technical Descriptions which is give detail information about machine

provide the detail about part by part explanation, labelled diagram of product’s components, list of product’s specifications and schematic diagram




Example of label diagram component



Example of technical data

Part/ Component Specification

Casing Aluminium

Heat exchange material Stainless steel

Water tank 0.7 litres / 24 oz

Used capsule container capacity 7 capsules

Pump 19 bar

Weight without packing 7.5 kg/265 oz

Voltage 230 V, 50 Hz (EU) ;120 V, 60 Hz (USA)

Power 1250 W (EU-USA)-With “ Power Save ” function

Electric cord length 1.5 m/ 59 inch

Size (WxDxH) 240 x 240 x 275 (mm)/ 9.4x9.4x10.8 (inch)

The manufacture reserves the right to make changes or improvements without notice.

Transportation and handling

Transport and handling equipment is used to move the equipment from one location to another within a facility or at a site

Basically the instruction manual provides the method on how to transport and handling the equipment with the right method to ensure the exact method is used


Transportation and handling


Example of handling equipment with right tool and right procedure.

Installation

it’s providing the guide how to set up the equipment. The example of installation procedure:-

i. Select a location that is dry and not subject to drafts or moving air from heating or air conditioning vents, or air blown by other equipment.

ii. Place the unit on a flat, preferably non-flammable surface.

iii. Allow sufficient room around the unit for access and cooling.

iv. Six inches minimum on all sides is suggested.

v. Plug the unit into a properly grounded outlet.

vi. Using the lifter, insert the block(s) into the well.

vii. The unit is now ready for use.


Maintenance

includes tasks such as lubricating, adjusting, and replacing parts

Maintenance manual – maintenance instruction & procedure

Maintenance covers two aspects of systems which is operation and performance

diagnosis is used to tell what's wrong with a system, or what needs maintenance

restore or prolong a previous state of operation


Maintenance


Example of daily maintenance

Item Check List/ Date 1 2 3 4 5

1 If the pressure setting is suitable

2 If the air filter regulator works

normally

3 If the machine part make noise

4 If operation switch and indicator

light are normal

5 If there is oil leakage

6 If the hydraulic oil tank level is

normal

7 If the lubrication oil tank level is

normal

8 If the coolant tank level is normal

9 If the chuck is greased

10 If the chuck proximity switches are

clean without any chip

11 Clean the dust on air filter

12 Clean the chips on chuck cylinder

drain outlet

13 Clean the chips on machine base

Inspector’s signature

Supervisor

Maintenance


Example of periodic

maintenance

Maintenance description Period Method Note

Vibration & Noise of Ball Screw 1,000 hours To feel S

Noise of spindle Motor and Transmission

Unit

1,000 hours To feel S

Hydraulic Oil 1,500 hours Replace

Hydraulic Oil Tank Cleaning 3,000 hours To clean

Chuck Cleaning 1,000 hours To clean

Lubrication Oil Tank 1,000 hours To clean

Lubrication Oil Filter 2,000 hours Replace

Lubrication Oil Tube 1,000 hours To lock

Hydraulic Oil Tube 1,000 hours To lock

Heat exchanger Filter Net 50 hours To clean

Machine Level 1,000 hours Measure S

Chip Conveyor Gear Reduce Grease 1,000 hours Grease Option

Coolant Tank Cleaning 1,000 hours To clean

Air Filter Regulator 500 hours To clean Option

Note : 1. Period counting is based on time period from machine power on to

machine power off.

2. “S” indicates the end user need to contact with agent while executing

this maintenance item.

Maintenance


Example of part maintenance to cleaning air filter

Maintenance

policies

OPERATING POLICIES OF EFFECTIVE MAINTENANCE

Policies with respect to

control

Policies with respect to interplant relations

Policies with respect to work force

Policies with respect to

work allocation

i) Policies with respect to work allocation

more than 10 workers and more than two or three crafts, some planning, other than day-to-day allocation of work by supervisor or leadsperson, can result in improved efficiency

Some aspects to be considered in arriving at a sound work-scheduling procedure are:-

Work unit

Size of jobs scheduled

Percent of total work load scheduled

Lead time for scheduling

A) Policies with respect to work allocation

ii) Selection and Implementation of a scheduling system:-

Flow-of-Work Requests

Determination of Priority

Coordinating and Dispatching

Preventive versus Breakdown Maintenance

Reliability Engineering

A) Policies with respect to work allocation

i) In-house work force or outside contractors

The primary factor in deciding whether to use an outside contractor is cost. Is it cheaper to staff internally for the performance of:-

The type of work involved

The amount of work involved

The expediency with which this work must be accomplished

B) Policies with respect to work force

ii) Coverage

In the process industries, where plants frequently operate continuously—three shifts, 7 days a week—some of the maintenance load can be separated and handled simply

Maintenance of buildings and grounds, for instance, is the same for three-shift operations as with one shift.

For the rest, however, special consideration is required to provide the service necessary for optimum production.


iii) Centralization versus Decentralization Advantages of a centralized maintenance shop are:-

Easier dispatching from a more diversified craft group The justification of more and higher-quality equipment Better interlocking of craft effort More specialized supervision Improved training facilities

The advantages of decentralized maintenance are:-

Reduced travel time to and from job More intimate equipment knowledge through repeated

experience Improved application to job due to closer alliance with the

objectives of a smaller unit-“production-mindedness” Better preventive maintenance due to greater interest Improved maintenance-production relationship


iv) Recruitment

Unfortunately policies for recruitment of personnel for the maintenance department are controlled a great deal more by local conditions and expediency than by the ideal approach

This in itself is a major argument for maintaining as stable a work force as is economically practical.

Age, attitude, past experience, educational background, and general level of intelligence are frequently considered in some mutually acceptable screening technique


v) Training

There are several methods for training personnel in a maintenance department. The simplest and most effective is an established and recognized apprentice-training program.

many plants have no formalized training for their craftsmen and depend entirely upon exposure, supervisory job coaching, and association with experienced workmen for their training.


i) Participation by maintenance personnel in selection of production equipment

In some plants one engineering department handles all phases of engineering activity from design through construction and maintenance.

In the majority of plants, however, the construction of major facilities or addition of major equipment is engineered by a separate organization, reporting at a higher level, or by outside engineering contractors.

C) Policies with respect to interplant relations

ii) Authority to shut down equipment for maintenance

The authority of a maintenance department to dictate shutdown of production equipment for needed repairs is controversial and has contributed a good deal to the friction that sometimes exists between maintenance and production departments.

In some plants the maintenance department does have this authority and it is generally recognized.


iii) Responsibility for safety

The maintenance department should play a large part in making its plant a safe one in which to work. Although general administration of the safety effort is usually delegated to a specialist group, the maintenance department is often the key to success of the program.

Not only is it responsible for the safety of its own personnel, but by definition it also is responsible for providing mechanical safeguards and for maintaining equipment and services in safe operating condition.

Because of this collateral responsibility, the safety function is often combined with maintenance in a small plant.


iv) Instrumentation

Instrument installation and maintenance theoretically should be considered in the same light as the addition of any other equipment.

several factors which make some other arrangement expedient, such as a separate department or assignment of this responsibility to the production department.


i) Communications

A starting point in analyzing the problem of communications and the types to be used is a study of the sort of information to be transmitted and the amount of detail involved through these three major channels:-

(i) Up through the supervisory organization

(ii) Down through the supervisory organization

(iii) Laterally across the same level of organization

D) Policies with respect to control

ii) Use of standard-practice sheets and manuals

There are many forms of standard-practice sheets, or standard job-instruction sheets, and instruction manuals used in maintenance departments.

They are excellent devices for planning work, ordering materials, improving estimating accuracy, and training crafts personnel.

Justification of cost of preparation and their ultimate effectiveness depend entirely on the particular problems of an individual plant.


iii) Maintenance Control System

Maintenance records are written notes that provide documentation about the upkeep of a certain piece of equipment.

This documentation can prove useful to a variety of different businesses- from a large industrial plant to a small lawn mowing company.

These records are particularly useful in maintenance management because they help businesses ensure their equipment is kept in good condition.


i) Department manual based on areas and documents need

Maintenance manual /Workshop manual –

Detailed instruction for repairing maintaining and overhauling of specified equipment's.

More detail information, with necessary drawing and blow up views, about minor and major repair and overhauling of specified equipment e.g pumps, compressors, engine etc

Normally supplied by the manufacturer of thus equipment's/components.

MAINTENANCE MANUAL AND DEPARTMENT MANUAL

ii) Techniques of maintenance time standard Maintenance Time Standard (i.e. standard times for various

maintenance jobs) is an effective means for planning, scheduling and controlling in order to cut down costs, not only in terms of money but also in terms of mental stress, strain and frustration that a chaotic control causes. In maintenance, the variety of jobs are too many and many job are

none repetitive, unlike the case in production/operation and so the setting of time standards is very difficult.

The work conditions are not fixed and vary from time to time. As an example, in one case, a bolt may be opened in one minute using simple tool while, in another case the similar bolt may not get opened by common tool due to jamming and may have to be chopped off, as such, how an uniform maintenance time standard can be establish even for repetitive jobs?

Procedure for shut-off of the equipment for long period and for restarting after long outage. Boilers, Steel Marking Furnaces, Blast Furnaces, Coke Ovens etc.

Detail about operating tools, tackles, jigs, guides, dies, rolls etc. Regular safety measures like blow down in boilers. Jobs, cares tests relating to quality output, etc.


iii) Level of maintenance operation liaison Effective communication between operation and maintenance

softens the strain operation/maintenance workmen relationship and improves the efficiency of the shop. Some of the other benefits are:-

a) Reduction in number of calls for maintenance men as operator develops a habit of fault diagnosis to some extent.

b) Improved operator appreciation for technical feature of equipment and need for save operation of equipment.

c) Improved economy and energy conservation.

d) Co-operation/help in fault finding and repair which is one step in the direction of total productive maintenance.

e) Identification of variations in the input materials or environmental status which may adversely affect the equipment or men.

f) Improved handling and availability of maintenance and operation record.

g) A higher standard of cleanliness for the equipment and surroundings.


jj616_chapter_3.1

Documents

maintenance manual

separate operating manual

department manual

operating steps

special operating instructions

normal operating instructions

winter operating instructions

work instruction