TASK: 6.

03 - EVALUATE MAINTENANCE WORK MODULE 4: MACHINE MAINTENANCE INTRODUCTION Preventive maintenance means planned repair of equipment at regular intervals to prevent uncalled breakdown. The length of the interval is based mainly on the complexity of the equipment and the loads acting on it. Preventive maintenance not only increased the life of the equipment but also ensure accuracy.

OBJECTIVES OF PLAN MAINTENANCE The maintenance of plan and equipment is an important part of the total productive effort. It also to serve the following adjectives:1. To minimize breakdown. 2. To minimize interruption of work. 3. To ensure the availability of machines when required for further operations.

IMPORTANCE OF MAINTENANCE Breakdown of equipment leads to loss of production 1. It required high maintenance charges. 2. It results in loss in production and productivity. 3. Stoppage of work over the whole plan. In production plans it causes the following problem:1. Loss in production time. 2. Spoilt material. 3. Need for rescheduling production. 4. Need for extra work and overtime to meet production targets. 5. Temporary work shortages may require alternative work arrangements.

DUTIES OF A MAINTENANCE ORGANISATION

Proper maintenance of tools and equipment involves sound organization, planning, operation and control. It requires proper maintenance of records, schedules and work orders. The duties of a maintenance organization can be divided as follows:1. To check, repair, adjust and lubricate the instrument as and what need. 2. To anticipate the need for repairs and alterations. 3. The other duties of a maintenance department can be classified as:a) Inspection b) Production c) Engineering d) Clerical e) Housekeeping f) Construction g) Salvage 4. Inspection is concerned with routine scheduled checks of the plan building and equipment to keep track of its condition. 5. The general inspection routine:a) Weekly checking b) Monthly checking c) Inspection of fire arm equipment after four to six months.

REPAIR CYCLE Preventive maintenance can be classified into the following four stages:1. Inspection 2. Small repair 3. Medium repair 4. Complete overhaul

INSPECTION Inspection of equipment is the first stage of maintenance. It involve the following:1. Inspect all the feeds and mechanisms according to the schedule routines. 2. Clean oil filters, lubricators, guides, mating part and etc. 3. Replace damaged nuts and bolts. 4. Replace oil and set it to the desired level.

SMALL REPAIR

Many parts, such as lathe apron often requires small repairs. It involves:1. Replacement of worn out parts. 2. Removal of dirt. 3. Assembly of parts. 4. Carrying out of various regulations of inspection and repair. 5. Restoring guide surfaces to desired smoothness.

MEDIUM REPAIR Repairs of small components but more number of units be grouped in medium repairs. It involves:1. Repair of tool post, apron and tailstock of a lathe. 2. Scraping/ grinding of all mating parts. 3. Replacement of bushes and gears.

COMPLETE OVERHAUL It involves inspection and repair of all the parts. 1. Each and every unit of the equipment is disassembled and worn out parts are replaced by new ones. 2. The machine is then assembled. 3. The foundation of the machine is checked.

ORGANISATION OF MAINTENANCE DEPARTMENT

MANAGER MAINTENANCE

ASSISTANT MANAGER

ASSISTANT MANAGER

FOREMAN FACILITIES

FOREMAN SHOP MAINTENANCE

PLANNING FOREMAN

FIELD FOREMAN

FOREMAN ENGINEERING

WORKER

WORKER

WORKER Execution of work order Preparation of estimate Scheduling Preparation of performance reports

WORKER

WORKER

Steam Power Water Sanitation Air

Engineering Design Procurement of material Production of alternatives

Repair Lubrication Construction Maintenance Overhauling Production repair of damaged parts

Buildings Stock yards Fire fighting equipment Disposal of waste