UNIT 1.

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General Objectives :Understand the maintenance function Specific Objectives :After learned this unit, you Makesure should be able to :-

Explain the function of maintenance

Make

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Makesure

E4101 / E4120

Click to edit Master tex Second level ● Third level Function of Maintenance ● Fourth level ● Fifth level Function of maintenance is :MAINTENANCE
1.

To makesure the product follow the specification. To makesure reasonable cost of product. To makesure the machine and equipment can be used optimumly.
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2. 3.

k to edit Master text styles nd level MAINTENANCE hird level Fourth level Function of Maintenance ● Fifth level
1.

E4101 / E4120

To makesure the product follow the specification.

Ø.

Most of the time we are facing a product that has been bought but fail to operate follow it’s specification. Many factors contribute to the failure such as :- Component in the circuit. - Wrongly programme the process. - The ability of product are below the specification. - Mistaken in operation installation process. - Environment effect (Pressure)

Ø.

To makesure product @ equipment follow the specification, full maintenance should be implement. 33
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k to edit Master text styles nd level hird level Fourth level ● Fifth level

E4101 / E4120

MAINTENANCE

Full Maintenance
Ø

It is include in below processes :a. Knowledge b. Protection c. Corrective d. Examine
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k to edit Master text styles nd level MAINTENANCE hird level Fourth level Full Maintenance ● Fifth level a. Knowledge

E4101 / E4120

It’s mean, to know what are the ability & the disability of the product @ equipment. - It’s include the ability of product to temperature, vibration & absolute max range of product. - In additional, it is important to understand below terms if we want to know whether the product follow the specification or not. Strength Sensitivity Accuracy Kelinearan Hysterisis
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k to edit Master text styles nd level hird level Fourth level ● Fifth level
b.

E4101 / E4120

MAINTENANCE

Protection Base on the knowledge, for sure maximum protection can be given to the equipment @ product. As example, if the equipment cannot operate in high temperature, the equipment should be placed at room temperature).
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k to edit Master text styles nd level hird level Fourth level ● Fifth level
c.

E4101 / E4120

MAINTENANCE

Corrective To makesure the product constantly operate in the specification limit, corrective maintenance should be routinely implemented. No matter major @ minor failure occur, the corrective maintenance should be urgently implement.

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o edit Master text styles level MAINTENANCE rd level ourth level Fifth levelChecking / Examine d.
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E4101 / E4120

The most important procedure in the process of full maintenance. Log book / form need to be prepared to makesure the checking / examination follow the procedure. The best examination/ checking that is include with the daily , weekly, monthly and also yearly checking maintenance.

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Exercises
1.

Give 3 factors that contribute to the failure of a product. State 4 basic method that are needed to implement full maintenance.

2.

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edit Master text styles evel level rth level fth level

MAINTENANCE

E4101 / E4120

To makesure reasonable cost of product

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To makesure the cost is reasonable, the first thing to do is to make an analysis. Analysis is made to the cost of time, labour and financial (profit/loss)

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Ø

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As an example , in a firm (industrial), the analysis is include with :1. Operation time loss ~ Maintenance period ~ Time of corrective / repair job ~ Report time period 2. Maintenance Cost 3. Labour Cost 4. “Machine breakdown” period cost For individual responsibility – to makesure the product is reasonable compare to the price, check the ability & disability of the product.

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E4101 / E4120 o edit Master text styles level MAINTENANCE rd level ourth level Fifth level makesure the machine and equipment To

can be used optimumly.

Ø

Below maintenance should be implement :- “Breakdown Maintenance” (penyelenggaraan kerosakan) - “Preventive Maintenance” (penyelenggaraan pencegahan) - “Predictive Maintenance” (Penyelenggaraan Jangkaan) - “Condition-Based Maintenance” (penyelenggaraan berdasarkan 1212 keadaan) ™‫ﺷﻬﺮﻭﺍﻟﻨﻴﻈﺎﻡ‬

edit Master text styles level MAINTENANCE d level urth level Ø Fifth level “Breakdown Maintenance” implement
machine @ equipment breakdown.

E4101 / E4120

after the

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“Preventive Maintenance” implement before the machine @ equipment breakdown to avoid a major failure. “Predictive Maintenance” – The maintenance method also known as Preventive maintenance. Implement by doing an analysis to detact problem at the equipment @ machine without disturbing the production schedule.

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edit Master text styles level d level urth level Fifth level
Ø

MAINTENANCE

E4101 / E4120

“Condition-base Maintenance” – dilakukan apabila perlu sahaja bagi mesin-mesin yang mempunyai sistem pengurusan berterusan. Ia dilakukan menggunakan sistem PLC dimana sistem mesin akan disambungkan kepada komputer pengawasan keadaan operasi. Jika terdapat masalah komputer akan melakukan penjajaran secara automatik atau komputer akan mengeluarkan tanda amaran dan memberi tahu samada perlu diservice secara manual atau tidak. Amat efektif tetapi kos permulaan sangat tinggi tetapi memberi pulangan jangka panjang yang amat tinggi.

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Click to edit Master text styles MAINTENANCE E4101 / E4120 Second level ● Third level Exercise ● Fourth level ● Fifth level 1. Why there is always exist a product that is

bought not fulfill customer needs?.

it’s

specification

and

2.

Why do we need to implement the full maintenance to an equipment?. State the basic maintenance. requirement to do the full

3.

4.

State the knowledge that are required to determine whether a product follow it’s specification.
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5.

What is the meaning of protection in a full maintenance? What are the cost type that is needed to makesure the product have a reasonable price? List the maintenance that is needed to makesure the machine @ equipment can be use optimumly.

6.

6.

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