BHARATHIYAR COLLEGE OF ENGINEERING AND TECHNOLOGY

KARAIKAL

DEPARTMENT OF MECHANICAL ENGINEERING

SUBJECT: MAINTENANCE AND SAFETY ENGINEERING

TWO MARKS QUESTIONS WITH ANSWER

UNIT I
1. Define maintenance?

Maintenance is the routine and recurring process of keeping a particular

machine or asset in its normal operating conditions. So that it can deliver the
expected performance or service without any loss or damage.

2. Whatare the objectives of maintenance?

The objectives of maintenance are to ensure the desired plant availability at an

optimum cost within the safety prescription. In other words, it may be mentioned
that the objective of maintenance is to minimize the total cost of unavailability and
resources.
3. List the types of maintenance.
a) Breakdown maintenance
b) Corrective maintenance
c) Preventive maintenance
d) Predictive maintenance
4. Define breakdown maintenance.
It is a type of maintenance approach in which equipment is allowed
to function / operate till no failure occurs that no maintenance work is
carried out ion advance to prevent failure.

5. Define preventive maintenance.

It is a maintenance program which is committed to the elimination or

prevention of corrective and breakdown maintenance. It is designed for day
to day maintenance like cleaning, inspection, lubricating, retightening etc. to
retain the healthy condition of equipment’s.
6. Define the term predictive maintenance.

Predictive maintenance is a management technique that uses regular evaluation

of the actual operating conditions of plant equipment, production systems and
plant management function to optimize total plant operation.

7. Define corrective maintenance.

Corrective maintenance is the program focused on regular planed tasks that

will maintain all critical machinery and system in optimum operation conditions.

8. List the objectives of corrective maintenance.

1.Elimination break downs

2.Elimination deviations from optimum operating condition.
3. Elimination unnecessary repair

9. List the benefits of implementing preventive maintenance.

1.It maintains the equipment in good condition to prevent them from

bigger problems.
2.Prolongs the effective life of the equipment’s.
3.Detects the problem at earlier stages.
4.minimizes/eliminates the rework/scrap and helps in reducing the
process variability
5.Significantly reduces unplanned downtime.

10. Write a note on lubrication.

Lubrication is one of the most important functions of maintenance.

Lubrication for the machine plays the same role as blood for the human
being.

11. What are the functions of lubrication?

a) Friction and wear control

b) Corrosion control
c) Temperature control
d) Contamination control.

12. How will you classify lubricants?

Lubricants are classified according to the usage.

a) Greases
b) Hydraulic
c) Engine oils.

13. What is limitation of breakdown maintenance?

1. Most repairs are poorly planned due to time constraint caused by

production and plant management. This will cost three to four times
than the same repair when it is well planned.
3. This approach focus only on repair or the symptoms of failure and not
on the root cause of failure. This results only in increase in the
frequency of repair and correspondingly the maintenance costs.

14.Define Repair cycle.

The stages through which a reparable item passes from the time of its
removal or replacement until it is reinstalled or placed in stock in a
serviceable condition.

15.What is Repair complexity?

Complex repair is defined as a repair that requires more than layered

closure, such as scar revision, debridement (as of traumatic lacerations),
extensive undermining, stents, or retention sutures. In dermatology the
overriding use of the code is for repairs of surgical excisions of malignant
and benign tumors. Such repairs may require extensive undermining or
retention sutures.

UNIT II

1. Classify various planned maintenance approach.

1. Preventive maintenance
2. Corrective maintenance
3. Predictive maintenance
4. Condition based maintenance

2. List out some condition based monitoring techniques and briefly discuss on
them

1. Vibration monitoring
2. Thermograph
3. Tribology
4. Electrical motor analysis

3. What does safety, health and environment pillar of TPM aims at?

This pillar aims at achieving Zero accident, Zero health damage and Zero
fires.

4. Name the five S principles used for implementations of TPM.

1. SEIRI – Sort out

2. SEITON –Organize
3. SEISO – Shine workplace
4. SEIKETSU – Standardization
5. SHITSUKE – Self discipline

5. List the various pillars of TPM?

(a) 5, S Principle
(b) Jishuhozen (JH)
(c) Kaizen
(d) Planned maintenance
(e)Quality maintenance.
(f) Training
(g) Office TPM
(h)Safety, health and environment

6. What are the objectives of TPM?

The main objectives of TPM are

1. To achieve zero defects

2. Achieve zero accidents and zero break downs in all functional
areas of an organization
3. To create different team of people to have active participation.
4. To aim at minimization of defects and
5. To inculcate autonomous policy

7. What is equipment health monitoring?

Conditions monitoring is one of the maintenance methods which are

used to assess the health and condition of equipment’s machines, systems
or process by absorbing checking, measuring and monitoring several
parameters. This technique is also called as equipment health monitoring.

8. List down the factors for increasing the demand condition monitoring.

1. Increased quality expectations reflected in produces liability legislation

 2. Increased automation to improve profitability and
maintain competitiveness
3. Increased safety and reliability expectations
4. Increased cost of maintenance due to labor and material cost.

9. List down the key features of condition monitoring.

1. Links between cause and effect

2. Systems with sufficient response
3. Mechanisms for objective data assessment

10. Write down the basic steps in condition monitoring

1. Identifying critical systems

2. Selecting suitable techniques for condition monitoring
3. Setting baselines
4. Data collection
5. Data assessment
6. Fault diagnosis and repair
7. System review

11. What are three types of condition monitoring?

a. Subjective condition monitoring

b. Minimized breakdown costs
c. Improved morality of the operating personnel and safety

12. State the advantages and disadvantages and disadvantages of

condition monitoring.

Advantages
1. Improved availability of equipment
2. Minimized breakdown cost
3. Improved
reliability
Disadvantages
1. Gives only marginal benefits
2. Increased running cost
3. Sometimes difficult to organize

13. Mention the various costs involved in costing of condition

monitoring.

I. Installation cost
II. Operating cost
14. State the methods of measuring vibration.

(a) Amplitude
(b)Frequency
(c)Phase

15. Name the types of pyrometers.

1.Total radiation pyrometers

2.Infra red pyrometers
3. Optical radiation pyrometers

16. State the application of thermistors.

1. It is used for varying temperatures

2. It is used in time delay circuits
3. Thermistors are used for temperature compensation.

17. What are two main types of infrared thermography?

1.Passive thermography
2.Active thermography

18. What are the principles very important for the study of eddy current test?

i.Permeability
ii.Conductivity
iii.Material thickness
iv.Edge effect and end effect
v. Lift off
vi.Fill factor

19. Describe the limitation of eddy current test.

The main limitation is the low penetration of parts being examined, using
limited to thin walls or near surface flaws. It is difficult to use on
ferromagnetic materials. False indications are possible because of mixed
variables, edge effects and lift-off effects. Extensive technical knowledge is
required for the development of inspection procedures, specific probes and
to interpret the inspection data.

20. What are the limitations of ultrasonic test?

a.Unfavorable geometries and coarse anisotropic grain

structures are difficult to inspect.
b.Extensive technical knowledge is required for the
development of inspection procedure.
c. Parts that are rough, irregular in shape, very small or thin
or not homogenous are difficult to examine, specific probes
and to interpret the inspection data.

21. Name some of the methods of leakage monitoring

1.Interstitial monitoring
2.level monitoring
3.Vapor monitoring
4.Liquid Monitoring

22. Define Total productive maintenance (TPM).

Total productive maintenance is a philosophy of continuous improvement that

creates a sense of ownership in the operators and other connected persons for
machine as well as in their supervisor.

23. Write a short note on economics of maintenance.

Both production and maintenance have the same objective to produce a quality
product at maximum efficiency and minimum cost.

24. What is computer aided maintenance?

Computer-aided maintenance refers to systems that utilize software to organize

planning, scheduling and support of maintenance and repair. A common
application of such systems is the maintenance of computers, either hardware or
software, themselves. It can also apply to the maintenance of other complex
systems that require periodic maintenance, such as reminding operators that
preventive maintenance is due or even predicting when such maintenance should
be performed based on recorded past experience.
UNIT III

1. Define reliability?

Reliability is defined as the probability that a component /system, when

operating under given condition, will perform its intended functions
adequately for a specified period of time. It refers to the like hood that
equipment will not fail during its operation.

2. State the benefits of reliability analysis in industries?

The main advantages of imposing reliability requirements are increased

productivity and reductions in forced outage equipment due to planned
maintenance activity.
 3. Define failure rate?

Failure rate is the ratio of the number of failures during particular unit
interval to the average population during that interval.
This failure rate is also known as hazard rate and instantaneous failure rate.

4. What is Mean Failure Rate?

The mean failure rate h is obtained by finding the mean of the

failures rates for specified period of time.

h = (Z1 + Z2 + Z3+....+ZT)
________________
T

Where Zt represents
Failure rates over the specified period of time T.

5. Define Mean Time to Failure.

Let t1 is the time to failure for the first specimen, t2 is the time to
failure for the second specimen and t n is the time to failurefor the nth
specimen. Hence the mean time to failure for N specimens are

MTTR = (t1+t2+......+t N) /N

6. What is Mean Time between Failures (MTBF)?

Mean Time between Failures (MTBF) is the mean or average time between
Successive failures of a product. Mean time between failures refers tom the
average time of breakdown until the device is beyond repair.

7. Define Mean Time to Repair (MTTR)?

Mean Time to Repair is the arithmetic mean of the time required to

perform maintenance action. MTTR is defined as theRatio of total
maintenance time and number of maintenance action. MTTR = Total
maintenance time/ Number of maintenance action.

8. Define Maintenance Action Rate?

Maintenance action rate is the number of maintenance action that can be carried
out on equipment per hour.
9. Define Failure Density?
Failure Density is the ratio of the number of failures during a given unit
interval of time to the total number of items at the very beginning of the
test.

10. State the types of reliability?

Reliability can be generally oftwo

types:
(i) Inherent Reliability: It is associated with the quality of the
material and design of machine parts.
(ii) Achievable Reliability: It depends upon other factors
such as maintenance and operation of the equipment.

11. Define maintainability?

Maintainability is defined as the probability that a unit or system will berestored

to specified working conditions within a given period when maintenance action is
taken in accordance with the prescribed procedures and resources.

12. Define availability?

Availability is the ratio of the time at which equipment is available for the
designated operation/service to the total time of operation and maintenance
of theequipment. It is also defined as the ratio of equipment’s uptime to
the equipment uptime and downtime over a specified period of time.

13. What is system reliability?

System reliability is defined as the probability that the system will perform its
intended function for a specified mission time under the random operational
environments.

14. Define series configurations.

A series system is a configuration such that, if any one of thesystem

components fails, the entire system fails. Conceptually, a series system is one
that is as weak as itsweakest link.

15. Define parallel configurations.

A parallel system is a configuration such that, as long as not allof the system
components fail, the entire system works. Conceptually, in a parallel
configuration the total system reliability is higher than the reliability of any
single system compo-net.

16. Define mixed configurations.

Some systems are made up of combinations of several series andparallel

configurations. The way to obtain system reliability insuch cases is to break the
total system configuration down intohomogeneous subsystems. Then, consider
each of these subsystems separately as a unit, and calculate their reliabilities.
Finally, put these simple units back (via series or parallel recombination) into a
single system and obtain its reliability.

UNIT IV

1. What is safety?

A thing is safe if its risks are justified to be acceptable designer thing is

said to be safe if for the person who judges the perceived risk is less.

2. Define productivity.

Productivity is a measure of economic efficiency which shows how effectively

economic inputs are converted into outputs. Productivity is measured by
comparing the amount of goods and services produced with the inputs, which
were used in production.

3. List any four causes of accidents in industries.

A) Taking shortcuts
b) Being over confident
c) Starting a Task with Incomplete Instructions
D) Poor housekeeping
4. What is an accident?
The term "accident" can be defined as an unplanned event that interrupts the
completion of an activity, and that may (or may not) include injury or property
damage.
5. How to report the accident in industries?
Employees injured on the job are to report the injury to their supervisor as
soon as possible after the incident/accident. Near miss accidents or
incidents should be reported as well.
6. What are the reasons to investigate a workplace accident include?

a) Most importantly, to find out the cause of accidents and to prevent similar
accidents in the future

b) To fulfill any legal requirements

c) To determine the cost of an accident

d) To determine compliance with applicable safety regulations

e) To process workers' compensation claims

7. Who should do the accident investigating?

Ideally, an investigation would be conducted by someone experienced in accident

causation, experienced in investigative techniques, fully knowledgeable of the
work processes, procedures, persons, and industrial relations environment of a
particular situation.

8. Should the immediate supervisor be on the team?

The advantage is that this person is likely to know most about the work and
persons involved and the current conditions. Furthermore, the supervisor can
usually take immediate remedial action. The counter argument is that there
may be an attempt to gloss over the supervisors shortcomings in the accident.
This situation should not arise if the accident is investigated by a team of
people, and if the worker representative(s) and the members review all
accident investigation reports thoroughly.

9. Why look for the root cause?

An investigator who believes that accidents are caused by unsafe conditions will
likely try to uncover conditions as causes. On the other hand, one who believes
they are caused by unsafe acts will attempt to find the human errors that are
causes. Therefore, it is necessary to examine some underlying factors in a chain of
events that ends in an accident.

10. What are the steps involved in investigating an accident?

 Report the accident occurrence to a designated person within the

organization
 Provide first aid and medical care to injured person(s) and prevent further
injuries or damage
  Investigate the accident
 Identify the causes
 Report the findings
 Develop a plan for corrective action
 Implement the plan
 Evaluate the effectiveness of the corrective action
 Make changes for continuous improvement

11. Write a note on measuring safety performance.

Performance management is a process that links an organization’s objectives,
the strategies to meet those objectives, its management systems, performance
measurement and reporting. Performancemeasurement provides the means of
determining the effectiveness of the performance management system and the
basis for making improvements that will enable objectives to be achieved.

12. What are the functions of safety organizations?

a) Monitoring implementation of all directives issued by RlyBoard & HQs in

matters pertaining to safety.
b) Ensuring super checks of functioning of operational &maintenance
machinery on the division.
c)Super check of coaching & goods trains, conduct nightinspections, joint
inspections with officers of civil, engineering, S& T, electrical& Mechanical
departments.
d)Implementation of safety circular & safety drives on thedivision.
e)Co-ordination of improvement in crew & guard bookinglobbies, running rooms
forrunning staff.
f)To coordinate disaster management functions, relief, &restoration etc.
g)Assisting authorities in conducting inquires in seriousaccidents.
h)Counseling & monitoring of staff involved in maintenance

UNIT V

1. What is color coding? Give examples.

A color code or color code is a system for displaying information by using

different colors.

WHITE – Proposed Excavation

PINK – Temporary survey marking

 RED – Electric power lines, cables and lighting cables.

2. What is safety standards?

Safety standards are standards designed to ensure the safety of products,

activities or processes, etc. They may be advisory or compulsory and are normally
laid down by an advisory or regulatory body that may be either voluntary or
statutory. China has recently experienced trouble with some of the post listed
associations.

3. Name the safety devices used in machine shop machineries.

a)Safety glasses

b) Closed toe shoes or boots

4. What are the safety considerations in material handling equipment’s?

When deciding what material handling equipment to use, it is important to take

into account the generalcharacteristics of the equipment types available in the
market. Then, the decision maker should determinewhich equipment matches
better to the required application.

5. Name the equipment’s used in material handling.

a)Conveyors
b)Cranes
c)Trucks
d)Hoists

6. What are the safety considerations in pressure vessels?

When deciding what pressure vessel to use, it is important to take into account
the generalcharacteristics of the equipment types available in the
market.Although pressure vessels designed and constructed to one of
therecognized design codes have had an excellent safety record, some recent
eventsindicate a basis for concern about continuing reliability and safety,
especially when coupled with the current trend of extending service usage.

7. What is the need of safety in industries?

In industries, the term safety refers to any act of accident prevention by

person qualified in the field. It is often reactionary to adverse events, also
described as incidents.
8. How to extinguish fire?

The best way to stop any full blown fire is to smother, or extinguish it in its
initial stages. It depends on what kind of fire it is, or how big and severe it is.

9. What are the common causes of fire in engineering industry?

(a) Scrap and trash

(b) Dust
(c) Flammable liquids
(d) Electrical problems
(e) Heat and ignition sources
(f) Smoking

10. What is the basis of safety programme and policy?

A health and safety policy is a written statement by an employer stating the
company's commitment for the protection of the health and safety of employees
and to the public. It is an endorsed commitment by management to its employees
regarding their health and safety.
A health and safety program contains the health and safety elements of an
organization, objectives which make it possible for the company to achieve its
goal in the protection of its workers at the workplace.

11. What are the safety considerations in welding equipment’s?

Some of the frequently encountered hazards as experienced by welders and

other related workersinclude mainly the electricity, radiation, heat, flames, fire,
explosion, noise, welding fumes, fuel gases, inert gases, gasmixtures solvents, etc.
In order to provide safe working conditions in a manufacturing environment, it
becomes mandatoryto take into consideration the aspects related to hazards. Risk
mitigation or risk assessment therefore needs to be carried outat various levels.