Subject:

Maintenance Engineering and Management Lab

Submitted to:
Sir Faisal Shahzad

Submitted by:
Group No: 10

Group Members: 2017-IM-20

2017-IM-25

2017-IM-36

2017-IM-37

Department of Industrial and Manufacturing Engineering

University of Engineering and Technology Lahore

 Experiment No.1
Learning Outcomes
 Organogram
 Information completeness
 Do’s and don’ts of Lab
 General Safety Procedures
 Responsibilities of Lab Staff and Beneficiary

What’s an Organogram?
Organogram is an intuitive reflection of organization
structure, one of the most common diagrams to illustrate the relationships among
departments, superiors, and subordinates vividly and briefly. It is defined as a top-bottom,
with icon list, architecture diagram which can automatically increase the vertical level.
Organogram shows the correlation among organizational unit in the form of graphics and it
provides great convenience for people to view detailed information on organizational units as
well as the associated position and personnel.
Example

Fig 1: ICS org Chart simple Template

Information Completeness

In order for information to be useful it needs to be complete. If parts of the information is

missing then you will not be able to make use of it or make accurate decisions.

Exams

Remember those exam papers that you were doing for revision during your study leave. Your
teacher wanted you to work your way through them and check your answers against the
model answers.

What if you were only given the second half of the model answer and the first half was
missing? How useful would it be to you?

 Weather forecast

You still want to plan the family picnic for tomorrow.

However when you check the weather forecast you are only told what the weather in the
morning will be like. There is nothing about the afternoon.

You can't really make a decision just based upon what the morning weather is likely to be.

 Doctor's appointment

Remember when you were feeling ill and you needed to make an appointment to see your
doctor.

How useful would it be if the receptionist just told you that you could have an appointment at
14.25?

Does she mean today, tomorrow or next week?

Do’s and Don’ts of Lab

Things to Do
1. Be on time. At the start of the lab period, there will be a short introduction to the
experiment you will perform that day. It is unfair to your partner and to others in the
lab if you are not up to speed when the work begins.
2. Inform the instructor and/or TA if there is a problem. You will have their immediate
attention if you have cut yourself (even if you consider it minor), if something broke
and needs cleaning up, or if you are on fire.
3. Be aware of all the safety devices. Even though the instructor and TA will take care of
emergencies, you should know where to find the first aid kit, the chemical spill kit, the
eye wash and the safety shower.
4. Keep clutter to a minimum. There is a coat rack to hang your jackets and there are
empty cabinets to store your backpacks. Anything left in the aisles is likely to be
stepped on and is a hazard to everyone.
5. Wash your hands before you leave the lab for the day.
 6. Be aware of others in the lab. Areas of the room may be crowded at times and you
should take care not to disturb the experiments of others in the lab.
7. Bring your lab notebook and an open mind to every lab meeting.
Things Not to Do
1. Do not eat, drink, chew gum, smoke or apply cosmetics in the lab. Just being in lab
makes your hands dirtier than you can imagine and you don't want to accidentally eat
any reagent (see item 5 on 'things to do' list).
2. Do not put pieces of lab equipment in your mouth. It sounds obvious but you'd be
surprised!
3. Do not work with chemicals until you are sure of their safe handling. This includes
some awareness of their flammability, reactivity, toxicity, and disposal.
4. Do not use the phone or computer with gloves on your hands.

General Safety Procedure

The following is a general list of safety precautions you must observe in any work area:

 Don’t fool around. “Horseplay” is one of the biggest causes of injuries on the job and
it may be grounds for dismissal.
 Never work while under the influence of drugs or alcohol, as you are a hazard to
yourself and your co-workers.
 Pay particular attention to moving objects, such as equipment, dollies, mixers, and
slicers.
 Walk, do not run, in the work areas.
 Stay completely alert on the job.
 Avoid back strain by lifting properly.

Responsibilities of Lab Staff

 Assists in the development of labs. Operational condition and maintenance of

teaching equipment
 Support students and faculty in using machines, tools and equipment within the
laboratory
 Supports faculty and students in resourcing and implementation phase of student
projects, as required
 Receives, installs and maintains laboratory equipment and supplies
 Maintains a schedule of preventative maintenance for all equipment and keeps
adequate manuals and maintenance logs for equipment and parts.
 Provides teaching assistance to Engineering Technology Faculty during workshop &
laboratory sessions.
 Perform teaching duties as required.
 Demonstrate the use of machines, tools and equipment within the lab.
 Maintain consumable materials store and ensures adequate inventory levels for
supplies.
  Maintains systems and procedures to track borrowed equipment and tools
 Observes and reinforces safety and housekeeping procedures and protocol within the
laboratory

Viva Questions:

1) What is the purpose of organogram?

Organograms are generally used to show the chain
of command within an organization. They can be tailored to meet the needs of the
organization, and may contain information such as the job titles, names, or areas of
responsibility for the staff.
2) What is the meaning of Organizational chart?
An organizational chart is a diagram that
visually conveys a company's internal structure by detailing the roles, responsibilities, and
relationships between individuals within an entity. Organizational charts are alternatively
referred to as "org charts" or "organization charts."
3) What are the 4 types of organizational structures?
Traditional organizational structures
come in four general types – functional, divisional, matrix and flat – but with the rise of the
digital marketplace, decentralized, team-based org structures are disrupting old business
models.
4) Why is data completeness important?
If data is complete, there are no gaps in it.
Everything that was supposed to be collected was successfully collected. If a customer
skipped several questions on a survey, for example, the data they submitted would not be
complete. If your data is incomplete, you might have trouble gathering accurate insights from
it.

References

 https://recruit.hct.ac.ae/webforms/ManageJD.aspx?jd=2115
 https://www.orgcharting.com/organogram-definition-purpose/
 https://en.wikipedia.org/wiki/Complete_information
 Experiment No.2
Conducting Visual Inspection of Machines, Equipment and Tools to know their
physical condition for probable chemical and/or mechanical damage.
Assigned Machine
Tool Grinder
Tool grinding may be divided into two subgroups: Tool manufacturing and Tool
sharpening. There are many types of tool and cutter grinding machine to meet these
requirements.
Simple single point cutting tool are occasionally sharpened by hand on bench or
pedestal grinder. However, tool and cutter with complex geometry like milling
cutter, drill, reamers and hobs require sophisticated grinding machine commonly
known as universal tool and cutter grinder.
Present trend is to use tool and cutter grinder equipped with CNC to grind tool
angles, concentricity, cutting edge and dimensional size with high precision.

Fig 1: Front view of Tool and Cutter Grinding Machine

Name of parts
1.Grinding wheel head
2.Grinding wheel (Standard equipment)
3.Left tailstock (Standard equipment)
4. Hexagonal nut for fixing turning table
5. Eccentric pin
6. Taper adjusting Screw
7.Dog
8. Knob for table travel
9.Stopper
10. Hand-wheel for grinding head cross movement
11. Grinding Wheel (Standard equipment)
12. Right tailstock (Standard equipment)
13. Turning table
14. Sliding table
15. Crank handle for table fine feed
16. Bolt for lifting machine Motor
17. Bridge

Fig 2: Side view of Tool and Cutter Grinding Machine

Name of parts
18. Motor
19. Belt cover
20. Grinding spindle
21. Swivel base
22. Angle base
23. Hexagonal nut for fixing base
24. Dust guard bellows
25. Hand wheel for grinding head cross movement
26. Hand wheel for grinding head Vertical
movement
27. Electromagnetic control box
28. Electromagnetic control box opening handle
29. Bed cover
30. Table fixing screw
31. Saddle
32. Electric operation panel
33. Levelling bolt
34. Nut
35. Mounting pad (Standard equipment)

Scope:
It can be used to inspect for surface-breaking discontinuities:
1. Cracks
2. Holes
3. Corrosion

Objectives
 Identify and state the purposes of the main parts of the cutter and tool
grinder
 Working principle of grinding
 Video demonstration on parts and assembly of Tool grinding machine
 Set up the grinder for cylindrical and internal grinding

Working Principle
 Work piece is fed against the rotating abrasive wheel.
 Due to action of rubbing or friction between the abrasive particles and work
piece material is removed.

Types of Visual Inspection:

Visual testing, often abbreviated as VT, is an optical or visual non-destructive
material testing. It is used for quality assurance or in maintenance and repair.
Visual inspections are carried out during series production or as final inspection.
Visual inspection distinguishes between direct and indirect visual inspection
Direct
In the case of direct visual inspection, the component to be inspected is tested by an
inspector. Testing, analysis and assessment are carried out by one person. The direct visual
inspection can be carried out with tools such as borescopes
Advantages
• Non-destructive testing with simple technical equipment
• Mobile use
• Ideal for sampling
Disadvantages
• No comparable test results, since no documentation
• Depends on the experience / the ability of an individual to judge

Indirect
In indirect visual inspection, the area to be inspected is captured by a camera and displayed
on a monitor. The test image can be subjected to further work steps. For example, the image
can be enlarged, details can be visually highlighted for analysis reasons or the image can be
saved for documentation purposes. By displaying on a screen, several people can judge.
The trend is towards indirect visual inspection, as the use of camera technology offers more
possibilities and leads to more efficient interruption of the production process. The indirect
visual inspection is carried out e.g. by means of video scopes or stationary inspection
solutions. In industries with high quality requirements, inspections solutions are used, that
provides high resolution images.
Advantages
Digitalization enables image optimization for better defect evaluation
Secure 100 % controls
Defects can be documented
Better analysis possible
tracking of documented defects for process optimization
Disadvantages
Acquisition costs higher than with direct visual inspection
More space required than with direct visual inspection
Condition of Machine

Fig 3: Visual Condition of Equipment

Viva Questions:
1) What do you mean by visual inspection?
Visual Inspection, or Visual Testing (VT), is the
oldest and most basic method of inspection. It is the process of looking over a piece of
equipment using the naked eye to look for flaws. It requires no equipment except the naked
eye of a trained inspector.

2) Why is visual inspection important?

Visual inspection is commonly used in both
manufacturing tasks and non- production environments. In manufacturing tasks, the purpose
is to verify that a product is free of defects before installation in the next level of assembly or
final distribution to the customer.

Video Demonstration
https://www.youtube.com/watch?v=rXUUahw7dv4
Key points
 Universal Tool and Cutter Grinder
 Different Attachments
 Lathe Tool Attachment
 Ball Cutter Attachment
 Drill Bit Attachment
 Single Phase Switch Operated Machine
 Variable Degree of Movement
 Adjustable Tool Positioning
 Adjustable Grinding Wheel Positioning
 Micro Feed Adjustment for Tool Holder
  Set Collect into Tool Holder
 Set Drill Bit on attachment
 Adjust Attachment in Holder for Grinding
 Quick and Easy Changing of Attachment
 Set the Tool on the Attachment
 Grind the Tool Lathe

References
 https://www.scribd.com/document/62107432/Tool-and-Cutter-Grinder
 https://en.wikipedia.org/wiki/Tool_and_cutter_grinder#:~:text=The%20tool%20itself
%20consists%20of,and%20left%20fixed%20throughout%20operations.
 Experiment No.3
Title:
To perform general maintenance activities with respect to cleaning on Universal Tool Cutter
Grinder machine in Machine Tools & Machining (MTM) laboratory.

Problem Statement:
A Universal tool grinder machine is being in operation at Industrial & Manufacturing
Engineering Department, University of Engineering & Technical Lahore. Machine is mostly
used for instructional purposes and for research projects of undergraduate/graduate level
studies. While, in summer vacations and winter vacations at university, there is no
appreciable amount of work being done on the machine. It means that the machine is most of
time stay idle. That is why it must cover with dust and debris. As a Maintenance Manager, we
have to follow different strategies to clean the machine with suitable equipment and cleaning
agent. Also, we must be familiar with safety precaution while using toxic cleaning agent.

Universal Tool Cutter Grinder Machine:

Figure 1: Universal tool cutter grinder machine

Theory
Maintenance:
Maintenance is the combination of all technical, administrative, and managerial actions
during the life cycle of an item intended to retain it in, or restore it to, a state in which it may
perform the required function.
There are two main types of Maintenance written as following;
1. Preventive Maintenance:
Control or prevent the deterioration process leading to failure of an engineered object
2. Corrective Maintenance:
Restore the object to its operational state through corrective actions after a failure
There are several aspects to maintenance and they may be grouped broadly into the following
three
categories:
• Technical (engineering, science, technology, etc.)
• Commercial (economics, legal, marketing, etc.)
• Management (from several different perspectives – manufacturer, customer and
maintenance service provider when maintenance is outsourced)
All the machines require maintenance on regular basis. To maintain the longevity and
minimizing the machine down time, it is necessary to do the preventive maintenance
operation. Cleaning is simple, essential and basic maintenance. For that purpose, there are a
lot of cleaning agents are available. These cleaning agents can be polar or non-polar.
These are cleaning agents which can be soluble in water. For example, detergents and soup
etc.
These are usable agents only, when there is no threat of corrosion on objective machine. On
the other hand, there are non-polar cleaning agents which are not water soluble. For example,
kerosene oil etc.
Now it depends on the machine that which cleaning agent will be suitable to clean that
particular machine.
Dust:
Dust is made of fine particle of solid matter. On earth, it generally consists of particles in the
atmosphere that come from various sources such as soils, dust lifted by wind and pollution.
According to WHO (world health Organization), dusts are solid particles, ranging in size
from below 1 micrometer up to at least 100 micrometer, which may be or become airborne,
depending on the origin, physical characteristics and ambient condition.
Types of Dusts:
Common types of dusts include:
• Filth: Foul matter such as excrement
• Grime: a black, ingrained dust such as soot
• Soil: the mix of clay, sand and humus which lies on top of bedrock
• Debris: scatter piece of rubbish, rubble (product of friction wear)
Different cleaning Agents:
• Petrol
• Kerosene oil
• WD-40
• Baking soda
• Vinegar (acetic acid)
Reasons to clean the Equipment:
There are several reasons to keep the equipment clean
• Improved wear
• Fuel efficiency increase
• Boost performance of the equipment
• Prevent corrosion
• Batter laboratory/company image
• More effective daily workarounds
Bill of Materials (BOM):
S/N Items Quantity From where buy Use
To clean heavy
machine floor
Bristle cleaning
1. 1 Availed in lab scrubber, all-
brush
purpose if
scrubber
Use to remove
material from
surfaces, either to
make them
2. Sand paper 1 Availed in lab
smoother (for
example, in
painting and wood
finishing),
to clean machine
parts from
3. Kerosene oil 150ml From local store old lubricant oil
before their
republication
For use it first
make a paste of
baking soda with
water then
A little
4. Baking soda From home apply on crude
amount
surface and
after some time
wash it to
clean the surface
 To secure our self
from
5. Face mask 4
hazardous
particles
Use for Cast iron
maintenance,
6. Paper towel 1 Composting,
Grease and gunk
absorber
7. WD40 Small bottle Use WD-40 To:

Condition of Machine before cleaning:

Figure 2: condition of different parts of machine before cleaning

Condition of Machine after cleaning:

Figure 3: condition of machine after cleaning

Procedure:
1. First of all, wear mask and gloves and lab coat
2. Take two pieces of clothes and two painting brush and clean dust on the surface of
machine
3. Remove the rust if available on machine by using emery paper
4. Spray kerosene oil on that dirt and clean the dirt which can’t be removed by dry piece of
clothes
5. Remove the grime by spraying WD-40 and cleaning with piece of clothes
6. Avoid using water, as it causes corrosion
7. Clean your hand with kerosene oil first and then with detergent

Comments:
• Safety precaution are necessary because the fumes of detergent and cleaning agents have
adverse effects on human health.
• In most of the local industries, they use the combination of diesel and petrol to clean the
industrial machines.
• Cleaning is the ab-initial of the maintenance.
• Some flecks or blisters cannot be removed after efficient cleaning. It means that there is
need of stronger cleaning agent for that filthy marks.
• Care must be taken while applying or spraying these cleaning agents. They may have
adverse effects on human health.
Viva Questions:
1. what is maintenance? How many types of it?
2. Why we clean the equipment? Give reasons.
3. Why cannot we wash the industrial equipment with water?
4. Which are the suitable cleaning agents to clean Tool Cutter Grinder Machines?
5. Why kerosene oil is preferred to clean the machine?
6. How many types of dust/dirt?
7. What is the effect of debris on working of machine?
8. How to remove the mark of corrosion?

References:
• Introduction to Maintenance Engineering by Mohammad Ben Daya (Book)
• www.texasfinaldrive.com
• www.vibralign.com
• www.wikipedia.com
 Experiment No.4
Title:
To prepare periodic schedules for the maintenance activities on various types of machines in
Machine Tools & Machining (MTM) laboratory based on maintenance strategies.
Problem Statement:
Universal Tool & Cutter Grinder machine is being in operation at Industrial & Manufacturing
Engineering Department, University of Engineering & Technical Lahore. Machine is only in
use for the research projects of undergraduate/graduate level studies. Otherwise there is no
appreciable amount of work being done on the machine during the whole year. As a
Maintenance Manager, we are required to develop its Maintenance Schedule appropriate to
its usage requirements with identification of lubrication points, type of lubrication &
lubrication method.
Theory:
Maintenance:
Maintenance, in general, can be defined as efforts taken to keep the condition and
performance of a machine always like the condition and performance of the machine when it
is still new.
Maintenance activities can basically be divided into two parts: planned maintenance activities
and unplanned maintenance activities.
Planned maintenance is maintenance that is organized and carried out with thought to the
future, control and recording in accordance with the plans that have been determined
previously.
The type of maintenance cannot be equated for each equipment, which depends on the
method, cost and critical level. The following types of maintenance methods are commonly
used in several industries.
• Preventive Maintenance
• Predictive Maintenance
• Corrective Maintenance
• Breakdown Maintenance
Preventive Maintenance:
It is a method for preventing damage to equipment by periodically replacing parts based on
time of use and carrying out minor maintenance and inspections to find out the current state
of the equipment / machinery.
Example: Cleaning, checking, lubricating, bolt tightening Periodic inspection Periodic and
small over haul restorations
Predictive Maintenance:
Predictive maintenance is a method for doing maintenance by replacing parts based on
predictions using a tool. The point is if the preventive method is only based on the schedule,
then the predictive method is based on the results of the measurement.
This method can also use the five senses, for example in bearing inspection can be
distinguished from the sound produced. Or checking temperature, by touching it we can feel
the difference or abnormality of the equipment.
Examples: Tachometer, to measure the rotation of the Thermometer, to measure the
temperature of the Ampere meter, to measure amperage
Corrective Maintenance:
It is a method intended to improve the reliability of equipment/machines by improvising. In
addition to equipment, it is also intended for parts that have a short life cycle (reduce the
frequency of damage) and speed up repair time.
In other words, this method is to extend MTBF (Mean Time between Failures) and accelerate
MTTR (Mean Time to Repair) because of its reliability (activity to prevent recurrence of
damage) and main tenability (activity to speed up repair time).
Example: The operator has difficulty checking the oil volume of the generator engine, so
improvisation is done by making a measuring cup equipped with a scale.
Breakdown Maintenance:
It is a method where inspection and replacement of parts are not carried out, so with this
method
we leave the equipment damaged and then we fix it or replace it
Usually this method is applied to equipment / machines with consideration:
• Equipment is only optional (additional) so that if it is damaged it does not interfere with
production
• The cost of repairing / replacing cheap parts
• Insignificant damage
• Easy and fast repair
Total productive maintenance (TPM):
Total productive maintenance is a maintenance activity that involves production operators in
maintaining equipment / machinery in addition to activities carried out by maintenance
operators.
Examples: Cleaning, lubricating, tightening nuts & bolts, daily checking (checking
equipment / machine state), simple repairs (replacing leaking hoses, welding tips) etc.
The objectives of the TPM are:
• Develop operators that are able to detect damage signals as early as possible. Because it is
the production operator that really knows the state of the equipment to even the most detailed
part.
• Creating a neat, clean workplace so that any irregularities can be detected as early as
possible
Planned Maintenance:
Planned maintenance is work that’s prepared for in advance of it taking place. According to
an Upkeep survey, it’s also the most popular key performance indicator (KPI) to track. A
high planned maintenance percentage indicates that a maintenance team will have resources
available to complete work for the time/day the work is scheduled for. Having a high planned
maintenance percentage also helps boost other maintenance KPIs like schedule compliance.
More planned maintenance means more successful completion of scheduled maintenance.
Scheduled Maintenance:
Scheduled maintenance is any repair and upkeep work performed within a set timeframe. It
details when given maintenance tasks are performed and by whom. Scheduled maintenance
may occur at repeating intervals or in response to a work request

Scheduled Maintenance Workflow

Benefits of Scheduled Maintenance:
In addition to minimizing downtime, scheduled maintenance serves a variety of other
purposes.
• Higher personnel utilization since maintenance workers spend more time working
• Increased asset life expectancy as breakdowns are prevented
• Lower maintenance costs as time is utilized efficiently and costly problems are prevented
• Culture of proactive efficiency as personnel perform needed tasks
• Reduced liability as assets are kept in safe working condition
Routine Maintenance:
Routine maintenance is a form of time-based maintenance and preventive maintenance,
though some organizations differentiate between routine maintenance and preventive
maintenance. They use the latter for smaller tasks (i.e. cleaning) performed at higher
frequencies (hourly, daily) and the former for larger tasks (i.e. inspections) performed at
lower frequencies (weekly, monthly, and annually). Additionally, routine maintenance is
performed by operators, janitors, and other staff member while preventive maintenance is
performed by technicians. Non-routine maintenance includes maintenance that is performed
reactively or only when needed based on an asset’s
conditions.
Procedure:
1. Preventive maintenance and planned maintenance techniques are best suited for this kind
of machine operation.
2. After the specific set period of 6 month, the machine will be check and standardized.
3. The movement of the bed of machine would be lubricated to make sure its movement
remains hinder free.
4. Using standard angle gauges, the accuracy of angles prepared with help of this machine
will be checked and if found out to be little variant, then the standard procedure must be
applied to correct that angles.
5. The wheel of the machine should be changed after every 6 month or owing to bad
condition can be changed before that.
6. Make sure that the calibration tools which are used in the maintenance operations are
reliable and accurate.
7. The abrasive particles which are removed from the cutting wheel due to formation of tools
are go down to the base of machine and stuck there and also some particles get attach to
bed which should be removed.
8. Cleaning should be done using WD 40 and kerosene oil.
Observations and Comments:
• Some part of the equipment does not require maintenance schedule, as they replaced just
after they breakdown (Corrective Maintenance) e.g. bulb.
• Electrical circuit of the machined attached at the backed should be touched using proper
care.
• Kerosene oil found out to be effective removing the grease from the base of bed.
• Alignment of the wheel should also be check and calibrated
Viva Questions:
What is Maintenance?
Ans: Maintenance is defined as the compilation of tasks carry out in an installation, in order
to avoid, analyze and outweigh the degradation of time or usage that they provoke in the
equipment and systems which form that installation.
What is Schedule?
Ans: A plan for carrying out a process or procedure, giving lists of intended events and times.
What type of lubrication systems are found in the above machine tool?
Heavy duty emulsifiable oil, Heavy-duty water-soluble oil, Light duty chemical and synthetic
oil are used for this machine.
Name the major element / component of lubrication system being found in the above
machine tool.
Just below the head a gauge is available with an opening hole for the machine oil to check the
level of oil and also to pour more oil in the machine if needed.
What are the time frames decided for maintenance of various components in the current
case, keeping in view standard practices and actual working conditions?
Maintenance is decided to be carried out twice a year (after every 6 months). But considering
the extra workload in which the machine is used extensively it can be checked before 6
month.

What type of instructions should be the part of operating procedure for this type of
equipment from maintenance point of view?
Electrical box should be touched using gloves. Kerosene oil should be used to clean the
machine.
A mask should be wear as the machine has abrasive particles on it which are being cut from
the cutting material and it is very dangerous for the operator health. Check the level of oil by
tapping off the oil gauge button at the back of machine. Calibration should be done using
proper care.

References:
• https://www.onupkeep.com/learning/maintenance-types/scheduled-maintenance
• https://automationforum.co/what-is-maintenance-types-of-maintenance/
• https://www.onupkeep.com/learning/maintenance-types/