Maintenance Engineering and Management

(IME-454)

Lab Report 06

SUBMITTED TO:

Dr. Faisal Shahzad

SUBMITTED BY:
Hafiz Sadoon Khan 2017-IM-18

DATE:
21st June 2020

Department of Industrial and Manufacturing Engineering, University of

Engineering and Technology Lahore
 Table of Contents
Lab Session 06.................................................................................................................................3
Title..................................................................................................................................................3
Problem Statement...........................................................................................................................3
Objective..........................................................................................................................................3
Theory..............................................................................................................................................3
1. Information Collection.............................................................................................................6
.........................................................................................................................................................6
Maintenance Plan.........................................................................................................................7
2. Identification of Systems.........................................................................................................8
3. Identification of System Functions..........................................................................................8
4. Selection of Systems................................................................................................................8
5. Identification of system functional failures and criticality ranking.........................................8
6. Identification of FSI’s..............................................................................................................9
Comments and Conclusion..............................................................................................................9
References........................................................................................................................................9

List of Tables
Table 1 System function failures....................................................................................................7
Table 2 FSI's...................................................................................................................................8
 Lab Session 06
Title
Determining Functionally Significant Items (FSIs) for the various types of
machines in Machine Tools & Machining (MTM) laboratory.
Problem Statement
Maintenance has always been of vital importance in any industry, it ensures the safe
working environment of an industry. However operations and maintenance is mostly overlooked
by some industries, and those industries which do not focuses on operations and maintenance, or
called it a burden are highly get affected under undesirable circumstances. Although it requires
an appreciable part of total industrial budget, yet it is justified by the lowering the risks and
allowing smooth operation of an industry therefore in order to optimize the available resources
and controlling time and costs to maximize the productivity of a system and avoiding any
haphazard situation the employees must be aware of the general SOPs of operations and
maintenance.
Objective
1. To determine FSI of NC Grinder
Theory
A functionally significant item is an item whose failure would affect safety or could have
significant operational or economic impact in a particular operating or maintenance context. The
process of identification of FSIs is based on the anticipated consequences of failures using an
analytical approach and good engineering judgment. The process also use a top-down approach,
and is conducted first at the system level, then at the subsystem level and, where appropriate,
down to the component level. An iterative process as shown in fig. 1 should be followed in
identifying FSIs. Systems and subsystem boundaries and functions are first identified. This
permits selection of critical systems for further analysis, which involves a more comprehensive
and detailed definition of system, system functions, and system’s functional failures.
The procedures such as information collection, system analysis, and so on outline a
comprehensive set of tasks in the FSI identification process. All these tasks should be applied in
the case of complex or new equipment. However, in the case of well-established or simple
equipment, where functions and functional degradation/failures are well recognized, tasks listed
under the heading of system analysis can be covered very quickly. They should, however, be
documented to confirm that they were considered. The depth and rigor used in the application of
these tasks will also vary with the complexity and newness of the equipment.
Figure 1 Flowchart for determining FSI's and developing preventive maintenance plan
1. Information Collection
1. This step requires the documentation of equipment’s detailing, including specifications
and systems

Figure 2 Labeled NC Grinder

Figure 3 Mechanical and Electrical System of NC grinder

Maintenance Plan
SR
No. Inspection Status Issues

Complete incomplet
e

Tasks
1 Check for orientation
2 Check for axis reference
points
3 Check for lubrication
initial levels
4
Check spindle lube tube
5 Check air lubricators
6 Inspect for cracked
hoses
7
Check for oil leaks
Check for hydraulic
8 pressure and maintain at
4.5MPa
9 Ensure the chuck
pressure is at right
10 Inspect air filter,
operating level
electrical cabinet
11
Change oil in oil cooler

12 Maintain optimum
oil temperature
13 Check for abnormal
force on headstock
14 Check tool knockout
 15 Check for heat and
vibration of headstock

2. Identification of Systems
There are three major systems in our assigned machine i.e. NC grinder,
1. Hydraulic
2. Mechanical
3. Electrical
3. Identification of System Functions
Mechanical system:
Mechanical system of surface grinder composed of dust exhaust unit, coolant
tank, and table majorly future parts included the grinding wheel which is the tool
controlled by a number of servo motors and gears mechanisms, foundation on which
the whole body is resting, bed on which magnetic chuck rests and holds work piece
tightly.

Electrical System:
All mechanical systems are operated with help of some electrical systems
composed of electrical components. The main electrical switchgear is housed in a
compartment at the front of the machine. The isolator is mounted on left hand side of the
machine and must be switched to the OFF position before attempting to remove the
switch gear cover.

4. Selection of Systems
 Rack and Pinion
 Table
 Bed
 Column
 Controller
 Tool Holder
 Gears
 Magnetic Chuck
 Drain
 Pump
o Hydraulic
o Electric
5. Identification of system functional failures and criticality ranking
 Table 1 System function failures

Failure Rank
1. Rack and pinion failure
2. Gears wear and tear High
3. Controller (Electric fault)
4. Pump (heat up, failure)
5. Drain (Leakage) Medium
6. Magnetic Chuck (demagnetization)
7. Bed
8. Column Low
9. Loosening of Hand Wheel

6. Identification of FSI’s
After going through in depth machine analysis, the identified FSI’s are given below

Table 2 FSI's

FSI System/s FSI function/s

Cross feed Controls table motion and
Motor Mechanical + Electrical

Hydraulic Hydraulic + Mechanical Converts electrical energy to mechanical

pump energy
motor
Gears Mechanical Transmit power
Ball Mechanical Reduce friction and support load
Bearings

Controller Electrical Controls the machine

Magnetic Electrical Holds the work piece
chuck

Comments and Conclusion

In this lab session i have observed about the functional significant items of NC surface
grinder enlisted them and observed how and what the role they plays in machine operations how
their failure retards the overall machine works. And FSIs are selected on the basis of a complete
procedure starting from information, system, system functions, then FSIs and their further
enlisting on basis of critical FSIs and their role in operations. 

Recommendations
If fSIs are not identified successfully the operations and woring of machine retards and it
also effects the economics maintenance costs as well. So FSIs should be selected critically
References
[1] https://www.rk-int.com/machine/perfect-pfg-cl-and-dl-3060-series-surface-grinders/
[2] MAINTENANCE ENGINEERING HANDBOOK Seventh Edition By R. Keith Mobley
Editor in Chief Lindley R. Higgins and Darrin J. Wikoff