JJ615 MECHANICAL

COMPONENTS &
MAINTENANCE
Prepared by:
Mr. Rahizal bin Mohd Khir
Mechanical Engineering Department
Ungku Omar Polytechnic
COURSE LEARNING OUTCOMES (CLO)
Upon completion of this course, students
should be able to:
1. classify clearly the basic concept of mechanical
components. (C4)
2. assemble correctly mechanical component base
on service manual maintenance by group. (P5)
3. organize properly maintenance procedure base
on standard operation procedure. (A4)
1.0 MAINTENANCE PRINCIPLES AND
PROCEDURES (CLO1)
1.1 Understanding of maintenance.
the meaning of maintenance.
maintenance is a set of organised
activities that are carried out in order to
keep an item in its best operational
condition with minimum cost acquired.
 Maintenance History
-Term terotechnology
introduced
(replacement &
Development of

removal)
Maintenance

-Recognition of need
to present equipment
failures. -Increased awareness of:
-Models for -Environment
preventive -Safety
Fix the equipment maintenance -Quality
when it breaks developed. -Need for reliable equipment.
-Reduction in costs.

Time
Pre-World War II Post-World War II 1980 Onwards
 Maintenance Objectives
Maintenance objectives should be consistent with and
subordinate to production goals.

The relation between maintenance objectives and production

goals is reflected in the action of keeping production machines
and facilities in the best possible condition.
 Maintenance Objectives
1. Maximising production or increasing facilities availability at
the lowest cost and at the highest quality and safety
standards.
2. Reducing breakdowns and emergency shutdowns.
3. Optimising resources utilisation.
4. Reducing downtime.
5. Improving spares stock control.
6. Improving equipment efficiency and reducing scrap rate.
7. Minimising energy usage.
8. Optimising the useful life of equipment.
9. Providing reliable cost and budgetary control.
10. Identifying and implementing cost reductions.
Maintenance Objectives
PLANT

Maximising Production Reduce Breakdowns

M
A
I
Minimising Energy N Reduce Downtime
Usage
T
E
N
Optimising Useful Life of Improving Equipment
Equipment
A Efficiency
N
C
Providing Budgetary E Improving Inventory
Control Control

Optimising Resources Implementing Cost

Utilisation Reduction
advantages of implement
maintenance.
1. Improved Efficiency. The overall efficiency of your system
will be improved, helping save on energy costs. Many
experts believe that regular maintenance will help a system
retain up to 95% of its original efficiency rating.
2. Fewer Repairs. Small problems can often be detected
before they become large problems with expensive repairs.
3. Extended Equipment Life. The life of your system will be
extended over what you can expect from a system that is
not regularly maintained.
4.Lower utility bills. A neglected HVAC system consumes
up to 25% more energy which means unnecessarily high
power bills.
advantages of implement
maintenance.
5. Identify Problems Early. Potentially hazardous conditions
can be identified.
6. Anticipate Failures. Many unexpected failures can be
prevented that could result in breakdowns during extreme
temperatures when operating systems are under maximum
workload.
7. Fewer “emergency” calls. Emergencies can be expensive
and frustrating. Your unit will be maintained and
emergencies can be avoided.
8. Added comfort and peace of mind. Know that your system
is being taken care of and that your unit is functioning
properly.
hadis.pptx
1.2 Cost consideration in maintenance

Types of cost in maintenance

Costs associated with maintenance are:
1. Downtime cost due to equipment breakdown.
2. Cost of spares and other material used for repairs.
3. Cost of maintenance labour and overheads of maintenance
department.
4. Losses due to inefficient operations of machines.
5. Capital requirement for replacement of machines .

The term downtime is used to refer to periods when a system is

unavailable (offline). Downtime or outage duration (Maintenance
Duration) refers to a period of time that a system fails to provide or
perform its primary function.
Explanation of all types of maintenance
cost related
 Because of breakdowns, both the
machinery as well as the manpower are left
idle, per force.
 This results in production, delay in
schedules and emergency repairs.
 The downtime costs generally exceed the
preventive maintenance costs of
inspection, service and scheduled repairs.
 Maintenance Costs
Cost

Breakdown Cost

Maintenance
Commitment
 Maintenance Costs
Cost

PM Cost

Breakdown Cost

Maintenance
Commitment
 Maintenance Costs
Cost
Total Maintenance Cost

PM Cost

Breakdown Cost

Maintenance
Commitment
 Maintenance Costs
Cost
Total Maintenance Cost

PM Cost

Breakdown Cost

Optimal Maintenance
Commitment
1.3 workplace safety.
1.3 workplace safety.
1.3.1 The benefit clean and safe working environment
1. reduced handling to ease the flow of materials
2. fewer tripping and slipping accidents in clutter-free
and spill-free work areas
3. decreased fire hazards
4. lower worker exposures to hazardous substances (e.g.
dusts, vapours)
5. better control of tools and materials, including
inventory and supplies
6. more efficient equipment cleanup and maintenance
7. better hygienic conditions leading to improved health
more effective use of space
8. reduced property damage by improving preventive
maintenance
9. less janitorial work
10. improved morale
11. improved productivity (tools and materials will be easy
to find)
1.3.1 The benefit clean and safe working
environment
Poor housekeeping can be a cause of accidents, such as:
1. tripping over loose objects on floors, stairs and platforms
being hit by falling objects.
2. slipping on greasy, wet or dirty surfaces
3. striking against projecting, poorly stacked items or misplaced
material
4. cutting, puncturing, or tearing the skin of hands or other parts
of the body on projecting nails, wire or steel strapping
5. To avoid these hazards, a workplace must "maintain" order
throughout a workday. Although this effort requires a great
deal of management and planning, the benefits are many.
Hadis 2

1.3.2 The important of Personal Protection Equipments (PPE)

What is PPE?
Equipment that workers wear to protect themselves from
hazards in their work environment.
Examples:
 hearing protection
 respirators
 hard hats (safety helmets)
 safety goggles
 safety glasses
 safety shoes
 gloves
1.3.2 The important of Personal Protection
Equipments (PPE)
 When hazards can not be eliminated through
engineering and/or administrative controls, PPE
must be used to protect the eyes, face, head, feet,
hands, arms, body, ears, and lungs.
 Preventable Injuries:
 Chemical burns to the eyes
 Chemical irritation to the eyes and skin
 Particulate matter in the eye
 Heat burns
 Slips, trips, and falls
 Cuts and abrasions
VIDEO LOGOUT AND TAGOUT
1.3.3 Use lock-out and tag-out
when needed. .Log-Out and Tag-Out (LOTO)

This practice helps safeguard employees from
hazardous energy while they are performing service
or maintenance on machines and equipment. E

The OSHA standard 29 CFR §1910.147, identifies

the practices and procedures necessary:

a written program and lockout procedures,

shut down and lockout or tagout of machines and
equipment,
employees training in their role in the lockout/tagout
program, and
periodic inspections conducted to maintain or
enhance the energy control program.
 1.3.3 Use lockout and tag-out when needed.
What are lockout devices?
 Lockout device: Any device that uses a positive
means, such as a lock, blank flanges and bolted
slip blinds, to hold an energy-isolating device in
a safe position, thereby preventing the
energizing of machinery or equipment.

Valve Devices What are Energy-Isolating devices?

Plug out
 Energy-isolating device: A mechanical device
that physically prevents the transmission or
release of energy, including but not limited to the
following: A manually operated electrical circuit
breaker; a disconnect switch; a line valve; a
block; and any similar device used to block or
isolate energy. Push buttons, selector switches
and other control circuit type devices are not
energy isolating devices.
Circuit
Circuit Breaker
Breaker Device
Device
1.3.3 Use lockout and tag-out when needed.
A good rule of thumb is: whenever the
guarding is removed, or by-passed, or
any part of your body can come in
contact with the working parts during
service/maintenance lockout must be
done!
When needed LOTO?
 before begin any servicing or maintenance
activities where the unexpected energization,
(start-up or release of stored energy) could
cause injury.
 Procedures for locking out equipment and
machinery are attached at the control panel.
 Information in the procedure:
1. will provide the location of energy sources,
2. the magnitude of energy, the isolation devices,
and
3. the sequence required to shut down and
restart the machine or equipment.
 hadis.pptx

1.3.4 The organization that governs the safety of hazardous material.

1. The Department of Occupational

Safety and Health (DOSH)

A department under the Ministry of Human Resources. This department is responsible for ensuring the
safety, health and welfare of people at work as well as protecting other people from the safety and health
hazards arising from the activities sectors which include:
Manufacturing
Mining and Quarrying
Construction
Hotels and Restaurant
Agriculture, Forestry and Fishing
Transport, Storage and Communication
Public Services and Statutory Authorities
Utilities - Gas, Electricity, Water and Sanitary Services
Finance, Insurance, Real Estate and Business Services
Wholesale and Retail Trades

As a government agency, the department is responsible for the administration and enforcement of
legislations related to occupational safety and health of the country, with a vision of becoming an
organisation which leads the nation in creating a safe and healthy work culture that contributes towards
enhancing the quality of working life.
1.3.4 The organization that governs the safety of hazardous
material.

2.

To develop the capacity and capability of the

construction industry through the enhancement of
quality and productivity by placing great emphasis on
professionalism, innovation and knowledge in the
endeavour to improve the quality of life.
1.3.4 The organization that governs the safety of hazardous material.
3. National Institute of Occupational Safety and
Health (NIOSH)

NIOSH is committed to ensure a safe and healthy working environment

to all employees and others involved in or affected by its operation
taking into account statutory requirement and relevant national and
international standards and codes of practices.
NIOSH will ensure that adequate resources, training and time are made
available.
Safety and Health management systems and programmes will be
regularly reviewed to ensure continuous improvement.
Humanistic approach will be adopted by NIOSH to promote a safe and
healthy work culture which employer and employees share the common
responsibility of creating a better work environment for all.
 HAND TOOLS
Hand Tools - Tools that
are manually operated
and powered by human
force such as screw
drivers, pliers, wrenches,
and cutting shears, etc.
 Wrenches:
Choose a wrench that properly fits the
fastener that is to be turned. Using the correct
size reduces the chances of wrench slippage.
Avoid using a length of pipe or other Wrench
extension to improve the leverage of a wrench. Set
Manufacturers design wrenches so that the
amount of leverage obtained with the handle
is the maximum safe application.
Use socket wrenches for hard-to-reach areas.
Always try to pull on a wrench (instead of
pushing) in case the fastener suddenly Ring
loosens. Ratchet
Inspect wrenches periodically for damage Wrench Set
such as cracking, severe wear, or distortion.

Adjustable
Socket Wrench
Wrench
Set
 Pliers:
Do not increase the handle length of
pliers to gain more leverage. Use a
larger pair of pliers or bolt cutters.
Do not substitute pliers for a wrench
when turning nuts and bolts. Pliers
cannot grip these items properly and
will slip.
Never use pliers as a hammer or
hammer on the handles. Such abuse is
likely to result in cracks or breaks.
Cut hardened wire only with pliers
designed for that purpose.
Always cut at right angles. Never
rock from side to side or bend the
wire back and forth against the
cutting edges.
 Hammers:
Do not use a hammer if the handle is
damaged or loose.
Never weld, heat, or regrind a
hammer head.
Remove from service any hammer
exhibiting signs of excessive wear
such as cracks, chips, or a
mushroomed head.
Match the proper type of hammer to
the job it is designed to perform.
Do not strike the surface at an angle.
The hammer face should contact the
striking surface squarely. Glancing
blows made with a hammer often
lead to injury.
 Screwdrivers:
Never use a screwdriver as a pry
bar, chisel, punch, stirrer, or
scraper.
Always use a screwdriver tip
that properly fits the slot of the
screw.
Throw away screwdrivers with
broken or worn handles.
Use magnetic or screw-holding
screwdrivers to start fasteners
in tight areas.
Never use pliers on a
screwdriver for extra leverage.
Only use a wrench on screw
drivers specifically designed to
accept them.
 POWER TOOL
Power Tools - Power tools
that are hand held,
manually operated, and
powered by electricity, air,
gasoline, diesel, or
explosion, such as circular
saws, sanders, drills,
reciprocating saws, air
wrenches, air grinders, air
fasteners, chainsaws,
Ramset guns & etc.
IMPORTANT OF INDICATING POWER TOOL
The two most common hazards associated with the use of hand
tools are misuse and improper maintenance.
Misuse occurs when a hand tool is used for something other than
its intended purpose. (An example would be using a screwdriver as
a chisel. This may cause the tip to break and strike someone).
Improper maintenance allows hand tools to deteriorate into an
unsafe condition.
(Examples would include cracked wooden handles that allow the
tool head to fly off or mushroomed heads that can shatter upon
impact).
Specially designed tools may be needed in hazardous
environments. (Always use non-sparking tools in the presence of
flammable vapors or dusts. Insulated tools with appropriate ratings
must be used for electrical work).