Ch 1.2 - Maintenance Function

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UNIT 1.2

General Objectives :Understand the maintenance

functionSpecific Objectives :After learned this unit, youshould be able to :- Makesure

Mak

Makesure

Explain the

function ofmaintenance
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Function of Maintenance

Function of maintenance is :-

1. To makesure the product follow thespecification.

2. To makesure reasonable cost of product.

3. To makesure the machine and equipmentcan be used optimumly.

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Function of Maintenance

1. To makesure the product follow the specification.

. Most of the time we are facing a product that has been bought but

fail to operate follow its specification. Many factors contribute tothe 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)

. To makesure product @ equipment follow the specification, fullmaintenance should be implement.

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Full Maintenance

It is include in belowprocesses :-

a. Knowledge

b. Protection

c. Corrective

d. Examine



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Full Maintenancea. Knowledge

- Its mean, to know what are the ability & thedisability of the product @ equipment.

- Its include the ability of product to temperature,vibration & absolute max range of product.- In additional, it is important to understand belowterms if we want to know whether the productfollow the specification or not.

Strength Sensitivity

Accuracy Kelinearan

Hysterisis



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b. Protection

Base on the knowledge, for sure maximumprotection can be given to the equipment @product.

As example, if the equipment cannotoperate in high temperature, the equipmentshould be placed at room temperature).



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c. Corrective

To makesure the product constantly operate in thespecification limit, corrective maintenance shouldbe routinely implemented.

No matter major @ minor failure occur, thecorrective maintenance should be urgentlyimplement.



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d. Checking / Examine

- The most important procedure in the process of fullmaintenance.

- Log book / form need to be prepared to makesure thechecking / examination follow the procedure.

-

The best examination/ checking that is include withthe daily , weekly, monthly and also yearly checkingmaintenance.

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Exercises

1. Give 3 factors that contribute to thefailure of a product.

2. State 4 basic method that are neededto implement full maintenance.


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To makesure reasonable cost of product

To makesure the cost is reasonable, the firstthing to do is to make an analysis.

Analysis is made to the cost of time, labourand financial (profit/loss)

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As an example , in a firm (industrial), theanalysis is include with :-1. Operation time loss

~ Maintenance period~ Time of corrective / repair job

~ Report time period2. Maintenance Cost3. Labour Cost4. Machine breakdown period cost

For individual responsibility to

makesure the product is reasonablecompare to the price, check the ability &disability of the product.


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To makesure the machine and equipmentcan be used optimumly.

Below maintenance should be implement

:-

- Breakdown Maintenance(penyelenggaraan kerosakan)

- Preventive Maintenance

(penyelenggaraan pencegahan)- Predictive Maintenance

(Penyelenggaraan Jangkaan)- Condition-Based Maintenance(penyelenggaraan berdasarkankeadaan)

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Breakdown Maintenance - implement after themachine @ equipment breakdown.

Preventive Maintenance - implement before themachine @ equipment breakdown to avoid a major

failure.

Predictive Maintenance The maintenance method alsoknown as Preventive maintenance. Implement by doingan analysis to detact problem at the equipment @

machine without disturbing the production schedule.

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Condition-base Maintenance dilakukan apabila perlusahaja bagi mesin-mesin yang mempunyai sistempengurusan berterusan. Ia dilakukan menggunakansistem PLC dimana sistem mesin akan disambungkankepada komputer pengawasan keadaan operasi. Jika

terdapat masalah komputer akan melakukan penjajaransecara automatik atau komputer akan mengeluarkantanda amaran dan memberi tahu samada perlu diservicesecara manual atau tidak. Amat efektif tetapi kospermulaan sangat tinggi tetapi memberi pulangan

jangka panjang yang amat tinggi.

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Exercise

1. Why there is always exist a product that isbought not fulfill its specification andcustomer needs?.

2. Why do we need to implement the full

maintenance to an equipment?.

3. State the basic requirement to do the fullmaintenance.

4. State the knowledge that are required todetermine whether a product follow itsspecification.

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5. What is the meaning of protection

in a full maintenance?

6. What are the cost type that isneeded to makesure the producthave a reasonable price?

6. List the maintenance that isneeded to makesure the machine@ equipment can be useoptimumly.

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Ch 1.2 - Maintenance Function