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Test 1 Dec 2014
Test 1 Dec 2014
09 January 2015
TEST 1
Section A: Short Essay Questions
CLO1
To point out the concepts of maintenance organization and strategies that increases productivity by
increasing availability and capacity at reduced cost. (C4)
CLO2
To relate the principles of maintenance strategies and elaborate on the significance of a system approach to
maintenance. (C6)
PLO 1
CLO
1, 2
QUESTION 1
i)
Discuss the needs for maintenance.
[2 marks]
ii)
iii)
Elaborate the relationship between preventive maintenance cost and breakdown cost as shown.
[15 marks]
PLO 1
CLO 1,
2
QUESTION 2
i)
Define the following terms:a) Preventive maintenance
c) Predictive maintenance
e) Overhaul
b)
d)
Corrective maintenance
Reliability
[5 marks]
ii)
iii)
CLO3
To organize maintenance management plan and schedule that integrates the whole management processes
and procedures by group in actual workplace. (A4)
QUESTION 3
By referring to an indenture diagram of a car system, study the different maintenance strategies that can be
applied for different levels of the car system.
[40 marks]
09 January 2015
TEST 1
CLO1
Point out the concepts of maintenance organization and strategies that increases productivity by increasing
availability and capacity at reduced cost. (C4)
CLO2
Relate the principles of maintenance strategies and elaborate on the significance of a system approach to
maintenance. (C6)
Question 1
i)
Answers:Since the Industrial Revolution, maintenance of engineering equipment in the field has been a
challenge. Although impressive progress has been made in maintaining equipment in the field in an
effective manner, maintenance of equipment is still a challenge due to factors such as size, cost,
complexity, and competition. Needless to say, todays maintenance practices are market driven, in
particular for the manufacturing and process industry, service suppliers, and so on.
An event may present an immediate environmental, performance, or safety implication. Thus, there
is a definite need for effective asset management and maintenance practices that will positively
influence critical success factors such as safety, product quality, the speed of innovation, price,
profitability, and reliable delivery.
ii)
On the other hand Failure Costs include: cost of idle production employees during the lost
time when equipment is down for repairs, production losses during breakdown taking into
consideration upstream and bottleneck equipment can be costly if it means the shutdown of
the whole plant, cost of penalties or damages claimed by the customer
The frequency of maintenance must be balanced with the cost if a failure should occur.
In some instances, it might be less costly to run a machine until it breaks down, and then to
perform the necessary emergency repairs.
The relationship between the maintenance costs and the cost of failures is illustrated in the
figure shown. The curve illustrates that there is an optimum level when preventive
maintenance programs should be carried out when Cost of Maintenance and Cost of
Breakdown are EQUAL.
Question 2
i)
Preventive maintenance
Corrective maintenance
Predictive maintenance
Reliability
Overhaul
Answers:a)
Preventive maintenance
All actions carried out on a planned, periodic, and specific schedule to keep an
item/equipment in stated working condition through the process of checking and
reconditioning. These actions are precautionary steps undertaken to forestall or lower the
probability of failures or an unacceptable level of degradation in later service, rather than
correcting them after they occur.
b)
Corrective maintenance
The unscheduled maintenance or repair to return items/equipment to a defined state and
carried out because maintenance persons or users perceived deficiencies or failures.
c)
Predictive maintenance
The use of modern measurement and signal processing methods to accurately diagnose
item/equipment condition during operation.
d)
Reliability
The probability that an item will perform its stated function satisfactorily for the desired period
when used per the specified conditions.
e)
Overhaul:
A comprehensive inspection and restoration of an item or a piece of equipment to an
acceptable level at a durability time or usage limit.
ii)
Answers:-