DJJ521012

MAINTENANCE ENGINEERING & MANAGEMENT

SESI 1 2022/2023
CASE STUDY

TITLE :
NEW MAINTENANCE STRATEGY ABD SYSTEM TO SOLVE THE PROBLEM

LECTURER :
EN HAMID BIN SALAMON

CLASS :
DKM 5C

GROUP MEMBERS :

NASHVIN A/L GANESAN 09DKM20F1064

NASHVIND A/L VEERAVIJIYEN 09DKM20F1047
THVIYEN RAJ A/L RUTHIRA MOORTHY 09DKM20F1113
GOKULA VIKNESWARAN A/L PARAMASIBAM 09DKM20F1109

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TABLE OF CONTENTS

CONTENTS PAGES
Title page 1

Table of contents 2

Workshop Introduction 3

Organization chart if Maintenance Team 4-6

Problem Analysis of Machine 6

Maintenance strategy 7

Method of Maintenance Strategy 7-10

Maintenance Planning 10

Maintenance Scheduling 10-11

Maintenance work order 11-12
Estimated Maintenance Cost 13

Conclusion 13-14

References 14

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1.0 Workshop Introduction

The workshop is a combination of two words i.e. Work + Shop “WORK” means a
physical or intellectual effort directed to some useful & meaningful activity. So, “SHOP”
means the place or location or area where this kinda work is efficiently carried out with
necessary efforts.
“Workshop is a place or area or location where physical or intellectual or necessary
resource gets properly utilized and make it efficient in proper manners for positive output.”
Every engineer/Technician is in one way or another associated with the workshop or
technical shop, whether he or she may be Civil, Mechanical, Electrical, Automobile or of any
other branch.

There are mainly two types of workshops.

• Training workshop
• Production workshop

Workshop practice is the backbones of the real world of industrial work situation or
condition, which helps in developing, growing and enhancement of relevant skills required by
the technician job or working in engineering industries, fields and workshops. The workshop
experiences would also help students to understand the complexity of industrial working in a
relatively shorter duration. If you are a student, the students are advised to undergo each skill
experience with an understanding of know-how and special emphasis on why the various
practices imparted to them in various shops or technical shops.

Maintenance, otherwise known as technical maintenance, refers to a set of processes

and practices which aim to ensure the continuous and efficient operation of machinery,
equipment, and other types of assets typically used in business. Diligence in implementing an
effective maintenance program is essential to the successful performance and longevity of
machinery, assets, facilities, and entire businesses

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2.0 Organization chart of Maintenance Team

What is the organizational structure of maintenance department?Traditionally, a maintenance

organization takes on a centralized or decentralized structure. A centralized organization
places the maintenance department outside the functional center of production, where all
needs are met from a separate and common base.

Type of Organization Chart

The Organization Chart we used to show our maintenance structure during the process task is
hierarchical organization chart. We choose this type of chart as it was easier to view each
section in one diagram. A hierarchical structure is typical for larger businesses and
organisations. It relies on having different levels of authority with a chain of command
connecting multiple management levels within the organisation. The decision-making process
is typically formal and flows from the top down.

Duties and Responsibilities of Maintenance Team

Maintenance Team means a group of Purchaser's technicians trained and certified in the
maintenance of the Hardware and Software and having the full competence to support the
delivered System. Maintenance Team means all of the Team Members involved in the
maintenance and rehabilitation of the Project.

1. Supervisor

• Hires and trains maintenance department staff.

• Organizes and oversees the schedules and work of maintenance staff.
• Conducts performance evaluations that are timely and constructive.
• Handles discipline and termination of employees as needed and in accordance with
company policy.

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 2. Production Team

A production team oversees a group of employees within a specific department and

manufacturing unit. They can assign tasks to team members and maintain high standards for
quality and safety.

i. Material/Equipment
• Ensures that materials and supplies are coordinated for all district departments, and keeps an
eye on inventory levels to ensure that needed resources are always on hand.
• Coordinates all departments' purchasing requirements.
• Regularly spot check inventory items for control counts and scheduling; ensures the
accuracy of orders and products received; and ensures accurate documentation of purchase
orders, receiving slips, and issue tickets.

ii. Machinery
• Ensures that projects are completed on time.
• Directs workplace safety inspections.
• Executes maintenance tasks as required.
• Assesses job sites to identify maintenance tasks that are required.
• Reports problems to management and makes suggestions for fixes.
• Assures the group adheres to all corporate rules and regulations.

iii. Assembling
• Monitoring the security of the workplace and ensuring that all safety procedures are
followed.
• Informing team members of production timetables and material requirements.
• Executing routine inspections to make sure goods adhere to quality standards
• Checking on the status of production operations to make sure they are proceeding as
planned

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 iv. Finishing

• Ensure staff efficiency and safety.

• Maintain the quality of finished products.
• Make sure the department is meeting the company's production goals.

v. Documentary / Media
• Document site photos and layout for client approval.
• Supports the development of standardized documents and templates.
• Preparing a plan to ensure system compliance, including creating and editing
documentation.
• Meticulous attention to detail. Adherence to strict policies and processes. Ability to verify,
update and maintain accurate records.
• Maintain Photoshop skills to update and maintain network design and cabling
documentation

3.0 Problem Analysis of Equipment

Problem analysis therefore involves identifying the overring problem and establishing
the causes and effects related to the problem. A key element of this analysis will ensure that
“root causes” not just the symptoms of the problem, are identified and subsequently
addressed in the equipment.

In Polytechnic Ibrahim Sultan, at machine workshop the lathe machine had a problem.
In lathe machine, one of the parts had a problem that is Lathe Quick Change tool post. The
tool post had a bolt broken head. It can cause damage to the machine. So we did corrective
maintenance to the tool post.

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4.0 Maintenance strategy

An effective maintenance strategy is concerned with maximizing equipment uptime

and facility performance while balancing the associated resources expended and ultimately
the cost. We need to ensure that we are getting sufficient return on our investment.

What are the 4 types of maintenance?

• Run-to-failure (breakdown maintenance)

• Preventive (scheduled) maintenance

• Predictive maintenance (PdM)

• Reliability-centered maintenance (RCM)

Method of Maintenance Strategy

I) SELECT THE EQUIPMENTS TO BE ANALYED

Tool post. The tool post holds and firmly supports the tool or tools. The tool post is fitted
on the top slide.

The common types of tool post are :

• American type tool post or single way tool post.

• Indexing type tool post or square tool post.

• Quick change tool post.

• British type tool post.

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 The tool post that needs to be analysed is Quick change tool post.

Quick change tool post

II) IDENTIFY FUNCTIONS

As its name implies the Our Quick Change Tool Post is for quickly changing various
tools required for different operations. Thus, it increases operational productivity by saving
on time and energy expended by a machine operator.

During complex machining operations frequent change of tools is necessary. A

conventional tool post makes the change – over difficult and time consuming, due to setting
each tool by centering each and every time. In comparison, in the Quick Change Tool Post
different tools can be premounted on various tool holders. Thus tools can be changed very
quickly and easily, with repetitive accuracy ensured. Also fine adjustments of the centre
height are possible with a Thumbscrew Adjustor provided on the tool holder.

III) FUNCTIONAL FAILURE

The quick-change tool holder had two of the holes had bolt broken head. The function of
the bolt is to tighten the tool bit holder known as carbide.

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 Bolt broken head

IV) IDENTIFY AND EVALUATE THE EFFECTS OF FAILURE

Because of the failure, the quick change tool post could not be used. The tool bit holder
cannot be tightened in the quick change tool post. So, it effects on working the project or
the workpiece.

V) IDENTITFY THE CAUSES OF THE FAILURE

The bolt broken head has happened because some of the people will use T-spindle to
tighten the screw. If T-spindle is used the force is higher so it causes to bolt broken head.
We should use the suitable tool to tighten the screw. Another cause of the bolt broken
head is there is no proper maintenance to the screw which cause it stuck in the slot.

VI) MAINTENANCE TASK

The tools and machine that we used for the maintenance is drill press machine, tap & die,
G clamp, coolant and lubrication oil. The maintenance steps are :

1. First, we set the bolt broken head under the drill bit on the drill press machine.
2. Then, we tighten the quick tool post with G-Clamp.
3. After tighten, we drill the bolt broken head. We set the speed for the machine on
medium speed. While drilling we used coolant to cool the drill process.
4. Repeat the process for another bolt broken head.
5. After drilling, we used tap & die to thread the internal. We used lubrication oil to
easily turn the tool. The tool should be in upright position.

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 6. Finally, clean the drill press machine and the work material. Rearrange the tools to its
original place.

5.0 Maintenance Planning

Maintenance planning can be defined as an end-to-end process that identifies and

addresses any possible issues ahead of time. This involves identifying the parts and tools
necessary for jobs and making sure they're available and laid out in the appropriate areas,
having a planner write out instructions on how to complete a job, and even determining and
gathering the necessary parts and/or tools before a job is assigned. Maintenance planning also
includes tasks related to parts like:

• Handling reserve parts

• Ordering nonstock parts
• Staging parts
• Illustrating parts
• Managing breakdowns and vendor lists
• Quality assurance (QA) and quality control (QC)

Maintenance planning should define the "what," "why" and "how." This means specifying
what work needs to be done with what materials, tools and equipment; why a particular
action was chosen (why a valve is being replaced instead of a seat); and how the work should
be completed.

6.0 Maintenance Scheduling

Maintenance scheduling refers to the timing of planned work, when the work should
be done and who should perform it. It offers details of "when" and "who." Scheduling is
meant to:

• Schedule the maximum amount of work with the available resources

• Schedule according to the highest priority work orders

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• Schedule the maximum number of preventive maintenance jobs when necessary

SIMPLE EQUIPMENT MAINTENANCE SCHEDULING

7.0 Maintenance Work Order

A maintenance work order is an authorization to perform requested activities on a work

request. Depending on the type of business, work requests can be submitted to maintenance
by any one of their many types of customers or staff. Once work requests are reviewed and
approved by maintenance, an official work order to complete the job is issued.

In addition to the details provided on the work request, the work order also contains key
information on how the job will be completed.

• Information that appears on a work order includes:

• Description of the task or need
• Name of requesting department or individual
• Estimated completion date
• Name of person or team to complete the task (may be in-house resource or
third party)
• Location of activities (name of facility, or name of area within a facility)

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• Prerequisites to completing the end goal (e.g., parts, tools, documentation)

The information on a work order is provided with the purpose of explaining the need,
scheduling resources, detailing instructions, and estimating costs of parts and labor. Use of a
CMMS also enables maintenance to schedule and document recurring work, like monthly
preventive maintenance activities (what is preventive maintenance?), and automatically
generate and monitor work order data.

EXAMPLE OF MAINTENANCE WORK ORDER FORM

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Estimated Maintenance Cost

8.0 Conclusion

Let’s begin with the core of what is Industrial Maintenance. According to

the Wikipedia definition, “The technical meaning of maintenance involves functional checks,
servicing, repairing, or replacing of necessary devices, equipment, machinery, building
infrastructure, and supporting utilities in industrial, business, and residential installations.”
For asset-intensive industries, industrial maintenance is important for sustaining reliable
performance of instruments and machinery, safety, energy efficiency, regulatory compliance,
and warranty coverage. In addition, preventive maintenance can have a significant impact to
the costs of operation as opposed to reactively dealing with a problem when it occurs.

Certainly, you can’t take the tact that everything can just run-to-failure
and be replaced. The risk to employee’s safety and risk to production stoppage are enough to
warrant a planned maintenance program. Here are some additional benefits of preventive
industrial maintenance:

• Increased safety through reducing the risk of injuries, fatalities, and therefore liability,
due to asset breakdown or problems.
• Prevent costly downtime events which can disrupt production and result in lost
business.
• Extend the useful lifespan of assets and increase their resale value at end-of-life.
• Reduce maintenance costs since repairs can be far more expensive than the cost of
preventive maintenance work. The old adage is true, an ounce of prevention is worth a
pound of cure. In fact, a key maintenance effectiveness metric is the ratio of planned
vs. unplanned maintenance.
• Keep assets running to meet schedule and budget commitments.
• Reduce energy consumption and operating costs.

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 • Retain warranty coverage with detailed service records to demonstrate adherence to
recommended maintenance requirements.

9.0 References

I. https://testbook.com/question-answer/indexing-type-tool-post-are-called-_____way-tool-p-
-5f604ba4f5cf320500b5cb22
II. https://www.sigga.com/blog/importance-industrial-maintenance -
:~:text=Increased%20safety%20through%20reducing%20the,at%20end-of-life.
III. https://www.fiixsoftware.com/blog/evaluating-maintenance-strategies-select-model-asset-
management/

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