"THE ACTION OF PRESERVING" (Oxford) includes corrective maintenance and Preventive Maintenance. It includes Lubrication 2. Cleaning 3. Adjustments - Return to normal operating condition. It also includes the use of safety devices such as HAND TOOLS and power tools.
"THE ACTION OF PRESERVING" (Oxford) includes corrective maintenance and Preventive Maintenance. It includes Lubrication 2. Cleaning 3. Adjustments - Return to normal operating condition. It also includes the use of safety devices such as HAND TOOLS and power tools.
"THE ACTION OF PRESERVING" (Oxford) includes corrective maintenance and Preventive Maintenance. It includes Lubrication 2. Cleaning 3. Adjustments - Return to normal operating condition. It also includes the use of safety devices such as HAND TOOLS and power tools.
1. INTRODUCTION TO MAINTENANCE 2. COST CONSIDERATION IN MAINTENANCE 3. WORKPLACE SAFETY 4. HAND TOOLS, POWER TOOLS AND MAINTENANCE EQUIPMENTS WHAT IS MAINTENANCE? THE ACTION OF PRESERVING (OXFORD) In engineering : Actions necessary for retaining or restoring a piece of equipment, machine, or system to the specified operable condition to achieve its maximum useful life. It includes corrective maintenance and preventive maintenance.
OBJECTIVES OF MAINTENANCE 1. Minimizing the loss of productive time because of equipment failure ( i.e. minimizing idle time of equipment due to breakdown) 2. Minimizing the repair time and repair cost 3. Minimizing the loss due to production stoppage 4. Prolonging the life of capital assets by minimizing the rate of wear and tear
OBJECTIVES OF MAINTENANCE 5. To keep all productive assets in good working conditions 6. To eliminate / minimize accidents through regular inspection and repair of safety devices 7. To minimize the total maintenance cost
ADVANTAGES OF IMPLEMENTING MAINTENANCE 1. Production capacity Machines idled by breakdowns cannot produce, thus the capacity of the system reduced 2. Production costs Labor costs per unit rise because of idle labor due to machine breakdowns. When machine malfunctions result in scrap, unit labor and material costs increase ADVANTAGES OF IMPLEMENTING MAINTENANCE 3. Product and service quality Poorly maintained equipments produce low quality products. 4. Employee or customer safety Worn-out equipment is likely to fail at any moments and these failure can cause injuries to the workers 5. Customer satisfaction When production equipment break-down, product often cannot be produced according to the master production schedules
COST OF MAINTENANCE Breakdown (B/D) cost = labour + downtime Preventive Maintenance (PM) cost = labour + downtime due to planned shutdown Cost of sub-standard performance = loss in process material + scrapping of material + wastage Cost of spares = cost of spares + other materials
Cost related to Maintenance 1. Lubrication 2. Cleaning 3. Adjustments - Return or slowdown the process of deterioration or wear 4. Application of protective coating 5. Examination of the state of the components 6. Analysis of history of behaviour of the machine and its components 7. Replacement of worn out component
Cost related to Maintenance 8. Repair of cracks or other repairable damages 9. Modification of design of the components or location of the equipment 10. Capital replacement - Replacement of the machine when the age of the existing machine requirements of quality and quantity of output and emergence of better machines make it economical to dislodge the present and install a new machine
WORKPLACE SAFETY Benefits of clean and safe working environment: 1. Prevent accidental slips with or around dangerous tools and machine 2. OSHA (Act 514, 1994) compliance 3. Prevent Chemical hazards mists, vapour, gases, dusts and fumes 4. Prevent Physical hazards noise, vibration, extremes of temperature and excessive radiation
WORKPLACE SAFETY 5. Prevent Biological hazards mould , fungi, bacteria and insects 6. Prevent ergonomics hazard related to design and condition of the workplace 7. Reduce operation and production cost including accident cost and other cost due to accident 8. Reduce downtime and shutdown including lost work hours, medical costs, insurance premium and administration, property damage, fire losses and other indirect costs
WORKPLACE SAFETY Important of Personal Protective Equipment (PPE) PPE Includes devices and clothing designed to be worn or used for the protection of safety of an individual while in potentially hazardous areas or performing potentially hazardous operations. PPE most commonly used for protection of the head, including eyes and ears and the torso, arms, hands and feet. Head protection Prevent head injuries caused by falling or flying objects, such as working below other employees who are using tools and materials that could fall, or by bumping the head against a fixed object. (PPE- safety hats)
WORKPLACE SAFETY Safety glasses, chemical goggles, face shields, welding goggles, welding face shield) Ear protection Prevent from excessive noise exposure to avoid hearing damage. (PPE- ear plug, ear muffs) Respiratory Protection Appropriate respirators should be worn to prevent atmospheric contamination caused by articulates (dust/mist/fumes) or gases/vapors WORKPLACE SAFETY Torso Protection Protect torso treated by heat, splashes from hot metals and liquids, impacts, cuts, and acids. (PPE- vest, jackets, aprons, coveralls, full body suits, kevlars) Arm and Hand protection- Protect arm and against various hazardous situation. (PPE-gloves, hand pads, sleeves, wristlets Foot and Leg Protection For protection of feet and legs from falling or rolling objects, sharp objects, molten metal, hot surfaces, and wet slippery surfaces. (PPE Foot guard, safety shoes/boots, legging)
WORKPLACE SAFETY Organization that governs the safety of hazardous material: 1. Department of Occupational Safety and Health, DOSH 2. (Occupational Safety and Health Act (Use and standards of exposure of hazardous To Health Regulation 2000)) 3. Lembaga Pelesenan Tenaga Atom (AELB) Akta Perlesenan Tenaga Atom, 1984 Standard Perlindungan sinaran (standard asas Keselamatan) Peraturan-peraturan 1988 Act 304. 1. Chemical Industry Safety and Health Council 2. Chemical Industries Association Limited
WORKPLACE SAFETY Lockout/ Tag out System The purpose of these instructions is to ensure that before any employees performs any servicing or maintenance on machinery or equipment, where the unexpected energizing, start up, or release of any type of energy could occur and cause injury, the machinery or equipment will be rendered safe to work on by being locked out or tagged out. When an employee performs work on machines, equipment, or systems is exposed or causes other employees to be exposed to the hazards of unexpected energization, these procedures must be followed.
WORKPLACE SAFETY OSHA Regulations (Standards - 29 CFR)(USA) The control of hazardous energy (lockout/tagout). - 1910.147 Standard Number: 1910.147 Standard Title: The control of hazardous energy (lockout/tagout). SubPart Number: J SubPart Title: General Environmental Controls
This standard covers the servicing and maintenance of machines and equipment in which the "unexpected" energization or start up of the machines or equipment, or release of stored energy could cause injury to employees. This standard establishes minimum performance requirements for the control of such hazardous energy This standard applies to the control of energy during servicing and/or maintenance of machines and equipment.
WORKPLACE SAFETY Example of a tag out/lock out system
WORKPLACE SAFETY Each person places their lockout keys in the box which is padlocked by one controlling person. During a lockout, any person joining the work team places their keys through the open slot without exposing the keys inside. Only when the job is checked and finished will the controlling person unlock the box and re-issue the keys.
WORKPLACE SAFETY Heavy duty steel constructed group lockout box with yellow powder coated finish has a standard 40 hook key capacity. Clear Perspex door allows contents to be easily checked. Lockable with up to 6 padlocks, ideal for larger group lockout applications 450mm high x 380mm wide x 80mm deep
TYPES OF HANDTOOLS, POWER TOOLS AND MAINTENANCE EQUIPMENTS
GROUP ASSIGNMENT 1 (GROUP A & B) : - LIST THE TYPES OF HAND TOOLS D - DEMONSTRATE THE PROPER USE OF HAND TOOLS - DETERMINE THE IMPORTANCE OF INSPECTING HAND TOOLS DUE : WEEK 8 (31 ST JAN 2013) TYPES OF HANDTOOLS, POWER TOOLS AND MAINTENANCE EQUIPMENTS GROUP ASSIGNMENT 1 (GROUP C & D) : - LIST THE TYPES OF POWER TOOLS - DEMONSTRATE THE PROPER USE POWER TOOLS - DETERMINE THE IMPORTANCE OF INSPECTING POWER TOOLS DUE : WEEK 8 (31 ST JAN 2013)
PRACTICAL TASK GROUPING BIL KUMPULAN A BIL KUMPULAN B 1. 02DKM10F1060 MOHAMAD NAQIUDDEN BIN MOHAMAD NAZRI 1. 02DKM10F1090 MUHAMMAD FAHYADH FAHMI BIN ABDUL MALIK 2. 02DKM10F1056 MOHAMAD JAMALUDIN B SUHAIMI 2. 02DKM10F1048 AMIMZA BIN AHMAD 3. 02DKM10F1083 MUHAMAD SYAFAIZ BIN ZULKIFLI 3. 02DKM10F1084 MOHAMAD HUSNI BIN ASBUDI 4. 02DKM10F1092 AHMAD FARIS BIN MOHD IMARAM @ MOHD IMRAN 4. 02DKM10F1070 MOHAMAD AFIQ BIN MAT ROZALI 5. 02DKM10F1047 SYED MUHAMMAD YUSUF BIN SYED HASHIM 5. 02DKM10F1087 MOHAMAD AMIRUL SHAFIQ B. ABDUL RAZAK 6. 02DKM10F1116 MOHD NOR FAIZAN BIN ABD JALIL 6. 02DKM10F1065 MUHAMMAD FARIS BIN AZANAN 7. 02DKM10F1055 MUHAMMAD FAIZAL BIN MD ZOR 7. 02DKM10F1069 SHARUL NIZAM BIN YAAKOP BIL KUMPULAN C BIL KUMPULAN D 1. 02DKM10F1079 NURUL SYUHADA BTE ALIAS 1. 02DKM10F1075 MUHAMAD NUR FAIZ BIN HAMIDON 2. 02DKM10F1049 NUR ATIKAH BINTI ABDUL RAZAK 2. 02DKM10F1062 MOHAMAD HAZIQ IZHAM BIN NAZAR 3. 02DKM10F1063 MOHAMAD HAFIZ IZMER BIN NAZAR 3. 02DKM10F1051 MOHD SAFWAN BIN MD NOR 4. 02DKM10F1080 NASHRUL AQIM BIN JAAFAR 4. 02DKM10F1086 MOHAMAD AZMI BIN MOHAMED NAZARI 5. 02DKM10F1057 MUHAMAD YUSRIZAL BIN OTHMAN 5. 02DKM10F1082 MOHAMMAD HASRUL BIN JALALUDIN 6. 02DKM10F1088 MOHAMAD SYAHAQIL BIN ABD TALIB 6. 02DKM10F1076 MUHAMAD AZRI BIN AZIZ 7. 02DKM10F1072 HASAN BIN SAPARUDDIN 7. 02DKM10F1188 MEGAVARNAN A/L THANGGASELVAM 8. 02DKM10F1077 PAVITHRAN A/L PARAMSIVAN