Repair methods for Material handling equipment - Equipment records –Job order systems -Use of computers in maintenance.

1. RAMCO INSTITUTE OF TECHNOLOGY
Mr.M.LAKSHMANAN
Assistant Professor (Senior Grade)
Department of Mechanical Engineering

2. UNIT V
REPAIR METHODS FOR MATERIAL
HANDLING EQUIPMENT

3. Syllabus
Repair methods for Material handling
equipment - Equipment records –Job order
systems -Use of computers in maintenance.

4. Material Handling
Material handling is the function of moving
the right material to the right place in the
right time, in the right amount, in sequence,
and in the right condition to minimize
production cost.

5. According to American Society of Material
Engineers
“Material handling is an art & science
involving the moving, packing & storing of
substances in any form.”
• It involves movement of material
mechanically & manually in batches or one by
one within the plant.

6. The most successful brands in the world uses
material handling and logistic solutions to
gain competitive edge,
 Toyota
 Wal-Mart
 Disney
 Coca Cola
 NASA
 John Deere
 Mitsubishi
 Pepsi-Cola

7. Goals of Material Handling
• The primary goal is to reduce unit costs of
production
• Maintain or improve product quality, reduce
damage of materials
• Promote safety and improve working conditions
• Promote productivity
material should flow in a straight line
use gravity! It is free power
move more material at one time
mechanize material handling
automate material handling

8. Types of Material Handling Systems
1. Equipments oriented systems
a) Convey or Systems
b) Tractor transfer system
c) Fork lift truck
d) Industrial truck system
e) Underground system
2. Material Oriented Systems
a) Unit handling system
b) Bulk handling system
c) Liquid handling system

9. 3. Methods oriented system
a) Manual systems
b) Automated systems
c) Job shop handling system
d) Mass production system
4. Function oriented system
a) Transportation systems
b) Conveying systems
c) Transferring systems
d) Elevating systems

10. Material Handling Equipments (MHE)
MHE is mechanical device for handling of
supplies with greater ease and economy.
The movement may be horizontal, vertical
or combination of both.
MHE is used for the movement , storage,
protection, consumption and disposal of
materials within a facility or at a site.

11. Various MHE are,
Carts, hand trucks, Fork lifts, conveyors, self
pickers, motorized pallet jacks (hand
trucks), tractor and specialized industrial
trucks powered by electric motors or
internal combustion engines.

12. Need for Maintenance of Material
Handling Equipment
• The breakdown, failure or malfunction of
material handling equipment can cost a
company time and money.
• MHE needs to be maintained to provide long
uninterrupted service and help to maintain
high efficiency.
• To reduce the cost of expensive repairs as a
result of a breakdown and reduction in the
potential for personal injury.

13. Maintenance of Material Handling
Equipments
• Preventive maintenance helps to keep the material
handling equipments always in running conditions
thereby minimizing the interruption during
operation.
• A periodic inspection and minor alignment may be
adequate to prevent the equipment breakdown.
Three stages of Preventive Maintenance:
 Inspection
 Repair
 Overhaul

14. Maintenance strategies for Hoists and Cranes
1. Portable Cranes:
• To keep loads within design limits on portable
cranes that are mounted on wheels.
• Frequent inspection of brakes, load hoisting.
• Inspection of bottom, base of platform for any sign
of stress (Cracks, Bends, etc.)

15. 2. Overhead cranes
• Keep the attachments in overhead cranes
loaded within the rating capacity.
• Keep rail level grounded, properly aligned,
properly spaced and securely attached to the
supporting structure.
• Examine over speed sensing/stopping
mechanisms, brakes and clutch, pins, gears,
cables, hooks, rails etc., for wear and
maladjustment.
• Check welded connections for cracks, bends,
abrasion and corrosion.

16. Stages of Preventive Maintenance for
Cranes
 Inspection:
All parts, open or covered are inspected for wear and
tear. Worn out or unworkable components like wire
ropes, wheels, bearings, bolts, etc., are removed.
 Repair:
The repairable parts of the system after inspection are
corrected for small repairs and minor defects and
rectified.
Systems like open gear transmission, coupling, riveted
and bolted joints, trolley and brakes may be repaired
according to the needs.

17.  Overhaul:
Dismantling complete mechanism and replacing all
damaged components.
Crank structure, buffers, rails, open gear transmission,
pulley blocks, etc may be replaced to ensure smooth
operation.

18. Maintenance strategies for conveyors
• Inspect the rollers, bearings, chains and
belts are subjected to wear and tear.
• Check conveyors to detect any belt slippage,
dragging or defective rollers.
• Be sure that all necessary guards are in
place to protect workers from mechanical
injury.

19. Stages of Preventive Maintenance for
Conveyors
 Inspection:
Belts and rollers are inspected for tension, wear
and tear. Gear box is properly lubricated,
various fasteners are tightened and safety
guards are checked.
 Repair:
Rollers and belts are adjusted or repaired.
Couplings, safety guards, steel structures, gear
transmission, bearing, fastener joints, etc are
repaired as per their conditions and
requirements.

20. Overhaul:
The conveyor system is completely dismantled,
components, worn out and beyond repair item
like belts, bearings, oil sealers, rollers,
fasteners and couplings are replaced.

21. Typical scheduled conveyor maintenance
plan
• Check/lubricate all bearings, universal joints
and pulleys.
• Check chain tension, wear and lubricate
• Check sprocket alignment, wear and screw set
• Check belt tension and wear
• Check electrical connections at conveyor
• Check gearbox and fill with lubricant to proper
level.
• Check general condition of system
• List any item requiring replacement or repair

22. Typical scheduled lift maintenance plan
• Check all safety devices on unit, such as
up/down limits, door switches, pressure relief
valves, etc.
• Check for presence and proper setting of all
snap rings and clips on axles, cylinders.
• Check rollers, pins and bushings for any sign of
wear such as flat spots, missing fasteners and
dislodged bearing material.
• Inspect all welds under and around the lift for
fatigue or failure.

23. • Check the hydraulic fittings for cracks or leaks
and cleanup any beneath the cylinders.
• Check hoses and electrical lines for abrasions
• Check general condition of lift. Operate the lift
after service. Check for any abnormal noise or
vibrations.
• List any items requiring replacement or repair.

24. Systems approach to maintenance
A good maintenance management can be
considered as having six phases.
1. Work identification
2. Planning
3. Scheduling
4. Execution
5. Recording
6. Analysis

25. Six phases of good maintenance management

26. Computerized maintenance management
system (CMMS)
• To integrate the decision support tools in
maintenance planning and execution for the
efficient discharge of the maintenance function.
• CMMS is used to track all maintenance costs
and equipment repairs.
• It is also achieved by the monitoring of
purchase and inventory costs.
• It can reduce over maintenance and increase
uptime and extended the life of the facilities
and equipment.

27. CMMS includes the following aspects:
• Development of database
• Analysis of available past records
• Development of maintenance schedules
• Availability of maintenance materials
• Feedback control system
• Project management

28. Advantages CMMS
• Improve maintenance efficiency
• Reduce maintenance cost
• Reduce equipment downtime by proper
scheduling
• Reduce the overtime and ensures optimal
utilization of manpower
• Increase the life of equipment
• Provide historical database to assist in
maintenance planning and budgeting
• Quicker access to plant maintenance statistics
• Conformity with health and safety standards.

29. Overall reduction of maintenance costs

30. General structure of CMMS
• Work order planning and scheduling
• Maintenance store controls
• Preventive maintenance
• Maintenance reports

31. Work order planning and scheduling
Computerized work orders are documents
that detail maintenance works.
Work order contains following information
such as:
• Work order
• Details of equipment for which work is
requested
• Description of work type of work such as
emergency, routine, preventive
maintenance, etc.

32. Work Order
A work order is an order received by an
organization from a customer or client, or an
order created internally within the
organization. A work order may be for
products or services.

34. Work order flow diagram

35. Work order Entry
Work order entry requires following
information to be filled by the user:
• Equipment number that requires
maintenance
• Priority and description of the work
• Estimated cost of work
• Information for dependent or associated
work tasks for a complex maintenance job.

36. Work order Backlog
• Maintenance backlog is made up of work that
needs to be completed for safety reasons and
to avoid further asset breakdown
• Example: an oil change for your truck is
scheduled for every 5000 miles.
• Its storage area for all active work orders. As
they entered, the work orders are taken by
CMMS and placed in the backlog files.
• These data of work orders will remain in the
system until they are either cancelled or
completed. Using the backlog, its possible to
look through all active work orders.

37. Work Order Systems
• The work order system is the information
system for the maintenance organization.
• Its important for an organization to
maintain proper records to perform any
meaningful analysis on its policies and
procedures. Its especially on the equipment
under their maintenance.
• It assist the plant in keeping track of
priorities, planning, scheduling, analyzing
and controlling maintenance work.

38. Maintenance work order
• Work order number and code
• Department address and code
• Date of issue
• Details of approval
• Date of receipt of work order
• Priority
• Location
• Equipment details
• Nature of work
• Materials requirements
• Completion date and report
• Special requirements

39. Work order control(work permit System)

40. CMMS work order planning
1. Labour requirements
2. Material requirements
3. Tool requirements
Labour requirements (Crafts):
Work order will require different crafts,
depending on the type of work to be performed.
The following information may be required by
CMMS environment,
 Craft
 Number of craftsmen
 Planned hours

41. Material requirements:
The material module should provide the
following information,
 Stock
 Quantity required
 Cost per item
 Description of item

42. Tool requirements:
CMMS require the following information
about the tool.
 Tool ID
 Description of tool
 Quantity required
 Cost of tool

43. CMMS work order Scheduling
Work order scheduling contains the list of
work orders to be performed. Scheduling
module of CMMS contains the following
information:
 Weekly schedules
 Work order completion
 Work order cost charges
 Labour records

44. Maintenance store controls
CMMS maintenance store module contains the
following information to satisfy its objectives:
• Store stock material issue status
• List of planned materials
• Stock return
• Stock item work order reference
• Store catalog-stock number
• Purchase order enquiry
• Purchase order update
• Purchase material receipts
• Stock return to the vendors

45. Maintenance Reports
This report contains the following informations:
• Work order priority analysis
• Planner efficiency
• Supervisor work order performance
• Skill work order performance
• Work order costs report
• Completed work order performance (total
labour cost, cumulative costs and labour hours
by craft)

46. • Work order backlog summary
• Equipment repair history
• Equipment maintenance costs report
• Safety work order backlog
• Stock item usage report
• Preventive maintenance overdue
maintenance

47. Job Cards
Job cards contain necessary details for
performing individual job in maintenance. It
may be in the form of a card, sheet o printout.
Job cards contains the following information:
• Equipment code and shop code
• Job code
• Nature of job & job details
• Job start and completion time
• Man power requirements
• Constraints /deviations

49. Benefits of Job card system
• Information about maintenance history
• Know the frequency of maintenance for
equipments
• Details of equipments
• Helps in job auditing
• Evaluation of cost of maintenance
• Information about equipment down time
• Estimation of loss of production
• Idea about man power utilization

50. Equipment Records
• Equipment records are information the
details of installation, service, repair,
maintenance activities, conditions, defects,
schedules and plans for future
implementation.
• Its used to control maintenance cost,
reliability and availability.

51. Types of Equipment Records:
• Planned work and percentage of planned work
achieved
• Ratio of planned to planned work
• Production delays and downtime
• Ratio of preventive work to corrective work
• Failure patterns
• Repetitive breakdown
• Instruction and operating manuals
• History cards and records
• Maintenance requirement records
• Cost reports
• Condition monitoring reports

52. Advantages of Equipment Records
• Clear picture about the details of
maintenance programme is obtained.
• Information about completed, pending and
regular jobs carriedout to the equipment are
available.
• Helps in standardization of procedures.
• Evaluation of performance of maintenance
tasks.
• Comparison of time taken for completing
the maintenance job with the past records.

53. Maintenance work execution, monitoring and
control
1. Monitoring:
• Gather information about deviation and
delay in execution of maintenance may
provide idea about the need to add more
resources to complete the maintenance
task in scheduled time frame.
• Communication of the changes in job
content to the various follow up agencies.

54. • Provide constraints in technical issues and
necessary steps can be taken to improve the
existing techniques.

55. Methods of Monitoring
• Brief meeting with maintenance personnel to
monitor the day to day maintenance activities.
• Repair coordinator: repair coordinator is
responsible to coordinate with various
agencies and to inform the maintenance
organization about deviations and corrective
actions taken.
• Line of Balance Methods
• Circulation of monitoring reports and progress
to create awareness to various functional units
of the industry.

56. 2. Feedback:
Feedback is interdepartmental or intra
communication related to the maintenance
tasks.
The feedback may contain following information:
• Unscheduled/Pending jobs
• Work status
• Suspended work
• Work completion
• Manpower requirements and actual utilization
• Cost of maintenance
• Technical difficulties

57. 3. Control:
The following are the three important role of
control of maintenance activities:
• Continuous or periodical monitoring
• Inspection of status
• Comparison of status with the
predetermined standard and initiating
corrective measures.

58. • In this system, there is a constant
interaction between shop supervisors and
maintenance task executors.
• This is the mechanism to drive the activities
to the maintenance objectives of the
organization through suitable delegation of
responsibilities at different levels of the
organization.

59. Maintenance Control system

60. Work order tree

61. Cranes and hoists:-
Over head bridge cranes

62. Jib Cranes

63. Gantry crane

64. Electrical hoists

65. Automated Guided Vehicles

66. Elevators

67. Stacker Crane

68. Monorail

69. Conveyors:-
Belt Conveyors

70. Roller conveyors

71. Bucket conveyors

73. Screw conveyors

74. Vibratory conveyors

75. Trucks

76. Tractors

77. Trailers

78. Rails

79. Ropeways and cableways

80. Pipelines

81. Auxiliary equipments
Weighing equipments

82. Containers

83. Pallet loader and unloader

84. Ramps

85. Dock boards