Maintenance important questions
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This document outlines the topics covered in 5 units on maintenance engineering. It includes definitions of key terms, explanations of maintenance strategies and systems, discussions of reliability and failure analysis techniques, and descriptions of condition monitoring tools and processes. The overall document focuses on planning and optimizing maintenance to improve equipment reliability, availability, and safety while reducing costs. It covers both traditional and computer-based approaches.
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The document discusses different types of maintenance including breakdown, preventive, predictive, corrective, and periodic maintenance. It describes maintenance as preserving equipment and infrastructure by repairing and replacing parts. Effective maintenance planning considers people, location, time, tools, and maintenance information. Key benefits include less downtime, fewer errors and repairs, and improved reliability and safety. Common causes of machinery breakdown include improper maintenance, worn parts, and operator errors. Preventive maintenance software helps coordinate maintenance tasks and store related data.
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Maintenance management involves actions to restore equipment to working condition to maximize its useful life. The objectives are to maximize availability, reduce costs from breakdowns, extend equipment lifespan, and ensure safety. This is achieved through preventive maintenance which aims to identify and address issues before failures occur. There are two main types of maintenance - breakdown maintenance which repairs equipment after failure, and preventive maintenance which repairs equipment based on predictions or inspections to prevent failures. A maintenance department is developed to achieve these objectives through functions like developing policies, maintaining records, and scheduling planned maintenance.
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The document discusses different types of maintenance including breakdown, preventive, predictive, corrective, and periodic maintenance. It describes maintenance as preserving equipment and infrastructure by repairing and replacing parts. Effective maintenance planning considers people, location, time, tools, and maintenance information. Key benefits include less downtime, fewer errors and repairs, and improved reliability and safety. Common causes of machinery breakdown include improper maintenance, worn parts, and operator errors. Preventive maintenance software helps coordinate maintenance tasks and store related data.
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Definition, types of corrective maintenance, steps and cycle;
Measures of corrective maintenance are: Mean Corrective Maintenance Time , Median Active Corrective Maintenance Time, Maximum Active Corrective Maintenance Time.
Then different models : a system that can either be in up (operating) or down (failed) state; a system that can either be operating normally or failed in two mutually exclusive failure modes; a system that can either be operating normally, operating in degradation mode, or failed completely; a two identical-unit redundant (parallel) system. At least one unit must operate normally for system success.
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This document discusses maintenance and methods for tracking losses and overcoming losses through proper maintenance activities. It defines maintenance as actions to retain or restore equipment to its maximum useful life. The three main types of maintenance are preventive, breakdown, and corrective. Preventive maintenance includes periodic and predictive maintenance. Periodic maintenance involves spare part replacement on a predefined schedule, while predictive maintenance uses equipment like bearing meters to determine condition-based maintenance. Breakdown maintenance repairs equipment after failure. Corrective maintenance aims to improve reliability through kaizen activities to reduce downtime and increase time between failures. Key metrics like mean time to repair, mean time between failures, and uptime are also explained.
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This document discusses different layout configurations for flexible manufacturing systems (FMS). It describes five types of FMS layouts: progressive or line type, loop type, ladder type, open field type, and robot centered type. For each type, it provides a brief explanation of the layout and flow of parts. It also lists some factors that influence the selection of an FMS layout, such as availability of materials and labor, transportation infrastructure, and local business conditions.
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Maintenance categories – Comparative merits of each category – Preventive maintenance, maintenance schedules, repair cycle - Principles and methods of lubrication – TPM
Maintenance policies and preventive maintenance
Here are the answers to the assignment questions:
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Q2. The importance of maintenance includes identifying failure causes, deciding maintenance actions, providing equipment life and reliability information, and enabling spare parts management.
Q3. The main types of maintenance are planned maintenance (preventive, predictive, corrective) and unplanned maintenance. Preventive maintenance is carried out according to schedules and aims to reduce failures. Corrective maintenance is carried out after failure. Predictive maintenance aims to
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This document discusses different types of planned maintenance including preventive, corrective, predictive, and condition-based maintenance. It provides details on the objectives, elements, and steps involved in preventive maintenance. The key steps in preventive maintenance include analyzing the maintenance system, reviewing systems, prioritizing maintenance, training staff, and implementing the maintenance plan. Predictive maintenance allows maintenance to be performed just before failure based on equipment monitoring rather than on a set schedule. Both preventive and predictive maintenance aim to reduce downtime but predictive maintenance more precisely targets maintenance needs.
Possible Interview Questions/Contents From Manufacturing Technology II
1. Machining is a process that removes material from a workpiece through cutting or other shear mechanisms in order to change its shape or size. The three fundamental machining parameters are cutting speed, depth of cut, and feed.
2. Material removal rate is the volume of material removed per minute during machining operations like turning, where it is calculated as MRR=Vfd. Chip formation affects surface finish, cutting forces, temperature, tool life, and tolerances.
3. Tool wear occurs due to interactions between the tool and chip like adhesion and abrasion, leading to flank wear, crater wear, chipping, and breakage. Tool wear degrades surface finish and increases tolerances and machining
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The document introduces automation, defining it as a set of technologies that allows machines and systems to operate without significant human intervention. It discusses key areas of industrial automation like controls, communication, and real-time computing. Reasons for automating include increasing productivity, reducing costs, improving quality and safety. The basic elements of an automation system are described as the program of instructions, control systems, process, and power. Advanced functions like safety monitoring, maintenance diagnostics, and error detection and recovery are also introduced.
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Pneumatic circuits
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ME6012 M E 2 Marks & QB.pdf
This document discusses principles and practices of maintenance planning and condition monitoring. It defines key maintenance terms like maintenance, reliability, failure rate, mean time to failure, and discusses reliability analysis, predictive maintenance, and condition based monitoring techniques. The document also covers maintenance policies, preventive maintenance approaches, total productive maintenance, and repair methods for machine elements.
Om 3 rd
This document provides fully solved assignments for SMU MBA Spring 2014. It lists assignments for courses in Operations Management, including questions on inventory management, engineering processes, demand types, operations strategy, Markov analysis, and decision making factors. It also includes assignments for courses in Enterprise Resource Planning, Supply Chain Management, and Advanced Production and Operations Management. Students are instructed to send their semester and specialization name to a provided email or call a phone number to receive the solved assignments. Samples can also be found by searching blog archives or assignments. Mailing is preferred, but calling is suggested for emergencies.
SMU mba sem 4 om fall 2014 assignments
Smu Mba Sem 4 OM Fall 2014 Assignments, smu solved assignments, smu mba assignments, smu mba fall 2014 assignments
Hyundai 20 l(g) 7a forklift truck service repair manual
This document provides instructions for disassembling and assembling hydraulic components, including:
1. Hydraulic gear pump disassembly instructions involving removing mounting bolts, draining oil, marking parts for reassembly, and removing individual parts like shafts, seals, and bearing blocks.
2. Hydraulic gear pump assembly instructions covering installing new seals, pressing in the shaft seal, installing bearing blocks and gears, and torquing mounting bolts.
3. Main control valve assembly instructions involving stacking sections with o-rings installed, inserting tie rods, and torquing nuts to attach sections.
Cbc auto servicing nc iii
The document outlines the competency-based curriculum for Automotive Servicing NC III. It includes modules on basic competencies like communication skills, problem-solving, and technology use. Common competencies cover tasks like vehicle movement, measurement, and shop maintenance. Core competencies focus on skills for servicing systems like electrical, engine, transmission, and air-conditioning. Additional modules provide instruction on installing LPG conversion kits, testing and adjusting LPG systems, and servicing auto LPG components. The course aims to enhance skills in automotive servicing according to industry standards over 440 hours of training.
IETM Software: Guidelines to OEMs
All IETM shall contain information, which explains the purpose and scope (e.g., organizational level troubleshooting and corrective maintenance for a particular system), content, and organization of the IETM Software.
Climate Control Student Guide
Here are the key points about solid, liquid, and gas states from the passage:
- Matter can exist in three main states: solid, liquid, or gas. The state depends on the molecular structure and energy level.
- In solids, molecules are tightly packed in fixed positions. In liquids, molecules move freely but remain in contact with neighboring molecules. In gases, molecules move rapidly and are spread far apart with empty space between them.
- Adding or removing heat energy can change a substance between these different states. As heat is added, molecules gain kinetic energy and the substance changes from a solid to a liquid to a gas. Removing heat reverses this process from a gas to a liquid to a solid.
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Implementing effective preventive and predictive maintenance programs
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Network management. media management.material mgmt. aravind 9901366442
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Hyundai 20 l(g) 7a forklift truck service repair manual
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More from Narayanasamy Pandiarajan
Friction Stir Processing and Friction Surfacing – A Review.ppt
This document discusses friction stir processing and friction surfacing techniques. It provides examples of how friction stir processing can be used to refine microstructures and enable superplasticity in aluminum alloys. It also discusses using friction surfacing to create surface metal matrix composites with improved properties like wear resistance. The techniques offer advantages over traditional processing like reduced complexity, costs and avoidance of detrimental phases. Parameters like traverse speed and tool geometry influence the bonding and properties of the modified materials.
Welding_Dissimillar_Presentation_Kovilpatti.ppt
The document discusses corrosion behavior of friction stir welded aluminum alloys. It provides an introduction to aluminum alloys, describing their properties like high strength to weight ratio and ability to form a protective oxide film. It then describes the friction stir welding process and its advantages over traditional welding, such as being defect-free. The document discusses various types of corrosion like atmospheric, pitting, intergranular, and provides examples of corrosion related accidents highlighting the importance of corrosion prevention.
Strengthening_Mechanisms_Workshop.pdf
This document discusses various mechanisms for strengthening metals, including grain size reduction, solid solution alloying, strain hardening through cold working, and annealing. It defines each mechanism and explains how they increase the strength of metals by impeding the movement of dislocations. Specifically, grain size reduction strengthens metals by adding more grain boundaries that act as barriers to dislocation slip. Solid solution alloying introduces impurity atoms that distort the lattice and generate stress barriers. Cold working increases dislocation density within the metal, making it harder. Annealing relieves strain through recovery, forms new strain-free grains through recrystallization, and allows grains to grow through grain growth.
084 - ME8073, ME6004 Unconventional Machining Processes - Question Bank.pdf
This document contains questions and study material about unconventional machining processes. It covers various mechanical, electrical, chemical, electrochemical, and thermal energy based processes.
The document is divided into 5 units covering different unconventional machining techniques:
1. Mechanical energy based processes like abrasive jet machining and water jet machining.
2. Electrical energy based processes like electrical discharge machining.
3. Chemical and electrochemical energy based processes like electrochemical machining.
4. Thermal energy based processes like laser beam machining and plasma arc machining.
Each unit provides questions to test understanding of the principles, parameters, advantages, limitations and applications of the different unconventional
SYLLABUS COPY.docx
This document outlines the syllabus for a course on unconventional machining processes. The course is divided into 5 units that cover various unconventional processes including mechanical, thermal, electrical, chemical, and advanced nano finishing processes. Upon completing the course, students will be able to explain the need for unconventional processes and how they are classified, compare various thermal and electrical energy based processes, summarize chemical and electro-chemical processes, explain nano abrasive processes, and distinguish recent trends in unconventional machining processes.
UNIT I.pptx
The document discusses various unconventional machining processes including abrasive jet machining (AJM), water jet machining (WJM), abrasive water jet machining (AWJM), and ultrasonic machining (USM). It provides an overview of the working principles, equipment used, process parameters, material removal rate, and applications of each process. Specifically, it explains that AJM uses a high-speed stream of abrasive particles to remove material, WJM uses a high-velocity water jet, AWJM adds abrasive particles to the water jet, and USM removes material using abrasive particles oscillated at ultrasonic frequencies. The document also discusses factors for selecting among these unconventional machining processes.
Unit i and ii
Unconventional machining processes remove material without direct contact between the tool and workpiece using various forms of energy. They are classified based on the shape of material removed, mechanism involved, material removal method, and energy transfer medium. Some key unconventional processes include abrasive jet machining, which uses a high velocity abrasive particle stream; water jet machining, which cuts using high pressure water; and ultrasonic machining, where the tool vibrates at high frequency to erode material with abrasives. These processes allow harder materials to be machined with closer tolerances compared to conventional techniques.
Unit 5 thermal based energy process
Thermal energy based machining processes like electron beam machining (EBM), laser beam machining (LBM), and plasma arc machining (PAM) work by concentrating heat energy on a small area of the workpiece to melt and vaporize material. EBM uses a beam of high velocity electrons, LBM uses a focused laser beam, and PAM uses a high temperature plasma jet, all to remove tiny bits of workpiece material through localized heating and repetition of the process. While each has advantages like precision and lack of mechanical contact, they also have disadvantages like high equipment costs and low material removal rates.
Unit 4 chemical and electrochemical energy based processes
This document discusses various chemical and electrochemical machining processes. It describes chemical machining (CHM) which uses chemical etching to remove material from a workpiece. It involves using etchants and maskants to selectively remove material. Electrochemical machining (ECM) uses electrolysis principles to remove material from a workpiece submerged in an electrolyte solution. Variations include electrochemical grinding (ECG) which combines ECM with conventional grinding, and electrochemical honing (ECH) which uses non-conductive honing stones instead of a grinding wheel. These processes allow burr-free machining of complex shapes in hard and brittle materials with good surface finish and accuracy.
Unit 3 electrical energy based process
Electrical discharge machining (EDM) is a machining process that uses electrical sparks to remove material from a conductive workpiece. EDM works by producing sparks between an electrode tool and the workpiece submerged in a dielectric fluid, which erodes away tiny amounts of material. This allows EDM to machine very hard or brittle materials and create complex shapes regardless of material hardness. EDM provides a high-precision, burr-free finish and can machine thin walls and small features. Wire cut EDM is a similar process that uses a continuously moving thin wire as the electrode to cut intricate shapes.
Unit 2 mechanical energy based process
The document discusses three mechanical energy-based machining processes: abrasive jet machining (AJM), water jet machining (WJM), and ultrasonic machining (USM). In AJM, a high-speed stream of abrasive particles erodes material from the workpiece. WJM uses a high-velocity water jet to convert kinetic energy into pressure that removes small chips. USM forces an abrasive slurry against the workpiece using a vibrating tool to remove extremely small chips. Key parameters for each process include abrasive properties, pressure, velocity, vibration frequency, and more. Each method can machine hard materials and provides advantages like avoiding heat, being noiseless, or enabling intricate shapes.
Unit 1 introdction
This document discusses unconventional machining processes as an alternative to conventional machining. Unconventional machining is needed to machine harder materials and allows for closer tolerances and less residual stress than conventional methods. Unconventional machining processes are classified based on the type of energy used, such as thermal, electrical, electrochemical, chemical, or mechanical energy, and the mechanism of material removal, such as erosion, ionic dissolution, or vaporization. Selection of the appropriate unconventional machining process depends on factors like the physical properties of the material, the desired shape, the process capabilities, and economic considerations.
2 marks
Ultrasonic machining (USM) and abrasive jet machining (AJM) are unconventional machining processes. USM uses ultrasonic vibrations to cause abrasive particles in a liquid slurry to impact and remove material from a workpiece. It can machine very hard materials with high accuracy and no heat generation. AJM uses a high-velocity stream of abrasive particles in gas to erode material. It is useful for cutting brittle materials and can access difficult areas. Laser beam machining uses an intense laser beam to melt and vaporize material with precision and no physical contact.
Unconventional machining processes
Unconventional machining processes remove material from a workpiece using energy-based techniques rather than direct contact cutting tools. They are used for hard and brittle materials that are difficult to machine with conventional tools. Unconventional processes are classified based on the type of energy used, such as mechanical, electrical, electrochemical, chemical, or thermo-electrical. Examples include electrical discharge machining, which uses electric sparks, and abrasive jet machining, which uses a high-velocity abrasive stream. These processes allow harder materials to be machined with higher accuracy and surface finish compared to conventional techniques.
Ucm tables for unit 1
Unconventional Machining Processes introduces several machining techniques including ECM, EDM, EBM, LBM, PAM, USM, and AJM. It provides details on the physical parameters, shapes that can be machined, process capabilities, and process economies for each. ECM is best for deep holes, contour machining, and honing. EDM and USM are well suited for shallow holes. USM and EDM can machine precision through cavities. AJM and EDM are used for grinding. PAM is well suited for clean, rapid cuts and profiles. EBM can produce small holes and LBM is best for micro holes. The document compares the techniques and provides technical specifications
Ucm comparison
This document compares various unconventional machining processes including EDM, ECM, EBM, LBM, PAM, USM, AJM, and WJM. It provides details on the metal removal technique, suitable work materials, tool materials, metal removal rate, surface finish, power requirements, capital costs, efficiency, applications, and limitations for each process. The processes can machine a variety of conductive and non-conductive materials and are used for complex shapes that would be difficult with traditional machining. However, some have limitations such as lower metal removal rates, accuracy, or an inability to machine large or non-conductive workpieces.
Laser beam machining
Laser beam machining uses an intense, monochromatic laser beam to melt and vaporize workpiece materials. It involves focusing the laser beam using a lens to increase power density and melt or evaporate the material. When the xenon flash tube is activated, it excites chromium atoms in the ruby crystal which emit red light, stimulating additional emissions that are focused into a laser beam. This beam is used with gas to cut materials by melting and evaporating the workpiece. Laser beam machining can precisely machine very small and hard-to-cut features and is widely used for electronics, medical devices and other applications.
Edm
Electrical Discharge Machining (EDM) uses electric sparks to erode metal parts into complex shapes. In the EDM process, a metal electrode is placed close to the workpiece and a voltage is applied, generating sparks that melt and evaporate small amounts of metal. The melted metal is flushed away by a dielectric fluid like kerosene. By repeating this process, intricate shapes can be precisely cut into metal dies, molds, and other parts. EDM allows machining of hard metals and complex geometries that would be difficult or impossible with other methods.
Amt
Water jet machining uses a high-pressure water jet to cut materials. The system includes a hydraulic pump, intensifier, accumulator, and cutting head. The intensifier converts low-pressure water to an ultrahigh-pressure water jet of around 3800 bar that is directed through a nozzle. This jet can precisely cut a variety of materials without heat and is used for cutting, drilling, deburring, surface treatment, and more. It has advantages over other methods like no heat affected zone and flexibility but higher hourly costs than mass production methods.
Abrasive jet machining
Abrasive jet machining (AJM) is a mechanical energy based unconventional machining process that uses a high velocity abrasive jet to remove material from hard metallic workpieces. It works by mixing compressed gas with abrasive particles in a mixing chamber and forcing the abrasive jet through a nozzle onto the workpiece. Key components include an abrasive jet, mixing chamber, compressor, nozzle, and various pressure and flow controls. AJM can be used to drill, bore, finish surfaces, cut, clean, deburr, etch, trim, and mill hard materials.
Water jet machining (WJM) is a similar non-traditional machining process that uses high pressure water instead of an
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Maintenance important questions
- 1. UNIT-1 PART-A 1.What is the difference between maintenance and maintainability? 2. What is meant by maintenance planning? 3. Define reliability. 4. What is MTBF, MTTR&MTTF? 5. What is maintenance? list the objectives of maintenance? 6. What are the benefits of a sound maintenance system? 7. What is maintenance economics? PART-B 1. Briefly explain the following. MTBF MTTR MTTF 2. What are the important factor to be considered in maintenance planning? 3. What are the objectives and principles of planned maintenance? 4. What is equipment availability and describe the three basic approaches in dedail? 5. Explain the maintenance organization structure in dedail. 6. Briefly explain the reliability centered maintenance. 7. Explain maintenance economics. 8. Explain the important and benefits of a sound maintenance system. 9. Explain briefly different types and classes of maintenance organization. PART-C 1. Explain the various cost associated with maintenance. state the steps necessary to reduce the maintenance cost in an industry.
- 2. Unit 2 Part-A 1.Define TPM. What are the benefits of TPM? 2.Define Repair Cycle. 3.How the maintenance is categorized? 4.What is meant by Reliability Centered Maintenance? 5.What are the advantages of Preventive Maintenance? 6.What is Lubrication? why it is needed? 7.What is the difference between predictive and corrective maintenance? 8.List the various pillars of TPM. Part-B 1.Explain the various maintenance categories with their merits and demerits 2.What are the functions of Lubrication? Briefly explain the methods of Lubrication. 3.What is TPM? Briefly explain the procedure for TPM. 4.Explain the repair cycle. 5.Discuss the various stages involved in implementation of TPM. 6.With an example explain maintenance schedule. Part-C 1.What are the steps involved in Preventive Maintenance? why preventive maintenance is better than reactive maintenance? 2.What do you understand by maintenance categories? Explain common types and explain the basis of their selection?
- 3. Unit 3 Part-A 1.What is condition Monitoring and list control Monitoring Techniques. 2.What are the advantages of condition Monitoring? 3.What are the instruments used in condition Monitoring? 4.What are the types of wear? 5.Explain the role of condition Monitoring? 6.What is pistol Thermometer? 7.Write a short note on Wear Debris Analysis? 8.What is meant by Thermography? 9.What are the types of Condition Monitoring Techniques? Part-B 1.Explain various levels/methods of condition monitoring? 2.Explain on-line and off-line condition monitoring? 3.Explain the basic steps in condition monitoring? 4.Explain the various methods and instruments for CM? 5.Explain the pistol thermometer with neat sketch? 6.What are the benefits of CM? 7.What is Wear Debris Analysis? What are the three wear debris techniques commonly used and compare their performance and uses?
- 4. UNIT-4 PART-A 1.What is failure analysis. 2.What is fault tree diagram? List down the benefits of FTA. 3.Differentiate between fault tree diagram and reliability block diagram. 4.Define Root cause analysis. 5.What are the repair methods for slide ways, bearings, lead screw and gears? PART-B 1.With the neat sketch explain repair methods of Lathe bed and guide ways. 2.What are the methods followed to repair spindles, gears, lead screw and bearings? 3.Discuss the logical fault location and sequential fault locating methods. 4.Discuss the steps involved in performing FMEA. 5. Explain with neat sketch about Fault tree analysis. PART-C 1.Explain the failure analysis of a machine element of your own interest.
- 5. UNIT-5 PART-A 1.Write the major stages in material handling system. Inspection Repair Overall 2. What is CMMS? Function of CMMS. Benefits of Computer Maintenance. 3. What s Job card system? List down it. 4.What do you mean equipment record. 5.List any 4 material handling equipment. 6.Role of equipment record in Maintenance Engg. PART-B 1.Explain the maintenance strategies for the following, (or) Explain repair methods for following i)Crane ,ii)Conveyor, iii)Elevator, iv)Hydraulic lift. 2.Explain Job order system with example. 3.Explain in details Computerized maintenance management system. 4.Need and important of equipment record with suitable example. 5.Explain the repair methods for Chain, Rope, Trolley (or) Crane.