Condition Monitoring – Cost comparison with and without CM – On-load testing and offload testing –Methods and instruments for CM – Temperature sensitive tapes – Pistol thermometers – wear-debris analysis
PRINCIPLES AND PRACTICES OF MAINTENANCE PLANNINGlaxtwinsme
Basic Principles of maintenance planning – Objectives and principles of planned maintenance activity– Importance and benefits of sound Maintenance systems – Reliability and machine availability –MTBF, MTTR and MWT – Factors of availability – Maintenance organization – Maintenance economics.
If you want to help or donate please donate at my paypal:
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NJM
MM
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Maintenance Planning and Scheduling are key elements that influence the true success of any organization. Many times we have a planner or planner/scheduler, but do not know how to use him or her effectively or efficiently.
REPAIR METHODS FOR BASIC MACHINE ELEMENTSlaxtwinsme
Repair methods for beds, slide ways, spindles, gears, lead screws and bearings – Failure analysis –Failures and their development – Logical fault location methods – Sequential fault location
Condition Monitoring – Cost comparison with and without CM – On-load testing and offload testing –Methods and instruments for CM – Temperature sensitive tapes – Pistol thermometers – wear-debris analysis
PRINCIPLES AND PRACTICES OF MAINTENANCE PLANNINGlaxtwinsme
Basic Principles of maintenance planning – Objectives and principles of planned maintenance activity– Importance and benefits of sound Maintenance systems – Reliability and machine availability –MTBF, MTTR and MWT – Factors of availability – Maintenance organization – Maintenance economics.
If you want to help or donate please donate at my paypal:
dyokimura@gmail.com
Credits:
NJM
MM
SUPPORT ME:
https://www.buymeacoffee.com/dyokimura6
CHECK MY GAMING CHANNEL:
https://www.youtube.com/channel/UCoKOObshfyyxhVkw1VjyQNA
Maintenance Planning and Scheduling are key elements that influence the true success of any organization. Many times we have a planner or planner/scheduler, but do not know how to use him or her effectively or efficiently.
REPAIR METHODS FOR BASIC MACHINE ELEMENTSlaxtwinsme
Repair methods for beds, slide ways, spindles, gears, lead screws and bearings – Failure analysis –Failures and their development – Logical fault location methods – Sequential fault location
Principle, interaction of X-Ray with matter, imaging, film and film less techniques, types and use of filters and screens, geometric factors, Inverse square law, characteristics of films - graininess, density, speed, contrast, characteristic curves, Penetrameters, Exposure charts, Radiographic equivalence. Fluoroscopy- xero-Radiography, Computed Radiography, Computed Tomography
THERMOGRAPHY AND EDDY CURRENT TESTING (ET)laxtwinsme
Thermography- Principles, Contact and non contact inspection methods, Techniques for applying liquid crystals, Advantages and limitation - infrared radiation and infrared detectors, Instrumentations and methods, applications. Eddy Current Testing-Generation of eddy currents, Properties of eddy currents, Eddy current sensing elements, Probes, Instrumentation, Types of arrangement, Applications, advantages, Limitations, Interpretation/Evaluation
Liquid Penetrant Testing - Principles, types and properties of liquid penetrants, developers, advantages and limitations of various methods, Testing Procedure, Interpretation of results. Magnetic Particle Testing- Theory of magnetism, inspection materials Magnetisation methods, Interpretation and evaluation of test indications, Principles and methods of demagnetization, Residual magnetism
NDT Versus Mechanical testing, Overview of the Non Destructive Testing Methods for the detection of manufacturing defects as well as material characterisation. Relative merits and limitations, Various physical characteristics of materials and their applications in NDT., Visual inspection – Unaided and aided
Numerical Control (NC) machine tools – CNC types, constructional details, special features, machining centre, and part programming fundamentals CNC – manual part programming – micromachining – wafer machining
shaping, milling and gear cutting machineslaxtwinsme
Shaper – Types of operations. Drilling, reaming, boring, Tapping. Milling operations-types of milling cutter. Gear cutting – forming and generation principle and construction of gear milling ,hobbing and gear shaping processes –finishing of gears.
Types and characteristics of plastics – Moulding of thermoplastics – working principles and typical applications – injection moulding – Plunger and screw machines – Compression moulding, Transfer Moulding – Typical industrial applications – introduction to blow moulding –Rotational moulding – Film blowing – Extrusion – Thermoforming – Bonding of Thermoplastics.
Sheet metal characteristics – shearing, bending and drawing operations – Stretch forming operations – Formability of sheet metal – Test methods –special forming processes-Working principle and applications – Hydro forming – Rubber pad forming – Metal spinning– Introduction of Explosive forming, magnetic pulse forming, peen forming, Super plastic forming – Micro forming.
Introduction Hot Working and Cold Working of Metals Forging Processes- Open, impression die forging, Closed die forging-forging operation Rolling of metals-types of rolling- Flat strip rolling-shape rolling operation -Defects in rolled parts- Principle of rod and wire drawing-tube drawing -Principle of extrusion Types-hot and cold extrusion.
Cosmetic shop management system project report.pdfKamal Acharya
Buying new cosmetic products is difficult. It can even be scary for those who have sensitive skin and are prone to skin trouble. The information needed to alleviate this problem is on the back of each product, but it's thought to interpret those ingredient lists unless you have a background in chemistry.
Instead of buying and hoping for the best, we can use data science to help us predict which products may be good fits for us. It includes various function programs to do the above mentioned tasks.
Data file handling has been effectively used in the program.
The automated cosmetic shop management system should deal with the automation of general workflow and administration process of the shop. The main processes of the system focus on customer's request where the system is able to search the most appropriate products and deliver it to the customers. It should help the employees to quickly identify the list of cosmetic product that have reached the minimum quantity and also keep a track of expired date for each cosmetic product. It should help the employees to find the rack number in which the product is placed.It is also Faster and more efficient way.
Forklift Classes Overview by Intella PartsIntella Parts
Discover the different forklift classes and their specific applications. Learn how to choose the right forklift for your needs to ensure safety, efficiency, and compliance in your operations.
For more technical information, visit our website https://intellaparts.com
Democratizing Fuzzing at Scale by Abhishek Aryaabh.arya
Presented at NUS: Fuzzing and Software Security Summer School 2024
This keynote talks about the democratization of fuzzing at scale, highlighting the collaboration between open source communities, academia, and industry to advance the field of fuzzing. It delves into the history of fuzzing, the development of scalable fuzzing platforms, and the empowerment of community-driven research. The talk will further discuss recent advancements leveraging AI/ML and offer insights into the future evolution of the fuzzing landscape.
Industrial Training at Shahjalal Fertilizer Company Limited (SFCL)MdTanvirMahtab2
This presentation is about the working procedure of Shahjalal Fertilizer Company Limited (SFCL). A Govt. owned Company of Bangladesh Chemical Industries Corporation under Ministry of Industries.
Explore the innovative world of trenchless pipe repair with our comprehensive guide, "The Benefits and Techniques of Trenchless Pipe Repair." This document delves into the modern methods of repairing underground pipes without the need for extensive excavation, highlighting the numerous advantages and the latest techniques used in the industry.
Learn about the cost savings, reduced environmental impact, and minimal disruption associated with trenchless technology. Discover detailed explanations of popular techniques such as pipe bursting, cured-in-place pipe (CIPP) lining, and directional drilling. Understand how these methods can be applied to various types of infrastructure, from residential plumbing to large-scale municipal systems.
Ideal for homeowners, contractors, engineers, and anyone interested in modern plumbing solutions, this guide provides valuable insights into why trenchless pipe repair is becoming the preferred choice for pipe rehabilitation. Stay informed about the latest advancements and best practices in the field.
Welcome to WIPAC Monthly the magazine brought to you by the LinkedIn Group Water Industry Process Automation & Control.
In this month's edition, along with this month's industry news to celebrate the 13 years since the group was created we have articles including
A case study of the used of Advanced Process Control at the Wastewater Treatment works at Lleida in Spain
A look back on an article on smart wastewater networks in order to see how the industry has measured up in the interim around the adoption of Digital Transformation in the Water Industry.
Water scarcity is the lack of fresh water resources to meet the standard water demand. There are two type of water scarcity. One is physical. The other is economic water scarcity.
Student information management system project report ii.pdfKamal Acharya
Our project explains about the student management. This project mainly explains the various actions related to student details. This project shows some ease in adding, editing and deleting the student details. It also provides a less time consuming process for viewing, adding, editing and deleting the marks of the students.
Vaccine management system project report documentation..pdfKamal Acharya
The Division of Vaccine and Immunization is facing increasing difficulty monitoring vaccines and other commodities distribution once they have been distributed from the national stores. With the introduction of new vaccines, more challenges have been anticipated with this additions posing serious threat to the already over strained vaccine supply chain system in Kenya.
Hybrid optimization of pumped hydro system and solar- Engr. Abdul-Azeez.pdffxintegritypublishin
Advancements in technology unveil a myriad of electrical and electronic breakthroughs geared towards efficiently harnessing limited resources to meet human energy demands. The optimization of hybrid solar PV panels and pumped hydro energy supply systems plays a pivotal role in utilizing natural resources effectively. This initiative not only benefits humanity but also fosters environmental sustainability. The study investigated the design optimization of these hybrid systems, focusing on understanding solar radiation patterns, identifying geographical influences on solar radiation, formulating a mathematical model for system optimization, and determining the optimal configuration of PV panels and pumped hydro storage. Through a comparative analysis approach and eight weeks of data collection, the study addressed key research questions related to solar radiation patterns and optimal system design. The findings highlighted regions with heightened solar radiation levels, showcasing substantial potential for power generation and emphasizing the system's efficiency. Optimizing system design significantly boosted power generation, promoted renewable energy utilization, and enhanced energy storage capacity. The study underscored the benefits of optimizing hybrid solar PV panels and pumped hydro energy supply systems for sustainable energy usage. Optimizing the design of solar PV panels and pumped hydro energy supply systems as examined across diverse climatic conditions in a developing country, not only enhances power generation but also improves the integration of renewable energy sources and boosts energy storage capacities, particularly beneficial for less economically prosperous regions. Additionally, the study provides valuable insights for advancing energy research in economically viable areas. Recommendations included conducting site-specific assessments, utilizing advanced modeling tools, implementing regular maintenance protocols, and enhancing communication among system components.
Overview of the fundamental roles in Hydropower generation and the components involved in wider Electrical Engineering.
This paper presents the design and construction of hydroelectric dams from the hydrologist’s survey of the valley before construction, all aspects and involved disciplines, fluid dynamics, structural engineering, generation and mains frequency regulation to the very transmission of power through the network in the United Kingdom.
Author: Robbie Edward Sayers
Collaborators and co editors: Charlie Sims and Connor Healey.
(C) 2024 Robbie E. Sayers
4. Breakdown / Reactive Maintenance
• The equipment is allowed to operate till no
failure occurs. No maintenance work is
carried out in advance to prevent the failure.
• The people wait till equipment fails and
repair.
• Its ineffective and extremely expensive.
• Poor planning and incomplete repair will be
contributed for high maintenance cost.
5. Limitations of Reactive Maintenance
• Most repairs are poorly planned due to time
constraint caused by production and plant
management.
• This approach focus only on repair or the
symptoms of failure and not on the root
cause of failure.
6. Planned Maintenance
• Corrective Maintenance:
Its focused on regular planned tasks that will
maintain all critical machinery and system
in optimum operating conditions.
Main Objectives:
1. Eliminate breakdowns
2. Eliminate deviations from optimum
operating conditions.
3. Eliminate unnecessary repairs
4. Optimize all critical plant systems.
7. • Corrective maintenance can be defined as
a maintenance task performed to identify,
isolate, and rectify a fault so that the failed
equipment, machine, or asset can be
restored to an operational condition within
the tolerances
• Corrective maintenance is maintenance
which is carried out after failure detection
and is aimed at restoring an asset to a
condition in which it can perform its
intended function.
8. Preventive Maintenance
• It is the maintenance program which is
committed to the elimination or prevention of
corrective and break down maintenance.
• It involves periodical evaluation of critical
equipment, machinery to detect problem and
schedule maintenance task to avoid
degradation in operating conditions.
• Its designed for day to day maintenance like
cleaning, inspection, lubricating, retightening
etc., to retain the healthy condition of
equipment.
9. Benefits of Preventive Maintenance
• It maintains the equipment in good
condition to preventing them from bigger
problems.
• Prolongs the effective life of the equipment.
• Detect the problem at earlier stages.
• Minimize / eliminates the rework.
• Reduces unplanned downtime.
10. Predictive Maintenance
• It is a management technique that uses
regular evaluation of the actual operating
conditions of plant equipment, production
systems and total plant operation.
• Predictive maintenance as regard to
maintenance management, based on need,
will provide necessary data for scheduling
of preventive and corrective maintenance
tasks.
11. • Predictive maintenance (PdM) techniques are
designed to help determine the condition of in-
service equipment in order to predict when
maintenance should be performed. This approach
promises cost savings over routine or time-based
preventive maintenance, because tasks are
performed only when warranted.
12.
13. Its helps to improve/increase,
• The production capacity
• Product quality
• Overall effectiveness of production function.
Benefits of predictive Maintenance:
• Reduced breakdown losses
• Reduction of Quality defects
• Increased net operating profit
• Reduced maintenance cost
14. Condition Based Maintenance
• Condition-based maintenance (CBM),
shortly described, is maintenance when
need arises. This maintenance is performed
after one or more indicators show that
equipment is going to fail or that equipment
performance is deteriorating.
15. Condition Based Maintenance Techniques
• Vibration Monitoring:
Determines the actual condition of
equipment/machines by studying the noise or
vibration produced during functioning.
• Thermography:
Determines the condition of plant machinery,
system etc. by studying the emission of infra
red energy ( Temperature)
16. • Tribology:
Determines the dynamic condition of bearing
lubrication, rotor support structure of
machinery etc. by adopting any one of the
techniques like lubricating oil analysis and
wear particle analysis.
• Electrical motor Analysis
Determines the problem within motors and
other equipments.
• Visual inspection:
Determines the conditions of working
elements visually based on the experience.
17.
18.
19. Reliability Centered Maintenance (RCM)
• RCM is one of the well established
systematic and a step by step instructional
tool for selecting applicable and appropriate
maintenance operation types.
• It helps in how to analyze all failure modes
in a system and define how to prevent or
find those failures early.
20.
21. The rough process of RCM is as follows:
• Target products or systems of maintenance
should be clearly identified, and necessary
data should be collected.
• All possible failures and their effect on
target products or systems are
systematically analyzed.
22. Applications of RCM
• When designing, selecting and installing
new systems in a plant
• When setting up preventive maintenance for
complex equipment and systems for which
are not clear on how they work.
23. Total Productive Maintenance (TPM)
• In industry, total productive maintenance
(TPM) is a system of maintaining and
improving the integrity of production and
quality systems through the machines,
equipment, processes, and employees that
add business value to an organization.
• It’s a maintenance program which involves a
newly defined concept of maintaining plants
and equipments.
24. • To increase the production, at the same time
increasing employee morale and job
satisfaction.
• To maximize plant and equipment
effectiveness to achieve optimum life cycle
cost of equipment.
Goal of TPM
25. Evolution of TPM
• Dr.W.Edward Deming – Japanese Industry
• Nippon Denso of Toyoto groups – Quality
circle, Involving employees participation
26. Implementation of TPM
Stage I
Initialization
(Preparatory)
Stage II
Introduction on TPM
(Take off phase)
Stage III
Implementation
Stage IV
Institutionalization
(Stabilization Phase)
27. Stage I Initialization
(Preparatory Phase)
• Discussions with workers union
representatives
• Establish basic TPM policies and goals –
Analyze the existing condition
• Preparation and formulation of master plan
28. Stage II Introduction on TPM
(Take off phase)
• Formal presentation by top executive with
all employees attending.
• To get the full support of all employees.
• Also invite our external customers,
suppliers, contractors and affiliated
companies to get their supports.
29. Stage III Implementation
• 5’S Principle
• Autonomous Maintenance (JISHU HOZEN)
• KAIZEN
• Planned Maintenance
• Quality Maintenance
• Training
• Office TPM
• Safety, Health and Environment
30.
31.
32.
33. Stage IV Institutionalization
(Stabilization Phase)
• Once TPM has been implemented, it should
be properly monitored and evaluated and
some reward system can be introduced for
further encouragement.
• The Japanese institute for productive
maintenance runs an annual PM Excellence
Award.
35. Benefits of TPM
• Enhanced/ improved productivity and
overall efficiency
• Reduction of manufacturing cost.
• Customer satisfaction by delivering right
quantity at right time with expected quality.
• Minimization of accidents.
• High confidence level among employees.
36. Category TQM TPM
Objective To have quality
output
To have reliable
equipment
Means of achieving Through
systematized
management
Through active
participation of
employees
Target Minimized defective
through planned
preventive
maintenance
Elimination losses
and wastes
42. Major losses in an organization
• Equipment efficiency based losses
1. Failure/Breakdown losses
2. Setup/adjustment losses
3. Minor stoppage/ idling loss
4. Speed loss-Operating at low speeds
5. Defect/Rework loss
6. Scheduled downtime loss
• Human work efficiency based losses
1. Management loss
2. Operating motion loss
3. Line organization loss
4. Measurement and Adjustment loss
43. • Effective use of Production Resources
1. Energy loss
2. Die, Jig and Tool breakage loss
3. Yield loss
45. Pillar -5: Quality Maintenance(QM)
1. Its aimed towards customer delight by
getting them the highest quality through
defect free manufacturing.
2. Its focused on eliminating non
conformances in a systematic manner.
3. Understanding of what parts of the
equipment affect product quality and begin
to move potential quality
concerns.
46. Pillar -6: Training
Its aimed to have multi skilled employees
whose morale is high and who are eager to
work and perform all the required
functions independently and effectively.
Its not sufficient to know only “Know-How”
but they should also learn “Know-Why”.
47. Target:
Achieve and sustain downtime at zero on
critical machines.
Achieve and sustain zero losses due to lack
of knowledge/skills/techniques.
Aim for 100% participation in suggestion
scheme.
48. Pillar -7: Office TPM
• To improve productivity, efficiency in the
administrative functions and identify-
eliminate losses.
• Analyzing processes and procedures
towards increased office automation.
49. Office TPM Major Losses
• Processing loss.
• Cost loss (Accounts, Marketing, Sales)
• Communication loss
• Idle loss
• Set-up loss
• Accuracy loss
• Office equipment breakdown
• Communication channel breakdown(Telephone,
Fax Lines)
• Non availability of correct on line stock status
• Customer complaints due to logistics
50. Benefits of Office TPM
• Involvement of all people in support functions for
focusing on better plant performance.
• Better utilized work area
• Reduce repetitive work
• Reduced inventory levels in all parts of the supply
chain.
• Reduced administrative cost
• Reduction in number of files
• Reduced manpower
• Clean and pleasant work environment
51. Pillar -8: Safety, Health and Environment
• Zero accident
• Zero health damage
• Zero fires
52.
53. Maintenance Scheduling
• Maintenance scheduling is a joint maintenance
operations activity in which maintenance agrees to
make the resources available at a specific time
when the unit can also be made available by
operations.
55. 1. Planner
He/She should ensure that the work is properly
planned with respect to customer requirements,
Stores material, directly purchased materials, etc.
also work to be carried out with line of safety
requirements should be described.
56. 2. Scheduler
He/She should ensure that,
• Trades are available to conduct the work
during the schedule duration.
• Materials and service availability.
• Communicating the details of the above to
person involved in maintenance and
operation.
57. 3. Maintenance Supervisor
He/She will be responsible for the day to day
activities comprised in weekly schedule and
also determine the business availability.
4. Craftman:
He/She execute the assigned task and keep
informing the maintenance team, the outcome
as well as any practical difficulty in their part,
for any further analysis.
58. 5. Storeroom personnel:
They maintain the records of receipt of goods
and notify if any damage exists.
6. Operation Superintendent:
He must be kept informed in advance about
the equipment condition.
7. Operator:
He is the person responsible for securing the
equipment and report back to maintenance
personnel if any deviation is observed.
59.
60.
61. Maintenance
Scheduling
Principles
Schedules are
important job
priorities are
important
Schedule from
forecast of
highest skills
available
Schedule for
every
workhour
available
Crew leader
handles current
day’s work
(Daily
schedules)
Measures
performance
by analysis of
schedule
compliance
Plans with
lowest
required
skill level
62. Repair
• To restore to a good or sound condition
after decay or damage.
• Inspection(I)
• Minor Repair (R1)
• Major Repair(R2)
• Overhauling(O)
63. Repair Cycle
• The repeated performance of all/some of
the above mentioned activities in sequence
between successive overhauling is termed
as Repair Cycle.
65. Lubrication
• To reduce wear and heat between contacting
surfaces in relative motion.
• Coefficient of friction could be reduced and inturn
heat and wear of the surfaces.
• Lubrication also aids to
1. Reduce oxidation and rust formation
2. Transmit mechanical power in hydro fluid
power systems.
3. Seal against dust, dirt and water.
66. Lubricants
• Any materials used to reduce friction between
wearing surfaces with high coefficient of
friction, by establishing low viscous film are
called lubricants.
Methods of Lubrication:
• Hydrostatic Lubrication
• Hydrodynamic/ Fluid film Lubrication
• Boundary Lubrication
• Elasto hydrodynamic Lubrication (EHD)
• Extreme pressure Lubrication (EPL)
67. Method of lubrication is based on:
Mean fluid film thickness
R =
Surface Roughness
Where,
R is less than or equal to 1 for Boundary/Hydrostatic
Lubrication
R is in between 5 and less than or equal to 100 for
mixed lubrication or EHD/EPL
R is between 1 and 5 for fluid film lubrication
68. 1. Hydrostatic Lubrication
A thin film of lubrication is created between
the journal and the bearing by supplying
lubricant under pressure with an external
source like pump.
69. 2. Hydrodynamic/ Fluid film Lubrication
In heavy loaded bearing such a thrust
bearings and horizontal journal bearings
apart from viscosity of fluid, higher fluid
pressure is also required to support the
load.
In hydrodynamic lubrication a fluid wedge is
formed by the relative surface motion of the
journals over their bearing surfaces.
72. 3. Boundary Lubrication
When a full fluid film is not developed
between rubbing surfaces, the thickness of
film may be reduced so that dry contact is
formed at high points of mating surfaces.
Ex: Gear Teeth
73. 4. Elasto hydrodynamic Lubrication (EHD)
• The lubrication principle is applicable to
rolling bodies such as ball or roller bearings.
• Elastic deformation of the contacting bodies
under load and hydrodynamic effects
forcing the lubricant to separate the
contacting surfaces while the pressure of
the load is deforming them.
• Ex: Ball bearings
74.
75. 5. Extreme pressure Lubrication (EPL)
In heavy loading applications, oil temperature
raises beyond the anti wear protection.
Under this situation lubricants containing
additives that protect against extreme
pressure (EP) lubricants are used.
EPL can be achieved by chemical compounds
of boron, phosphorus, sulphur, chloride or
combination of these.