This document provides an overview of a technical training for maintenance teams. It covers various topics related to industry safety, PPE use, machine safety, confined space safety, electrical safety, preventative maintenance, breakdown maintenance, proper tool use, common machine parts, electrical items, energy conservation, and increasing machine performance. The trainer is Engr. Md. Zakirul Islam and the training is aimed at engineers, technicians, and operators.

1. Technical Training for Maintenance Team
Perticipants: Engineers and Technical team with Operators
Trainer: Engr. Md. Zakirul Islam
Assistant Chief Engineer

2. Topics

7. Industry safety
Safety and Accidents in Industrial Plants
Factory safety refers to the management of all processes
and activities within a factory to protect its workers and
assets by reducing hazards, risks and accidents.
Main reasons include-
● Disorderly activities and environment
● Proper training
● Weak structure and management
● Inattentive thinking/inattentiveness
● No Safety P,P,E
● Mechanical problems
● Unsafe workplaces, activities
● Proper planning and preparation
● Gaps in communication
● Etc

8. PPE use

9. Height
work
safety

10. Confined
space
safety

11. Machine safety

12. Safety of
electricity

14. Others

15. Breakdown
Maintenance!

16. Advantages of Preventive Maintenance
Production downtime is reduced, machine breakdowns
are reduced.
Increases the life of the machine.
When machine parts wear out, they usually damage
other parts. Preventive measures therefore reduce
secondary failures and reduce repair costs.
The cost of planned maintenance is always low.
Safety measures are improved as well as helping to
produce quality products.
Disadvantages of Breakdown Maintenance
Breakdowns usually occur at inopportune times, making
it very difficult to fix the machine without sufficient
inventory.
Excessive delays in production reduce productivity and
adversely affect production planning.
Increases the chances of accidents and makes both
workers and machines insecure.
There is a direct loss of dividend.
Maintenance costs increase.

17. Use of proper equipment at work
Benefits:
1. Can work quickly
2. Waste of equipment is reduced
3. Chances of accidents are reduced
4. Corrosion of metal is reduced
5. It takes less energy during work
Misuse of equipment

18. 1
• Check your equipment regularly.
2
• Use the right tool for the job.
3
• Keep your equipment clean and in
good condition.
4
• Use proper safety equipment.
5
• Keep hands clean when working with
moving parts.

19. Bad practices for tools keeping Good practices for tools keeping

20. 1.Bearing
2.Belt
3.Lubricants
4.Gasket
5.Nut-Bolt
6.Seal
7.Valve
8.Pump
9.Electrical items
10.HVAC
Some goods/machines required for repair and their description

21. Bearing

22. Belt

24. Application for SKF bearings

25. Gasket
3 types of gasket
1. Metalic
2. Non metalic
3. Composite or semi metalic gesket

26. Nut bolt

27. Mechanical seal

30. Several types of HVAC we have using in factory
likes
1. AHU (Air handling unit)
2. Chiller
3. AC
4. Cooling tower
5. Panel AC
6. Fridge
7. Evaporative cooling fan (ECF)
8. Cooling conveyor
9. Water dispenser
10. Compressor dryer
Factory Application
What is HVAC?
H-Heating
V-Ventilation
AC-Air conditioning

31. How AC work?

32. Hazards/accidents caused by HVAC
1. Lack of preventive maintenance/checks.
2. 2. Applicable area isolation/lack of insulation.
3. 3. Electrical loose connection/over current.
4. 4. Not cleaning the filter on a regular basis.
5. 5. Compressor continues to run with full load.
6. 6. Refrigerant gas line leakage.
7. 7. Refrigerant gas increases to high pressure.
8. 8. Keep flammable items near AC.
9. 9. AC outdoor sunlight or indoor.

33. Inventory Time frame
Fast Moving Before 3 month
Slow Moving After 3 Month
Non Moving After 6 Month
Reasons for increasing repair costs Reasons for increasing inventory
1. If repairs are not done in time.
2. 2. If repairs are carried out by unskilled persons.
3. 3. Minimize the importance of small problems.
4. 4. If you don't follow the check list regularly.
5. 5. If SOP is not followed.
6. 6. If you don't use the right equipment.
7. 7. Unless using good quality parts.
1. If you bring more goods than necessary.
2. 2. Comes with wrong goods.
3. 3. Bringing unplanned goods.
4. 4. If fabrication items are made more.
5. 5. If you don't get the goods on time.

34. Relay Magnetic Contactor Over load relay Safety relay VFD Breaker
Types of swicth
Temperature
controller
PLC Monitor Sensor
Electrical items

36. Important record file for Maintenance

37. Types of energy we use directly or indirectly in our
factories.
1. Power
2. Water
3. Air
4. Steam
Energy Conservation

38. 1. Room door open
2. Insulation gape
3. Wall gape
4. Window gape
5. Extra gape for delivery conveyor
6. Mezzanine floor insulation/carpeting
gape
7. Metallic wall/pillar insulation gape
1. AHU run without production
2. Chiller run without production
3. Exhaust fan run without production
4. Floor light misuse in day
5. Cooling tower run without production
6. ECF use without production/without man
7. AC running unnecessary
8. Insulation absent/damage with cooling
line/steam line
9. Production running with less demand in
Friday
10. Machine running without production/less
speed
Cause of power wastage
Common causes All the reasons that are caused
by the cooling room

39. What can be done to prevent wastage of water
1. Using water songs
2. 2. Using as thin a pipe line as possible.
3. 3. Reuse the water used in the machine.
4. 4. Automate the basin.
5. 5. Fixing makeup line of cooling tower.
6. 6. Fixing leakage of water pipe line.
7. 7. Stop draining water from chiller tank.
8. 8. Do not use good water for road cleaning.

40. The process of making compressed air

41. Causes of Air Loss
1. Need to use more pressure.
2. 2. Use for cleaning.
3. 3. Using air directly.
4. 4. If the wind pipe line is too big.
5. 5. For leaks in air lines.

42. Causes of Steam Loss
1. If the insulation is missing or damaged.
2. 2. If more pressure is required.
3. 3. If the steam trap is damaged.
4. 4. If the PRV valve is broken.
5. 5. If there is leakage in the line.

43. Machine Performance by OEE Calculation

44. Ways to increase machine performance
1. Timely repair work is according to preventive maintenance.
2. Follow the checklist.
3. Timely use of lubricant or grease.
4. Regularly keep the rotating parts of the machine clean.
5. Operating the machine according to the readings of pressure gauge, temperature gauge.
6. If there is a bad noise from inside the machine, it should be repaired immediately.
7. Machine operation as per SOP.
1. Energy loss increases.
2. 2. Wastage increases in product production.
3. 3. Repair costs go up.
4. 4. Productivity decreases.
5. 5. Machine breakdown time increases.
The loss that occurs when the performance of the machine decreases

45. Preventive
maintenance
ME
Consumption
Inventory 5S and Safety
Power
consumption
by machine
Product
quality by
machine
Productivity
by machine