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REPAIR METHODS FOR MATERIAL HANDLING EQUIPMENT
- 1. RAMCO INSTITUTE OFTECHNOLOGY Mr.M.LAKSHMANAN Assistant Professor (Senior Grade) Department of Mechanical Engineering
- 2. UNIT V REPAIR METHODSFOR MATERIAL HANDLING EQUIPMENT
- 3. Syllabus Repair methods forMaterial handling equipment - Equipment records –Job order systems -Use of computers in maintenance.
- 4. Material Handling Material handlingis 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 AmericanSociety 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 successfulbrands 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 MaterialHandling • 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 MaterialHandling 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 orientedsystem 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 Maintenanceof 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 MaterialHandling 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 forHoists 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 PreventiveMaintenance 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 completemechanism 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 forconveyors • 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 PreventiveMaintenance 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 systemis completely dismantled, components, worn out and beyond repair item like belts, bearings, oil sealers, rollers, fasteners and couplings are replaced.
- 21. Typical scheduled conveyormaintenance 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 liftmaintenance 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 thehydraulic 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 tomaintenance 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 ofgood 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 thefollowing 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 • Improvemaintenance 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 ofmaintenance costs
- 30. General structure ofCMMS • Work order planning and scheduling • Maintenance store controls • Preventive maintenance • Maintenance reports
- 31. Work order planningand 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 workorder 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 flowdiagram
- 35. Work order Entry Workorder 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(workpermit System)
- 40. CMMS work orderplanning 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 materialmodule should provide the following information, Stock Quantity required Cost per item Description of item
- 42. Tool requirements: CMMS requirethe following information about the tool. Tool ID Description of tool Quantity required Cost of tool
- 43. CMMS work orderScheduling 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 CMMSmaintenance 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 reportcontains 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 orderbacklog summary • Equipment repair history • Equipment maintenance costs report • Safety work order backlog • Stock item usage report • Preventive maintenance overdue maintenance
- 47. Job Cards Job cardscontain 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 Jobcard 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 • Equipmentrecords 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 EquipmentRecords: • 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 EquipmentRecords • 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 constraintsin 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 isinterdepartmental 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 followingare 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 thissystem, 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.
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- 61. Cranes and hoists:- Overhead bridge cranes
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- 83. Pallet loader andunloader
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