assignment

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LECTURE-2

- PREVENTIVE MAINTENANCE- HEALTH AND SAFETY GUIDELINE

15FMCE214: PREVENTIVE MAINTENANCE TECHNIQUES

Eng. Meryem Kanzari

▪ The role of Preventive Maintenance

▪ What is Involved in Preventive Maintenance

▪ The steps to create efficient Preventive Maintenance plan

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Learning Outcome

By the end of this chapter you should be able to describe:

Eng. Meryem Kanzari

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WHY PREVENTIVE MAINTENANCE ?

❑ Preventive maintenance is a routine for periodical inspection with the goal of noticing small problems and fixing them before major ones develop

▪ Protect assets and prolong the useful life of production equipment

▪ Improve system reliability ▪ Decrease cost of replacement ▪ Decrease system downtime ▪ Reduce injury

❑ Preventive maintenance helps to:

Eng. Meryem Kanzari

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WHAT IS INVOLVED ?

❑ To be effective, preventive maintenance function should incorporate the following elements:

▪ Planned replacements of components designed around the following:

o Maintaining equipment service records and Scheduled replacement of components

o Acquiring and maintaining inventories :least reliable components, critical components

o Replacing service-prone equipment with more reliable performers

Eng. Meryem Kanzari

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WHAT IS INVOLVED ?

▪ Exploratory maintenance to anticipate and prevent breakdowns. Diagnostic measures include:

o Operating and performing specifications of equipment

o Past experience with components: inspection records , servicing records, replacement frequency ,inspected component failures

o Regularly scheduled lubrication program: identify lubrication points on equipment and lubrication frequency

Eng. Meryem Kanzari

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IDENTIFYING MAINTENANCE HAZARDS

❑ To determine the exact nature of the hazards likely to be encountered during maintenance activities, the process layout of the area, and the equipment used should be examined .

❑ The hazard identification for maintenance tasks shall be conducted in advance of the activities by the employees who will carry out these tasks and must be shared with all involved employees.

Eng. Meryem Kanzari

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STEPS TO CREATE EFFICIENT PREVENTIVE MAINTENANCE PLAN

Eng. Meryem Kanzari

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In manufacturing engineering, process layout is a design for the floor plan of a plant which aims to improve efficiency by arranging equipment according to its function. The main advantage of the process layout is to provide visual control of activities, use space efficiently, and facilitate communication and interaction between workers and supervisors.

IDENTIFYING MAINTENANCE HAZARDS

Practical Process plant layout

Eng. Meryem Kanzari

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IDENTIFYING MAINTENANCE HAZARDS

❑ The hazards associated with maintenance activities can be classified as follows:

▪ Safety Hazards o Mechanical o Electrical o Pneumatic o Hydraulic o Thermal

Eng. Meryem Kanzari

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IDENTIFYING MAINTENANCE HAZARDS

▪ Health Hazards o Chemical Agents :process chemicals, cleaning solvents,

unexpected reaction products, dusts, etc. o Physical Agents: noise, vibration, etc.

▪ Ergonomic Hazards o Biomechanical: lifting, pushing, pulling (manual

handling), stretching, etc. o Work/process design: poorly designed tools, hard to

access work locations, ill fitting personal protective equipment, etc.

Eng. Meryem Kanzari

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CONTROLLING MAINTENANCE HAZARDS

❑ Ideally, the hazards likely to occur during maintenance activities should be addressed in the planning stage.

▪ Process Selection Depending on the nature of the process, special precautions may be needed to protect workers when disassembling and cleaning equipment. The following factors contribute to the level of risk of maintenance activities:

o How easy temporary structures are to erect o How easy they are to access o How much disassembly is required to access affected

equipment Eng. Meryem Kanzari

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CONTROLLING MAINTENANCE HAZARDS

▪ Equipment Selection: Selected process will determine the type of needed equipment while considering:

o Reliability: manufacturer’s data, in-plant operating experience

o Complexity of repair procedures o Ease and frequency of required lubrication o Manufacturer/supplier follow-up: availability of parts,

availability of service time.

Eng. Meryem Kanzari

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DEVELOPING PROCEDURES

❑ When servicing equipment, hazards are likely to be introduced. For this reason, it is important to:

o A clear, step-by-step procedure for disassembly and inspection in checklist form

o Identification of hazards associated with procedures and sub-procedures

o Selection and specification of personal protective equipment

o Selection and specification of tools to be used

▪ Prepare written servicing procedures that include the following:

Eng. Meryem Kanzari

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DEVELOPING PROCEDURES

▪ Examine each procedure thoroughly to ensure that the least hazardous method is selected

▪ Keep records of all your maintenance activities: indicating the machine(s) involved, the part(s) involved, type of maintenance and date on which performed.

Eng. Meryem Kanzari

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TRAINING

❑ Maintenance personnel need more thorough training in accident prevention than regular workers.

❑To avoid serious consequences, maintenance personnel should be well trained in:

▪ Hazard identification ▪ Selection, use, and care of equipment, machine tools, personal

protective clothing/equipment, etc. ▪ First-aid and life-saving techniques ▪ Control methods for substances which may be encountered in

the workplace such as irritating, toxic or corrosive dusts. ▪ How to inspect chains, blocks, fall protection devices and ropes ▪ Understanding stresses

Eng. Meryem Kanzari

16 Eng. Meryem Kanzari