AIT 105 - Modern Maintenance Operations

3 Credits, 5 Contact Hours
2 lecture periods 3 lab periods

Introductory course into the practice of modern maintenance operations. Includes correct and safe usage of maintenance tools (e.g., hand tools, power tools), measuring instrumentations (e.g., tape, caliper, micrometer) and reading various engineering documents (e.g., blueprints, flowcharts, parts diagrams). Also includes the use and conversion of units in SI and imperial. Includes basic discussion of industrial safety procedures, machine operations, troubleshooting, failure analysis, modern maintenance principles, rigging, workplace organization, and records keeping.

Course Learning Outcomes

Apply knowledge of machine maintenance and operation procedures and effects on factory outputs including machine operation, safety systems, e-stops, lock-out test-out tag-out, startup, shutdown, manual functions, maintenance practices and procedures, troubleshooting methodologies, Overall Equipment Efficiency (OEE) calculations, and measurements.
Describe the different documents related to maintenance operations and their responsible parties including operators manuals, exploded parts diagrams, service manuals, flowcharts, maintenance procedure, Standard Operating Procedures (SOPs), Safety Data Sheets (SDS), blueprint part and assemblies drawings with tolerances and basic Geometric Dimensioning and Tolerancing (GD&T).
Demonstrate the proper use of legacy and modern tools to perform maintenance operations including rigging tools, hand tools, power tools, and measuring tools.

Outline:

Machine maintenance, operation, and effects
1. Safe machine operation for production and maintenance
  1. Safety checklist:
    1. Ready/come online
    2. Correct operation of safety devices
    3. Check operation of machine interlocks
  2. Operation scenarios
    1. Startup
    2. Emergency shutdown
    3. Scheduled shutdown
    4. Manual functions
  3. Machine malfunction definition
  4. Standard operating procedures definition
  5. Machine shutdown indicators procedures
  6. Lockout process aka “Lock-out, Tag-out, Test-out”
  7. Modern and legacy machine safety systems
    1. Guards: physical and passive
    2. Interlocks: physical and passive
  8. E-stop categories: 1,2,3.
  9. Monitoring machines for production performance
  10. Confirming machine operations within specifications
  11. Observation of machine operation and vibration via five senses
    1. Correct machine operation
    2. Malfunction symptoms
  12. Evaluation of an operator’s adherence to machine procedures
  13. Leaks, dirt, and loose connections
  14. Measurement readings
    1. Pressure gauge
    2. Flowmeter
    3. Fluid level
    4. Temperature gauge
    5. Voltage
    6. Current
  15. HMI for machine monitoring
  16. Machine operation meets documented performance specifications
  17. Documentation of machine operation history (manual log or computer database)
2. Machine maintenance procedures
  1. Planned and unscheduled machine maintenance procedures
  2. Total productive maintenance (TPM)
    1. Definition
    2. Preventative maintenance
      1. Definition
      2. Benefits
      3. limitations,
    3. Predictive maintenance
      1. Definition
      2. Benefits
      3. Limitations
    4. Total company buy-in
    5. Maintenance and production communication procedures
  3. Use of Computer Maintenance Management Systems (CMMS)
  4. Work orders
    1. Reading
    2. Interpretation
    3. Resolution
  5. Autonomous maintenance
  6. Elements of a comprehensive maintenance plan
  7. Methods of eliminating unplanned maintenance events
  8. Types of preventive, planned/unplanned, and predictive maintenance procedures and tasks
  9. Contamination removal
    1. Source identification
    2. Removal methods
  10. Predictive maintenance plan
  11. Types of predictive maintenance methods and their applications using basic senses (hearing, feeling, smell, sight) and their techniques:
    1. Vibration analysis
    2. Thermography
    3. Oil analysis
    4. Acoustic analysis
    5. Motor current analysis.
    6. Performing predictive maintenance
3. Troubleshooting methodologies
  1. Methodologies to isolate problems to a particular sub-system, part, or a piece.
    1. 5-why
    2. Fishbone
    3. Flow charts
    4. Half-split method
    5. Root Cause Failure Analysis (RCFA)
    6. Parts diagrams
    7. Troubleshooting flow charts
  2. Effective interpersonal skills
    1. Production personnel
    2. Vendors
    3. Other colleagues
  3. Effective observation and interview strategies
    1. Problem validation
    2. Troubleshooting strategy determination
  4. Document analysis
    1. Production information documents
    2. Maintenance documents
    3. Operation documents
  5. Troubleshooting flowchart
4. Workplace organization methods
  1. Toyota Production System? (TPS)
  2. 5S
  3. 6S
  4. Lean manufacturing
  5. Kizens
5. Overall Equipment Efficiency (OEE) calculations & measurements
Maintenance operations documents
1. Machine operation and maintenance documentation
  1. Methods of storing machine operation and maintenance documentation
  2. Locating and interpreting documents
    1. Machine operation in Manual and Auto modes
      1. Identification of safety requirements and features
      2. Performance specifications
      3. Standard operating procedures
      4. Startup/shutdown procedures
  3. Spare parts lists, vendor sources, and maintenance procedures
  4. Machine operation history logs
    1. Computer-based
    2. Manual
    3. Safety data sheets
    4. Machine operating history from an HMI database
2. Machine lubrication and preventive maintenance schedules
  1. Company documentation
  2. Machine manufacturer documentation
3. Reading and interpreting technical drawings
  1. Line types
    1. Part
    2. Hidden
    3. Center
    4. Section
    5. Breakout Section
  2. Basic symbology
  3. Multi-view drawings of cylindrical and prismatic shaped parts
    1. 1st angle projection
    2. 3rd angle projection
  4. Metric and English dual dimension standards/types
  5. Dimension lines for linear, circular, and angular dimensions.
  6. Title blocks
  7. Feature sizes using a drawing scale
  8. Standard dimensional tolerance
  9. Geometric Dimensioning and Tolerancing (GD&T) per American Society of Mechanical Engineers (ASME) Y14.5
    1. Datums, MMC, LMC
    2. Feature control frames
    3. Symbols, and use of: Form, Profile, Orientation, Location, Runout
  10. Assembly drawings with Bill of Materials
  11. Blueprints
Legacy and modern tools
1. Rigging tools
  1. Types of tools
  2. Basic concepts and calculations of force, weight, volume, center of gravity, rated load, safety factors, and crush force
  3. Rigging safety
    1. Load capacity description and demonstration
    2. Inspection points, defects, damage, and contamination
    3. Corrective action
    4. Proper use of eyebolts and shims for lifting parts
    5. Proper containment methods to storage
  4. Basic rigging components and techniques
    1. Slings
    2. Chains
    3. Wire-ropes
    4. Come-a-longs
    5. Blocking
    6. Hoist
    7. Cranes
  5. Heavy load movement
    1. Horizontal movement
      1. Rollers
      2. Come-a-longs
      3. Dolly
      4. Pry-bar
      5. Truck
      6. Skates
    2. Vertical movement
      1. Manual and powered hoists
      2. Chain hoist
      3. Jacks
      4. Pry-bar
2. Hand tools
  1. Threaded and non-threaded fasteners
    1. Système international (SI) & Imperial (US) fasteners (bolts), washers, pins, nuts, and locking devices
      1. Nomenclature
      2. Identification by visual inspection and measurement
        
        Types
        
        Length
        
        Diameters (I.D., O.D., Major D., Minor D.)
        
        Thread pitch
        
        Thread tolerance
      3. Failure modes
      4. Construction
      5. Strength
    2. Force, torque, press fits,
      1. Dynamic and static torques
      2. Assembly tolerances and interference fit
    3. Proper fastener selection
    4. Methods to protect parts, hardware, and components during handling and storage.
  2. Basic hand tool safety rules and application for use and OSHA standards (decibel noise limits).
  3. Proper use of Common Hand tools
    1. Screw Divers
    2. Nut Drivers
    3. Hex Drivers
    4. Wrenches;
      1. Boxed end
      2. Open end
      3. Adjustable
      4. Ratcheting
    5. Ratcheting socket wrenches
      1. ¼ Drive
      2. ⅜ Drive
      3. ½ Drive
      4. Crows Foot
    6. Pliers
      1. Needle nose
      2. Slip joint aka standard
      3. Tongue and groove aka adjustable pliers
      4. Locking, aka channel-lock
      5. Safety wire twisting aka safety wire pliers
    7. Clamps
      1. C-clamp
      2. Trigger clamp
      3. Spring clamp
      4. Bench vice
    8. Mallets
    9. Cordless, electric brushless powered hand tools
      1. Drills with keyless chucks and clutch settings
      2. Hex impact drivers
      3. Square drive impact drivers
      4. Legacy drills with key chucks
  4. Assembling parts
    1. Types
      1. Threaded fasteners
      2. Washers
      3. Nuts
      4. Pins
      5. Keys
      6. Clips
      7. Snap rings
      8. Roll pins
      9. Tie-wraps (safety-wire)
    2. Tightening parts
      1. Bolt pattern sequence correction
      2. Torque correction with click type torque wrench
3. Measurement Tools
  1. Metric and inch pocket rulers and tape rulers
    1. Common inch fractional scales:
      1. 64th scale
      2. 32nd scale
      3. 16th scale
      4. 8th scale
    2. Common inch decimal scales
      1. 64th scale
      2. 50th scale
      3. 32nd scale
      4. 16th scale
      5. 10th scale
      6. 8th scale
    3. Common metric decimal scales
      1. 10th scale
      2. 50th scale
  2. Metric unit conversions
    1. Micrometer
    2. Millimeter
    3. Centimeter
    4. Kilometer
    5. Megameter
  3. Imperial and metric unit conversions
  4. Tool selection
    1. Calipers
      1. Digital
      2. Analog
    2. Micrometers
      1. Digital
      2. Vernier (Analog)
    3. Dial indicator
  5. Accurate use and measurement tool concepts
    1. Accurate use
      1. Resolution
      2. Repeatability
      3. Error types
    2. b. Measurement tool concepts
      1. Calibration
      2. Total Indicated Run-out (TIR)
      3. Flatness
      4. Indirect measurement
      5. Other features