AIT 105 - Modern Maintenance Operations

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

Introduction to 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. Further 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. Precsion Dimensional Measurement reading
  12. HMI for machine monitoring
  13. Documentation of machine operation history (maintance logs or computer database)
2. Machine maintenance procedures
  1. 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. Maintenance and production communication procedures
  2. Elements of a comprehensive maintenance plan
  3. Methods of eliminating unplanned maintenance events
  4. Types of preventive, planned/unplanned, and predictive maintenance procedures and tasks
  5. Types of predictive maintenance methods and their applications using basic senses (hearing, feeling, smell, sight) and their techniques
3. Troubleshooting methodologies
  1. Methodologies to isolate problems to a particular sub-system, part, or a piece
    1. Root Cause Failure Analysis (RCFA)
    2. Parts diagrams
    3. Troubleshooting flow charts
4. Workplace organization methods
  1. 5S
  2. Lean manufacturing
5. Overall Equipment Efficiency (OEE) calculations & measurements
Maintenance operations documents
1. 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. Assembly drawings with Bill of Materials
  10. Blueprints
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
      1. Types
      2. Length
      3. Diameters (I.D., O.D., Major D., Minor D.)
      4. Thread pitch
      5. Thread tolerance
    3. Failure modes
    4. Construction
    5. Strength
  2. Force, torque, press fits,
    1. Dynamic and static torques
  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
4. 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. Imperial and metric unit conversions
  3. Tool selection
    1. Calipers
      1. Digital
      2. Analog
    2. Micrometers
      1. Digital
      2. Analog
    3. Dial indicator
  4. Accurate use and measurement tool concepts
    1. Accurate use
      1. Resolution
      2. Repeatability
      3. Error types
    2. Measurement tool concepts
      1. Calibration
      2. Indirect measurement
      3. Other features