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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.

1. 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.
2. 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).
3. Demonstrate the proper use of legacy and modern tools to perform maintenance operations including rigging tools, hand tools, power tools, and measuring tools.

A. Safe machine operation for production and maintenance  

1. Safety checklist:

a. Ready/come online

b. Correct operation of safety devices

c. Check operation of machine interlocks

2. Operation scenarios

Startup

a. Emergency shutdown

b. Scheduled shutdown

c. 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

a. Guards: physical and passive

b. 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

a. Correct machine operation

b. Malfunction symptoms 

12. Evaluation of an operator’s adherence to machine procedures

13. Leaks, dirt, and loose connections

14. Measurement readings

a. Pressure gauge

b. Flowmeter

c. Fluid level

d. Temperature gauge

e. Voltage

f. Current

15. HMI for machine monitoring

16. Machine operation meets documented performance specifications 

17. Documentation of  machine operation history (manual log or computer database)

B. Machine maintenance procedures 

1. Planned and unscheduled machine maintenance procedures 

2. Total productive maintenance (TPM) 

a. Definition

b. Preventative maintenance

i. Definition

ii. Benefits

iii. limitations, 

c. Predictive maintenance

i. Definition 

ii. Benefits

iii. Limitations

d. Total company buy-in

e. Maintenance and production communication procedures 

3. Use of Computer Maintenance Management Systems (CMMS)

4. Work orders

a. Reading

b. Interpretation

c. 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

a. Source identification

b. 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:

a. Vibration analysis

b. Thermography

c. Oil analysis

d. Acoustic analysis

e. Motor current analysis.

f. Performing predictive maintenance

C. Troubleshooting methodologies

1. Methodologies to isolate problems to a particular sub-system, part, or a piece.

a. 5-why

b. Fishbone

c. Flow charts

d. Half-split method

e. Root Cause Failure Analysis (RCFA)

f. Parts diagrams

g. Troubleshooting flow charts

2. Effective interpersonal skills

a. Production personnel

b. Vendors

c. Other colleagues

3. Effective observation and interview strategies

a. Problem validation

b. Troubleshooting strategy determination

4. Document analysis

a. Production information documents

b. Maintenance documents

c. Operation documents

5. Troubleshooting flowchart

D. Workplace organization methods

1. Toyota Production System? (TPS)

2. 5S

3. 6S

4. Lean manufacturing

5. Kizens

E. Overall Equipment Efficiency (OEE) calculations & measurements

II. Maintenance operations documents

A. Machine operation and maintenance documentation

1. Methods of storing machine operation and maintenance documentation 

2. Locating and interpreting documents

a. Machine operation in Manual and Auto modes 

i. Identification of safety requirements and features 

ii. Performance specifications

iii. Standard operating procedures

iv. Startup/shutdown procedures

3. Spare parts lists, vendor sources, and maintenance procedures

4. Machine operation history logs

a. Computer-based

b. Manual

c. Safety data sheets

d. Machine operating history from an HMI database

B. Machine lubrication and preventive maintenance schedules

1. Company documentation

2. Machine manufacturer documentation

C. Reading and interpreting technical drawings 

1. Line types

a. Part

b. Hidden

c. Center

d. Section

e. Breakout Section

2. Basic symbology

3. Multi-view drawings of cylindrical and prismatic shaped parts

a. 1st angle projection

b. 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

a. Datums, MMC, LMC

b. Feature control frames

c. Symbols, and use of: Form, Profile, Orientation, Location, Runout

10. Assembly drawings with Bill of Materials

11. Blueprints

III. Legacy and modern tools 

A. 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

a. Load capacity description and demonstration

b. Inspection points, defects, damage, and contamination

Corrective action

c. Proper use of eyebolts and shims for lifting parts

d. Proper containment methods to storage

4. Basic rigging components and techniques

a. Slings

b. Chains

c. Wire-ropes

d. Come-a-longs

e. Blocking

f. Hoist

g. Cranes 

5. Heavy load movement

a. Horizontal movement 

i. Rollers

ii. Come-a-longs

iii. Dolly

iv. Pry-bar

v. Truck

vi. Skates

b. Vertical movement

i. Manual and powered hoists 

ii. Chain hoist 

iii. Jacks

iv. Pry-bar

B. Hand tools

1. Threaded and non-threaded fasteners

a. Système international (SI) & Imperial (US) fasteners (bolts), washers, pins, nuts, and locking devices

i. Nomenclature 

ii. 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

iii. Failure modes

iv. Construction

v. Strength

b. Force, torque, press fits,

i. Dynamic and static torques

ii. Assembly tolerances and interference fit 

c. Proper fastener selection

d. 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

a. Screw Divers

b. Nut Drivers

c. Hex Drivers

d. Wrenches;

i. Boxed end

ii. Open end

iii. Adjustable

iv. Ratcheting

e. Ratcheting socket wrenches

i. ¼ Drive

ii. ⅜ Drive

iii. ½ Drive 

iv. Crows Foot

f. Pliers

i. Needle nose

ii. Slip joint aka standard

iii. Tongue and groove aka adjustable pliers

iv. Locking, aka channel-lock

Safety wire twisting aka safety wire pliers

g. Clamps

i. C-clamp

ii. Trigger clamp

iii. Spring clamp

iv. Bench vice

h. Mallets

i. Cordless, electric brushless powered hand tools

i. Drills with keyless chucks and clutch settings

ii. Hex impact drivers

iii. Square drive impact drivers

iv. Legacy drills with key chucks

4. Assembling parts

a. Types

i. Threaded fasteners

ii. Washers

iii. Nuts

iv. Pins

v. Keys

vi. Clips

vii. Snap rings

viii. Roll pins

ix. Tie-wraps (safety-wire)

b. Tightening parts

i. Bolt pattern sequence correction

ii. Torque correction with click type torque wrench

C. Measurement Tools

1. Metric and inch pocket rulers and tape rulers

a. Common inch fractional scales: 

i. 64th scale

ii. 32nd scale

iii. 16th scale

iv. 8th scale

b. Common inch decimal scales

i. 64th scale

ii. 50th scale

iii. 32nd scale

iv. 16th scale

v. 10th scale

vi. 8th scale

c. Common metric decimal scales 

i. 10th scale

ii. 50th scale 

2. Metric unit conversions

a. Micrometer

b. Millimeter

c. Centimeter

d. Kilometer

e. Megameter

3. Imperial and metric unit conversions  

4. Tool selection

a. Calipers

i. Digital

ii. Analog

b. Micrometers

i. Digital

ii. Vernier (Analog)

c. Dial indicator

5. Accurate use and measurement tool concepts

a. Accurate use

i. Resolution

ii. Repeatability

iii. Error types

b. Measurement tool concepts

i. Calibration

ii. Total Indicated Run-out (TIR)

iii. Flatness

iv. Indirect measurement

v. Other features

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