UAIT 105 - Maintenance Operations

Overview of the area of maintenance operations of a manufacturing facility. Preparation to sit for the NIMS Duty Area 1: Maintenance Operations Certification Exam.

Course Learning Outcomes:

Perform machine operation including startup, emergency, and normal shutdown and manual functions.
Monitor machine operation and verify that performance meets safety, production, and maintenance requirements.
Locate, interpret, and store machine operation and maintenance documentation.
Perform planned and unscheduled machine maintenance procedures in accordance with a company-approved maintenance plan.
Perform a preventative maintenance procedure for a given machine to extend machine life and minimize downtime.

Outline:

Machine Operation
- Safety checklist:
- Machine malfunction definition
- Standard operating procedures definition
- Operations to start and stop an operation
- When a machine needs to be shut down
- Lockout process (perform process)
Monitoring Machine Operation; Verifying Performance Meets Production Requirements
- Confirming (with operator) machine is operating within specifications
- Five senses to observe machine operation and vibration (i.e. determine machine operating correctly, recognize malfunctions symptoms)
- Operator use of correct operation procedure evaluation
- Leaks, dirt, and loose connections
- Read:
  - Pressure gauges
  - Flow meters
  - Fluid levels
  - Temperature gauges
  - Voltages and current
- HMI (monitor machine)
- Machine reading comparisons (i.e. machine documentation and performance specifications to determine if machine is performing within specifications)
- Record machine operation history (manual log or computer database)
Locate, Interpret, and Store Machine Operation and Maintenance Documentation
- Methods of storing machine operation and maintenance documentation (accessible to the maintenance technicians and operators)
- Locate and interpret (for a given machine):
  - Machine operation manuals, including: identification of safety requirements and features, performance specifications, stand operating procedures, startup/shutdown procedures
  - Spare parts lists, vendor sources, and maintenance procedures
  - Machine operation history logs, computer-based and manual
  - Machine operating history from an HMI database
  - Machine lubrication and preventive maintenance schedules from company or machine manufacturer documentation
Planned and Unscheduled Machine Maintenance Procedures (In Accordance with a Company-Approved Maintenance Plan)
- Concept of total productive maintenance (TPM) definition (e.g. combination of preventive, predictive, and total company buy-in)
- Benefits and limitations of preventive/predictive maintenance
- Company procedures to inform production personnel of maintenance to be done on a machine
- Use of CMMS description
- When a work order is needed
- Steps to perform an unscheduled/planned maintenance procedure
- Concept of autonomous maintenance
- Elements of a comprehensive maintenance plan
- Methods of eliminating unplanned maintenance events
- Types of planned/unplanned maintenance procedures
- How to read, interpret, and resolve a work order
Preventative Maintenance Procedure(s) for a Given Machine to Extend Machine Life and Minimize Downtime
- Describe preventive maintenance procedure given machine documentation
- Types of preventive maintenance tasks
- Identify and remove sources of contamination (e.g. select best methods of cleaning machine based upon continuous improvement principle)
Predictive Maintenance on a Given Machine to Extend Machine Life and Minimize Downtime
- Basic elements and benefits of a predictive maintenance plan
- Types of predictive maintenance methods and their applications using basic senses (hearing, feeling, etc.) and their techniques:
- Vibration analysis
- Thermography
- Oil analysis
- Acoustic analysis
- Motor current analysis.
- Performing predictive maintenance
Reading/Interpreting Technical Drawings of Parts and Assemblies with Tolerances and Basic GD&T
- Reading/interpreting technical drawings (of parts/assemblies with tolerances, basic GD&T)
- Line types and basic symbology
- Multi-view drawings of cylindrical and prismatic shaped parts
- Metric and English dimension conversions
- Dimension lines for linear, circular, and angular dimensions
- Title blocks
- Feature sizes using a drawing scale
- GD&T feature control frames
- Standard dimensional tolerance
- GD&T tolerances for form orientation, location
- Assembly drawings
- Assembly tolerances, interference fit concept
- Maximum material condition symbols
- Sectional cutaway views
- Threaded and non-threaded fastener specifications
- Type of fastener (given a sample)
- Fastener selection (for a given application)
- Sizes and types of washers, pins, nuts, locking devices
Hand Tools to Inspect, Adjust/Tighten, and Assemble/Disassemble Equipment to Support Preventive Maintenance, Inspection, and Troubleshooting Activities
- Basic hand tool safety rules and application for use as defined by OSHA standards
- Concepts of how a fastener works, force, torque, dynamic and static torques, press fits, assembly tolerances
- Proper fastener selection
- Select and (proper) use of:
  - Screw and nut drivers

1. - Fixed wrenches
  - Allen/hex key wrenches
  - Ratchet wrenches
  - Click-type torque wrench
  - Pliers, clamps, and mallets.
  - Pneumatic powered torque wrenches
  - Electric powered hand tools (e.g. drills, torque wrenches, and screwdrivers)
- Methods to protect parts and components during handling and storage
- Assembling parts using:
  - Threaded fasteners, washers, and nuts

1. - Pins, keys, clips, snap rings, and tie wraps
- Tightening parts using correct bolt pattern sequence

Hoists and Other Tools to Safely Handle and Move Parts and Equipment
- Rigging safety including load capacity (description and demonstration)
- Hoist inspection, determining if safe to use
- Manual and powered hoists (using cantilevered and gantry configurations)
- Calculating center of gravity for load balance
- Proper use of eyebolts for lifting parts
- Basic rigging techniques; types of slings, come-a-longs, blocking, chaining to lift a load
- Basic concepts of force, center of gravity, force vectors, rated load, and crush force
- Manual pry bar and truck to move a load
- Hydraulic jack to lift a load
- Dolly to move a load
- Proper containment methods to store a component
- Handling parts using proper containment prevention methods
- Components inspection (for contamination; to take corrective action)
Troubleshooting Methodologies to Find Malfunctions in Machine Systems (to Return the System to Reliable, Productive Use in the Shortest Time Possible)
- Methodologies to isolate problems to a particular sub-system, 5-why, fishbone, flow charts, half-split method, etc.
- Effective interpersonal skills to interact with production personnel, vendors, and colleagues
- Effective observation and interview strategies to validate the problem and determine the most effective troubleshooting strategy
- Analyzing production information, maintenance, and operation documents to assist in troubleshooting a malfunction.