maintenance proses
Content
Course Outline (Maintenance Project)
************************ 1. Maintainability and Maintenance Maintainability concept, maintainability in product life cycle, life cycle cost, cost effectiveness, total life cycle cost visibility, maintainability and related interfaces, maintenance definition, maintenance category, optimum maintenance, maintenance time relationship. 2. Reliability Factors Reliability function, failure rate and mean time between maintenance (MTBF), main time to failure (MTTF), main time to first failure (MTFF), probability of survival, probability growth curve. 3. Planning and Scheduling Maintenance planning, types of work to be planned, how to plan maintenance work, job estimating and scheduling techniques, gross versus net capacity, work order planning in detail, plan follow up. 4. Maintenance Information Flow Purposes of maintenance information flow, maintenance work order, design of work order, work order types, three main parts of work order. 5. Managing Preventive Maintenance Preventive maintenance, PM strategy for 3 equipment life cycles, justifying PM expenditures, PM System installation, access to equipment, PM frequency, common task, staffing the PM effort, strategies to get PM done, steps to install PM system, survey, PM system improve professionalism. 6. Introduction to Predictive Maintenance Introduction, advantages of predictive maintenance, failure in machinaries/equipment, somes techniques in predictive maintenance.
7. Optimum Predictive Maintenance Program Selection of predictive maintenance system, microprocessor-based system, microprocessor, host computer, transducer. 8. Predictive Maintenance Program Implementation Predictive maintenance program application, a successful program, the long term objectives and goals of a predictive maintenance program, management support, dedicated and accountable personnel, efficient data acquisition and analysis, equipment classification. 9. Parameter Monitoring Vibration theory overview, mechanical equipment, machine-train component, unbalance, misalignment, mode shape and resonance, bearing and bearing type, gear and gearboxes, running speed (s). 10. Vibration Measurement Measurement, general scheme of vibration measurement, transducer, conditioning amplifier, dynamic signal analyzer, transducer selection.
Untuk
mekanik
yang sudah
sering tidak
menangani asing lagi
trouble dengan mekanik
unit istilah untuk
dilapangan,mungkin troubleshooting yang
troubleshooting,disini sedikit saya akan memberikan beberapa step benar,guna mempermudah menemukan penyebab kerusakan yang terjadi pada unit yang sedang mereka tangani ( tulisannya sendiri dalam bahasa inggris,namun saya yakin para mekanik sudah tidak asing lagi dengan bahasa Inggris teknik yang sering digunakan di dalam service / shop manual.
Sebelum melakukan troubleshooting dilapangan,disarankan agar mekanik menyiapkan segala sesuatu yang diperlukan untuk melakukan hal tersebut,diantaranya adalah : Common tools,measuring
tools / diagnostic tools , shop manual ,dan lainnya. Baiklah, guna untuk mempersingkat waktu,silahkan untuk membaca lanjutan tulisan ini,semoga bermanfaat….
8 ( Eight ) Step of Troubleshooting : (Langkah langkah perawatan perbaikan)
1. Make sure the problem really does exist - Gathering / acquire information - Operator / driver complaint : Ø What happened ? Ø What was it doing when the problem occurred ? Ø Was everything else working all right ?
2. State the problem by writing it down - Organize fact gathering - Interpret information - Operation condition : Ø What is geography ? ( rocky, sandy, high altitude ,etc ) Ø What were the weather conditions ? (extreme cold, extreme head, high humidity, etc ) Ø Was an experience operator using the machine at time the problem occurred ?
- Machine history: Ø What preventive maintenance has been completed ? Ø What repair have been in the past ? 3. Visually inspect the engine or machine
- Collect additional information as needed : Ø Sensory check such as looking, listening, touching, smelling. Ø Technical tests such as operational adjustments, standard operating procedures and technical procedures. Ø Job aids such as manuals, bulletins, and schematic diagrams. Ø Technical supports such as suppliers, manufactures, and experts. - Verify operational problem - Collect evidence 4. List all possible causes - Identify possible faults : Ø Identify as many possible causes of problem as you can. Ø If the problem does not have a set of clear possible causes, narrow the problem to a sub-system and then try to identify causes. Ø Collect more information if possible fault are difficult to identify. - Think logically with the facts - Analyze the evidence - Generate potential fault list 5. Run the test and record data - Check-out possible faults : Ø Collect additional information to checkout the possible faults. Ø Vary one thing at a time to test the possible causes when you are not familiar with the system or device. Ø If testing is time consuming or expensive, try to eliminate as many possible causes as possible each test ( use split-half strategy ) Ø Do not assume that new parts always work Ø Reduce the number of possible causes with a systematic approach. Ø Always return the system to its original configuration after replacing a part or making tests. - Duplicate the problem: Ø Operate the device yourself to check the accuracy of the
information you have been given. Ø Have operator duplicate the situation that causes the problem - Take note about test results, parts replaced, and adjustment made. - Always observe safety precaution/rules. 6. Find the root cause (eliminate everything that could not create the problem) - Narrow list of causes - Determine the problem root causes 7. Repair the fault and fix the problem - Perform necessary procedures to remove the fault from the system - Take note about test result, parts replaced, and adjustment made. - Always observe safety precaution/rules. 8. Analyze failure why did the problem occur - Check every solution you reach with some kind of test. - If the faults remains after checking the solution (or a new one appears), go through the troubleshooting procedure again. - Complete required Fault Analysis paperwork, make Service Report.
Sumber :CAT Training Handbook
************************ 1. Maintainability and Maintenance Maintainability concept, maintainability in product life cycle, life cycle cost, cost effectiveness, total life cycle cost visibility, maintainability and related interfaces, maintenance definition, maintenance category, optimum maintenance, maintenance time relationship. 2. Reliability Factors Reliability function, failure rate and mean time between maintenance (MTBF), main time to failure (MTTF), main time to first failure (MTFF), probability of survival, probability growth curve. 3. Planning and Scheduling Maintenance planning, types of work to be planned, how to plan maintenance work, job estimating and scheduling techniques, gross versus net capacity, work order planning in detail, plan follow up. 4. Maintenance Information Flow Purposes of maintenance information flow, maintenance work order, design of work order, work order types, three main parts of work order. 5. Managing Preventive Maintenance Preventive maintenance, PM strategy for 3 equipment life cycles, justifying PM expenditures, PM System installation, access to equipment, PM frequency, common task, staffing the PM effort, strategies to get PM done, steps to install PM system, survey, PM system improve professionalism. 6. Introduction to Predictive Maintenance Introduction, advantages of predictive maintenance, failure in machinaries/equipment, somes techniques in predictive maintenance.
7. Optimum Predictive Maintenance Program Selection of predictive maintenance system, microprocessor-based system, microprocessor, host computer, transducer. 8. Predictive Maintenance Program Implementation Predictive maintenance program application, a successful program, the long term objectives and goals of a predictive maintenance program, management support, dedicated and accountable personnel, efficient data acquisition and analysis, equipment classification. 9. Parameter Monitoring Vibration theory overview, mechanical equipment, machine-train component, unbalance, misalignment, mode shape and resonance, bearing and bearing type, gear and gearboxes, running speed (s). 10. Vibration Measurement Measurement, general scheme of vibration measurement, transducer, conditioning amplifier, dynamic signal analyzer, transducer selection.
Untuk
mekanik
yang sudah
sering tidak
menangani asing lagi
trouble dengan mekanik
unit istilah untuk
dilapangan,mungkin troubleshooting yang
troubleshooting,disini sedikit saya akan memberikan beberapa step benar,guna mempermudah menemukan penyebab kerusakan yang terjadi pada unit yang sedang mereka tangani ( tulisannya sendiri dalam bahasa inggris,namun saya yakin para mekanik sudah tidak asing lagi dengan bahasa Inggris teknik yang sering digunakan di dalam service / shop manual.
Sebelum melakukan troubleshooting dilapangan,disarankan agar mekanik menyiapkan segala sesuatu yang diperlukan untuk melakukan hal tersebut,diantaranya adalah : Common tools,measuring
tools / diagnostic tools , shop manual ,dan lainnya. Baiklah, guna untuk mempersingkat waktu,silahkan untuk membaca lanjutan tulisan ini,semoga bermanfaat….
8 ( Eight ) Step of Troubleshooting : (Langkah langkah perawatan perbaikan)
1. Make sure the problem really does exist - Gathering / acquire information - Operator / driver complaint : Ø What happened ? Ø What was it doing when the problem occurred ? Ø Was everything else working all right ?
2. State the problem by writing it down - Organize fact gathering - Interpret information - Operation condition : Ø What is geography ? ( rocky, sandy, high altitude ,etc ) Ø What were the weather conditions ? (extreme cold, extreme head, high humidity, etc ) Ø Was an experience operator using the machine at time the problem occurred ?
- Machine history: Ø What preventive maintenance has been completed ? Ø What repair have been in the past ? 3. Visually inspect the engine or machine
- Collect additional information as needed : Ø Sensory check such as looking, listening, touching, smelling. Ø Technical tests such as operational adjustments, standard operating procedures and technical procedures. Ø Job aids such as manuals, bulletins, and schematic diagrams. Ø Technical supports such as suppliers, manufactures, and experts. - Verify operational problem - Collect evidence 4. List all possible causes - Identify possible faults : Ø Identify as many possible causes of problem as you can. Ø If the problem does not have a set of clear possible causes, narrow the problem to a sub-system and then try to identify causes. Ø Collect more information if possible fault are difficult to identify. - Think logically with the facts - Analyze the evidence - Generate potential fault list 5. Run the test and record data - Check-out possible faults : Ø Collect additional information to checkout the possible faults. Ø Vary one thing at a time to test the possible causes when you are not familiar with the system or device. Ø If testing is time consuming or expensive, try to eliminate as many possible causes as possible each test ( use split-half strategy ) Ø Do not assume that new parts always work Ø Reduce the number of possible causes with a systematic approach. Ø Always return the system to its original configuration after replacing a part or making tests. - Duplicate the problem: Ø Operate the device yourself to check the accuracy of the
information you have been given. Ø Have operator duplicate the situation that causes the problem - Take note about test results, parts replaced, and adjustment made. - Always observe safety precaution/rules. 6. Find the root cause (eliminate everything that could not create the problem) - Narrow list of causes - Determine the problem root causes 7. Repair the fault and fix the problem - Perform necessary procedures to remove the fault from the system - Take note about test result, parts replaced, and adjustment made. - Always observe safety precaution/rules. 8. Analyze failure why did the problem occur - Check every solution you reach with some kind of test. - If the faults remains after checking the solution (or a new one appears), go through the troubleshooting procedure again. - Complete required Fault Analysis paperwork, make Service Report.
Sumber :CAT Training Handbook
