1. JJ615-MECHANICAL COMPONENTS &
MAINTENANCE
CHAPTER 1 :
MAINTENANCE PRINCIPLE &PROCEDURES
SHATIS KUMAR A/L KALIMUTHU
AHMAD SUHAIB ANSARI BIN BAHIKI
JIVINDERRAN A/L PRABAGARAN
NOR ASYIKIN BINTI ABDULLAH
NUR MAIZATUL FAZIRA BNTI MOHD AZAHA
PARANITHARAN A/L BRAPAKARAN
15DKM11F1087
15DKM11F1094
15DKM11F1095
15DKM11F1096
15DKM11F1097
15DKM11F1099

2. Maintenance
• In general, Maintenance means to
hold, keep, sustain or preserve
• Maintenance is an activity involved in keeping
something in good working order, and actions
performed to keep systems functioning or in
service.

3. Principle Of Maintenance
• To achieve product quality and customer
satisfaction through adjusted and serviced
equipment
• Maximize useful life of equipment
• Keep equipment safe and prevent safety
hazards
• Minimize frequency and severity of
interruptions

4. Objectives
• Must be consistent with the goals of
production (cost, quality, delivery, safety)
• Must be comprehensive and include specific
responsibilities

5. Continuous
improvement
Reduced
inventory
Improved
capacity
Faster and more
dependable
troughput
Higher
productivity
ADVANTAGES OF
IMPLEMENT
MAINTENANCE
Lower
operating
cost
Improved
quality

6. • Reduced inventory
-Reducing stores and buffer stock.
• Continuous improvement
-Is on going effort to improve product
services or process.
• Higher productivity
-Is high ratio of output to input of
production.

7. • Improved capacity
-Improve the capacity of product.
• Improved quality
-Achieve a step change in quality through
contracting out the service with the new
service level agreement.
• Lower operating cost
-Expenses which are related to the
operation of a organization in a lower
cost.

8. TYPE OF COST MAINTENANCE
COST
MAINTENANCE
UNPLANNED
MAINTENANCE
EMERGENCY @
BREAKDOWN
MAINTENANCE
OPPORTUNITIE
MAINTENANCE
CORRECTIVE
MAINTENANCE
PLANNED
MAINTENANCE
CORRECTIVE
MAINTENANCE
PREDECTIVE
MAINTENANCE
ROUTINE
MAINTENANCE
DESIGN OUT
MAINTENANCE
PERVENTIVE
MAINTENANCE
CONDITION
BASE
MAINTENANCE
SCHEDULE
MAINTENANCE

9. VARIOUS TYPE OF COST
MAINTENANCE AND RELATED
• Emergency @ breakdown maintenance
It means that people waits until equipment fails
and repair it.
• Periodic maintenance
It means periodically inspecting, servicing and
cleaning equipment and replacing parts to prevent
sudden failure and process problems.
• Corrective maintenance
It improves equipment and its components so that
preventive maintenance can be carried out reliably.

10. VARIOUS TYPE OF COST
MAINTENANCE AND RELATED
• Routine maintenance
-It is a daily maintenance ( cleaning, inspection, oiling
and re-tightening ),
• Preventive maintenance
-It design to retain the healthy condition of
equipment and prevent failure
• Predictive maintenance
-It is a method in which the service life of important
part is predicted based on inspection or diagnosis, in
order to use the parts to the limit of their service life.

11. WORKPLACE SAFETY

12. Benefits Of Clean and Working
Environment
• Reduced Accidents
– reduce accidents that can result in employees
injuring their backs, legs, shoulders or other body
parts because of broken equipment, and also wet
areas where people can slip.
• Air Quality
– Employees will literally breathe easier in safe
workplaces free from chemical pollution,
asbestos, dust, cigarette smoke or other allergens.

13. • Reduced stress
– Unsafe workplaces may cause unhealthy stress
levels among employees fearful of threats from
co-workers, dramatic altercations with
management or persistent problems related to
parking lot theft and other challenges.

14. Personal Protective Equipment (PPE)
• Personal protective equipment (PPE) refers to
protective clothing, helmets, goggles, or other
garments or equipment designed to protect
the wearer's body from injury.The hazards
addressed by protective equipment include
physical, electrical, heat, chemicals,
biohazards, and airborne particulate matter.

15. Examples
Gloves
Hearing
protection
Protective
clothing
Safety
helemt
respirator
Goggles
Safety
boots

16. Important Of Personal Protective
Equipment
• To reduce employee exposure to hazards
when engineering and administrative controls
are not feasible or effective in reducing these
exposures to acceptable level.PPE is needed
when there are hazards present.PPE has the
serious limitation that it does not eliminate
the hazard at source and may result in
employees being exposed to the hazard if the
equipment fails.

17. Lockout and Tagout
• Lockout/Tagout refers to the procedures
established for Control of Hazardous Energy as
described by the Occupational Safety and
Health Administration (OSHA) under Federal
Registry 29 CFR1910.147.
• Lockout/Tagout ensures employee safety
during inspection, maintenance, or service of
equipment by controlling all energy flow to
and from the equipment.

18. • To achieve system lockout, all energy sources
are turned off or disconnected, and stored
energy is released, restrained, or dissipated. A
lock or lockout device applied to each energy
source prevents accidental startup.
• Tag out is a labelling process that is always
used when lockout is required.The process of
tagging out a system involves attaching or
using an indicator.

19. Lock out/tag out sign
Tag out label
Lock out

20. Lock out/tag out program
• Lockout/Tagout specification includes the
following:
–
–
–
–
–
Plant or company-wide safety policies.
Machine-specific lockout procedures.
Lock and key and tag control.
Program review and certification.
Outside contractor rules and regulations.
• All companies whose employees service or
maintain equipment with potentially hazardous
energy sources must have an OSHA-compliant
Lockout/Tagout program.

21. Purpose of lock out/tag out
• A lockout/tag out program will help prevent:
– Contact with a hazard while performing tasks that
require the removal, by-passing, or deactivation of
safe guarding devices.
– The unintended release of hazardous energy
(stored energy).
– The unintended start-up or motion of machinery,
equipment or processes.

22. When lock out/tag out is required?
• Lockout/Tagout is required whenever
employees are exposed to hazardous energy
• It is also a procedures that are required
whenever you must remove or bypass a
machine guard or other safety device, and
place any part of your body where you could
be caught by moving machinery.

23. Hazardous materials
• Hazardous materials or Hazmat, are solids,
gases, and liquids that can hard people,
animals property, and the environment.
Throughout the U.S.hazardous materials are
moved by marine vessels, air, rail, and truck.
• During the servicing and maintenance of
machines and equipment, the unexpected
startup or release of stored energy could
cause injury to employees.

24. Hazardous Energy
Electrical
mechanical
hydraulic
Hazardous
energy
pnuematic
chemical
thermal

25. Hazardous materials sign

26. Organizations that given safety at
Hazardous materials
• The Occupational Safety and Health Act (OSH
Act) gives OSHA authority to promulgate the
hazardous materials regulations.
• EPA Hazoardous materials organization has
primary responsibility for regulating the
transport of hazardous materials across all
modes except pipelines

27. Hand Tools
Chisel
• Remove unwanted timber
or to carve it out
Clamps
• to create inward pressure to
secure objects or materials
together to prevent
movement or separation.

28. Hammer
• To deliver an impact or
force such as pounding or
striking to an object.
Hand saw
• used to cut materials with
its blade.

29. Screwdrivers
• Screwdrivers are used for
driving screws into
materials or for securing or
loosening parts on
machinery.
Planer
• A planer is used to shape or
thin out a piece of timber
by removing small amounts
of wood.

30. Wrench
• It s used to for
gripping, fastening,rotating
,loosing or turning
bolts,nuts and screw.
Pliers
• These are used to hold
objects firmly for bending
or physical compression.

31. Power Tools
Circular saw
• Circular saws are similar to
jigsaws only the blade is
round and much larger
which means it is better for
straight cuts.
Drill
• Used for drilling holes or
inserting and removing
screws from a material.

32. Jigsaw
• used for cutting curves
much like a coping saw as it
uses a similar sized blade
only it cuts much quicker.
Electric Planer
• Electric planers are the
same as hand planers only
they work automatically
which makes planning much
faster and easier.

33. Router
• create curved edges and
mill out timber making
them very useful.
Belt sander
• creates scratches if it is used
against the woods grain but
it removes more material.

34. Air Compressor
• An air compressor is a
device that converts power
(usually from an electric
motor, a diesel engine or a
gasoline engine)
4″ Angle Grinder
• also known as a side
grinder or disc grinder, is a
handheld power tool used
for cutting,grinding
and polishing.

35. Important of inspecting a hand tools &
power tools
• The purpose of the inspection is to ensure a
well-functioning tools
• Identify tools that are not broken
• Keep the tool to be used does not pose a high
risk