UNIT 1.

2
General Objectives :Understand the maintenance
function
Specific Objectives :After learned this unit, you
should be able to :- Makesure

Explain the Make

function of
maintenance

Makesure
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 E4101 / E4120

MAINTENANCE Click to edit Master tex

Second level
● Third level
Function of Maintenance
● Fourth level

● Fifth level

Function of maintenance is :-

1. To makesure the product follow the

specification.

2. To makesure reasonable cost of product.

3. To makesure the machine and equipment

can be used optimumly.
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nd level MAINTENANCE
hird level
Fourth level Function of Maintenance
● Fifth level

1. To makesure the product follow the specification.

Ø. Most of the time we are facing a product that has been bought but
fail to operate follow it’s specification. Many factors contribute to
the failure such as :-
- Component in the circuit.
- Wrongly programme the process.
- The ability of product are below the specification.
- Mistaken in operation installation process.
- Environment effect (Pressure)

Ø. To makesure product @ equipment follow the specification, full

maintenance should be implement.
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nd level MAINTENANCE
hird level
Fourth level
● Fifth level

Full Maintenance

Ø It is include in below
processes :-

a. Knowledge
b. Protection
c. Corrective
d. Examine
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nd level MAINTENANCE
hird level
Fourth level Full Maintenance
● Fifth level
a. Knowledge
- It’s mean, to know what are the ability & the
disability of the product @ equipment.
- It’s include the ability of product to temperature,
vibration & absolute max range of product.
- In additional, it is important to understand below
terms if we want to know whether the product
follow the specification or not.
Strength Sensitivity
Accuracy Kelinearan
Hysterisis

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nd level MAINTENANCE
hird level
Fourth level
● Fifth level

b. Protection

Base on the knowledge, for sure maximum

protection can be given to the equipment @
product.

As example, if the equipment cannot

operate in high temperature, the equipment
should be placed at room temperature).

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nd level MAINTENANCE
hird level
Fourth level
● Fifth level

c. Corrective

To makesure the product constantly operate in the

specification limit, corrective maintenance should
be routinely implemented.

No matter major @ minor failure occur, the

corrective maintenance should be urgently
implement.

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level MAINTENANCE
rd level
ourth level
Fifthd.levelChecking / Examine

- The most important procedure in the process of full

maintenance.

- Log book / form need to be prepared to makesure the

checking / examination follow the procedure.

- The best examination/ checking that is include with

the daily , weekly, monthly and also yearly checking
maintenance.

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 Exercises

1. Give 3 factors that contribute to the

failure of a product.

2. State 4 basic method that are needed

to implement full maintenance.

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evel
level
rth level
fth level
To makesure reasonable cost of product

Ø To makesure the cost is reasonable, the first

thing to do is to make an analysis.
Ø Analysis is made to the cost of time, labour
and financial (profit/loss)

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Ø As an example , in a firm (industrial), the
analysis is include with :-
1. Operation time loss
~ Maintenance period
~ Time of corrective / repair job
~ Report time period
2. Maintenance Cost
3. Labour Cost
4. “Machine breakdown” period cost
Ø For individual responsibility – to
makesure the product is reasonable
compare to the price, check the ability &
disability of the product.

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level MAINTENANCE
rd level
ourth level
Fifth level
To makesure the machine and equipment
can be used optimumly.
Ø Below maintenance should be implement
:-
- “Breakdown Maintenance”
(penyelenggaraan kerosakan)
- “Preventive Maintenance”
(penyelenggaraan pencegahan)
- “Predictive Maintenance”
(Penyelenggaraan Jangkaan)
- “Condition-Based Maintenance”
(penyelenggaraan berdasarkan
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E4101 / E4120
level MAINTENANCE
d level
urth level
Fifth
Ø level
“Breakdown Maintenance” - implement after the
machine @ equipment breakdown.

Ø “Preventive Maintenance” - implement before the

machine @ equipment breakdown to avoid a major
failure.

Ø “Predictive Maintenance” – The maintenance method also

known as Preventive maintenance. Implement by doing
an analysis to detact problem at the equipment @
machine without disturbing the production schedule.

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level MAINTENANCE
d level
urth level
Fifth level
Ø “Condition-base Maintenance” – dilakukan apabila perlu
sahaja bagi mesin-mesin yang mempunyai sistem
pengurusan berterusan. Ia dilakukan menggunakan
sistem PLC dimana sistem mesin akan disambungkan
kepada komputer pengawasan keadaan operasi. Jika
terdapat masalah komputer akan melakukan penjajaran
secara automatik atau komputer akan mengeluarkan
tanda amaran dan memberi tahu samada perlu diservice
secara manual atau tidak. Amat efektif tetapi kos
permulaan sangat tinggi tetapi memberi pulangan
jangka panjang yang amat tinggi.

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MAINTENANCE E4101 / E4120
Second level
● Third level
Exercise
● Fourth level

1. Why there is always exist a product that is

● Fifth level

bought not fulfill it’s specification and

customer needs?.
2. Why do we need to implement the full
maintenance to an equipment?.
3. State the basic requirement to do the full
maintenance.
4. State the knowledge that are required to
determine whether a product follow it’s
specification.

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5. What is the meaning of protection
in a full maintenance?
6. What are the cost type that is
needed to makesure the product
have a reasonable price?
6. List the maintenance that is
needed to makesure the machine
@ equipment can be use
optimumly.

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