Objective 01: Plant Maintenance

Question 1

What is a critical factor in the successful operation of all types of equipment?

Answer 1

Proper maintenance

Question 2

Maintenance

Answer 2

The combination of all technical and administrative actions, including supervision actions, intended to retain an item in, or restore it to, a state in which it can perform a required function.

Question 3

What does ‘item’ refer to in the formal definition of maintenance?

Answer 3

All hardware and associated software such as equipment, components, devices, systems, and other physical assets.

Question 4

What does ‘required function’ refer to in the formal definition of maintenance?

Answer 4

A combination of design (which defines the limits of use) and operation (which describes its actual use)

Question 5

What does ‘to retain an item in, or restore it, to a state’ refer to in the formal definition of maintenance?

Answer 5

The purpose of maintenance is either to perform actions that keep equipment performing as required by doing preventive maintenance (to retain), or to repair it when it has failed by doing corrective maintenance (to restore).

Question 6

What does ‘combination of all technical and administrative actions, including supervision action” refer to in the formal definition of maintenance?

Answer 6

Maintenance is not only the execution of maintenance tasks, but also administrative actions (such as planning and scheduling) and supervisory actions (such as hiring and training skilled personnel)

Question 7

What are the 4 categories of the major aspects of maintenance?

Answer 7

1. Overall Planning
2. Preventive Maintenance
3. Corrective Maintenance
4. Maintenance Enhancement

Question 8

What does Overall Planning entail for maintenance?

Answer 8

• management of maintenance
• maintenance program development
• maintenance planning and scheduling

Question 9

What does Preventive Maintenance entail?

Answer 9

• maintenance planning and scheduling
• maintenance execution
• maintenance assessment
• maintenance improvement

Question 10

What does Corrective Maintenance entail?

Answer 10

• Maintenance Planning and Scheduling
• Maintenance Execution
• Maintenance Assessment
• Maintenance Improvement

Question 11

What does Maintenance Enhancement entail?

Answer 11

• maintenance improvement
• maintenance program development
• maintenance planning and scheduling

Question 12

Whose responsibility is Management of Maintenance?

Answer 12

Supervisors and Managers

Question 13

What does Management of Maintenance include?

Answer 13

1. Developing a high-level maintenance strategy for an organization
2. Managing, coordinating, and supervising maintenance groups
3. Providing finances and managing maintenance budgets
4. Providing resources for maintenance, such as skilled staff, spare parts and materials, maintenance facilities, tools and support equipment, and manual and computerized information systems

Question 14

Whose responsibility is the Maintenance Program Development?

Answer 14

Maintenance planners with involvement from maintenance personnel

Question 15

What does Maintenance Program Development include?

Answer 15

1. Identifying preventive maintenance tasks

2. Determining support resources needed for preventive maintenance tasks

Question 16

Whose responsibility is the Maintenance Planning and Scheduling

Answer 16

Maintenance Planners

Question 17

What does Maintenance Planning and Scheduling include?

Answer 17

1. Planning resources needed to carry out specific preventive and corrective maintenance tasks
2. Scheduling maintenance tasks within the limits of available resources

Question 18

Whose responsibility is Maintenance Execution?

Answer 18

Maintenance Staff

Question 19

What does Maintenance Execution include?

Answer 19

1. Obtaining resources, e.g. spare parts and specialized tools
2. Traveling to the work site
3. Following safety and environmental procedures
4. Dismantling, repairing, and reassembling equipment
5. Investigating and diagnosing failures
6. Documenting the results of work done and resources used

Question 20

Whose responsibility is Maintenance Assessment?

Answer 20

Maintenance Planners and Maintenance Personnel

Question 21

What does Maintenance Assessment include?

Answer 21

1. Assessing and documenting the success of maintenance actions
2. Measuring maintenance performance indicators
3. Performing failure analysis, especially for major failures
4. Assessing equipment availability, reliability, and cost
5. Reviewing the success of preventive maintenance programs

Question 22

Whose responsibility is Maintenance Improvement?

Answer 22

Maintenance Staff and others, e.g. design engineering

Question 23

What does Maintenance Improvement include?

Answer 23

1. Design improvements or modifications
2. Changes to operating procedures
3. Changes to maintenance procedures
4. Improvements to preventive maintenance tasks and resources

Question 24

What are 2 ongoing cyclical processes that occur in maintenance?

Answer 24

1. Maintenance Cycle

2. Continuous Improvement

Question 25

What does the Maintenance Cycle entail?

Answer 25

Maintenance tasks are identified or triggered, planned, scheduled, executed, and assessed

Question 26

What does the Continuous Improvement entail?

Answer 26

Incorporating changes and improvements in equipment, procedures, and tasks

Question 27

How is reliability achieved in operating machinery?

Answer 27

1. Equipment is designed for the required operating conditions and performance
2. Equipment is operated within design limits and according to specified operating procedures
3. Required maintenance is carried out

Question 28

What are some factors that can be used to measure the success of a maintenance program?

Answer 28

• reliability
• availability
• product quality
• production capacity
• cost