Mechanical maintenance for production lines

Chapter 1: Maintenance Management

1. Maintenance principles and definitions
2. P-F curve
3. Maintenance bases
4. Maintenance importance and objectives
5. Maintenance history
6. Proactive process
7. Equipment malfunctions
8. Types of maintenance philosophies

Chapter 2: Asset Management

1. Asset definition
2. Asset life cycle
3. CAPEX & OPEX
4. Asset cost control
5. Asset management DPT
6. Inventory management
7. BOM & spare parts

Chapter 3: Maintenance System implementation

1. System principles
2. Maintenance flow
3. Corrective management
4. O management
5. Equipment LOG
6. Daily LOG
7. Preventive management
8. O.P creation
9. Check list management
10. Maintenance plan
11. On-job training
12. Tradeoff Between Repairs and PM
13. Predictive techniques
14. How Speedy Should Repairs Be?
15. CMMS/EAMS
16. Failure management
17. CMMS/EAMS implementation

Chapter 4: Reliability

1. Reliability definitions
2. Reliability calculation
3. Failure pattern
4. Availability definitions
5. Availability calculation
6. MTBF
7. MTTR
8. Failure rate
9. System reliability calculations

Chapter 5: planning and scheduling

1. Planning and scheduling history
2. Planning and scheduling definitions and differences
3. Job priority
4. Planning deliverables
5. Scheduling consideration
6. Backlog
7. Preventive maintenance planning & scheduling – intervals
8. Criticality analysis
9. Criticality matrix

Chapter 6: mechanical element

• Types of drive belts
• Difference between drive belts design and usage
• Belt tension and life time
• Types of pullies
• Belt selection and standards
• Types of belts manufacturing
• Belts malfunctions

1. Chain Drive

• Sprocket
• Chain
• Roller Chain Layout and classification
• Chain clearances malfunctions

2. Gears

• Classification of gears
• hypoid gear vs spiral bevel gear
• Gear functions
• Gear mates
• Enclosed Gear Drives
• Gear train types
• Gear train types calculations
• Gear lubricant
• Gear maintenance
• Gear fixation
• Gear materials
• Gear failure

3. CAMs & CAM followers

• Types of cams
• Types of cam followers
• Followers displacement diagram
• Cam failures

4. Shafts

• Types of shafts
• Shaft materials
• Shaft fixations
• Shaft malfunctions
• Spline shafts
• Shaft Alignment (coupling Alignment)

5. Couplings

• Types of couplings
• Couplings design
• Couplings selection
• Coupling failures mechanisms

6. Bolts, screws, nuts and washers
7. Threading tools

• Bolts selection and threading malfunction solving (practical)

8. Keys, Pins, Cotters and circlips

Chapter7: Measuring

1. Vernier caliper (mm – inch)
2. Thread Measuring
3. Tap chart

Chapter8: Oiling and lubrication

1. Lubrication principle
2. Surface roughness
3. Viscosity
4. function of lubricants
5. Types of lubricants
6. Selection of lubricants
7. Methods of oil lubrication
8. Methods of grease lubrication
9. Grease lubrication equipment
10. Lubricants-Handling, Storing & Dispensing
11. Gear and bearing lubrication
12. Protective Devices
13. Lubrication Fittings
14. Related Safety, Care and Maintenance
15. Difference between oiling and lubrications

Chapter9: sealing and packing

1. Sealing principles
2. Oil seal
3. Mechanical seal
4. Packing
5. O- Ring
6. Valve sealing
7. Gearbox sealing

Chapter10: Bearing technology

1. Stresses definition
2. Tensile strength principles
3. Mechanical properties of materials
4. Stress and strain diagram
5. Mechanical loads
6. Stress concentration
7. History of bearings
8. Bearing fundamentals
9. Bearing applications
10. Tolerances
11. Bearing seats and alignment
12. Operating temperature
13. Classification of bearings
14. Bearing component
15. Journal bearings types
16. Anti-friction bearing types
17. Tapered bearing
18. Ball bearing
19. Self-aligning ball bearing
20. Linear ball bearing
21. Sliding bearing
22. Spherical bearing
23. Needle bearing
24. Ball joint bearing (male &female)
25. Cylindrical bearing
26. Thrust bearing
27. HUB bearing
28. Bearing assembly and remove
29. Related Safety, Care and Maintenance
30. Bearing cleaning
31. Oiling and lubrication principles
32. Bearing lubrication
33. Bearing maintenance
34. Machine vibration
35. Bearing spectrum
36. Misalignment spectrum
37. Run out spectrum
38. Bearing assembly and remove and manufacturing

Bearing selection and measuring using SKF and FAG catalogue (practical)

Chapter11: Maintenance Tooling and workshop orientation