Standard
Jobs and Troubleshooting Guides
Quite
often, specific jobs are not consistently performed in
the safest and most efficient manner possible. As well,
the ability of maintenance personnel to effectively and
accurately troubleshoot equipment and process problems
varies from person to person. Performance Associates can
prepare standard job procedures and troubleshooting guides
to assist your maintenance personnel in performing maintenance
tasks in a timely and efficient manner.
Performance
Associates’ personnel develop standard jobs for
specific tasks that you want to be completed in a specific
manner.
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Years
of plant specific experience, the experience of maintenance
personnel, and pertinent information from vendor operating and
maintenance manuals are compiled and utilized to develop an
optimum method for performing a specific job. Once compiled,
standard jobs are available for new personnel, personnel who
are unfamiliar with particular tasks, and personnel who have
not performed certain tasks for a considerable amount of time.
The standard job provides the necessary guideline for performing
tasks as safely and efficiently as possible. Following standard
job procedures maximizes the productivity of your maintenance
personnel while also maximizing equipment availability. Each
standard job includes:
-
Manpower
requirements for each craft involved in the standard job.
-
A
required parts and materials list.
-
A
required tools and equipment list.
-
A
Gantt bar chart detailing each step in the job, the personnel
involved in each step, and the time required to perform each
step.
-
Important
safety procedures that must be followed.
Performance
Associates will also prepare troubleshooting manuals that provide
simple step-by-step instructions that maintenance personnel
can use to recognize equipment problems, identify the source
of problem, and take the appropriate action to correct the problem.
Performance Associates troubleshooting guides typically incorporate
a Fault/Cause/Remedy table format that lists equipment problems
and indicates the possible causes of the problem, as well as
recommend actions to eliminate the problem. Performance Associates
will also prepare troubleshooting guides in any other format
you may require such as flowcharts or decision trees. Troubleshooting
manuals provide operations and maintenance personnel with the
necessary tools to identify and correct equipment problems in
as little time as possible, thus maintaining maximum equipment
availability.
Sample
Fault/Cause/Remedy chart:
No.
1, 2, and 6 SHAW BOX HOT METAL CRANES— MECHANICAL TROUBLE
SHOOTING LOGIC CHART
Problem
|
Observation
and Possible Cause
|
Action |
GEARBOXES
Bridge/Trolley/Main Hoist/Auxiliary Hoists
Common Problems
|
Note:
All observations and possible causes are for the bridge,
trolley, main hoist, and auxiliary hoists gearboxes unless
otherwise stated. |
Note:
All actions to be taken are for the bridge, trolley, main
hoist, and auxiliary hoists gearboxes unless otherwise stated |
| Gearbox
malfunction |
- Inoperative,
worn bearings or worn or damaged gearing.
* Bearings (input & output).
* Gearing (shinning teeth on one side).
- Improper
oil viscosity or oil is breaking down.
- Insufficient
lubricant (oil or grease).
- Too
much lubricant or high pressure in gear case.
|
- Check
out the specific problem and correct if possible.
- Remove
and replace gearbox. (Note: If the gearbox is the bridge
drive assembly, Reference Shaw Box Hot Metal Cranes
Bridge Drive Gearbox Removal/Installation Standard Job).
|
- Drain
and replace oil with the specified lubricant. (Note:
Reference BHP Hot Metals Maintenance Converter Crane
Work Schedule—Weekly-HMC 1, 2, and 6 Mechanical
- PM).
|
- Add
the proper quantity of specified oil. (Note: Reference
BHP Hot Metals Maintenance Converter Crane Work Schedule—Weekly-HMC
1, 2, and 6 Mechanical - PM).
- Check
the grease in the bearing retainers.
|
- Check
for proper oil level. If oil level is too high, adjust
to proper level.
- Check
that the breather in the gear case is not clogged and
located above the oil level. Clean out breather or replace.
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| PAI
Sample Manual:
Komatsu
830 Haul Truck
PAI
Downloads:
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Control System
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Manager
Software
Instructions |
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Services:
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Manuals and Training
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and Materials:
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Improvement Programs
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Maintenance Programs
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