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.
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- 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).
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- 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).
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- 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.
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- 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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