CASE STUDY MAINTENANCE AND

TROUBLESHOOTING

COURSE CODE: DJJ50203

LECTURER’S NAME: ENCIK MOHD AMIRUL
SESSION: 1 2022/2023
CLASS: DKM5B

GROUP MEMBERS MATRIX NO

NURIN WIRDANI BINTI BASHARUDIN 18DKM20F1005

NUR ADILA BINTI MOHAMAD SAUFI 18DKM20F1008

ADHAM HAKIM BIN HASSAN 18DKM20F1002

AHMAD ZIKRY BIN AHMAD EZAN 18DKM20F1011

1.0 Maintenance & Troubleshooting Principles and Procedures

1.1 Explain the principles of maintenance and troubleshooting.

1.1.1 Define the meaning of maintenance and troubleshooting

Maintenance troubleshooting is the process of identifying what is wrong with these faulty
components and systems when the problem is not immediately obvious. Maintenance
troubleshooting usually follows a systematic, four-step approach; identify the problem, plan a
response, test the solution, and resolve the problem. Steps one to three are often repeated
multiple times before a resolution is reached.

1.1.2 List the objectives of maintenance and troubleshooting

Maintenance objectives:

• To increase functional reliability of production facilities

• To maximize the useful life of the equipment
• To maximize production capacity from the given equipment

Troubleshooting objectives:

Troubleshooting is a systematic approach to solving a problem. The goal of

troubleshooting is to determine why something does not work as expected and explain how to
resolve the problem. The first step in the troubleshooting process is to describe the problem
completely. Problem descriptions help you and IBM®️ Software Support know where to start
to find the cause of the problem.

1.1.3 Explain the needs and importance of maintenance and troubleshooting.

By performing regular preventive maintenance, you will always be assured that your
equipment will operate under safe conditions, both for the machine and the operators. Possible
issues can be cut off before it tends to cause any harm, without taking any chance.
1.2 The problem and solutions of lathe machine
• Tool holder problem in lathe operation
Problem: If your cutting tool has not been installed properly, you are likely to have improper
metal cuts. So, before you start working, do not forget to check that the cutting tool is set
correctly in the center of it. The trick to perfect installation is to remember to get accurate and
immaculate cuts. Because of cutting metal, due to continuous friction, the head of the cutting
tool often becomes too hot.
Solutions: Pause the machine frequently. Let it cool down and then start again.
• Noise and unsettling vibration?
Problem: Abruptly, you may find that your machine is not working perfectly. Don't get
panicked. This can happen when the tailstock of the lathe machine is not fixed properly. There
is no certain purpose of this tailstock. Still, it needs to be locked down firmly before you begin
cutting. The cut of the metal will not be proper if the tailstock remains unattached or loose.
Solutions: Examine the screws properly to tighten the tailstock. If you find them loose, do
tighten them well.
• The carriage stuck or improper.
Problem: With time you can get a 'stuck carriage' in your lathe machine. Not only the carriage
but also the power providing handles need to be working perfectly for the machine to run
efficiently.
Solutions: It is foremost you know how to move or unstuck the carriage. Because it has
particular tracks to move within. It is better to be well versed in fixing the carriage to get
efficient work from the machine.
• Precision graduation
Problem: These lathe machines have a dial to control the threads cut. Test the dial using various
feeds and different speeds to have efficient control over the dial.
Solutions: Inspect the smoothness of handling with every speed and feed. It will give you a
better feel of working along with controlling the dial. Do this at the outset of employing your
equipment on the metal.
• Awkward noise
Problem: Many lathe users have faced grinding noises in their machines. The most obvious
reason for this noise is that the machines might not have been lubricated properly. Lubrication
is needed in all the moving parts of a machine. If the gears, bearings, and seals are dry, lubricate
those.
Solutions: Give a look at your manufacturer's descriptions and lubricate them as per
requirement. It is important to use proper lubricant for the parts. If your machine continues to
make this sound, you better see your manufacturer know the cause and fix this problem.
1.3 Indicate workplace safety

1.3.1 List benefits of clean and safe work environment

• The health and safety of your employees is incredibly important, and a key part of that
is preventing the spread of any harmful bacteria or germs. Businesses who fail to keep
a clean work environment may see an increase in sick days and absences among staff,
which can have a damaging impact on overall productivity.

• A safe and healthy workplace not only protects workers from injury and illness, it can
also lower injury/illness costs, reduce absenteeism and turnover, increase productivity
and quality, and raise employee morale. In other words, safety is good for business.

1.3.2 Explain the importance of personal protection equipment.

Professionals in every occupation face varying levels of risk of becoming injured or falling
ill. OSHA (https://www.osha.gov/personal-protective-equipment) describes how, on a regular
basis, “these injuries and illnesses may result from contact with chemical, medical,
radiological, physical, electrical, mechanical, or other workplace hazards.” To ensure
workplace safety, different organizations establish regulations according to OSHA standards.
Here are some proactive tips about managing PPE in all types of work environments, according
to “The Best Way to Manage PPE for Employees (https://safesitehq.com/ppe-management/).”

• Hearing protective devices, such as ear muffs and ear plugs

• Respirators
• Eye and face protection, such as goggles
• Safety helmets and sun hats
• Gloves and safety boots
• Clothing, such as high visibility vests or life jackets.

1.3.3 Apply the usage of lockout and tag-out when needed.

• LOCKOUT is defined as the placement of a lockout device on an energy-isolating

device in accordance with an established procedure to ensure that the energy-isolating
can ensure that the equipment being controlled cannot be operated until the lockout
device is removed.
 • TAG-OUT is the placement of a tagout device on an energy-isolating device, in
accordance with an established procedure, to indicate that the energy-isolating device
and the equipment being controlled may not be operated until the tagout device is
removed.

1.3.4 Classify the organizations that regulate the safety of hazardous materials.

• Occupational Safety & Health Administration (OSHA)

• National Institute for Occupational Safety and Health (NIOSH)
• National Safety Council (NSC)
• American Society of Safety Engineers (ASSE)
• Canadian Society of Safety Engineering (CSSE)
• International Commission on Occupational Health (ICOH)
• International Safety Equipment Association (ISEA)
• International Association of Safety Professionals (IASP)
• American Federation of Labor and Congress of Industrial Organizations (AFL-CIO)
• U.S. / European Cooperation on Workplace Safety and Health
• Tri-National Working Group of Government Experts on Workplace Safety and Health
• International Ergonomics Association (IEA)
• Canadian Centre for Occupational Health and Safety (CCOHS)
• Corporate Alliance to End Partner Violence
• Center for Research on Occupational and Environmental Toxicology (CROET)
1.4 Classify types of hand tools and power tools equipment.

1.4.1 List the most common types of hand tools and power tools.

• Brush
• Chuck

1.4.2 Demonstrate the proper use of various types of hand tools and power tools.

• Before maintenance
• After maintenance

• Procedure
Standard operating procedures (SOP) of lathe machine

1.4.3 Indicate the importance of inspecting hand tools and power tools.

• The purpose of this inspection process is to verify that all of the needed tools for hand
tool production are free from any damage, defects or any loose joints to ensure proper
and consistent production when the operation starts