Daily Check & Maintenance
Daily Check & Maintenance
Daily Check & Maintenance
1 AVAILABILITY
Utilization and availability metrics depend on how many hours a machine must
work, and how much time can be devoted to maintenance and repair.
Utilization = The time the machine is used divided by The time the machine is required
to work and able to work
Availability = The time the machine is required to work and able to work divided by The
time the machine is required to work
The diagram at top shows how this works over a 24-hour period and gives the following
formulas:
Utilization = W / T-D
Availability = T-D / T
Where:
Scheduled
Downtime Scheduled Production Time
Set-up
Time
Available Operating Time
Availability Unplanned
Reported Actual Operating Time
Stoppages
Minor
Unrecorded Actual Production Time
Stoppages
Throughput
Rate Reduced
Full Rate Production Time
Speed
Rejects &
Quality Rate Rework
In-Quality Production Time
8.2 DAILY CHECK & MAINTENANCE
I. DAILY CHECK
• Every heavy equipment checklist must have areas where the date of the
inspection can be documented. Along with the date of inspection, the
checklist must have a section where the equipment can be identified,
generally with a heavy equipment identification number. Each heavy
equipment checklist must have the inspector's name documented or listed
somewhere as well as the operator's name. These two names are
generally the same because OSHA requires that the operator perform an
operational inspection before use.
2. Fluids and Gauges
• The operator of the heavy equipment must check the fluid levels in the
machinery before operating the vehicle or equipment. All fluids must be
checked including hydraulic fluids, coolant levels, oil levels and any other
fluids used by the heavy equipment. Once the operator has checked to
make sure all fluid levels are within allowable limits, he needs to check the
gauges of the equipment to make sure they are operating properly and
recording properly. These gauges include air pressure levels, fluid levels,
temperature gauges, electrical fault lights and other gauges used during
operation of the heavy equipment.
3. Movable Parts
• The operator must check to make sure all visible movable components are
working properly and without obstructions. Every piece of heavy
equipment is required to have properly inflated tires, tracks that are not
obstructed by any debris and free flowing members such as dump beds,
buckets or turning capabilities. The operator or inspector must run the
heavy equipment through its entire capabilities to make sure the
equipment has a full turning radius and the buckets or dump beds can be
moved through their full cycle or radius. The checklist must have a section
for checking fans, belts, wiper blades and other small movable
components on the heavy equipment.
4. Safety Equipment
1. Exterior Inspection
• Walk around your heavy equipment every morning before the workday
begins. With your safety checklist in hand, look for cracks or damage to
the exterior frame of the vehicle. Shocks and springs should not show
signs of leakage. Determine whether the axles are straight, check for
loose or sagging wiring and look for signs of oil leakage under the vehicle.
You should also remove excess debris accumulated on the exterior before
you start the operating the equipment. Debris may hide a problem.
• Check all tires if the heavy equipment has wheels. Properly inflate tires to
the recommended pressure. Look for signs of wear, such as tread or
sidewall separation, and immediately change tires that show bulges. Make
sure all lug nuts are present on the wheel and replace wheels if you see
cracks in them.
• If the vehicle runs on a track, check for the proper amount of slack.
Replace worn or damaged treads immediately.
2. Engine
3. Operator's Cab
II. MAINTENANCE
Heavy Equipment Maintenance
Operating heavy equipment costs a lot of money. Failing to make repairs to that
equipment due to a poor equipment maintenance policy is simply not good business.
Running through a maintenance checklist can take as little as 15 minutes a day and
may easily catch a problem before it becomes several days' lost work due to equipment
repairs. Poorly maintained heavy equipment may also pose a safety hazard to your
employees.
A. Definitions
1. Corrective maintenance:
3. Productive maintenance:
• Set a schedule for equipment maintenance and stick to it. There are
certain tasks to perform daily, while other tasks need completing on a
longer schedule. Once you decide on a schedule, prepare a maintenance
checklist.
Walk around each piece of heavy equipment in operation daily. While you
perform a visual inspection, look for worn parts and signs of oil or coolant
leakage. Make sure to inflate tires to the required pressure. Take time to
clean debris away from the machine. Feel belts and chains to make sure
there isn't too much slack in them. Lubricate linkages that call for daily
grease. Make sure safety signage and safety equipment is in place. Check
the fluid levels on oils, coolant and hydraulics. Top them up as needed.
Failure to keep the proper amounts of fluids in your heavy equipment can
shorten its life. Check the air filter and clean it if necessary.
2. Quarterly Maintenance
• When your piece of heavy equipment has 500 service hours or about 3
month's services, you should perform a more thorough maintenance
check. Change the engine's oil and both the engine oil filter and hydraulic
oil filter. Replace the diesel fuel filter also as part of the 3-month
equipment maintenance procedure.
• At the end of the season or at least once a year, change the transmission
fluid as well as the hydraulic oil. Check your radiator to make sure it's in
good condition. Check hoses and belts.
Wash the entire vehicle. Pay special attention to cleaning the engine and
the undercarriage. Clean the cab and its air filters. Make sure the air
conditioning unit is clean. Make sure all lights are operational and replace
defective bulbs.
Inspect the tires for signs of wear and tear. Replace worn tires during the
off season so you don't lose valuable work time.
4. Preventive Maintenance (PM)
Identify problem areas and prevent premature failure caused from conditions
such as lube fittings that aren’t taking grease, lines that are worn, frayed and
exposed electric lines, leaking fluids, and any part that is broken or worn-out.
View them as part of the overall maintenance program.
4.1 Four Categories of PM
PM-D is the category for major, planned jobs. This maintenance pertains
to work such as in-frame or out-of-frame diesel engine overhauls or
replacing or rebuilding gasoline engines. Service in this category
generally is performed between 75,000 to 250,000 miles or 16 to 24
months.
A. Process
NEW EQUIPMENT
ARRIVES
PREVENTATIVE WORK STEPS, SCHEDULE AND SAFETY PLACED ON
MAINTENANCE FORM
RECORD FORM
CREATED PREVENTATIVE MAINTENANCE WORK RECORDED
All records must be legible, readily retrievable, protected and stored to
prevent damage, deterioration or loss.
B. Equipment Register
• Description
• Make
• Model
• Serial Number
• Location
• Next Scheduled PM Date
• Equipment data
• Safety instructions for the item
• Description of preventative maintenance requirements for the
equipment
• Preventative maintenance frequency and history
As scheduled preventative maintenance is performed on the equipment
the maintenance record shall be completed.
A. Process
REPAIR OR MAINTENANCE
MAINTENANCE REQUEST FORM IS
REQUEST IS COMPLETED AS WORK IS PERFORMED
REQUIRED NEEDED
• Originators Information
• Location of the problem
• Defective equipment details
• Description of the problem or corrective action requested
Each Work Order Form activity is then entered onto the Maintenance Log
form. If equipment, parts, etc. are required the Material Requisition Form
shall be completed and approved prior to purchasing.
Material is requested for and approved via the Material Requisition Form.
The form is submitted to the Project Manager for review and approval.
Any single Material Requisition Form representing a single value of say
P50,000 or more requires approval from senior management prior to
placing any orders.
The Material Requisition Form is to be kept with all Work Order Forms.
5. Total Productive Maintenance
Investigate if the introduction of TPM will help you reduce lost time on
operating equipment to a tune of 30% or better. This is typical for companies
that do not have advanced Preventive Maintenance and Predictive
Maintenance (PdM) practices in place. Insure you meet the requirements for
a Successful TPM introduction to your facility.
C. Checklists
1. Checklist for an Equipment Operator
• In some cases, a piece of machinery will have its own set of safety
equipment that goes with it. A list of the safety equipment that should be
with a machine should be listed on the machine itself, or on a separate
list included with the maintenance log. Check to make sure all necessary
safety equipment is in place and that it is functional. Some pieces of
safety equipment include small fire extinguishers, chains to anchor the
equipment and blocks to hold the equipment in place when you park. If
safety equipment is missing or not functioning properly, point it out to
your supervisor.
• Take the time to look around the area where you will be operating the
machinery to identify potential safety issues so you can avoid them
during your workday. Low power lines, steep drop-offs of roads or open
floors, muddy roads and narrow roadways should be noted, and you
should develop a plan to avoid them during the day.
2. Inspection Checklist (PM)
Equipment inspections should be performed by drivers or operators on a
routine basis and periodically by fleet mechanics. As part of these inspections,
a visual inspection should include the following:
• Tires, wheels, steering, suspension, drive systems
• Coolant, exhaust, fuel systems
• Lights and other electrical system parts
• Leaks, both liquid and air
• Body damage, both accumulated and new
• Mirrors, interior and exterior
• Brakes, service and parking
• Windshield wipers
• Instruments and gauges
• Coupling devices
• Safety devices
• Emergency equipment
3.1 General
The operation of heavy equipment must be safe and to ensure the safety of
the operators a daily checklist must be maintained. This checklist makes sure
the heavy equipment is safe to use and will not harm any employees working
around the machinery. The Occupational Safety and Health Administration
(OSHA) have general guidelines concerning the daily inspection, but it leaves
a lot of the specifics of the checklist up to the employer.
3.2.1 Safety
A good way to create safety checklists is to study the manual from the
equipment manufacturer. Research will have already been conducted in
several different areas of stress testing. The manufacturer will perform
tests, ranging from heat and cold exposure to corrosion and conductivity.
Using the manual will help establish the general limitations of your
equipment.
3.3.2 Engineering Protocols
A good practice in determining risk is performing a Zurich Hazard
Analysis. Using engineering methods, you evaluate the risk as it pertains
to the equipment and how it is used by you or the business. The
equipment may pose a minimal risk in a benign environment, where the
risk is substantially higher in a corrosive atmosphere. Determining the
prolonged exposure between the two environments by means of
operation and stress tests allows the user to establish safety checks that
are necessary to prolong the equipment's lifespan and ensures overall
safety.
3.3.3 Preventive Maintenance
Perform preventive maintenance routinely. Doing this will allow the user
to examine equipment's regular use. For example, using a bulldozer
every day will require lubrication checks, and making sure fluid levels,
hoses and fasteners like screws and bolts are in place and secure. For
simpler things like manual hand tools, you can look for corrosion like
rust, and make sure it is maintaining its original physical appearance. If
you use a screwdriver every day, the edges on the head will need to
maintain smooth, machined lines like every hand tool.
3.3.4 Visual Inspections
In some cases, all that is needed are visual verifications. Looking at
things like windshields on vehicles is self-explanatory; if there are no
cracks or huge chips in the glass, they are structurally sound. Inspect the
tread on tires for foreign objects like nails or other sharp objects, and
that the tread is free from wear. You can inspect the items for corrosion
buildup. Examine electrical cords for exposed wiring. Inspect lines and
hoses for leaks. Check temperature and pressure gauges on equipment
that runs continuously.
3.3.5 Audit Yourself
Perform audits to maintain the integrity of your safety. Have a checklist
for your checklist. Keeping a record of your safety checks will help you
determine if you are adequately checking for the safe use of your
equipment; if an accident does occur, you have a written document that
the equipment was being cared for. The complete picture in safety
checklists is using the checklists to verify everything is operable. Human
error is the root cause of most accidents. The equipment may fail, but it's
up to the human factor to foresee or prevent its failure.
4. Operator/Equipment Inspection Checklist (Selected Equipment only)
Daily operational inspection - this inspection is done with a checklist that must
be signed by the operator and filed in the maintenance department.
• Every front end loader operator checklist must have the basic
information recorded at the top of the checklist. This includes the
operator's name, date of the inspection, equipment number to
identify the front end loader and time of the inspection. Most
checklists record the type of machine as well as the model
number.
• Most front end loader checklists are broken up into sections, such
as a section on what to inspect on the outside, inside the cab and
inside the engine as well as a section on the safety devices that
are required to be on the machinery. Each section is also broken
up into categories or lists what to check under that particular
section. The sections record comments about the part, whether it
is in good shape or needs attention and whether the operator
needed to do anything to the part such as add oil, grease or
replace a minor part. This record keeping assists the maintenance
department keep a proper preventive maintenance program and
lets them know what needs repaired when the operator finds
defects or damage.
• Once your equipment and other attachments are in place, you are
now set to mount the operator's station. Make sure to fasten your
seat belt and keep the platform clear of debris. You have to clean
up your boots and hands to remove mud and grease prior to
operation as handling the controls with oily and greasy hands
proves dangerous.
4.2.5 Controls
• Before starting the machine, you have to ensure that all controls
are in neutral position. Allow the hydraulic system to warm up for
operation. Check the dials and gauges to ensure that the gears
are working properly. All control levers must also be checked, in
addition to the brakes, steering and transmission.
4.2.6 Clearance
• After the physical inspection of the backhoe loader, the next thing
on your checklist is the safety of people and objects around the
equipment. Get to know the location before moving to ensure
enough clearance. To do this, you have to be aware of the
dimensions and weights of your machine.
D. Summary
The need to improve safety and maintenance records and the extreme competitiveness
of the construction business demands that contractors continuously look for new ways
to improve safety and reduce maintenance costs. Companies in the industrial sector
have found effective equipment maintenance increases profits and improves safety
performance.
E. FORMS (SAMPLE ONLY)
Inspection Date: __ /__/ __ Time: ____ Equipment Type __________ Unit # ______