Maintenance Engineering and Management
(IME-454)
Lab Report 08
SUBMITTED TO:
Dr. Faisal Shahzad
SUBMITTED BY:
Group No. 8
Department of Industrial and Manufacturing Engineering, University of
Engineering and Technology Lahore
Table of Contents
Lab Session 08.................................................................................................................................3
Title..................................................................................................................................................3
Problem Statement...........................................................................................................................3
Objective..........................................................................................................................................3
Theory..............................................................................................................................................3
1. Information Collection.............................................................................................................6
.........................................................................................................................................................6
Maintenance Plan.........................................................................................................................7
2. Identification of Systems.........................................................................................................8
3. Identification of System Functions..........................................................................................8
4. Selection of Systems................................................................................................................8
5. Identification of system functional failures and criticality ranking.........................................8
6. Identification of FSI’s..............................................................................................................9
Comments and Conclusion..............................................................................................................9
References........................................................................................................................................9
List of Tables
Table 1 System function failures....................................................................................................7
Table 2 FSI's...................................................................................................................................8
Lab Session 08
Title
Determining Functionally Significant Items (FSIs) for the various types of
machines in Machine Tools & Machining (MTM) laboratory.
Problem Statement:
Maintenance ensures the safe working environment of an industry. However operations
and maintenance is mostly overlooked by some industries. Although it requires an appreciable
part of total industrial budget, yet it is justified by the lowering the risks and allowing smooth
operation of an industry.
Objective:
1. To determine FSI of Surface Grinder
Theory
A functionally significant item is an item whose failure would affect safety or could have
significant operational impact in a particular operating or maintenance context. The process use a
top-down approach, and is conducted first at the system level, then at the subsystem level and,
where appropriate, down to the component level. An iterative process as shown in fig. 1 should
be followed in identifying FSIs. Systems and subsystem boundaries and functions are first
identified.
The procedures such as information collection, system analysis, and so on outline a
comprehensive set of tasks in the FSI identification process. All these tasks should be applied in
the case of complex or new equipment. However, in the case of well-established or simple
equipment, where functions and functional degradation/failures are well recognized, tasks listed
under the heading of system analysis can be covered very quickly. They should, however, be
documented to confirm that they were considered.
Figure 1
1. Information Collection
1. This step requires the documentation of equipment’s detailing, including specifications
and systems
Figure 2 Labeled NC Grinder
Figure 3 Mechanical and Electrical System of surface grinder
Maintenance Plan
SR
No. Inspection Status Issues
Complete incomplete
Tasks
1 Check for orientation yes
2 Check for axis reference yes
points
3 Check for lubrication No Friction would produce
initial levels
4 yes
Check spindle lube tube
5 Check air lubricators yes
6 Inspect for cracked yes
hoses
7 No Machine would dirty
Check for oil leaks
8 Ensure the chuck yes
pressure is at right
9 yes
Change oil in oil cooler
12 Maintain optimum yes
oil temperature
13 Check for abnormal yes
force on headstock
14 Check tool knockout yes
15 Check for heat and No It leads to deterioration
vibration of headstock
2. Identification of Systems
Following are the main systems in surface grinder machine
Mechanical
Electrical
3. Identification of System Functions
Mechanical system:
Mechanical system of surface grinder composed of dust exhaust unit, coolant
tank, and table majorly future parts included the grinding wheel.
Electrical System:
All mechanical systems are operated with help of some electrical systems
composed of electrical components. The main electrical switchgear is housed in a
compartment at the front of the machine.
4. Selection of Systems
Table
Bed
Column
Controller
Tool Holder
Gears
Magnetic Chuck
5. Identification of system functional failures and criticality ranking
Table 1 System function failures
Failure Rank
1. Rack and pinion failure
2. Gears wear and tear High
3. Controller (Electric fault)
4. Pump (heat up, failure)ss
5. Drain (Leakage) Medium
6. Magnetic Chuck (demagnetization)
7. Bed
8. Column Low
9. Loosening of Hand Wheel
6. Identification of FSI’s
After going through in depth machine analysis, the identified FSI’s are given below
Table 2 FSI's
FSI System/s FSI function/s
Cross feed Controls table motion and
Motor Mechanical + Electrical
Hydraulic Hydraulic + Mechanical Converts electrical energy to mechanical
pump energy
motor
Gears Mechanical Transmit power
Ball Mechanical Reduce friction and support load
Bearings
Controller Electrical Controls the machine
Magnetic Electrical Holds the work piece
chuck
Comments and Conclusion
In this lab session I have learnt about the functional significant items of surface grinder
and observed how and what the role they plays in machine operations how their failure retards
the overall machine works.
Recommendations
If FSIs are not identified successfully the operations and working of machine retards and
it also effects the economics maintenance costs as well. So FSIs should be selected carefully.
References
[1] https://www.rk-int.com/machine/perfect-pfg-cl-and-dl-3060-series-surface-grinders/
[2] MAINTENANCE ENGINEERING HANDBOOK Seventh Edition By R. Keith Mobley
Editor in Chief Lindley R. Higgins and Darrin J. Wikoff
