Importance of Maintenance

Learning Objective: After reading this INFORMATION SHEET, you must be able to know,
understand and appreciate maintenance and its importance.

Maintenance is an excellent means of improving the performance and condition of

equipment and facilities. An effective maintenance program identified problems long
before any equipment or facility breaks down or deteriorate. A good maintenance system
presents the early discovery of problems, thus providing plenty of lead time for effective
maintenance planning. The trainer has to value the importance of maintaining the
training facilities, equipment and tools he is using or under his care if he values the presence
and availability of these resources for effective training and learning processes.

The Growth of Interest in Maintenance

The factors contributing to the rapidly growing interest in maintenance

are:

1. Technological development
This trend leads to a more mechanized and automated equipment, resulting in
great productive potential which must be kept working. This means that training
facilities are becoming more complicated and required more advanced
maintenance.

2. Increasingly expensive raw materials

Finite raw materials, in combination with a growing population and
increasing assumption, inevitably result in higher raw material prices.
Unavoidably, the costs of all by-products must rise. It is therefore often more
profitable to maintain existing equipment than purchase new ones.

3. Greater complication
A complicated facility of piece of equipment includes many components,
any or all of which can constitute possible sources of trouble. Although the
operational reliability of each individual component may be very high, it is
necessary to multiply reliability factor of all components that are dependent on
each other in a system in order to arrive at the total system reliability.

4. Increased fixed costs

Capital costs constitute a considerable part of the total costs of training and
must be covered by the added value created. If
training stops as a result of inadequate maintenance, capital costs (depreciation)
must still be paid, so that the standstill results in a net loss. Still, the salaries
and overhead expenses must be paid while training is stopped.

5. Reduce delayed activities and eradicate uncompleted work

Many work processes depend on an uninterrupted flow of activities to produce
desired result. If an activity is delayed, the entire work stops. If all the facilities
and equipment are reliable working well, work delay can be reduced.

6. Environmental concern
The growing quantity of electronic wastes (monitors, laptops, cellular phones,
other electronic gadgets and its substances), the increasing use of chemicals such
as cleaning agents, paints, fuel and its derivatives, the by-products created from
its use, and its disposal, pose danger to the environment and all living things.
Mass awareness on waste management brings the relevance of conserving the natural
resources and the products (machines, tools) thru proper maintenance to lengthen its
 useful life.

Why Maintain?

General Objective:
• To keep the optimum condition of physical facilities at acceptable levels and
minimum cost to satisfy the expected of programs, services and activities at
acceptable and minimum costs

Specific Objectives:
• To extend the useful life of physical facilities
• To assure the operational readiness of
installed equipment and maximum
possible return on investments
• To properly discard hazardous wastes
• To ensure the safety of personnel using the facilities,
physical properties and the environment

What can we gain from maintaining our facilities?

• Ensured SAFE environment
• Improved MORALE of human resources
• Reduced operational COST
• Increased PRODUCTION
• Prolonged LIFE of facilities
• Prompt DELIVERY of services/product
• WASTE/Garbage reduction

Who are involved?

• Who will manage the activities?
• Who will monitor and evaluate the operations?
• Who will prepare the maintenance schedule?
• Who will implement the program?
• Who will keep the records?
• Who will conduct inspection?
• Who will certify and accept the work?
• Who will prepare the report?

What, Where, When?

• What routine actions must be done to keep the device on working order?
• Where is the maintenance activity to be carried out?
• When do you perform the maintenance activities?

How to maintain?
The question on how do we implement the
maintenance program will center on the 5Ms are as
follows:
• Manpower
• Money (Financial Resources)
• Methods and System
• Machines (Facilities)
• Materials and Supplies

A maintenance program is a
comprehensive list of maintenance and its incidents. This would include all maintenance
activities to be undertaken, manpower needed, maintenance methods to be used, all the
materials and supplies needed and cost involved in the maintenance.
 A maintenance schedule is a list allocating specific maintenance of an area, including
equipment and tools to a specific period. The maintenance schedule is just a part of the
maintenance program. A maintenance checklist is a list of maintenance tasks (preventive
or predictive) typically derived through some form of analysis, generated automatically as
work orders at a predetermined frequency.

The following templates are examples of inspection checklist for a comfort room
(as a practical work area) in Housekeeping NC II (Sample Template #2,) and GMAW NC
III (Sample Template #3)

Sample Template #2

HOUSEKEEPING SCHEDULE
Qualification GMAW NC III Station/Bldg Welding (WAF)

Area/Section Practical Work Area

In-Charge Lorenzo A. Ladia

Schedule for the 2nd Semester, 2011

Responsible
ACTIVITIES Daily Every Weekly Every Month ly Remarks
Person other 15th
Day Day
1. Clean and check welding Trainees/
equipment/ accessories from dust Janitors (in X
and oil; dry and the absence of
properly laid-out/ trainees)
secured/stable
2. Clean and free welding Trainees/
booths and welding positioners Janitors (in X
from dust/rust the absence of
/gums, used Mig wire stubs trainees)
and metal scraps
3. Clean and arrange working tables Trainees/
according to floor plan/lay-out; Janitors (in X
check stability the absence of
trainees)
4. Clean and check floor, Trainees/
walls, windows, ceilings Janitors (in X
• graffiti/dust/rust the absence of
• cobwebs and trainees)
outdated/unnecessary
objects/items
• obstructions
• any used materials/scraps
(slugs, stubs) spilled liquid
• open cracks (floor)

5. Clean and check work shop Trainees/

ventilation and Janitors (in X
illumination by dusting the absence of
lamps/bulbs, replacing non- trainees)
functional lamps and keeping
exhaust clean
6. Clean and check computer set - Trainees/
monitor, CPU, Janitors (in X
keyboards, mouse – free, the absence of
unnecessary markings, dust; trainees)
cables and plugs are in order; well-
arranged; all items functional

7. Clean, inspect air conditioning Trainees/

equipment: Janitors (in X
• keep screen and filter free the absence of
from dust/rust trainees)
• Check selector knobs if in
normal positions and are
functional
• Check if drainage is OK
8. Clean, check and maintain Trainees/
Tool Room Janitors (in X
• Free of dust, not damp the absence of
• Tools in appropriate trainees)
positions/locations
• With visible
labels/signage
• Logbook and forms are
complete, in order and
updated
• Lights, ventilation – OK
10. Clean and check Rest Trainees/
Room Janitors (in X
• Urinals, bowls, wash basins, the absence of
walls and partitions are free trainees)
from stains, dirt, oils, graffiti
and unnecessary objects;
• Ceilings free from cobwebs
and dangling
items
• Floor is kept dry; no broken
tiles or protruding objects
• Equipped with dipper and
pails; properly located after
use
• Water systems is
functional: no
dripping/damaged faucets
or pipes
• Drainage system is working,
no water- clogged areas
• No offensive odor
• Lights /Ventilation – OK

9. Clean and check wash area: Trainees/

• Walls/Floors- –free from Janitors (in X
oils, molds, broken tiles, the absence of
gums, stains or graffiti trainees)
• Drainage system is
functional
• Water system functional; no
dripping faucets or leaking
pipes
• Free from unnecessary
objects (mops, rags)

10. Clean and maintain work Trainees/

shop surroundings by sweeping/ Janitors (in X
removing fallen leaves, branches, the absence of
debris and other refuse, trainees)
impounded water, clearing
pathways of obstructions

11. Disposal of waste Trainees/

materials Janitors (in X
(Follow waste segregation the absence of
system) trainees)

Sample Template #3
GMAW WORKSHOP HOUSEKEEPING SCHEDULE
DAILY TASK YES NO
Dispose segregated waste; clean garbage cans

Sweep floors; if wet, wipe dry

Wipe and clean whiteboards

Clean and arrange working tables

Clean and check mounting of machines/equipment

Before leaving, collect stubs and other welding wastes.

WEEKLY TASK YES NO

Clean posters, visual aids and update accomplishment/Progress Charts
 Clean bulbs/lamps/ceilings/walls

Clean/Wash of windows/glasses/mirrors

Clean and check tools, machines, supplies, materials

Sanitize garbage receptacles

Empty water collector; clean body of Water Dispenser

MONTHLY TASK YES NO

Conduct inventory

Clean and arrange tool room

Inspect electrical system; clean cables, wires

Clean instructional materials & modules; arrange and put in order

Inspect and clean air-conditioning equipment filter; clean body

To perform the maintenance of specific equipment, a maintenance schedule is drawn.

Again, the best source of the list of the maintenance activities of equipment is its
manufacturers/user’s manual. In the absence of it, the plan can be derived from the known
maintenance methods of the equipment and in accordance with the organization’s policy and
procedures. Following herein are maintenance schedules for welding equipment wherein the
basis is the number of running hours (Sample Template #4) while another template
(Sample Template #5) used the periodic or routinary schedule (daily, weekly).
Sample Template #4
WELDING EQUIPMENT MAINTENANCE SCHEDULE*
8 HOURS 50 Hours 100 HOURS
• Wipe up oil and fuel spills • Check electrode oven • Change oil
immediately heating elements • Change oil filter (refer to engine manual for
• Check fluid levels (oil and fuel) • Check equipment specifics)
• Service the air filter (refer to engine V-belts • Clean and tighten battery connections
manual for specifics) • Note: Refer to • Clean aircon cooling system (refer to engine
• Clean and tighten weld Service Manual manual for specifics)
terminals • Clean and check electrical panel board

Sample Template #5
EQUIPMENT MAINTENANCE SCHEDULE
EQUIPMENT TYPE GMAW welding machine (MILLER)
EQUIPMENT CODE GMAW-01to10
LOCATION PRACTICAL WORK AREA/WAF
Schedule for the Month of March
MANPOWER Daily Every Weekly Every Monthly Remarks
ACTIVITIES
Other 15th
Day Day
1. Check panel board, and circuit Electrician Activity is done
breakers’ electrical connections, Trainer X before and after
cables and outlets using the
• Clean and kept dry equipment
• Parts are well-
secured/attached
• Properly labeled

2. Check Mig gun (nozzle, contact Trainees Activity is done

tip, diffuser) and ground cable: Trainer X before using the
• Clean and kept dry equipment
• Parts are well- secured/
attached
• Inspect for damages and
replace parts if
necessary

3. Check adjustment lever’s if Trainees Activity is done

functional (amperages/speed); if not, Trainer X before using the
calibrate equipment
4. Check Gas cylinder outfit for any Trainees Activity is done
abnormality Trainer X before using the
• Gate valve equipment
• Co2 regulator
• Gas hose Fittings
• Fittings

5. Check/Clean wire feeder (rollers, Trainees

wire speed/spool adjustment); remove Trainer X
used oil, dust; keep dry.

6. Run the equipment for 5 minutes Check warranty

and observe for unusual noise or X and after service
abnormal operation; if repair is assistance from
necessary, send to technician. dealer

Along the equipment maintenance schedule is the equipment maintenance inspection

checklist. The checklist will confirm if the maintenance activities have been performed in
order to prolong the life of this particular equipment or workshop. The Inspection items are
stated in a question form as these serve as the criteria or standards of maintenance. Sample
Template #6 is inspection checklist for the workshop area of GMAW NC III while Sample
Template #7 reflects a welding equipment inspection checklist.

Sample Template #6

WORKSHOP INSPECTION CHECKLIST

Qualification GMAW NC III

Area/Section Practical Work Area In-Charge Lorenzo Ladia

YES NO INSPECTION ITEMS

1. Are the welding equipment/ accessories clean from dust and oil? Dry and properly laid-out?
Secured/stable?
2. Are the welding booths and welding positioners free from dust/rust/gums, Mig wire/stubs, metal
scraps, graffiti, unnecessary mark/signage, stable, dry & odor-free? Area of machine can enable the
trainee to move safely?
3. Are the working tables clean and dry? Arranged according to floor plan/lay- out? Stable?

4. Are floor, walls, ceilings, windows and doors clean, neat, without obstructions or unnecessary
odor? All hinges and locks functional? With exit plans?
5. Is the workshop well-ventilated and with enough illumination?

6. Is the computer set clean and dry? Cables, plugs, mouse, properly laid out and functional? No cuts
or splices in flexible wires?
7. Is the air conditioning equipment clean and functional?
8. Is the Tool Room free of dust, with legible and visible labels/signages, logbook and forms complete,
in order & updated? Tools with safety guards and in appropriate positions/ locations?

9. Is the wash area clean, sanitized, free from unnecessary objects such as mops, rags? Are all water,
drainage and electrical systems functional?
10. Is the rest room well-cleaned, dry and sanitized, no unacceptable odor and free from unnecessary
objects such as mops, rags, outdated signage, dangling objects? Are the urinals, bowls, washbasins,
walls and partitions free from stains, dirt, oils, graffiti and unnecessary objects? Is it equipped with
adequate dipper and pails and properly located after use? Are all water, drainage and electrical systems
functional?’

11. Is the workshop surroundings clean and cleared of obstructions, no impounded water and with
adequate lights?
12. Are there available receptacles for waste? Are the waste materials properly segregated and
disposed?

Remarks:

Inspected by: Date:

 Sample Template #7
EQUIPMENT MAINTENANCE INSPECTION CHECKLIST
Equipment Type : Welding Machine (MILLER)
Property Code/Number : GMAW-01
Location : PRACTICAL WORK AREA/WAF
YES NO INSPECTION ITEMS
1. Are the panel board and circuit breakers’ electrical connections, cables and outlets clean and
dry? Parts are well-secured/attached, no cracks? Properly labeled?

2. Are the Mig guns (nozzle, contact tip, diffuser) and ground cables, clean and dry?
Parts are well-secured/attached? In good condition?
3. Are the adjustment lever’s amperages/speed,) functional?
4. Are the gas cylinder outfits (gate valve, Co2 regulator, gas hose fittings, cleaned and in good
condition? No leaks?
5. Are the wire feeder (rollers, wire speed adjustment, wire spool) free from dust, rust, oil? Dry?

6. Is the equipment mounted properly?

7. Is the equipment in A1 condition?? If not, was a report prepared and submitted to authorized
personnel?
Remarks:

Inspected by: Date:

Technical Support Services

The maintenance of facilities is manned by the different specialist or group of

specialists. Frequently, a matrix organization is established which can be seen in Diagram
No. 1.

Diagram No. 1