HAND TOOLS AND POWER TOOLS

1.6   HAND TOOLS

TYPE OF HAND TOOLS

Wrenches:

Figure 1.3

•  Choose a wrench that properly fits the fastener that is to be turned. Using the correct size reduces the chances of wrench slippage.

•  Avoid using a length of pipe or other extension to improve the leverage of a wrench.

•  Manufacturers design wrenches so that the amount of leverage obtained with the handle is the maximum safe application.

•  Use socket wrenches for hard-to-reach areas.

•  Always try to pull on a wrench (instead of pushing) in case the fastener suddenly loosens.

•  Inspect wrenches periodically for damage such as cracking, severe wear, or distortion.

Pliers:

Figure 1.4

•  Do not increase the handle length of pliers to gain more leverage. Use a larger pair of pliers or bolt cutters.

•  Do not substitute pliers for a wrench when turning nuts and bolts. Pliers cannot grip these items properly and will slip.

•  Never use pliers as a hammer or hammer on the handles. Such abuse is likely to result in cracks or breaks.

•  Cut hardened wire only with pliers designed for that purpose.

•  Always cut at right angles. Never rock from side to side or bend the wire back and forth against the cutting edges.

Hammers:

Figure 1.5

•  Do not use a hammer if the handle is damaged or loose.

•  Never weld, heat, or regrind a hammer head.

•  Remove from service any hammer exhibiting signs of excessive wear such as cracks, chips, or a mushroomed head.

•  Match the proper type of hammer to the job it is designed to perform.

•  Do not strike the surface at an angle. The hammer face should contact the striking surface squarely. Glancing blows made with a hammer often lead to injury.

Screwdrivers:

Figure 1.6

•  Never use a screwdriver as a pry bar, chisel, punch, stirrer, or scraper.

•  Always use a screwdriver tip that properly fits the slot of the screw.

•  Throw away screwdrivers with broken or worn handles.

•  Use magnetic or screw-holding screwdrivers to start fasteners in tight areas.

•  Never use pliers on a screwdriver for extra leverage. Only use a wrench on screw drivers specifically designed to accept them.

Utility Knives/Blades:

Figure 1.7

•  Always use a sharp blade. Dull blades require more force and thus are more likely to slip. Replace the blade when it starts to “tear” instead of cut.

•  Never leave a knife unattended with the blade exposed. Consider using a self-retracting knife with a spring-loaded blade. (The blade will retract when pressure on the knife is released).

•  Keep your free hand away from the line of the cut.

1.7   POWER TOOLS

Circular saw:

Figure 1.8

•  Circular saws are similar to jigsaws only the blade is round and much larger which means it is better for straight cuts.

Drill:

Figure 1.9

•  Used for drilling holes or inserting and removing screws from a material.

Jigsaw:

Figure 2.0

•  used for cutting curves much like a coping saw as it uses a similar sized blade only it cuts much quicker

Electric Planer:

Figure 2.1

•  Electric planers are the same as hand planers only they work automatically which makes planning much faster and easier.

Belt sander:

Figure 2.2

•  Creates scratches if it is used against the woods grain but it removes more material.

Air Compressor:

Figure 2.3

•  An air compressor is a device that converts power (usually from an electric motor, a diesel engine or a gasoline engine)

4″ Angle Grinder:

Figure 2.4

•  Also known as a side grinder or disc grinder is a handheld power tool used for cutting, grinding and polishing.

WORKPLACE SAFETY

1.5   WORKPLACE SAFETY

a) Benefits Clean and safe working Environment

•  Reduces accident 

Reduce accidents can result in employees injuring their backs, leg, shoulders or other body             part because of the  broken equipment and also wet areas here people can slip.

•  Air Quality

Employees will literally breathe easier in safe workplaces free form chemical pollution, asbestos, dust cigarette smoke and other allergens.

•  Reduce stress

Unsafe workplace may cause unhealthy stress levels among employees fearful of threats from co-workers, dramatic altercations with management problems related to parking lot theft or other challenges.

b) Personal Protective Equipment (PPE)
  Refers to protective clothing, helmet, goggles or other equipment design to protect the wearer’s body from injury. The hazards addressed by protective equipment include physical, electrical, heat, chemical, biohazards and air bone particulate matter.

Figure 1.1

c) Important of Personal Protective Equipment (PPE)

•  Reduces employee exposure to hazards when engineering and administrative controls are not feasible or effective in reducing these exposures to acceptable level. Personal Protective Equipment needed hen hazard presents. It has serious limitations does not eliminate the hazard at source and result employees being exposed to hazard if the equipment fail.

Head Protection: Prevent head injuries caused by falling or flying object such as working below other employees who are using tools and material that could fall. 

Examples: safety glasses, face shield, welding goggles

Ear Protection: Prevent from excessive noise exposure to avoid hearing damage.

Examples: Ear muff, earplug

Arm and hand protection: protect arm and hand from hazardous situation.

Examples: Glove, hand pads, sleeves

d) Logout or Tag out

•  Definition: safety procedures which are used in industry and research settings to ensure the dangerous machines are properly shut off and not started up again prior to the completion of maintenance. 

•  Refers to the procedures established for control of Hazardous Energy as described by Organisation Safety and Health (OSHA) under Federal Registry 29 CFR 1910.147

•  Ensure employees safety during inspection maintenance or service of equipment by controlling all energy flow to and from equipment. 

•  To achieve system lock, energy source must all turn off or disconnected and store energy at release. 

•  Tag out is a labeling process that is always used hen lockout is required. The process of tag out is using indicator.

Figure 1.2

e) Logout Program

•  Company idea safety policies
•  Machines specifics lockout procedures
•  Lock and key and tag control
•  Program review and certification
•  Outside contractor rules and regulations.

f) Purpose of lockout or tag out

  A lockout will help to prevent :

1) A contact with hazard while performing tasks that require the removal, by-passing, or deactivation of safe guarding devices.

2) The united start-up motion of machinery, equipment or processes.

g) When lockout or tag out required?

•  Required whenever employees are exposed to hazardous energy.

•  It is also a procedure that are required whenever you must remove or by pass a machine guard or other safety device, and place any part of your body where you could be caught by moving machinery.

INTRODUCTION

1.1   INTRODUCTION
     Maintenance, repair, and operations (MRO) or maintenance, repair, and overhaul involve fixing any sort of mechanical, plumbing or electrical device should it become out of order or broken. It also includes performing routine actions which keep the device in working order or prevents trouble from arising.

       MRO may be defined as, "All actions which have the objective of retaining or restoring an item in or to a state in which it can perform its required function. The actions include the combination of all technical and corresponding administrative, managerial, and supervision actions.

1.2   OBJECTIVES

• Must be consistent with the goals of production (cost, delivery, safety).

• Must be comprehensive and include specific responsibilities.

1.3   PRINCIPLE OF MAINTENANCE

• To achieve product quality and customer satisfaction through adjusted and serviced equipment

• Maximize useful life of equipment

• Keep equipment safe and prevent hazards

• Minimize frequency and severity of interruptions

1.4   TYPES OF MAINTENANCE

1. Breakdown maintenance

• It means that people waits until equipment fails and repair it. Such a thing could be used when the equipment failure does not significantly affect the operation or production or generate any significant loss other than repair cost.

2. Preventive maintenance (1951)

• It is a daily maintenance (cleaning, inspection, oiling and re-tightening), design to retain the healthy condition of equipment and prevent failure through the prevention of deterioration, periodic inspection or equipment condition diagnosis, to measure deterioration. It is further divided into periodic maintenance and predictive maintenance. Just like human life is extended by preventive medicine, the equipment service life can be prolonged by doing preventive maintenance.

3. Periodic maintenance (Time based maintenance - TBM)

• Time based maintenance consists of periodically inspecting, servicing and cleaning equipment and replacing parts to prevent sudden failure and process problems.

4. Predictive maintenance

• This is a method in which the service life of important part is predicted based on inspection or diagnosis, in order to use the parts to the limit of their service life. Compared to periodic maintenance, predictive maintenance is condition based maintenance. It manages trend values, by measuring and analyzing data about deterioration and employs a surveillance system, designed to monitor conditions through an on-line system.

5. Corrective maintenance (1957)

• It improves equipment and its components so that preventive maintenance can be carried out reliably. Equipment with design weakness must be redesigned to improve reliability or improving maintainability.

6. Maintenance prevention (1960)

• It indicates the design of new equipment. Weakness of current machines are sufficiently studied on site information leading to failure prevention, easier maintenance and prevents of defects, safety and ease of manufacturing) and are incorporated before commissioning a new equipment.