Maintenance and

Safety
Chapter 10

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 Machine break down. Management must provide
for this eventually in a way that maintains the
reliability and minimize the risk in the production
system. Whenever a machine breakdown. These
kinds of cost occur:
 Machine downtime and possible lost sales
 Idle direct and indirect labor
 Delays in other processes that may depend for material
supply on the machine that is down
 Increase scrap
 Customer dissatisfaction from possible delays and
deliveries
 The actual cost of repairing the machine.

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In general the reliability of the machines
can be maintained and improved by:
• Increasing the size of repair facilities and crews.
• Utilizing preventive maintenance where practical
so that critical parts are replaced before they fail.
• Providing for slack in the system at critical stages
so as to have parallel paths available. This
means the excess capacity so some machines
down will not affect the system substantially.

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 Plant maintenance. Planning and
Scheduling produces are aimed at
improving maintenance function and control
cost of maintaining plant and equipment.

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 Planning scheduling elements Requirements

6. Good work order system 6. Clear communication

7. Date of origin of the work 7. As far in advance as possible
8. Required completion date 8. Realistic, fair, and honest
9. Description of work needed. 9. Accurate, reliable,
coordinated, and
knowledgeable
11. Approval of work order.
10. Responsible, delegated, and
Authoritative
13. Scheduling the work order.
11. Cooperation, coordination,
accurate, complete, and
supported.

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 Maintenance Planning Operating
Policies
 Maintenance planning is applicable to the
Plant Maintenance Department which is
responsible for achieving desired
effectiveness in maintenance planning and
scheduling. The primary purpose of which
is to keep all machineries and devices in
proper working condition.

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 Maintenance Scheduling. It means the
arrangement in proper sequence, the many
phases of maintenance and fabrication
work, and the accomplishment of
preliminary activities to insure that each job
will be performed smoothly and effectively.

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 Purpose of Scheduling
 It provides a full day’s work for each craft man each day
 To achieve coordination among different shops and crew
on multi-craft job
 To smoothen flow of work to each craft’s man
 To meet required and realistic completion dates
 For assuring the availability and delivery of needed
materials.

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 Maintenance Planner
 He reviews and discusses with foreman
concerned the work order to be planned;
list down and sequences the events in the
job plan summary and prepares bill of
materials.

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 Factors influencing Maintenance
Scheduling. Maintenance scheduling can
only be properly implemented if certain
factors are taken into consideration. These
factors involve the availability of materials,
tools, equipment, and manpower.

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 There are several kinds of priorities. They are:
 Top priority (Emergency)- these are un-programmed jobs
that have to be attended to immediately due to their high
economic implications, like jobs involving safety hazards.
 Priority “A”- Jobs of an urgent nature requiring completion
seven days.
 Priority “B”- Jobs whose completion is required within
seven days to three weeks.
 Priority “C”- Jobs whose completion is more than three
weeks.

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 Daily Work Schedule. Good and effective
communication must always be maintained
between Plant Maintenance and Operation
personnel. A short Daily Scheduling
Meeting with participation of the
maintenances foreman, operating
personnel, planners and warehouse
materials expenditer must be held at 8:00
A.M. or earlier.

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 Material Control. The Plant Maintenance
Department must be amply authorized to
hedge on stock-outs of regularly used parts
through their equipment inventory parts list
that guides warehouse in reordering.

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 Maintenance Planner
 Accomplishes bill of materials for problem
materials or parts needed on the work order
as reviewed and discussed by him with
maintenance foreman concerned.

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 Maintenance Cost control. Another
important objective of maintenance
planning is to provide the maintenance
foreman a tool for monitoring maintenance
costs and control them to the extent that
correctable causes are discovered and
remedied.

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Maintenance Equipment
 Stairs and Ladders.
 1. Riser must be 7 inches
 Tread must be 11 inches
 Nosing must be 1 inches
 Width, not less than 36” or more than 88”
 Hand rail, 30” to 34” from top rail.
 Landing 3’6” wide.
 If made of concrete, tread must be rough finish.

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 Well designed ladders must have the following
characteristics
 Rungs must be spaced 12 inches from centers.
 It must be provided with ‘Gooseneck’ to hold on to ledge.
 A cage of 24” x 20” must be provided ladders with a height
of over 20 feet.
 Rubber footing must be provided.
 Rungs must be rectangular in cross-section.
 Wooden parts specially the side pieces must be of
longitudinal grains.

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 Common Defects of Ladders. There are a
number of things to watch out to make ladders
safe to use. They present varying degrees of
hazard to workmen which may trigger a bad fall.
They are:
 Uneven rung spacing
 Loose or missing rung
 Slippery rungs
 Poor material or cross grain
 Lack of toe clearance at the back of the ladder
 Poor construction

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 Types of Ladder. A great variety of ladders
have been developed to suit any kind of
job. However, one common characteristic
of ladder is that they are light and portable.
One unique characteristic of some of them
is that they are collapsible for ease of
transport and storage and some are
telescoping for jobs at various elevations

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 Today there are 12 known types of ladders, viz:
 Fixed ladder — one fastened to a structure in permanent
position
 Portable ladder — light ladder usable at various locations.
 Single ladder — sometime called a straight ladder
 Extension ladder — one consisting of 2 or more sections
traveling in guides or brackets adjustable to different
lengths.
 Step ladder — it has treads so constructed to be self-
supporting.

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 Side rolling ladder — a ladder that rides on a guide rail
 Trolley ladder — a unit running on track
 Sectional ladder — one consisting of 2 or more sections
so that when combined, functions as single ladder.
 “A” or trestle ladder — a unit consisting of 2 single ladders
hinged at the top to form equal angels at the base.
 Extension trestle — similar to above but it has an
additional single extension ladder adjustable vertically and
locked in place.
 Telescoping ladder — a unit mounted on rubber tired
platform with adjustable height.
 Chain or Rope ladder — one designed for emergency or
rescue work.

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 Ladder Safety Program. In a
comprehensive safety program, safety in
the use of the ladder must be included. This
is to protect the safety and well-being of
fields workers and servicemen. If a ladder
safety program is implemented, the
cooperation of the workers is very
essential.

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 This program must consider the following:
 Inspect every ladder as soon as it is received from suppliers.
 Set up a routine for regular or thorough inspections.
 Keep record for each ladder which indicates the following:
 Date purchased or built
 Date of inspections
 Condition and needed repairs
 Date of next inspection
 Record system supplemented by stenciling on ladder the date
of next inspection.
 Instruct men to observe precaution.
 Report to maintenance department any defect of the ladder.

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 Scaffolds. In the construction industry, a great
number of work must be done at varying heights
above the ground. This is specially so in the
construction of buildings, their maintenance and
repair. To facilitate in the work insure safety of
workmen, temporary elevated structures are often
built. In vary tall buildings, these working
platforms are suspended from above the building
by rope or steel cables. Some states in the U.S.A.
particularly New York have laws requiring
scaffolds more than 24 feet from the ground to be
secured or suspended from overhead supports.

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 Requirements in the use of scaffolds:
 Scaffolds must be of good design and well-
maintained.
 It must be suspended from overhead supports.
 When supported by rope, it must be of good
quality.
 Life lines must be attached to workmen’s belt
and to the building.

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 Types of Scaffolds:
 Tubular steel – for large construction and for
great heights.
 Swinging – a type generally used for painting,
window glazing, washing, and others.
 Suspended – one supported by an outrigger I-
beam to the frame of buildings of 5 storey or
higher, lowered and raised by steel cables.
 Built up – a wooden temporary type of scaffold.

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 Scaffold Design Requirements:
 They must be provided with railing 36 to 42
inches high.
 They must be have toe board.
 It must be provided with overhead protection.
 Materials used must be of good quality.
 Suspending rope or cable must be good quality.

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 Ramp
 This is a sloping or passageway connecting 2
floors of different levels. When a building is
constructed in installments or modules, it often
happens that floors are of uneven elevation.

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 Requirement of Ramps.
 Slope must be small, possibly about 1 foot to every 10
feet distance.
 Railing of 42 inches high must be provided.
 If made of cement or granolithic, it must be rough finish.
 If smooth finished, abrasive materials must be mixed in
the cement.
 When the ramp is used for construction, it must be
provided with cross-cleats with 11 inches intervals.
 If constructed in buildings, they should be at least 48
inches wide between railings.

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