Planning is performed by the...
Firs-line, general, and top-level supervisors
maintain equipment in good operating condition to
meet production goals, minimize downtime, and operate production line safely
A Leadman's responsibility is limited to
instructing
The first maintenance organization was a/an
line organization
In a functional organization, work is divided according to...
equipment type
An area organization...
borrows craftsman as needed
in a centrally controlled organization
control is limited in the field, large projects are handled separately, work is assigned as requests are processed
At different times , maintenance is controlled by the...
maintenance superintendent
An organization chart
contains all necessary detail
you can overcome resistance to organization changes by
advance preparation, bargaining, and discussion
The written work order used for short duration running repairs is a
job ticket
There are______________________ types of written orders you could use.
Five types of written orders
Work orders -
major planned and scheduled tasks
Job tickets
Short duration running repairs
standing work orders
repeated job actions
master schedules
service and frequency of work under standing work order
Special work orders
Preventative maintenance
Reserve ______________________ instructions for emergencies, as when a worker is injured, or a piece of equipment is nearing breakdown
Verbal instructions
It is important for a supervisor to sign the stock issue record T/F
false
Emergencies -
work that must be done immediately
Unscheduled work—
repairs you can delay safely because the equipment won't deteriorate further.
• Planned and scheduled work—
projects that require much advance preparation (usually not handled by first-line supervisors).
Which type of maintenance includes the inspection of equipment?
preventive
scheduling maintenance work is one of the maintenance planners duties t/f
false
installing, modifying, and relocating equipment is considered non-maintenance work and should be funded separately. t/f
false
the maintenance supervisor can approve schedules for all equipment in the plant t/f
false
Project work
construction, installation, relocation, or modification of present equipment and buildings
construction
building or changing structure of facility
installation
installing new or rebuilt equipment
equipment modiication
major changes in existing equipment or facilities
The term maintenance work refers to the repair and upkeep of equipment and facilities. The work covers preventive maintenance, unscheduled repairs, scheduled maintenance, emergency repairs, and ______________________ support
facility
Preventive maintenance
means any action taken to extend equipment life or prevent failure before an item malfunctions. It includes inspecting, testing, lubricating, adjusting, cleaning, and replacing components.
Unscheduled repairs are ______________________ work that can be completed in less than two manhours. The term also covers work that can be delayed for a short time with little risk of equipment failure.
Nonemergency
Scheduled maintenance refers to major repairs, ______________________, and overhauls.
rebuilds
Emergency repairs
are repairs needed immediately
Facility support is a term that covers ______________________work, building and grounds maintenance, and tool sharpening.
janitorial
unscheduled repairs are usually defined as taking not more than how many manhours?
2
• Adjustments. Minor changes requiring only ______________________ tools, no parts, and usually less than 0.5 manhours.
hand
Backlog
Estimated manhours required to complete all work currently behind schedule. Usually divided into categories according to need: parts and materials, downtime, manpower, or outside support.
Deferred maintenance.
Maintenance you can safely postpone (becomes part of the backlog).
Equipment repair history. List of repairs made on a piece of equipment that includes ______________________ and cost information.
dates
Failure coding
List of causes of equipment failure. The causes include lack of lubrication, operator abuse, and material fatigue, for example.
Inspection
Checking equipment to determine needed repairs.
Maintenance work order. A detailed ______________________ request for maintenance services
written
Major repairs.
Extensive, nonroutine repairs requiring a repair crew.
Minor repairs
Repairs completed by one worker using hand tools, completed in less than two hours. (In many cases, two workers are used for safety's sake.)
Modification. Change in equipment capability or ______________________.
configuration
Overhaul.
Inspection teardown and repair of equipment to restore it to effective operating condition.
Planning. Determining the resources and ______________________ needed for a major job.
actions
Priority.
Listing jobs according to their importance or urgency
Rebuild
Restore equipment to operating condition, using new parts as required.
Repetitive maintenance. Regularly ______________________ maintenance jobs.
recurring
Schedule compliance
Number of scheduled jobs completed on time. Also, actual hours worked compared with planned manhours.
Scheduling
Determining the best time to perform specific jobs.
Workload Manhours required to carry out a maintenance program. Includes all scheduled and unscheduled work and ______________________ support.
project
use a standing work order for
repeated job actions
PM services include
cleaning, inspecting, testing, and lubricating
work that must be done immediately
emergency work
the person who evaluates PM results and reviews all maintenance costs is known as the
maintenance engineer
construction, equipment installation, modification, and relocation are often done
by outside contractors
the amount of non-maintenance work a maintenance group can do is limited by
the amount of maintenance work required
close a work order when
the job is completed
major changes made in existing equipment or facilities are called
equipment modification
minor changes requiring only hand tools, no parts, and usually less than 0.5 manhours are called
adjustments
extensive, non-routine repairs requiring a crew are called
major repairs
work orders can originate from
maintenance operators,PM inspectors,Production personnel
which of the following is true of the work description included on a work order
it should only describe the symptoms observed
which of the following is true of assigning priorities
Production should join in
labor use is reported on the
Time sheet
Maintenance work involves which of the following tasks
repair of existing equipment
besides ordering engineering services from maintenance, the EWO can also be used to
order work from a contractor
the figure on a work order that explains why the work was necessary is called the
failure code
which of the following is true of reporting labor and material data from standing work orders?
the data are accumulated
the primary control document used by the maintenance planner is the
MWO
to carry out routine, repetitive chores, the master schedule can be used in combination with
the standing work order
which of the following is not among the questions a supervisor should ask himself when evaluating a decision
is the scope of the job established
the only practical way to reduce overall maintenance costs is to
reduce material installation time
the first step in developing a computer-based information program is to
decide what information services are needed
detailed labor information from past jobs can enable you to
decide how much labor you need to meet the workload.estimate how much overtime to schedule. measure the workload.
on which of the following would you not find labor use reported
Purchase order
The repair history
lists, by unit, significant repairs to key units of equipment
supplementary information that need not be collected regularly nor processed by computer is called
noncomputer information
informal information, or sampling
fills gaps in formal information
you can establish a generally reliable performance index by watching the ratio of
manhours used to unit of production output
reliable formal and informal information can help the supervisor by
expanding his/her influence in the department.identifying important performance factors.making day to day problems easier to control.
maintenance planning reduces costs because of a planned job
takes less time to perform
which of the following questions is not important in setting the time frame of a planned job
when was the job requested
if the detailed cost estimate on a job is considerably higher than the preliminary estimate, you should
notify the person who approved the job
setting priority on a job
should be done only after consulting the equipment user
finding a source for materials needed on a job
is a task for the purchasing department
the technique that determines which skills work together and the general order in which skills will be applied is called
job phase plan
when the planner leaves the separation of manpower needs and available craftsmen to the supervisor,
the supervisor loses confidence in the planner
which of the following accounts for the most planned work?
PM inspections
which of the following is true of planned jobs
they show 12 to 15% savings in labor
the principal result of planning major jobs is
a reduction in job time
a description of how work will be done to achieve a desired result is called a(n)
quality standard
quantity standards measure performance against which of the following
Time
which of the following conditions must your maintenance department meet if standards are to be workable
a good work order system.a means of measuring crew performance against standards.a standards use policy.
which standard technique is used to determine what percent each element of a job contributes to the total time spent on the job
work sampling
the most carefully measured standards used are called
engineering time standards
which of the following is true of benchmarks
They are based on historical data.they are typical jobs.they provide a predetermined time standard.
engineered performance standards are based on
the elements going into a job
receiving job instructions and planning equipment use are part of
job perpetration
backlog data comparing actual and estimated manhours can be used to control
the size and composition of the workforce
if you analyze a rising backlog by craft, you will see
which crafts may be understaffed
which of the following is a form of information returned by computer
Email.file transfer.Printed report.
the time sheet provides the computer with
labor information
a failure code, indicating why a repair was necessary, is an example of a computer
table
the computer program defines
which tables and files are used
the stock issue form provides computer data on
cost of contractor services. cost of issued stock parts.quantity of parts issued.
which of the following is true of a package program
it can be customized to meet specific needs.it is purchased by the client.it provides a universal application to any organization.
computers that connect to a central server and access standard shared information are
networked
which of the following is true of optical scanning
it requires a special input device
with proper programming, the computer information available to you should include
backlog reports.cost of maintaining specific equipment.status of jobs in progress.
a proper program allows you to answer
how your crew is performing.whether actual PM matches estimated PM.whether this PM reduces unscheduled work.
which of the following is a PM function
Lubricating.Replacing Components.Testing.
with which kind of equipment is PM effective
equipment that is up to standard.
emergency labor is usually more expensive then regular labor by
15%
if you cannot inspect every piece of equipment, PM can still be effective by concentrating on equipment whose failure can
affect product quality.cause large losses by functioning improperly.endanger the health of personnel.
when conducting inspections
concentrate on key areas
which of the following offer the greatest opportunity for both immediate and long-term improvements
planning
priorities for maintenance jobs should be assigned during which stage of the planning process
decision
which of the following is true of the maintenance job order
it authorizes work to proceed.it is a tool for allocating job costs.it is prepared by whoever needs the work done..
scheduled maintenance that must be completed within two weeks to avoid safety hazards, downtime, or equipment damage is considered
priority two
Deferred maintenance that should be completed only as labor becomes available is considered
priority five
to make sure that scheduled work is performed
a compliance measurement is used
when starting a PM program
stimulate interest immediately
when very few deficiencies are uncovered in PM inspections, you may wish to
extend the time between inspections
the initial startup of a PM program
is often on a trial and error basis
A technique that uses non destructive testing is called
predictive maintenance
which of the following is true of checklists
they link supervisor and crew
Equipment operators can often handle such minor chores as
checking lube and oil levels.testing hydraulic controls.verifying safety equipment device functions.
you can make certain that each piece or equipment is lubricated on schedule by
developing specific lube routes
How often you lubricate depends on which of the following factors
chemical decomposition.internal pressure and temperature.the machines operating speed.
in large facilities, lubrication crews usually work from a
master schedule
scheduling should precede
job execution
work that is not planned
can still be scheduled
production must be consulted in scheduling
jobs requiring equipment shutdown
cooperation in planning between production and maintenance can lead to what degree of cost reduction
12 to 15%
repair histories are helpful in determining
repetitive problems.time required for repair.which equipment is critical to production.
which of the following is true of forecasts
they are useful for planning several major jobs. they look ahead ten or more weeks.they help determine target dates for scheduling.
which of the following would be found on a schedule for production personnel
work description
once maintenance has verified the importance of recommended jobs and resource availability,
it prepares a rough schedule
scheduled compliance should be measured by
checking the number of jobs worked on against the number scheduled
the preliminary schedule is presented for approval
when available craft manhours are assigned
in order to respond effectively to an emergency, you must know
what is wrong.when the emergency occurred.who is reporting it.
when few resources are needed to remedy an emergency,
a job ticket is used
which of the following is true of unscheduled work
it is less costly than scheduled work
most PM services can be monitored with
a checklist
the standing work order is used to direct
a single, specific activity.repetitive PM work.snow removal.
the document that controls all maintenance work is the
work order
actual work completion should be reported
directly to the supervisor
which of the following is true of the engineering work order
it is used to order non-maintenance work.it is usually cross-referenced with an MWO.it is used for major equipment modifications.it is not a maintenance document.
janitorial work is controlled by
work standards and routes
the key person in control of maintenance work is the
first line supervisor
the single most important source of work identification for a supervisor is the
preventive maintenance program
the two most important aspects of PM work identification are
equipment inspection and testing
in which of the following would you find a parts description
the authorized stockage list.the parts fabrication drawings.the schematic blow up assembly drawings.
a major responsibility in the use of heavy industrial equipment and rigging is
availability.transportation.safety.
during routine or unscheduled work, an effective supervisor should
try to see each crew member several times each day
the first requirement on a worksite is
safety
when a major job has been completed
paper work for material procurement must be checked.the worksite should be cleaned up.repair must be recorded in equipment repair history.
to measure job performance
compare performance against a standard
after completing a major job, an effective supervisor will
join crew members in a positive critique
a major consideration after completing a job is
if the supervisor spent enough time on the jobsite
work performed exclusively by the same personnel is called
assigned maintenance
unscheduled repairs require
a relatively short period of time
which of the following are results of preventive maintenance
downtime minimized
how many hours does the average crew member work each year
1800
work is scheduled on an annual calendar called a
forecast
as a general rule, scheduled maintenance should represent how much of total workload
between 50 to 60%
when emergency repairs take up 5% of your total maintenance manpower
you are doing well
overtime is frequently caused by
emergency work.poor planning.unexpected work.
the number of estimated hours of planned work identified but not completed is called a
backlog
the right crafts are available in the correct number when
the workload is balanced
preventative maintenance is controlled by
the master schedule
routine janitorial and building and grounds chores are part of
plant support
unscheduled repairs should not be performed
on a first come, first served basis
operations support work
is often unsupervised
a well run PM program
allows more scheduled work to be done
which of the following is a contributing factor to absenteeism
bad working conditions.lack of job satisfaction.poor leadership.
limiting the number of employees who can take vacations at any one time is a halfway measure because
the makeup of the workforce must be considered.
when slight differences exist between time available for vacations and needed labor, you should consider
deferring work until later
the best source for determining skills needed for any particular period is
historical data
the productivity of the maintenance crew
is your personal responsibility
the stockroom in a small facility of 50 employees or less is usually run by
the maintenance department
control of inventory is shifted away from maintenance and toward accounting or purchasing when
computers are used
the role maintenance planners have in obtaining materials includes
helping supervisors write purchase requisitions
one material controller usually supports
two or more planners
the parts catalog
lists the most accurate parts information available
which of the following is used to enter costs into the work order reporting system
stockroom issue form
what portion of a parts purchase price is spent keeping it in stock for a year
25%
when determining the order point (OP), WP stands for the peak weekly usage. The peak weekly usage should represent
the worst week on record
The EOQ and the OP should be recalculated
at least once per year.when delivery times change significantly.when prices change significantly.
the two-bin system requires
continuous physical inventory
shop planners have a clear understanding of all the facets of the job because
they were craftsmen once
generally, work requiring planning support is directed first to the
planning staff
Noncraft personnel are often used to convey stock to the first station becuase
work moves more smoothly that way
routine maintenance and adjustments performed on a machine tool are usually handled by
the craftsman assigned to the machine
most component rebuilding is done
in the shop
which of the following is true of heavy mobile equipment shops
bays are usually laid out for specific equipment types.effective floor communication is vital. overhead cranes must be carefully placed.mechanics do not go to the stockroom themselves.
which of the following do machine, fabrication, and mobile equipment shops have in common
the parts and materials used by each are unique
performance in a mobile equipment shop is measured by
downtime
the location of facilities in a workplace
is highly important
which of the following is true of a central shop
all crafts are on hand.special tools are available.work planning is done in detail.response is not quick.
the greatest contribution a maintenance supervisor can make to cost control is
increased productivity on individual jobs
more labor per unit of material is usually spent on
small jobs involving little work
which of the following is not a budget commonly used
competitive budget
in zero-based budgeting, supervisory personnel
devise methods for meeting objectives
which form of budgeting requires that each activity must be broken down into resource requirements and related to production
performance budget
which form of budgeting measures production targets in terms of maintenance manhours
factored budget
one advantage of the factor budget is that
it is developed largely at supervisory level
when 40% of a facility's equipment is responsible for 70% of total maintenance costs,
it should get special attention in the budget
which of the following maintenance jobs are not in keeping with a successful maintenance cost reduction program
good will" jobs
which of the following is not a factor in material costs
efficiency of equipment
obtaining parts quickly is most likely to be the concern of the
maintenance supervisor
which of the following data are critical to performance at the first line supervisory level
costs.labor utilization.material use.
cost per production hour
measures labor utilization
how much time should a supervisor try to devote to supervising the workforce
60% or more
the supervisor in charge of a 20 worker crew generally has more control than
a supervisor in charge of 30 workers
the trend line shows
the degree of imporvement
the distribution of manhours among the work categories reflects
labor use
maintenance cost reports should show
major jobs such as lubrication.particular standing work orders.the cost of labor and materials.
comparing monthly maintenance costs with total units of production reveals
maintenance cost per unit
the real objective of measuring performance is to
identify areas that need improvement
The percentage of time the workforce is available for productive work is called
labor utilization
labor utilization and effectiveness together are the measure of
maintenance crew productivity
failure to anticipate labor or material needs
lowers productivity.reduces labor effectiveness.results in delays.
the number of workers needed to perform identical jobs
varies with worker effectiveness
cooperation between the maintenance and operations departments can be measured by
the degree of schedule compliance
who must have a complete responsibility for effective use of the labor force
the first line supervisor
excessive union grievance activities and high labor costs are often the result of
inadequate supervision
which of the following do maintenance reports typically not include
information on crew performance
which of the following is not a function of work sampling
to test workforce performance
which of the following is true of observation routes
routes should include areas of high density
effective training can
improve work quality.raise safety levels.save money.
when using self-study materials, do not
leave trainees entirely on their own
if you supervise a multicraft crew
make sure that all workers receive needed training
basic job skills
should be established in the classroom
on the job apprentice training is
the supervisors responsibility
one of the best way to find out if instructions are understood is to
inspect a job in progress
the most important consideration to emphasize to trainee is
safety
competition
must be used carefully
which of the following can slow learning progress
monotony
the first step in successful training is
preparation
quality supervision
reduces pressure
for a crew to be 40% productive, how much time must the supervisor spend in direct supervision
60%
the forecast
is a technique for setting objectives
planning
is a closer look at activities at short range.organizes a specific job in advance.saves execution time.
anticipating major tasks or problems
sharply reduces the number of emergencies
delegating work successfully
gives you more time to use elsewhere
when passing along work to your crew,
describe the job, emphasizing the desired results.
in planning a days work,
estimate the time needed for each job
learn to say no
when it is the most reasonable answer
when you must say no
suggest other ways of getting the desired result
the manner in which a department, section, or group is set up is called
organization
maintenance does not have complete control over PM procedures because
scheduling depends on equipment availability
the maintenance department has the least control over which of the following workload elements
engineering activities
which of the following factors does maintenance have the most control over
technology
which of the following is necessary in building an effective maintenance system
setting realistic objectives
in order to develop a maintenance concept, you must first
accurately determine maintenance needs
the primary monitor of maintenance needs is the
PM program
the cost estimate of the job normally determines
the level at which approval is obtained
the statement "major maintenance work must be classified by priority" is a typical
maintenance policy
practical, step by step instructions are called
procedures
in order to identify the workload, you must take which of the following into account
amount of work.available time.type of work.
to employ crew members effectively, you must
know their capabilities
your estimate of how long a job should take should become your
job goal
if one of your workers turns in low quality work, you should
provide training and point out any improvements in performance
while disciplining a worker, also use
counseling
the measure of how much work is done in a given time is called
productivity
overhauls and other major jobs may
need the help of a planner.require hiring additional workers.require the equipment to be shut down.
emergency jobs are unexpected conditions that
should be personally supervised
when an ex-pipefitter supervises electricians, he should
learn enough about electrical work to direct the job
which of the following may be duties of a facility engineering maintenance crew
construction.equipment modification.installation.
the person who usually establishes the facility maintenance system and sets the department goals is called the
maintenance manager
productivity goes down if workers are
afraid of accidents.uncomfortable.worried about the environment.
in matters concerning safety and comfort, you will earn the crew's cooperation if you.
try to correct the problems yourself
incomplete job instructions
force crew members to make decisions
offering training to employees often encourages
productivity
temporary repairs
cause maintenance problems
workers will be more likely to meet a high professional standard if
you set a standard of excellence
which of the following can result from absenteeism
decreased productivity.higher overtime costs.higher operating costs.
if you are new at the job and lack experience,
ask the crew to be patient until you catch on
if you are angry or impatient with one worker,
avoid transferring that feeling to others
to encourage group cooperation, you should
discuss job plans
the crew responds positively when
work quality improves
company rules apply to which of the following
contractors.employees.visitors.
which factor(s) should you consider when determining corrective action?
the attitude of the employee involved
how can rules best be presented to employees
by explaining them and giving each employee a copy
if you have been lax in enforcing rules, what must you do before "cracking down
let your employees know in advance of the change
when dealing with the steward, you should not
trade grievances
a worker needs to know he is
appropriate for the job.important to the team.properly rewarded.
motivation is decreased by
bad management
which of the following can result in lost time
accidents.parts arriving late.workers arriving late.
when employees feel no loyalty toward a company,
accidents will occur.turnover will be high.work quality will deteriorate.
a successful leader
praises good performance
supervisory training should always stress
leadership development
what is the most important aspect of your job as a supervisor
supervising employees
the best time keeping method is one in which employees
report time to their supervisor
which of the following is not usually a part of a group leaders job
applying discipline
making job planning a group effort
improves productivity
if you respect your crew members,
they will respond positively
you can expect a union representative to
compete with supervisor for the leadership position
what is the best method for settling industrial disputes
grievance procedure
which of the following actions would not be considered insubordination
misunderstanding an order
if an employee fails to follow an order given by a supervisor, as punishment, during a heated argument, a third party would probably
uphold the employee
when are late starts and early quits considered insubordinate acts
only if starting and quitting times are posted
if you cannot calm an abusive worker, you should
have the worker leave the facility
the appropriate corrective actions for vocal threats or threatening gestures is
discharge
the most serious insubordinate act is
physical assault
in order to take corrective action against an employee who physically assaults you away from the facility, you must prove that the
assault was work related
when should you not take action against horseplay
you should always take action against horseplay
if it is demonstrated that a supervisor did nothing to end a feud among employees, and a fight breaks out, a third party might
reduce the penalty against the fighters
what is the accepted way of handling two employees who engage in fighting
deal more severely with the worker who started the fight
corrective action decisions should not involve
impulsive action
your goal in taking corrective action should be to
develop good employees
a step by step procedure used to correct improper behavior is called
progressive discipline
if you take a punishing approach to corrective action,
you will create an adversarial relationship
which of the following is not acceptable as evidence
hearsay
who is responsible for informing employees of corrective action measures
supervisor
if an employee is physically unable to do his or her normal work, your first step should be to
find other work for the employee
if you see an employee sleeping on the job, your first action should be to
obtain a reliable witness
when an employee damages company property, you should first
complete an asset damage report
an arbitrator at a corrective action hearing will consider whether or not
you did your best to make a good employee.your action was consistent with past practice.your action was reasonable.
when an employee comes to you with a question
take the time to get the right answer
which of the following is a characteristic of an effective supervisor
handles problems promptly
grievances involving corrective action are often handled differently form other grievances in that
they skip steps in the normal procedure
if you answer to a problem is not acceptable to an employee, what will probably happen
a written grievance will be filed
when you receive a written grievance. what should you do
discuss it with your supervisor
it is an arbitrators job to
act as a judge.determine the arbitration settlement.determine which party to uphold.
an arbitrators reputation can be investigated by
calling other companies.checking with labor attorneys.reviewing past awards.
the best witness at an arbitration hearing is
an observer of the matter
when should you begin investigating a problem
as soon as it enters the grievance procedure
what is the best answer for a witness to give when asked by a union counsel, "where you told to say that
i was told to tell the truth
discrimination complaints are handled by the
EEOC
an affirmative action program involves
an analysis by job group
when interviewing a potential employee, do not ask him or her about
age.family status.religion.
the basic labor/management law of this country is the
wagner Act
which of the following is not a function of the national labor relations board
investigating discrimination complaints.
under the Taft-Hartley Act, the president can order workers back on the job by requesting a
temporary injunction
which act of congress regulates day to day affairs of unions
Landrum-Griffin Act
if an OSHA violation is not corrected within the specified time period,
a further penalty is imposed
OSHA requires that records be kept on
accidents and illnesses.exposure to hazardous materials.preventative maintenance.
the minimum wage is fixed by the
fair labor standards act