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Tier 2 · Fabrication Technician

Preventive maintenance and shop quality

Keep folders and measuring tools in known condition from their makers' manuals and OSHA's servicing rules, then catch bad parts with quality checks and fix the root cause with the 5 Whys and PDCA.

4 lessons · about 43 min · 10 diagrams · 4 videos

Version 1.1.0

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Lessons

0 of 4 complete

  1. Lesson 1 · 12 min · 12 slides · 10 questions

    Preventive maintenance and shop quality: principles and terminology

    The terms used for maintenance, why a folder needs care, how checks and records catch a bad part, and the OSHA rules that treat maintenance as servicing.

    You will be able to: Define reactive, preventive and predictive maintenance, name where a folder wears and what AFS's order system records around a quality check, and state the safety boundaries that apply to maintenance work.

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  2. Lesson 2 · 13 min · 12 slides · 11 questions

    Preventive maintenance and shop quality: materials, standards and design constraints

    Where maintenance intervals come from, two brake makers' published schedules, the OSHA rules that are inspections, caliper and tape care with a published tape benchmark, traceability, and the AFS limits a quality check uses.

    You will be able to: Identify what governs a maintenance plan (the maker's manual, use and climate, OSHA inspection rules), how measuring tools are kept trustworthy, and the AFS limits a quality check measures against.

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  3. Lesson 3 · 10 min · 12 slides · 7 questions

    Preventive maintenance and shop quality: methods and worked application

    A five-step method for a maintenance card, the pre-use walk-round, and four worked examples: a tape check, hours since service, an inspection record and a Pareto ranking of rejects, plus the restart and logging rules.

    You will be able to: Build a maintenance card from the manuals, run a pre-use check, check a tape against a benchmark, track machine hours, record an annual energy control inspection and rank defects with a check sheet and Pareto chart.

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  4. Lesson 4 · 8 min · 11 slides · 6 questions

    Preventive maintenance and shop quality: defects, verification and case study

    Defects that point at the machine or the measuring tools, root cause analysis, an illustrative case of marks along every bend worked through the 5 Whys and PDCA, the safety boundary for cleaning, and the evidence for review.

    You will be able to: Trace a defect on the piece back to a machine or tool condition, find its root cause with the 5 Whys, fix it with a PDCA trial, and document the evidence a reviewer needs.

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Practical task

Build a documented maintenance and quality packet for one machine or measuring tool you can get to (a brake, a shear, a caliper or a tape), from its own manual and the OSHA rules, then analyse one defect so a reviewer can follow every decision without asking.

Hand in

  • A maintenance card in four bands (before use, periodic, by hours, yearly), every task and interval cited to the maker's manual by model, or to the OSHA rule
  • A marked-up sketch of the machine or tool showing where each card task is done, with a lettered legend
  • A measuring-tool check: a tape against a reference length or a zeroed caliper, with the measured values, the benchmark used and the decision
  • A check sheet of rejects (real, or labelled hypothetical) with a Pareto ranking and the arithmetic
  • A defect analysis: the symptom, 5 Whys to a root cause, a PDCA trial with its measure, and the evidence a reviewer would read

Rubric

CriterionMeets the standard when
SourcesEvery interval names its source (maker and model, or the OSHA paragraph); none is invented or taken from a different machine without saying so.
Roles and safetyEach task names who does it; servicing tasks note energy control under 1910.147, and technician-only work is marked as such.
MeasurementMeasured values carry units, the benchmark is named, and the keep-or-remove decision follows from the numbers.
AnalysisThe Pareto shares add to 100 percent, and the defect analysis reaches a cause in the process, not a person.
VerificationThe PDCA Check step has a measure compared before and after, and the first piece after the fix is re-inspected and recorded.
AFS factsNothing in the packet claims an AFS schedule, log or interval that is not on record; AFS's folder is named without a model number.

Module quiz

10 questions drawn from a bank of 34; a new set each attempt. Pass mark 80%.

1. How many hours since the last service does the worked example find?
2. In the case study, what is the root cause of the marks?
3. Under 29 CFR 1910.147, lubricating a machine is part of what?
4. What does root cause analysis identify, as ASQ describes it?
5. What does predictive maintenance use to decide when to act?
6. Who does the periodic inspection of an energy control procedure?
7. In AFS's order system, which stage follows Forming?
8. Apart from ordinary use, what does Hasty name as the main cause of electronic failure?
9. Why does Hasty keep folder tooling clean and rust-free?
10. In the hypothetical month, what share of rejects do the top two causes make?