meet production goals, minimize downtime, and operate production line safely
question
A Leadman's responsibility is limited to
answer
instructing
question
The first maintenance organization was a/an
answer
line organization
question
In a functional organization, work is divided according to...
answer
equipment type
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An area organization...
answer
borrows craftsman as needed
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in a centrally controlled organization
answer
control is limited in the field, large projects are handled separately, work is assigned as requests are processed
question
At different times , maintenance is controlled by the...
answer
maintenance superintendent
question
An organization chart
answer
contains all necessary detail
question
you can overcome resistance to organization changes by
answer
advance preparation, bargaining, and discussion
question
The written work order used for short duration running repairs is a
answer
job ticket
question
There are______________________ types of written orders you could use.
answer
Five types of written orders
question
Work orders -
answer
major planned and scheduled tasks
question
Job tickets
answer
Short duration running repairs
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standing work orders
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repeated job actions
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master schedules
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service and frequency of work under standing work order
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Special work orders
answer
Preventative maintenance
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Reserve ______________________ instructions for emergencies, as when a worker is injured, or a piece of equipment is nearing breakdown
answer
Verbal instructions
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It is important for a supervisor to sign the stock issue record T/F
answer
false
question
Emergencies -
answer
work that must be done immediately
question
Unscheduled workβ
answer
repairs you can delay safely because the equipment won't deteriorate further.
question
β’ Planned and scheduled workβ
answer
projects that require much advance preparation (usually not handled by first-line supervisors).
question
Which type of maintenance includes the inspection of equipment?
answer
preventive
question
scheduling maintenance work is one of the maintenance planners duties t/f
answer
false
question
installing, modifying, and relocating equipment is considered non-maintenance work and should be funded separately. t/f
answer
false
question
the maintenance supervisor can approve schedules for all equipment in the plant t/f
answer
false
question
Project work
answer
construction, installation, relocation, or modification of present equipment and buildings
question
construction
answer
building or changing structure of facility
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installation
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installing new or rebuilt equipment
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equipment modiication
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major changes in existing equipment or facilities
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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
answer
facility
question
Preventive maintenance
answer
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.
question
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.
answer
Nonemergency
question
Scheduled maintenance refers to major repairs, ______________________, and overhauls.
answer
rebuilds
question
Emergency repairs
answer
are repairs needed immediately
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Facility support is a term that covers ______________________work, building and grounds maintenance, and tool sharpening.
answer
janitorial
question
unscheduled repairs are usually defined as taking not more than how many manhours?
answer
2
question
β’ Adjustments. Minor changes requiring only ______________________ tools, no parts, and usually less than 0.5 manhours.
answer
hand
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Backlog
answer
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.
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Deferred maintenance.
answer
Maintenance you can safely postpone (becomes part of the backlog).
question
Equipment repair history. List of repairs made on a piece of equipment that includes ______________________ and cost information.
answer
dates
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Failure coding
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List of causes of equipment failure. The causes include lack of lubrication, operator abuse, and material fatigue, for example.
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Inspection
answer
Checking equipment to determine needed repairs.
question
Maintenance work order. A detailed ______________________ request for maintenance services
answer
written
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Major repairs.
answer
Extensive, nonroutine repairs requiring a repair crew.
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Minor repairs
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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.)
question
Modification. Change in equipment capability or ______________________.
answer
configuration
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Overhaul.
answer
Inspection teardown and repair of equipment to restore it to effective operating condition.
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Planning. Determining the resources and ______________________ needed for a major job.
answer
actions
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Priority.
answer
Listing jobs according to their importance or urgency
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Rebuild
answer
Restore equipment to operating condition, using new parts as required.
you can make certain that each piece or equipment is lubricated on schedule by
answer
developing specific lube routes
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How often you lubricate depends on which of the following factors
answer
chemical decomposition.
internal pressure and temperature.
the machines operating speed.
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in large facilities, lubrication crews usually work from a
answer
master schedule
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scheduling should precede
answer
job execution
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work that is not planned
answer
can still be scheduled
question
production must be consulted in scheduling
answer
jobs requiring equipment shutdown
question
cooperation in planning between production and maintenance can lead to what degree of cost reduction
answer
12 to 15%
question
repair histories are helpful in determining
answer
repetitive problems.
time required for repair.
which equipment is critical to production.
question
which of the following is true of forecasts
answer
they are useful for planning several major jobs.
they look ahead ten or more weeks.
they help determine target dates for scheduling.
question
which of the following would be found on a schedule for production personnel
answer
work description
question
once maintenance has verified the importance of recommended jobs and resource availability,
answer
it prepares a rough schedule
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scheduled compliance should be measured by
answer
checking the number of jobs worked on against the number scheduled
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the preliminary schedule is presented for approval
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when available craft manhours are assigned
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in order to respond effectively to an emergency, you must know
answer
what is wrong.
when the emergency occurred.
who is reporting it.
question
when few resources are needed to remedy an emergency,
answer
a job ticket is used
question
which of the following is true of unscheduled work
answer
it is less costly than scheduled work
question
most PM services can be monitored with
answer
a checklist
question
the standing work order is used to direct
answer
a single, specific activity.
repetitive PM work.
snow removal.
question
the document that controls all maintenance work is the
answer
work order
question
actual work completion should be reported
answer
directly to the supervisor
question
which of the following is true of the engineering work order
answer
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.
question
janitorial work is controlled by
answer
work standards and routes
question
the key person in control of maintenance work is the
answer
first line supervisor
question
the single most important source of work identification for a supervisor is the
answer
preventive maintenance program
question
the two most important aspects of PM work identification are
answer
equipment inspection and testing
question
in which of the following would you find a parts description
answer
the authorized stockage list.
the parts fabrication drawings.
the schematic blow up assembly drawings.
question
a major responsibility in the use of heavy industrial equipment and rigging is
answer
availability.
transportation.
safety.
question
during routine or unscheduled work, an effective supervisor should
answer
try to see each crew member several times each day
question
the first requirement on a worksite is
answer
safety
question
when a major job has been completed
answer
paper work for material procurement must be checked.
the worksite should be cleaned up.
repair must be recorded in equipment repair history.
question
to measure job performance
answer
compare performance against a standard
question
after completing a major job, an effective supervisor will
answer
join crew members in a positive critique
question
a major consideration after completing a job is
answer
if the supervisor spent enough time on the jobsite
question
work performed exclusively by the same personnel is called
answer
assigned maintenance
question
unscheduled repairs require
answer
a relatively short period of time
question
which of the following are results of preventive maintenance
answer
downtime minimized
question
how many hours does the average crew member work each year
answer
1800
question
work is scheduled on an annual calendar called a
answer
forecast
question
as a general rule, scheduled maintenance should represent how much of total workload
answer
between 50 to 60%
question
when emergency repairs take up 5% of your total maintenance manpower
answer
you are doing well
question
overtime is frequently caused by
answer
emergency work.
poor planning.
unexpected work.
question
the number of estimated hours of planned work identified but not completed is called a
answer
backlog
question
the right crafts are available in the correct number when
answer
the workload is balanced
question
preventative maintenance is controlled by
answer
the master schedule
question
routine janitorial and building and grounds chores are part of
answer
plant support
question
unscheduled repairs should not be performed
answer
on a first come, first served basis
question
operations support work
answer
is often unsupervised
question
a well run PM program
answer
allows more scheduled work to be done
question
which of the following is a contributing factor to absenteeism
answer
bad working conditions.
lack of job satisfaction.
poor leadership.
question
limiting the number of employees who can take vacations at any one time is a halfway measure because
answer
the makeup of the workforce must be considered.
question
when slight differences exist between time available for vacations and needed labor, you should consider
answer
deferring work until later
question
the best source for determining skills needed for any particular period is
answer
historical data
question
the productivity of the maintenance crew
answer
is your personal responsibility
question
the stockroom in a small facility of 50 employees or less is usually run by
answer
the maintenance department
question
control of inventory is shifted away from maintenance and toward accounting or purchasing when
answer
computers are used
question
the role maintenance planners have in obtaining materials includes
answer
helping supervisors write purchase requisitions
question
one material controller usually supports
answer
two or more planners
question
the parts catalog
answer
lists the most accurate parts information available
question
which of the following is used to enter costs into the work order reporting system
answer
stockroom issue form
question
what portion of a parts purchase price is spent keeping it in stock for a year
answer
25%
question
when determining the order point (OP), WP stands for the peak weekly usage. The peak weekly usage should represent
answer
the worst week on record
question
The EOQ and the OP should be recalculated
answer
at least once per year.
when delivery times change significantly.
when prices change significantly.
question
the two-bin system requires
answer
continuous physical inventory
question
shop planners have a clear understanding of all the facets of the job because
answer
they were craftsmen once
question
generally, work requiring planning support is directed first to the
answer
planning staff
question
Noncraft personnel are often used to convey stock to the first station becuase
answer
work moves more smoothly that way
question
routine maintenance and adjustments performed on a machine tool are usually handled by
answer
the craftsman assigned to the machine
question
most component rebuilding is done
answer
in the shop
question
which of the following is true of heavy mobile equipment shops
answer
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.
question
which of the following do machine, fabrication, and mobile equipment shops have in common
answer
the parts and materials used by each are unique
question
performance in a mobile equipment shop is measured by
answer
downtime
question
the location of facilities in a workplace
answer
is highly important
question
which of the following is true of a central shop
answer
all crafts are on hand.
special tools are available.
work planning is done in detail.
response is not quick.
question
the greatest contribution a maintenance supervisor can make to cost control is
answer
increased productivity on individual jobs
question
more labor per unit of material is usually spent on
answer
small jobs involving little work
question
which of the following is not a budget commonly used
answer
competitive budget
question
in zero-based budgeting, supervisory personnel
answer
devise methods for meeting objectives
question
which form of budgeting requires that each activity must be broken down into resource requirements and related to production
answer
performance budget
question
which form of budgeting measures production targets in terms of maintenance manhours
answer
factored budget
question
one advantage of the factor budget is that
answer
it is developed largely at supervisory level
question
when 40% of a facility's equipment is responsible for 70% of total maintenance costs,
answer
it should get special attention in the budget
question
which of the following maintenance jobs are not in keeping with a successful maintenance cost reduction program
answer
"good will" jobs
question
which of the following is not a factor in material costs
answer
efficiency of equipment
question
obtaining parts quickly is most likely to be the concern of the
answer
maintenance supervisor
question
which of the following data are critical to performance at the first line supervisory level
answer
costs.
labor utilization.
material use.
question
cost per production hour
answer
measures labor utilization
question
how much time should a supervisor try to devote to supervising the workforce
answer
60% or more
question
the supervisor in charge of a 20 worker crew generally has more control than
answer
a supervisor in charge of 30 workers
question
the trend line shows
answer
the degree of imporvement
question
the distribution of manhours among the work categories reflects
answer
labor use
question
maintenance cost reports should show
answer
major jobs such as lubrication.
particular standing work orders.
the cost of labor and materials.
question
comparing monthly maintenance costs with total units of production reveals
answer
maintenance cost per unit
question
the real objective of measuring performance is to
answer
identify areas that need improvement
question
The percentage of time the workforce is available for productive work is called
answer
labor utilization
question
labor utilization and effectiveness together are the measure of
answer
maintenance crew productivity
question
failure to anticipate labor or material needs
answer
lowers productivity.
reduces labor effectiveness.
results in delays.
question
the number of workers needed to perform identical jobs
answer
varies with worker effectiveness
question
cooperation between the maintenance and operations departments can be measured by
answer
the degree of schedule compliance
question
who must have a complete responsibility for effective use of the labor force
answer
the first line supervisor
question
excessive union grievance activities and high labor costs are often the result of
answer
inadequate supervision
question
which of the following do maintenance reports typically not include
answer
information on crew performance
question
which of the following is not a function of work sampling
answer
to test workforce performance
question
which of the following is true of observation routes
answer
routes should include areas of high density
question
effective training can
answer
improve work quality.
raise safety levels.
save money.
question
when using self-study materials, do not
answer
leave trainees entirely on their own
question
if you supervise a multicraft crew
answer
make sure that all workers receive needed training
question
basic job skills
answer
should be established in the classroom
question
on the job apprentice training is
answer
the supervisors responsibility
question
one of the best way to find out if instructions are understood is to
answer
inspect a job in progress
question
the most important consideration to emphasize to trainee is
answer
safety
question
competition
answer
must be used carefully
question
which of the following can slow learning progress
answer
monotony
question
the first step in successful training is
answer
preparation
question
quality supervision
answer
reduces pressure
question
for a crew to be 40% productive, how much time must the supervisor spend in direct supervision
answer
60%
question
the forecast
answer
is a technique for setting objectives
question
planning
answer
is a closer look at activities at short range.
organizes a specific job in advance.
saves execution time.
question
anticipating major tasks or problems
answer
sharply reduces the number of emergencies
question
delegating work successfully
answer
gives you more time to use elsewhere
question
when passing along work to your crew,
answer
describe the job, emphasizing the desired results.
question
in planning a days work,
answer
estimate the time needed for each job
question
learn to say no
answer
when it is the most reasonable answer
question
when you must say no
answer
suggest other ways of getting the desired result
question
the manner in which a department, section, or group is set up is called
answer
organization
question
maintenance does not have complete control over PM procedures because
answer
scheduling depends on equipment availability
question
the maintenance department has the least control over which of the following workload elements
answer
engineering activities
question
which of the following factors does maintenance have the most control over
answer
technology
question
which of the following is necessary in building an effective maintenance system
answer
setting realistic objectives
question
in order to develop a maintenance concept, you must first
answer
accurately determine maintenance needs
question
the primary monitor of maintenance needs is the
answer
PM program
question
the cost estimate of the job normally determines
answer
the level at which approval is obtained
question
the statement "major maintenance work must be classified by priority" is a typical
answer
maintenance policy
question
practical, step by step instructions are called
answer
procedures
question
in order to identify the workload, you must take which of the following into account
answer
amount of work.
available time.
type of work.
question
to employ crew members effectively, you must
answer
know their capabilities
question
your estimate of how long a job should take should become your
answer
job goal
question
if one of your workers turns in low quality work, you should
answer
provide training and point out any improvements in performance
question
while disciplining a worker, also use
answer
counseling
question
the measure of how much work is done in a given time is called
answer
productivity
question
overhauls and other major jobs may
answer
need the help of a planner.
require hiring additional workers.
require the equipment to be shut down.
question
emergency jobs are unexpected conditions that
answer
should be personally supervised
question
when an ex-pipefitter supervises electricians, he should
answer
learn enough about electrical work to direct the job
question
which of the following may be duties of a facility engineering maintenance crew