Intro To Industrial Maintenance| 168
Questions| With Complete Solutions
Course
Industrial Maintenance
1. What is industrial maintenance and why is it important?
Solution:
Industrial maintenance refers to the upkeep, repair, and optimization of machines and systems in
industrial settings to ensure efficient and safe operation. It is important because it:
Minimizes downtime
Extends equipment lifespan
Ensures safety for workers
Maintains product quality
Reduces operational costs
2. Name and briefly explain three types of industrial maintenance.
Solution:
1. Preventive Maintenance: Regular and scheduled maintenance to prevent breakdowns
(e.g., oiling machines monthly).
2. Corrective Maintenance: Repairing equipment after a fault is detected.
3. Predictive Maintenance: Using sensors and data analysis to predict failures before they
happen.
3. A motor is rated at 5 kW. If it runs 8 hours a day, how much energy does it consume in a
week (in kWh)?
Solution:
Energy per day = 5 kW × 8 h = 40 kWh
Energy per week (7 days) = 40 kWh × 7 = 280 kWh
4. What is the function of lubrication in machines?
,Solution:
Lubrication reduces friction between moving parts, minimizes wear and tear, dissipates heat,
prevents rust, and helps maintain efficient operation of the machine.
5. Describe two safety precautions to take before performing maintenance on industrial
equipment.
Solution:
1. Lockout/Tagout (LOTO): Disconnect and isolate energy sources before servicing.
2. Wear PPE (Personal Protective Equipment): Such as gloves, safety goggles, and
protective clothing.
6. What is the difference between mechanical and electrical maintenance?
Solution:
Mechanical maintenance involves upkeep of physical parts like gears, belts, and shafts.
Electrical maintenance deals with components like motors, wiring, and control systems.
7. A machine has a Mean Time Between Failure (MTBF) of 100 hours and Mean Time To
Repair (MTTR) of 5 hours. What is its availability?
Solution:
Availability = MTBF / (MTBF + MTTR)
= 100 / (100 + 5) = ≈ 0.952 or 95.2%
8. Explain how a maintenance schedule benefits an industrial plant.
Solution:
A schedule helps in planning resource use, reduces emergency repairs, improves reliability,
tracks history of maintenance, and supports budgeting and compliance with standards.
9. What is condition-based maintenance? Give one example.
Solution:
Condition-based maintenance involves performing maintenance based on real-time equipment
, condition.
Example: Replacing a machine bearing only when vibration sensors detect imbalance.
10. List three tools commonly used in industrial maintenance and their uses.
Solution:
1. Multimeter – Measures voltage, current, and resistance.
2. Wrench – Tightens or loosens bolts and nuts.
3. Thermal camera – Detects overheating in electrical systems.
11. What is the purpose of a maintenance logbook?
Solution:
A maintenance logbook records details of maintenance activities, including date, time, type of
work done, spare parts used, and signatures. It helps in tracking equipment history and planning
future maintenance.
12. Define the term “downtime” in industrial maintenance.
Solution:
Downtime refers to the period during which a machine or system is not operational due to
failure, repairs, or maintenance activities, leading to reduced productivity.
13. Name two causes of excessive vibration in industrial machines.
Solution:
1. Misalignment of shafts or pulleys
2. Worn-out bearings or unbalanced rotating parts
14. What does the abbreviation “PPE” stand for and why is it important?
Solution:
PPE stands for Personal Protective Equipment. It is crucial for protecting workers from
injuries due to exposure to mechanical, electrical, or chemical hazards.
15. Explain the term “Root Cause Analysis” (RCA).
Questions| With Complete Solutions
Course
Industrial Maintenance
1. What is industrial maintenance and why is it important?
Solution:
Industrial maintenance refers to the upkeep, repair, and optimization of machines and systems in
industrial settings to ensure efficient and safe operation. It is important because it:
Minimizes downtime
Extends equipment lifespan
Ensures safety for workers
Maintains product quality
Reduces operational costs
2. Name and briefly explain three types of industrial maintenance.
Solution:
1. Preventive Maintenance: Regular and scheduled maintenance to prevent breakdowns
(e.g., oiling machines monthly).
2. Corrective Maintenance: Repairing equipment after a fault is detected.
3. Predictive Maintenance: Using sensors and data analysis to predict failures before they
happen.
3. A motor is rated at 5 kW. If it runs 8 hours a day, how much energy does it consume in a
week (in kWh)?
Solution:
Energy per day = 5 kW × 8 h = 40 kWh
Energy per week (7 days) = 40 kWh × 7 = 280 kWh
4. What is the function of lubrication in machines?
,Solution:
Lubrication reduces friction between moving parts, minimizes wear and tear, dissipates heat,
prevents rust, and helps maintain efficient operation of the machine.
5. Describe two safety precautions to take before performing maintenance on industrial
equipment.
Solution:
1. Lockout/Tagout (LOTO): Disconnect and isolate energy sources before servicing.
2. Wear PPE (Personal Protective Equipment): Such as gloves, safety goggles, and
protective clothing.
6. What is the difference between mechanical and electrical maintenance?
Solution:
Mechanical maintenance involves upkeep of physical parts like gears, belts, and shafts.
Electrical maintenance deals with components like motors, wiring, and control systems.
7. A machine has a Mean Time Between Failure (MTBF) of 100 hours and Mean Time To
Repair (MTTR) of 5 hours. What is its availability?
Solution:
Availability = MTBF / (MTBF + MTTR)
= 100 / (100 + 5) = ≈ 0.952 or 95.2%
8. Explain how a maintenance schedule benefits an industrial plant.
Solution:
A schedule helps in planning resource use, reduces emergency repairs, improves reliability,
tracks history of maintenance, and supports budgeting and compliance with standards.
9. What is condition-based maintenance? Give one example.
Solution:
Condition-based maintenance involves performing maintenance based on real-time equipment
, condition.
Example: Replacing a machine bearing only when vibration sensors detect imbalance.
10. List three tools commonly used in industrial maintenance and their uses.
Solution:
1. Multimeter – Measures voltage, current, and resistance.
2. Wrench – Tightens or loosens bolts and nuts.
3. Thermal camera – Detects overheating in electrical systems.
11. What is the purpose of a maintenance logbook?
Solution:
A maintenance logbook records details of maintenance activities, including date, time, type of
work done, spare parts used, and signatures. It helps in tracking equipment history and planning
future maintenance.
12. Define the term “downtime” in industrial maintenance.
Solution:
Downtime refers to the period during which a machine or system is not operational due to
failure, repairs, or maintenance activities, leading to reduced productivity.
13. Name two causes of excessive vibration in industrial machines.
Solution:
1. Misalignment of shafts or pulleys
2. Worn-out bearings or unbalanced rotating parts
14. What does the abbreviation “PPE” stand for and why is it important?
Solution:
PPE stands for Personal Protective Equipment. It is crucial for protecting workers from
injuries due to exposure to mechanical, electrical, or chemical hazards.
15. Explain the term “Root Cause Analysis” (RCA).
