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TPM & Predictive Maintenance Flashcards

7 cards from real CPM practice questions. Tap to flip, then mark Knew It or Still Learning — missed cards come back until you master them.

Read the first 7 TPM & Predictive Maintenance flashcards as text

  1. A manufacturing plant implements TPM and tracks its OEE. If availability is 90%, performance is 85%, and quality rate is 95%, what is the OEE?

    Answer: 72.7%

    OEE = Availability × Performance × Quality = 0.90 × 0.85 × 0.95 = 0.7268, approximately 72.7%.

  2. What is the main advantage of route-based predictive maintenance data collection over continuous online monitoring?

    Answer: Lower cost and flexibility to cover many assets

    Route-based data collection is more economical and allows a single technician to monitor many assets without the cost of permanent sensor installations.

  3. Which of the following best describes a 'failure finding task' in RCM?

    Answer: A task to check whether a hidden function has failed

    Failure-finding tasks are performed to detect hidden failures, particularly in protective devices that are not apparent during normal operation.

  4. In motor current signature analysis (MCSA), broken rotor bars typically produce sidebands around the supply frequency at what spacing?

    Answer: 2 × slip frequency

    Broken rotor bars create sidebands at ±2sf (twice the slip frequency) around the fundamental supply frequency in the current spectrum.

  5. A company calculates its maintenance cost as a percentage of estimated replacement value (ERV). A world-class benchmark for ERV percentage is typically in what range?

    Answer: 1–3%

    World-class maintenance organizations typically spend 1–3% of ERV annually on maintenance, while poorly performing plants often exceed 5%.

  6. What is the key difference between predictive maintenance (PdM) and preventive maintenance (PM)?

    Answer: PdM is condition-based and performed only when indicators warrant it; PM follows fixed schedules

    Predictive maintenance uses real-time condition data to determine when maintenance is needed, while preventive maintenance follows fixed time or usage intervals.

  7. In TPM, what does the term 'zero breakdown' goal specifically mean?

    Answer: Reducing unplanned equipment failures to zero through proactive maintenance

    Zero breakdown is a TPM goal that aims to eliminate unplanned stoppages through proactive care, not to stop all planned maintenance activities.