CPM TPM & Predictive Maintenance 3 — Questions and Answers
Question 1: Which step of the 7-step autonomous maintenance process involves restoring equipment to its basic condition by eliminating contamination sources?
- Step 3 – Develop cleaning and lubrication standards
- Step 1 – Initial cleaning and inspection (Correct answer)
- Step 4 – General inspection
- Step 2 – Eliminate contamination sources and hard-to-access areas
Correct answer: Step 1 – Initial cleaning and inspection
Step 1 of autonomous maintenance is initial cleaning, which exposes defects and establishes a baseline equipment condition.
Question 2: A plant uses ultrasonic detection on compressed air systems. What failure mode is this technique best suited to detect?
- Bearing race spalling
- Leaks and partial discharge (Correct answer)
- Shaft misalignment
- Thermal fatigue cracks
Correct answer: Leaks and partial discharge
Ultrasonic detectors excel at identifying the high-frequency sound generated by compressed air leaks and electrical partial discharge.
Question 3: What does the 'maintenance prevention' pillar of TPM aim to achieve during the equipment design phase?
- Reduce spare parts inventory
- Design equipment that requires minimal maintenance and is easy to maintain (Correct answer)
- Train operators to perform corrective repairs
- Establish lubrication frequencies
Correct answer: Design equipment that requires minimal maintenance and is easy to maintain
Maintenance prevention incorporates lessons learned from existing equipment into new equipment designs to minimize future maintenance needs.
Question 4: Which failure distribution pattern is best described by the Weibull distribution when the shape parameter (β) is less than 1?
- Wear-out failures increasing over time
- Random failures with constant failure rate
- Infant mortality failures decreasing over time (Correct answer)
- Bathtub curve complete lifecycle
Correct answer: Infant mortality failures decreasing over time
A Weibull shape parameter β < 1 indicates a decreasing failure rate, characteristic of infant mortality or early-life failures.
Question 5: In a reliability-centered maintenance (RCM) analysis, what is the first question asked about each function?
- What is the consequence of the failure?
- What causes the failure?
- In what way can the item fail to fulfill its function?
- What are the performance standards required? (Correct answer)
Correct answer: What are the performance standards required?
RCM begins by defining functions and their associated performance standards before identifying failure modes and consequences.
Question 6: A maintenance planner notices that a pump's MTTR has doubled over six months. What does this most likely indicate?
- The pump is failing less frequently
- Repairs are taking longer, possibly due to parts availability or skill gaps (Correct answer)
- Preventive maintenance intervals are too short
- The pump has reached its design life
Correct answer: Repairs are taking longer, possibly due to parts availability or skill gaps
Increasing Mean Time To Repair (MTTR) suggests that repair activities are becoming less efficient, often due to spare parts delays or workforce skill issues.
Question 7: Which lubrication principle is associated with the formation of a full fluid film between bearing surfaces, completely separating them?
- Boundary lubrication
- Mixed-film lubrication
- Hydrodynamic lubrication (Correct answer)
- Elastohydrodynamic lubrication
Correct answer: Hydrodynamic lubrication
Hydrodynamic lubrication occurs when a pressurized fluid film fully separates surfaces, achieving minimal wear and friction.
CPM TPM & Predictive Maintenance 3
Which step of the 7-step autonomous maintenance process involves restoring equipment to its basic condition by eliminating contamination sources?