CPT Maintenance Awareness 3 — Questions and Answers
Question 1: A production technician finds a machine leaking hydraulic fluid onto the floor. What is the MOST appropriate immediate action?
- Continue operating and report at shift end
- Stop the machine, contain the spill, and report to maintenance (Correct answer)
- Add more fluid and keep running
- Place a sign near the leak and move on
Correct answer: Stop the machine, contain the spill, and report to maintenance
Hydraulic fluid leaks create slip hazards and indicate a potential system failure; stopping the machine and containing the spill prevents injury and equipment damage.
Question 2: What is the purpose of a work order system in maintenance management?
- To track employee attendance during repairs
- To document, prioritize, and assign maintenance tasks (Correct answer)
- To schedule production output targets
- To record raw material usage
Correct answer: To document, prioritize, and assign maintenance tasks
Work orders document requested tasks, assign responsibility, track parts used, and provide history for future planning and analysis.
Question 3: In the context of TPM (Total Productive Maintenance), what are autonomous maintenance tasks typically performed by?
- External contractors only
- Production operators themselves (Correct answer)
- Quality inspectors
- Plant engineers exclusively
Correct answer: Production operators themselves
TPM involves production operators in basic maintenance tasks such as cleaning, inspecting, and lubricating their own equipment.
Question 4: Which safety procedure ensures that stored energy (electrical, hydraulic, pneumatic) is safely released before maintenance begins?
- 5S methodology
- Lockout/Tagout (LOTO) (Correct answer)
- Kaizen event
- Root cause analysis
Correct answer: Lockout/Tagout (LOTO)
Lockout/Tagout (LOTO) procedures control hazardous energy by locking energy sources and tagging equipment to prevent accidental startup during maintenance.
Question 5: What is a 'zero-defect' mindset in maintenance awareness?
- Eliminating all maintenance records
- Striving to prevent defects through proper equipment care and inspection (Correct answer)
- Accepting a small percentage of defects as normal
- Reducing the maintenance workforce to zero
Correct answer: Striving to prevent defects through proper equipment care and inspection
A zero-defect mindset drives operators and maintainers to prevent defects at the source rather than catching them after they occur.
Question 6: Compressed air lines should be bled (depressurized) before disconnecting because:
- It saves compressed air costs
- Pressurized lines can release stored energy and cause injury (Correct answer)
- Regulations require a 10-minute bleed time
- It makes the fitting easier to unscrew
Correct answer: Pressurized lines can release stored energy and cause injury
Pressurized pneumatic lines contain stored energy that can cause fittings to fly off or equipment to move suddenly, injuring workers.
Question 7: When should a production technician use a personal arc flash PPE kit near electrical panels?
- Only when replacing fuses
- Whenever working within the arc flash boundary of energized electrical equipment (Correct answer)
- Only when instructed by an engineer
- Only during scheduled outages
Correct answer: Whenever working within the arc flash boundary of energized electrical equipment
Arc flash PPE must be worn whenever an authorized worker enters the established arc flash boundary of energized equipment, as defined by an arc flash hazard analysis.
CPT Maintenance Awareness 3
A production technician finds a machine leaking hydraulic fluid onto the floor.
What is the MOST appropriate immediate action?