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MAINTENANCE Management
MAINTENANCE Management
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                                    MAINTENANCE MANAGEMENT QUIZ
                             
Evaluate your basic understanding of the maintenance management functions through the following quiz?

To answer, please fill in, tick or explain as per the requirement.
                                          
(1) An important statement, such as “achieving maximum plant availability at minimum cost” can be regarded as ………………………………….

(2) The ratio of ‘MTBF’ to ‘MTBF + MTTR + MWT’ is supposed to be representing ………………………………………….                 
     
(3) The stages during which 80% of the whole life cycle costs of an asset get decided are described as …………………………………………       

(4) A popular methodology of ‘Root Cause Analysis’, used to establish causes for maintenance problems, is based on diagrams and frequently called as .…………………      

(5) If the failure of a system is given as the sum of the individual failure rates of different elements constituting the system, then the configuration of the system is called as  
…………………………………….

(6) A fixed time replacement policy is usually suggested for an item with random failure characteristic showing a constant probability of failure at all ages. True or False?      

(7) Do we need to improve maintenance productivity in industry? Why?
        
(8) What will happen if MTBF of a machine in your department gets reduced?

(9) The sum of direct maintenance cost and indirect maintenance cost is called as
…………………………………………..

(10) The ‘Up Time’ of a machine on four consecutive occasions was noticed as UT1, UT2, UT3 & UT4.

      If   X = UT1 + UT2 + UT3 + UT4
                                     4
      Then, X will represent ………………………..

(11) The ratio of ‘Capital Investment’ to ‘Profit’ is known as …………………………..

(12) When maintenance is done only because it needs to be done since it has already been planned and scheduled, or because that is an established practice though, in real sense, there may not be any need of it, then such type of maintenance can be referred as ………………………………………..
 
(13) In maintenance stores, the inventory of ‘C’ class of items in terms of money value is often found lower than that of ‘A’ or ‘B’ class items in different companies. True or False?

(14) The art of directing and inspiring people and the process of getting things done through them is usually referred as ……………………………………

(15) The purpose of planned maintenance is mainly to reduce breakdowns and downtime but not necessarily the total maintenance cost. True or False? 

(16) Conventionally, in many plants, maintenance activities are devoted to achieving maximum plant availability which is influenced by the down time losses only. However, there are other equipment losses also which are frequently found present in many cases. It’s therefore equipment availability alone cannot formulate the correct parameter for evaluating the overall equipment performance. True or False?

(17) Roughly, what (%) may be the ‘Inventory Carrying Cost’ in your company’s stores as per your guesstimate?                                                                                                  
(18) Maintenance technique which is usefully employed not only to reduce downtime due to excessive shutdowns but also to reduce downtime due to excessive breakdowns is frequently known as …………………………………………
 
(19) For many industries operating in a developing country like ours, the ratio of cost of maintenance materials to cost of maintenance labour may be found in the range of about 70% (maintenance materials) to 30% (maintenance labour) or alike. True or False?

(20) An accident occurs when an unsafe condition is combined with an unsafe act. Many safety surveys indicate that eighty to ninety percent of the accidents are caused due to “unsafe conditions”. Therefore, “unsafe conditions” constitute the major cause for most of the industrial accidents. True or False?

(21) Certain maintenance activities that turn out to be uneconomical in a developed country can very well become economical in a developing country. Why? 
 
(22) What is the characteristic of equipment design that is generally represented by MTBF?                                                                                                                                               
(23) Preventive maintenance carried out on scheduled fixed-time basis is often likely to have elements of both over maintenance as well as under maintenance. In order to control ill effects of both over maintenance and under maintenance, the concept of condition-based Predictive Maintenance was evolved and recommended by the experts. True or False?

(24) Statements, such as, “I am working in the maintenance department for the last 20 years. I know my problems best. Nobody else can do the way I have been doing. What more can you expect from me!” are supposed to represent ……………………………….. 

(25) Once the daily maintenance work is recorded in a log book, there is practically no need to transfer it to the respective history cards, and if somebody is doing so, he is fruitlessly duplicating the work. True or False? Why? 

(26) The ratio of ‘Output’ (representing production) to ‘Input’ (representing ‘3M’ resources) is popularly known as …………………………………….  

(27) Knowing in advance “What” and “Where” is going wrong in different machines does not help much because if any breakdown is to occur, it will occur certainly. True or False?  
 
(28) A machine, for which both MTTR and MTBF are high, is likely to yield low 
       machine availability. True or False? Why?

(29) The technique that is based on infrared radiation to detect hot spots or high 
       temperature conditions in various plant equipment is called as ………………..

(30) Readings about vibration amplitude were taken on an equipment at different time
       intervals. A higher vibration will directly reveal the cause of trouble through such 
       readings. True or False? 

(31) The ‘Down Time’ of a machine on four consecutive occasions was noticed as DT1, DT2, DT3 & DT4.

       If   Y = DT1 + DT2 + DT3 + DT4
                                    4
       Then, Y will represent ………………………………

(32) For effective lubrication programme, the following “5 Right” things are always considered essential:
 
(i) Right Type
(ii) Right Quantity
(iii) Right Method
     (iv)    Right …………
     (v)     Right …………

(33) Good maintenance can often result in lower consumption of electrical power. For example, worn out pumps or motors running on loose V-belts, etc. are supposed to consume more electrical power. True or False?

(34) A Gantt Chart forever provides better effectiveness in planning & scheduling various activities of a maintenance job compared to PERT/CPM.

(35) The inventory carrying cost in the stores of a company was estimated at 20%. However, the yearly inflation rate was recorded close to 7%. If an item is kept in the stores for a period of 1 year, how much more will it actually cost compared to its original price after 1 year?  

(36) The third generation findings prove that failure rate of an item (or in other words, reliability of the item) does not always depend on its operating age. True or False?

(37) Bathtub curve describes a particular form of the hazard function and indicates failure rate pattern observed in some products during their lifetime which comprises of three distinctive parts. True or False?

(38) If stock-in cost for an item is more than its stock-out cost, then there is no need to stock the item in stores. True or False? Why?

(39) RCM technique advocates if the criticality of a failure falls in insignificant category, it can be left to “run to failure” strategy. True or False?

(40) If availability of a machine is influenced by its reliability, what is the other machine characteristic that also affects its availability? 

(41) Which one of the following statements explains the meaning of ‘Preventive Maintenance’ in a better way:

     (i) Replacing failed parts with new parts when required.
     (ii) Finding defects of the machine before breakdowns.
     (iii) To anticipate machine defects & failures in advance and take
           proper proactive action before they get converted into breakdowns.

(42) During 20th Century, improvement in productivity was considered much necessary. However, during 21st Century, improvement in productivity has proved more or less meaningless because profitability is supposed to be of greater value. True or False?

(43) The approach which is a combination of management, financial, engineering and other practices applied to physical assets in pursuit of economic life-cycle costs; that is concerned with the specification and design for reliability and maintainability of plant, machinery, equipment, buildings and structures, with their installation, commissioning, maintenance, modification and replacement, and with feedback of information on design, performance and costs is known as …………………………………………

(44) The more the maintenance workload in a maintenance department, the better will be the management of maintenance function. True or False? Why?

(45) At high pressures with impact conditions, the abrasion that involves removal of sizeable particles from a surface by the action of a coarse abrasive material is called as 
……………………………………..

(46) The time interval between the point at which the onset of failure can be detected and the point at which functional failure occurs is called as…………………….. 

(47) A failure mode describes how equipment can fail and potentially result in a functional failure. True or False?

(48) The science and practice of wear, friction and lubrication applied to engineering surfaces in relative motion is called as …………………………………..

(49) Third generation research originally carried out by two Americans, Stanley Nowlan and Howard Heap revealed that not one or two but “Six Failure Patterns” actually occur in practice. True or False?               

(50) The maintenance practice which suggests that maintenance should ideally be carried out just at that point of time when plant equipment and machinery actually requires maintenance is called as ……………………………………… 

(51) The wear mechanism that is attributed to the cyclic loading of two surfaces in mutual contact and usually occurs without prior indication of major loss of the surface material is known as ……………………………………………

(52) A failure mode whose failure effects do not become apparent to the operators
on its own under normal circumstances is known as ………………………………………

(53) In a system involving a pump, coupling and a motor, the reliability of each component is 90%. In such a case, the reliability of the overall system (pump-coupling-motor together) will be much less than 90%. True or False?

(54) In complex systems, as high as 60% cases represent “Bathtub” type of failure pattern. (Tick):                                                       

(55) The probability of failure - free operation of a machine within a given time and specified working conditions is called as..........................................
(56) A process that is used to determine "What maintenance must be done" to ensure that a physical asset continues to fulfill its intended functions in its present operating context,
is called as.....................................................

(57) Why should V-belts be avoided to run in loose condition? How Flat belts become preferable over V-belts in certain cases?

(58) In brainstorming, the role of logic should start after the creative process gets over. We should use our logic in separating out the useful ideas from the list of brainstormed ideas and finally in evaluating them for proper selection. True or False?

(59) In order to effect reduction in overall inventory of maintenance stores, we need to be guided by the broad principles, viz.  (i) “Reduce Consumption Cost” of maintenance items (ii) “Reduce Stocking Cost” of maintenance items. True or False? Why? 

(60) TPM is somewhat analogical to family team approach where all family members are ready to co-operate and act as a harmonious team to contribute to common objectives and solve problems jointly. For example, in TPM, both production and maintenance need to share a common objective, i.e. maximum overall equipment effectiveness. True or False? 
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