TOOL EQUIPMENT AND

FACILITY
FOR
ENGINE MAINTENANCE
BY
UNTUNG MAHARGO BUDI PRANOTO
TOOL EQUIPMENT ENGINEERING DEPARTMENT OF ENGINE MAINTENANCE
JAKARTA 2008

1
Comply with Procedures

2
In addition to yourself is the
customer, treat with the
best treatment

Pranoto, UMB. 1990

3
READINESS WILL BE OBTAINED , IF
THE MAINTENANCE ON THE TOOL
EQUIPMENT FACILITY PERFORMED
OPTIMALLY

Pranoto, UMB. 2005

4
 CONTENT
1. INTRODUCTION
2. GENERAL
3. DESCRIPTION
4. CATEGORY
5. TEF MANAGEMENT
6. TEF MAINTENANCE BUSINESS PROCESS
7. TOOLS AND EQUIPMENT INTERESTED
8. CONTROL
9. FINANCE
10. TEF RELATED REGULATION
5
1. INTRODUCTION

6
 PHILOSOPHY

• Means of production, is the tool, equipment

and facility are the company’s assets
• To produce goods or services
• If a fully orientation on production and forget
about maintenance, it will gradually lose their
expected result, and even lose the asset itself,
means the same as the close of business
forever
7
 PRODUCTION
PROCESS

READINESS
AVAILABLE

RELIABLE
TOOL, EQUIPMENT AND
FACILITY

MAINTENANCE

8
TOOL EQUIPMENT ENGINEERING
BUSINESS PROCESS

9
 CUSTOMER ACTIVITY PRODUCT
CALIBRATION SHOP CALIBRATION OOTN

MODIFICATION DRAWING & PDS

TROUBLE SHOOT TE REP & REC

REPLACEMENT TE REP & REC

PRODUCTION
PMI REPAIR TE REP & REC

PRESERVATION PRESERVE LOG

MAINTENANCE CHECK PMI LOG

PPC PRODUCT SCHEDULING READINESS REPORT

PROCUREMENT T E PROCURE SPECIFICATION

TQDR

QUALITY APPROVED T E ETEAR

NCR

ENGINEERING DEVELOP LISTED & SPEC

PROJECT REPORT
MANAGEMENT PROJECT
BUDGET

PLANNER DEVELOP LISTED & SPEC

OTHER UNIT (GSE, FACILITY) REPAIR REPORT & CHECK 10

 SUPPLIER or VENDOR
PROCESS

Procurement Farm out In house Facility Receiving

Store

LEARNING & TOOL EQUIPMENT MAINTENANCE ENGINEERING FINANCE

GROWTH

PRODUCTION PPC PLANNER QUALITY MANAGEMENT OTHER

ENGINEERING
INTERNAL CUSTOMER

11
2. GENERAL

12
 COMPONENT SUPPORTING COMPANY

HUMAN MATERIAL
FINANCE
RESOURCES

ORDER PROCESS PROFIT

SYSTEM FACILITY
ENVIRONMENT
MACHINE

13
 TOOL

EQUIPMENT

FACILITY

14
 Tool

• Anything used as a means of accomplishing a

task or purpose
• Anything used as a means of performing an
operation or achieving an end
• is a device that can be used to produce an
item or achieve a task, but that is not
consumed in the process.

Ref. the Free Online Dictionary

15
 EQUIPMENT

• An instrumentality needed for an undertaking

or to perform a service
• Anything kept, furnished, or provided for a
specific purpose
• A machine in which incorporated of
mechanical, electrical, electronic, pneumatic,
hydraulic and measuring tool, that can make a
product and or process
Ref. to the Free Online Dictionary
16
 FACILITY
• BUILDING
• ELECTRIC
• CRANE
• COMUNICATION NET (INCL. COMPUTER)
• PART RACKS
• PNEUMATIC (AIR PRESSURE)
• WATER

17
3. DESCRIPTION

18
 Tooling, base on products are as follows

• Special Tools - Tooling specially designed by

manufacture. Identified by designated tool number
and description.
• Standard Tools - Tooling not available through normal
channels of trade, but procurable from a specific tool
manufacturer. They have no special identification
and are defined by name only.
• Locally Manufactured Tools - Simple tooling designed
by manufacture and locally manufactured by the
operator. Described by nomenclature and
illustration.
19
Ref. to Illustrated Tool and Equipment Manual
 The basic functions of tools are
• Cutting tools, such as the knife, scythe or sickle, are wedge-
shaped implements that produce a shearing force along a
narrow face.
• Moving tools move huge and tiny things, e.g. concentrating
force tools like the hammer moves a nail, the maul moves a
stake, or a whip moves flesh on a horse
• Guiding, measuring and perception tools include the ruler,
glasses, set square, sensors, straightedge, theodolite,
microscope, monitor, clock, phone, printer
• Shaping tools, such as moulds, jigs (fixture), trowels
• Fastening tools, such as wrench, screwdriver
• Joining, such as welders, rivet guns, nail guns, or glue guns

Some tools may be combinations of other tools.

20
 The basic functions of equipment are
• equipment designed to serve a specific
function
• equipment used to achieve automatic control
or operation; automation and robotic
equipment

21
4. CATAGORY

22
 Kind Of Tool
• GENERAL TOOL
– HAND TOOL
– POWER TOOL
• SPECIAL TOOL
– MECHANICAL
– PNEUMATIC
– HYDRAULIC
– ELECTRIC
– ELECTRONIC
– Some tools may be combinations
• MEASUREMENT TOOL
– CALIBRATED
– SELF CALIBRATION
– INDICATION ONLY

23
 Kind of equipment

• Fix equipment
• Moveable/Portable equipment

24
 Hand tool
an implement, that is used by hand. There are :
• Hammer ball pen • Plier duck bill
• Hammer plastic tip • Plier bent nose
• Wrench open end • Plier wire twister
• Wrench box end • Plier gripping
• Wrench combination • Plier side cutter
• Wrench socket • Plier half round
• Wrench Pipe • Chisel
• Screwdriver flat • Punch
• Screwdriver philip • Ratchet
• Screwdriver offset flat • Paint brush
25
Hand tool

26
 Power Tools
• Heat gun • Sander
• Impact wrench • Scroll saw
• Torque multiplier • Soldering gun
• Needle gun scaler • Thickness planer
• Random orbital • Wood router
sander • Wood shaper
• Rotary tool • Drill gun
• Router table
27
Power tool

28
 Special tools
• Tool that is used specifically, to dismantle
assemble and repair certain parts or components
• Tools are:
• Fixture
• Adapter
• Wrench
• Lift tool

29
Special tools

30
 Measurement tools
• Commonly called the Inspection
Measurement Test Equipment (IMTE)
• Grouped :
Calibrated measuring tools
Self calibration
Indication only

31
 Measurement Tools
• Length • Speed meter
– Steel ruler • Pressure gage
– Vernier caliper • Flow indicator
– Micrometer • Weighing (mass)
– Deepmeter
• Temperature indicator
• Torquemeter
• Vibration indicator

32
Measurement tools
Inspection Measuring Test Equipment

33
 FIX EQUIPMENT
• Lathe Machine
• Grinding Machine
• Milling Machine
• Boring Machine
• Universal testing Machine
• Engine tester
• Balancing Machine
• Shot peen Machine
• Blasting Machine
• Thermal spray
34
Equipment

35
 MOVABLE EQUIPMENT
• Abradable Cutting Machine
• Hydraulic pump
• Borescope set

36
5. TEF MANAGEMENT

37
• For TRJ2/3 (Disassembly & Assembly section)
– General Tool and IMTE keep in Tool Crib
– Special Tools on bay
• TRJ5 (Test Cell Section)
– General Tool and IMTE keep in Tool Crib (test cell)
– Special Tools on bay
• TRP (Repair Section)
– General Tool and IMTE on bay
– Special Tools on bay

38
 Equipments places
• All Fix Equipment placed refer to the layout as
defined
• Moveable /Portable Equipment put on the bay
where the activity to perform

39
6. TEF MAINTENANCE BUSINESS
PROCESS

40
 Tools and equipment

1. Managing General tool and IMTE in Tool Crib

2. Maintenance data Update
3. Preventive maintenance inspection
4. PMI control
5. IMTE management
6. Layout revision for new capability
7. Complain from production
8. Development program for new capability

41
42
43
44
45
46
47
48
7. Tools and equipment
Interested

49
 Interest tool & equipment
Critical tools reference :
 Load
 Frequency / usage
 Sensitivity

50
 Load
• Mechanical load:
– Lift tools
– and support, etc.

• Temperature load
– Welding machine
– Thermal spray machine
– Heatreatment machine, etc.
51
 Frequency used

• Wrench
• and power tools

52
 Sensitivity

• Linipot (hardware, software)

• CDP bore
• Balancing machine
• Test cell (hardware, software)
• CMM (Coordinate Measuring Machine), etc.

53
8. Tools and equipment
Maintenance method

54
 Tools and equipment
maintenance

Schedule Un schedule
maintenance maintenance

Periodical Un planed corrective

Repair
preservation maintenance

Periodical Repair &

maintenance check Replacement

Planed corrective
Replacement
maintenance

Modification Rework

55
 Tools and equipment
maintenance
Preventive maintenance
 Periodical maintenance check
 Periodical preservation
Corrective maintenance
 Repair
 Replacement
 Repair and Replacement

56
 Preventive maintenance for tool
equipment
• Easy to perform
• Easily create a schedule in conjunction with
scheduling parts, workers, and process
• Easily (base on schedule) estimate the
maintenance budget
• To reduce the frequency of breakdown and
repair
• To reduce money losses.
57
 Preventive maintenance
• Preservation : For all tools and equipments
– Use Soft Cloth And Kerosene For Clean And Apply
A Light Coat Of Preventive Oil Ardrox 3962 Or Alt.
On All Unpainted Surfaces Of Tools

• Periodical check :
– NDT and/or Load test: For lift tools
– Calibration: Measurement tools

58
 Repair
• Special tool :
– Dimensional Repair/Correction
– Structural Repair

• Equipment:
– Functional Repair
– Operational Repair

59
 Replacement
• Tool : total damage
• Part of Equipment : damage

60
REPAIR AND REPLACEMENT INSTRUCTION

• PD Sheet non routine

• Drawing
• Wiring diagram

61
 MODIFICATION
• PD Sheet non routine
• Drawing (modification)
• Wiring diagram (modification)

62
 Proactive Maintenance
• Result from predictive maintenance, base on
PMI & repair rectification log data
• Planned corrective maintenance action for
tools & equipment:
• Parts/component Repair
• Parts/component Replacement

63
TOOLS AND EQUIPMENT
IMPROVEMENT

64
TOOLS AND EQUIPMENT IMPROVEMENT

• Design
• Drawing
• Wiring diagram

65
9. TOOLS AND EQUIPMENT
CONTROL

66
 Tools and equipment control
• Tools and equipment listed
• Preventive maintenance (preservation,
periodical maintenance)
• Repair & Rectification
• Replacement
• IMTE out of tolerance
• T/E Procurement

67
 Tools and equipment listed
• All of tools and equipment listed:
• Inventory number
• Description
• Part/Tool/Equipment Number
• Serial Number
• Reference Task number
• Quantity T/E req. per task
• Quantity T/E available
• Location
68
 Preventive sheet

• Preservation log
• Preventive Maintenance Inspection log
(periodical maintenance)
• Repair rectification log

69
 Preventive action
• Preservation : every 3 moths
• Preventive maintenance :
– Periodical maintenance -- reference maintenance
of tool or equipment (expl.; 3 months, 6 months,
yearly, etc)
– Clean after used

70
 Tool Equipment Repair Doc.
Special tool
o Specification dimension & material (see drawing)
o Non-routine PD sheet

Equipment
o Technical report
o SEO T/E

71
 Tool Equipment Replacement
Document

• Technical report
• Drawing
• Wiring diagram
• SEO T/E

72
 IMTE out of tolerance sheet:
• Calibration report
• Out of tolerance notification & respon
• Sticker for IMTE Out Of Tolerance
• Corrective action report for out of tolerance
report
• Condemned label IMTE condemned

73
 Tools and equipment
procurement
• Technical service information: feasibility study
of tool or equipment
• Listing and/or drawing.
• Pre acceptance
• Acceptance
• Listing : inventory numbering, location state

74
10. MAINTENANCE SHEET

75
 Form GMF/Q-276
Tool, Special Tool and Equipment Log Sheet

76
 THE LIST OF PRESERVATION SCHEDULE OF SPECIAL TOOLS AND FIXTURES

SPEC. TOOL GROUP : LIST No. :

UNIT/USER : PERIOD : 2011

2011
NO INVENTORY No. DESCRIPTION PN QTY LOC. Q1 Q2 Q3 Q4
REMARK DATE REMARK DATE REMARK DATE REMARK DATE

PRESERVED BY :

APPROVED BY MANAGER :

NOTE : (1) PRESERVATION ACTION : USE SOFT CLOTH AND KEROSENE FOR CLEAN AND APPLY A LIGHT COAT OF PREVENTIVE OIL ARDROX 3962 OR ALT. ON ALL UNPAINTED SURFACES OF TOOLS

(2) WRITE IN BLANKET REMARK : S : SERVICEABLE ; R : REPAIRABLE ; C : CONDEMNED ; M : MISSING

(3) DENOTES THE DATE OF DUE CHECK IN BLANKET

(4) USE LOG OF T/E REPAIR & RECTIFICATION (GMF/Q-305) FOR REMARK REPAIREABLE ( R ) CONDITION

GMF/ PAGE OF

77
 ENGINE MAINTENANCE
LOG of TOOL/EQUIPMENT MAINTENANCE CHECK
T/E Name : T/E No. :

Part Number/Model/Type : User/Unit :

Serial No. : Reference :

Manufacture : Rev./date :
DATE of CHECK
Interval
NO. MAINTENANCE ITEM between
check Date & Sign Date & Sign Date & Sign Date & Sign Date & Sign Date & Sign

A
1 A R A R A R A R A R
R

A
2 A R A R A R A R A R
R

A
3 A R A R A R A R A R
R

A
4 A R A R A R A R A R
R

A
5 A R A R A R A R A R
R

A
6 A R A R A R A R A R
R

A
7 A R A R A R A R A R
R

A
8 A R A R A R A R A R
R

A
9 A R A R A R A R A R
R

A
10 A R A R A R A R A R
R

NOTE : (1) DENOTES YOUR SIGN AND THE DATE OF DUE CHECK IN BLANKET
(2) APPLIED SIGN CIRCLE (O) TO A FOR ACCEPTABLE or R FOR REPAIRABLE
(3) USE LOG OF T/E REPAIR & RECTIFICATION FOR RECORD REPAIREABLE CONDITION

Pag
e
….of
GMF/Q - 306 ….

78
79
11. TEF FINANCE

80
 Maintenance Cost
1. Tool Equipment Facility Repair Cost
2. Tool Equipment Facility Maintenance
replacement Cost
3. Tool Equipment Facility development
4. Tool Equipment Facility depreciation
5. Tool Equipment Facility Budget
6. Tool Equipment Facility return investment
and actual utility
81
 Tool Equipment Facility
Maintenance Cost
• Preservation cost
• Preventive maintenance inspection cost
• Repair cost
• Replacement cost

82
 Tool Equipment Facility
replacement
• Engineering evaluation (engineering
information)
• Technical requirement
• Quotation - by procurement department
• Acceptance

83
 Tool Equipment Facility
development
• Ref. to engine maintenance development
program
• Make feasibility study
• Evaluation Technical requirement
• Quotation - by procurement department
• Technical Acceptance

84
12. TEF RELATED REGULATION

85
 RELATED REGULATION
• MOE 2.4 • QP 204 – 01 • WI-TR-002
• MOE 2.5 • QP 205 – 01 • WI-TR-019
• MOE 2.6 • QP 205 – 03 • WI-TR-020
• QP 206 – 01 • WI-TR-022
• QP209 – 13

86
 QP-209-03
ENGINE MAINTENANCE PROCESS CONTROL

7.4.40 The inventory system of tools and equipment:

• All tooling and equipment including special tool are to be in
such inventory system that easily controlled, as per the
following actions:
• The Tool Engineer will:
a. Define all tooling and equipment required for production base on
approved data.
b. Evaluate alternate or equivalent tool equipment base on QP-206-01
c. Develop inventory system for all tooling & equipment including special
tools in such way that easily to be controlled.
d. Provide the tool inventory list to production.
e. Develop preventive maintenance inspection for tool and equipment
that need to be maintained periodically
87
THANK YOU

88