White paper on Basic Of Preventive Maintenance And Troubleshooting
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Wikipedia
Preventive maintenance checks and services (PMCS) in the United States Army or preventive maintenance inspections (PMI) in the United States Air Force are the checks, services, and maintenance performed before, during, and after any type of movement or before the use of all types of military equipment. Most pieces of military equipment have PMCS charts used to go over every detail needed or noted to ensure the proper function of every mechanical item or non-mechanical surface. A PMCS check is required before, during, and after a piece of equipment or vehicle is used. Checks are also done at weekly, monthly, semi-annual, annual, or bi-annual intervals, depending on the specific part.
Doing a PMCS check every time equipment is used may reduce the number of failures. This reduces the number of injuries during training exercises, improve effectiveness in combat, and increase the operator’s ability to implement their equipment.
A PMCS is required before a vehicle can be dispatched and before a piece of equipment, such as a weapon, can be issued. A PMCS sheet, as listed above, for vehicles is called a DA 5988E. This sheet is used to write down any deficiency found during the PMCS procedure. The steps taken to perform the PMCS are explained in a Technical Manual and performed by the operator. A PMCS is also used at the unit level.
The technical meaning of maintenance involves functional checks, servicing, repairing or replacing of necessary devices, equipment, machinery, building infrastructure, and supporting utilities in industrial, business, and residential installations. Over time, this has come to include multiple wordings that describe various cost-effective practices to keep equipment operational; these activities occur either before or after a failure.
Maintenance functions can defined as maintenance, repair and overhaul (MRO), and MRO is also used for maintenance, repair and operations. Over time, the terminology of maintenance and MRO has begun to become standardized. The United States Department of Defense uses the following definitions:
- Any activity—such as tests, measurements, replacements, adjustments, and repairs—intended to retain or restore a functional unit in or to a specified state in which the unit can perform its required functions.
- All action taken to retain material in a serviceable condition or to restore it to serviceability. It includes inspections, testing, servicing, classification as to serviceability, repair, rebuilding, and reclamation.
- All supply and repair action taken to keep a force in condition to carry out its mission.
- The routine recurring work required to keep a facility (plant, building, structure, ground facility, utility system, or other real property) in such condition that it may be continuously used, at its original or designed capacity and efficiency for its intended purpose.
Maintenance is strictly connected to the utilization stage of the product or technical system, in which the concept of maintainability must be included. In this scenario, maintainability is considered as the ability of an item, under stated conditions of use, to be retained in or restored to a state in which it can perform its required functions, using prescribed procedures and resources.
In some domains like aircraft maintenance, terms maintenance, repair and overhaul also include inspection, rebuilding, alteration and the supply of spare parts, accessories, raw materials, adhesives, sealants, coatings and consumables for aircraft maintenance at the utilization stage. In international civil aviation maintenance means:
- The performance of tasks required to ensure the continuing airworthiness of an aircraft, including any one or combination of overhaul, inspection, replacement, defect rectification, and the embodiment of a modification or a repair.
This definition covers all activities for which aviation regulations require issuance of a maintenance release document (aircraft certificate of return to service – CRS).
The marine and air transportation, offshore structures, industrial plant and facility management industries depend on maintenance, repair and overhaul (MRO) including scheduled or preventive paint maintenance programmes to maintain and restore coatings applied to steel in environments subject to attack from erosion, corrosion and environmental pollution.
Troubleshooting is a form of problem solving, often applied to repair failed products or processes on a machine or a system. It is a logical, systematic search for the source of a problem in order to solve it, and make the product or process operational again. Troubleshooting is needed to identify the symptoms. Determining the most likely cause is a process of elimination—eliminating potential causes of a problem. Finally, troubleshooting requires confirmation that the solution restores the product or process to its working state.
In general, troubleshooting is the identification or diagnosis of “trouble” in the management flow of a system caused by a failure of some kind. The problem is initially described as symptoms of malfunction, and troubleshooting is the process of determining and remedying the causes of these symptoms.
A system can be described in terms of its expected, desired or intended behavior (usually, for artificial systems, its purpose). Events or inputs to the system are expected to generate specific results or outputs. (For example, selecting the “print” option from various computer applications is intended to result in a hard copy emerging from some specific device). Any unexpected or undesirable behavior is a symptom. Troubleshooting is the process of isolating the specific cause or causes of the symptom. Frequently the symptom is a failure of the product or process to produce any results. (Nothing was printed, for example). Corrective action can then be taken to prevent further failures of a similar kind.
The methods of forensic engineering are useful in tracing problems in products or processes, and a wide range of analytical techniques are available to determine the cause or causes of specific failures. Corrective action can then be taken to prevent further failure of a similar kind. Preventive action is possible using failure mode and effects (FMEA) and fault tree analysis (FTA) before full-scale production, and these methods can also be used for failure analysis.
Usually troubleshooting is applied to something that has suddenly stopped working, since its previously working state forms the expectations about its continued behavior. So the initial focus is often on recent changes to the system or to the environment in which it exists. (For example, a printer that “was working when it was plugged in over there”). However, there is a well known principle that correlation does not imply causality. (For example, the failure of a device shortly after it has been plugged into a different outlet doesn’t necessarily mean that the events were related. The failure could have been a matter of coincidence.) Therefore, troubleshooting demands critical thinking rather than magical thinking.
It is useful to consider the common experiences we have with light bulbs. Light bulbs “burn out” more or less at random; eventually the repeated heating and cooling of its filament, and fluctuations in the power supplied to it cause the filament to crack or vaporize. The same principle applies to most other electronic devices and similar principles apply to mechanical devices. Some failures are part of the normal wear-and-tear of components in a system.
The first basic principle in troubleshooting is to be able to reproduce the problem, at wish. Second basic principle in troubleshooting is to reduce the “system” to its simplest form that still show the problem. Third basic principle in troubleshooting is to “know what you are looking for. In other words, to fully understand the way the system is supposed to work, so you can “spot” the error when it happens.
A troubleshooter could check each component in a system one by one, substituting known good components for each potentially suspect one. However, this process of “serial substitution” can be considered degenerate when components are substituted without regard to a hypothesis concerning how their failure could result in the symptoms being diagnosed.
Simple and intermediate systems are characterized by lists or trees of dependencies among their components or subsystems. More complex systems contain cyclical dependencies or interactions (feedback loops). Such systems are less amenable to “bisection” troubleshooting techniques.
It also helps to start from a known good state, the best example being a computer reboot. A cognitive walk through is also a good thing to try. Comprehensive documentation produced by proficient technical writers is very helpful, especially if it provides a theory of operation for the subject device or system.
A common cause of problems is bad design, for example bad human factors design, where a device could be inserted backward or upside down due to the lack of an appropriate forcing function (behavior-shaping constraint), or a lack of error-tolerant design. This is especially bad if accompanied by habituation, where the user just doesn’t notice the incorrect usage, for instance if two parts have different functions but share a common case so that it is not apparent on a casual inspection which part is being used.
Troubleshooting can also take the form of a systematic checklist, troubleshooting procedure, flowchart or table that is made before a problem occurs. Developing troubleshooting procedures in advance allows sufficient thought about the steps to take in troubleshooting and organizing the troubleshooting into the most efficient troubleshooting process. Troubleshooting tables can be computerized to make them more efficient for users.
Some computerized troubleshooting services (such as Primefax, later renamed MaxServ), immediately show the top 10 solutions with the highest probability of fixing the underlying problem. The technician can either answer additional questions to advance through the troubleshooting procedure, each step narrowing the list of solutions, or immediately implement the solution he feels will fix the problem. These services give a rebate if the technician takes an additional step after the problem is solved: report back the solution that actually fixed the problem. The computer uses these reports to update its estimates of which solutions have the highest probability of fixing that particular set of symptoms.