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WorksheetsSafety and Maintenance Quiz
Total questions: 90
Worksheet time: 45mins
What is an accelerometer used for?
Temperature measurement
Acoustic monitoring
Vibration measurement
Oil analysis
Corrective work is performed following preventive maintenance when __________.
The supervisor requests it
The schedule calls for it
The equipment is new
Problems are discovered
The PM work was performed incorrectly
Slips and falls are the worst safety hazards when __________.
Cleaning fans
Mopping floors
Lifting heavy objects
Driving a tug
Supply errors can be caused by relying on __________ without monitoring their performance.
Customers
Employees
Suppliers
Inspectors
Preventive maintenance is best described as what?
Periodic in nature
Reactive in nature
Unplanned in nature
Emergency in nature
A board with tool outlines for placement is called a __________ and is a good way to make sure tools are returned to their proper storage space between uses.
Storyboard
Shadow board
Board of tools
Storage bin
The frequency of maintenance is usually an item found on the __________.
Preventive maintenance schedule
Work order
Warranty card
Hold card
A maintenance technician should arrange to have all routine tools and supplies ready to perform preventive maintenance on a machine in order to __________.
Minimize equipment downtime
Increase equipment downtime
Make sure that the machine parts are still available
Make sure that the job is done correctly
Ensure the technician is busy
Placing tools and equipment where they can be reached with minimal strain is a characteristic of a __________.
Poorly designed workstation
Well-designed workstation
Old style workstation
Pull system
What can be done after a corrective action form is completed?
The form is saved in a safe and secure place.
The maintenance technician reviews the work order.
The supervisor is summoned to determine whether the job is complete.
Preventive maintenance should be documented as completed.
The first thing an employee should do when discovering a building maintenance issue that negatively impacts his/her work area is __________.
Report the situation to the supervisor
Try to fix the problem
Go home until the problem is fixed
Ignore the problem
How often the maintenance will occur is the primary consideration of what type of maintenance?
Predictive
Reactive
Responsive
Preventive
Reactive Maintenance is considered a(n) __________ activity.
Unplanned maintenance
Planned maintenance
Highly responsive maintenance
Chemical-related maintenance
In a well-organized plant, it should take a worker __________ to find the right tool.
30 seconds
1 minute
5 minutes
10 minutes
__________ should preside over housekeeping inspections or audits.
Unbiased auditors or inspectors
The company president
The safety team
The immediate supervisor
Sensor monitoring is the most useful aspect of what program?
Preventive maintenance
Predictive maintenance
Reactive maintenance
Corrective maintenance
A workstation designed to __________ can reduce repetitive/stress injuries.
Maximize range of motions
Minimize motions
Increase unnecessary motion
Increase product output
An example of preventive maintenance is __________.
Replacing an item that has been damaged
Replacing components after they have failed
Scheduled replacement of minor parts that wear out quickly
Arranging for an OSHA inspection of equipment
Ignoring minor issues until they become major problems
What contains equipment histories as well as maintenance, service, and preventive maintenance records?
Computerized maintenance management systems (CMMS)
Computerized maintenance management information systems (CMMIS)
Equipment maintenance management software (EMMS)
All of the above
Predictive maintenance is a type of maintenance program that does what function?
Determines regular maintenance intervals when maintenance should be performed
Predicts the specific date when maintenance should be performed
Identifies machine part or component failures before a major breakdown
Provides startup and shutdown guidelines
What is an example of failure to follow preventive maintenance?
Lubricating bearings as prescribed
Skipping a scheduled cleaning
Replacing V-belts in sets
Filter replacement
To make sure tools remain in good working order, __________.
Store them properly
Do not use them unless absolutely necessary
Use oversized tools
Do not clean them off after use
Where should trash be disposed of in the aisle?
In the aisle
In appropriate trash/recycle bin
On the floor
In a corner
Bearing seals can be damaged by what?
Routine lubrication processes
Excessive lubrication
Shortening the run time
Proper burn-in
What is most closely associated with the repair of broken parts?
Preventive maintenance
Predictive maintenance
Breakdown maintenance
PDCA cycles
Equipment should be inspected and reported to whom at the start of the production day?
The incoming shift
The auditor
All personnel
Appropriate parties
Workers should perform an emergency shutdown of their equipment and notify their supervisor in which of the following circumstances?
They notice that the equipment temperature is gradually rising but still within allowable limits.
They hear a loud banging noise coming from the equipment.
They detect vibration levels that are within the allowable range.
They are notified of a family emergency and need to go home.
__________ are not permitted on the floor of a workstation.
Extension cords
Painted lines
Trash cans
Non-slip mats
What is preventive maintenance defined as?
Condition-based servicing
Run-to-breakdown production
Plan-Do-Check-Act (PDCA) cycles
Routine servicing at predetermined intervals
The best way to store liquids such as paint or cleaning fluids is __________.
Sealed and in a cabinet
On the workbench
Near a window for ventilation
Under the workbench for easy access
__________ should be replaced immediately if found to be missing during an equipment inspection.
Safety guarding
Foot rests
A maintenance report
A borescope
Perhaps the best place to store preventive maintenance records is __________.
In a digital database
In a safe and secure location
A plastic folder attached to the equipment
In the supervisor's office
In the maintenance office
What should a technician do before performing preventive maintenance?
Acquire tools and supplies, then shut down the machine
Interview the operator
Review the user manual
Make sure that the machine parts are still available
A borescope or fiberscope can be used to __________ internal components.
Graph vibrations of
Monitor sounds of
Visually inspect
Clean and sanitize
Zero defects and breakdowns is a goal of __________.
TPM
FDA
UAW
WPA
A thorough check for a history of similar problems should occur __________.
On problems that keeps recurring at regular intervals
Only when a new problem arises
After every maintenance session
Once a year
On what type of problems should maintenance be focused?
On problems that have not occurred in the past
On problems that warrant a repair
For new problems
On problems that keep recurring at regular intervals
Design failure in a production line can be apparent by repeated maintenance failures and __________.
The high output achieved
Employee turnover
Supply material used
The inability to meet performance demands
__________ should be disposed of in an OSHA-approved fireproof container.
Oily rags
Paper
Wood
Metal scraps
What is established when operating equipment is in good condition?
The best operator for the job
Normal running levels for physical characteristics
Optimal order schedules for part inventory
The storage of maintenance logs
What is everyone responsible for?
Scheduling maintenance after equipment breakdown
Completing work orders on time
Keeping the work area clean of dirt, dust, and debris
Filling out corrective action reports
Results of tests, inspections, and a schedule for future maintenance can be found where?
In the equipment manual
On the company website
In the maintenance log
In the employee handbook
The employee verifies that preventive maintenance is complete when __________.
Closing out a PM work order
Beginning a PM work order
Making random equipment inspections
Completing a corrective action report
A maintenance log records work performed on a piece of equipment. A maintenance log should be kept for __________.
Machines without safety guards
Two weeks following a machine failure
Machines that show signs of wear
Every machine
Brooms and mops should be stored __________.
Next to the machine
In pairs
In chemical cabinets
In a designated area or cleaning closet
If a machine is obviously leaking, __________.
The employee should notify a supervisor
The employee should attempt to fix the machine
The employee should shut down the machine immediately and evacuate
The employee should throw some rags on the floor to soak up the leak. What should the employee actually do?
Notify a supervisor
Ignore the leak
Use a mop
Call maintenance
Product buildup is the most common vibration problem on __________.
Cylinder pistons
Hydraulic pump vanes
Air fans
Pneumatic valves
A __________ is important for a timely closure of PM work orders.
Completion date
Computerized system
Incentive award
Well-maintained machine
To reduce the time needed to clean inaccessible areas, what should operators do?
Make areas more accessible.
Prevent contamination from occurring.
Skip routine cleanings as needed.
Only A and B
__________ normally include verification that the floor is clean.
Routine housekeeping inspections
Corrective action reports
Maintenance logs
Work orders
Recurring events can be analyzed to troubleshoot problems because what is recorded in daily records?
Completed work orders
Employee schedules
Equipment manuals
Safety protocols
What is often outlined and detailed in a maintenance log?
Maintenance scheduling
A list of qualified operators
Shift leader contact information
Date of equipment purchase
W. Edwards Deming's plan for continuous improvement is __________.
Plan-do-check-act (PDCA)
Ask-verify-plan-enact (AVPE)
Plan-perform-review-document (PPRD)
Design-create-implement-review (DCIR)
Proper guarding, lockout/tagouts, and electrical box covers are all verified during what?
New operator training
Machine shutdown procedures
Shift changes
Visual inspections of machines
Daily preventive maintenance procedures, such as machine lubrication, are __________.
Optional and can be done only when there is time
Require a maintenance team to perform
Not really necessary and can be skipped several days in a row
Unscheduled events and the worker should put in overtime to prevent a drop in production rates
Planned maintenance activities
Noise, temperature, and vibration should be monitored when?
During machine operation
Only during maintenance shutdowns
Once a year
When a new operator is trained
When should machinery operations be conducted?
During machinery operations
Before an audit
After an audit
Only after a work order is submitted
A common sign of a misaligned coupling is __________.
Excessive oil temperature
Excessive vibration
Excessive machine speed
Machine won't start
What introduces energy to a mechanical system?
Solid bearing
Ball bearing
Driven device
Prime mover
What causes soft foot?
Uneven mounting surfaces
Too much lubrication
Not enough lubrication
Out-of-round shafts
What is more efficient than a v-belt drive?
Chain drive
Gear drive
Machine tool drive
Compressor
A shaft coupling may be out of round if a dial indicator shows what?
Any movement
Offset
Damage
Full range movement
True or false: A pillow block can only be designed as a one-piece assembly.
True
False
Which flange is shown with the correct tightening sequence?
A
B
C
D
Too little lubrication of what component can cause seizing in a machine?
Belts
Sprockets
Sheaves
Bearings
What type of bearing should be used for axial motion?
Radial bearing
Thrust bearing
Solid bearing
Ball bearing
Motor shaft runout is checked to make sure of proper __________.
Alignment
Lubrication
Speed
Temperature
Mechanical power transmission systems usually convert what type of power received from other sources into mechanical power?
Electrical
Thermal
Fluid
All of the above
__________ all machine components before coupling them together will reduce the number of shims required for alignment.
Polishing the shafts of
Lubricating
Leveling
Bolting down
Painting
Which of the following is NOT a type of shaft-to-adjacent shaft power transmission?
Belt drive
Chain drive
Clutch drive
Gear drive
If gear X turns clockwise at a constant speed of 10 rpm, how does gear Y turn?
Counterclockwise at 10 rpm
Clockwise at 10 rpm
Counterclockwise at 5 rpm
Clockwise at 5 rpm
To calculate the speed of a gear, the speed ratio and the __________ will be needed.
Gear ratio
Gear sizes
Number of gear teeth
Gear teeth ratio
Gears are pre-aligned at the factory; however, the shafts of the gear box must be attached using a __________ device to other shafts.
Coupling
Strapping
Pairing
Welding
Which of the following gear types is used in machine tools like lathes, drills, and planer machines?
Spur
Double helical
Bevel
Rack and pinion
What is the name of the clearance that allows lubricant to reach the gear teeth?
Gap
Backlash
Offset alignment
Improper alignment
A gear drive has a minimum of two gears called __________.
Driver and driven
Leader and follower
Primary and secondary
Master and slave
What is the gear ratio?
Driven gear diameter divided by driver gear diameter
Driven gear pitch diameter divided by driver gear pitch diameter
Driven gear teeth size divided by driver gear teeth size
Driven gear thickness divided by driver gear thickness
The gear drive torque is __________ the gear ratio.
Reverse of
Unrelated to
Inverse of
Indirectly proportional to
Directly proportional to
The gear system shown is added to a motor rotating at 200 rpm. What is the speed of the driven gear?
50 rpm
50 fps
200 rpm
800 rpm
In a spur gearing system, the small gear is called the __________.
Worm
Driven
Spline
Pinion
The shaft of a belt drive may be bent if the maintenance person performs an alignment check with a straight edge and finds what condition?
The straight edge cannot touch both of the sheaves at the same time.
The straight edge initially contacts all four points, and after rotating the shaft, it only contacts two points.
The straight edge contacts only three of four points of the two sheaves.
The straight edge scrapes the sheave.
Timing belts are used in which of these drive belt drive applications?
Stepper motor applications and automobile engines
Conveyor systems and machine tools like lathes and band saws
Farm equipment like conveyors and balers
Fans, heavy industries, and pumps
Measuring a groove angle for wear is a maintenance check performed on what machine component?
Bearing race
Chain sprocket
Belt drive sheave
End shaft chamfer
What is the diameter of the driven pulley that is turning 700 rpm, when the 6-inch driver is rotating 2,100 rpm?
12 inches
18 inches
24 inches
30 inches
Which drive alignment method is faster and more accurate than the straight edge method?
Laser alignment
Visual alignment
String alignment
Dial indicator alignment
In contrast to other types of belts, which of the following is determined to be properly adjusted when belt slap is eliminated?
V-belts
Flat leather belts
O-ring belts
Multi-V belts
Prior to maintenance, a machine produced 100 parts per minute. The machine was designed to produce 200 parts per minute. The drive belt was replaced. The machine should now be monitored in order to verify that __________.
It will produce 200 parts per minute
Preventive maintenance is being performed
The new motors do not stress other machine components
The machine's temperature does increase
The following condition is an indicator of improper v-belt alignment.
Excessive bearing and belt wear
Extended belt wear
Increased productivity
Less downtime
The belt drive ratio is also used to calculate the belt drive torque. The formula is __________ proportional to the drive ratio.
Directly
Inversely
Acutely
Not
