Punjab Tianjin University of

Technology

CASE STUDY
CENTRE LATHE MACHINE

LECTURER:Engr.Ali Mansoor

21MT003 Taha Ameer

21MT027 Nafees Hafeez
21MT037 Tayyab Hussain shah
21 MT041 Muhammad Usama
21MT043 Hannan Arif
 TABLE OF CONTENTS

1. Introduction

2. Organization Chart to Maintenance Team

3. Problem Analysis of Machine

4. Maintenance Strategy

5. Estimated Maintenance Cost

6. Conclusion

7. References
Introduction
Machine Workshop is a place where students acquire knowowledge on the operation of various
processes involved in manufacturing and production. The Workshop Practice course makes
students competent in handling practical work in engineering environment. Machine Workshop
is also involved in different maintenance or repair works for polytechnic.

Students are taught with the skills of handling conventional manufacturing machines and
producing products. Among the machines and equipment used are:

1. Hand tools

2. Measuring tools

3. Marking tools

4. Testing tools

5. Machines:

L Power Hacksaw Machine

II. Bench Drilling Machine

Ⅲ. Pillar Drilling Machine

IV. Centre Lathe Machine

V. Vertical Turret Milling Machine

VI. Universal Horizontal Milling Machine

VII. Bench Grinding Machine

VIII Pedestal Grinding Machine

IX. Surface Grinding Machine

X. Cylindrical Grinding Machine

Problem Analysis of Maching

Lathe machine is the most common and oldest equipment to be used in industries in turn, cut,
groove, shrill, and de other machine, related operations into a cylindrical shape. It has superior
performance, high precision, light rate and high adaptability, but it also has some problems.

1. Bearing fault. The drive shaft is the core component of the lathe for machining. It carries the
man load during operation and is therefore one of the most prone to failure lathe parts. On a
lathe, we usually assemble the main shaft with a rolling bearing or a plain bearing Thereby
generating a large amount of heat. The main shaft bearing is the main heat source in the
headstock. If the heat generated by it is not discharged in time, the bearing will overbeat and
the temperature of the corresponding part of the lathe will rise, resulting in thermal
deformation. In severe cases, the main shaft and the tailstock will not be equal. This not only
affects the accuracy and machining accuracy of the lathe itself, but also barns the bearings and
even the main shun.

2. Carriage is not moving. It is important to know how to move the carriage of the equipment.
The carriage moves along its tracks. Moving the carriage is something that needs to he
mastered in order for the machine to work efficiently. Along with the carriage, the power feed
handles also have to be worked properly.

The cause of the failure of the lathe cases by many factors. The common faults in the use of
ordinary lathes can be divided in two categories. The lathe itself is not working properly and the
lathe machining work piece is defective.

1. Installation and assembly accuracy. Lathe installation and assembly mainly involve slippery
scraping, bed assembly, slide box, feed box and spindle box installation, etc. Any error in any
part may reduce the accuracy of the lathe

2. Improper daily maintenance and maintenance. The quality of lathe maintenance and
maintenance can directly affect the processing quality and production efficiency of the different
processing ranges and processing capableness. If we do not strictly operate according to the
processing scope of the lathe during use, we cannot guarantee the reasonable use of the lathe.
Maintenance Strategy

1. Maintenance of beadstock

a) Prepare for the analysis:

 Problem: Bearing breaks

 Effect: Shaft heat up and effect to spindle

b) Select the equipment to be analyzed

 The new bearing

 New shaft

c) Identify functions

 To reduce friction and allow for smoother rotation

d) Identify functional failures

 Effect to work piece operation, spindle not be function normally.

e) Identify and evaluate the effects of failure

 Can be repaired

f) Identify the causes of failure

 Bearing has been used and not changed

g) Select maintenance tasks

 Corrective maintenance
 2. Maintenance of carriage

a) Prepare for the analysis:

 Problem: Stuck carriage

 Effect: The cutting tool not be moved

b) Select the equipment to be analysed

 Brush
 Spanner
 Lubricant oil

c) Identify functions

 To move the cutting tool

d) Identify functional failures

 Effect to workpiece operation

e) Identify and evaluate the effects of failure

 Can be repaired

f) Identify the causes of failure

 Loose nut
 Not cleaning properly after use

g) Select maintenance tasks

 Preventive maintenance
Estimated Maintaince Cost
Centre Lathe Machine breakdown at Politeknik Ibrahim Sultan Machine Workshop for the
last year.

No. Month Quantity of Breakdown

1 January 0

2 February 1

3 March 0

4 April 2

5 May 1

6 June 3

7 July 0

8 August 2

9 September 0

10 October 0

11 November 1

12 December 3
 Breakdown of Lathe Machine = RM300
 Third Party Service Contract = RM300

Breakdown Month Break down Frequencey Expected of

occurs Breakdown

0 5 5/12=0.417 0 x 0.417=0

1 3 3/12=0.25 1 x 0.25=0.25

2 2 2/12=0.167 2 x 0.167=0.334

3 2 2/12=0.167 3 x 0.167=0.501

Total 12 1.805

Expected of Breakdown = Total [(Breakdown)x(Frequency)]

= (0x0.417) + (1x0.25) + (2x0.167) + (3x0.167)

= 1.085 breakdown per month

Expected Breakdown cost = Without Hired Third Party

= (Expected of Breakdown) x (Cost per Breakdown)

= (1.085) x RM300 = RM325.50 per month

= Hired Third Party

= Cost of expected breakdown x cost of service contract

=(1 breakdown per month x 300) + (RM300)

= RM600 per month

So, polytechnic use breakdown maintenance because its less expensive which is
RM325.50 per month.
 Conclusion
Maintenance is very important for a machine. This is because maintenance can extend
the life of a machine. Besides, it can make the machine work well. In addition, maintenance
management are to make sure a business doesn't stop producing and improperly
maintained equipment can lead to safety hazards. If a machine is not done any
maintenance, then the machine will make a lot of losses because once it is damaged it will
be expensive cost. So, maintenance management give many benefits to the company.
References

 Mitchell Franklin. Patty Graybeal and Dixon Cooper (2019), Principles of

Accounting. Volume 2: Managerial Accounting. OpenStax.
 Salih O. Duffuaa, A. Raouf (2015), Planning and Control of Maintenance Systems:
Modelling and Analysis, Second Edition, Springer.
 Benjamin W. Niebel (1994), Engineering Maintenance Management, Second
Edition, CRC Press.
 Joel Levitt (2008), Lean Maintenance, Industrial Press.
 http://www.pis.edu.my/index.php/ms/senarai-kepakaran/131-aka/jkm
 https://www.doityourself.com/stry/5-common-metal-working-lathe-problems-
to-prevent
 http://www.spindleoilchiller.com/lathe-machine/
 https://www.reliableplant.com/maintenance-management-31856