Mechanical Maintenance

Understanding the fundamental mechanical elements:

Power Transmission:

Bearings:
Support rotating shafts and reduce friction:
- Ball Bearings: Point contact, high speed, low loads
- Roller Bearings: Line contact, heavier loads
- Tapered Roller: Combined radial and thrust loads
- Sleeve/Plain Bearings: Simple, for oscillating motion
- Proper lubrication is critical for bearing life

Gears:
Transmit power with speed/torque change:
- Spur Gears: Parallel shafts, most common
- Helical Gears: Quieter, higher capacity
- Bevel Gears: Intersecting shafts (90° common)
- Worm Gears: High ratio, right angle, non-reversible
- Backlash adjustment and wear monitoring

Belts and Pulleys:
Flexible power transmission:
- V-Belts: Traditional, forgiving of misalignment
- Synchronous/Timing Belts: Positive drive, no slip
- Flat Belts: High speed, wide applications
- Tension and alignment critical for life

Chains and Sprockets:
Positive drive for heavier loads:
- Roller Chain: Most common industrial type
- Silent Chain: Higher speed, quieter
- Lubrication, tension, and alignment maintenance

Couplings:
Connect shafts while accommodating misalignment:
- Rigid: No misalignment tolerance
- Flexible: Elastomer, metallic, others
- Universal Joints: Large angular misalignment
- Alignment is critical for coupling life

Different approaches to keeping equipment running:

Reactive Maintenance:
Fix it when it breaks:
- Simplest approach
- Unplanned downtime
- Emergency repairs are expensive
- Appropriate for non-critical, cheap equipment

Preventive Maintenance (PM):
Scheduled service based on time or usage:
- Oil changes, filter replacement
- Inspection and adjustment
- Component replacement before failure
- Reduces unexpected failures

Predictive Maintenance (PdM):
Condition-based maintenance using data:
- Vibration analysis for bearing/gear condition
- Oil analysis for wear particles
- Thermography for electrical/mechanical heat
- Ultrasonic for leaks and bearing noise
- Service when condition indicates need

Reliability-Centered Maintenance (RCM):
Strategic approach based on failure consequences:
- Identify failure modes
- Assess consequences
- Select appropriate strategy
- Optimize maintenance investment

TPM (Total Productive Maintenance):
Operator involvement in maintenance:
- Daily cleaning and inspection by operators
- Early problem detection
- Ownership of equipment
- Maintenance and operations partnership

CMMS (Computerized Maintenance Management System):
Software for maintenance management:
- Work order tracking
- PM scheduling
- Spare parts inventory
- History and analysis

Systematic approach to diagnosing mechanical problems:

Symptom Analysis:
Gather information before acting:
- What exactly is happening?
- When did it start?
- What changed before the problem?
- Intermittent or constant?
- Operating conditions when problem occurs

Sensory Inspection:

Visual:
- Leaks, damage, wear patterns
- Alignment indicators
- Belt/chain condition
- Lubrication condition

Sound:
- Abnormal noises (grinding, squealing, knocking)
- Changes from normal operation
- Location and frequency

Feel:
- Vibration (by hand for gross problems)
- Temperature (carefully)
- Looseness or play

Smell:
- Burning, overheating
- Lubricant breakdown

Measurement:
- Vibration analysis (accelerometer)
- Temperature (IR thermometer)
- Alignment (dial indicators, laser)
- Clearances and wear

Root Cause Analysis:
Don't just fix symptoms:
- 5 Whys technique
- Fishbone diagrams
- Failure mode identification
- Address underlying cause

Documentation:
Record findings and repairs:
- Equipment history
- Pattern recognition
- Knowledge sharing
- Continuous improvement

Mechanical maintenance offers solid career growth:

Entry Positions:

Maintenance Helper:
- Assist skilled technicians
- Learn equipment and procedures
- Basic tasks under supervision
- $35,000-$45,000

Maintenance Technician I:
- Perform routine PM tasks
- Basic repairs with guidance
- Developing troubleshooting skills
- $40,000-$55,000

Skilled Positions:

Maintenance Technician II/III:
- Independent troubleshooting
- Complex repairs
- Equipment rebuilds
- $55,000-$75,000

Multi-Craft Technician:
- Mechanical + electrical/controls
- Highest technical value
- Most versatile
- $65,000-$85,000

Leadership:

Maintenance Supervisor:
- Lead maintenance team
- Schedule and prioritize work
- Manage contractors
- $70,000-$95,000

Maintenance Manager:
- Department leadership
- Budget responsibility
- Strategic planning
- $85,000-$120,000

Industries:
- Manufacturing (all types)
- Food and beverage
- Pharmaceutical
- Power generation
- Mining and heavy industry
- Building maintenance

Skills Development:
- Mechanical fundamentals
- Blueprint reading
- Precision measurement
- Welding basics
- Electrical fundamentals
- PLC awareness
- Predictive maintenance techniques

Certifications:
- SMRP (Society for Maintenance & Reliability Professionals)
- Vibration analysis (Level I, II, III)
- Manufacturer-specific training