MAINTENANCE-TYPES-PLANS-AND-SCHEDULES-ON-4-WHEELED-CAR-1.pptx

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1. KATHMANDU UNIVERSITY SCHOOL OF ENGINEERING DEPARTMENT OF MECHANICAL ENGINEERING MAINTENANCE TYPES, PLANS AND SCHEDULES ON 4 WHEELED CAR Presented By Dipesh Acharya [41059] Bibek Chaudhary [41066] Samir Dhodari [41067] Krishna Kumar Gupta [41069] Sajeeb Katuwal [41072] Ramesh Shrestha [41086] Dipendra Thakuri [41087] Philemon Gharti Magar [41335] Presented To Er. Uren Amatya Lecturer, DoME

2. OUTLINE Types of Maintenance Service Plan Maintenance Plan Schedule Service types, causes and maintenance

3. TYPES OF MAINTENANCE (before a failure) (after a failure)

4. Types of Maintenance (Preventive Maintenance) Time Based Maintenance (TBM) Replacing or renewing an item to restore its reliability at a fixed time, interval or usage Task : Scheduled overhaul Objective : Restore or replace regardless of condition Failure Finding Maintenance (FFM) Detecting hidden failures typically associated with protective functions Task : Functional test Objective : Determine if hidden failure has occurred

5. Types of Maintenance (Preventive Maintenance) Condition Based Maintenance (CBM) Not all the failure is age related, most failure give some sort of warning that they are in the process of occurring or are about to occur Task : measurement of condition Objective : restore or replace based on a measured condition compared to a defined standard Fig : p-f curve

6. Types of Maintenance (Preventive Maintenance) Predictive Maintenance (PM) Maintenance that incorporates predictive analytics with the use of both real-time and historical data that forecast activity, behavior, and faults that might hamper vehicles if not corrected in real time Uses data from ECUs to predict Remaining Useful Life (RUL) of the components

7. Types of Maintenance (Corrective Maintenance) Deferred Corrective Maintenance Deferred maintenance is the practice of postponing maintenance of redundant or non-critical asset  Causes : cost, inaccessibility, unavailable parts, Emergency Maintenance (EM) Maintenance family where a vehicle had an unexpected failure of a part required to keep it running Task type : repair/replace Immediate intervention required and is the most expensive maintenance type World Class organizations ensure that less than 2% of their total maintenance is Emergency Maintenance Experts recommend that your balance of Preventive vs Corrective maintenance should be 80/20

8. SERVICE PLAN A Service Plan helps you keep your vehicle on the road by making sure its recommended scheduled services are taken care of by approved dealers, making worrying about car servicing something from the past. Offers you a convenient way of budgeting so that you can spend less time worrying about your car service and more time enjoying the open road. Source : https://www.acko.com/articles/car-insurance/why-a-routine-car-servicing-is-a-must-for-your-vehicle/

9. SERVICE PLAN INCLUDES……. Replaceable items on a car that are predetermined by the manufacturer to keep a car running perfectly such as Oil, air filters, spark plugs , cam belts, brake fluid, Coolant.

10. COVERAGE OF SERVICE PLAN It covers the cost of regular services on four wheelers as specified by the vehicle manufacturer. It pays for the servicing of a vehicle either on an annual basis or according to the vehicle manufacturer's mileage requirements. Labour is also covered in a service plan.

11. BENEFITS OF A SERVICE PLAN Car servicing can be expensive, but Service Plan comes with the following benefits: Provides peace of mind that your car servicing is taken care of Includes original equipment manufacturer (OEM) required services Fixed, affordable monthly cost for car servicing Qualified technicians Genuine parts A Service Plan, helps to maximize the resale value of your car.

12. MAINTENANCE PLANNING What? process of determining  what maintenance  work should be done and how it should be carried out. Why? For more effective and efficient maintenance operations resulting high quality operations. To achieve organizational objectives: Availability, Reliability, quality and delivery dates How? Capacity planning Maintenance scheduling

13. CAPACITY PLANNING What? The determination of the maintenance resources need to meet the maintenance load. Manpower(numbers and skills),overtime capacity, contract maintenance How? Maintenance forecasting

14. MAINTENANCE PLANNING PRINCIPLE Protect the planner Focus on future work Component-level files Use planner judgement for time estimates Recognize the skill of techs Measure performance with work sampling

15. BASIC GOAL OF MAINTENANCE PLAN Maintain vehicles in safe operating condition. Ensure each vehicle is operating at peak efficiency. Maximize vehicle life. Minimize loss of accessibility due to equipment failure. Maintain vehicle exterior and interior appearance. Maintain a system of permanent vehicle maintenance records.

16. CAR MAINTENANCE PLAN It covers both the labour and expenses of parts while also providing cover for wear and tear replacement items such as fuses, wiper blades, and brake pads. It also covers mechanical components such as the gearbox, engine, and exhaust system. Windscreens, alignment, and tyres are not covered in maintenance plans.

17. BENEFIT OF THE CAR MAINTENANCE PLAN   Fixed and affordable monthly premiums for regularly scheduled vehicle maintenance. Specified item wear and tear cover. Qualified technicians and professional service. Remain unaffected by the ripple effect of inflation on labour and parts cost increases.

18. Maintenance schedule refers to tasks such as inspections and repairs that are performed according to a pre-defined maintenance schedule occurring periodically or occasionally. Maintenance schedule can be very handy when it comes to avoiding expensive repairs, prolonging machine life and maximizing safety. Maintenance schedule includes various activities ranging from routine monitoring to yearly services. SCHEDULE

19. Routine inspections Check engine light Tire pressure light Headlights and tail lights Wiper blades Monthly inspections Engine oil level Coolant Windshield wiper fluid

20. Inspections after every 3 months or 5000 km Battery and cables Belts Engine air filter Power steering fluid Exhaust Tire threads and condition

21. Inspections after every 6 months or 8000 km Engine oil Chassis lubrication Brake pads Annual inspections Automatic transmission fluid Brakes Cabin air filter Tires

22. Services types Causes/Failure Maintenance / affected area Exhaust system service Loud noise, exhaust leak, exhaust pipe breaking, fuel smell, poor fuel economy with previous comparison. Catalytic converter , EGR system, exhaust pipe parts, oxygen sensors(along exhaust muffler) Car wash and detailing service Dirt deposits, chipping paint. Stain, mold build up, rusting, part degrading . Washing, waxing, conditioning, detailing the interior and exterior, painting and decorating. Tire replacement service Thread depth below prescription, flat shape, holes, wear and tear. Inspection(Thread depth , puncture, wear and tear, shape), traction test and replacement if necessary. Shocks and struts inspection and replacement service Suspension creaking and popping, steering trouble, car sagging, jerks over bumps and holes. Shock absorber and strut alignment and parts inspection(replacement if necessary), breakage, Joints connection. SERVICE TYPES, CAUSES/FAILURE AND MAINTENANCE

23. Fuel system cleaning Engine delay, engine stalls, variable engine performance at different speeds, fuel passage blockade. Fuel system cleaning with additives or solvents, test inspection after cleaning to meet prescribed fuel transfer characteristics. Bumper repair service Scraches , small dents, peeling paint, minor looseness, damaged impact bar. Repaint, extrusion or intrusion of defect area, polish, clip fitting, replacement(rare case). Paintless dent repair Tiny or compound hollow surface, parts collision. Dent kit pulling, parts inspection and replacement(rare). Minor maintenance service Unusual sound , light, rough smoothness, jerk, electrical equipments defect, overheat, bad odour . Inspection in related area with washing and testing for smooth drive, oil inspection and tyre pressure. Intermediate maintenance service Rough smoothness, reduced mileage, starting and overheat problem. Inspection(Battery, filter, engine oil, exhaust , fuel economy, cooling system, radiator, tyre and brake).

24. Services types Causes/Failure Maintenance / affected area Brake pad Replacement and rotor resurfacing service Wear & tear, vibration, squealing noise, spongy, increase in stopping distance Inspection (brake pad & rotor), flush brake fluid, replacement if necessary Engine timing belt replacement service Stretch & wear, vibrating, squealing and rubbing noise, ticking noise from engine Need to be replaced every 60,000-100,000 miles Coolant fluid flush and Exchange service Engine overheating, sweet maple syrup smell Inspect cooling system, flush and fill the coolant if necessary Tire rotation service Tread wear, Pattern noise Each tire and wheel are removed and moved to a different position to ensure that all tires wear evenly and last longer, rotated every six months or 6,000 to 8,000 miles.

25. Battery replacement service Slow engine cranking, problem with electrical accessories, excessive corrosion on battery terminal, leaking battery fluid Periodic check-ups of battery, replacement if necessary Headlight resurfacing and restoration service Deep scratching or crack, foggy, hazy, yellowish, excessive abrasion Inspect the headlight, cleaning to remove dirt Sensing technology repair and replacement ECU cannot know whether the amount of gasoline injected is correct, ABS not working properly, cold start difficulty, the engine may be shaken and the acceleration response may be delayed Testing (oxygen sensor, wheel speed sensor, air flow meter, water temperature sensor throttle valve position sensor), replaced oxygen sensor every 60,000-90,000 miles

26. Services Types Causes/Failure Maintenance/ affected area Check engine light Failing oxygen sensor, Excessive air in air intake system, loose gas cap, bad spark plug/ignition coil, bad spark plug wires, Dirty catalytic converter, bad mass air flow sensor, bad condition of battery, EGR valve problem, parts that attached to the diagnostic part of engine Fender Repair Service Accident (Bent, Scratched or completely damaged fenders), impact load Repair damaged fender, washing, coloring Spark Plug Replacement spark plug degrading, dirty spark plugs, old spark plug, (trouble when starting, larger engine problem, loss of power and fuel economy) once a season, clean a spark plug from wire brush, replace the spark plug (don’t tight over) Battery Inspection & Testing overheated, overcharged temperature change, dust & dirt, loose fan belt, (headlights appear dimmer than normal, clicking sound while turning the key, engine backfires, battery system warning light is on, check engine light is on) once a season, use a voltmeter to test, Tight any loose cables, Replace the fan belt if it is cracked, replace (in case of failure), apply a thin coating of high temperature grease to posts and cable connections, check the State of Charge Indicator (voltage & charge)

27. Water Pump Replacement Service Over time, over heat, Coolant leakage, Smoke/Steam from the engine, mineral deposits, normal wear and tear, noise (engine damage, runs hotter, and uses more fuel) Change coolant on time, check coolant level & pressure of coolant, replace water pump (if needed) Four Wheel Alignment Service Tires wearing, road condition, Vehicle collisions, use over time checking the condition of your tires and air pressure, Adjusting the angles of the wheels Complete Front Brake Service Apply brake at high speed, high temperature, Low brake fluid, Low brake pedal, wearing & tearing the brake brake lining replaced, replacing the brake rotors, and inspecting the brake lines and related components

28. Services types Causes/Failure Maintenance / affected area Power steering system fluid exchange service Contaminated fluid, Improper fluid levels, Broken belts, Leakage Check hoses and power steering pressure, Inspect steering fluid levels Transmission replacement service leaking fluid, transmission solenoid issue, Torque converter problem Service the coolant system, transmission repair Transmission fluid exchange service Varnish and dirt deposit, Wrong type of transmission fluid Check transmission fluid, flush the transmission Dent removal service Round dents, Creased dent, extreme dents damage Traditional dent removal, Paint less dent removal Transmission service Low transmission fluid and quality, clogged transmission fluid filter Check transmission fluid, change transmission filter

29. Wiper blade replacement Environment factor like sun, dust, freezing temperature, oil, saltwater & acid rain Clean windshield, pull wiper from windshield during winter months, use ice scraper or defroster to melt snow and ice Tire patch and repair service Sharp instrument, heat Patch Repair (up to ¼ inch or less, not approved for sidewall puncture, puncture must be on tire tread) Tire tread and pressure check Improper inflation pressure, potholes and sharp instruments, out of specific tire alignment Check condition of the tire and alignment, check tires pressure, check tires tread depth, cautious driving

30. THANK YOU!!!!