DUTIES AND RESPONSIBILITIES OF MECHANICAL ENGINEERING IN INDUSTRIAL FACTORIES

 An industry or company or more popularly is a factory, be it a small or large scale factory that is active in producing activities to process or make finished goods or semi-finished goods.

This can be ensured that a factory has or uses machines for production or to produce processed products from that factory.

And the components of the machines used by the factory are inseparable from movement, be it manual or automatic movements.

From the effect of continuous work movements of the machine in life time, it will reduce the optimization of work and work productivity on the production machine.

To avoid this, it is possible that a factory or industry will recruit a technician or person who is competent in handling production machinery problems. In percentage terms, the movement of production machines is dominated by the mechanical working mechanism.

On this occasion, the author tries to describe the duties and responsibilities as well as the daily activities of a mechanical technician in an industrial factory or company.

The main duties and responsibilities of a mechanical technician are as follows:

• Perform maintenance on production machine parts mechanically so that there is no damage or fatal trouble while the machine is in production.
• Repairing production machines that are physically damaged, so that the machines can start operating immediately
• Repairing production machines through improvement or increasing the quality of the production machine.
• Registering and preparing engine parts as spare parts to anticipate repeated trouble.

The following are some forms of activity to carry out the duties and responsibilities generally carried out by a mechanical technician in the production machine of an industrial factory or company:

1) DAILY CHECK (DAILY CHECKING)

Daily check or daily check is the activity of checking the condition of the production machine by a mechanical technician which is carried out regularly every day.

The goals of this daily check are:

• To know the condition of the machine optimally both in terms of work functions and work processes so that we can minimize the occurrence of trouble or problems experienced by the engine.
• To list data on the condition of machine parts or components that require special handling.
• Ensure that the production machine is in top condition.

The types of activities or things a mechanical technician does in a daily check are as follows:

a) Check the condition of lubrication or lubrication on the production engine parts

The purpose of this check is to ensure that the machine parts that use or require lubrication or lubrication are completely lubricated and ensure that the lubrication or lubrication system functions optimally.

Because lubrication or lubrication is the most important thing in the work movement of production engine parts, Without a lubrication in the engine parts movement system, it can be sure that engine parts will overheat and wear out.

So in this case the lubrication or lubrication of engine parts can be said to be the life of a machine.

The materials used as lubricants in production machines are usually in the form of grease and oil.

The lubrication system used is a circulation system using an electric motor pump and a pneumatic air pump.

Meanwhile, the things that need to be checked in this job are:

• Check the grease content or volume in the grease tube
• Check the flow out condition or grease output in the engine part
• Check the oil content or volume in the oil tank
• Check and visually see the flow of lubricating or lubricating oil on the oil flow glass.
• Check drain or reverse circulation of lubricating oil
• Check for lubrication leaks in pipping grease or oil.
• Check the function of the entire lubrication system.
• Etc.

b) Check the condition of the production machine movement visually whether it is abnormal or not.

Make sure that every movement of the machine part is in accordance with what it should be, for example, back and forth movements, up-down movements, rotating movements, half-circle zig-zag movements and other movements.

If a mechanical technician finds an abnormality in the movement of this machine part, make sure it can be classified in urgency, whether the production machine can still produce products or not.

If it is still within the tolerance of the product, it can be done as a list of problems, but if the machine cannot produce a product at all from the effect of the problem of moving the part, then it can be done directly.

c) Check the function of a part or component of the production machine whether it is functioning properly or not.

To ensure that the production machine part is functioning or cannot be done by viewing or monitoring the machine while it is running, provided that we must maintain our safety as mechanical technicians when checking the machine visually.

An example of this activity is ensuring that machine parts can function such as being able to open and close, function ON - OFF, function clamp or not, can cut or not, can flow or not, can be hot or not, can be cold or not, can suck or not, can throw or not, etc.

d) Check the condition of the part of the production machine whether there is damage or not.

Damage to production machine parts can be seen visually both through running and stopping machines, this can be seen from a physical change or shape of the machine part.

One example if an engine part is damaged is a change in the shape of the part, a strange sound in the part, an abrasion mark from a part, an oil or oil leak in a hydraulic part, a scar in the part, a wind leak in the part. pneumatics, and others.

e) Check the condition of a production machine part or component in terms of a change in position or not.

To ensure whether or not there is a change in the position of the engine part or component, you can check it while the engine is running.

With the condition of the engine running, at that time we can see that there is a change in the position of the engine part with the characteristics, For example; 

• The movement of the engine part is shaking because the bolt is loose so that it affects the position of the sliding part. 
• The presence of a worn lock bolt that makes the part slide and the position changes. 
• The fastener bolts are broken so that the part changes position, and so on.

f) Check the condition of nuts and bolts on engine parts.

The purpose of checking the condition of the nuts and bolts on the engine part is whether there is looseness or not the nuts and bolts are tightened in binding the engine part.

The condition of this looseness can be seen from the nut head and the bolts are not tightly attached to each other.

The presence of loose nuts and bolts can also be seen from the shaking body when the production machine is running.

Also check whether there are incomplete nuts and bolts, because between nuts and bolts is a unit that cannot be separated.

Also check the completeness of the number of pairs of nuts and bolts that should be installed in the engine part.

g) Check the condition and situation in the area around the production machine to meet cleanliness standards or not.

Good companies or factories are those who care about the cleanliness of the surrounding environment, be it in the machine or in the environment outside the production machine.

This includes one of the duties of a mechanical technician.

Make sure the area around the production machine is clean or there are no unused machine parts or items in the form of trash.

This is of course to maintain the quality of the products that the machine will produce.

If there are items that are not used around the production machine, it is feared that there will be contamination between the products and the unused items or waste.

h) Check whether there are parts or other objects that can interfere with the work activities of the production machine.

In addition to avoiding the production machine area from waste or unused parts, making sure the production machine work area does not have other work equipment that could potentially interfere with the activities of production members.

Suppose that our work tools as mechanical technicians are in the production member work area or close to production machines.

i) Coordination and input of input or information from production machine operators.

Collaborating with production members is one way to keep the machine in safe condition, no problem. 

Because production members are people who are always in touch and know the ins and outs of the engine's condition when running.

So that not infrequently production members always provide input or input and request for improvements or development to improve on the condition of production machines.

And from the information of production members, we can also know the actual conditions that occur in the production machine so that we can continue to investigate the machine and make repairs.

2) WEEKLY CHECK (WEEKLY CHECKING)

Weekly check or weekly Activities is an activity to check the condition of the production machine by a mechanical technician which is done regularly every week.

The objectives of the weekly check are:

• This is to determine the temperature or hot temperature conditions of production machine parts such as bearings, pillow blocks and rotating parts.
• Avoiding engine part fires that are caused due to engine overheat parts that are not known before.

In checking the temperature of these parts using a temperature check tool. The check tool model is in the form of a laser and touches with a digital number display.

The parts that need to be checked for temperature or hot temperatures are as follows:

a) Pillow block

 Pillow block Is a part of the machine that functions as a support for the rotation of the shaft roll with small to large diameter.

Pillow blocks have various sizes from small to large depending on the needs of the production machine. And pillow blocks use lubrication with grease.

Pillow blocks consist of a collection of ball-ball bearings wrapped in a casing which then one unit of the bearing casing is wrapped again by a separate body casing which is designed to be able to supply grease lubrication at any time. Because pillow blocks are equipped with neple grease or a line for manual grease supply.

Pillow blocks tend to be more durable and strong in terms of life time because the ball - ball bearings of pillow blocks that always rotate according to the rotation of the shaft roll can be lubricated continuously.

The way to check the temperature or hot temperature of the pillow block is by directing a laser beam or attaching a temperature check tool to the body pillow block. For a safe pillow block standard temperature is below 70 degrees Celsius.

If the pillow block temperature is high, then you can be sure that there is an abnormal condition of the pillow block.

Usually this happens because:

• There is no lubricating grease on the pillow block, the way to handle it is to immediately add or supply the pillow with grease.
• The condition of the ball - the ball bearing is worn, injured or oblagged, the handle is to replace a new pillow block.
• The condition of the shaft roll line is worn so that when it rotates it becomes rocky and causes high vibration in the pillow block, the handling is to replace or repair the worn shaft roll.

b) Bearings

A bearing is a part of a production machine that functions as a support for the rotating shaft roll, ranging in size from small to large.

Bearings have a variety of sizes from small to large depending on the diameter of the shaft.

The use of bearings can be used by small to large diameter shaft rolls depending on the fabrication needs of the production machine. For the lubrication system used by bearings is grease.

Bearings consist of a collection of ball - ball bearings wrapped in a casing only. 

Bearings with pillow block are the same parts that use grease lubrication, 

While the difference between the two is that if the PILLOW BLOCK ball bearing can be supplied with lubricated grease through the neple grease that integrates with the pillow block casing, 

While BEARING cannot be grease lubricated, because bearing does not have neple grease.

Life time or the level of durability of bearings tends to be shorter than pillow blocks because the condition of ball bearings only relies on lubricated grease from the beginning of fabrication, and then it cannot be lubricated anymore.

If we want the bearing to be greased, like a pillow block, we can do it by improving or modifying the grease lubrication system on the bearing by adding pipping lubrication to distribute grease to the ball-ball beaing.

Checking the bearing temperature is the same as checking the hot pillow block temperature, namely by directing a laser beam or attaching a temperature check tool to the bearing body. For a safe bearing temperature is below 70 degrees Celsius.

The same thing happens to bearings when high heat occurs due to the following:

• The level of grease lubrication in the ball bearing is depleted or dry so that the ball bearing is not lubricated directly when it rotates, for a model bearing condition that cannot be supplied with new grease because there is no pipping grease installation, the handling is to immediately replace the bearing unit with the bearing unit the new one. Whereas for bearing models that have pipping installations to supply grease, handling if the ball bearing is dry because there is no grease is to immediately supply or fill the bearing with new grease.
• Ball - ball bearings are worn or damaged, the handle is to immediately replace the bearing unit with a new bearing unit.
• The bearing casing is worn or oblagged and also because the roll shaft is worn so it becomes oblagged, this can cause the roll rotation to become unstable so that it has the effect of high vibrations in the beairing unit. The handling is to replace or repair the bearing casing and repair or replace the worn or oblagged shaft roll.

c) METAL BUSHING

Metal bushing is a part of a production machine that functions as the support for the rotation of the large diameter shaft roll.

The function is basically the same as the function of pillow block and bearing. However, this metal bushing is different in terms of material, because metal bushing is made of copper material while pillow block and bearing are made of alloy steel.

Metal bushing tends to be used as a rotation support for large rolls, so the type of lubrication that is used to lubricate the metal bushing is the flow of oil supplied from the circulating oil lubrication pump system.

The way to check the hot temperature on the metal bushing is by directing a laser beam or attaching a temperature check tool to the metal bushing body. For a safe metal bushing temperature is below 60 degrees Celsius.

The things that can cause the metal bushing's hot temperature temperature are high are:

• The volume of lubricating oil flowing in the metal bushing system is too small. The handle is resetting the volume of the lubricating oil flow.
• The flow of lubrication oil in the metal bushing is not smooth, this is due to the presence of dirt clogging the lubrication oil circulation channels. The handling is cleaning the lubrication oil circulation channel in the metal bushing.

3) MONTHLY CHECK (MONTHLY CHECKING)

Monthly check or monthly Activities is checking the condition of the production machine which is done by mechanical technicians and is done regularly once a month.

The monthly check that is done is to check the vibration or vibration of the important parts in the machine, with the following objectives:

• To detect vibrations from engine parts so that safe limits can be detected of these parts.
• To find out the performance conditions of these engine parts.
• To detect the level of wear and tear of these engine parts.

The purpose of checking the vibration or vibration of this machine part is to find out how much the vibration of the machine part is, the greater the vibration or vibration of the machine part indicates that the condition of the machine part has experienced wear or other abnormalities.

Check the machine parts vibration using a vibration detection device or vibrator check. For vibration or vibration on safe machine parts is below 3mm / S.

While the machine parts that need to be checked for vibration are as follows:

a) GEAR BOX

Gear Box is a set of gears or gears that are united in a box that functions to transfer or forward the motor drive rotation to the work load or work side.

Gear box can also be useful for reducing from high rotation of the motor drive to low rotation of the workload depending on the desired ratio.

To lubricate the rotation between gears or gears, the gear box is filled with oil with a certain viscosity or viscosity as needed.

The existence of oil as a lubricant for this gear box with the intention to reduce or lubricate and dampen the rotation between the gears or gears, so that there is no fatal wear on the gears or gears.

The way to check the vibration or vibration of the gear box is by attaching the end of the check tool to the body of the gear box that is needed, usually at the base of the gear box shaft or flange. If there is a large vibration it is usually caused because the condition of the gear or gear is worn or it could also be because the condition of the bearing as the support for the shaft gear box is worn.

b) CYCLO DRIVE

The cyclo drive is a drive unit that only has an input shaft as a link from the motor drive and a shaft out put as a continuation of rotation to the workload.

Inside the cyclo drive box, there is a set of rollers that function to stabilize the in put and out put turns according to the required ratio. Roller rollers and bearings are soaked by rotating lubricating oil in the cyclo drive box.

The function of the cyclo drive is basically the same as the gear box, which is to continue the rotation from the motor drive to the work load, Changing the high rotation of the motor drive into low rotation to the work load according to the gear ratio or the gear in the cyclo drive

To lubricate the gears and rollers in the cyclo drive, oil and grease are usually used depending on the type and model of the cyclo drive itself.

The method of checking the vibration on the cyclo drive is the same as when checking the vibration of the gear box.

4) SHUT DOWN

Small shut-down is the activity of a technician to make repairs to a production machine when the machine is stopped at a time that has been scheduled or that has been set every month.

A large shut down is a schedule of machine repair activities carried out annually.

This shut down involves all technicians related to production machines, including mechanical technicians, electrical technicians, electricians, instrument technicians, and others.

The purpose of shutdown is to perform total maintenance of production engine parts so that the engine is always in good condition and to minimize any serious trouble shooting.

The things that were done by the technicians at the time of shutdown were as follows;

• Make repairs to damaged production machines that can only be done when the production machine has to stop.
• Follow Up, repair abnormal conditions in production machines that are found during daily checks.
• Follow Up for repair of abnormal conditions on production machines that are found during the monthly check.
• Inspection or check by taking data on certain parts.
• Application of improvement or addition of certain parts.
• Re-new all engine parts or total replacement for parts that are no longer suitable for use
• Doing jobs - job requests from production members or other departments related to production machines in terms of safety and productivity delivery.

Shutting down which is done every month usually takes about 2 to 4 hours for each machine.

Meanwhile, the planned annual shutdown usually takes about a day to 10 days depending on the policies and needs of each company.

5) TROUBLE SHOOTING

Trouble shooting is handling or repairing a production machine when the machine has an abnormal condition or trouble or the production machine is damaged.

Trouble shooting can be done when the engine stops suddenly or the technician negotiates to the production member to stop the machine from doing repairs. 

Troubleshoot occurs due to malfunctioning of production machine parts according to the standard.

6) PREFENTIVE MAINTENANCE

Prefentive Maintenance is a repair work activity for a production machine that is carried out by a technician when the machine stops by negotiating or asking for time from production members.

The working time for prefentive maintenance usually doesn't take long, which is between 5 - 60 minutes and is faster than shutting down.

The objectives of this Preventive Maintenance are as follows:

• Make repairs to machine damage that is urgent or damage to machines that must be repaired immediately.
• Prevent more fatal damage to engine parts.
• There is a trouble product quality so that it must be repaired immediately.
• There is trouble regarding the safety or safety of production operators and machines.

7) WORK SHOP JOB

A work shop job is an activity carried out by a technician to prepare parts as a spare production machine which is carried out in a work shop or workshop.

The activities are as follows:

• Make repairs to damaged engine parts so that they are ready to use to replace when a part failure occurs in a production machine.
• Making parts if there are no spare parts in the production machine.
• Designing or assembling improvement results that will be installed or applied to the machine.

8) IMPROVEMENT.

Improvement is a work activity carried out by a technician which includes developing the quality of machine part functions, improving the performance of machine part life time, increasing the quantity of machine parts, changing the way machine parts work and the work area environment, making changes to better machine conditions.

The objectives of this Improvement are as follows:

• Reduce the cost of using machine parts.
• Minimizing the number of machine parts used.
• Changing from parts that are no longer suitable for use into new parts.
• Avoiding unexpected trouble that is more fatal.
• Minimizing the use of natural resources.
• Creating a safe and comfortable work area.
• Creating a clean work area.

9) DATA and ORDER OF MACHINE SPARE PART

Recording engine spare parts is to determine the number and types of spare parts used and needed by production machines.

It is intended to :

• Anticipating the availability of stock spare parts in the inventory warehouse.
• To avoid the absence of spare part stock when there is trouble urgent that requires spare parts.
• To maintain a minimum stock of spare parts in the warehouse.
• To make a spare part procurement order.

As for what is done when checking spare parts on the machine includes:

• Part name.
• Part type.
• Marker part
• The number of parts used.

After recording the parts in the machine, then make sure that the parts have spare stock in the warehouse of at least 1 or 2 items so that when the engine part is in trouble and requires replacement, then we can automatically replace it immediately and the engine condition returns. safe and can produce again.

Imagine if the part in the engine is damaged and cannot be repaired and you have to replace a new part, but we don't have any spare parts in the warehouse .. ?? This will definitely make our production machines stop completely and wait a long time.

If in our warehouse there is no stock of spare parts, then order immediately to procure parts before there are trouble parts in the engine.

This is a brief description of Jobdesc Mechanical Technician Or the duties and responsibilities of a mechanical technician in an industrial plant or company.