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Quizzes > Quizzes for Business > Manufacturing

Autonomous Maintenance Knowledge Assessment Quiz

Challenge Yourself with Expert Autonomous Maintenance Questions

Difficulty: Moderate
Questions: 20
Learning OutcomesStudy Material
Colorful paper art quiz banner for Autonomous Maintenance Knowledge Assessment trivia

Dive into this free autonomous maintenance quiz to assess your process mastery and boost equipment reliability. This knowledge assessment is perfect for maintenance technicians, process engineers, and quality professionals seeking hands-on challenges. Explore similar tests like the Maintenance Technician Knowledge Assessment or the Mechanical Engineering Maintenance Knowledge Test for broader practice. You'll gain clear insights into inspection routines, cleaning protocols, and preventive strategies to optimize your workflow. Feel free to edit questions and customize the quiz in our easy-to-use quizzes editor.

What is the primary objective of autonomous maintenance?
Operators perform basic maintenance tasks on their own equipment
All maintenance responsibilities are transferred to a centralized team
Robots handle all routine maintenance processes
Machines automatically repair themselves without human intervention
Autonomous maintenance empowers operators to maintain and troubleshoot equipment, increasing ownership and early detection of issues. This reduces downtime and reliance on specialized maintenance staff.
Which of the following is one of the 5S pillars in autonomous maintenance?
Service
Safety
Sort
Standard Tools
The 5S methodology includes Sort, Set in Order, Shine, Standardize, and Sustain, with Sort focusing on removing unnecessary items. It lays the foundation for a clean and organized workspace.
Regular cleaning and inspection help primarily detect which type of issue?
Scheduling conflicts
Excess staffing
Budget overruns
Leaks
Regular cleaning and inspection reveal leaks by exposing fluid trails and spotting seals and hose degradation. Early detection of leaks prevents contamination and reduces the likelihood of major failures.
What element is essential on an autonomous maintenance checklist to ensure lubrication?
Strategic planning
Lubrication point inspection
Market analysis
Root cause analysis
Inspecting lubrication points ensures that bearings and moving parts receive proper lubrication to reduce friction and wear. Including lubrication checks in autonomous maintenance prevents premature component failure.
Which metric measures the proportion of planned production time that equipment is actually running?
Mean Time to Repair (MTTR)
Return on Investment (ROI)
Overall Equipment Effectiveness (OEE)
Total Cost of Ownership (TCO)
Overall Equipment Effectiveness (OEE) measures the proportion of planned production time that is truly productive, calculated as Availability × Performance × Quality. It is a key metric for assessing equipment utilization and efficiency.
Which is a best practice when performing equipment cleaning during autonomous maintenance?
Use coarse abrasive brushes for all surfaces
Skip regular cleaning to save time
Flood the machine internals with high-pressure water
Use approved solvents that are compatible with machine surfaces
Approved solvents effectively remove contamination without damaging equipment or leaving harmful residues. Using water or abrasive brushes can cause corrosion or surface damage.
What root cause analysis tool uses a fishbone-shaped diagram to identify potential causes?
Pareto chart
Box plot
Control chart
Fishbone diagram
A fishbone diagram (Ishikawa) visually categorizes potential causes of a problem, making it easier to analyze root causes. It is widely used in maintenance for structured problem-solving.
Which scheduling technique plans maintenance based on equipment usage hours rather than fixed calendar intervals?
Time-based maintenance
Usage-based maintenance
Failure-based maintenance
Condition-based maintenance
Usage-based maintenance schedules tasks according to actual equipment running hours, aligning maintenance with wear and service needs. This approach can reduce unnecessary downtime compared to fixed intervals.
OEE is calculated as the product of availability, performance, and which other factor?
Efficiency
Utilization
Quality
Reliability
OEE is the product of Availability, Performance, and Quality metrics, where Quality represents the proportion of good parts produced. Including Quality ensures that defects are accounted for in overall efficiency.
Contamination, lubrication failure, misalignment, and overload are common causes of failure in what component?
Hydraulic tank
Control panel
Bearing
Safety guard
Bearings are susceptible to failure from contamination, lack of lubrication, misalignment, and overload. Identifying these root causes is essential for preventive maintenance.
What is the correct sequence of steps in an autonomous maintenance cycle?
Clean > Inspect > Correct > Standardize
Document > Train > Execute > Review
Sort > Shine > Set in Order > Sustain
Detect > Clean > Inspect > Correct
The correct autonomous maintenance cycle begins with detecting abnormalities, followed by cleaning, inspecting components, and correcting any issues. This structured approach ensures early fault detection and remediation.
Which of the following is a leading indicator of equipment health?
Repair costs
Vibration levels
Downtime hours
Number of breakdowns
Vibration levels are a leading indicator of mechanical issues and can detect faults like imbalance or misalignment before breakdowns occur. Monitoring vibration helps preemptively address problems.
Which daily task should be included in an autonomous maintenance checklist?
Check oil levels
Overhaul the gearbox
Replace bearings
Approve maintenance budgets
Checking oil levels daily allows maintenance teams to identify leaks or low lubrication before serious damage occurs. Other tasks like gearbox overhauls are periodic, not daily.
A key principle of autonomous maintenance is that operators should be responsible for which activity?
Basic upkeep of their equipment
Issuing purchase orders
Developing capital budgets
Designing new machinery
Autonomous maintenance principles assign operators responsibility for basic upkeep tasks like cleaning, lubrication, and inspections. This practice fosters ownership and continuous improvement.
FMEA is primarily used for which purpose?
Forecasting sales
Scheduling staff shifts
Identifying potential failure modes
Tracking daily tasks
Failure Modes and Effects Analysis (FMEA) systematically identifies potential failure modes and their effects to prioritize risk mitigation. It is a proactive tool for reducing equipment failures.
A high amplitude at the bearing ball pass frequency in a vibration spectrum most likely indicates what issue?
Imbalance
Misalignment
Looseness
Bearing defect
Bearing ball pass frequency (BPF) peaks in vibration spectra are classic signs of bearing defects such as pitting or spalls. Detecting these allows timely replacement before catastrophic failure.
According to the P-F curve concept, when should preventive maintenance tasks be scheduled?
Immediately after functional failure occurs
Before the potential failure point, even if no warning signs are present
At fixed monthly intervals regardless of condition
After the potential failure point but before the functional failure
The P-F curve illustrates the window between potential failure detection and functional failure. Scheduling maintenance after the potential failure point but before functional failure prevents breakdowns.
Which KPI best reflects increased operator engagement in autonomous maintenance programs?
Number of improvement suggestions implemented
Number of completed breakdown repairs
Total training hours logged
Overall labor cost reduction
An increase in improvement suggestions implemented by operators indicates higher engagement and ownership in autonomous maintenance. Suggestions reflect proactive involvement in maintenance processes.
In root cause analysis of repeated belt slippage, investigation shows inconsistent tension and worn pulleys. What is the most probable root cause?
Excessive lubrication on pulley surfaces
Insufficient belt tension
Operator error during start-up
Manufacturer design defect
In cases of belt slippage, insufficient tension is most often the root cause rather than pulley wear or operator error. Correct tension ensures proper grip and power transmission.
Analyzing changes in MTBF over time helps optimize maintenance routines by providing insight into what?
Failure interval trends
Equipment utilization rates
Staff productivity
Inventory usage levels
Monitoring Mean Time Between Failures (MTBF) trends highlights patterns in failure intervals, guiding optimization of maintenance frequency and tasks. This analysis helps in adjusting maintenance strategies for reliability improvements.
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Learning Outcomes

  1. Identify key principles of autonomous maintenance processes
  2. Apply best practices for equipment cleaning and inspection
  3. Analyse root causes of common machinery faults
  4. Demonstrate proper use of autonomous maintenance checklists
  5. Master scheduling techniques for preventive maintenance tasks
  6. Evaluate performance metrics to optimize maintenance routines

Cheat Sheet

  1. Understand the 7 Steps of Autonomous Maintenance - Dive into each step from initial cleaning to setting lubrication standards, and discover how these building blocks empower you to keep machines running like clockwork. This roadmap helps you spot hidden issues before they snowball into downtime disasters. Explore the full guide
  2. Master Equipment Cleaning Techniques - Become a cleaning ninja by learning the right tools and methods to banish grime and debris. Regular, targeted cleaning uncovers sneak-attack leaks and wear, keeping your gear in tip-top shape. See pro cleaning tips
  3. Develop Inspection Skills - Hone your senses - sight, sound and touch - to detect odd noises, vibrations or discolorations before they turn into major faults. A sharp inspection routine is like having a sixth sense for machine health. Learn inspection tricks
  4. Apply Root Cause Analysis - Don't just slap on a band-aid when equipment fails; dig deep with methods like the "5 Whys" to unearth the true culprits. Solving the real problem means fewer repeat malfunctions and a smoother workflow. Master the 5 Whys
  5. Utilize Autonomous Maintenance Checklists - Checklists are your maintenance sidekick, ensuring you never miss a critical step. They help you log tasks, track progress and build consistency into your machine-care routine. Grab your checklist
  6. Schedule Preventive Maintenance Tasks - Learn to craft smart schedules based on usage patterns and manufacturer guidelines, so surprises are the only thing you won't see coming. Proper timing slashes breakdowns and maximizes uptime. Plan your schedule
  7. Monitor Equipment Performance Metrics - Keep an eye on key figures like Overall Equipment Effectiveness (OEE) to measure your maintenance success. Tracking trends helps you fine-tune routines and celebrate wins when performance soars. Track your metrics
  8. Embrace Continuous Improvement - Turn the dial up on excellence by regularly reviewing and refining your practices. A mindset of constant upgrades means every maintenance cycle is better than the last. Join the improvement journey
  9. Understand the Role of Operators in Maintenance - Operators are your frontline heroes, spotting quirks and reacting faster than a blinking light. Their daily care and quick fixes keep the production line humming smoothly. Discover operator strategies
  10. Implement Visual Maintenance Management - Spice up your workspace with color-coded tags, charts and signs that make tasks instantly clear. Visual cues help everyone stay on the same page and boost overall efficiency. See visual management ideas
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