Factory Clinic

8/14/2019 Factory Clinic

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Most of us, once in our life time, would have visited a typical

medical practitioner in our neighborhood -- This Doctor, in his

small clinic, will have quite a few commonly used instruments

for diagnosing regularly treated diseases.

Of course, for advanced tests and check-up, if need arises, the

Doctor will refer us to a bigger hospital or testing labs

Arent maintenance technicians sort of doctors diagnosingmachines and their problems?

Shouldnt they also possess certain critical tools / measuring

devices for effective diagnosis and troubleshooting?

Welcome to Factory Clinic.. Know what basic things you

have to keep in your clinic for treating the patient !!


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SPIRIT LEVEL A simple device used to measure the

alignment of almost anything from long pipe lines tomachines. Sealed small glass or plastic tube consists of

spirit usually Methyl Alcohol with a bubble in it which

shifts from the center line based on its alignment. The

accuracy of spirit level is measured like 0.1 or 0.01 or

0.001 millimeter per meter. Generally, 0.01 per meter

Spirit Level is sufficient for all day to day activities.

It is suggested to have X-Y (as shown above) dual axis

Spirit Level for easier alignment / checking in both

directions.


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VERNIER CALIPER A simple measuring tool for

checking dimensions like length, diameter (internal &

external) with accuracy of 0.01 millimeter (called Least

Count) is sufficient for day to day quick measurements. It

can also be used for checking the depths of anycomponent . Calipers are available in different sizes.

Usually 300mm / 12 is commonly used. It is also

available in digital format which not only precisely displays

the value but also stores it for recollecting later.


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FEELER GAUGE It is a collection of hardened steel

sheets of different sizes varying from 0.0001mm up to

5mm combined together. By adding the sheets of different

sizes we can easily determine many dimensions bearing

clearance, gap between two mating parts, spark plug

clearance, valve clearances, eccentricity in a circularassembly and many more

A simple yet powerful piece of tool which can be tucked

inside a pocket too.


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MICROGAUGE or MICROMETER It is yet another small

piece of measuring instrument that can be used to

measure critical dimensions. Its limitation is that it cannot

be used for large measurements. Using this tool, we can

measure cable strand diameters (for example to checkincoming material quality and compare to standards),

sheet thicknesses (you may want to insert some shims

into an assembly), valve dimensions, critical washer

dimensions and more


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DIAL INDICATOR A very sensitive measuring device

which can be obtained in many accuracy levels. It can

even measure a variation of 0.001mm when mounted

correctly. Usually it is fixed to a magnetic stand. This dial

indicator can be used to measure axial and radial run

outs, parallelism of a bar or a straight bar or object,

variations in any pattern over a period of time, vibration of

any rotating equipment. It can also be used to sense any

changes in stroke length variation of actuating cylinders or

rods


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MAGNETIC STAND A compulsory supplement to thedial indicator, it can also serve many other purposes. It

can be used to hold any other measuring device or probe

in the intended location. With a simple ON-OFF switch the

stand can be magnetized or demagnetized.


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LITMUS PAPER Litmus is basically a water soluble

mixture of many natural dyes obtained from lichens, a type

of organism. It is absorbed into filter paper which when

dipped in any liquid changes its color depending on pH

value. It therefore, broadly, tells whether the liquid is

acidic or alkaline. It turns red when the dipped liquid isvery acidic and blue when it is very alkaline. It can also

change to intermediate color. Although it is widely used for

checking engine coolant mixture, it can also be used for

checking many liquids in a typical plant including drinking,

sanitary water.


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TORQUE WRENCH In TPM there is a fundamental

concept taught to the operators. It is called CLIT standard

in which T stands for TIGHTENING. How much tightness

a bolt requires depends on its application and criticality. A

25mm (1) bolt definitely can be tightened more than a

5mm (1/5) bolt for example. And if an assembly hasmultiple bolts, it is essential to TIGHT them to same value

which can only be determined by using a torque wrench. It

can be a simple mechanical torque wrench as shown in

picture or advanced one which clicks on reaching set

torque and does not allow over tightening


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MAGNETIC COMPASS Although considered as a

scientific instrument, it will be helpful in determining

direction for construction and orientation purpose. It helps

instantly determine the latitude and longitude of a position.


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ANALOG MULTIMETER Any fluctuation in the voltage,

resistance and / or current can be easily understood by

this simple analog meter. Digital multi-meters measures

the RMS value of any parameter and does not clearly

show the fluctuation of a value. One of the best example

of analog multi-meter is checking resistance variation in abrush type DC motor. It is also useful in analyzing outputs

from various feedback devices like potentiometer, encoder

and more.


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DMM Digital Multi-Meter is a simple measuring

instrument with wide range of selections. DMMs measure

RMS (Root Mean Square) value of any parameter and

many basic models will not show the Peak values. Some

of the common features that a DMM should have are: i)

Hold option to lock a particular value ii) Diode Test

Indicator iii) Internal fuse for protection iv) AC / DC voltage

and current measurement options v) Resistance

measurement option up to 20 Mega Ohms vi) Auto Range

selection vii) Auto Power off to conserve battery


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MEGGER An indispensible measuring device for

determining insulation resistance of any electrical

component electric motor, transformer, cable and more.

Although electro-mechanical meggers are economical,

digital meggers are more easier to use and different

voltage levels can be easily set. They also have data

storage and transfer facility with ability to retain data for

longer periods.


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LCR Meter It is quite possible that DMMs can also have

option to measure LCR or Inductance (L Henry),

Capacitance (F-Farad) and Resistance (R-Ohms). But a

separate LCR meter is recommended for troubleshooting

and maintenance purposes. A typical LCR should haveauto range and hold facility. More advanced LCR (and

even DMMs) have a serial data transfer port which can be

connected to a computer for continuous data acquisition.


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ANEMOMETER It is a simple hand held device to

measure the velocity of air. Its application can vary from

measuring output across a radiator (which will help check

the blockage) to measuring output from a fan or

centralized air handling system. The measurement can bedisplayed in any linear units of velocity like centimeter per

second, miler per second, kilometer per hour etc.


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DECIBEL or SOUND METER With stringent regulations

on noise pollution in and around a factory, it is quite

essential to have sound knowledge of noise levels.

Although our ears are best judges, it is essential to

measure noise produced from various equipments. It will

also help in early detection of arriving problems. Forexample, a loose coupling or a faulty bearing from an

equipment can influence the noise levels. This simple

measuring device measure noise in dB (deciBels).


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(Electro Static Discharge) Wrap Independent of our

ability to handle any electronic boards, especially the ones

which have memory storage ICs, it is essential to

discharge static electricity from our body. This simple wrap

must be worn around wrist and grounded to prevent

damaging expensive electronic boards.


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LUX METER No facility can run without sufficient

lighting. How much is sufficient should not be a guess

work since lighting has direct influence on a persons

efficiency. Some facility might need bright lighting and

some may need just enough lighting. A simple lux meter,

which measures intensity of lighting usually in LUMEN

units can help avoid guessing. It will also help selecting

right type of lighting and understanding the distribution.


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RH / Temperature Gauge - Temperature and Relative

Humidity are two factors that will help determine many

conditions including efficiency of air conditioner for

example. Relative Humidity indicates percentage of

moisture present in atmosphere


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TACHOMETER - A device used for measuring the RPM

(Revolutions Per Minute) of any rotating equipment. With

additional components, it can measure the surface speed

of various elements like conveyor belts, chains and more.

Contactless tachometers are also available.

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