viii Contents MAINTENANCE OPERATIONS Chapter 1 ■ Careers in Industrial Maintenance .........................................................2 1.1 Manufacturing in the United States ..................4 1.2 Education ......................................................5 1.3 Careers..........................................................6 1.4 Applying for a Position ....................................9 1.5 Succeeding in the Workplace ........................12 1.6 Certifi cations and Credentialing .....................17 Chapter 2 ■ Industrial Safety and OSHA .................................................................22 2.1 Safety Standards and Regulations..................24 2.2 Professional Conduct and Safety ....................26 2.3 Securing the Work Area ................................27 2.4 Personal Protective Equipment (PPE) .............30 2.5 Safe Lifting and Fall Protection .....................32 2.6 Confi ned Spaces ..........................................34 2.7 Electrical Safety ..........................................35 2.8 Flammable Materials ....................................37 2.9 Practical Measures to Promote Safety ............38 Chapter 3 ■ Maintenance Principles and Record Keeping .......................................42 3.1 Maintenance Methods ..................................44 3.2 Maintenance Resources and Costs .................44 3.3 Operating and Monitoring a Machine ..............46 3.4 Operation and Maintenance Documentation ....47 3.5 Reactive Maintenance ..................................49 3.6 Proactive Maintenance .................................50 3.7 Reliability-Centered Maintenance (RCM) ........54 3.8 Total Productive Maintenance ........................55 3.9 Maintenance Strategies ................................55 Chapter 4 ■ Maintenance Tools .............................................................................58 4.1 Safety .........................................................60 4.2 Wrenches ....................................................60 4.3 Screwdrivers ................................................64 4.4 Pliers, Cutters, Strippers, and Crimpers ..........66 4.5 Measuring Tools ...........................................68 4.6 Hammers and Mallets ...................................69 4.7 Pullers ......................................................70 4.8 Chisels and Punches ..................................70 4.9 Files .........................................................70 4.10 Hacksaw ...................................................72 4.11 Power Tools ...............................................73 4.12 Handling and Storage .................................77 Chapter 5 ■ Fasteners ...........................................................................................80 5.1 Thread Terminology ......................................82 5.2 Thread Specifi cations ...................................83 5.3 Metric Threads ............................................83 5.4 Threaded Fasteners ......................................84 5.5 Taps and Dies ..............................................89 5.6 Thread Inserts .............................................91 5.7 Non-Threaded Fasteners ...............................91 Chapter 6 ■ Print Reading ...................................................................................100 6.1 Print Reading Basics ..................................102 6.2 Title Blocks ...............................................102 6.3 Multiview Drawings ....................................104 6.4 Dimensions ...............................................107 6.5 Assemblies, Tolerances, and Fits .................108 6.6 Geometric Dimensioning and Tolerancing (GD&T) ....................................109 6.7 Electrical Symbols and Diagrams .................111 6.8 Fluid Power Symbols and Diagrams .............115 6.9 Welding Drawings .......................................120