Diesel Engine Repair Quality Control Procedures
Diesel Engine Repair Quality Control Procedures
(OP)
Good Day Gents
I will really appreciate any feedback with regards the following. We carry out frequent diesel engine overhauls ourselves. We have quite a large fleet of earthmoving equipment which we utilise in the mining industry. My problem however, is the fact that basically every repair job has some or other comeback. The quality of the repair procedures are just not up to scratch. I have taken the issue up with the relevant manager and he just always seems to have some or other excuse. I obviously just cannot carry on like this. I woulod really appreciate any pointers or guidelines in this area. I have thought of putting together a quality control matrix, where the craftsman is forced to systematically follow strict guidelines in the form of a checklist or matrix.
Any assistance or help will really be appreciated.
Thank You
Ken
South Africa
I will really appreciate any feedback with regards the following. We carry out frequent diesel engine overhauls ourselves. We have quite a large fleet of earthmoving equipment which we utilise in the mining industry. My problem however, is the fact that basically every repair job has some or other comeback. The quality of the repair procedures are just not up to scratch. I have taken the issue up with the relevant manager and he just always seems to have some or other excuse. I obviously just cannot carry on like this. I woulod really appreciate any pointers or guidelines in this area. I have thought of putting together a quality control matrix, where the craftsman is forced to systematically follow strict guidelines in the form of a checklist or matrix.
Any assistance or help will really be appreciated.
Thank You
Ken
South Africa





RE: Diesel Engine Repair Quality Control Procedures
Maybe you need a new manager, or maybe he needs the appropriate resources.
Regards
pat pprimmer@acay.com.au
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RE: Diesel Engine Repair Quality Control Procedures
In many engineering courses, a segment is taught about quality control. We call it "accountability".
Consider how the equipment performs when new. “Proper” repair procedures, following the original manufacturers manual or guidelines, should not encounter any more comebacks then a new piece of equipment. Note the emphasis on the word “proper”!
It is the service or maintenance managers responsibility to balance the cost of repairs (rebuild or replace), assigning the proper skill level technician to the appropriate task, and providing the necessary training and other resources to the technicians to allow them to do their job properly.
Now, to be totally fair, a comeback is when the original repair failed, or was not properly diagnosed or repaired according to manufacturers specs. Secondary failures should not be considered a comeback. Replacing a waterpump and then encountering connected hose failure should be considered a comeback. Repairing a radiator after a flat tire is not, unless the flat tire caused the radiator to fail (object impact).
Engine failures caused by improper machining is relatively easy to backtrace, as are failures caused by failed air or oil filtration, which is not related to comeback, unless the rebuilding procedure was faulty.
Is your equipment totally remanufactured or refurbished to like new condition or is only the failed component serviced?
Franz
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RE: Diesel Engine Repair Quality Control Procedures
Thanks for your response. I thank you for your valuable input. The problem I am faced with is, the fact that when we experience engine, transmission failiures etc. we do not generally ascertain the root cause of the problem in the first place. I attribute this to a lack of skill and management skills. I have just been given the responsibility of the maintenance of our entire plant fleet operation of mining & earthmoving equipment. My first task in the new position was to generate an Asset Management Strategy for the division. The problem I am faced with now, i.e. engine repair & diagnostic effeciveness, is a typical area that needs to be improved dramatically. Any technical references or websites that could possibly assist me in this regard will highly appreciated. I do take your points that the plant manager could be the problem, as I tend to agree with the possible suggestion that he indeed might be the problem. It is however not that simple, to just replace him. Skill shortages are quite prevalent in this area and effective leadreship & management is definitely required on my behalf.
RE: Diesel Engine Repair Quality Control Procedures
For example, engine bearings may be giving short life. Basic cause might be insufficient lubrication.
Root cause might be a damaged oil pick up that also sucks air with the oil, or a change in oil quality, or a dirty oil cooler or the bearing crush might be wrong or the bearing quality might have changed or or.
I can only recommend tight control of procedures, if in doubt replace part worn or near spec parts as well as damaged parts. Specify first class parts and materials.
Regards
pat pprimmer@acay.com.au
eng-tips, by professional engineers for professional engineers
Please see FAQ731-376 for tips on how to make the best use of Eng-Tips Fora.
RE: Diesel Engine Repair Quality Control Procedures
And what shift they could work and not be so worn out on.
RE: Diesel Engine Repair Quality Control Procedures
As others have already said you need supervisory staff that have the required skills and experience to make the correct decisions. It is not simply a matter of laying down set procedures, supervisors need to be able to make correct value judgments on the spot.
Fixed written procedures only seem to work where the work is fairly repetitive and somewhat routine, as in perhaps routine maintenance. Breakdown repairs can be quite an adventure in comparison, because of the inability to plan ahead. As a first step I wold look towards the qualifications, experience and suitability of key people.
RE: Diesel Engine Repair Quality Control Procedures
RE: Diesel Engine Repair Quality Control Procedures