Workplace Incident & Troubleshooting TKA Bahasa Inggris SMK

Term	Operational Definition	Workshop Example
Correction (Containment)	Immediate action to eliminate an existing non-conformity or symptom.	Mop up leaked hydraulic oil and wipe the machine bed clean.
Corrective Action	Action to eliminate the cause of a detected non-conformity to prevent recurrence.	Replace the ruptured high-pressure hose and recalibrate pressure relief valve.
Preventive Action	Proactive action to eliminate the cause of a potential non-conformity before it occurs.	Install automated vibration/thermal telemetry sensors across all hydraulic pumps.

Pernyataan	Benar	Salah
Diagnostic flowcharts use conditional branching (Yes/No) to guide technicians through systematic fault elimination.	Benar	Salah
A CAPA plan must include verifiable success metrics and scheduled effectiveness audits.	Benar	Salah
Shopfloor oil spills should be concealed from EHS inspectors to avoid completing paperwork.	Benar	Salah
Preventive maintenance tasks in automated CMMS software ensure critical servicing intervals are not overlooked.	Benar	Salah

Soal 4 Pilihan Ganda mudah

5 Poin

Formal Incident Investigation Report: Hydraulic Power Unit Overheating and Line Rupture

INCIDENT INVESTIGATION REPORT (EHS-IR-2026-044)
FACILITY: PT Indometal Presisi Stamping, Karawang Plant
DATE OF INCIDENT: September 22, 2026 | TIME: 14:15 WIB
EQUIPMENT INVOLVED: 400-Ton Hydraulic Stamping Press #03 (HPU-400)
INCIDENT CLASSIFICATION: Level 2 (Equipment Damage & Environmental Spill; No Personnel Injury)

1.0 EVENT DESCRIPTION
During normal stamping operations of automotive seat brackets, the primary hydraulic fluid reservoir of HPU-400 overheated to 94°C (maximum safe operational threshold: 65°C). The elevated thermal stress degraded an elastomer flexible return hose, causing a catastrophic burst under 180 bar operating pressure. Approximately 240 liters of ISO VG 46 mineral hydraulic oil sprayed across the press pit and adjacent gangway. The operator immediately depressed the master E-Stop, de-energizing the main pump.

2.0 IMMEDIATE CONTAINMENT ACTIONS (CORRECTION)
- EHS response team deployed hydrophobic absorbent booms and granular silicate to contain oil within the secondary pit sump, preventing runoff into municipal storm drains.
- Maintenance technicians tagged out HPU-400 using red padlocks (LOTO #4412).
- Contaminated components and spent absorbents were sealed in hazardous waste drums (UN 1993 class).

3.0 ROOT-CAUSE ANALYSIS (5-WHYS TECHNIQUE)
1. Why did the flexible return hose burst? -> Elevated temperature (94°C) weakened the synthetic elastomer wall under pressure.
2. Why did the fluid overheat? -> The shell-and-tube oil cooler heat exchanger failed to dissipate thermal energy.
3. Why did the heat exchanger fail? -> Cooling water flow through the secondary tube bundle had dropped by 85%.
4. Why had cooling water flow dropped? -> An upstream particulate strainer was completely clogged with calcium scale and biological bio-fouling.
5. Why was the strainer clogged? -> Preventive maintenance protocol PM-CL-04 had not been executed during the preceding two scheduled monthly maintenance cycles due to a staffing shortage.

ROOT CAUSE: Breakdown in preventive maintenance scheduling and absence of automated differential pressure monitoring across cooling water strainers.

Sumber: Industrial Health, Safety, and Equipment Reliability Engineering Case Archive

In Incident Report EHS-IR-2026-044 (Passage 1), what was the maximum safe operational temperature threshold for the HPU-400 hydraulic reservoir?

A 25°C B 65°C C 94°C D 180°C

Soal 5 Pilihan Ganda sedang

5 Poin

Formal Incident Investigation Report: Hydraulic Power Unit Overheating and Line Rupture

INCIDENT INVESTIGATION REPORT (EHS-IR-2026-044)
FACILITY: PT Indometal Presisi Stamping, Karawang Plant
DATE OF INCIDENT: September 22, 2026 | TIME: 14:15 WIB
EQUIPMENT INVOLVED: 400-Ton Hydraulic Stamping Press #03 (HPU-400)
INCIDENT CLASSIFICATION: Level 2 (Equipment Damage & Environmental Spill; No Personnel Injury)

1.0 EVENT DESCRIPTION
During normal stamping operations of automotive seat brackets, the primary hydraulic fluid reservoir of HPU-400 overheated to 94°C (maximum safe operational threshold: 65°C). The elevated thermal stress degraded an elastomer flexible return hose, causing a catastrophic burst under 180 bar operating pressure. Approximately 240 liters of ISO VG 46 mineral hydraulic oil sprayed across the press pit and adjacent gangway. The operator immediately depressed the master E-Stop, de-energizing the main pump.

2.0 IMMEDIATE CONTAINMENT ACTIONS (CORRECTION)
- EHS response team deployed hydrophobic absorbent booms and granular silicate to contain oil within the secondary pit sump, preventing runoff into municipal storm drains.
- Maintenance technicians tagged out HPU-400 using red padlocks (LOTO #4412).
- Contaminated components and spent absorbents were sealed in hazardous waste drums (UN 1993 class).

3.0 ROOT-CAUSE ANALYSIS (5-WHYS TECHNIQUE)
1. Why did the flexible return hose burst? -> Elevated temperature (94°C) weakened the synthetic elastomer wall under pressure.
2. Why did the fluid overheat? -> The shell-and-tube oil cooler heat exchanger failed to dissipate thermal energy.
3. Why did the heat exchanger fail? -> Cooling water flow through the secondary tube bundle had dropped by 85%.
4. Why had cooling water flow dropped? -> An upstream particulate strainer was completely clogged with calcium scale and biological bio-fouling.
5. Why was the strainer clogged? -> Preventive maintenance protocol PM-CL-04 had not been executed during the preceding two scheduled monthly maintenance cycles due to a staffing shortage.

ROOT CAUSE: Breakdown in preventive maintenance scheduling and absence of automated differential pressure monitoring across cooling water strainers.

Sumber: Industrial Health, Safety, and Equipment Reliability Engineering Case Archive

According to the 5-Whys root-cause analysis in Section 3.0, what was the foundational organizational failure that caused the cooling water strainer to clog?

A The cooling water pipes were made of cheap glass tubing. B Scheduled preventive maintenance protocol PM-CL-04 had been skipped for two consecutive cycles. C An earthquake in Karawang cracked the underground municipal water main. D The operator mistakenly poured engine gasoline into the hydraulic reservoir.

Soal 6 Benar / Salah sedang

6 Poin

Formal Incident Investigation Report: Hydraulic Power Unit Overheating and Line Rupture

INCIDENT INVESTIGATION REPORT (EHS-IR-2026-044)
FACILITY: PT Indometal Presisi Stamping, Karawang Plant
DATE OF INCIDENT: September 22, 2026 | TIME: 14:15 WIB
EQUIPMENT INVOLVED: 400-Ton Hydraulic Stamping Press #03 (HPU-400)
INCIDENT CLASSIFICATION: Level 2 (Equipment Damage & Environmental Spill; No Personnel Injury)

1.0 EVENT DESCRIPTION
During normal stamping operations of automotive seat brackets, the primary hydraulic fluid reservoir of HPU-400 overheated to 94°C (maximum safe operational threshold: 65°C). The elevated thermal stress degraded an elastomer flexible return hose, causing a catastrophic burst under 180 bar operating pressure. Approximately 240 liters of ISO VG 46 mineral hydraulic oil sprayed across the press pit and adjacent gangway. The operator immediately depressed the master E-Stop, de-energizing the main pump.

2.0 IMMEDIATE CONTAINMENT ACTIONS (CORRECTION)
- EHS response team deployed hydrophobic absorbent booms and granular silicate to contain oil within the secondary pit sump, preventing runoff into municipal storm drains.
- Maintenance technicians tagged out HPU-400 using red padlocks (LOTO #4412).
- Contaminated components and spent absorbents were sealed in hazardous waste drums (UN 1993 class).

3.0 ROOT-CAUSE ANALYSIS (5-WHYS TECHNIQUE)
1. Why did the flexible return hose burst? -> Elevated temperature (94°C) weakened the synthetic elastomer wall under pressure.
2. Why did the fluid overheat? -> The shell-and-tube oil cooler heat exchanger failed to dissipate thermal energy.
3. Why did the heat exchanger fail? -> Cooling water flow through the secondary tube bundle had dropped by 85%.
4. Why had cooling water flow dropped? -> An upstream particulate strainer was completely clogged with calcium scale and biological bio-fouling.
5. Why was the strainer clogged? -> Preventive maintenance protocol PM-CL-04 had not been executed during the preceding two scheduled monthly maintenance cycles due to a staffing shortage.

ROOT CAUSE: Breakdown in preventive maintenance scheduling and absence of automated differential pressure monitoring across cooling water strainers.

Sumber: Industrial Health, Safety, and Equipment Reliability Engineering Case Archive

Based on Passage 1, evaluate whether each statement accurately describes the incident and containment measures (Benar) or contains an error (Salah).

Tentukan apakah setiap pernyataan di bawah ini Benar atau Salah!

Pernyataan	Benar	Salah
Approximately 240 liters of mineral hydraulic oil was discharged across the press pit during the burst.	Benar	Salah
The incident resulted in severe burn injuries to three press operators.	Benar	Salah
Hydrophobic absorbent booms and silicate prevented oil runoff into municipal storm drains.	Benar	Salah
The damaged hydraulic unit was isolated under LOTO lock #4412 immediately after shutdown.	Benar	Salah

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5 Poin

Technical Troubleshooting Protocol: High-Speed Milling Spindle Thermal Overload

STANDARD TROUBLESHOOTING GUIDE: TSG-MEC-102
EQUIPMENT: 24,000 RPM Motorized High-Speed Spindle (Electro-Spindle HSK-F63)
SYMPTOM: Alarm 5102 – "Spindle Motor Over-Temperature Fault" during machining.

DIAGNOSTIC ALGORITHM & DECISION LOGIC:

STEP 1: THERMAL MEASUREMENT & AMBIENT CHECK
- Query digital temperature telemetry on CNC console. If temperature is \u2264 60°C, the fault is an erroneous thermistor sensor reading. (Action: Test PT100 sensor resistance across terminals T1-T2. Nominal resistance at 25°C should be 109 \u03a9. If open-circuit, replace sensor).
- If actual temperature exceeds 60°C, proceed immediately to STEP 2.

STEP 2: CHILLER CIRCUIT VERIFICATION
- Inspect the dedicated closed-loop refrigeration chiller unit.
- Is chiller operational and coolant fluid level within green range?
* NO -> Replenish ethylene-glycol/water mixture (50/50 ratio) and inspect hoses for external kinks or fluid leaks.
* YES -> Proceed to STEP 3.

STEP 3: FLOW RATE & PRESSURE VERIFICATION
- Check inline flow meter sensor FM-01. Does coolant flow rate exceed 4.5 Liters/min at 3.0 bar pressure?
* NO -> Coolant circulation pump impeller is damaged or inline filter cartridge is saturated. (Action: Replace 20-\u03bc filter cartridge and test pump motor relay).
* YES -> Proceed to STEP 4.

STEP 4: MECHANICAL BEARING DEGRADATION
- Rotate the spindle shaft manually with motor power locked out. Is rotation stiff, gritty, or accompanied by metallic friction noise?
* YES -> Angular contact hybrid ceramic bearings have suffered lubrication starvation and brinelling damage. (Action: Abort operation; dismount spindle for precision spindle re-build facility overhaul).
* NO -> Check inverter drive parameters for excessive current draw caused by aggressive feed-rate override.

Sumber: Precision Machine Tool Spindle Engineering & Diagnostics Manual

In Troubleshooting Guide TSG-MEC-102 (Passage 2), what should a technician conclude if Alarm 5102 triggers but the actual measured spindle temperature is \u2264 60°C?

A The spindle motor has melted completely inside. B The alarm is an erroneous reading caused by a faulty thermistor sensor. C The machine requires immediate scrap disposal. D The factory cooling water has frozen into solid ice.

Soal 8 Pilihan Ganda sedang

5 Poin

Technical Troubleshooting Protocol: High-Speed Milling Spindle Thermal Overload

STANDARD TROUBLESHOOTING GUIDE: TSG-MEC-102
EQUIPMENT: 24,000 RPM Motorized High-Speed Spindle (Electro-Spindle HSK-F63)
SYMPTOM: Alarm 5102 – "Spindle Motor Over-Temperature Fault" during machining.

DIAGNOSTIC ALGORITHM & DECISION LOGIC:

STEP 1: THERMAL MEASUREMENT & AMBIENT CHECK
- Query digital temperature telemetry on CNC console. If temperature is \u2264 60°C, the fault is an erroneous thermistor sensor reading. (Action: Test PT100 sensor resistance across terminals T1-T2. Nominal resistance at 25°C should be 109 \u03a9. If open-circuit, replace sensor).
- If actual temperature exceeds 60°C, proceed immediately to STEP 2.

STEP 2: CHILLER CIRCUIT VERIFICATION
- Inspect the dedicated closed-loop refrigeration chiller unit.
- Is chiller operational and coolant fluid level within green range?
* NO -> Replenish ethylene-glycol/water mixture (50/50 ratio) and inspect hoses for external kinks or fluid leaks.
* YES -> Proceed to STEP 3.

STEP 3: FLOW RATE & PRESSURE VERIFICATION
- Check inline flow meter sensor FM-01. Does coolant flow rate exceed 4.5 Liters/min at 3.0 bar pressure?
* NO -> Coolant circulation pump impeller is damaged or inline filter cartridge is saturated. (Action: Replace 20-\u03bc filter cartridge and test pump motor relay).
* YES -> Proceed to STEP 4.

STEP 4: MECHANICAL BEARING DEGRADATION
- Rotate the spindle shaft manually with motor power locked out. Is rotation stiff, gritty, or accompanied by metallic friction noise?
* YES -> Angular contact hybrid ceramic bearings have suffered lubrication starvation and brinelling damage. (Action: Abort operation; dismount spindle for precision spindle re-build facility overhaul).
* NO -> Check inverter drive parameters for excessive current draw caused by aggressive feed-rate override.

Sumber: Precision Machine Tool Spindle Engineering & Diagnostics Manual

According to Step 3 of TSG-MEC-102, what is the minimum acceptable coolant flow rate through sensor FM-01 to ensure proper thermal dissipation?

A 0.5 Liters/min B 1.2 Liters/min C 4.5 Liters/min D 20.0 Liters/min

Soal 9 Pilihan Ganda Kompleks sedang

5 Poin

Technical Troubleshooting Protocol: High-Speed Milling Spindle Thermal Overload

STANDARD TROUBLESHOOTING GUIDE: TSG-MEC-102
EQUIPMENT: 24,000 RPM Motorized High-Speed Spindle (Electro-Spindle HSK-F63)
SYMPTOM: Alarm 5102 – "Spindle Motor Over-Temperature Fault" during machining.

DIAGNOSTIC ALGORITHM & DECISION LOGIC:

STEP 1: THERMAL MEASUREMENT & AMBIENT CHECK
- Query digital temperature telemetry on CNC console. If temperature is \u2264 60°C, the fault is an erroneous thermistor sensor reading. (Action: Test PT100 sensor resistance across terminals T1-T2. Nominal resistance at 25°C should be 109 \u03a9. If open-circuit, replace sensor).
- If actual temperature exceeds 60°C, proceed immediately to STEP 2.

STEP 2: CHILLER CIRCUIT VERIFICATION
- Inspect the dedicated closed-loop refrigeration chiller unit.
- Is chiller operational and coolant fluid level within green range?
* NO -> Replenish ethylene-glycol/water mixture (50/50 ratio) and inspect hoses for external kinks or fluid leaks.
* YES -> Proceed to STEP 3.

STEP 3: FLOW RATE & PRESSURE VERIFICATION
- Check inline flow meter sensor FM-01. Does coolant flow rate exceed 4.5 Liters/min at 3.0 bar pressure?
* NO -> Coolant circulation pump impeller is damaged or inline filter cartridge is saturated. (Action: Replace 20-\u03bc filter cartridge and test pump motor relay).
* YES -> Proceed to STEP 4.

STEP 4: MECHANICAL BEARING DEGRADATION
- Rotate the spindle shaft manually with motor power locked out. Is rotation stiff, gritty, or accompanied by metallic friction noise?
* YES -> Angular contact hybrid ceramic bearings have suffered lubrication starvation and brinelling damage. (Action: Abort operation; dismount spindle for precision spindle re-build facility overhaul).
* NO -> Check inverter drive parameters for excessive current draw caused by aggressive feed-rate override.

Sumber: Precision Machine Tool Spindle Engineering & Diagnostics Manual

In Step 4 of TSG-MEC-102, which two physical symptoms indicate severe hybrid ceramic bearing damage requiring complete spindle overhaul? (Choose two correct answers)

Centang semua pilihan yang kamu anggap benar! A. Manual rotation feels stiff and gritty when turned by hand. B. Audible metallic friction noise during manual shaft rotation. C. The CNC screen glowing bright green. D. The spindle motor generating musical chime melodies.

Soal 10 Pilihan Ganda sedang

5 Poin

Corrective and Preventive Action (CAPA) Plan: Elimination of Hydraulic Overheating Risks

CORRECTIVE AND PREVENTIVE ACTION (CAPA) PLAN
CAPA TRACKING ID: CAPA-2026-088
INITIATING INCIDENT: EHS-IR-2026-044 (HPU-400 Burst Hose & Oil Spill)
OWNER: Plant Engineering & Reliability Department
EFFECTIVE DATE: October 1, 2026 | TARGET COMPLETION: November 15, 2026

1.0 CORRECTIVE ACTIONS (SHORT-TERM RECTIFICATION)
- CA-1: Replace all flexible elastomer return hoses on Stamping Press #03 with steel-wire-braided PTFE high-temperature lines rated up to 150°C and 250 bar (Completed by Oct 5).
- CA-2: Chemical descaling and pressure washing of shell-and-tube oil cooler heat exchangers on Presses #01 through #05 (Completed by Oct 10).

2.0 PREVENTIVE ACTIONS (LONG-TERM RE-ENGINEERING & PREVENTION)
- PA-1: Digitalization & Automated Interlocks: Retrofit an electronic differential pressure sensor (delta-P) across cooling water strainers linked directly to the main PLC. If differential pressure exceeds 0.8 bar (indicating clogging), the PLC triggers a pre-alarm. If temperature reaches 70°C, the PLC executes an automated graceful press cycle shutdown to prevent hose bursting.
- PA-2: Overhaul of CMMS Scheduling: Reconfigure the Computerized Maintenance Management System (CMMS) so that safety-critical preventive maintenance tasks (like PM-CL-04) cannot be closed or postponed by technicians without written sign-off from the Engineering Plant Manager.
- PA-3: Standard Operating Procedure Revision: Update weekly inspection checklist to include ultrasonic water flow measurement.

3.0 VERIFICATION OF EFFECTIVENESS AUDIT
- The reliability engineering team will conduct unannounced monthly temperature and pressure audits on all HPUs for six consecutive months following implementation.
- Success Metric: Zero hydraulic oil temperature excursions above 60°C across 1,000,000 continuous stamping cycles.

Sumber: Total Productive Maintenance (TPM) & ISO 9001/14001 Quality Assurance Documentation

Under Corrective Action CA-1 in Passage 3, with what material are the ruptured elastomer flexible hoses on Stamping Press #03 being replaced?

A Cardboard paper tubes wrapped in plastic tape. B Steel-wire-braided PTFE lines rated up to 150°C and 250 bar. C Unreinforced garden irrigation rubber hoses. D Copper refrigeration capillary piping.

Soal 11 Pilihan Ganda sedang

5 Poin

Corrective and Preventive Action (CAPA) Plan: Elimination of Hydraulic Overheating Risks

CORRECTIVE AND PREVENTIVE ACTION (CAPA) PLAN
CAPA TRACKING ID: CAPA-2026-088
INITIATING INCIDENT: EHS-IR-2026-044 (HPU-400 Burst Hose & Oil Spill)
OWNER: Plant Engineering & Reliability Department
EFFECTIVE DATE: October 1, 2026 | TARGET COMPLETION: November 15, 2026

1.0 CORRECTIVE ACTIONS (SHORT-TERM RECTIFICATION)
- CA-1: Replace all flexible elastomer return hoses on Stamping Press #03 with steel-wire-braided PTFE high-temperature lines rated up to 150°C and 250 bar (Completed by Oct 5).
- CA-2: Chemical descaling and pressure washing of shell-and-tube oil cooler heat exchangers on Presses #01 through #05 (Completed by Oct 10).

2.0 PREVENTIVE ACTIONS (LONG-TERM RE-ENGINEERING & PREVENTION)
- PA-1: Digitalization & Automated Interlocks: Retrofit an electronic differential pressure sensor (delta-P) across cooling water strainers linked directly to the main PLC. If differential pressure exceeds 0.8 bar (indicating clogging), the PLC triggers a pre-alarm. If temperature reaches 70°C, the PLC executes an automated graceful press cycle shutdown to prevent hose bursting.
- PA-2: Overhaul of CMMS Scheduling: Reconfigure the Computerized Maintenance Management System (CMMS) so that safety-critical preventive maintenance tasks (like PM-CL-04) cannot be closed or postponed by technicians without written sign-off from the Engineering Plant Manager.
- PA-3: Standard Operating Procedure Revision: Update weekly inspection checklist to include ultrasonic water flow measurement.

3.0 VERIFICATION OF EFFECTIVENESS AUDIT
- The reliability engineering team will conduct unannounced monthly temperature and pressure audits on all HPUs for six consecutive months following implementation.
- Success Metric: Zero hydraulic oil temperature excursions above 60°C across 1,000,000 continuous stamping cycles.

Sumber: Total Productive Maintenance (TPM) & ISO 9001/14001 Quality Assurance Documentation

Under Preventive Action PA-1 in Passage 3, what automated safety action will the PLC execute if hydraulic fluid temperature reaches 70°C?

A It will accelerate stamping speed to finish parts before the machine explodes. B It will execute an automated graceful press cycle shutdown to prevent hose bursting. C It will email the invoice to the customer automatically. D It will spray compressed air onto the factory ceiling.

Soal 12 Pilihan Ganda Kompleks sedang

5 Poin

Corrective and Preventive Action (CAPA) Plan: Elimination of Hydraulic Overheating Risks

CORRECTIVE AND PREVENTIVE ACTION (CAPA) PLAN
CAPA TRACKING ID: CAPA-2026-088
INITIATING INCIDENT: EHS-IR-2026-044 (HPU-400 Burst Hose & Oil Spill)
OWNER: Plant Engineering & Reliability Department
EFFECTIVE DATE: October 1, 2026 | TARGET COMPLETION: November 15, 2026

1.0 CORRECTIVE ACTIONS (SHORT-TERM RECTIFICATION)
- CA-1: Replace all flexible elastomer return hoses on Stamping Press #03 with steel-wire-braided PTFE high-temperature lines rated up to 150°C and 250 bar (Completed by Oct 5).
- CA-2: Chemical descaling and pressure washing of shell-and-tube oil cooler heat exchangers on Presses #01 through #05 (Completed by Oct 10).

2.0 PREVENTIVE ACTIONS (LONG-TERM RE-ENGINEERING & PREVENTION)
- PA-1: Digitalization & Automated Interlocks: Retrofit an electronic differential pressure sensor (delta-P) across cooling water strainers linked directly to the main PLC. If differential pressure exceeds 0.8 bar (indicating clogging), the PLC triggers a pre-alarm. If temperature reaches 70°C, the PLC executes an automated graceful press cycle shutdown to prevent hose bursting.
- PA-2: Overhaul of CMMS Scheduling: Reconfigure the Computerized Maintenance Management System (CMMS) so that safety-critical preventive maintenance tasks (like PM-CL-04) cannot be closed or postponed by technicians without written sign-off from the Engineering Plant Manager.
- PA-3: Standard Operating Procedure Revision: Update weekly inspection checklist to include ultrasonic water flow measurement.

3.0 VERIFICATION OF EFFECTIVENESS AUDIT
- The reliability engineering team will conduct unannounced monthly temperature and pressure audits on all HPUs for six consecutive months following implementation.
- Success Metric: Zero hydraulic oil temperature excursions above 60°C across 1,000,000 continuous stamping cycles.

Sumber: Total Productive Maintenance (TPM) & ISO 9001/14001 Quality Assurance Documentation

Which two management and software controls are instituted under PA-2 and PA-3 in Passage 3? (Choose two correct answers)

Centang semua pilihan yang kamu anggap benar! A. Reconfiguring the CMMS so critical maintenance tasks require written sign-off from the Plant Manager. B. Revising weekly inspection checklists to incorporate ultrasonic water flow measurement. C. Eliminating all preventive maintenance entirely to save operational costs. D. Banning all maintenance technicians from entering the press shop.

Soal 13 Pilihan Ganda sedang

5 Poin

Corrective and Preventive Action (CAPA) Plan: Elimination of Hydraulic Overheating Risks

CORRECTIVE AND PREVENTIVE ACTION (CAPA) PLAN
CAPA TRACKING ID: CAPA-2026-088
INITIATING INCIDENT: EHS-IR-2026-044 (HPU-400 Burst Hose & Oil Spill)
OWNER: Plant Engineering & Reliability Department
EFFECTIVE DATE: October 1, 2026 | TARGET COMPLETION: November 15, 2026

1.0 CORRECTIVE ACTIONS (SHORT-TERM RECTIFICATION)
- CA-1: Replace all flexible elastomer return hoses on Stamping Press #03 with steel-wire-braided PTFE high-temperature lines rated up to 150°C and 250 bar (Completed by Oct 5).
- CA-2: Chemical descaling and pressure washing of shell-and-tube oil cooler heat exchangers on Presses #01 through #05 (Completed by Oct 10).

2.0 PREVENTIVE ACTIONS (LONG-TERM RE-ENGINEERING & PREVENTION)
- PA-1: Digitalization & Automated Interlocks: Retrofit an electronic differential pressure sensor (delta-P) across cooling water strainers linked directly to the main PLC. If differential pressure exceeds 0.8 bar (indicating clogging), the PLC triggers a pre-alarm. If temperature reaches 70°C, the PLC executes an automated graceful press cycle shutdown to prevent hose bursting.
- PA-2: Overhaul of CMMS Scheduling: Reconfigure the Computerized Maintenance Management System (CMMS) so that safety-critical preventive maintenance tasks (like PM-CL-04) cannot be closed or postponed by technicians without written sign-off from the Engineering Plant Manager.
- PA-3: Standard Operating Procedure Revision: Update weekly inspection checklist to include ultrasonic water flow measurement.

3.0 VERIFICATION OF EFFECTIVENESS AUDIT
- The reliability engineering team will conduct unannounced monthly temperature and pressure audits on all HPUs for six consecutive months following implementation.
- Success Metric: Zero hydraulic oil temperature excursions above 60°C across 1,000,000 continuous stamping cycles.

Sumber: Total Productive Maintenance (TPM) & ISO 9001/14001 Quality Assurance Documentation

What is the defined success metric in Section 3.0 for the Verification of Effectiveness Audit in CAPA-2026-088?

A Selling 5,000 tons of scrap metal to local recycling centers. B Zero hydraulic oil temperature excursions above 60°C across 1,000,000 continuous stamping cycles. C Purchasing five new stamping presses from Japan every month. D Reducing factory shift hours from 8 hours to 2 hours per day.

Workplace Incident Reporting, Equipment Troubleshooting, and CAPA – Materi & Latihan TKA Bahasa Inggris SMK/MAK

Materi & Pembahasan Konsep

1. Frameworks for Industrial Incident Resolution

Incident Report

5-Whys Analysis

Diagnostic Flowchart

CAPA Plan

Correction vs. Corrective Action vs. Preventive Action

Latihan Interaktif (18 Soal)

Cek Pemahaman

Latihan TKA

Formal Incident Investigation Report: Hydraulic Power Unit Overheating and Line Rupture

Formal Incident Investigation Report: Hydraulic Power Unit Overheating and Line Rupture

Formal Incident Investigation Report: Hydraulic Power Unit Overheating and Line Rupture

Technical Troubleshooting Protocol: High-Speed Milling Spindle Thermal Overload

Technical Troubleshooting Protocol: High-Speed Milling Spindle Thermal Overload

Technical Troubleshooting Protocol: High-Speed Milling Spindle Thermal Overload

Corrective and Preventive Action (CAPA) Plan: Elimination of Hydraulic Overheating Risks

Corrective and Preventive Action (CAPA) Plan: Elimination of Hydraulic Overheating Risks

Corrective and Preventive Action (CAPA) Plan: Elimination of Hydraulic Overheating Risks

Corrective and Preventive Action (CAPA) Plan: Elimination of Hydraulic Overheating Risks

Tantangan Penalaran

Sudah Selesai Mengerjakan?

Nomor Soal

Pernyataan	Benar	Salah
Diagnostic flowcharts guide immediate acute fault isolation, while CAPA ensures permanent systemic durability.	Benar	Salah
Maintenance departments should rely on individual technician memory rather than automated CMMS software schedules.	Benar	Salah
Integrating automated PLC temperature and differential pressure interlocks provides failsafe defense against human oversight.	Benar	Salah
A CAPA plan is considered 100% verified immediately upon installing new hardware without requiring any performance audits.	Benar	Salah