Assembly and Installation (ESC1)
PREFACE
Hands-on course designed to develop and strengthen the mechanical skills required to achieve world-class Precision Maintenance®. While most craft technicians have foundational abilities, precision principles are often untaught, forgotten, or inconsistently applied.
This course addresses that gap by teaching reliable, repeatable methods that improve equipment performance, reduce failures, and increase manufacturing profitability.
Format
On-Site Training. This course is delivered at your facility or venue of choice.
Recommended class make-up is 10 crafts personnel and 5 from the other mentioned roles.
15 participants.
OBJECTIVES
Upon successful completion, participants will be capable of :
Precision Measurement & Installation
- Determining proper bearing and shaft fits
- Using micrometers, dial indicators, gauges, torque wrenches, calipers, and alignment systems
- Documenting all installation results for “as found/as left” validation
Dynamic Condition Assessment
- Using vibration meters, stroboscopes, and infrared tools to verify machine health
- Applying dynamic measurements to improve reliability
Correcting Assembly & Alignment Errors
- Fixing soft foot, pipe strain, bolt-bound and base distortion problems
- Completing precise cold alignment and calculating thermal growth
- Plotting alignment conditions and determining the “best move”
Improving Balance & Belt Drive Performance
- Understanding and correcting static/couple/dynamic unbalance
- Achieving proper belt tension, alignment, and sheave setup
Lubrication & Bearing Reliability
- Calculating correct grease amounts and intervals
- Identifying bearing types and common failure mechanisms
- Preserving evidence for root-cause analysis
PROCESSES COVERED
-
DAY 1 – Foundations Of Precision & Initial Measurements
> Introductions & course overview
> Maintenance philosophies & vibration tools
> “As-found” demonstrator hands-on exercise
> Operating context & maint. requirements
> Rough alignment and pre-alignment practice
> Precision measurement labs & report-outs -
DAY 2 – Fits, Tolerances, and Assembly Error Correction
> Fits & tolerances
> Bearing fit measurement lab
> Soft foot & shim consolidation exercises
> Keys, set screws, pulled threads, torque issues
> Assembly error correction labs -
DAY 3 – Precision Shaft Alignment
> Alignment checklist & angular soft foot
> Shaft plotting (exercises 1–2)
> Vertical/horizontal alignment plotting (exercises 3–5)
> Introduction to “Optimum Move”
> Begin precise alignment hands-on work -
DAY 4 – Thermal Growth, Balance, and Belt Systems
> Continue precision alignment exercises
> Thermal growth calculations
> Intro to balance principles
> Dynamic balance hands-on
> Belt drive systems and manufacturer guidance -
DAY 5 – Bearings, Lubrication, Couplings & Final Application
> Belt-drive practical exercises
> Bearing types, failure modes, and applications
> Lubrication viscosity & calculations
> Coupling requirements & common pitfalls
> Final review, report-out & graduation
TARGET PARTICIPANTS
- Maintenance Craft Personnel (mechanics, millwrights, technicians)
- Operations & Production Personnel
- Engineers responsible for asset reliability
- Front-line Supervision & Maintenance Leaders
PREREQUISITES
Craft Personnel are expected to have a set of basic skills or ECS Field Prep.
DURATION
5 days.