Procedure for maintenance

Uncategorized 2 Minutes

1. SCOPE

This procedure defines the actions and responsibilities of the maintenance manager in maintaining the Machinery & equipment in good working condition. This covers activities from receiving maintenance request up to a turnover of machine & equipment to the concerned unit

2. PURPOSE

To ensure sustenance of machine and equipment capability by periodic preventive maintenance.

3. REFERENCE DOCUMENTS

3.1 XXX Quality Manual,
3.2 Procedure for Manufacturing.
3.3 Work instructions for Preventive Maintenance
3.4 Procedure for Equipment Calibration and Maintenance

4. TERMS & DEFINITIONS
4.1 Preventive Maintenance –Preventive maintenance is maintenance that is regularly performed on a piece of Machinery or equipment to lessen the likelihood of it failing. It is performed while the equipment is still working so that it does not break down unexpectedly.

4.2 Breakdown Maintenace–Breakdown maintenance is maintenance performed on a piece of machinery or equipment that has broken down and is unusable. It is based on a breakdown maintenance trigger. It may be either planned or unplanned.

5. RESPONSIBILITY AND AUTHORITY

The maintenance manager is responsible to plan and carry out periodic preventive maintenance and ensure continued process capability. Also responsible for oil spillage, vibration, emission, and noise level.

6. DETAILS OF PROCEDURE

6.1 Based on conditions of use and experience, periodic maintenance work on machines is planned by maintenance dept. it is identified in relevant preventive maintenance work
instruction.
6.2 Maintenance is done based on the maintenance schedule.
6.3 Work instruction for daily maintenance like checking, filling of oil/grease of production machine is given to PROD for execution.
6.4 Scheduled and other maintenance plans are executed by maintenance dept personnel
and records are maintained in the respective machine file.
6.5 When breakdown occurs necessary repair/rectification work is carried out and records are maintained. Maintenance manager reviews the record and classifies the machine break down as either ‘Minor’ or ‘Major’ and maintains records of downtime hours, spares consumed and the approximate cost of spares/repair. Root cause analysis and corrective/preventive action records shall be maintained for all the major machine breakdowns, The records shall include details of breakdown experienced/attended, the effectiveness of action taken and preventive action if any.
6.6 If the root cause of machine break-down is due to normal wear and tear of the repaired/rectified parts then same shall be considered as ‘Minor’, but in case ‘Minor’ is repeated then it shall be considered as ‘Major’.
6.7 Machine Details like make, capacity, location and spares parts of the machine shall be maintained in the respective machine file.
6.8 Maintenance Manager plans to procure and stock essential spare parts to ensure maintenance with minimal downtime. List of critical spares and existing stock is maintained.
6.9 All the spares/accessories with shelf life shall be identified with the label containing details like Name, the location of use/application and date of receipt etc.
6.10 Breakdown hours reported in the machine breakdown report shall be analyzed for all production machines on a regular basis.
6.11 Maintenance of production draw dies, rolls & edge rollers are verified to ensure proper working condition. Records are maintained in respectively.
6.12 Maintenance department should check and maintain the record for Oil spillage, vibration, emission and noise in work area

7. RETAINED DOCUMENTED INFORMATION

7.1 Preventive Maintenance Schedule – (MAINT/F/01)
7.2 Maintenance History Card – (MAINT/F/02)
7.3 Corrective/Preventive action-for Major Breakdown – (MAINT/F/03)
7.4 Critical Spare Parts – (MAINT/F/04)
7.5 Maintenance Work Order – (MAINT/F/05)
7.6  Breakdown Analysis – (MAINT/F/05)
7.7 Oil spillage/Vibration/emission/Noise level – (MAINT/F/05)
7.8 Non-conformance Report (QC / QF/01)

Published by Pretesh Biswas

Pretesh Biswas has wealth of qualifications and experience in providing results-oriented solutions for your system development, training or auditing needs. He has helped dozens of organizations in implementing effective management systems to a number of standards. He provide a unique blend of specialized knowledge, experience, tools and interactive skills to help you develop systems that not only get certified, but also contribute to the bottom line. He has taught literally hundreds of students over the past 5 years. He has experience in training at hundreds of organizations in several industry sectors. His training is unique in that which can be customized as to your management system and activities and deliver them at your facility. This greatly accelerates the learning curve and application of the knowledge acquired. He is now ex-Certification body lead auditor now working as consultancy auditor. He has performed hundreds of audits in several industry sectors. As consultancy auditor, he not just report findings, but provide value-added service in recommending appropriate solutions. Experience Consultancy: He has helped over 100 clients in a wide variety of industries achieve ISO 9001,14001,27001,20000, OHSAS 18001 and TS 16949 certification. Industries include automotive, metal stamping and screw machine, fabrication, machining, assembly, Forging electrostatic and chrome plating, heat-treating, coatings, glass, plastic and rubber products, electrical and electronic equipment, assemblies & components, batteries, computer hardware and software, printing, placement and Security help, warehousing and distribution, repair facilities, consumer credit counseling agencies, banks, call centers, etc. Training: He has delivered public and on-site quality management training to over 1000 students. Courses include ISO/TS -RAB approved Lead Auditor, Internal Auditing, Implementation, Documentation, as well as customized ISO/TS courses, PPAP, FMEA, APQP and Control Plans. Auditing: He has conducted over 100 third party registration and surveillance audits and dozens of gap, internal and pre-assessment audits to ISO/QS/TS Standards, in the manufacturing and service sectors. Other services: He has provided business planning, restructuring, asset management, systems and process streamlining services to a variety of manufacturing and service clients such as printing, plastics, automotive, transportation and custom brokerage, warehousing and distribution, electrical and electronics, trading, equipment leasing, etc. Education & professional certification: Pretesh Biswas has held IRCA certified Lead Auditor for ISO 9001,14001 and 27001. He holds a Bachelor of Engineering degree in Mechanical Engineering and is a MBA in Systems and Marketing. Prior to becoming a business consultant 6 years ago, he has worked in several portfolios such as Marketing, operations, production, Quality and customer care. He is also certified in Six Sigma Black belt .

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