The following document templates (tool kits) are provided totally complimentary, free of charge to use as a starting point for Production and Maintenance. As each business is different, additional documents or revisions would be required to meet your organization’s specific needs, requirements, context, risk profile, etc. If after reading through all of these documents, you feel like you still need a consulting partner to help you develop your new documents – Contact Us. We’re always looking for interesting new clients and projects.
1.0 Consolidated Timesheet for the month
2. Daily Work Control and Time sheet
| SN. | Empl. No. | NAME | DESIGNATION | Working Time | Time allocation | |||||||||
| JO / / | JO / / | JO / / | Maintainance/ Other Works | |||||||||||
| In | Out | HRS | OT | HRS | OT | HRS | OT | HRS/OT OT | ||||||
3 Production Planning and Control
| S.No | Job No | Client | Description | QTY | Date | Allocation | Review | ||||||
| Delivery | Material | Production | INSP & TEST | Men | Machine | Completion | Performance | ||||||
| Client Req. | In Shop | Start | End | Final | |||||||||
| Prepared by Approved by: | |||||||||||||
4. Customer /Supplier Property Record
| S. No. | Receipt / Delivery Order No. | Date | J.O / W.O. No. | Customer / Supplier Name | Type of Property | Description | Qty. / Copy No. | Disposition details & date | Receipt By | |
| Product / Instrument Identification No. | Document Ref No. (with current Rev No. and Date) | |||||||||
| Prepared By: | Approved By: | |||||||||
| Name: | Name: | |||||||||
| Sign: | Sign: | |||||||||
| Date: | Date: | |||||||||
| Issue No / Date : xx/xx.xx.xxxx Rev No / Rev Date: xx/xx.xx.xxxx | ||||||||||
5.0 Operation and Execution Plan
Product / Service Details
| Asset Owner / Client | |||
| Job description | |||
| Purchase order | Location | ||
| JOB NO | Country | ||
Section I: General
| Synopsis: |
| 1.1 Scope of Work: |
| 1.2 Location (Suitable work environment): |
| 1.3 Codes and Specifications: |
Section II: Initial Information about the Job
| 2.1 Product / Customer Specified requirements: | |||
| S. No | Product Description | Quantity | Customer requirement |
| 2.2 Legal and Other applicable requirements: | |||
| 2.3: Design and Development Requirements: | |||
Section III: Activities and Responsibilities
| S. No | Activities (Operational, inspection and testing activities) | Responsibilities | Target Date |
| 1 | |||
| 2 | |||
| 3 | |||
| 4 | |||
| 5 | |||
| 6 | |||
| 7 | |||
| 8 | |||
| 9 | |||
| 10 | |||
| 11 |
Section IV: Risk Assessment, Contingency & MOC
| Scope: |
| Risk: |
| Action taken: |
| Conclusions from the risk assessment: |
Section V: Method Statement
| S. No | Activities (Operational, inspection and testing activities) | Reference Standard / Procedures / Work Instruction |
| 1 | ||
| 2 | ||
| 3 | ||
| 4 | ||
| 5 | ||
| 6 | ||
| 7 | ||
| 8 |
Section VI: Required Resources and Records
| 6.1 Resources (Machines / Equipment / Manpower) |
| 6.2 Records |
6. Breakdown Maintenance Report
| EQUIPMENT Details | M/C No. | ||
| Manufacturer | Serial No. | ||
| Breakdown reported by | Date |
| TOTAL BREAKDOWN HOURS | |
| PROBLEM DESCRIPTION | |
| PROBLEM DIAGNOSED | |
| REMEDIAL ACTION TAKEN | |
| PARTS REPAIRED & REPLACED | |
| ADDITIONAL REMARK | |
| Maintenance Engineer (Name & Signature & Date) | Operationa Manager (Name & Signature & Date) |
7. Breakdown Maintenance Register
| Sr. No. | Date | Machine No. | Reason for breakdown | Damaged parts | Down time | Re-start | Spare used | Sign of Mechanic | Remarks |
| Total Breakdown Hours : | |||||||||
| Prepared by | Reviewed by | Approved by | |||||||
| Name | Name | Name | |||||||
| Signature | Signature | Signature | |||||||
| Date | Date | Date | |||||||
| Issue No / Date : xx/xx.xx.xxxx Rev No / Rev Date: xx/xx.xx.xxxx | |||||||||
8. Complete Overhauling / Reconditioning Plan
| EQUIPMENT DETAILS | SOS M/C NO. | |||||||||
| MANUFACTURER | SERIAL NO. | |||||||||
| START DATE | COMPLETION DATE | |||||||||
| MECHANICAL | ELECTRICAL | |||||||||
| A | HYDRAULIC SYSTEM | YES/ No | A | POWER SUPPLY | YES / NO | |||||
| 1)Pump | 1)Incoming Power Supply | |||||||||
| 2)Valves | 2)Earthing | |||||||||
| 3)Hydraulic Lines | B | CONTROL WIRING(Control panel) | ||||||||
| 4)Lubrication System | 1)MCB’S & Contractors | |||||||||
| 5)Filtering System | 2)Fuses & Terminal Blocks | |||||||||
| 6)Clutch System (If any) | 3)Relays & Timers | |||||||||
| B | GUIDS & MOVEMENT | 4)Push Buttons & Lights | ||||||||
| 1)Scrapping (If needed) | 5)Wiring | |||||||||
| 2)Polishing of Guide & Bed | C | POWER WIRING(Control Panel) | ||||||||
| C | MAINDRIVE | 1) MCCB | ||||||||
| 1)Gears & Shafts | 2)MCB’S & Contractors | |||||||||
| 2)Bearings | 3)Fuses & Terminal Blocks | |||||||||
| 3)All Moving & Engaging Parts | 4)Wiring | |||||||||
| D | FEED SYSTEM | D | MACHINE SIDE | |||||||
| 1)Gears & Shafts | 1)Motors | |||||||||
| 2)Beams | 2)Coolant pump | |||||||||
| 3)Head Screw | 3)Lights | |||||||||
| 4)screw Nut / Sleeve | 4)Wiring | |||||||||
| Remarks: | ||||||||||
| Prepared by | Reviewed by | Approved by | ||||||||
| Name | Name | Name | ||||||||
| Signature | Signature | Signature | ||||||||
| Date | Date | Date | ||||||||
| Iss No / Date : 01/20.07.2020 Rev No / Rev Date: 00/– | ||||||||||
9. Annual Preventive maintenance plan
| SRL# | MACHINE NAME | ASSET # | DAILY | WEEKLY | MONTHLY | QUARTERLY | YEARLY | |
| 1 | AIR COMPRESSOR | Daily | _ | _ | Mar,Jun,spt,dec | 25-Dec | ||
| 2 | RADIAL DRILLING M/C | Daily | _ | _ | Mar,Jun,spt,dec | 23-Dec | ||
| 3 | LATHE M/C | Daily | Thursday | _ | Mar,Jun,spt,dec | 26-Dec | ||
| 4 | VTL M/C | Daily | Thursday | 11th | _ | 24-Dec | ||
| 5 | MILLING M/C | Daily | Thursday | 10th | _ | 21-Dec | ||
| 6 | BORING M/C | Daily | Thursday | 10th | _ | 21-Dec | ||
| 7 | PIPE THREADING M/C | _ | Monday | 12th | _ | 23-Dec | ||
| 8 | FURNACE | _ | Tuesday | 13th | 21-Dec | |||
| 9 | ELECTRODE OVEN | Daily | Tuesday | 5th | _ | 17-Dec | ||
| 10 | WELDING M/C | _ | Saturday | 15th | _ | 30-Dec | ||
| 11 | SA WELDING M/C | Daily | _ | _ | Mar,Jun,spt,dec | 21-Dec | ||
| 12 | OVERHEAD CRANE | _ | Wednesday | 5th | _ | 22-Dec | ||
| 13 | BENCH GRINDER | _ | Tuesday | 10th | _ | 27-Dec | ||
| 14 | ELECTRODE QUIVER | Daily | Saturday | 15th | _ | 30-Dec | ||
| 15 | BANDSAW CUTTING M/C | Daily | Monday | 10 th | _ | 20-Dec | ||
| 16 | PIPE BEVELING M/C | _ | Sunday | 11th | _ | 27-Dec | ||
| 17 | HYDROSTATIC TEST PUMP | Daily | Wednesday | 5th | _ | 20-Dec | ||
| 18 | Air PRESSURE PUMP | Daily | Wednesday | 5th | _ | 20-Dec | ||
| 19 | WATER PRESSURE PUMP | Daily | Wednesday | 5th | _ | 20-Dec | ||
| 20 | TORQUE WRENCH PUMP | Daily | _ | _ | Mar,Jun,spt,dec | 20-Dec | ||
| 21 | SAND BLASTING MACHINE | Daily | Monday | 20th | _ | 19-Dec | ||
| 22 | PORTABLE AIR COMPRESSOR | Daily | _ | _ | Mar,Jun,spt,dec | 25-Dec | ||
| 23 | HIGH PRESSURE PAINT SPRAYER M/C | Daily | _ | 20th | _ | 19-Dec | ||
| 24 | ELECTRODE OVEN | Daily | Tuesday | 5th | _ | 17-Dec | ||
| Prepared by | Reviewed by | Approved by | ||||||
| Name | Name | Name | ||||||
| Signature | Signature | Signature | ||||||
| Date | Date | Date | ||||||
| Issue No / Date :xx/xx.xx.xxxx Rev No / Rev Date: xx/xx.xx.xxxx | ||||||||
10. Preventive Maintenance Checklist
| Month/Year: | Machine Name: | Machine ID / No – | |||||||||||||||||||||||||||||||
| Frequency | Sl.No | Activity | Days | ||||||||||||||||||||||||||||||
| 1 | 2 | 3 | 4 | 5 | 6 | 7 | 8 | 9 | 10 | 11 | 12 | 13 | 14 | 15 | 16 | 17 | 18 | 19 | 20 | 21 | 22 | 23 | 24 | 25 | 26 | 27 | 28 | 29 | 30 | 31 | |||
| Daily | 1 | ||||||||||||||||||||||||||||||||
| 2 | |||||||||||||||||||||||||||||||||
| 3 | |||||||||||||||||||||||||||||||||
| 4 | |||||||||||||||||||||||||||||||||
| Quarterly | 1 | ||||||||||||||||||||||||||||||||
| 2 | |||||||||||||||||||||||||||||||||
| 3 | |||||||||||||||||||||||||||||||||
| Yearly | 1 | ||||||||||||||||||||||||||||||||
| 2 | |||||||||||||||||||||||||||||||||
| 3 | |||||||||||||||||||||||||||||||||
| 4 | |||||||||||||||||||||||||||||||||
| Last PM Month: | Quarterly: | Half Yearly: | Yearly: | ||||||||||||||||||||||||||||||
| Remarks: | |||||||||||||||||||||||||||||||||
11 Preventive Maintenance Checking Parameters
- Preventive Maintenance For Air Compressor
- Daily:
- a) Clean the compressor
- b) Check the oil level
- c) Check the coolers & Clean if required
- d) Check for any oil leakage
- Quarterly:
- a) Check the section coolers
- b) Remove air filter and clean
- c) Check all the flexible hoses
- Yearly:
- a) Replace Oil filters
- b) Change Oil
- c) Change Oil separator
- d) Check all electrical and safety controls
- Daily:
- Preventive Maintenance for Drilling Machine
- Daily:
- a) Clean the machine
- b) Lubricate all moving parts
- c) Check hydraulic oil level
- d) Check for any oil leakage
- Quarterly:
- a) Check all the electrical controllers
- b) Apply grease on greasing points
- Yearly:
- a) Check all functions of machine
- b) Check all the electrical and safety controls
- c) Change spares as required
- Daily:
- Preventive Maintenance For Lathe Machine
- Daily:
- a) Clean the machine
- b) Lubricate all moving parts
- c) Check the oil level
- d) Check for any oil leakage
- Weekly:
- a) Check the coolant tank
- b) Apply grease on greasing ports
- c) Check the spindle unit
- Quarterly:
- a) Check all the electrical and safety controls
- b) Clean the coolant tank and Top up the coolant
- c) Check the hydraulic unit
- Yearly:
- a) Overall cleaning of the machine
- b) Check the overall conditions of machine c) clean & change the parts as required
- Daily:
- Preventive Maintenance for VTL Machine
- Daily:
- a) Clean the machine
- b) Lubricate all moving parts
- c) Check the oil level
- d) Check for any oil leakage
- Weekly:
- a) Check lead screws & feed shaft
- b) Apply grease on greasing ports
- Monthly:
- a) Check main spindle unit
- b) Clean the coolant tank and Top up the coolant
- c) Check & adjust lead screw nuts
- d) Check the cross bar leveling & Adjust if required
- Yearly:
- a) Overall cleaning of the machine
- b) Check the overall conditions of machine c) clean & change the parts as required d) Check all the electrical devices
- Daily:
- Preventive Maintenance for Milling Machine
- Daily:
- a) Clean the machine
- b) Lubricate all moving parts
- c) Check the oil level
- d) Check for any oil leakage
- Weekly:
- a) Check lead screws & feed shaft
- b) Apply grease on greasing ports
- Monthly:
- a) Check main spindle unit
- b) Clean the coolent tank and Top up the coolent
- c) Check & adjust leadscrew nuts
- Yearly:
- a) Overall cleaning of the machine
- b) Check the overall conditions of machine
- c) Clean & change the parts as required
- d) Check all the electrical devices
- Daily:
- Preventive Maintenance for Boring Machine
- Daily:
- a) Clean the machine
- b) Lubricate all moving parts
- c) Check the oil level
- d) Check for any oil leakage
- Weekly:
- a) Check lead screws & feed shaft
- b) Apply grease on greasing ports
- Monthly:
- a) Check main spindle unit
- b) Clean the coolent tank and Top up the coolent
- c) Check & adjust leadscrew nuts
- d) Check main drive belt
- Yearly:
- a) Overall cleaning of the machine
- b) Check the overall conditions of machine
- c) clean & change the parts as required
- d) Check all the electrical devices
- Daily:
- Preventive Maintenance for Pipe Threading M/C
- Weekly:
- a) Clean the machine
- b) Lubricate all moving parts
- c) Check the foot switch
- d) Check the emergency stop
- Monthly:
- a) Check the electrical devices
- b) Check & lubricate the gear box
- c) Check & stop oil leakage
- Yearly:
- a) Overall cleaning of the machine
- b) Check the overall conditions of the machine
- c) Check all the electrical devices
- d) Clean & change parts as required
- Weekly:
- Preventive Maintenance for furnace
- Weekly:
- a) Clean the machine
- b) Lubricate all moving parts
- c) Check the foot switch
- d) Check the emergency stop
- Monthly:
- a) Check the electrical devices
- b) Check & lubricate the gear box
- c) Check & stop oil leakage
- Yearly:
- a) Overall cleaning of the machine
- b) Check the overall conditions of the machine
- c) Check all the electrical devices
- d) Clean & change parts as required
- Weekly:
- Preventive Maintenance for Electrode oven
- Daily:
- a) Check the A/C cables
- b) Check the A/C plug
- Weekly:
- a) Check the thermostat
- b) Check the temperature
- Monthly:
- a) Overall function checking of the oven
- b) Overall cleaning of the oven
- c) Clean the thermostat
- Yearly:
- a) Overall cleaning of the oven
- b) Overall functional checking of the oven
- c) Change the parts if required
- Daily:
- Preventive Maintenance for Welding Machine
- Daily:
- a)Clean the machine
- b) Check the cables
- c) Check the cooling system
- Quarterly:
- a)Check the flow meter/regulator
- b)check the cables
- c)Check the electrode holder
- Yearly:
- a)Check the electrode holder
- b)Check wear & tear on cables
- c) Check the isolation switch
- d)Change the parts as required
- Daily:
- Preventive Maintenance for SA Welding Machine
- Daily:
- a)Clean the machine
- b)Lubricate All Moving Parts
- c)Check for any oil leakage
- Quarterly:
- a)Check the limit switches
- b)Check & fill Lubricating Oil
- c)Check & clean Job Holder
- Yearly:
- a)Overall cleaning of the machine
- b)Check all electrical connections
- c) Check all the functions
- d)Check and change parts if required
- Daily:
- Preventive Maintenance for Overhead crane
- Weekly:
- a)Check cables
- b)Check the safety switches
- c)Check for the propper functioning of remote control
- Monthly:
- a)Check lifting slings
- b)Check the lifting hook condition
- c)Check the oil level in gear motor
- Yearly:
- a)Overall cleaning
- b)Check all electrical parts
- c) Change the parts if required
- Weekly:
- Preventive Maintenance for Bench Grinder
- Weekly:
- a) Clean & remove grinding stone particles
- b) Check the grinding wheel
- c) Dress the wheel
- Monthly:
- a) Check the machine guards
- b) Check the electrical connections
- c) Apply grease on greasing points
- Yearly:
- a) Check the main power supply
- b)Check the spindle bearing
- Weekly:
- Preventive Maintenance for Electrode Quiver
- Daily:
- a)Check the A/C cables
- b)Check the A/C plug
- Weekly:
- a)Check the thermostat
- b)Check the temperature
- Monthly:
- a)Overall function checking of the oven
- b)Overall cleaning of the oven
- c)Clean the thermostat
- Yearly:
- a)Overall function checking of the oven
- b)Overall cleaning of the oven
- c) Change the parts if required
- Daily:
- Preventive Maintenance for Band saw Cutting Machine
- Daily:
- a) Clean the machine
- b)Check blade for wear
- c)Check functionality of shield & emergency stop
- Weekly:
- a)Remove shavings from coolant tank
- b)Clean pump suction filter & suction zone
- Monthly:
- a)Check the tightening of the drive wheel screw
- b)Check the blade guide bearings
- Yearly:
- a)Check the tightening of the screws of the motor, pump, & accident protection guard
- b)Changing gear oil
- c)Check the tightening of the drive wheel screws
- Daily:
- Preventive Maintenance for Pipe Beveling Machine
- Weekly:
- a)Clean the machine
- b)Lubricate all moving parts
- c)Check for any physical damage
- Monthly:
- a)Overall cleaning of the machine
- b)Check the overall conditions of the machine
- c)Check the electric & pneumatic
- motors
- Yearly:
- a)Overall cleaning of the machine
- b)Check the overall conditions of the machine
- c)Check the electric & pneumatic motors
- d)Clean & change the parts as required
- Weekly:
- Preventive Maintenance for Hydrostatic Test Pump
- Daily:
- a) Clean the Pump
- b)Check for any leakage
- Weekly:
- a)Check the Valves
- b)Check the Hoses
- Monthly:
- a)Check & Clean the Air filter
- b)Check the safety Valve
- c)Check the NRV
- Yearly:
- a)Overall cleaning of the pump
- b)Do the functional test
- c)Change the parts if required
- Daily:
- Preventive Maintenance for Air Pressure Pump
- Daily:
- a) Clean the Pump
- b) Check for any leakage
- Weekly:
- a) Check the Valves
- b) Check the Hoses
- c) Lubricate the parts
- Monthly:
- a) Check & Clean the Air filter
- b) Check the safety Valve
- Yearly:
- a) Overall cleaning of the pump
- b) Electrical motor inspection
- c) Replaced damaged seals & hoses
- Daily:
- Preventive Maintenance for Water Pressure Pump
- Daily:
- a) Clean the Pump
- b)Check for any leakage
- Weekly:
- a)Check the Valves & hoses
- b)Check the tightening of the fittings
- c)Check for any damage in power codes
- Monthly:
- a)Check & Clean the filters & nozzles
- b)Check the correct oil level
- Yearly:
- a)Pump oil & filters replaced
- b)Filters & nozzles replaced
- c)All valves are checked & cleaned
- Daily:
- Preventive Maintenance for Torque Wrench Pump
- Daily:
- a) Check couplings,lock pins & safety cables
- b) Inspect blast hose, couplings & nozzle holders for leaks
- c) Check all external piping, control hoses & valves for leaks
- Weekly:
- a) Inspect the blast hose for wear & worn
- b) Check the nozzle & washer condition
- c) Check & clean the filter
- Monthly:
- a) Check for wear pop-up valves urethane coating
- b) Inspect the rubber pop-up seal,replace at first sight of wear or cracking
- Yearly:
- a) Overall cleaning of the machine
- b) Inspect the whole machine & replace any parts if required
- Daily:
- Preventive Maintenance for Sand Blasting Machine
- Daily:
- a)Check couplings,lock pins & safety cables
- b)Inspect blast hose, couplings & nozzle holders for leaks
- c)Check all external piping, control hoses & valves for leaks
- Weekly:
- a)Inspect the blast hose for wear & worn
- b)Check the nozzle & washer condition
- c)Check & clean the filter
- Monthly:
- a)Check for wear pop-up valves urethane coating
- b)Inspect the rubber pop-up seal,replace at first sight of wear or cracking
- Yearly:
- a)Overall cleaning of the machine
- b)Inspect the whole machine & replace any parts if required
- Daily:
- Preventive Maintenance for Portable Air Compressor
- Daily:
- a)Clean the compressor
- b)Check the oil level
- c)Check the coolers & Clean if required
- d)Check for any oil leakage
- Quarterly:
- a)Check the section coolers
- b)Remove air filter and clean
- c)Check all the flexible hoses
- Yearly:
- a)Replace Oil filters
- b)Change Oil
- c)Change Oil separator
- d)Check all electrical and safety controls
- Daily:
- Preventive Maintenance for High Pressure Paint Sprayer Machine
- Daily:
- a) Flush hose & gun
- b) Drain water from air filter
- c) Clean the suction tube
- Monthly:
- a) Check & tighten all fluid connections
- b) Check for any leakage
- c) Clean fluid line filter
- Yearly:
- a) Overall cleaning of the machine
- b) Check hoses,tubes & couplings replace if required
- Daily:
- Preventive Maintenance for Electorde Oven
- Daily:
- a) Check the A/C cables
- b)Check the A/C plug
- Weekly:
- a)Check the thermostat
- b)Check the temperature
- Monthly:
- a)Overall function checking of the oven
- b)Overall cleaning of the oven
- c)Clean the thermostat
- Yearly:
- a)Overall function checking of the oven
- b)Overall cleaning of the oven
- c) Change the parts if required
- Daily:
| Prepared by : | Approved by : |
| Signature : | Signature : |
| Designation : | Designation : |
