Example of documentation template for Plant Maintenance process in IATF

The following document templates (tool kits) are provided totally complimentary, free of charge to use as a starting point for Plant Maintenance Process in IATF. 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 Process Approach of Plant maintenance process

2.0 Turtle diagram of Plant maintenance process

3.0 Master list of Machines

  S. No  Machine NameEquipment Code  Dept/AreaLine no.  Range  Make
       
       
       
       
       
       
       
       
       
       
       
       
       
       
       
       
       
       
       
       
       
       
       
       
       
       
       
Prepared By :   Approved By :

4.0   List of Critical Spares

  S.NO.  Name of parts  Min.stock level  Max.Stock Level  Remarks
A.Mechanical   
     
     
     
     
B.Hydraulic   
     
     
     
     
CElectrical   
     
     
     
     
DPneumatic   
     
     
     
     
     
     
  PREPARED BY                                                                                                                     Approved By

5.0 Preventive Maintenance Schedule

  S. No  Machine NameEquipment Code  Dept/AreaAMC REQ  Apr  May  Jun  Jul  Aug  Sep  Oct  Nov  Dec  Jan  Feb  Mar
                 
                 
                 
                 
                 
                 
                 
                 
                 
                 
                 
                 
                 
                 
                 
                 
                 
                 
                 
                 
                 
                 
                 
                 
                 
                 
                 
                 
                 
                 
                 
                 
                 
Prepared By :    Approved By :

6.0 Predictive Maintenance Schedule

  S. No  Machine NameEquipment Code  Dept/Area  Apr  May  Jun  Jul  Aug  Sep  Oct  Nov  Dec  Jan  Feb  Mar
                
                
                
                
                
                
                
                
                
                
                
                
                
                
                
                
                
                
                
                
                
                
                
                
                
                
                
                
                
                
                
                
                
Prepared By :   Approved By :

7.0 Why-Why Analysis

Machine Code:Date:Report No :
  PROBLEM OBSERVED :
  CONTAINMENT ACTION :
  RESULT :
WHYANSWERACTIONANALYSIS
    
    
    
    
    
    
    
    TEAM MEMBERS :  
 
 
 
  Root Cause:
  Prepared by:    Approved by:
 

8.0 Monthly Breakdown Summary

  Month :
  Sr. No.Area WiseMachine B/D Frequency (No.s)Machine B/D Time (Hrs.)MTTR (Hrs.)MTBF (Hrs.)
MECHELECTELECT & MECHMECHELECTELECT & MECHMECHELECTELECT & MECHM/C AVL. Hrs.MECHELECTELECT & MECH
1             
2             
3             
4             
5             
6             
7             
8             
9             
10             
11             
12             
13             
14             
15             
16             
17             
PLANT LEVELB/D FREQUENCY MECHANICAL (No.s)             
B/D FREQUENCY ELECTRICAL (No.s) 
B/D FREQUENCY ELECT & MECH (No.s) 
B/D TIME MECHANICAL (Hrs.) 
B/D TIME ELECTRICAL (Hrs.) 
B/D TIME ELECT & MECH (Hrs.) 
MTTR MECHANICAL (Hrs.) 
MTTR ELECTRICAL (Hrs.) 
MTTR MECHANICAL & ELECTRICAL (Hrs.) 
MACHINE AVAILABLE HOURS (Hrs.) 
MTBF MECHANICAL (Hrs.) 
MTBF ELECTRICAL (Hrs.) 
MTBF MECHANICAL & ELECTRICAL (Hrs.) 
  PREPARED BY:           
APPROVED BY :

9.0 Diesel Consumption Record

  Diesel Consumption for the Month:  
Sr. No.  DateStart TimeClose TimeTotal HoursCause of runingFuel opening LitersFuel close LitersDiesel Consum.Consum. Per HoursDiesle Refling Qty LtrsDiesle Purchase QTY. LtrsStand By Stock LtrsTotal cost Per DayCost Per Hour
               
               
               
               
               
               
               
               
               
               
               
               
               
               
               
               
               
               
               
               
               
               
               
               
               
Prepared ByApproved by

10: Overhauling schedule

      OVERHAULING SCHEDULE
S. NoMachine NameEquipment CodeDept/AreakwAprMayJunJulAugSepOctNovDecJanFebMar
                 
                 
                 
                 
                 
                 
                 
                 
                 
                 
                 
                 
                 
                 
                 
                 
                 
                 
  Prepared By :  Approved By :

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