QUALITY SYSTEM
PROCEDURES
Maintenance
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1.0
Objective:
To maintain all machinery and equipment related to
production serviceable at all term.
2.0
Scope:
All machinery, equipment, and utilities in use at Plant.
3.0
4.0
Process Owner:
Process Performance
Indicators:
Maintenance Incharge
5.0
6.0
8.5.1.5
IATF Clause:
Process Inputs & Outputs:
1.
2.
3.
4.
5.
Breakdown hours
Breakdown Cost
MTTR (Mean Time to Repair)
MTBF ( Mean Time between Failure)
Preventive maintenance compliance
S.NO.
Inputs
6.1
Machine & Equipment
Outputs
Master list of machine
6.2
Machine Breakdown slip
Machine History Card
6.3
Critical spare
Master list of critical spares
6.4
Calibration plan for electronic devices
Calibration record
6.5
Machine breakdown
Maintenance Log book
6.6
PM Plan
PM check sheet
6.7
Predictive abnormality
Predictive maintenance sheet
6.8
History Card
Periodic overhauling
PREPARED BY:
ISSUED BY:
APPROVED BY:
CONTROL STATUS:
QUALITY SYSTEM
PROCEDURES
Maintenance
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7.0
Reference:
S.No.
7.1 Machine Manual
7.2
Document Name
Document No.
Master list of machines & critical spare
8.0 Records:
S.No.
Document Name
Document No.
8.1
Master List of machines & critical spare parts
8.2
Annual Preventive maintenance plan
8.3
PM check points
8.4
Breakdown Register
8.5
Breakdown intimation slip
8.6
Machine history card
8.7
Daily Check Sheet
8.8
Predictive maintenance check points
8.9
WHY-WHY analysis
8.10
Breakdown hours, MTTR & MTBF monitoring sheet
9.0
Procedure:
S.No
Process Sequence
Responsibility
9.1
9.1.1
Breakdown Maintenance:
Breakdown intimation shall be received from
concern department.
9.1.2
Breakdown analysis shall be carried out by
maintenance person as per top one breakdown time
/ critical machine.
PREPARED BY:
ISSUED BY:
Concern
department
head/executive
Maintenance Eng. /
Sr. Manager
APPROVED BY:
Reference
Documents &
Records
Breakdown
intimation slip
_
CONTROL STATUS:
QUALITY SYSTEM
PROCEDURES
Maintenance
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9.1.3
Decision: If problem cannot be solved in-house
Maintenance Eng. /
Sr. Manager
_
Maintenance Eng. /
Sr. Manager
_
Action: Outsource party shall be called for
breakdown maintenance.
9.1.4
Decision: If problem can be solved in-house
Action: Root cause analysis shall be performed in
order to find the root cause of the
problem/breakdown.
9.1.5
Check the availability of spare parts, if found not
available than material indent shall be raise to
procure the relevant spare parts
Maintenance Eng. /
Sr. Manager
_
9.1.9
A list of critical spare shall be maintained, reviewed
and updated whenever the new spares procured and
minimum stock of critical spare shall be
maintained.
Maintenance Eng. /
Sr. Manager
Master list of
Machine & critical
spares
9.1.7
Appropriate corrective action shall be taken to
resolve the problem as per breakdown complaint.
Maintenance Eng. /
Sr. Manager
_
9.1.8
After resolving the problem, machine shall be
handover to concern department
Maintenance Eng. /
Sr. Manager
_
9.1.9
Details of breakdown shall be entered in Machine
history card and record shall be maintained.
Maintenance Eng. /
Sr. Manager
Machine history card
9.20
Why- why analysis shall be carried out for repeated
breakdowns
Maintenance Eng.
Why-why analysis
9.2
Preventive & Predictive Maintenance:
9.2.1
Master list of machine, equipment & utilities shall
be prepared and maintained.
Maintenance Eng. /
Sr. Manager
Master list of
machines & critical
spare
PREPARED BY:
ISSUED BY:
APPROVED BY:
CONTROL STATUS:
QUALITY SYSTEM
PROCEDURES
Maintenance
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9.2.2
An annual preventive maintenance schedule shall
be prepared taking input from following:
 Master list of machines
 Past history and records
 Related machine manual
Maintenance Eng. /
Sr. Manager
Annual PM Plan
9.2.4
Annual PM plan shall be circulated to concern
departments
Maintenance Eng. /
Sr. Manager
_
9.2.5
Intimation for releasing the machine shall be given
to the concern department one day before PM
schedule through E-mail/ phone.
Maintenance Eng. /
Sr. Manager
_
9.2.9
If on the day of PM schedule, machine is not
available for preventive maintenance than
rescheduling shall be done for the same machine
and update the annual and monthly PM schedule.
Maintenance Eng. /
Sr. Manager
_
9.2.7
Preventive maintained shall be carried out as per
monthly PM schedule and maintain the record in
machine wise PM check sheet.
Maintenance Eng. /
Sr. Manager
PM Check Sheet
9.2.8
If any abnormality found during preventive Maintenance Eng. /
maintenance than repair activities shall be carried Sr. Manager
out to resolve the issue.
PM Check Sheet
9.2.9
In case of major issues, details shall be entered in Maintenance Eng. /
Sr. Manager
machine history card and record is maintained.
_
9.2.10 After preventive maintenance machine shall be Maintenance Eng. /
Sr. Manager
handover to concern department.
_
9.2.11 PM plan shall be reviewed at least once in a year Maintenance Eng. /
for any amendment, changes, adjustment need to be Sr. Manager
done for achieve PM plan compliance
_
9.2.12 Daily preventive maintenance activities shall be Maintenance Eng.
carried out for sand plant and record shall be
maintained in daily check list maintenance
Daily check sheet
9.2.13 The predictive maintenance methods such as Maintenance Eng. /
correlation of SPC data, daily machine performance Sr. Manager
through production reports, any abnormalities
observed or unusual problems reported by the
machine operator / supervisor are recorded on
Predictive
maintenance check
points
PREPARED BY:
ISSUED BY:
APPROVED BY:
CONTROL STATUS:
QUALITY SYSTEM
PROCEDURES
Maintenance
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Predictive Mnt. Reg. & these are reviewed monthly
& are in-built into planned maintenance schedules
as appropriate.
9.3
Overhauling:
9.3.1
Identify the machines and situations based on
history for which the over hauling is required.
Maintenance Eng. /
Sr. Manager
_
9.3.2
Maintenance Eng. /
Machine overhauling shall be planed taking input Sr. Manager
from following:
_



Master list of machines
History card and records
Related machine manual
9.3.3
Intimation for releasing the machine shall be given Maintenance Eng. /
to the concern department one day before Sr. Manager
overhauling schedule through E-mail/ phone.
_
9.3.4
Carryout machine overhauling and enter the
overhauling details in machine history card and
maintain the record
Machine history card
9.4
Maintenance Objectives:
9.4.1
Top management shall define the objectives for Top Management
maintenance process.
_
9.4.2
Maintenance objectives like breakdown hours, Maintenance Sr.
preventive maintenance compliance, MTTR & Manager
MTBF shall be monitored and maintained.
Breakdown hours,
MTTR & MTBF
monitoring sheet
9.4.3
Performance of maintenance plan and objectives
shall be reviewed in MRM.
Maintenance Sr.
Manager
_
9.4.4
Action plan shall be prepared when objective not
achieved and shall contain the following inputs action taken, responsibility, target date and resource
required.
Maintenance Sr.
Manager
Action Plan
PREPARED BY:
ISSUED BY:
Maintenance Eng. /
Sr. Manager
APPROVED BY:
CONTROL STATUS:
QUALITY SYSTEM
PROCEDURES
Maintenance
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10.0 Amendment Sheet:
S.No.
Date
Amendment Details
10.1
02/01/2018
11.0 Abbreviations:
S.No. Abbreviation
1
2
4
5
6
7
MNT
MRM
MTTR
MTBF
PM
SPC
PREPARED BY:
Revision No.
New release as per IATF requirements
00
Description
Maintenance
Management Review Meeting
Mean time to repair
Mean time between failure
Preventive maintenance
Statistical Process Control
ISSUED BY:
APPROVED BY:
CONTROL STATUS: