Department: Maintenance Issue Date: 01.03.

06 Subject

DOC. No. : AV/ME/SOP/001 Page No. : Page 1 of 5 Revision No. & Date : (00)-01.03.06

Procedure for Plant Equipment Maintenance.

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REVISIONS Revision Description Original Issue

Date Revision 01.03.06

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Department: Maintenance Issue Date: 01.03.06 Subject

DOC. No. : AV/ME/SOP/001 Page No. : Page 2 of 5 Revision No. & Date : (00)-01.03.06

Procedure for Plant Equipment Maintenance.

1.0 Purpose To ensure proper and timely maintenance of a machine to achieve efficient & trouble free performance and longer life of the machine. 2.0 Scope 2.1 All Machines, 2.2 Operator, Line & Shift In charges, Quality Assurance Staff, Production & Maintenance Crew. 3.0 Responsibility 3.1 Operators: (1)To carry out the routine maintenance & cleaning activity as per the checklist, at the scheduled time. (2)To complete the specific checklist for that type of routine maintenance and cleaning activity. (3)To keep the filler and surrounding area clean and free of broken glass. (4)Ensure that no oil & grease spillage takes place. (5)To run the machine to ensure satisfactory and normal operation after the maintenance. (6)To assist technicians / fitters during preventive maintenance activities. (7) To record the activity in the logbook. 3.2 Maintenance Technicians: (1)To carry out the preventive maintenance activity as per the checklist, at the scheduled time. (2)To complete the specific checklist for that type of maintenance. (3)To keep the filler and surrounding area clean and free of any lubricants, used spares, tools etc. after the maintenance activity. (4)To ensure that no oil & grease spillage takes place. Also ensure that lubricants should not be allowed to get into the drainage lines. (5)To run the machine to ensure satisfactory and normal operation after the maintenance. 3.3 Maintenance Engineers:
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Department: Maintenance Issue Date: 01.03.06 Subject

DOC. No. : AV/ME/SOP/001 Page No. : Page 3 of 5 Revision No. & Date : (00)-01.03.06

Procedure for Plant Equipment Maintenance.

(1)To supervise the complete activity for proper execution, with safe and standard procedures. (2)To confirm for proper execution of all the steps sequentially and sign the checklist. (3)To ensure cleanliness, after execution of the job. (4)To record any kind of wear & tear and abnormality in the machine, to provide basis for future CBM activities. (5)To observe the machine in running condition for normal operation after maintenance. 3.4 HOD Engineering: (1)To plan the maintenance activity and ensure its execution at scheduled time. (2)To plan for alternate arrangements during the impairment period, co-ordinate and convey prior information about the impairment to the affected ones, if required. (3)To arrange necessary spares/ tools and other resources required. (4)To confirm successful completion of the activity. (5)To observe personally about the Wear & Tear observations of maintenance engineers and plan CBM, as early as required. 4.0 Definition (1)Routine maintenance (RM): maintenance procedures carried out as a standard part of start up shut down of equipment. (2)Preventive maintenance (PM): It is the practice of servicing or replacing parts before they fail, to avoid unplanned and/or costly breakdowns. (3)Condition based maintenance (CBM): It uses checks that require only human senses and/or instrumentation to predict the need for maintenance. (4)Run to Failure(RTF): it is a strategy based on the inability to prevent or predict equipment failure in a cost effective way.
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Department: Maintenance Issue Date: 01.03.06 Subject

DOC. No. : AV/ME/SOP/001 Page No. : Page 4 of 5 Revision No. & Date : (00)-01.03.06

Procedure for Plant Equipment Maintenance.

(5)Annual maintenance plan (AMP): year specific maintenance procedures planned and carried out, in addition to the yearly preventive maintenance activities, based on (1) the condition of the machine, (2) previous years performance of the machine and (3) improvements required. 5.0 Procedure 5.1 Information, Supplies and Equipment 5.1.1 Information 5.1.1.1 Equipment 5.1.2 Supplies 5.1.2.1 Spares, Manpower 5.1.3 Equipment 5.1.3.1 Tools & instruments to carry out the task. 5.2Frequency As on need basis. 5.3 Step By step Instructions: 5.3.1 Do the criticality analysis of each equipment. 5.3.2 On the basis of criticality analysis plan preventive maintenance schedule for equipment. 5.3.3 On the basis of criticality analysis preventive maintenance schedule checklist prepare for each equipment. 5.3.4 On the basis of criticality analysis prepare critical spares list for the critical equipment. 5.3.5 Maintain the critical spares inventory to assist breakdown maintenance. 5.3.6 Do the analysis of breakdown maintenance time spent. 5.3.7 Compare the breakdown maintenance time with the time spent on preventive maintenance to measure the effectiveness of preventive maintenance. 5.3.8 Take the action on the above results. 6.0 Documentation Criticality Analysis.
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Department: Maintenance Issue Date: 01.03.06 Subject

DOC. No. : AV/ME/SOP/001 Page No. : Page 5 of 5 Revision No. & Date : (00)-01.03.06

Procedure for Plant Equipment Maintenance.

Critical spare list 7.0 References Maintenance checklist.

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