SOP-09 Preventive Maintenance - Machine

Standard Operating Orient Refractories Limited
Procedure
Issue No.01 Rev No.00
Issue date: 1st Jan 2016 Revision Date: 1st Jan SOP Doc No.: ORL/EL/SOP/09
2016
Department: Electrical Activity: Preventive
Maintenance Maintenance
Title : SOP for Preventive Maintenance
PURPOSE:To carry out Preventive Maintenance of Plant and Machinery
SCOPE: All Electrical Maintenance activities carried out by Electrical Department

Input :
Sl. No. Inputs Source
1. Preventive Maintenance Schedule Electrical Deapartment
2. Equipment History Card Electrical Maintenance
3. Tool Set Electrical Maintenance
4. Spares Stores and Electrical Maintenance
5. Consumables (Cotton Clothes, PVC Electrical Maintenance
Tape
6. Grease Gun Electrical Maintenance
7. PPE (Gloves, Helmet, Shoes, etc.) Electrical Maintenance
8. Machine Manuals Library/Electrical Department
9. Electrical Drawing Electrical Department
10. Formats, Files, Check lists, Log As issued to department
Books and Registers
11. Quality Manual, EMS Manual QMS and EMS Document issued to
Process flow chart department
RESPONSIBILITY:
Sl. No. Activity Responsibility
1. Planning of preventive Maintenance Shift Sr. Foreman/Asst.
Foreman/Supervisor
2. Carrying out of Maintenance Activities Charge Hand and Electrician
3. Issue of Spares and Consumables Sr. Foreman/Asst.
Foreman/Supervisor (Elect.
Maintenance)
4. Receipt of Completion Certificate Charge Hand and Electrician
5. Filling of Records & log book Shift Charge Hand/Supervisor
DESCRIPTION OF ACTIVES:
1. Preventive Maintenance
1. The Preventive maintenance schedule taken by Foreman/Supervisor.
2. Sr. Foreman/Supervisor identifies the actual schedule of the preventive
maintenance and assigns the appropriate electrical person to carry out the job.
3. Charge Hand/Electrician prior to starting any job, displays the board, “Machine
under Preventive Maintenance” on the operating panel and switches’ “OFF” the
power of the machine.
4. lCharge Hand/Electrician properly cleans the working area.
5. Appropriate tools for carrying out the maintenance activities are taken by the
Prepared by(HOD) Approved By (Head-Opn) Issued by(M R-QMS)
Signature Signature Signature

Procedure
2016
Charge Hand/Electrician.
6. Sr. Foreman/Asst. Foreman/Supervisor based on the requirements identifies
appropriate spares and consumables gets it issued from the store by filling up the
indent.
7. As per the requirement machine manuals are taken on issue by the Sr.
Foreman/Supervisor from the Library.
8. As per the requirement machine electrical drawings are taken by the Sr.
Foreman/Supervisor from the electrical department.
9. For this appropriate work instruction as given of annexure to this SOP are used for
carrying out preventive maintenance activities such as Dismantling of Equipment,
(Annexure 1), Assembly of Equipment (Annexure 2).
10. Supervisor ensures that the charge hand/electrician and other personnel involved in
this activity wears required PPEs (Gloves, Helmet, Shoes, and Mouth Mask, etc.).
11. After maintenance job completion check the machine with machine’s (M/C)
operator/Supervisor related to the M/C.
12. If the machine is running properly, removes the Board “Machine under Preventive
Maintenance” from the operating panel.
13. Collect all used items (such as used cloth, removed damage spare parts) from the
working area and dispose in the proper identified areas.
14. The waste generated from the maintenance activities is managed as per OCP on
waste management/ Hazardous waste management.
15. The signature of respective department’s HOD/supervisor is obtained on checklist
after preventive maintenance job completion.
16. Details in the check list and respective equipment’s history cards are recorded by
Sr. Foreman/Supervisor.
17. Check list properly file up for further record.
CROSS REFERENCE :
Aspect impact document no. AI/EL/04

Annexure 1 - Work Instruction for Dismantling of Equipment
Annexure 2 - Work Instruction for Assembly of Equipment
Annexure 3 - Work Instruction for Welding
Annexure 4 - Work Instruction for Cutting
Annexure 5 - Work Instruction for Grinding
Annexure 6 - Work Instruction for Lubrication
Annexure 7 - Work Instruction for Change of Oil
Output:
Sl. No. Output Location

Procedure
2016
1. Maintained Machine/Equipment Respective Departments

2. Filled Formats, Files, Check lists and Electrical Department
Registers
3. Logs and History Cards Electrical Department
4. Machine Availability Electrical Department

Procedure
2016
Annexure 1
Work Instruction for Dismantling of Equipment
1. Shutdown of machine/equipment in consultation with the user department’s authorized

person.
2. Shutdown of electrical panel of the equipment.
3. Display of equipment under electrical maintenance tag.
4. Appropriate tools for carrying out the maintenance activities are taken.
5. Ensures that the supervisor/chargehand/electrician personnel involved in this activity.
6. Based on the requirements appropriate equipment/spares dismantling to be carried out.

Procedure
2016
Annexure 2
Work Instruction for Assembly of Equipment
1. Assembly of the Equipment.
 Shutdown of machine/equipment in consultation with the user department’s authorized

person.
 Shutdown of electrical panel of the equipment.
 Display of equipment under electrical maintenance tag.
 Appropriate tools for carrying out the maintenance activities are taken.
 Ensures that the supervisor/chargehand/electrician personnel involved in this activity
wears required PPEs (Gloves, Helmet, Shoes, and Mouth Mask etc.)
 Based on the requirements appropriate equipment/spares assembly to be carried out.
2. Test Run of the Equipment.

 Clean the equipment which to be maintain.
 Appropriate tools for carrying out the maintenance activities are taken.
 Ensures that the supervisor/chargehand/electrician personnel involved in this activity
wears required PPEs (Gloves, Helmet, Shoes, and Mouth Mask etc.)
 Ensure that all connections have been screwed tight again.
 Check that all materials, tools, equipment, etc. that were required for maintenance and
repair work been removed from the materials testing machine's working area.
 Ensure all safety devices such as MCB, Breakers, limit switches, proximity switches and
the materials testing machine's EMERGENCY OFF button in perfect working order.
 Ensure all of the above work must be first correctly done free of error before the
materials testing machine is to be used by the operating personnel.

Procedure
2016
Annexure 3
Work Instruction for Welding
1. Check the Welding cable for good condition and not to create a tripping hazard.
2. Keep area clean and free of grease, oil and other flammable material.
3. Before welding work make a visual inspection of all equipment for damage.
4. Ensure the earthen cable is properly fixed.
5. Check that the area is well ventilated and fume extracting passes available.
6. Faulty equipment not to be used. Immediately report suspect equipment to
Supervisor/ Shift Incharge.
7. Carry out the Welding activity is carried out with appropriate welding electrode as
per the fabrication drawing/ sample. Ensure proper current setting as per the
welding requirement.
Sl. No Type of Welding Type of Current Range Remarks
recommended
welding electrode
8. Ensure proper Fire Fighting equipment and Guard person as per the requirement.
9. Wear required PPEs (Gloves, Helmet, Shoes, and Mouth Mask, Goggles etc.).
10. HOD/supervisor checks and signs for work completion in the check-sheet.
11. Hang up welding cable and screen properly on the stand after completion of
activity.
12. Complete the respective equipment logs, history cards

Procedure
2016
Annexure 4
Work Instruction for Cutting
a. Check the Gas hoses for good condition and not to create a tripping hazard.
b. Keep area clean and free of grease, oil and other flammable material.
c. Before lighting up make a visual inspection of all equipment for damage.
d. Check that the area is well ventilated and fume extracting passes available.
e. Do not use Faulty equipment. Report suspect equipment to Supervisor/Shift
Incharge.
f. Carry out Gas Cutting activity as per the drawing/sample/ instruction from
supervisor. Ensure proper flame setting.
g. Ensure availability of proper Fire Fighting equipment and Guard person as per
the requirement.
h. Wear required PPEs (Gloves, Helmet, Shoes, and Mouth Mask, Goggles etc.).
i. Supervisor checks the work completion and signs on the check-sheet.
j. Hang up welding blowpipe and hoses properly on the trolley stand after
completion of activity.
k. Complete respective equipment logs, history cards after completion of work.

Procedure
2016
Annexure 5
Work Instruction for Grinding
1. Use only in designated grinding area and erects screens if necessary.

2. Wears required PPEs (Gloves, Helmet, Shoes, and Mouth Mask, Goggles etc.).
3. Check the power cord, extension lead, plugs, sockets and power outlet for
damage.
4. Ensure that the grinding disc, guard and attachments (including handle) are
secure and correctly fitted.
5. Inspect the grinding disc for damage. Do not use damaged grinding disc.
6. Always inspect the work piece to ensure that there aren’t any items which might
damage the grinding wheel or cause injury to the operator.
7. Secure and support the work piece using clamps, bench vices, etc.
8. Keep fingers and hands & power cords clear of the grinding disc.
9. Never make adjustments while the angle grinder is running.
10. Do not switch off the angle grinder when it is under load, except in an
emergency.
11. Allow angle grinder to reach operating speed before applying to work piece &
increase load gradually.
12. Do not lift or drag angle grinders by the cord.
13. Keep flexible electrical cords clear of oil, grease, machines and sources of heat.
14. Be aware of flying sparks. Hold grinder so that sparks fly away and flammable
materials.
15. Do not leave the angle grinder running & only use the grinder when hand held.
16. Do not touch the work piece immediately after grinding operation as it may be
extremely hot.
17. Clean bench and work area & place all waste material in bin.
18. Return angle grinder & rolled up extension leads to storage area.
19. Complete respective equipment logs, history cards after completion of work.

Procedure
2016
Annexure 6
Work Instruction for Lubrication

Procedure
2016
Annexure 7
Work Instruction for Change of Oil

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Standard Operating Orient Refractories Limited

Title : SOP for Preventive Maintenance

PURPOSE:To carry out Preventive Maintenance of Plant and Machinery

SCOPE: All Electrical Maintenance activities carried out by Electrical Department

Prepared by(HOD) Approved By (Head-Opn) Issued by(M R-QMS)

Signature Signature Signature

Aspect impact document no. AI/EL/04

Signature Signature Signature

1. Maintained Machine/Equipment Respective Departments

Prepared by(HOD) Approved By (Head-Opn) Issued by(M R-QMS)

Signature Signature Signature

1. Shutdown of machine/equipment in consultation with the user department’s authorized

Prepared by(HOD) Approved By (Head-Opn) Issued by(M R-QMS)

Signature Signature Signature

1. Assembly of the Equipment.

 Shutdown of machine/equipment in consultation with the user department’s authorized

2. Test Run of the Equipment.

Prepared by(HOD) Approved By (Head-Opn) Issued by(M R-QMS)

Signature Signature Signature

Prepared by(HOD) Approved By (Head-Opn) Issued by(M R-QMS)

Signature Signature Signature

Prepared by(HOD) Approved By (Head-Opn) Issued by(M R-QMS)

Signature Signature Signature

1. Use only in designated grinding area and erects screens if necessary.

Prepared by(HOD) Approved By (Head-Opn) Issued by(M R-QMS)

Signature Signature Signature

Prepared by(HOD) Approved By (Head-Opn) Issued by(M R-QMS)

Signature Signature Signature

Prepared by(HOD) Approved By (Head-Opn) Issued by(M R-QMS)

Signature Signature Signature

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