Maintenance:

Purpose:
1. Maintain properties of the company wherever required.
2. Ensure usefulness of all property or production equipment.
3. Develop or tune machinery and equipment and tools to suit production/product.
4. Arrange and operate plant service equipment (including IT and communication networks) to maintain operations
flow.
5. Ensure employee safety and property safety by validation of infrastructure and building fitness and other
equipment fitness.
6. Ensure plant readiness for emergency response by maintaining, escape routes, first aid firefighting and other
medical emergency equipment as per procedure.
7. Execute disaster management program when needed.

Working plan:
1. List down all machineries and equipment and structural being maintained.
2. Draw preventive maintenance plan for every individual item listed above.
3. Write a maintenance procedure and a checklist for validation of the item.
4. Schedule and carry out maintenance (PM) of the items and have record.

1. Have utilization history of all items being maintained.

2. Register item breakdown occasions and downtime of the same.
3. Attend and restore the item for service as quick as possible to ensure availability.
4. Analyze and find root cause for the breakdown.
5. Plan and resolve the issue by corrective action in a cost effective manner.
6. Document all the above processes for review.
7. Device and have a practicable contingency plan to ensure process continuity.

1. Validate all equipment for the required quality output, consistency, reliability, safety and environment
protection.
2. Plan and execute improvement and up gradation of the machinery or equipment.
3. Affect Changes and follow up for feedback until positive return.

1. Set appropriate service lines and equipment. Have a blue print of layout and circuit.
2. Determine an operation plan. Get it approved and agreed by management and users.
3. Log usage and account consumption.
4. Update equipment, system procedures to meet demands.
5. Report troubles, failures and changes.

1. Do HIRA for all plant operations and record.

2. Plan and execute Safety Management programs.
3. Get equipment, accessories and infrastructure validated and certified by approved third party.
4. Revise HIRA on changes, modifications, addition & deletion of equipment.
5. Make appropriate work spot emergency response plan.

1. Prepare plant layout indicating emergency pathway, assembly, first aid equipment, remote work places, and
remote access of employee presence etc as per ERP.
2. Ensure ready for use of fire alarms, system elements and equipment periodically by testing and record.
3. Participate in mock drills.
4. Prepare and train people for disaster management.
5. Plan and executes plans to Environment and CSR compliance.
KPIs. 1. PM of all equipment and machineries carried out as per plan. PM checklists, procedures and observations
recorded and available.
a. PM (daily and periodic) carried out for machine-
Equipment-
b. New machine/equipment added-
c. New CL prepared or Revision of PM checklist or any other changes affected

2. Production down time due to equipment, machinery breakdown or maintenance.

a. Equipment, Machine down instances and downtime Hours (including PM hours).
b. Time taken to restore the equipment/machine –hours
c. Root cause analysis done and corrective action plan deployed.

3. MTTB and MTTR

a. Data analysis report on B/D instances, down time, causes and time taken to restore

4. CAPA on maintenance issues taken.

a. Study of effectiveness of CAPA undertaken.

5. Equipment validation study report for Machineries and tools are available.
a. Validation study completed for equipment/machine/tool/jig/fixture/PQR
b. Improvement program planned and undertook for equipment/machine/etc.

6. Changes implemented in maintenance procedures, techniques, resources etc.

a. Documentation of changes made

7. Utilization log and consumption records of utilities available.

a. Electricity, Water, Comp.Air and Gas consumption report.
b. Abnormal incidents and Non routine task/ activities
c. Monthly report on the above.

8. AIAR and HIRA updated reports available for all listed equipment and machineries with maintenance
department.
a. New equipment/machine, method, tool – AIAR, Safety Risk study report and subsequent action pan.

9. Contingency or mitigation plan available for all identified risks and that includes emergency response plan.
a. Follow-up report on contingency and mitigation programs.

10. Housekeeping survey report and 5S score card prepared periodically.

a. 5S participation, implementation, action follow-up report

11. Work spot emergency mock drills conducted.

a. mock drill report.
b. Emergency evacuation readiness audit report.

12. Working environment monitoring for safety, environment and other legal compliance reports taken.
a. Fitness certificates acquired for all material handling, lifting equipment, buildings, structural, scales and
pressure vessels.
b. Working environment, drinking water, discharges, pollution, STP outlet, stack monitoring reports taken.
c. Waste disposal records and valid forms are made available.

13. CSR matrices measured and reported.

a. Service contracts are made and safety/environment compliance reports are prepared.
b. LCAR are prepared for existing production equipment and machinery and relevant programs are executed
for prolong the service life, recycle the discarded spares and machines and integrating new equipment.

14. EMP and SMP progress reports and MOM available.

 a. Current/new action follow-up reports

Skills:
1. Job knowledge
2. Machine equipment operation
3. Tools use.
4. Preservation of tool
5. Immediate attention to B/D.
6. Manual/technical drawing, circuit understanding
7. Programming
8. Spares
9. Documentation of work and Department
10. Learning new skills
11. Improvements initiation
12. Sourcing local for machining spares
13. Safety of equipment and personnel- procedures
14. Legal requirements-safety and pollution
15. Discipline
16. Conduct

Grade of work.
Sl. KPI subject Daily report Monthly report Actual KPI
No Targets measure/Rem
KRA 1- Preventive
maintenance 1. PM daily/planned maintenance Scheduled maintenance
KPI 1. PM Schedule missed out today for completed for
adherence 1.Production equipment 1. production equipment
2. Service equipment 2. Service equipment
3. Office equipment 3. Office equipment
New machine/ equipment added Total number of machines,
today equipment covered under PM.
New PM Check List or CL revised Changes made in PM
today for? procedure/methods.
KRA 2 Breakdown 1. Break down instance today of 1. Down time of the
Maintenance Production machines Production machines
KPI 1. Availability of Service equipment Service equipment
machines and Office equipment Office equipment
equipment for use. Other services Other services
2. Production hours lost due to MTTR
breakdowns -today MTTB
CAPAs initiated after root cause
analysis.
KRA 3 Utilization 1. Validation study completed and a. Validation study completed for
improvement Improvement program planned equipment/machine/tool/jig/fixtur
KPI 1. Improving Process today for e/PQR
equipment. equipment/machine/tool/jig/fixture b. Improvement program planned
/PQR. and undertook for
equipment/machine/etc.
c. Changes incorporated towards
process improvement.
2. Service contracts for Service output evaluation reports.
maintenance tasks -executed today
3. Housekeeping improvements a. 5S participation reports
done. b. Action Plan-MOM
KPI 2 Working ambiance 1. Utility maintenance – non Down time of common facility
availability of any common Light, sound and air, land, water
facility/provision pollution monitoring
2. Emission incidents if any today. measurement report.
3. Lighting faults/discomfort
reported
KRA 4 Safety and 1. AIAR and HIRA study new or a. New equipment/machine,
environment revision made today. method, tool – AIAR, Safety Risk
KPI 1. Environment 2. LCAR done today. study report and subsequent
protection and Safety 3. Mock drill or Emergency action pan.
measures evacuation audit done today b. LCAR are prepared for existing
4. Electricity, Water, Comp.Air and production equipment and
Gas consumption daily report. machinery and relevant programs
5. Abnormal incidents and Non are executed for prolong the
routine task/ activities- registered service life, recycle the discarded
today spares and machines and
integrating new equipment.
c. mock drill report.
d. Emergency evacuation
readiness audit report.
d. Monthly consumption report.
e. Accident incident analysis and
CAPA reports
Sl. KPI subject Daily report Monthly report Actual KPI
No Targets measure/Rem
KPI 2. Legal compliance 1. Breaching/violation reported a. Fitness certificates acquired for
today. all material handling, lifting
equipment, buildings, structural,
scales and pressure vessels.
b. Working environment, drinking
water, discharges, pollution, STP
outlet, stack monitoring reports
taken.
c. Waste disposal records and valid
forms are made available
KRA 5 Development 1. Changes implemented today. 1. Capacity, Capability, Safety
improvements done on equipment
and plant facility.
2. Trainings underwent
3. New facility added.
4. Improvements in Maintenance
and machines operating
procedures.
5. Organizational changes