QUALITY SYSTEM PROCESS DOC. No.

: IF/QMS/13
REV. No.& Date : 02&
08.09.22
TITLE: PROCESS FOR MAINTENANCE & TOOL MANAGEMENT Efft. Date :-01/04/15

Revision History :-

Change
Made By Approved Affected Revision
Date Changes Made
(QMS By (HOD) Section No.
HEAD)
01.08.2021 Trolley maintenance point Lavneet R.K.Dubey 01
include
08.09.2022 Predictive Maintenance added Jagmohan R.K.Dubey 02
21.01.2023 Tools Breakdown analysis Jagmohan R K Dubey 03
requirement added

Document Ownership and Timelines

Title Process for Maintenance Date of Origin 01.04.2016

Document Prepared By Navneet

Document Issued By Jagmohan

Document Approved By R.K. Dubey

Document Classification " Internal document"

Prepared By: Issued By: Approved By:

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 QUALITY SYSTEM PROCESS DOC. No. : IF/QMS/13
REV. No.& Date : 02&
08.09.22
TITLE: PROCESS FOR MAINTENANCE & TOOL MANAGEMENT Efft. Date :-01/04/15

Purpose:- To maintain the machine /equipment /Die-Tool for ensuring continuing process performance

1. PROCESS SCOPE:-

This Process is applicable to establish& maintain a system for maintenance of the entire infrastructure
including Plant, machinery and equipment, utilities, material handling equipment to ensure the
improvement in effectiveness and efficiency of available infrastructure and for smooth production run &
Poka-Yoke & Trolley & Bin maintenance & This process is applicable to define the method to control of
production tooling management.

2. PROCESS OWNER: - HOD- MAINTENANCE & HOD-TOOL ROOM

3. DEFINITIONS:- BD- BREAKDOWN ,TR- TOOL ROOM

Machine: Any machinery, equipment or processing facility used for production

and utility purpose.

4. PROCESS DESCRIPTION: -
A. Preventive Maintenance:

Sr.
Activity Responsibility Ref. Doc.
No.

5.1
1) Prepare list of machine. Maintenance MASTER LIST OF
2) Prepare a daily maintenance checklist. MACHINES ML/02

5.2
Depending on nature of machine, prepare preventive
maintenance check sheet for each category/family of Machine preventive
equipment Maintenance
maintenance check sheet
IF/PRD/13

5.3
Prepare an ANNUALPREVENTIVE MAINTENANCE Maintenance Machine preventive
PLAN for in-house maintenance.(In house maintenance maintenance
plan& AMC Preventive maintenance plan made ) schedule-IF/PRD/07
5.4
Carry out preventive maintenance as per schedule using Maintenance Machine history card-
check sheet and update the history card. IF/PRD/16

5.5
In case, due to unavoidable reasons, it is not possible to carry
out maintenance as per schedule, prepare s a next earliest ----
possible date and carry out maintenance. Maintenance

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 QUALITY SYSTEM PROCESS DOC. No. : IF/QMS/13
REV. No.& Date : 02&
08.09.22
TITLE: PROCESS FOR MAINTENANCE & TOOL MANAGEMENT Efft. Date :-01/04/15

5.6
Two in a year, review the annual maintenance plan on the
basis of maintenance history of machine and, if required ----
change the maintenance frequency. If required modify the Maintenance
check sheet also.
5.7
1:-The machines, for which in-house maintenance facilities Maintenance
are not available, get the machines maintained by Competent
External agencies through ANNUAL MAINTENANCE
CONTRACT. AMC
2:-M/C Handover after machine / tool to production
department after preventive maintenance and fill 4”M”

C. Breakdown Maintenance
5.9
A:- Intimate maintenance department whenever any User department
Breakdown Record
breakdown of the machine takes place. F/PRD/08

B:- Attend the problem and identify the root cause and
trouble shooting if problem is solved in house
C:-If problem is not solved in house then call External
Agency which is taken AMC or other specialist which is
short out the problem

5.10 Carryout the maintenance and record the detail of action

Maintenance
taken in history card.
C-1: About Daily maintenance check sheet

5.10. 1:- Daily machine check sheet filled by operator before start Daily machine check sheet
Maintenance
1 the machine (F/MNT/01)
2:-Daily machine check sheet approved by supervisor and
filled Judgment.
3.: If any problem occurred by operator or supervisor then
used (x) mark and inform to maintenance department by
supervisor.
4:-Machine handover after maintenance to production
department.
5:- Maintenance record maintenance in machine history card
and machine break down record maintain.

D. Breakdown Analysis criteria

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 QUALITY SYSTEM PROCESS DOC. No. : IF/QMS/13
REV. No.& Date : 02&
08.09.22
TITLE: PROCESS FOR MAINTENANCE & TOOL MANAGEMENT Efft. Date :-01/04/15

5.11 1-Receipt of information of machine breakdown slip

Maintenance
2-Recognition of problem & cause of problem
3-If problem does not solved at in house then inform out
source
4-Handover machine to production department after
breakdown maintenance & update history card.
5- Carry out necessary Maintenance and indicate, in break
down slip
6-In case of BD, BD slip will be prepared by and the related
problem will be rectified.
7-CAPA will be applicable on monthly top breakdown. And
breakdown analysis in second weak of the month.
8- M/C history card will be updated in break down
9-Machine Break down at night shift then M/C stop and do
the work at problem at next working day ( at day shift )
Break down summary sheet maintain on the daily basis. (If
applicable)
10- If any repeated break down on particular machine more
than three times in a month then analyze the problem & take
necessary corrective action.
11- On monthly basis complete why-why analysis done for
top one break down for particular machine which has more
contribution in breakdown hours.

E. Spares management ( Critical Spare parts)

5.12
Prepare a list of essential replacement forkey manufacturing
equipment along with the min. quantity to be maintained in
inventory. Maintenance List of Critical Spares
IF/MNT/CSP/10
Send a copy of inventory norm to stores for maintaining the
stock as per defined norms.
Critical spare parts review on monthly basis (until second
week of the month)

F. Shutdown Maintenance

5.13
On the basis of breakdown history and shutdown need as ----
desired by production, make shutdown plan.
Maintenance
Carryout maintenance and prepare report,

Given information about shutdown detail before one week.

G. Poka-Yoke

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 QUALITY SYSTEM PROCESS DOC. No. : IF/QMS/13
REV. No.& Date : 02&
08.09.22
TITLE: PROCESS FOR MAINTENANCE & TOOL MANAGEMENT Efft. Date :-01/04/15

5.14 List of Poka-Yoke ML-05

1-Prepare a list of Poka-Yoke Maintenance
2-Poka – yoke check daily maintenance check sheet. And if POKA YOKE MONITORING
any poka yoke is not checked during daily maintenance
CHECK :-IF/QA/50
check sheet then checked separately if required.
3-poka yoke checked during preventive maintenance.
If poka yoke fail in machine then record maintain in machine
history card
If poka –Yoke fail in tool then record maintain in tool history
card
If poka yoke fail in gauge or fixture then record maintain in
gauge or fixture history card
4-Poka-Yoke fail, analysis and CAPA submit within 8
working day
5.Production stop until poka poke is not working proper ,
and inform to customer immediately

H. UTILITY MAINTENANCE

5.15 1. Master list of existing utility equipment (installed in the Maintenance Master List of Machine
plant) is maintained. &Utilities

2.The utility operation is monitored regularly to ensure un-

interrupted supply to avoid production losses.

3.In case of any failure alternate / standby utility equipments

(From Master List of Equipment) are used and maintenance
activities are started to remove breakdown.

5.If maintenance team could not carry out the maintenance

activities then subcontractor’s are selected (based on their
capability to provide regular services) by purchase
department and annual maintenance contract is signed with
the sub-contractors.

PREDECTIVE MAINTENANCE & MTTR & MTBF

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 QUALITY SYSTEM PROCESS DOC. No. : IF/QMS/13
REV. No.& Date : 02&
08.09.22
TITLE: PROCESS FOR MAINTENANCE & TOOL MANAGEMENT Efft. Date :-01/04/15

Maintenance identifies the machines that are subject to

predictive maintenance.
The predictive maintenance methods such as correlation of
SPC data, daily machine performance through production
reports, any abnormalities observed or unusual problems
reported by the machine operator / supervisor, are recorded
on Predictive Maintenance sheet & these are reviewed
monthly & are in-built into planned maintenance schedules
as appropriate.
Predictive maintenance may include but not limited to the
following:
 Undue vibration
 Undue temperature raise
 Undue noise
 Undue wear and tear of mating /sliding parts.
 Any oil & air leakage from machine.
Record is kept of the observations made on the machine
history card.

Corrective actions are initiated in case any of the

characteristics goes beyond the normal or is about to do so.

1:- Calculated MTTR & MTBF in every months of the third

week

2:-Target defined of MTTR & MTBF

CUTTING OIL:-

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 QUALITY SYSTEM PROCESS DOC. No. : IF/QMS/13
REV. No.& Date : 02&
08.09.22
TITLE: PROCESS FOR MAINTENANCE & TOOL MANAGEMENT Efft. Date :-01/04/15

1:-Cutting oil monitoring as per requirement, DAILY CUTTING OIL %

2:-Cutting oil tank clean as per defined frequency and MONITORING SHEET
record maintain. IF/PRD/21
3:-After clean tank, review tank cleanness by work
instruction. And record maintain. Cutting oil change check sheet
4:- Cutting oil mixture as per defined work instruction IF/WI/109
5:- Cutting oil change work instruction
Cutting oil Mixing WI
:-IF/WI/108

Cutting oil change wi

IF/WI/110

J:-BIN & TROLLEY

5.17 1:-Prepared master list of Trolley & Bin

1:-Bin & Trolley preventive maintenance plan

2:-Trolley preventive maintenance once time in a year.

3:-Trolley maintenance as per maintenance check sheet if

found not ok then taken action and review it

4:- Trolley checked as per trolley checked point.

5:-Used hydraulic lifter if trolley or bin heavy ( if applicable )

5.18 1:-Trolley and Bin scraped when trolley and bin is damage

2:-Master list of trolley and review once in a year

K:- LUX LEVEL

5.19 1:-Lux Level monitoring as per defined WI LUX LEVEL STANDARD

(IF/HR/42)
2: Lux level monitoring by as per CFT Team
LUXLEVELMONITORING
3.Lux level monitoring as per defined check sheet depend CHECK SHEET(IF/HR/41)
to area.

New Tool / Fixture/ Gauges Development & Production Tool / Fixture Management

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 QUALITY SYSTEM PROCESS DOC. No. : IF/QMS/13
REV. No.& Date : 02&
08.09.22
TITLE: PROCESS FOR MAINTENANCE & TOOL MANAGEMENT Efft. Date :-01/04/15

5.20 The need for new Tools / Jigs / Fixtures / Gauges is

identified and receive request for new tool design/
development

5.21 Prepare tool development plan Micro macro level plan &
action taken accordingly. In case of urgency or
breakdown ,wire cut process, or grinding process arranged
from approved source

5.22 . Get the sample inspection by QA Department. Review

inspection Report & take necessary actions

5.23 Issue to Production Department for Production

Break down maintenance of Tools / Jigs / Fixtures

Intimate Tool room department whenever any

breakdown of the tools takes place.

Carryout the maintenance and record the detail of

action taken in history card.

Updating of tool / jig / fixture history card.

Breakdown Analysis of Tool / Jigs /Fixture Criteria

If any repeated break down on particular Tool/

Jigs/Fixture more than three times in a month then
analyze the breakdown & take necessary corrective
action.

If any Tool/Jigs/ Fixture breakdown more than 4hrs in a

day then breakdown analysis will be done

On monthly basis complete why-why analysis done for

top one breakdown for particular Tool/Jig/Fixture which
has more contribution in breakdown hours.

CAPA will be applicable in above conditions and

breakdown analysis will be done in 2nd week of the
month.

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 QUALITY SYSTEM PROCESS DOC. No. : IF/QMS/13
REV. No.& Date : 02&
08.09.22
TITLE: PROCESS FOR MAINTENANCE & TOOL MANAGEMENT Efft. Date :-01/04/15

M:- Safety Point During Under maintenance & Machine shifting

1:-During maintenance properly used PPE as per

requirement

2:-During maintenance time all electric supply off at

particular machine or particular area.

3:- unauthorized person not allow at maintenance area

4:- Lux level properly ok at maintenance area.

5:-At Machine Restart time after maintenance electric supply

on care full and fire extinguisher available at near machine or
area

6.: Maintenance person are awareness about safety and

properly used fire extinguisher.

7. At machine shifting time area will be blocked where do

pickup and drop the machine.

Note: 1:-Before carrying maintenance which requires WELDING, GAS CUTTING & HIGH ALTITUDE
work, obtain WORK PERMIT from management. Also ensure to use required PPE’s.

2:- Master list of machine review once time in a year

5. KEY PERFORMANCE INDICATORS:-

 Breakdown in hours

 Compliance to machine maintenance plan

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 QUALITY SYSTEM PROCESS DOC. No. : IF/QMS/13
REV. No.& Date : 02&
08.09.22
TITLE: PROCESS FOR MAINTENANCE & TOOL MANAGEMENT Efft. Date :-01/04/15

6. REFERENCE DOCUMENTS & RECORDS:-

`Sr. Description Responsibility

Format/ Doc. No.
No.
01 Daily machine check sheet F/MNT/01 Maintenance

02 Machine history card IF/PRD/16 Maintenance

03 PreventiveMaintenance Plan of machines F/PRD/07 Maintenance

&equipments
04 Master List of critical spares Parts F/MNT/02 Maintenance

05 daily machine check sheet F/MNT/01 Maintenance

06 Machine/tool breakdown record F/PRD/08 Maintenance

07 machine/tool breakdown analysis report IF/MNT/02 Maintenance

08 PreventiveMaintenance Plan of tool F/TR/01 Maintenance

09 Preventive Maintenance Check Sheet IF/PRD/13 Maintenance

10 List of Trolley IF/HR/F/03A Maintenance

11 Trolley pm plan IF/MNT/F/41 Maintenance

12 Trolley preventive check sheet IF/MNT/09A Maintenance

13 Trolley maintenanc Maintenance

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