SOP Title: Preventive Maintenance of Equipment
- Objective:
To lay down a procedure for Preventive Maintenance Programme for the Equipment and to ensure that Preventive Maintenance of the Equipment is performed in order to maintain the efficiency of the equipment.
- Scope:
This procedure is applicable to all critical equipment installed at site.
- Responsibility:
3.1 Engineering Department: To prepare and review the SOP. To follow the procedure laid down for the Preventive Maintenance of the Equipment as per this SOP.
3.2 Functional Department: To assist the execution of Preventive Maintenance activity and review the same as per SOP.
3.3 Quality Assurance Department: To review and approve the SOP and Annexure. To ensure compliance of the procedure.
- Accountability:
Head, Engineering Department / Head, Quality Assurance Department.
- Procedure:
- Definitions:
5.1.1 Engineering Associate: Executive or Operator of Engineering Department trained to perform duties as per this SOP.
- Preventive Maintenance: Maintenance activity performed to ensure that the Equipment will function smoothly and to avoid breakdowns. These activities are performed as per predefined frequency.
5.2. Operational Procedure:
| Safety Precautions/Instructions: | ||
| 5.2.1 | Wear appropriate Personal Protective Equipment while operating equipment. | |
| 5.2.2 | Ensure all the electrical connections are properly earthed. Ensure the power plug of the all equipment is fixed in the socket properly. | |
| Operation: | ||
| 5.2.3 | Prepare a list of the equipments as per Annexure to be included in the Preventive Maintenance Programme based on the assessment of criticality and need for Preventive Maintenance. | |
| 5.2.4 | Prepare the ‘Annual Preventive Maintenance Programme’ as per Annexure. Based on the Annual Preventive Maintenance Programme prepare a Preventive Maintenance Checklist. Refer Preventive Maintenance Checklist of current approved SOP prepared for equipment. | |
| 5.2.5 | Submit Annual Preventive Maintenance Programme to the Functional Department for review. | |
| 5.2.6 | Review the Annual Preventive Maintenance Programme and send back to Engineering Department. | |
| 5.2.7 | Submit the Annual Preventive Maintenance Programme list to Quality Assurance Department for review and approval. | |
| 5.2.8 | Review and approve the ‘Annual Preventive Maintenance Programme’. | |
| 5.2.9 | Plan the ‘Activity Chart’ for the month as per Annexure and submit to the Functional Department to confirm the availability of the equipment/machine for Preventive Maintenance. | |
| 5.2.10 | Review the ‘Activity Chart’ for any changes; confirm the availability of the equipment/machine for Preventive Maintenance and communicate to Engineering Department. | |
| 5.2.11 | Sign the “Activity Chart” and returned back the chart to the Associate Engineering for execution. | |
| 5.2.12 | Update the Status Label of equipment as “Equipment Under Maintenance Do Not Start”. | |
| 5.2.13 | Perform the Preventive Maintenance jobs as defined in the Preventive Maintenance Checklist and complete the work sheet. | |
| 5.2.14 | In case of any other job carried out other than the defined jobs, enter the same in the worksheet under the heading ‘ANY OTHER JOBS’ as per Annexure. | |
| 5.2.15 | Inform Quality Assurance in case of any unplanned maintenance activities are performed. | |
| 5.2.16 | Sign the completed work sheet and hand over to the relevant department person for review. | |
| 5.2.17 | Review and comment on the observations & actions if necessary. Sign the document and hand it over to Associate Engineering. | |
| 5.2.18 | File the executed check list in the Preventive Maintenance folder of the respective equipment. | |
| 5.2.19 | Update the Preventive Maintenance Status Labels as per Annexure and Preventive Maintenance Schedule. | |
| 5.2.20 | During the execution of Preventive Maintenance if any repair or any major modification needs to be done, make a detailed assessment as per Annexure “Job Order For Unplanned Maintenance”. | |
| 5.2.21 | Initiate a Change Control based on the above Job Order Assessment done for the particular equipment. | |
| 5.2.22 | If there are any changes in the Preventive Maintenance Procedure, Frequency and Tolerance limit, then initiate a change control as per the current edition. | |
| 5.2.23 | Initiation of change control is not required in case of Like to Like changes i.e. Change Parts, Bearings, Gearbox, Gaskets, Filters, Belts, Valves and other electrical components or parts if purchased from Original Equipment Manufacturer / Local Supplier without any hardware modifications. | |
| 5.2.24 | If any major spare part of the machine is replaced enter the same in the work sheet. | |
| 5.2.25 | Execute the Preventive Maintenance of the equipment as per the frequency and date mentioned in the schedule. If the Preventive Maintenance is not performed within 7 days after the date mentioned in the schedule, it shall be justified and informed to QA Department with proper documentation system. | |
| 5.2.26 | If new equipment is installed in any department, then incorporate the new equipment in the next edition of Annual Preventive Maintenance Programme. | |
- Abbreviation:
| Abbreviation | Expansion |
| SOP | Standard Operating Procedure |
| QAD | Quality Assurance Department |
| EGD | Engineering Department |
| UTL | Utility |
*Note – Ready to use SOP available in “DOWNLOAD” Section.