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DOCUMENT: Procedure DOC.

NO: TRYJ/MTCE-02
DIVISION: MMC, Jamshedpur REV. NO: 00
DEPARTMENT: Production/Maintenance DATE : 30.10.2004
SECTION: 7. 5. 1. 4 SHEET 1 OF 3
TITLE : Preventive and Predictive Maintenance

1 PURPOSE To establish the procedure for Preventive and Predictive


Maintenance of Equipment.

2 SCOPE This is applicable to all the machinery of Tata Ryerson


Limited, Jamshedpur.

3 REFERENCE Section 7.5.1.4 ISO/TS 16949: 2002(E)

4 DEFINITION Nil

5 ANNEXURES 3

6 DISTRIBUTION Chief of Business Jamshedpur Unit.


Manager (Quality and Process Control)
Dy. Manager (Maintenance)
Dy. Manager (Materials)
Management. Representative

PREPARED BY ASHOK KUMAR AUTHORISED BY: Ravi Inder Singh


DESIGNATION: Dy. Manager (Maintenance) DESIGNATION: Chief of Business Unit
SIGNATURE: SIGNATURE:

DATE: 30.10.2004 DATE:30.10.2004


DOCUMENT: Procedure DOC. NO: TRYJ/MTCE-02
DIVISION: MMC, Jamshedpur REV. NO: 00
DEPARTMENT: Production/Maintenance DATE : 30.10.2004
SECTION: 7. 5. 1. 4 SHEET 2 OF 3
TITLE : Preventive and Predictive Maintenance

7.0 Procedure

7.1 Deputy Manager (Maintenance) is responsible for the execution of this procedure.

7.2 All the machines and other equipment are maintained at the shop-floor in a proper
manner. The following types of maintenance activities are carried out at shop
floor.

 Break-down maintenance
 Preventive maintenance
 Predictive maintenance

7.3 Break Down Maintenance

 Whenever there is any breakdown, the machine operating Associates


gives information to Associates maint/ Executive maint / Dy. Manager
(Maint). The problem is logged into the maintenance log sheet
immediately. The present maintenance associate/ Exec maint / Dy.
Manager (Maint) Inspects the problem, and decides about the necessary
actions to be taken. If some spare parts are needed maintenance person
checks the availability of that part in their almirah. If part is not available
they contact the Executive (Maint) / Dy. Manager (Maint), and Executive
production in night shift to open the stores. The person arranges the spare
parts. If there is major breakdown and the spare part is not available
necessary procurement action is initiated by Dy. Manager (Maint) in
consultation with Dy. Manager (Materials).
 Technical guidance is provided by the Executive (Maint) / Dy. Manager
(Maint)
 The testing of the faulty equipment is carried out after problem solution.
 The trial run is carried out in conjunction with the production associates on
the machine.
 Then the machine handover to the production department.
 One Electrical & Mechanical Maintenance logbook is maintained to record
the entire breakdown and rectification job carried out in the plant.

7.4 Preventive Maintenance

 Preventive maintenance of the Equipment’s listed in the Annexure – 1 are


carried out as per schedule mentioned. The spares availability is planned
and executed as per clause 7.3.

The Preventive maintenance is carried out as per the checklists. If the Check list
compliance is less than 90% than it is not considered as the compliance to PM.For spare
parts,procedure of clause 7.3 is followed.
DOCUMENT: Procedure DOC. NO: TRYJ/MTCE-02
DIVISION: MMC, Jamshedpur REV. NO: 00
DEPARTMENT: Production/Maintenance DATE : 30.10.2004
SECTION: 7. 5. 1. 4 SHEET 3 OF 3
TITLE : Preventive and Predictive Maintenance

7.6 Predictive maintenance:

Predictive maintenance activities may include, as appropriate: dismantling of machines


for inspection and testing of parts; fluid analysis; infrared monitoring of circuits; vibration
analysis; replacement of fluids, filters, seals, gaskets, drive belts, and so forth .if required.

The Following matrix indicates the Condition monitoring of the equipments.

Activity Load Hydraulic Gearbox oil Pressure Earth


Testing oil oil testing. insultion testing resistance
Equip cleanliness testing testing
ment
Cranes Yeraly NA NA NA NA NA

Chain Pulley Yeraly NA NA NA NA NA


Blocks
Fortklift 3 Yearly NA NA NA NA NA
- TON
Hydraulic Power NA Monthly NA NA NA NA
Packs
Power NA NA NA Yearly NA NA
Transformers
Pressure NA NA NA NA Yearly NA
Vessels
Electrical Earth NA NA NA NA NA Yearly
Pits

Major Gear NA NA Yearly NA NA NA


Boxes

Note –
Vibration monitoring is done with a small metal stick. The basis of basis for
monitoring is daily observation and the persons experience.

7.7 Equipment Performance Monitoring

In order to identify equipment problems at an early stage and prevent breakdowns,


process equipment associates are instructed to monitor tool wear (done by operation),
process performance, vibration etc., and report any abnormal functioning to the Executive
(Maint) / Deputy Manager (Maint).

7.8 Maintenance Objectives

Increase in MTBF by 5% compared to last year, on individual workstations


Decrease in MTTR by 5% compared to last year, on individual workstations
Preventve maintenance compliance – 100 % machine Item wise.
Continuous Improvement - 4 Nos per month.
DOCUMENT: Procedure DOC. NO: TRYJ/MTCE-02
DIVISION: MMC, Jamshedpur REV. NO: 00
DEPARTMENT: Production/Maintenance DATE : 30.10.2004
SECTION: 7. 5. 1. 4 SHEET 4 OF 3
TITLE : Preventive and Predictive Maintenance

Weight Scales performance – within norms.

7.8.1 Evaluating and improving maintenance objectives

To evaluate effectiveness of the preventive maintenance program, Deputy manager


(Maint) monitors unscheduled equipment downtime, reviews the correlation between SPC
data and maintenance activities and collects and evaluates other such relevant
information and data, for example, tool wear, oil consumption. Data and trends related to
the effectiveness of preventive maintenance are periodically reported to the Head of
operations for review.

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