DOCUMENT: Procedure DIVISION: MMC, Jamshedpur DEPARTMENT: Production/Maintenance SECTION: 7. 5. 1.

4 TITLE : Preventive and Predictive Maintenance

DOC. NO: TRYJ/MTCE-02 REV. NO: 00 DATE : 30.10.2004 SHEET 1 OF 3

1 2 3 4 5 6

PURPOSE SCOPE REFERENCE DEFINITION ANNEXURES DISTRIBUTION

To establish the procedure for Preventive and Predictive Maintenance of Equipment. This is applicable to all the machinery of Tata Ryerson Limited, Jamshedpur. Section 7.5.1.4 ISO/TS 16949: 2002(E) Nil 3 Chief of Business Jamshedpur Unit. Manager (Quality and Process Control) Dy. Manager (Maintenance) Dy. Manager (Materials) Management. Representative

PREPARED BY DESIGNATION: SIGNATURE: DATE: 30.10.2004

ASHOK KUMAR Dy. Manager (Maintenance)

AUTHORISED BY: Ravi Inder Singh DESIGNATION: SIGNATURE: DATE:30.10.2004 Chief of Business Unit

DOCUMENT: Procedure DIVISION: MMC, Jamshedpur DEPARTMENT: Production/Maintenance SECTION: 7. 5. 1. 4 TITLE : Preventive and Predictive Maintenance

DOC. NO: TRYJ/MTCE-02 REV. NO: 00 DATE : 30.10.2004 SHEET 2 OF 3

7.0
7.1 7.2

Procedure
Deputy Manager (Maintenance) is responsible for the execution of this procedure. 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 Equipments 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 DIVISION: MMC, Jamshedpur DEPARTMENT: Production/Maintenance SECTION: 7. 5. 1. 4 TITLE : Preventive and Predictive Maintenance

DOC. NO: TRYJ/MTCE-02 REV. NO: 00 DATE : 30.10.2004 SHEET 3 OF 3

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 Equip ment Load Testing Yeraly Yeraly Yearly NA NA NA NA Hydraulic oil cleanliness NA NA NA Monthly NA NA NA Gearbox oil testing. NA NA NA NA NA NA NA oil insultion testing NA NA NA NA Yearly NA NA Pressure testing NA NA NA NA NA Yearly NA Earth resistance testing NA NA NA NA NA NA Yearly

Cranes Chain Pulley Blocks Fortklift 3 - TON Hydraulic Power Packs Power Transformers Pressure Vessels Electrical Earth Pits Major Gear Boxes

NA

NA

Yearly

NA

NA

NA

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 DIVISION: MMC, Jamshedpur DEPARTMENT: Production/Maintenance SECTION: 7. 5. 1. 4 TITLE : Preventive and Predictive Maintenance

DOC. NO: TRYJ/MTCE-02 REV. NO: 00 DATE : 30.10.2004 SHEET 4 OF 3

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.