Quality System Procedure Document No QSP-05 R2

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Process: Maintenance of Infrastructure and TPM
12.7.2018
Process Owner: Maintenance Manager Issue Date
PSPL
Approved By: MD Control

Step Activity Performed by Inputs Outputs

1.1 Identify equipment’s and utilities Maintenance Equipments used (process List of equipment’s in Annexure 1
Manager equipments, Handling equipment’s &
utilities,)
1.2 Identify Information and computing Maintenance Servers, Desktops, laptops, printers, List of equipment’s in Annexure 2
systems Manager
2 Prepare maintenance plan Maintenance  Past experience Preventive maintenance plan. Annexure 1
Manager  Maintenance recommendations
 Maintenance methods
 Agencies
3 Carry out daily PM checks Operator  Check list(QSF-05-01) Filled checklist

4 Carryout/ coordinate preventive Maintenance  Preventive maintenance plan  Preventive maintenance records/ Service
maintenance activities assistants/  PM schedule reports
Operators  Critical Spares Used  List of Critical spares in DS-05-01
Carryout predictive maintenance Maintenance  As per Annexure:1 & 4  Filled checklist(QSF-05-03)
activities Assistants/  As per checklist maintained for
5* Operators applicable equipment

6.1 Carry out/ coordinate breakdown Maintenance  Process Equipments under  Breakdown Register of process
maintenance activities Assistants/ breakdown equipment’s (QSF-05-04)
Operators  Breakdown history  Service reports
6.2* Carry out periodic Overhauling &Take Maintenance  periodic overhauling as per  Decisions on overhauling
decisions on Overhauling Manager Annexure:1 in (QSF-05-02)
requirements  Cost effectiveness of overhaul

QSP-05 R2
 Total Productive maintenance
1 Identify critical equipments for TPM Maintenance  Process cannot be outsourced List of equipment’s for TPM
Manager  No stand by equipment
 Utilization is high (identified Annex 3)

2 Identify replacement parts / spares Maintenance  Recommendations in Equipment  Spares required (DS-05-01)
Manager manual/ manufacturer
 Breakdown history
 Time to obtain spares
3 Define maintenance objectives and Maintenance  Breakdown hours  Maintenance objectives and targets
targets Manager  OEE  (DS-05-02)
 MTTR & MTBF(QSF-05-05)

4 Conduct awareness program HR  Persons concerned Training records

 methodology to be followed
 Equipments for TPM

5 Conduct study of existing performance Maintenance  Study plan  Results of study

Manager  recording format (QSF-05-05)  OEE of equipments

6 Identify opportunities for Maintenance Analysis of:  Targets for OEE

improvement Manager  Actions plan for implementation
 Equipment downtime
 speed losses
 Quality losses
7 Implement actions Maintenance  Actions plan for implementation  Implemented actions
Manager  OEE study  OEE results
 Review in Management review

8 Standardize activities Maintenance  Implemented actions  Modified work instructions

Manager  Monitoring of results over time

QSP-05 R2
Annexure 1: List of equipment’s Cum Preventive maintenance, Predictive maintenance & TPM

*Predictive Maintenance *TPM *Overhauling

Preventive maintenance plan
plan Plan freq
Equipment
# Equipment Description Agency Methods Frequency * Predictive * Predictive
Code
maintenance maintenance
Methods freq

1 Sheet Cutting Machine SCM-01 Self PPM-01 QUARTERLY ----- ----- ----- -----

2 SHEET Shearing MACHINE SSM-01 Self PMM-02 QUARTERLY ----- ----- ----- -----

3 Roll Cutting Machine RCM-01 Self PMM-03 QUARTERLY ----- ----- ----- -----

4 SCREEN EXPOSURE UNIT SEU-01 Self PMM-04 QUARTERLY ----- ----- ----- -----

5 SCREEN WASHING BOOTH SWB-01 Self PMM-05 QUARTERLY ----- ----- ----- -----

6 SCREEN DRYING OVEN SDO-01 Self PMM-06 QUARTERLY ----- ----- ----- -----

7 SCREEN EXPOSURE UNIT-2 SEU-02 Self PMM-07 QUARTERLY ----- ----- ----- -----

8 SCREEN WASHING BOOTH-2 SWB-02 Self PMM-08 QUARTERLY ----- ----- ----- -----

9 SCREEN DRYING OVEN-2 SDO-02 Self PMM-09 QUARTERLY ----- ----- ----- -----

10 INK MIXING STIRRER-1 IMS-01 Self PMM-10 QUARTERLY ----- ----- ----- -----

11 GRINDING MACHINE PMM-11 QUARTERLY ----- ----- ----- -----

Self
SQUEEGE GMS-01

12 PRINTING MACHINE SAKURI PMS-01 Self PMM-12 QUARTERLY PRM-01 Yearly once Monthly 3 years once

13 PRINTING MACHINE SAKURI PMS-02 Self PMM-13 QUARTERLY PRM-02 Yearly once ----- 3 years once

14 PMS-03 Self PMM-14 QUARTERLY PRM-03 Yearly once ----- 3 years once
PRINTING MACHINE

QSP-05 R2
 Cylindrical SAKURI

15 PRINTING M/C FLAT BED PMFB-01 Self PMM-15 QUARTERLY ----- ----- ----- -----

16 PRINTING M/C FLAT BED PMFB-02 Self PMM-16 QUARTERLY ----- ----- ----- -----

17 PRINTING M/C FLAT BED PMFB-03 Self PMM-17 QUARTERLY ----- ----- ----- -----

18 PRINTING M/C FLAT BED PMFB-04 Self PMM-18 QUARTERLY ----- ----- ----- -----

19 PRINTING M/C FLAT BED PMFB-05 Self PMM-19 QUARTERLY ----- ----- ----- -----

20 PRINTING M/C FLAT BED PMFB-06 Self PMM-20 QUARTERLY ----- ----- Monthly -----

21 LAMINATING MACHINE LM-01 Self PMM-21 QUARTERLY ----- ----- ----- -----

22 LAMINATING MACHINE LM-02 Self PMM-22 QUARTERLY ----- ----- ----- -----

23 LAMINATING MACHINE LM-03 Self PMM-23 QUARTERLY ----- ----- ----- -----

24 PUNCHING MACHINE PM-01 Self PMM-24 QUARTERLY ----- ----- ----- -----

25 PUNCHING MACHINE PM-02 Self PMM-25 QUARTERLY ----- ----- ----- -----

26 PUNCHING MACHINE PM-03 Self PMM-26 QUARTERLY ----- ----- ----- -----

27 PUNCHING MACHINE PM-04 Self PMM-27 QUARTERLY ----- ----- Monthly -----

28 PUNCHING MACHINE PM-05 Self PMM-28 QUARTERLY ----- ----- ----- -----

29 PUNCHING MACHINE PM-06 Self PMM-29 QUARTERLY ----- ----- ----- -----

30 PUNCHING MACHINE PM-07 Self PMM-30 QUARTERLY ----- ----- ----- -----

31 ATLAS QUV M/C WEATHERO PMM-31 QUARTERLY ----- ----- ----- -----
Self
METER AM-01

32 TENSILE TESTING MACHINE TTM-01 Self PMM-32 QUARTERLY ----- ----- ----- -----

33 HUMIDITY CHAMBER HC-01 Self PMM-33 QUARTERLY ----- ----- ----- -----

QSP-05 R2
34 DOMING M/C -1 DM-01 Self PMM-34 QUARTERLY PRM-04 Yearly once Monthly 3 years once

35 DOMING M/C -2 DM-02 Self PMM-35 QUARTERLY ----- ----- ----- -----

36 ELECTRICAL PANNEL BOARD EPB-01 Self PMM-36 QUARTERLY ----- ----- ----- -----

37 SERVO STABILISER SS-01 Self PMM-37 QUARTERLY ----- ----- ----- -----

38 OVEN O-01 Self PMM-38 QUARTERLY ----- ----- ----- -----

39 DRYER UNIT DR-01 Self PMM-39 QUARTERLY ----- ----- ----- -----

40 DRYER UNIT DR-02 Self PMM-40 QUARTERLY ----- ----- ----- -----

41 DRYER UNIT DR-03 Self PMM-41 QUARTERLY ----- ----- ----- -----

42 DRYER UNIT DR-04 Self PMM-42 QUARTERLY ----- ----- ----- -----

43 DRYER UNIT DR-05 Self PMM-43 QUARTERLY ----- ----- ----- -----

44 DRYER UNIT DR-06 Self PMM-44 QUARTERLY ----- ----- ----- -----

45 AIR COMPRESSOR 1 AC-01 amc PMM-45 QUARTERLY ----- ----- ----- -----

46 AIR COMPRESSOR - 2 AC-02 amc PMM-46 QUARTERLY ----- ----- ----- -----

47 GENERATOR 250KVA G-01 amc PMM-47 QUARTERLY ----- ----- ----- -----

48 AIR INLET BLOWER AIB-01 amc PMM-48 QUARTERLY ----- ----- ----- -----

49 AIR INLET BLOWER AIB-02 amc PMM-49 QUARTERLY ----- ----- ----- -----

50 AIR OUTLET BLOWER AOB-01 amc PMM-50 QUARTERLY ----- ----- ----- -----

51 AIR OUTLET BLOWER AOB-02 amc PMM-51 QUARTERLY ----- ----- ----- -----

52 Plotter CUTTING M/C DCM-01 Self PMM-52 QUARTERLY ----- ----- ----- -----

53 Digital Flat bed Cutting M/c DFBC-01 Self PMM-53 QUARTERLY ----- ----- ----- -----

QSP-05 R2
54 ROUTER M/C 1 RM-01 Self PMM-54 QUARTERLY ----- ----- ----- -----

55 ROUTER M/C 2 RM-02 Self PMM-55 QUARTERLY ----- ----- ----- -----

56 ROUTER M/C 3 RM-03 Self PMM-56 QUARTERLY ----- ----- Monthly -----

57 ROUTER M/C 4 Roller RM-04 Self PMM-57 QUARTERLY ----- ----- ----- -----

58 UPS FOR Plotter UPS-01 amc PMM-58 QUARTERLY ----- ----- ----- -----

59 UPS FOR ROUTER UPS-02 amc PMM-59 QUARTERLY ----- ----- ----- -----

60 UPS FOR SAKURI UPS-03 amc PMM-60 QUARTERLY ----- ----- ----- -----

61 UPS FOR LIGHTING LOAD UPS-04 amc PMM-61 QUARTERLY ----- ----- ----- -----

62 UPS FOR LASER M/C UPS-05 amc PMM-62 QUARTERLY ----- ----- ----- -----

63 BOREWELL PUMP BP-01 Self PMM-63 QUARTERLY ----- ----- ----- -----

64 KROMEX FORMING M/C KFM-01 Self PMM-64 QUARTERLY PRM-05 Yearly once Monthly 3 years once

65 Neibling Forming M/C NFM-01 Self PMM-65 QUARTERLY ----- ----- ----- -----

66 LASER MACHINE-01 LSR-01 Self PMM-66 QUARTERLY ----- ----- ----- -----

67 LASER MACHINE-02 LSR-02 Self PMM-67 QUARTERLY ----- ----- ----- -----

68 LASER MACHINE-03 LSR-03 Self PMM-68 QUARTERLY ----- ----- ----- -----

69 LASER MACHINE-04 LSR-04 Self PMM-69 QUARTERLY ----- ----- ----- -----

70 LASER MACHINE-05 LSR-05 Self PMM-70 QUARTERLY ----- ----- ----- -----

QSP-05 R2
Annexure 2: List of Information system infrastructure
Preventive maintenance method Remarks
Sl. Equipment/ Remarks
Dept Processor Intel GHz RAM Hard Disk
No Machine Name
Agency Method Frequency
1 Mrutunjaya Design Intel Core2 Duo 2.93 GHz 3 GB 300 GB
2 Uthappa Design Intel Core2 Duo 2.66GHz 2 GB 200 GB
3 Shashikala Accounts Intel Core2 Duo 2.4 GHz 2 GB 256 GB
4 Wahab Accounts Intel Core2 Duo 2.4 GHz 2 GB 180 GB
5 Sunil Kumar Accounts Intel Core i3 CPU 3.10 GHz 4 GB 200 GB
6 Manjunath Accounts Intel Core2 Duo 2.9 GHz 2 GB 250 GB
7 Sumithra Marketing Intel Samsung Laptop 2.10 GHz 2 GB 500 GB
8 Router-1 Production Intel Core i3 CPU 3.10 GHz 4 GB 500 GB
9 Router-2 Production Intel P4 2.80 GHz 2 GB 80 GB
10 Router-3 Production Intel Core2 Duo 2.93 GHz 2 GB 180 GB
11 Digital 1 Production Intel Core2 Duo 2.2 GHz 2 GB 160 GB
Pinnacle ---- ----
12 Pradeep Production Intel Core2 Duo 2.66 GHz 2 GB 160 GB
13 Reddy Store Intel Core i3 CPU 3.30 GHz 4 GB 500 GB
14 Vasanth Production Intel Core i3 CPU 3.20GHz 4 GB 500 GB
15 Nikhil QA Intel Core i3 CPU 3.10 GHz 4 GB 500 GB
16 Sales Production Intel Core i3 CPU 3.07 GHz 4 GB 350 GB
17 Laser Cutting Digital Intel Core i3 CPU 3.07 GHz 2 GB 500 GB
18 Charan Production Intel Core i5 CPU 3.20 GHz 4 GB 1 TB
20 Mahadevswamy Maintenance Intel Core 2 Duo 2.66 Ghz 2 GB 500 GB
22 Girish QA Intel Core i3 CPU 3.07 Ghz 4 GB 500 GB
23 Design Design Intel Samsung Laptop 2.10 GHz 2 GB 500 GB
24 Doming Doming Intel Core i5 CPU 3 GHz 4 GB 500 GB

QSP-05 R2
25 Sumithra QA Intel Core i3 CPU 3.30 GHz 4 GB 500 GB

26 Wahab Accounts Intel Core 3.10 GHz 1 GB 160 GB

25 Lakshmi Accounts Intel Dell Laptop 2.10 GHz 2 GB 300 GB
26 Girish PA Intel Acer Laptop 2.10 GHz 2 GB 500 GB
27 Marketing Marketing Intel Core i3 CPU 3.10 GHz 4 GB 500 GB
28 NavaratnaRaju PM Intel Samsung Laptop 2.10 GHz 2 GB 500 GB
29 GururajAchari S Production Intel HP Laptop 2.40 GHz 2 GB 500 GB
29 Manu Kumar M R PPC Intel Dell Laptop 2.10 GHz 2 GB 300 GB
30 Chethan QC Intel I3 CPU 3 GHz 8 Gb 1 TB
31 HARISH QC Intel I3 CPU 2.40 Ghz 4 GB 1 TB

*Annexure 3: List of Equipment’s for TPM.

# Equipment Description Equipment Code

1 Printing Machine-Flat bed PMS-01

Sakurai 1

2 Die Cut Punching Machine PM-04

3 Router Machine-3 RM-03

4 Kromex Forming Machine KFM-01

5 Doming M/c DM-01

6 Printing Machine Flat bed PMFB-06

QSP-05 R2
*Annexure 4: List of Equipment’s for Predictive Maintenance

# Equipment Description Equipment Code

1 Printing Machine-Flat bed Sakurai 1 PMS-01

2 Die Cut Punching Machine PM-04

3 Router Machine-3 RM-03

4 Kromex Forming Machine KFM-01

5 Front Doming M/c DM-01

QSP-05 R2
 Quality System Procedure Document No QSP-05 R2
Page 12.7.2018

TITLE: Revision History Details Issue Date 5.6.2018

PSPL
Control

Rev Date Modification History Initiated By Reviewed By Approved By Release Date

1 5.6.2018 1. Point no: 5 & 6.2 inputs on Mahadev Swamy Prasad B.R Sumithra 5.6.2018
predictive maintenance & overhauling
in the procedure.

2. Annexure-1 frequency & plan for

Predictive maintenance and
overhauling.

2 12.7.2018 Adding up one more machine to Venkatesh Prasad Rakshith Sumithra 12.7.2018
monitor TPM (Printing M/c Flat bed –
PMFB-06) in Annexure-1 & Annexure-
3

QSP-05 R2