SOP-02for Breakdown Maintenance

Standard Operating Orient Refractories Limited
Procedure
Issue No.01 Rev No.00
Issue date: 1st Revision Date: 1st SOP Doc No.: ORL/EM/SOP/01
Januaru'2016 Januaru'2016
Department: Electrical Activity: Break Down
Maintenance Maintenance
Title : SOP for Breakdown Maintenance
PURPOSE:To carry out Breakdown Maintenance of Plant and Machinery
SCOPE: All Electrical Maintenance activities carried out by Electrical Department
Input :
Sl. No. Inputs Source

1. Breakdown Slips Various Departments of ORL
2. Equipment History Card Electrical Maintenance
3. Tool Set Electrical Maintenance
4. Spares Stores and Electrical Maintenance
5. Consumables (Cotton Clothes, PVC Electrical Maintenance
Tape
6. Grease Gun Electrical Maintenance
7. PPE (Gloves, Helmet, Shoes, etc.) Electrical Maintenance
8. Machine Manuals Library/Electrical Department
9. Electrical Drawing Electrical Department
10. Formats, Files, Check lists, Log As issued to department
Books and Registers
11. Quality Manual, EMS Manual QMS and EMS Document issued to
Process flow chart department
RESPONSIBILITY:
Sl. No. Activity Responsibility

1. Reporting the breakdown maintenance Shift Sr. Foreman/Asst.
requirement Foreman/Supervisor
2. Receipt of Break Down Slip Charge Hand/Electrical
Foreman/Supervisor
3. Issue of Spares and Consumables Sr. Foreman/Asst.
Foreman/Supervisor (Elect.
Maintenance)
4. Carrying out of Maintenance Activities Charge Hand and Electrician
5. Receipt of Completion Certificate Charge Hand and Electrician
6. Filling of Records & log book Shift Charge Hand/Supervisor
DESCRIPTION OF ACTIVES:
Prepared by(HOD) Approved By (Head-Opn) Issued by(M R-QMS)
Signature Signature Signature

Procedure
1. Breakdown Maintenance
1. The Breakdown slip is received by the Charge Hand/Electrical
Foreman/Supervisor.
2. Shift Sr. Foreman/Supervisor/ Charge Hand visits the reported place and identify
the actual problem in the machine.
3. Shift Sr. Foreman/Supervisor assigns the jobs to Shift Charge Hand/Electrician
with information about the job.
4. Shift Charge Hand/Electrician prior to starting any job, displays the board,
“Machine under Breakdown Maintenance” on the operating panel and switches’
“OFF” the power of the machine.
5. Shift Charge Hand/Electrician properly cleans the working area.
6. Appropriate tools for carrying out the maintenance activities are taken by the Shift
Charge Hand/Electrician.
7. Sr. Foreman/Asst. Foreman/Supervisor based on the requirements identifies
appropriate spares and consumables and gets the same issued from the store by
filling up the Store issue voucher.
8. As per the requirement machine manuals are issued by the Sr. Foreman /
Supervisor from the Library.
9. As per the requirement machine electrical drawings are taken by the Sr.
Foreman/Supervisor from the electrical department.
10. For this, appropriate work instruction as given in the annexure to this SOP are
used for carrying out maintenance activities such as Dismantling of Equipment,
(Annexure 1), Assembly of Equipment (Annexure 2).
11. Supervisor ensures that the charge hand/electrician and other personnel involved
in this activity wears required PPEs (Gloves, Helmet, Shoes, and Mouth Mask,
etc.).
12. After break down job completion, the machine is trialed with machine’s (M/C)
operator/Supervisor.
13. If the machine is running properly, remove the Board “Machine under Breakdown
Maintenance” from the operating panel.
14. Collect all used items (such as used cloth, removed damage spare parts) from the
working area and dispose in the proper identified areas.
15. The waste generated from the maintenance activities is managed as per OCP on
waste management/ Hazardous waste management.
16. The signature of respective department’s HOD/supervisor is obtained after break
down job completion for closing breakdown slip.
17. Details in the log book and respective equipment’s history cards are recorded by
Sr. Foreman/Supervisor.
18. Breakdown slip is properly pinned-up for further record in the Pin Stand.
CROSS REFERENCE :

Procedure
Annexure 1 - Work Instruction for Dismantling of Equipment

Annexure 2 - Work Instruction for Assembly of Equipment
Output:
Sl. No. Output Location

1. Maintained Machine/Equipment Respective Departments
2. Filled Formats, Files, Check lists Electrical Department
and Registers
3. Logs and History Cards Electrical Department
4. Machine Availability Electrical Department
Annexure 1
Work Instruction for Dismantling of Equipment
1. Shutdown of machine/equipment in consultation with the user department’s authorized

person.
2. Shutdown of electrical panel of the equipment.
3. Display of equipment under electrical maintenance tag.
4. Appropriate tools for carrying out the maintenance activities are taken.
5. Ensure that the supervisor/charge hand/electrician personnel is involved in this activity.
6. Based on the requirements appropriate equipment/spares dismantling needs to be
carried out.

Procedure
Annexure 2
Work Instruction for Assembly of Equipment
1. Assembly of the Equipment.
 Shutdown of machine/equipment in consultation with the user department’s authorized

person.
 Shutdown of electrical panel of the equipment.
 Display of equipment under electrical maintenance tag.
 Appropriate tools for carrying out the maintenance activities are taken.
 Ensures that the supervisor/chargehand/electrician personnel involved in this activity
wears required PPEs (Gloves, Helmet, Shoes, and Mouth Mask etc.)
 Based on the requirements appropriate equipment/spares assembly to be carried out.
2. Test Run of the Equipment.

 Clean the equipment which is to be maintained.
 Appropriate tools for carrying out the maintenance activities are taken.
 Ensures that the supervisor/chargehand/electrician personnel involved in this activity
wears required PPEs (Gloves, Helmet, Shoes, and Mouth Mask etc.)
 Ensure that all connections have been screwed tight again.
 Check that all materials, tools, equipment, etc. that were required for maintenance and
repair work been removed from the materials testing machine's working area.
 Ensure all safety devices such as limit switches, proximity switches and the materials
testing machine's EMERGENCY OFF button in perfect working order.
 Ensure all of the above work must be first correctly done free of error before the
materials testing machine is to be used by the operating personnel.

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Standard Operating Orient Refractories Limited

Title : SOP for Breakdown Maintenance

PURPOSE:To carry out Breakdown Maintenance of Plant and Machinery

SCOPE: All Electrical Maintenance activities carried out by Electrical Department

Sl. No. Inputs Source

Sl. No. Activity Responsibility

Prepared by(HOD) Approved By (Head-Opn) Issued by(M R-QMS)

Signature Signature Signature

Signature Signature Signature

Annexure 1 - Work Instruction for Dismantling of Equipment

Sl. No. Output Location

1. Shutdown of machine/equipment in consultation with the user department’s authorized

Prepared by(HOD) Approved By (Head-Opn) Issued by(M R-QMS)

Signature Signature Signature

1. Assembly of the Equipment.

 Shutdown of machine/equipment in consultation with the user department’s authorized

2. Test Run of the Equipment.

Prepared by(HOD) Approved By (Head-Opn) Issued by(M R-QMS)

Signature Signature Signature

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