Operational Procedure MIYOSHI PRECISION (MALAYSIA) SDN BHD
Equipment Maintenance
Operational Procedure : OP-6.3.1 Revision: 7 Page 1/7
Revision History
Rev No Details of Revision Date
00 Initial Release 01.01.02
01 Update the procedure to reflect the current practice 03.11.03
02 To update the procedures and to include environmental aspects 01.02.06
03 To update the procedure and to add-in TS16949 requirement as a
current practice. Additional clause for 3 Predictive maintenance
(3.1, 3.2, 3.3, 3.4, 3.5 &3.6), 4 Management of production tooling 28.02.07
(4.1, 4.2, 4.3, 4.4, 4.5 & 4.6), 5 Equipment & tooling performance
monitoring (5.2)& 7 Plant, facility and equipment planning (7.1,
7.2 & 7.3)
04 To update the procedure and to add-in Revision History as a front 30.08.07
page for procedure.
05 Upgrade to ISO 9001:2008 requirement 14.10.10
06 Changes at approval Authorities and other minor amendments 13.12.10
07 Changes at approval Authorities and other minor amendments 03.05.11
Approval Authorities
Prepared Reviewed Reviewed Reviewed Approved By
By By By By
Name Kala Allan Teen Nicole Lee S.H.Yu C.A.Tan
Date 03.05.2011 03.05.2011 03.05.2011 03.05.2011 03.05.2011
Designation Doc. Cont. EMR OSHMR QMR GM
Signature
Responsible Outline of Procedure Interfaces
Equipment Maintenance
Operational Procedure : OP-6.3.1 Revision: 7 Page 2/7
Production/QA/Tool Room Personnel Machine/Equipment/Tooling
Identify key processes
machines and equipments
Maint./Tool Room/Prod. Personnel Preventive Maintenance Schedule Daily Preventive Maintenance C/List
Compressor Preventive Maintenance
Maint./Tool Room/Prod. Personnel Machine abnormal function
Machine and equipment
performance monitoring Inspection Results
Maint./Tool Room/Prod. Personnel Corrective Maintenance Need Tool Repair Record
Maint./Tool Room/Prod. Personnel Carry out Corrective Maintenance Tool Services Report
Maint/Tool Room/Prod. Personnel Corrective Maintenance by Contractor Service Report from Contractor
Machine/tooling/equipment verification
Tool Room/QA Personnel Tool Repair Record
I PURPOSE
The purpose of this procedure is to provide for a system and instructions, and to
assign responsibilities for the maintenance of key process equipment.
Equipment Maintenance
Operational Procedure : OP-6.3.1 Revision: 7 Page 3/7
II APPLICATION
This procedure applies to process machines, factory and office equipments, crane,
forklift, lift trucks, toolings and information system.
III RESPONSIBLE DEPARTMENT
This procedure concerns Production, Maintenance, QA and Tool Room Departments.
IV PROCEDURE
1. Key process equipment
1.1 Production, QA and Tool Room Personnel are responsible for identifying key process
equipment and machines to be included in a formal, planned preventive maintenance
program.
1.2 At a minimum the program must include those machines that are critical for
maintaining continuing process capability (i.e., uninterrupted production flow) and
those machines or equipment breakdown of which could adversely impact products
quality and environment, safety & health.
1.3 Maintenance personnel are responsible for maintenance on the production
machineries and environmental protection equipment. For the maintenance of the
building such as painting, repair of roof leaking, crane & etc, it shall be carried out as
when required by external vendor. The co-ordination works shall be done by
maintenance department.
1.4 For maintenance if forklift and lift truck and other material handling equipments, it
shall be done by external vendor as and when required. The Co-ordination works
shall be done either Warehouse or Production departments.
1.5 For the maintenance of the information system (e-mail server), it shall be done by
HQ in Singapore.
1.6 For the maintenance of office equipment, it shall be done by external vendor as and
when required. The co-ordination works shall be done by Administration department.
1.7 Tool room personnel are responsible for maintenance on the tooling in good
condition.
Equipment Maintenance
Operational Procedure : OP-6.3.1 Revision: 7 Page 4/7
2. Preventive maintenance plan and schedule
2.1 For each identified key process equipment, Maintenance, Tool Room and Production
Personnel prepare a machine preventive maintenance plan and schedule. The plan
defines the scope and frequency of routine maintenance activities and inspections.
2.2 The plan is established based on equipment/tooling manufacturer's recommendations
and experience with equipment reliability. Where equipment manuals specify
maintenance requirements, the manuals may be used directly, eliminating the need
for the maintenance plan.
2.3 All key equipment and machines included in the maintenance program are inspected
and serviced at prescribed intervals. Preventive maintenance activities may include,
as appropriate: dismantling of machines/tooling for inspection of parts; fluid level;
replacement of fluids, lubricants, filters, seals, gaskets, drive belts, and so forth.
2.4 Inspection, maintenance and repair activities are recorded in Daily Maintenance
Check List (Machine) or Tool Repair Record. At a minimum, an entry in the log
includes: classification of the activity (inspection, maintenance, or repair); description
of what was done: listing of replaced parts and/or supplies; and when relevant, test
results.
2.5 Maintenance personnel shall coordinate with Production Planning and Control to plan
for the Compressor Preventive Maintenance.
2.6 Whenever new equipment/tooling is procured, Maintenance / Production / Tool
Room personnel shall update it onto the above preventive plan and schedule.
2.7 After the maintenance, Maintenance, Production personnel shall initiate on the
preventive plan and schedule as record evidence, while Tool Room Personnel
initiates Tool Service Report for records.
3 Predictive Maintenance
3.1 Predictive Maintenance is based on process data aimed at the avoidance of
maintenance problems by predication of likely failure modes.
3.2 Predictive Maintenance in Miyoshi Precision (Malaysia) Sdn Bhd include tool life
monitoring, change of hydraulic & lubricant oil for metal stamping machine based on
yearly, service of air compressor based on number of operating hours (4000 hours).
Equipment Maintenance
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3.3 Tool life monitoring shall be done by production based on daily accumulated
production output. Predefined tool life in term of allowable quantity produce for each
tooling before the next service shall be identified in tool life record.
3.4 Once the accumulated production quantity approaching the next service quantity,
production shall issue Tool Service Report (Blue Color) to Tool Room for
notification of tooling service request.
3.5 For tooling, once the next service quantity reach the limit and can’t be down for
service due to busy production schedule, tool room technicians or supervisor shall
discuss with production for the most suitable time frame to down the toolings for
maintenance or services. Meanwhile QC will perform in process measurement &
inspection to ensure the part conformity is achieved.
3.6 Pre-defined allowable operating hours for compressor & change of hydraulic oil shall
be establish and monitored closely by maintenance.
4. Management of Production Tooling
4.1 During storage of tooling, they shall be persevered to prevent damage & rusty .Each
tooling will be applied with lubricants oils to prevent rusty. Handling of tooling shall
be done by designated trained tooling personnel.
4.2 In case of tooling being transferred to contractor for modification, tooling movement
shall be indicated in the delivery note .Delivery note shall be clearly indicated lead
time for the tool modification. If the tooling transfer to sub-con for production will
be indicated in Tooling Master List.
4.3 Tooling sub-con shall be selected & monitored based on Supplier Evaluation OP
7.4.1.
4.4 When there is tooling modification relevant documentation such as tooling drawing
and relevant spec shall be revised accordingly by person in charge.
4.5 Once there is order for inactive tooling (more then 1 year), usual procedure shall be
Equipment Maintenance
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followed such as first piece confirmation by QC.
4.6 Tooling status such as waiting for repair, completed repair & etc shall be monitored
& indicated on Tool Repair Record.
5. Equipment & Tooling performance monitoring
5.1 In order to identify equipment problems at an early stage and prevent breakdowns,
process equipment operators are instructed to monitor tool wear, process
performance, vibrations, etc., and report any abnormal functioning or sound to their
section head or supervisors.
5.2 Maintenance performance objective such as tooling down time machine down time
shall be monitored and evaluated regularly. Improvement action shall be trigger if
necessary.
6. Equipment performance monitoring
6.1 In order to identify equipment problems at an early stage and prevent breakdowns,
process equipment operators are instructed to monitor tool wear, process
performance, vibrations, etc., and report any abnormal functioning or sound to their
section head or supervisors.
7. Corrective Maintenance
7.1 Production personnel shall inform tool room personnel immediately all the
breakdown of tooling respectively by issuing Tool Service Report.
7.2 Maintenance / Production / Tool Room personnel shall carry out necessary repair to
put the machine or equipment back into normal running condition. If beyond his
capability to repair, he shall then arrange external contractor to do.
7.3 Upon completion of repair, Tool Room personnel shall issue Tool Repair Record to
capture the breakdown details.
7.4 Tool Room personnel shall update the Tool Repair Record after corrective
maintenance and submit the first piece to QA verification, where applicable.
7.5 Tool Room personnel shall maintain the stock of tooling spare parts to ensure the
necessary spare parts are available at all time.
Equipment Maintenance
Operational Procedure : OP-6.3.1 Revision: 7 Page 7/7
7.6 Control of Contractor & Maintenance Waste
7.6.1 Maintenance / relevant dept shall ensure contractor has competency and
awareness to prevent environmental pollution, injury & ill health when carry
out the maintenance activities.
7.6.2 Maintenance waste shall be segregated and disposed as per the EOP-1.5.1
Waste Management.
8 Plant, facility & Equipments Planning
8.1 Each year management shall use team approach for developing plant, facility &
equipments plans.
8.2 The plan shall cover plant renovation, commission of new machine, upgrade of new
machine, improvement of plant layout to optimize material travel, handling and value
added use for floor space, smooth material flow, etc
8.3 Project Gantt chart shall be establishing to keep track the pre identified activity.
Evaluation shall be carried out to access the effectiveness of improvement
V RECORDS
The following records shall be properly maintained by respective personnel as per
OP-4.2.4 Control of Records
a. Daily Maintenance Check List (Machine).
b. Compressor Preventive Maintenance.
c. Tool Repair Records
d. Tool Service Report
VI ASSOCIATED DOCUMENTS
Operational Procedure OP-7.5.2 Work Instruction
Operational Procedure EOP-1.5.1 Waste Management
Equipment Maintenance
Operational Procedure : OP-6.3.1 Revision: 7 Page 8/7
VII APPENDIX
Nil
