Plant Maintenance SOPs — Field Quick Guide

1. Breakdown Maintenance 🔧 Detailed Steps:

• 1. Technician logs the breakdown in the daily report during production.
• 2. If repair or replacement is needed, a Material Request Form (MR) is prepared.
• 3. Supervisor reviews the MR to confirm actual requirement.

2. Preventive Maintenance 🔧 Detailed Steps:

• 1. Technician and operator perform daily checks using designated checklists.
• 2. CLTI Form (Cleaning, Lubrication, Tightening, Inspection) is filled.
• 3. If fault found, process continues as Breakdown or External Repair.

3. Spares Management 🔧 Detailed Steps:

• Storekeeper prepares monthly inventory report.
• Good Receipt Note (GRN) entries, consumption, and adjustments are verified in ERP.
• Safe stock limits are reviewed.

4. Vendor Service Management 🔧 Detailed Steps:

• Supervisor maintains an Annual Maintenance Contract (AMC) Tracker with contract/service schedule data.
• Start of each month: upcoming services are reviewed and vendor notified.
• Vendor is reminded 1 week in advance with equipment and service details.

5. Employee Training Program 🔧 Detailed Steps:

• Maintenance Manager prepares an annual training plan based on skill gaps, new tech, and safety practices.
• Trainings scheduled for the year.
• Topics include CLTI, breakdown handling, spare management, safety.

6. Overhauling 🔧 Detailed Steps:

• Annual overhaul schedule created for off-season.
• Includes critical equipment needing cleaning, replacement, or alignment.
• List shared with Plant Manager for review.

7. External Repairs 🔧 Detailed Steps:

• If in-house repair is not possible, part is dismantled.
• Repair Request raised and ERP Gate Pass issued.
• Security stamps Gate Pass before part leaves.