ABC
MASTER LIST OF MACHINES
LOCATION OF
S.NO NAME OF MACHINE CAPACITY MACHINE CODE
MACHINE
MAKE OF MACHINE REMARKS
PREPARED BY : APPROVED BY :
F/MNT/01 REV NO. 00 REV DATE -01.12.15
REV DATE -01.12.15
ABC MACHINE BREAK DOWN SLIP S.No.
M/C : DATE: SHIFT TIME
NATURE OF MAINTENANCE / BREAK DOWN :
SIGN.SHIFT INCHARGE(PRODN.)
ACTION TAKEN :
MACHINE HAND OVER DATE : TIME TOTAL B/D (MIN.) :
SIGN. MAINT TECHNICIAN VERIFICATION SIGN.(SHIFT INCHARGE) HOD MAINT.
F/MNT/02 REV NO. 00 REV DATE - 01.12.15
MACHINE HISTORY CARD
MACHINE NAME : MACHINE NO.
DATE OF TYPE DURATION OF PART CHANGE IF
S.NO. (BREAKDOWN/ PROBLEM WITNESSED ACTION TAKEN REMARKS
PROBLEM PRVENTIVE MAINT.) PROBLEM (HRS) ANY
F/MNT/03 REV. NO. 00 REV. NO. 01.12.15
PREVENTIVE MAINTENACE PLAN (YEAR 2016)
SR Machine
Machine Name FREQ. Jan 16 Feb. 16 Mar. 16 Apr. 16 May 16 Jun. 16 Jul. 16 Aug. 16 Sep 16 Oct 16 Nov 16 Dec 16 REMARKS
NO No.
SIX MONTH
SIX MONTH
Planned
Done as per Plan
PREPARED BY APPROVED BY
F/MNT/04 REV. NO. 00 REV DATE - 01.12.15
PM CHECK SHEET
MACHINE NAME- MACHINE NO. :
INSPECTION
S.NO. PM CHECK POINTS FREQUENCY ACTUAL OBSERVATION ACTION TAKEN REMARKS
METHOD
SIGN (PRODUCTION) : SIGN (MAINT.) :
F/MNT/05 REV DATE - 01.12.15
ABC
( PREVENTIVE MAINTENANCE CHECK LIST)
AREA INJECTION MOULDING MACHINE M/C NAME & NO.
TENTATIVE STANDARDS FOR CLEANING , LUBRICATION , INSPECTION & TIGHTENNING MONTH :-
S.N
WHAT ELEMENT STANDARD WHO WHEN HOW 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31
O
Tie bar ( should be free
1 CLEAN OPERATOR Daily
from dust )
Safety gate & upper
2 CLEAN OPERATOR Daily
CLEANING
surface of machine
Lower portion of M/C Base
3 CLEAN OPERATOR Weekly
& Vibration pad
4 Toggle Cleaning CLEAN OPERATOR Monthly
5 Hose pipe cleaning CLEAN OPERATOR Weekly
6 Ancillary equipment CLEAN OPERATOR Weekly
No dirt / dust &
7 Oiling / Greasing of tie bars OPERATOR Weekly
smooth functioning
LUBRICATION
No dirt / dust & Automati
8 Toggle lubrication OPERATOR AUTO
smooth functioning c
No dirt / dust &
9 Tie riods of injection unit OPERATOR Weekly
smooth functioning
Mould height adjustment No dirt / dust &
10 OPERATOR Weekly
gear smooth functioning
Full level / Mark
11 Lubrication tank oil level OPERATOR Daily
level
Full level / Mark
12 Hydraulic oil level OPERATOR Weekly
level
Limit switch front & back Out put Signal /
13 OPERATOR Daily
INSPECTION
door safety
14 System pressure gauges Min. & Max. OPERATOR Daily
No abnormal noise /
15 Hydraulic Motor MAINTENANCE Daily
no excess heat
No leakage /
16 Hose pipes MAINTENANCE Daily
damage
No leakage /
17 UPS / battery MAINTENANCE Weekly
damage
Should be below 50 OPERATOR /
18 Oil temperature MAINTENANCE Daily
0
C
OPERATOR /
19 Sound of clamping unit No abnormality MAINTENANCE Daily
OPERATOR /
20 Clamping bolt of moulds Should not be loose MAINTENANCE Weekly
TIGHTENING
OPERATOR /
21 Hose pipe joints Should not be loose MAINTENANCE Weekly
OPERATOR /
22 Ejector Should not be loose MAINTENANCE Weekly
Should not be loose OPERATOR /
23 Bolts of hydraulic cylinder MAINTENANCE Weekly
/ No oil leakage
NOTE : Mark( ) on completion of checklist of machine.
PREPAIRED BY: APPROVED BY:
F/MNT/06 REV NO. 00 REV DATE - 01.12.15
ABC MOULD BREAK DOWN SLIP S.No.
MOULD : DATE: SHIFT TIME
NATURE OF MAINTENANCE / BREAK DOWN :
SIGN.SHIFT INCHARGE(PRODN.)
ACTION TAKEN :
MACHINE HAND OVER DATE : TIME TOTAL B/D (MIN.) :
SIGN.MAINT TECHNICIAN VERIFICATION SIGN.(SHIFT INCHARGE) HOD MAINT.
F/MNT/07 REV NO. 00 REV DATE - 01.12.15
MOULD BREAKDOWN RECORD
PROBLEM REPORTED PROBLEM CORRECTED TOTAL
WHICH TARGET
S.NO. PROBLEM DETAIL ACTION PLANNED RESP. BREAKDO REMARKS
MOULD DATE WN (HRS)
DATE TIME DATE TIME
F/MNT/08 REV. NO. 00 REV. NO. 01.12.15
MASTER LIST OF MOULD
NEXT
VALIDATION VALIDATION
S.NO. MOULD NO. LOCATION CUSTOMER VALIDATION REMARKS
FREQ. DATE
DUE DATE
F/MNT/09 REV. NO. 00 REV. NO. 01.12.15
MOULD PREVENTIVE MAINTENACE PLAN
SR
Mould Number Mould Name Customer FREQ. Jan 16 Feb. 16 Mar. 16 Apr. 16 May 16 Jun. 16 Jul. 16 Aug. 16 Sep 16 Oct 16 Nov 16 Dec 16 REMARKS
NO
Planned
Done as per Plan
PREPARED BY APPROVED BY
F/MNT/10 REV. NO. 00 REV DATE - 01.12.15
MOULD PM CHECK SHEET
MOULD NUMBER- MOULD NAME - CUSTOMER :
INSPECTION
S.NO. PM CHECK POINTS FREQENCY ACTUAL OBSERVATION ACTION TAKEN REMARKS
METHOD
SIGN (PRODUCTION) : SIGN (MAINT.) :
F/MNT/11 REV NO. 00 REV DATE - 01.12.15
MOULD TRIAL REPORT
ABC
PURPOSE OF TRIAL : NEW MATERIAL AND VENDOR DEVELOPMENT Trial No: DATE:
Trial Team : Coustmer Name :
PART NAME : MACHINE NAME : MOULD SIZE: X X MM
RAW MATERIAL NAME: PC-ABS (BLACK)
PART NO: CAVITY NO: RAW MATERIAL GRADE: HR 5006A
SHOT WT(gm): PART WT(gm): RunnerWT(gm):
TEMPRATURE : ( ±10 C◦) COOLING SYSTEM : YES / NO
Zozzle (Z1) Z2 Z3 Z4 Z5 Z6 Normal Water Chilled Water Hot Water Hot oil Temp
COLOUR BLENDING : YES / NO MATERIAL PREHEATING : YES / NO
NAME OF MASTERBATCH : TIME IN HOURS( ± 30 MIN) :
% OF MASTERBATCH : TEMPRETURE ( ±10 C◦)
MOULD CLOSE MOULD OPEN
POSSITION PRESSURE SPEED TIME POSSITION PRESSURE SPEED TIME
STEP-1
STEP-2
MOLD SAFETY
Mold LOCK UP
TONNAGE
EJECTOR FORWORD EJECTOR RETURN HOT RUN. TEM. :±10˚C , (K/J)
STEP-1 STEP-2 STEP-3 STEP-1 STEP-2 STEP-3 ZONE1: ZONE6:
SPEED
±10 % ZONE2: ZONE7:
PRESSURE
±10 Kg/cm2 ZONE3: ZONE8:
POSSITION mm
ZONE4: ZONE9:
TIME ZONE5: ZONE10:
INJECTION HOLD ON CHARGING SUCK BACK
STEP-1 STEP-2 STEP-3 STEP-4 STEP-1 STEP-2 STEP-1 STEP-2 STEP-3 STEP-1 STEP-2
SPEED
±10 %
PRESSURE
±10 Kg/cm2
POSSITION mm
TIME
CORE SETTING :
IN SETTING PRESSURE SPEED TIME POSSITION CONDITION
CORE-1
OUT SETTING PRESSURE SPEED TIME POSSITION CONDITION
IN SETTING PRESSURE SPEED TIME POSSITION CONDITION
CORE-2
OUT SETTING PRESSURE SPEED TIME POSSITION CONDITION
INJECTION TIME:
INJ. SEQUENCE TIMER :N/A
HOLD ON TIME: GATE NO. 1 2 3 4 5 6 7 8 9
OPENING TIME:
DELAY
CLOSING TIME:
OPEN
COOLING TIME :
MODE (A/B)
TOTAL CYCLE TIME :
ANY OTHER REQUIRMENTS:
REMARK:
PREPARED BY APPROVED BY
F/MNT/12 REV NO. 00 REV DATE - 01.12.15
TOOL HISTORY CARD
DEPARTMENT TYPE OF TOOL DATE OF HAND OVER
PART NO. NO. OF CAVITY TOOL NO.
PART NAME PART WEIGHT (in grams) TOOL LIFE
RAW MATERIAL SHOT WEIGHT (in grams) CYCLE TIME
TOOL SIZE (L*W*H) YELD% MAX. SHOTS/RUN*
LOADING UNLOADING RECTIFICATION
DEFECT SIGN.
BALANCE RECPT.
DATE TIME SIGN. PROD. REMARKS DATE TIME REASION SIG. PROD QTY. PROD
TOOL LIFE DATE
TGT DATE ACT. DATE OBSERVWD /ACTION
TAKEN DM ENG.
* TOOL MUST BE TAKEN UP FOR PREVENTIVE MAINTENANCEAFTER THIS RUN.
F/MNT/13 REV NO. 00 REV DATE - 01.12.15
LIST OF CRITICAL SPARE PARTS
MACHINE SPARE PARTS
SL. MIN STOCK LEAD TIME FOR LOCATION IN
REMARKS
No MACHINE
LEVEL PROCUREMENT STORE
MACHINE NUMBER DESCRIPTION SPECIFICATION
DESCRIPTION
F/MNT/15 REV NO. 00 REV DATE - 01.12.15
