sop for Preventive Maintenance of Compression Machine

1.0 Objective
To lay down a procedure for the Preventive Maintenance of Compression Machine.
2.0 Scope
This Standard Operating Procedure is applicable for Preventive Maintenance of all Compression Machines to be followed at formulation plants
3.0 Responsibility
3.1 Officer / Executive Engineering shall be responsible for the execution of this procedure.
3.2 Engineering Manager shall be responsible for the compliance of this SOP.
3.3 Head QA/designee shall be responsible for the compliance of this SOP.
4.0 Abbreviations and Definitions
SOP : Standard Operating Procedure
No : Number
QA : Quality assurance
Qty : Quantity
St : Station
ER : Engineering
5.0 Procedure
5.1 General Conditions
5.1.1 Refer the master plan of preventive maintenance.
5.1.2 Equipment shall be available for preventive maintenance.
5.1.3 Clean oil / grease stains & remove unwanted material, spares after completion of work .
5.2 Precautions
5.2.1 Use necessary safety wears, while doing the work.
5.2.2 Ensure covers & guards are properly fixed.
5.3 Procedure for Preventive Maintenance of Compression Machine.
5.3.1 Ensure that electrical supply is in off position in main panel and display “Under Maintenance” Board on the panel board and inform all the concerned.
5.3.2 Operator or above has to ensure and verify the check points for the preventive maintenance as shown in the Annexure – 1,2 and 3 of this SOP.
5.3.3 After the completion of preventive maintenance, check the machine for smooth operation.
5.3.4 Remove “Under Maintenance” Board on the panel board after completion of the maintenance.
5.3.5 The operator / technician who perform the job will enter his name / sign in “DoneBy” Column and responsible Engineer/ Officer will put sign in “Checked by” column Department head will review the record every month.
5.3.6 Quarterly maintenance will include the jobs of monthly maintenance, half yearly Maintenance will include the jobs of monthly and quarterly maintenance.
5.3.7 Quarterly Preventive Maintenance is to be carried out as per the following check points:
5.3.7.1 Check the force feeder, motor & gear box for normal functioning. Check the Worm wheel & worm shaft, if worn out, replace it.
5.3.7.2 Check the force feeder impeller blades for normal free rotation. (If not proper, Check side clearance, check bearings, if worn, replaces and realigns the impeller Blades.
5.3.7.3 Check all adjustment rollers of tablet weight, thickness working (If not Check Adjusting nuts on the tie rods, check drive key, if parts are worn, replace Parts).
5.3.7.4 Check the working of automatic intermittent lubrication system. (If not Satisfactory, check oil level in the reservoir, check if the tubing is punctured, Replace the part). (Oil used is Enclo-68).
5.3.7.5 Check the Power pack assembly for normal functioning. (If not satisfactory).
5.3.7.6 Check the oil level in the reservoir through the oil level indicator). (Oil used is Enklo-32)(Note: Oil level is checked when the overload is set at zero pressure).
5.3.7.7 Check the clutch assembly for proper engagement/disengagement. (If any of the Parts/pads of the clutch assembly has worn, repair/replace it).
5.3.7.8 Check the free movement of compression rollers.
5.3.7.9 Check the all electrical terminal connections and tighten the same.
5.3.7.10 Check the variable speed pulley/belt for proper functioning (if the pulley is worn out, remove it & replace it, ensure that the pulley is lubricated). Also checks the belt for any wear/tear if needed replace the belt. (Ensure proper alignment in between drive pulley & driven pulley.)
5.3.7.11 Check the pressure adjustment assembly.(If any of the part is worn out, replace it).
5.3.7.12 Check belt pads/oil cups used for lubrication of punches.
5.3.7.13 Check the proper earthing.
5.3.8 Half Yearly Preventive Maintenance is to be carried out as per the following check points.
5.3.8.1 Check the main gear box/motor for normal operation. (If not proper, check the Bearings if worn replace it else lubricate them, check worm gear if worn out, Advisable to replace it). Top up Enklo-68 gear box oil in Gear box.
5.3.8.2 Check all interlocks of the machine for proper operation.
5.3.8.3 Check the electrical panel for any loose connection.(If observed tightened.
5.3.8.4 Check the all electrical controls, switches for normal working. (If observed).

6.0 Forms and Records
6.1 Quarterly Preventive Maintenance Check List of Compression Machine
6.2 Half Yearly Preventive Maintenance Check List of Compression Machine-
7.0 Distribution
7.1 Master copy – Documentation Cell (Quality Assurance)
7.2 Controlled copies – Engineering Department

sop for Preventive Maintenance of Compression Machine

sop for Execution of Preventive Maintenance

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