Procedure for Tool, Fixture & Gauge maintenance in manufacturing

Purpose:

This Procedure is to explain and understand the steps of attending to Tool, Fixture and gauge maintenance.

Scope:

• To ensure the Tool, Gauge and Fixture list is available and updated as on date
• This procedure covers the planning, monitoring & controlling of maintenance operations.
• To ensure timely inspection and safety of Tools, Gauges and Fixtures.
• To ensure that all testing and measuring equipment available for maintenance should be calibrated periodically.

Responsibility:

Tool maintenance In-charge is responsible for all the activities on time.

Procedure:

Infrastructure and availability of Resources:

• Prepare a master list of Tools, Gauges and Fixture
• Tool, Gauge and Fixture location should be mentioned in the List.
• The list should be updated at every three months for any deletion /addition.

Identification and Traceability of Tool, Fixture & Gauge:

• All tools, Gauges and Fixtures should have Unique identification nos. for easily traceable at the shop floor like any of as Model and operation No.
• Ensure identification is marked on every Tool, Gauge and Fixture.

Preventive Maintenance of Tool, Fixture & Gauge:

• To ensure that Tool, Gauge and Fixture preventive maintenance schedule is prepared
• To ensure that preventive maintenance parameters are defined for all the Tools, Gauges and Fixtures.
• To ensure preventive maintenance is done as per the schedule defined based on no. of stock/production.
• If any problem is found during the preventive maintenance, Tool, Gauge and Fixture should be repaired in-house if possible or immediately call to the external agency without any delay and duly inform to Tool Maintenance Head.
• If not repaired please put a tag under maintenance.
• The work carried out is recorded in the prescribed format.

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Breakdown Maintenance of Tool, Fixture & Gauge:

• A Verbal Intimation and Breakdown Slip is made from the respective department to the Tool Maintenance Technician regarding the breakdown of the Tool, Gauge and Fixture
• The Tool Maintenance Shift Technician will immediately go and assess the problem. At this time, he will organize manpower to attend to the problem on a priority basis. He will communicate the expected time of completion of work. Also if more than one breakdown is to be attended then priority is taken from HOD Maintenance in consultation with the concerned departments
• Once work is done, the trial is conducted and the Breakdown Maintenance of Tool, Gauge and Fixture are to Production after successful running. If some temporary arrangement is made to run the Breakdown Maintenance of the Tool, Gauge and Fixture at this particular point of time due to production requirements or other reasons then the same is communicated to the Production and Quality In charge.
• If the problem is not rectified in-house, immediately call the external agency without any delay and duly inform to Tool Maintenance Head.
• The work carried out is recorded in the prescribed format.

Breakdown Analysis:

• Breakdown analysis will be done for top 1 breakdowns & in case of repetitive (more than 4 times.) & more than 2hrs.
• Horizontal deployment (if applicable) is also to be ensured for the corrective action & preventive action taken against the breakdown.

Spare Parts Procurement and Inventory:

• A record is maintained for die spare inventory, consumption, Lead time and procurement.