Revisions Revisi On No. Revis Ed Pages Revision Description Date Of Revision

Department: Maintenance Issue Date: 01.03.06 Subject

DOC. No. : AV/ME/SOP/002 Page No. : Page 1 of 4 Revision No. & Date : (00)-01.03.06

Criticality Analysis.

Revisi Revis on No. ed Pages 0 0

REVISIONS Revision Description Original Issue

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01.03.06

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Department: Maintenance Issue Date: 01.03.06 Subject

DOC. No. : AV/ME/SOP/002 Page No. : Page 2 of 4 Revision No. & Date : (00)-01.03.06

Criticality Analysis.

1.0 Purpose To develop a methodology to ensure proper and cost effective maintenance of the plant equipments by adopting appropriate maintenance strategies to control the downtime. 2.0 Scope 2.1 Plant machineries, Engg. Stores. 2.2 Production & Maintenance Crew. 3.0 Responsibility 3.1 Operators & technicians: (1)Actively participate with the maintenance engineers to prepare the Asset lists, complete with their specifications. (2)Under stand the concept and importance of asset Priority in general as a Maintenance tool and in specific to his own machines. (3)Participate in the brain storming to prepare exhaustive lists of possible failures on his respective machines, the possible causes, remedies and the importance of the impact of such breakdowns. 3.2 Maintenance Engineers: (1) Prepare the Asset Lists with complete specifications by involving the respective operators. (2) Prepare an exhaustive list of possible failures on the machine. (3) Assign tentative priorities to the enlisted assets. (4) Assign tentative criticality ratings to the failures. (5) Identify and suggest the possible maintenance measures and strategies to avoid the failures.

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Factory Manager

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Department: Maintenance Issue Date: 01.03.06 Subject

DOC. No. : AV/ME/SOP/002 Page No. : Page 3 of 4 Revision No. & Date : (00)-01.03.06

Criticality Analysis.

3.4 HOD Engineering: (1)To organize trainings and ensure awareness and involvement of the maintenance crew in the Criticality Analysis. (2)Verify, update and finalize assets list and their specifications with the authenticated sources and with the physical verification of the machines. (3)Assign Asset Priority, based on the norms. (4)Finalize the criticality analysis by properly assigning the criticality to the causes of each failure. (5)Complete the Criticality analysis by assigning appropriate strategies and frequencies. (6)Get the Criticality Analysis, thus prepared, documented and available to the concerned operators. (7)Make the crew aware of the meaning and usages of the Criticality Analysis. 4.0 Definition Nil 5.0 Procedure 5.1 Information, Supplies and Equipment 5.1.1 Information 5.1.1.2 Machine History. 5.1.1.3 Operation & Maintenance manual from the OEM of the machines. 5.1.2 Supplies 5.1.3 Equipment 5.1.3.1 Stationery and Personal computer. 5.2Frequency Updation annually. 5.3 Step By step Instructions: 5.3.1.1 List out all Assets. And their sub assemblies. 5.3.1.2 Assign Asset Priority 3 to an asset without which the whole operation can come to stand still. 5.3.1.3 Assign Asset Priority as 2 to an asset which can partially hamper the activity but the line need not be stopped completely. Prepared By

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Department: Maintenance Issue Date: 01.03.06 Subject

DOC. No. : AV/ME/SOP/002 Page No. : Page 4 of 4 Revision No. & Date : (00)-01.03.06

Criticality Analysis.

5.3.1.4 Assign Asset Priority as 1 to an asset which have its standby arrangement, and the system did not get affected by its stoppage. 5.3.1.5 Complete Asset Master by adding all the relevant information about the equipment. 5.3.1.6 List out all possible failures and their causes for all the machines. 5.3.1.7 Prioritize the causes of the possible failures on the basis of severity of the faults, 5.3.1.8 Assign Failure criticality as 3 if the failure is very severe and can stop the whole process for very long times. 5.3.1.9 Assign Failure criticality as 2 if the breakdown can be rectified with moderate inconvenience and time requirement. 5.3.1.10 Assign Failure Criticality as 1 if the failure is minor in nature and can be rectified easily. 5.3.1.11 Decide and list down the remedy and the possible strategic maintenance to avoid down time due to the listed out failure. 5.3.1.12 Fix up the frequency of the maintenance measures for the criticalities identified.

6.0 Documentation: Assets master records 7.0 References Maintenance checklist

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Factory Manager

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