Integrated Management System: Departmental Functional Manual

QMS,EMS& OHAS
DEPARTMENTAL Shaurya Cement

FUNCTIONAL MANUAL
Industries Private
MECHANICAL Limited
DEPARTMENT
INTEGRATED MANAGEMENT SYSTEM
Quality Management System,

Environmental Management System
&
Occupational Health &Safety Management System
Departmental Functional Manual
Department: MECHANICAL
Document No. : SCIPL/MECH/DFM

Issue No. : 01
SHAURYA CEMENT INDUSTRIES PRIVATE LIMITED

MIRCHAIYA
SIRAHA DIST, NEPAL
Revision.00 Issue Date: 00/00/0000

Issue : 01 Page 1 of 40
QMS,EMS& OHAS
FUNCTIONAL MANUAL
Industries Private
MECHANICAL Limited
DEPARTMENT
Number Revision &

Sl. Description Section Code
of Pages Effective Date

QMS,EMS& OHAS
FUNCTIONAL MANUAL
Industries Private
MECHANICAL Limited
DEPARTMENT
1. Table of contents SCIPL/MECH/DFM/1 02

2. Revision Record Sheet SCIPL/MECH/DFM/2 01
3. Abbreviations SCIPL/MECH/DFM/3 02
4. List of Controlled Copy Holders SCIPL/MECH/DFM/4 01
5. Dept. Organization chart SCIPL/MECH/DFM/5
6. Responsibility and authority SCIPL/MECH/DFM/6
7. List of processes SCIPL/MECH/DFM/7 01
SCIPL/MECH/DFM/7.
8. Preventive inspection 03
1
SCIPL/MECH/DFM/7.
9. Corrective Maintenance 03
2
SCIPL/MECH/DFM/7.
10. Preventive maintenance 03
3
SCIPL/MECH/DFM/7.
11. Breakdown maintenance 03
4
SCIPL/MECH/DFM/7.
12. Planned modifications 03
5
Calibration of equipment / SCIPL/MECH/DFM/7.
13. 03
instruments 6
SCIPL/MECH/DFM/7.
14. Spares management 03
7
SCIPL/MECH/DFM/7.
15. Legal obligations compliance 03
8
16. Risks & Opportunities SCIPL/MECH/DFM/8 01
Environmental aspects register
17. including significant SCIPL/MECH/DFM/9 01
environmental aspects
Hazard Identification and Risk
18. Assessment (HIRA) register SCIPL/MECH/DFM/10 01
including significant hazards
19. Functional Objectives SCIPL/MECH/DFM/11 01
20. Records SCIPL/MECH/DFM/12 02
21. Action plan SCIPL/MECH/DFM/13 02

QMS,EMS& OHAS
FUNCTIONAL MANUAL
Industries Private
MECHANICAL Limited
DEPARTMENT
TITLE: REVISION RECORD SHEET
Previous
Current
Section Rev. No. & Brief Description of
Rev. No. & Effective
No. Effective Changes
Date
Date

QMS,EMS& OHAS
FUNCTIONAL MANUAL
Industries Private
MECHANICAL Limited
DEPARTMENT
TITLE: ABBREVIATIONS
Abbreviation Full Form

SCIPL Deccan Cements Limited
MECH Mechanical
DFM Department System Manual
NO Number
REV Revision
PCS Processes
QMS Quality Management System
EMS Environmental Management System
OHSMS Occupational Health & Safety Management System
IMS Integrated Management System
HOD Head Of Department
EHS Environment, Health & Safety
RR Risk register
AR Aspect register
TITLE: LIST OF CONTROL COPY HOLDERS

QMS,EMS& OHAS
FUNCTIONAL MANUAL
Industries Private
MECHANICAL Limited
DEPARTMENT
MANUAL DISTRIBUTION
Soft copy of Functional Manual in the form of PDF – Read only is kept in the intranet / share
folder of DCL for reference to authorized users.
Master Copy – hard copy is kept with IMS coordinator for reference to any user.

QMS,EMS& OHAS
FUNCTIONAL MANUAL
Industries Private
MECHANICAL Limited
DEPARTMENT
DEPT. ORGANIZATION CHART
RESPONSIBILITY AND AUTHORITY
DESIGNATION RESPONSIBILITY

QMS,EMS& OHAS
FUNCTIONAL MANUAL
Industries Private
MECHANICAL Limited
DEPARTMENT
Responsible for all work related to IMS within his area of control, e.g.:
 Approval of plans for Shutdown and Breakdown maintenance
 Annual maintenance contracts (AMC)
 Deciding KPIs and developing QMPs for the same.
 Making quality plans and adhering to those.
 Identification of non-conforming products and recording in prescribed
formats and taking action for its disposition. Similarly long term corrective
actions are decided.
 IMS non-conformities are identified and corrective actions are decided.
HOD (MECH)  Identifying changing aspects of operations and updating IMS accordingly.
 Active participation in IMS audit
 Participation in management Review Committee meeting.
 Suggesting ways to improve IMS related issues and minimization of waste
 Preparation of EMP’s for the department
 Identifying key environmental performance indicators of department and
monitoring for deviation
 Advising precautionary measures, registering/reporting relevant persons in
case of incidents / harmful effects
 Identification of HIRA and its updating.
DESIGNATION AUTHORITY
 Correspond with other top Management.

 Authorized to form committee/task force to carry out any specific activity.
 Authorized to finalize new contractor / system improvement plan and
HOD (MECH)
forward for management approval.
 To approve purchase requisitions related to mechanical maintenance through
stories manager.
Manager/
Assistant RESPONSIBILITY
Engineer
Supervising and ensuring that instructions regarding IMS issues are followed
by his sub-ordinates in the following:

QMS,EMS& OHAS
FUNCTIONAL MANUAL
Industries Private
MECHANICAL Limited
DEPARTMENT
 Schedule, Shutdown and Breakdown maintenance co-ordination with HOD.

 Assisting in Annual maintenance contracts
 Identification of non-conformities (including N.C. products) and reporting to
immediate superior and HOD.
 Deciding in consultation with immediate superior and departmental head,
actions to be taken in case of deviation from existing IMS standards.
 Making suggestions for actions to comply with legislation and measures for
reducing environmental impact.
 Identification of aspects and impacts of environmental hazards and its
updation.
 Ensuring proper disposal of wastes as per guidelines.
 Ensuring proper storage and handling of hazardous materials.
 Identification of HIRA and its updation
 Assist HOD on active participation in IMS audit
case of incidents/harmful effects.
DESIGNATION AUTHORITY
 Authorized to sign on Monthly reports and other MI's reports.

 To accept suggestions related to process improvement / Maintenance
practices / Safety and forward to apex committee for further reference and
Manager/
Assistant approval.
Engineer
 To prepare purchase requisitions related to instrumentation maintenance
through HOD.
Senior Engineer  Schedule, Shutdown and Breakdown maintenance co-ordination with

manager/assistant manager.
 Assisting in Annual maintenance contracts.

QMS,EMS& OHAS
FUNCTIONAL MANUAL
Industries Private
MECHANICAL Limited
DEPARTMENT
 Ensuring proper disposal of wastes as per guidelines.

 Ensuring proper storage and handling of hazardous materials.
 Identification of HIRA and its updation
 Assist manager/assistant manager on active participation in IMS audit
case of incidents/harmful effects.
 Allocation of work carried out with respect to section wise.
 Record manuals will be carried out with proper suggestion from
manager/assistant manager.
 Assisting work schedule & shift to manager/assisting manager.
AUTHORITY
 Authorized to sign on Monthly reports and other MI's reports.

 To accept suggestions related to process improvement / Maintenance
practices / Safety and forward to apex committee for further reference and
Senior Engineer
approval.
 To prepare purchase requisitions related to mechanical maintenance through
manager/assistant manager
 Schedule, Shutdown and Breakdown maintenance co-ordination with

Supervisors
Engineer/
 Reporting to Assistant manager/Senior Engineer.
Assistant
 To Co - Ordinate with the technicians while repairing the equipment’s
Engineer
 Spare Planning
 Department IMS Coordinator and supporting to Assistant Manager
 Awareness on IMS
AUTHORITY
Authorized to sign on Instrumentation Maintenance records.

QMS,EMS& OHAS
FUNCTIONAL MANUAL
Industries Private
MECHANICAL Limited
DEPARTMENT
RESPONSIBILITY
DESIGNATION
 Following the procedures, work instructions and providing the feedback

about the changes required if any.
 Follow the safety regulations imposed by SCIPL from time to time
 Ensuring the good health of equipment/machineries in production/utilities
departments.
Junior Engineer/  To Co - Ordinate with the technicians while repairing the equipment’s
Foreman Schedule, Shutdown and Breakdown maintenance co-ordination with
Supervisors.
AUTHORITY
 Authorized to sign on Mechanical Maintenance records.

 Reporting to section head .
General works will be recorded in general log book
 Reporting to Manager.
 To observe the work allotted to the workmen in the shift.
 Take a walk through inspection of all equipment in the shift.
Shift Engineer  Packer weights checking and correction.
 Work permit and risk assessment are issued to shift technicians.
 Coordinating section engineers in keeping the plant smooth running.
 Awareness on IMS.
AUTHORITY
TECHNICIAN  Following the procedures, work instructions and providing the feedback
about the changes required if any.

QMS,EMS& OHAS
FUNCTIONAL MANUAL
Industries Private
MECHANICAL Limited
DEPARTMENT
 Assisting section Engineers and superiors in making quality plans

 Informing immediate superiors on identified non conformities w.r.t to
product and IMS.
 Follow the safety regulations imposed by SCIPL from time to time
case of incidents / harmful effects
 Ensuring the good health of equipment/machineries in production/utilities
departments.
AUTHORITY

 Reporting to shift incharge.
LIST OF PROCESSES
Relevant Relevant
Relevant
S Process No. of Revision No. / ISO OHSAS
Process Title ISO 9001
No. code pages Effective Date 14001 45001
Clause
Clause Clause
Preventive
1 SCIPL/MECH/PCS/01 03 7.1.3 7.1 4.4.6
inspection

QMS,EMS& OHAS
FUNCTIONAL MANUAL
Industries Private
MECHANICAL Limited
DEPARTMENT
Corrective
2 SCIPL/MECH/PCS/02 03 7.1.3 10.2 4.5.3
maintenance
SCIPL/MECH/PCS/03 03 7.1.3 7.1 4.4.6
Preventive
3
maintenance
Breakdown
4 SCIPL/MECH/PCS/04 03 7.1.3 10.2 4.4.6
maintenance
Planned
5 SCIPL/MECH/PCS/05 03 8.5.6 10.3 4.6
modifications
Calibration of
7.1.3/
6 equipment / SCIPL/MECH/PCS/06 03 9.1.1 4.5.1
7.1.5.2
instruments
Spares
7 SCIPL/MECH/PCS/07 03 7.1.3 7.1 4.4.6
management
Legal
8 obligations SCIPL/MECH/PCS/08 03 8.2.2 9.1.2 4.3.2
compliance
PROCESS: PREVENTIVE INSPECTION – SCIPL/MECH/PCS/01
1. OBJECTIVE
To measure the operating parameters of identified equipment to enable a scientific

analysis and evaluation of the health of the equipment.

QMS,EMS& OHAS
FUNCTIONAL MANUAL
Industries Private
MECHANICAL Limited
DEPARTMENT
2. BOUNDARY
From identification of equipment operating parameters to be measured to generation

of measurement records for analysis and inference.
3. PROCESS OWNER
Head Maintenance
Section Head - Mechanical Maintenance
4. REFERENCES
IMS Apex Manual, Section : 7.1

OEM Manuals
PI Schedule
5. RECORDS
PI Check sheet
PI Schedule
6. PROCESS FLOW SHEET
ACTIVITY RESPONSIBILITY RECORD

QMS,EMS& OHAS
FUNCTIONAL MANUAL
Industries Private
MECHANICAL Limited
DEPARTMENT
1. Identification of equipment /system and the parame

ters to be measured and monitored
2.Selection of identified equipment/system for measu
rement of different parameters
Preparation of schedule, frequency of measurements Mechanical PI Check sheet

& check sheet for the identified equipments/system a Maintenance Team
nd the parameters to be recorded with limits and incor PI Schedule
porate of it’s parameters.
Entering the data to SAP (IP02,IP10)
Receipt the Scheduled notification and Carry out data

collection as per scheduled frequency at the identified
location of each equipments
Entering the data to SAP (IW22, IW41)
Submission the measurement results to HOD for ana

lysis and future action
NO
SCIPL
Action
Coordinator
required
review
Yes
Planning for corrective/preventive maintenance base

d on analysis and inference.
7. PROCESS MAP
Receivers of
Sources of Inputs Preventive Outputs Outputs
Inputs Revision.00 Inspection Issue Date: 00/00/0000
QMS,EMS& OHAS
FUNCTIONAL MANUAL
Industries Private
MECHANICAL Limited
DEPARTMENT
List of equipments
and parameters to
be monitored.
Required condition
monitoring Result of Completion
OEM Manuals instruments. measurements updating in SAP
Required technical
skills for
measurement and
analysis.
Required
information to
carry out
measurements
8. PERFORMANCE INDICTORS
S No Performance Indicator
1 PI Schedule compliance
PROCESS: CORRECTIVE MAINTENANCE – SCIPL/MECH/PCS/02

QMS,EMS& OHAS
FUNCTIONAL MANUAL
Industries Private
MECHANICAL Limited
DEPARTMENT
1. OBJECTIVE
To provide the appropriate action plan & implement it for equipment which has
abnormal operating parameter trends or results.
2. BOUNDARY
Assessing the data collected from Preventive inspection or receipt of

notification raised by operations & preparing correction action plan, getting
implemented and maintain records of work done.
3. PROCESS OWNER
Head Maintenance
4. REFERENCES

OEM Manuals
5. RECORDS
Corrective maintenance report

Permits

QMS,EMS& OHAS
FUNCTIONAL MANUAL
Industries Private
MECHANICAL Limited
DEPARTMENT
Collect the qualitative data of equipments performan

ce as per checklist which has failure or abnormal tren
d and receipt the notifications raised by operations
SAP (Issue the Notification, IQS21,IW21)
Prepare a detailed action plan to rectify the problem and c Corrective

heck material maintenance
Mechanical report
Not available
Maintenance Team
Head Mainte
Permits
Check nance for N/
availability A
Available
Take permit and execution of work as per OEM procedure

manual / Departmental procedures
Entering the data to SAP (IW22,IW41)
Submission the measurement results to HOD for analysis

and future action
NO
SCIPL
Action
Coordinator
required
review
Yes
Planning for corrective/preventive maintenance based on

analysis and inference.
7. PROCESS MAP

QMS,EMS& OHAS
FUNCTIONAL MANUAL
Industries Private
MECHANICAL Limited
DEPARTMENT
Receivers of
Sources of Corrective Outputs
Inputs Outputs
Inputs Maintenance
 Root
cause analysis
recommendatio
n.
 Equipmen Equipment Power generation

t history ready for process
records. operations
Operations
 Corrective
action plan.
 Work
permit.
 Required
materials /
8 . PERFORMANCE INDICTORS
S No. Performance Indicator
1 % of completed notifications / defects raised.
PROCESS: PREVENTIVE MAINTENANCE – DCL/MEC/PCS/03

QMS,EMS& OHAS
FUNCTIONAL MANUAL
Industries Private
MECHANICAL Limited
DEPARTMENT
1. OBJECTIVE
The objective of the process is to prevent failure of equipments.
2. BOUNDARY
From the preparation of preventive maintenance (PM) schedule to completion of PM

and handing over the equipment to Operations.
3. PROCESS OWNER
Head Maintenance
4. REFERENCES

SOPs
OEM Manuals
5. RECORDS
PM Check sheet
Permits
PM Schedule


QMS,EMS& OHAS
FUNCTIONAL MANUAL
Industries Private
MECHANICAL Limited
DEPARTMENT
Preparation of preventive maintenanc

e check list on equipment wise and fr
equency for identified equipments as
per OEM Manual / Maintenace proce
dure
Planning and scheduling of maintenance as per check list and in
Entering the data to SAP(IP02,IP10)
Receipt of work notification by maintenance group from SAP
Estimate for job contract and required resources.

(Spare or Man Power)
Not available Mechanical PM Check

Maintenance Team sheet
Check Head Mainten
availability ance for N/A
Permits
Available
PM Schedule
Take permit and execution of work as per OEM procedure manu
al / Departmental procedures
Submission the measurement results to HOD for analysis and f

uture action
NO
SCIPL
Action Coordinator
required review
Yes
Planning for corrective/preventive maintenance based on analy

sis and inference.

QMS,EMS& OHAS
FUNCTIONAL MANUAL
Industries Private
MECHANICAL Limited
DEPARTMENT
7. PROCESS MAP
Receivers of
Sources of Inputs Preventive Outputs Outputs
Inputs Maintenance
Equipments and
its technical
details.
Availability of
Preventive
equipment
As per SAP maintenance Plan
notifications & Schedule.
Completion
Spare parts &
updating in SAP
Consumables.
Skilled
technicians with
duration of hours.
OEM Procedures.
S No. Performance Indicators
1 PM Schedule compliance
2 Equipment Availability
3 MTBF
PROCESS: BREAKDOWN MAINTENANCE – SCIPL/MECH/PCS/04

QMS,EMS& OHAS
FUNCTIONAL MANUAL
Industries Private
MECHANICAL Limited
DEPARTMENT
1. OBJECTIVE
To rectify defects and ensure return of the equipment into full operation within the
shortest possible time.
2. BOUNDARY
From initiation of work request by the Operations department to return of equipment

for service.
3. PROCESS OWNER
Head Maintenance
4. REFERENCES

OEM Manuals
5. RECORDS
Permits
Breakdown analysis report

QMS,EMS& OHAS
FUNCTIONAL MANUAL
Industries Private
MECHANICAL Limited
DEPARTMENT

Collect the qualitative data of equipments performance as
per checklist which has failure or abnormal trend and recei
pt the notifications raised by operations
SAP (Issue the Notification, IQS21,IW21)
Permits
Prepare a detailed action plan to rectify the problem and c
heck material
Mechanical
Maintenance Team
Not available Breakdown
analysis report
Check Head Mainte
availabilit nance for N/
y A
Available
Take permit and execution of work as per OEM procedure

manual / Departmental procedures
Submission the measurement results to HOD for analysis

and future action
NO
SCIPL
Action
Coordinator
required
review
Yes
Planning for corrective/preventive maintenance based on

analysis and inference.
7. PROCESS MAP

QMS,EMS& OHAS
FUNCTIONAL MANUAL
Industries Private
MECHANICAL Limited
DEPARTMENT
Breakdown Receivers of
Sources of Inputs Outputs Outputs
Maintenance
Inputs
 Work
Request from
operations
Equipment Power generation
.Operations  Spares and ready for process
consumables operations
 OEM
Procedure
manual /
Departmental
Procedure
 Work Permit
1 Downtime of equipment
2 MTTR
PROCESS: PLANNED MODIFICATIONS –SCIPL/MECH/PCS/05

QMS,EMS& OHAS
FUNCTIONAL MANUAL
Industries Private
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DEPARTMENT
1. OBJECTIVE
To undertake modifications in a planned way to enable enhance system

performance/Safety/Reliability of the process or Equipment.
2. BOUNDARY
From preparing schedule for modification to successful completion and evaluation of

results.
3. PROCESS OWNER
Plant Manager
Operations Manager
Maintenance Manager
4. REFERENCES

P&IDs
O&M Manuals / TIL
Learning
5. RECORDS
Plant Modification Report


QMS,EMS& OHAS
FUNCTIONAL MANUAL
Industries Private
MECHANICAL Limited
DEPARTMENT
Modification Suggestion by any of the user ( SCIPL)
Reviewing the suggestion by concerned department HOD
No
Sufficient
Prepare the de Mechanical Plant
tail report
document Maintenance Team Modification
Report
Yes
Second Modification Committee Meeting (SCIPL)
No
Approved
SAP (Issue the Notification, IW21)
Prepare a detailed action plan, material
No
Head
Check availability maintenance
of N/A
Yes
Take permit and execution of work as per OEM procedure manu

al / Departmental procedures

uture action
Yes No
Planning for correctiv SCIPL
e/preventive mainten Action Coordinator
Required
ance based on analys review
is and inference.

QMS,EMS& OHAS
FUNCTIONAL MANUAL
Industries Private
MECHANICAL Limited
DEPARTMENT
7. PROCESS MAP
Planned
Receivers of
Sources of Inputs Modifications Outputs Outputs
Inputs
Modification
request
Technical Job completion

details of the Organization
Modification job to be Modified
suggestions carried out system /
equipment /
Impact on the Process
current state
of affairs
Cost-benefit
analysis of the
proposal
1 Number of modifications implemented

QMS,EMS& OHAS
FUNCTIONAL MANUAL
Industries Private
MECHANICAL Limited
DEPARTMENT
PROCESS: CALIBRATION OF EQUIPMENT / INSTRUMENTS –SCIPL/MECH/PCS/06
1. OBJECTIVE
To control the monitoring & measuring devices in order to ensure accurate

measurement of various parameters / characteristics required to be monitored.
2. BOUNDARY
This covers all monitoring and measuring devices having effect on power generation.
This process starts from identification of measurement and monitoring devices to
completion of calibration of measuring instruments traceable to relevant national /
international standards.
3. PROCESS OWNER
Head Maintenance
4. REFERENCES

OEM manuals
5. RECORDS
Calibration Schedules
Calibration Reports / Calibration Certificates

QMS,EMS& OHAS
FUNCTIONAL MANUAL
Industries Private
MECHANICAL Limited
DEPARTMENT

Identifying monitoring and measuring devices need calibration
Preparing calibration schedule for each tools an

d instruments Calibration
Schedules
Provide internal review report Mechanical
Monthly basis by concerned person Maintenance Team Calibration
Reports
Submission the report to HOD for Maintaining status
analysis and future action of calibration Calibration
Certificates
No
SCIPL
Calibration Coordinator
Required review
Yes
Provide calibration request and

document
Issue Service Request to SAP

(ME51N, ME54N)
Maintaining calibration records

QMS,EMS& OHAS
FUNCTIONAL MANUAL
Industries Private
MECHANICAL Limited
DEPARTMENT
7. PROCESS MAP
Calibration of Outputs Receivers of

Sources of Inputs equipment / Outputs
Inputs instruments
 List of
tools and
instruments
requiring Calibrated To relevant
calibration monitoring and processes of
Calibration Operations &
measuring
schedule  Specific Maintenance
equipment
ation / range
of instruments
including
frequency of
calibration
 Approve
d Calibration
agencies
1 Adherence to calibration schedule.

QMS,EMS& OHAS
FUNCTIONAL MANUAL
Industries Private
MECHANICAL Limited
DEPARTMENT
PROCESS: SPARES MANAGEMENT - SCIPL/MECH/PCS/07
1. OBJECTIVE
The objective is to ensure availability of spare parts at the right time and in
right quantities and at the same time optimize on the inventory of spares.
2. BOUNDARY
From identification spare parts, establishing minimum stock and reorder levels and
monitoring status on monthly basis.
3. PROCESS OWNER
Head Maintenance
4. REFERENCES

OEM manuals
5. RECORDS
PR
List of Critical Spares

QMS,EMS& OHAS
FUNCTIONAL MANUAL
Industries Private
MECHANICAL Limited
DEPARTMENT
Preparation of spare parts list required

for maintenance
Analyze/review Identify the spare parts

equipment history as per decided
& critaris/plan
other relevant
History of spare parts and Review the spare parts for

decided on its procurement six months for procurement
strategy/inventory policy
(SAP ME53N)
Submission of report to HOD for analysis and future action PR

Mechanical
NO Maintenance Team
List of Critical
Action
required Spares
Planning for procurement (quotation, vendor information)
Issue the material to SAP (ME51N)
Information to VPGL coordinator for review and action
Update the material procure plan

QMS,EMS& OHAS
FUNCTIONAL MANUAL
Industries Private
MECHANICAL Limited
DEPARTMENT
7. PROCESS MAP
Spares Outputs Receivers of

Sources of Inputs Outputs
management
Inputs
1. Equipme
nts and its
technical
details Availability of Procurement
2. Perform spare parts as
OEM Manuals ance history per Minimum Maintenance
of the Stock Levels Dept
equipment
3. Previous
consumption
pattern of
spare parts
4. Lead
time of spares
1 Adherence to Critical Spares availability list
2 Adherence to consumables & other Spares availability at MSL

QMS,EMS& OHAS
FUNCTIONAL MANUAL
Industries Private
MECHANICAL Limited
DEPARTMENT
PROCESS: LEGAL OBLIGATIONS COMPLIANCE –SCIPL/MECH/PCS/08
1. OBJECTIVE
To ensure compliance to Statutory Inspections applicable to the activities of

Mechanical dept.
2. BOUNDARY
From identification of statutory requirements to preparation of schedule and

compliance.
3. PROCESS OWNER
Head Maintenance
4. REFERENCES

Statutory requirements
5. RECORDS
Legal Register

QMS,EMS& OHAS
FUNCTIONAL MANUAL
Industries Private
MECHANICAL Limited
DEPARTMENT
Identification of equipment requiring a
nnual inspections/testing as per appli
cable statutory rules/regulations (elec
tricity act/Factory act /Boiler act) by H
ead of the department
Preparation of schedule for inspection and Coordination with a

dministrative department to finalize inspection schedule with st
atutory authorities. Mechanical Legal register
Maintenance Team
Issue work request to maintenance group for carrying out Mainte

nance/ routine checks before inspection
Entering the data to SAP(IW21)
Receipt of work notification by maintenance group from SAP
Carry out the work and maintain the report

uture action
NO
SCIPL Confirm the sc

Action Coordinator hedule
required review
Available
Planning for corrective/ preventi Submit all the report

ve maintenance based on analy
sis and inference.
Obtain certificate

QMS,EMS& OHAS
FUNCTIONAL MANUAL
Industries Private
MECHANICAL Limited
DEPARTMENT
7. PROCESS MAP
Legal Receivers of
Sources of Inputs Outputs Outputs
obligations
Inputs
compliance
1. Equipme
nts and its
technical
details
Duly inspected
Statutory 2. Docume MIS Report
& certified
requirements nts
equipment
preparation as
necessary
3. Statutory
inspection
plan &
schedule
4. Arrangin
g required
Agency
1 Fulfillment of compliance obligations.

QMS,EMS& OHAS
FUNCTIONAL MANUAL
Industries Private
MECHANICAL Limited
DEPARTMENT
OBJECTIVES & ACTION PLANS

QMS & EMS:
DESCRIPTION OF THE
Sl. No TARGET RESPONSIBILITY SCHEDULE
OBJECTIVE.
Aiming for the availability of

PYRO section equipment to 90 %
1 90% Section Incharge Monthly
with adopting of the preventive and
regular maintance schedules

Grinding section equipment to 90
2 90% Section Incharge
% with adopting of the preventive Monthly
and regular maintance schedules

WHRS equipment to 90 % with
3 90% Section Incharge Monthly
adopting of the preventive and
regular maintance schedules
To Sustains Zero
4 Zero Section Incharge Monthly
Incidents/Accidents
72 hrs. per
5 Train for department employees HOD Yearly
head / year
Waste disposal like Oils &

6 Document Section Incharge 3 Months
Lubricants.
Auxiliary bag filters maintenance

7 Document All section heads Monthly
schedule
Once in six
Safety guards for rotating
8 85% Section Incharge months
equipment’s
Once in six
9 MSDS for all lubricants Document Section Incharge
months

QMS,EMS& OHAS
FUNCTIONAL MANUAL
Industries Private
MECHANICAL Limited
DEPARTMENT
OHSAS OBJECTIVES:
SL.NO OBJECTIVE ACTION PLAN FOR OBJECTIVES
1. Regular Checklist and its implementation

as per schedule.
Aiming for the availability of PYRO
section equipment to 90 % with
1
adopting of the preventive and regular
maintance schedules 2. Implementation of system modification to
increase the system reliability as and when
required
3. Procurement of critical spares in time.
Aiming for the availability of Grinding as per schedule.
section equipment to 90 % with 2. Implementation of system modification to
2 increase the system reliability as and when
adopting of the preventive and regular
maintance schedules required
Aiming for the availability of WHRS as per schedule.
equipment to 90 % with adopting of the 2. Implementation of system modification to
3
preventive and regular maintance increase the system reliability as and when
schedules required
1. Identifying the unsafe conditions, unsafe
acts avoiding.
4 To Sustains Zero Incidents/Accidents
2. If near miss ,reporting the same to the
concern
1. Department knowledge will be shared and
5 Train for department employees
external agencies deputed, if required.
1. Disposing of the Oil & Lubricants waste as

6 Waste disposal like Oils & Lubricants.
per procedure.
1. Dust emission if any from stacks and

Auxiliary bag filters maintenance regular maintenance.
7
schedule

QMS,EMS& OHAS
FUNCTIONAL MANUAL
Industries Private
MECHANICAL Limited
DEPARTMENT
1. Implementing proper preventive

8 Safety guards for rotating equipment’s maintance and regular inspection of
equipments
1. Regular Checklist and update as per

9 MSDS for all lubricants
schedule.


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QMS,EMS& OHAS

DEPARTMENTAL Shaurya Cement

INTEGRATED MANAGEMENT SYSTEM

Quality Management System,

Departmental Functional Manual

Document No. : SCIPL/MECH/DFM

SHAURYA CEMENT INDUSTRIES PRIVATE LIMITED

Revision.00 Issue Date: 00/00/0000

Number Revision &

Revision.00 Issue Date: 00/00/0000

1. Table of contents SCIPL/MECH/DFM/1 02

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TITLE: REVISION RECORD SHEET

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Abbreviation Full Form

TITLE: LIST OF CONTROL COPY HOLDERS

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RESPONSIBILITY AND AUTHORITY

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 Correspond with other top Management.

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 Schedule, Shutdown and Breakdown maintenance co-ordination with HOD.

 Authorized to sign on Monthly reports and other MI's reports.

Senior Engineer  Schedule, Shutdown and Breakdown maintenance co-ordination with

Revision.00 Issue Date: 00/00/0000

 Ensuring proper disposal of wastes as per guidelines.

 Authorized to sign on Monthly reports and other MI's reports.

 Schedule, Shutdown and Breakdown maintenance co-ordination with

Authorized to sign on Instrumentation Maintenance records.

Revision.00 Issue Date: 00/00/0000

 Following the procedures, work instructions and providing the feedback

 Authorized to sign on Mechanical Maintenance records.

 Authorized to sign on Mechanical Maintenance records.

Revision.00 Issue Date: 00/00/0000

 Assisting section Engineers and superiors in making quality plans

 Authorized to sign on Mechanical Maintenance records.

Revision.00 Issue Date: 00/00/0000

PROCESS: PREVENTIVE INSPECTION – SCIPL/MECH/PCS/01

To measure the operating parameters of identified equipment to enable a scientific

Revision.00 Issue Date: 00/00/0000

From identification of equipment operating parameters to be measured to generation

IMS Apex Manual, Section : 7.1

6. PROCESS FLOW SHEET

ACTIVITY RESPONSIBILITY RECORD

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1. Identification of equipment /system and the parame

Preparation of schedule, frequency of measurements Mechanical PI Check sheet

Entering the data to SAP (IP02,IP10)

Receipt the Scheduled notification and Carry out data

Entering the data to SAP (IW22, IW41)

Submission the measurement results to HOD for ana

Planning for corrective/preventive maintenance base

PROCESS: CORRECTIVE MAINTENANCE – SCIPL/MECH/PCS/02

Revision.00 Issue Date: 00/00/0000

Assessing the data collected from Preventive inspection or receipt of

IMS Apex Manual, Section : 7.1

Corrective maintenance report

6. PROCESS FLOW SHEET

Revision.00 Issue Date: 00/00/0000

ACTIVITY RESPONSIBILITY RECORD

Collect the qualitative data of equipments performan