16 WORKSHOP

16.3 FUNCTIONS

a. To perform routine preventive and breakdown maintenance

for the mill machinery/equipment.
b. To enable minor fabrication and modification works.

16.4 MACHINERY/EQUIPMENT

The common machinery / equipment for workshop are:

a. Welding set
b. Lathe machine
c. Pedestal drill, pedestal grinder
d. Electric power saw or disc cutter
e. Pedestal Drill, Pedestal Grinder
f. Oxy-acetylene sets

16.5 MACHINERY/EQUIPMENT OPERATION PROCEDURE

Welding
16.5.1 Set

16.5.1 Safety and Environmental Aspects

a. Safe and correct procedure of using the workshop tools could
prevent both major and
minor accidents. Ensure that only trained workshop
personnel are to use these
equipment.
b. For details/additional Safety Aspect, refer to OSH Manual for
Plantations
c. For details/additional Environment Aspect, refer to Section
VII: Handling of
Environmental Aspect
16.5.2 Operating Procedure
a. The machine must be kept free from water or moist/greasy
areas to prevent short-circuiting.
b. Always ensure that both the power input and output cables are
insulated.

c. Do not attempt to earth the work piece through the factory

building, structure, platform or another machine. It must be
earthed directly to work piece.
d. Do not try to weld without proper welding shield.

e. When performing extensive welding works, use welding apron.

 f. Coil the cables after using in a neat manner.

For works which involve combustible material, a permit to work

must be obtained prior to commencement of work.
16.5.2 Electric Disc Grinder/Hand Drills
Safety and
16.5.2.1 Environmental Aspects
a. Before starting the equipment check that the power cable is
insulated; the disc/drill is
firmly secured; guard cover is in place and the disc is not chipped.
b. On starting, check for excessive vibration; abnormal noise and
excessive sparking of carbon brush.

c. Always use goggles and do not overload the equipment.

d. Stand away from the path of grinding sparks or drill chips.

e. Clean the equipment and coil the power cable after use. Also
clean the grinding dust or drilling chips from place of work.
d. For details/additional Safety Aspect, refer to OSH Manual for
Plantations

f. For details/additional Environment Aspect, refer to Section VII:

Handling of
Environmental Aspect

Electric Power Saw or

16.5.3 Disc Cutter

16.5.3.1 Safety and Environmental Aspects

For the power saw, check the saw blade condition and re-
a. tension if necessary and let
the saw run free before applying to the work piece.
For the disc cutter, check for chips or cracks on the disc
b. before starting and on starting
observe for abnormal vibration.
Do not add additional weights or extend the handle of the
c. lever.
d. On stopping, clean the equipment of iron fillings and dirt.
For details/additional Safety Aspect, refer to OSH Manual for
e. Plantations
For details/additional Environment Aspect, refer to Section
f. VII: Handling of
 Environmental Aspect

16.5.4 Lathe Machine

16.5.4.1 Safety and Environmental Aspects

a. Before starting check for lubricating oil level in the gear unit,
coolant level (if applicable) and ensure that the chuck can be
turned freely by hand. Apply oil on all sliding surfaces.
b. The operator is to wear goggle and do not use hand gloves or wear
long sleeve shirt.

c. Do not allow another person to stand near the rotating work piece.

Use the correct speed for different materials/mass of work

d. piece. Always counter check
the grip of the chuck on the work piece.
e. Clean the machine after use.
For details/additional Safety Aspect, refer to OSH Manual for
f. Plantations
For details/additional Environment Aspect, refer to Section
g. VII: Handling of
Environmental Aspect
Pedestal Drill,
16.5.5 Pedestal Grinder

16.5.5.1 Safety and Environmental Aspects

For the pedestal grinder reset the rest and the wheel
a. clearance and dress the grinding
wheel if required.
b. At all times use goggles provided.
When operating the pedestal drill, do not use hand gloves
c. and roll-up long sleeve
shirts.
Ensure that the work piece is firmly secured and the chuck
d. grip on the drill is firm.
e. Do not attempt to overload the equipment.
For details/additional Safety Aspect, refer to OSH Manual for
f. Plantations
For details/additional Environment Aspect, refer to Section
g. VII: Handling of
Environmental Aspect
 Oxy-
Acetylene
16.5.5 Set

16.5.5.1 Safety and Environmental Aspects

Before using, check for leakage of gas at regulator, hose or
a. torch. Do not use it till the
leakages are rectified.

b. Ensure that flash back arrestors are installed.

For details/additional Safety Aspect, refer to OSH Manual for
c. Plantations

d. Always keep a minimum working distance of 5 metres from the gas

cylinders.

e. Turn off the gas at its cylinder after each use and coil the hose
neatly.

f. Always wear hand gloves and goggles while cutting metal or

brazing.

g. The regulating valves should be kept free of oil/grease.

h. Gas cylinder should not be stored near to areas where arc welding
is been carried out.

i. The cylinders should be kept standing upright.

j. For works which involve combustible material, a permit to

work must be obtained prior to commencement of work.
k. For details/additional Environment Aspect, refer to Section VII:
Handling of
Environmental Aspect
16.6 PLANT MAINTENANCE SYSTEM

a. Refer to Plant Maintenance System

b. Machinery running hours are to be recorded in the Machinery

Running Log. All observations requiring the attention of the
Senior Manager/Manager or workshop must be clearly
recorded.
c. The overhead hoist/crane must be inspected weekly and all
observations recorded in the Crane Inspection/Maintenance
Record.
d. All plant maintenance are carried out according to the
Maintenance Schedule list. Urgent repairs such as those
requested in the Maintenance Request Book will however be
given priority.
e. Details of work done in machinery maintenance are to be
recorded in the Maintenance Record Sheets.
f. Daily Maintenance (Defect) Request Book - Mill/Shift & Technical
Supervisor

g. Maintenance Report Book/Records -Technical Supervisor of Spare

Parts Used

h. Ad-Hoc Maintenance to be carried out for:-

1. Major breakdown – Mill stop processing.
.
2. For major breakdown Shift/Mill supervisor is to inform
maintenance Technical Supervisor immediately, who shall
evaluate the damages and further inform Senior
Manager/Manager/ Senior Assistant Engineer for on-
onward action.
3. Minor breakdown – Machine breakdown only
For minor breakdown, shift supervisor is to inform
maintenance Technical Supervisor who shall arrange
repair work to be carried out immediately.
16.7 PROCESS MONITORING

16.7.1 Sampling and Analysis

N/A
Specificat
16.7.2 ions

N/A

STATION
16.8 RECORDS/DATA

Serial No. Title Record by Check by Verify by (if any)

WS161 Maintenance Check-sheet
WS162 Breakdown Record - Mechanical
WS163 Breakdown Record - Electrical
WS164 Machinery Maintenance – Out Standing

16.9 LAYOUT PLAN

N/A