Free Work Instruction Manual

DOCUMENT CONTROL INFORMATION

• Manual Title: Machine Maintenance Procedure

• Document ID: WI-001-MMP

• Effective Date: 11/22/2064

• Version Number: 1.0

• Prepared By: [YOUR NAME]

• Approved By: Drake Feeney

• Company Name: [YOUR COMPANY NAME]

1. PURPOSE

This document provides detailed instructions for performing machine maintenance procedures to ensure operational efficiency, extend equipment life, and maintain a safe working environment at [YOUR COMPANY NAME].

2. SCOPE

This manual applies to the Maintenance Department and all employees who are responsible for maintaining CNC Machines, Milling Machines, and Lathes in the manufacturing facility. This procedure is essential for machine upkeep and is required for all scheduled maintenance activities.

3. RESPONSIBILITIES

• Employee: Ensure all maintenance steps are performed according to the outlined instructions. Report any malfunctions or safety concerns to the supervisor immediately.

• Supervisor: Monitor the execution of maintenance activities, provide support when necessary, and verify that all steps are correctly followed.

• Manager: Oversee the overall implementation of the maintenance process and ensure the training of staff. Approve any changes to the work instruction.

4. RESOURCES/TOOLS REQUIRED

• Equipment: CNC Machine Model X200, Milling Machine Model M600, Lathe Model L900

• Materials:

  • Lubricants: Hydraulic Oil (ISO 46)

  • Grease: Mobilith SHC 007

• Tools: Wrenches, Torque Wrench (Model: TQ-500), Screwdrivers, Multimeter (Model: MM-350)

• Software/Systems: Machinist Maintenance Tracking System (MMTS)

5. STEP-BY-STEP INSTRUCTIONS

5.1 Preparation

1. Ensure the machine is powered down and completely shut off.

2. Verify that all required tools and materials are available:

   • Lubricants: Hydraulic Oil (ISO 46)

   • Tools: Wrench set, Torque Wrench (Model: TQ-500)

3. Verify that all safety equipment is worn:

   • Safety goggles

   • Steel-toe boots

   • Gloves

   • Hearing protection

5.2 Execution

• Step 1: Check Oil Levels

  • Open the access panel of the CNC Machine Model X200 and locate the oil reservoir.

  • Inspect the oil level using the dipstick. If the level is below the minimum mark, add Hydraulic Oil (ISO 46) until it reaches the proper level.

• Step 2: Clean the Air Filter

  • Using a screwdriver, remove the air filter cover.

  • Inspect the air filter for any blockages. Clean the filter with compressed air or replace it if necessary.

• Step 3: Check the Electrical Connections

  • Use a Multimeter (Model: MM-350) to test electrical connections for any faults.

  • Tighten any loose wiring or connectors as necessary. Ensure all connections are free of corrosion.

• Step 4: Lubricate the Machine

  • Use Mobilith SHC 007 Grease to lubricate the key moving components such as the spindle, bearings, and ball screws.

  • Apply grease according to the manufacturer’s recommendations for each machine part.

• Step 5: Test the Machine

  • After maintenance is complete, power up the machine and perform a short test cycle to ensure that everything is operating smoothly.

  • Check for any unusual noises or vibrations.

5.3 Completion

1. Perform a final inspection to ensure that all parts are properly assembled and lubricated.

2. Complete the Machine Maintenance Log in the Machinist Maintenance Tracking System (MMTS), noting the maintenance date and any issues discovered.

3. Report any anomalies to the supervisor immediately.

6. SAFETY GUIDELINES

• Always wear Personal Protective Equipment (PPE), including safety goggles, steel-toe boots, gloves, and hearing protection.

• Before starting any maintenance, ensure that the power to the machine is completely turned off. Lock out and tag the equipment as per [YOUR COMPANY NAME]'s Lockout/Tagout procedure.

• Do not bypass safety features such as emergency stop buttons or safety interlocks on the machines.

• Ensure that the work area is clean and free of obstructions to avoid tripping hazards.

7. QUALITY ASSURANCE

• All maintenance activities must be logged in the Machinist Maintenance Tracking System (MMTS) for future reference.

• Supervisors will perform random audits to ensure compliance with this work instruction and report any discrepancies.

• Maintenance staff should attend quarterly training to stay updated on machine maintenance protocols.

8. REVISION HISTORY

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