Preventive Tool Maintenance - Preventive and Predictive Maintenance requirements

try2makeit

Quite Involved in Discussions
#1
Hi everyone,

during our recent surveillance audit I received a minor non-conformance against Preventive and Predictive Maintenance requirement.

The write up is at follows:

The organization does not always ensure evidence of all Preventive and Predictive Maintenance requirements. Evidence of Predictive Maintenance where not able to be verified at time of Audit. (Tool Repair tracking sheet not up to date).

Few years back I started to keep track of our steel rule Die's that we maintenance ourselves, i.e Punches changed, rule changed, etc. But then with the slow down and down sizing in our Company, and people wearing more hats, I neglected to enter information into the log, therefor the write-up.

Now I want to make the log more simple, instead of this massive spreadsheet with this abundance of information as too Punch change, rule change, soldering etc, and just focus on how many parts are being produced of the Die before it is brought to the Tool room for repairs.

Our Tool guy says in general you can run approx.4500 parts of a die, before it needs any maintenance. Okay sounds good, but I don't want to answer the NC by giving a specific number and say that the tool needs to go to the tool room and be fixed. Because if the tool runs good, and parts are good, beyond the 4500 part mark, I am not going to a) have the Operator stop and tear her setup down, and b) my experience with a set number, if we are not right on the money and my CB comes in and audits and let's say we ran 4510 parts of the Die, it will result in a NC.

Then I have to take in consideration that every Operator runs different and also the Press(es) the Die's can be ran at.
I also don't want to hand our Operators another piece of paper for them to record the info. Papers can be lost easily, something could be forgotten to be recorded etc.

So my solution to this is, that I can record the Die #, date and amount of parts ran at First Piece Inspection ( I have all the above Info on the Shop order ) and just enter it on a Spreadsheet there.
When the Die does have to go to the Tool room, currently the Press Operators affix a Die repair tag to it, circle what needs to be done, what Press it came from and date. I can match the info to that and then add the parts total and eventually get some more current results to when to do Preventive maintenance.

My question is, does this sound simple enough, or am I'm making more work for myself? I mean with the log I had started, it just got bigger and bigger, but I couldn't really get no good results, and I don't want that to happen again. Any advise would be appreciated. :thanx:

P.S Sorry this is so long.
 
Elsmar Forum Sponsor

Stijloor

Staff member
Super Moderator
#2
Hi everyone,

during our recent surveillance audit I received a minor non-conformance against Preventive and Predictive Maintenance requirement.

The write up is at follows:

The organization does not always ensure evidence of all Preventive and Predictive Maintenance requirements. Evidence of Predictive Maintenance where not able to be verified at time of Audit. (Tool Repair tracking sheet not up to date).

Few years back I started to keep track of our steel rule Die's that we maintenance ourselves, i.e Punches changed, rule changed, etc. But then with the slow down and down sizing in our Company, and people wearing more hats, I neglected to enter information into the log, therefor the write-up.

Now I want to make the log more simple, instead of this massive spreadsheet with this abundance of information as too Punch change, rule change, soldering etc, and just focus on how many parts are being produced of the Die before it is brought to the Tool room for repairs.

Our Tool guy says in general you can run approx.4500 parts of a die, before it needs any maintenance. Okay sounds good, but I don't want to answer the NC by giving a specific number and say that the tool needs to go to the tool room and be fixed. Because if the tool runs good, and parts are good, beyond the 4500 part mark, I am not going to a) have the Operator stop and tear her setup down, and b) my experience with a set number, if we are not right on the money and my CB comes in and audits and let's say we ran 4510 parts of the Die, it will result in a NC.

Then I have to take in consideration that every Operator runs different and also the Press(es) the Die's can be ran at.
I also don't want to hand our Operators another piece of paper for them to record the info. Papers can be lost easily, something could be forgotten to be recorded etc.

So my solution to this is, that I can record the Die #, date and amount of parts ran at First Piece Inspection ( I have all the above Info on the Shop order ) and just enter it on a Spreadsheet there.
When the Die does have to go to the Tool room, currently the Press Operators affix a Die repair tag to it, circle what needs to be done, what Press it came from and date. I can match the info to that and then add the parts total and eventually get some more current results to when to do Preventive maintenance.

My question is, does this sound simple enough, or am I'm making more work for myself? I mean with the log I had started, it just got bigger and bigger, but I couldn't really get no good results, and I don't want that to happen again. Any advise would be appreciated. :thanx:

P.S Sorry this is so long.

Can someone with this type of expertise help?

Thank you very much.

Stijloor.
 
F

fsheikh99

#3
Hello there. I am sorry don't know answer to your that long question :) but the purpose of writing here is that, I am also looking for some "paper-based" preventive and other types of Equipment Maintenance Formats. If someone could held it would be highly appreciated.

Thanking you in anticipation.

Cheers.
 

harry

Super Moderator
#4
B

Big-R

#5
I just joined the board and my background is in equipment maintenance. Here’s my opinion:

Most regulations refer to preventive maintenance requirements, understanding there is a difference between preventive (scheduled tasks based on time, # of cycles, etc.) and unscheduled maintenance (break-fix, EQ failure, etc.). Findings are almost always phrased in the terms of “preventive maintenance.” As you described your process, you cannot determine a time or cycle based schedule for die maintenance. In general terms, this pushes these events to “unscheduled”.

Logging the number of the die with the shop order is a good idea, but it doesn’t address the finding. Based on your post, you’re missing two things; a maintenance procedure for your dies, and evidence the maintenance was carried out.

For the procedure, I recommend creating a document which states you’ll run a die until it needs to be repaired (run to failure). Seems in your process, normal inspection would catch a die-induced defect in the finished product. At that time, the die is replaced, the repair tag created, and it’s sent to the tool room.

For the evidence, you could use a paper-based repair form, keeping it simple. Suggested data includes work order number (could use sequentially numbered forms, etc.), date work was completed, die ID, comments, and signature of individual performing the maintenance. I recommend retaining these documents by die ID for easy finding later.

Ryan
 

antoine.dias

Quite Involved in Discussions
#6
Hi,

We have never used a fixed number of parts before the tooling was sent to repair.
Instead the tooling was checked before each order (first piece) and after each order run.
When it was still OK after the order it was tagged OK (with indication of cumulative number of parts produced) and was sent to storage.
When it was not OK it was tagged accordingly including the repair wanted.

This has worked well for years on end and has been accepted by different auditors.

Best regards,

Antoine
 
R

Rick Fox

#7
I can assume that you inspect dies on a regular basis.
I would fully document what is called for in a die inspection, and how often one is held. This is your PM.

This should be a formal document with a document number that is referenced by the PM tracking system which can be as simple as an Excel spreadsheet. (which should contain a formal document number as well (and called out on the PM).

After this, you should not receive any NC for the program. You have to follow what you document though.....
 

try2makeit

Quite Involved in Discussions
#8
Thank you all for your kind replies. It surprised me that this subject came back up in the Forum list.

Here is a update on what I implemented:

I started to record the tooling number, amount ran and date in a excel spreadsheet. Once the Operator brings the tool in to be fixed, I get the repair tag and record the date it was done and then add all the several runs together to get a part total. Excel is wonderful to me..:D
I set it up that it will add the totals and average it out for me, so when I enter another job setup and can take a glance at were we at and give the operator the heads up that it needs to go in for repairs or if we are still good.
Some tooling takes a bit longer to collect data, because they are not run very often, but others are used weekly.
Our new auditor that did our Re-certification this year, audited it and he was happy that I could show him that we are doing it with the corresponding dates and averages.

Again Thank you for all your replies.:thanx:
 
Thread starter Similar threads Forum Replies Date
M Minitab tool to evaluate PM (Preventive Maintenance) process Using Minitab Software 6
F QS-9000 Clause 4.9.g.1 - Preventive Maintenance - Tool Wear Predictive Maintenance QS-9000 - American Automotive Manufacturers Standard 1
C FMEA as corrective tools or preventive tool? FMEA and Control Plans 11
L Separate Corrective Action and Preventive Action Procedures ISO 13485:2016 - Medical Device Quality Management Systems 13
D Preventive Maintenance vs. General Cleaning ISO 13485:2016 - Medical Device Quality Management Systems 2
J Help settle a disagreement: Should external providers of preventive maintenance be on your ASL? AS9100, IAQG, NADCAP and Aerospace related Standards and Requirements 5
Q Determining Adverse Effects of Corrective/Preventive Actions ISO 13485:2016 - Medical Device Quality Management Systems 2
K Generic preventive maintenance form wanted Document Control Systems, Procedures, Forms and Templates 2
R Non conformance (NC) or Corrective & Preventive action (CAPA) CE Marking (Conformité Européene) / CB Scheme 7
C If it doesn't prevent a non-conformance, is it a preventive action? IATF 16949 - Automotive Quality Systems Standard 13
S Are there ISO9001:2015 Requirements for Preventive Maintenance? ISO 9000, ISO 9001, and ISO 9004 Quality Management Systems Standards 36
R Evaluating the need for preventive action Preventive Action and Continuous Improvement 3
GURU SDI Rust preventive oil mixed with kerosene Problem Solving, Root Cause Fault and Failure Analysis 2
B Stakeholder Initiated Corrective and Preventive Action Misc. Quality Assurance and Business Systems Related Topics 5
B Corrective and Preventive Action (CAPA) A Key Process of the Quality Management System Dec 17... Training - Internal, External, Online and Distance Learning 0
Jimmy123 FMEA - Preventive vs Detection Control FMEA and Control Plans 7
D Preventive Maintenance Implementation 21 CFR Part 820 - US FDA Quality System Regulations (QSR) 5
M Training in 8D Problem Solving as a Preventive Action? Problem Solving, Root Cause Fault and Failure Analysis 9
J If Corrective and Preventive Action were truly Effective IATF 16949 - Automotive Quality Systems Standard 3
R Preventive Action - confusing ISO 13485:2016 - Medical Device Quality Management Systems 5
T Proactive / Preventive Post Market Surveillance question ISO 13485:2016 - Medical Device Quality Management Systems 4
Q Preventive Action - How to call the prevention when there is not a clause ISO 9000, ISO 9001, and ISO 9004 Quality Management Systems Standards 5
M Preventive Maintenance Spreadsheet in Excel Quality Assurance and Compliance Software Tools and Solutions 2
somashekar The Preventive Action Demystified ISO 13485:2016 - Medical Device Quality Management Systems 8
Q Evaluating Effectiveness of a Preventive Action after Closure Preventive Action and Continuous Improvement 7
A Preventive Action and Risk Assessment Audit Process Audits and Layered Process Audits 5
K CAPA (Corrective and Preventive Action) - ISO 13485 Nonconformance and Corrective Action 1
J Software and Methods for Tracking CAPA (Corrective and Preventive Action) items US Food and Drug Administration (FDA) 3
A Preventive Action or Corrective Action - Paper cuts Nonconformance and Corrective Action 14
H Combined Procedure - Control of Non-conforming Product, Corrective and Preventive Document Control Systems, Procedures, Forms and Templates 14
M Corrective and Preventive Action - Prevent Recurrence is not Preventive Action? Nonconformance and Corrective Action 24
K Definition Correction, Corrective Action and Preventive Action - Definition of terms Definitions, Acronyms, Abbreviations and Interpretations Listed Alphabetically 28
F Software recommendations for corrective and preventive action Quality Assurance and Compliance Software Tools and Solutions 2
K Corrective and preventive action for Non Conformance on PFMEA FMEA and Control Plans 30
B Struggling With Writing PA (Preventive Action) Procedure Preventive Action and Continuous Improvement 11
E Can anyone share a Preventive Action Form or Template ? AS9100, IAQG, NADCAP and Aerospace related Standards and Requirements 3
H Corrective and Preventive Actions Process Examples IATF 16949 - Automotive Quality Systems Standard 2
J Continuous Improvement vs. Preventive Actions - Differences Preventive Action and Continuous Improvement 3
E Manufacturer Responsibility (vs. User/Customer) for Preventive Maintenance/Repair 21 CFR Part 820 - US FDA Quality System Regulations (QSR) 4
W Compliance to 8.5.2 Corrective action 8.5.3 Preventive action ISO 9000, ISO 9001, and ISO 9004 Quality Management Systems Standards 13
J Is a Procedure required for Corrective, Preventive, and Non Conformities ISO 9000, ISO 9001, and ISO 9004 Quality Management Systems Standards 9
P Customer Complaint Preventive Action Assistance Preventive Action and Continuous Improvement 3
A Assessing a Preventive Maintenance Strategy - Reliability or Maintenance Statistics Reliability Analysis - Predictions, Testing and Standards 2
T Corrective Action and Preventive Action in a Holding Company Nonconformance and Corrective Action 6
O Corrective Actions identifed as Preventive Actions Nonconformance and Corrective Action 10
S How to determine Preventive Maintenance and Calibration Grace Periods General Measurement Device and Calibration Topics 4
M What is Preventive Action taken as part of a Corrective Action? Nonconformance and Corrective Action 5
MarilynJ6354 Definition Improvement Suggestion vs. Preventive Action - Clear Definitions and Differences Definitions, Acronyms, Abbreviations and Interpretations Listed Alphabetically 6
C The prudence of combining non-conformance reports with corrective/preventive action Nonconformance and Corrective Action 10
J Methods to control Efficiency of Corrective and Preventive Actions Quality Manager and Management Related Issues 9

Similar threads

Top Bottom