Amendment Checklist & Form 2

FORM NO: QC-PCSECTION : CORE SHOP
SECTION PREVENTIVE MAINTENANCE PROGRAMME

NO
MACHINE/EQUIPMENT
1 CORE MACHINE AT THE SECTION:Check /Replace if needed of Sliding Rail
Check /Replace if needed of Heater
Cleaning
Check / Replace if needed of Sensors
Check/Replace if needed of Hopper
Check/ Replace if needed of Temperature Controller
Check / Replace if needed of Air Regulator and Gauge
Check / Replace if needed of Panel Wiring
Check / Replace if needed of Valves
Check / Replace if needed of Hoses
FREQUENCY
3
3
3
3
3
3
3
3
3
3
QUANTITY
Months
Months
Months
Months
Months
Months
Months
Months
Months
Months
4 units
4 units
1 job
5 units
1 job
1 job
1 job
1 job
1 job
1 job
3 Months
3 Months
3 Months
1 pc
1 pc
1 unit
2 SAND MIXER MACHINE

Check / Replace if needed of Motor
Check / Replace if needed of Wiring
Check / Replace if needed of Body
ISSUED BY
DATE
RECEIVED BY
DATE
FORM NO: QC-PC-016/09/REV.0
QUANTITY
PERSON IN CHARGE
4 units
4 units
1 job
5 units
1 job
1 job
1 job
1 job
1 job
1 job
Shift Supervisor S1
1 pc
1 pc
1 unit
Shift Supervisor S1
RECEIVED BY
DATE
Form NO: QC-PC-017

SECTION : CASTING
NO
1 FURNACE
MACHINE/EQUIPMENT
Cleaning - break dross / bottom

Degassing
Check Securing Bolt & Nut
Check / Change Thermocouple
Check & Change Cable Head
Check Coil and Change Gasket
Channel Cleaning
FREQUENCY
QUANTITY
Weekly
Daily
Weekly
Weekly
Weekly
6 Months
6 Months
2 units
1 times/ day
18 pcs
1 pc
3 units
2 units
1 job
Weekly
Weekly
Weekly
6 Months
1 unit
1 job
4 units
200 A - 6 units
6 A - 1 unit
Weekly
Weekly
2 Years
3 Months
6 Months
Monthly
1 unit
N/A
1 job
19 pcs
1 pc
1 job
Weekly
Weekly
3 Months
3 Months
1 job
1 job
1 pc
1 pc
Weekly
3 Months
3 Months
1 unit
1 unit
1 unit
Weekly
Weekly
1 job
3 units
2 CONTROL PANEL
Check Timer
Clean Dust Accumulation
Clean Contactors of Carbon Build Up
Check and Change Fuse
3 CASTING M/C
Check and Cleaning
Check and Top Up of Oiling/Greasing
Check /Change if needed of Hydraulic Fluid
Check/Replace if needed of Sensor
Check/Change of Rubber Coupling of Hydraulic Pump
Change of Dycote
4 SAND BLASTING M/C
Clean Sand in Vacuum Bag
Clean Machine
Check / Change of Blasting Nozzle
Cleaning of Filter Bag
5 CHIMNEY
Check and Cleaning
Check Blower Motor
Check Extractor Motor
6 GENERAL
Top Up Dycote
Check / Change Air Hoses and Valves
ISSUED BY
DATE
:
:
RECEIVED BY
DATE
Form NO: QC-PC-017/09/REV. 0
PERSON IN CHARGE
Shift Supervisor S2
Shift Supervisor S2
Shift Supervisor S2
Shift Supervisor S2
Shift Supervisor S2
Shift Supervisor S2
Page : 1 OF 2
FORM NO : QC-PC-018/09/REV.0
SECTION : FETTLING
NO
MACHINE/EQUIPMENT
1 DOUBLE CUT - OFF MACHINE
FREQUENCY
QUANTITY
2 Weeks
3 Months
Monthly
2 Weeks
6 Months
2 units
2 pcs
3 pcs
1 job
1 unit
Daily
Yearly
Daily
1 job
4 pcs
1 job
Yearly
Months
Months
Months
Months
2 pcs
2 liter
1 unit
2 sets
1 unit
2 Weeks
6 Months
6 Months
Yearly
1 unit
1 unit
1 job
1 job
a Turbine
- Visual Check - Wear and Tear Cleaning
3 Months
1 unit
b Spindle Housing Lubrication

- Check / Refill
3 Months
1 unit
c Transmission Belt Chain Stretching

- Check/Cleaning/Tightening
3 Months
1 unit
d Lining & Bolt

- Check/Replace
6 Months
1 unit
e Feed Duct
- Check and Cleaning
6 Months
1 unit
Cleaning
Check and Change Bearing
Check and Replace V Belt
Greasing
Check Motor
2 GRINDING MACHINE
Cleaning
Check Grinding Stone
3 RUMBLING MACHINE
Change of Oil - Gear Box
Check and Change Chain
Check and Change Sprocket
Check Motor
6
6
6
6
4 CYCLONE MACHINE
Clean Dust Collector
Ducting Hose
Check Motor
Painting (Epoxy)
5 TOSCA MACHINE
Page : 2 OF 2
SECTION : FETTLING
NO
MACHINE/EQUIPMENT
f Abrasive Valve Tile
- Check/Replace
g Gear Boxes Lubricant Level
- Check/Refill
FREQUENCY
QUANTITY
6 Months
1 unit
6 Months
1 unit
6 Months
1 unit
i Elevator Bucket
- Check/Replace
- Cleaning
Yearly
Yearly
1 unit
1 unit
j Filter Bag
- Check/Cleaning
Yearly
1 unit
Yearly
1 unit
Yearly
Yearly
1 unit
1 unit
m Elevator Belt
- Check/Repair
Yearly
1 unit
n Vibrator
- Check/Repair
- Cleaning
Yearly
Yearly
1 unit
1 unit
o Sleeve
- Check / Replace
- Cleaning
Yearly
Yearly
1 unit
1 unit
h Hydraulic Plant Piping

- Check and Cleaning
k Pneumatic Electrovalves Lubrication

- Check/Refill
l Runnerhead Sand/Shot Separator
- Check/Replace
- Cleaning
ISSUED BY
DATE
:
:
F2
QC-PC-018/09/REV.0
F2
PERSON IN CHARGE
Section Head S3
Section Head S3
Section Head S3
Section Head S3
Section Head S3
QC-PC-018/09/REV.0
PERSON IN CHARGE
Section Head S3
FORM NO : QC-PCSECTION : MACHINING

NO
MACHINE/EQUIPMENT
1 RIELLO 1 AND 2
FREQUENCY
QUANTITY
Topping Up Grease
Check of Brake Coil
Change of Hydraulic Fluid
Cleaning
Check / Replace Sensor & Limit Switch
Check Motor and Timing Belt
Check Gas at Accumulators
Check Hydraulic Pump and System
Check Panel Contactors, Timers, Wiring
Top Up Coolant
Check Jaw / Reamer
Weekly
6 Months
6 Months
Daily
3 Months
Yearly
6 Months
6 Months
6 Months
Weekly
Daily
30 points
16 pcs
208 litres
2 units
38 pcs
14 pcs
11 units
1 job
1 job
1 job
5sets / 3 sets
2 BROACHING
Check Motor
Lubricating Oil
Check Tool / Jaws
Cleaning
Check Press Button
Top Up Hydraulic oil
Yearly
Daily
Daily
Daily
Monthly
Monthly
1
1
1
1
1
1
job
job
job
job
job
job
3 JINFA DM 1,2, AND 3

Check / Replace V-Belt
Check / Replace Limit Switch
Clean Electrical Panel
Check Motor Condition
ISSUED BY
DATE
:
:
Yearly
6 Months
Monthly
Monthly
3 Months
8 pcs
100 liters
12 pcs
1 job
1 job
RECEIVED BY
DATE
QUANTITY
PERSON IN CHARGE
30 points
16 pcs
208 litres
2 units
38 pcs
14 pcs
11 units
1 job
1 job
1 job
5sets / 3 sets
Section Head S4
1
1
1
1
1
1
job
job
job
job
job
job
Section Head S4
8 pcs
100 liters
12 pcs
1 job
1 job
Section Head S4
RECEIVED BY
DATE
FORM NO : QC-PCSECTION : BRAZING

SECTION : PREVENTIVE MAINTENANCE PROGRAMME
NO
MACHINE / EQUIPMENT
1 INDUCTION BRAZING M/C
FREQUENCY
QUANTITY
3 Months
1 unit
b Coil
- Check / Cleaning
- Change
Weekly
1 unit
c Foot Switch
- Check / Replace
6 Months
1 unit
d Connection
- Check
Weekly
8 units
e Cooling Water System Connection

- Check / Replace
Weekly
6 units
Weekly
I unit
a Main Power Switch Panel

- Cleaning Cover Panel Fan
- Check / Top Up Water
2 BRAZING TORCH
- Clean / Replace Brazing Nozzle
ISSUED BY
DATE
:
:
RECEIVED BY
DATE
QUANTITY
PERSON IN CHARGE
1 unit
1 unit
1 unit
Section Head S5
8 units
6 units
I unit
RECEIVED BY
DATE
FORM NO : QC-PCSECTION : SUB ASSEMBLY

NO
MACHINE / EQUIPMENT
1 AIR TESTING 1 AND 2
Check
Check
Check
Check
Check
& Cleaning Tank

& Service Air Cylinder
/ Replace of Pressure Gauge
/ Replace of Limit Switch
/ Repair of Testing Jig
FREQUENCY
QUANTITY
Daily
3 Months
3 Months
3 Months
Monthly
2
2
2
2
2
units
units
units
units
units
Monthly
Yearly
6 Months
Yearly
Monthly
1 unit
2 pcs
1 unit
1 unit
2 units
Monthly
6 Months
3 Months
Monthly
Monthly
1
1
1
1
1
2 WATER TESTING M/C PUMP

Check and Cleaning
Check/ Replace if needed of Seal
Check & Service of Motor
Check / Replace Pressure Gauge
Check/ Replace of Control Valves
3 WASHING MACHINE
Check and Cleaning
Service, Check Valve
Check /Replace of Air Cylinders
Check Nuts & Bolts
Check / Replace of Water Supply Control Valve
ISSUED BY
DATE
:
:
unit
unit
unit
unit
unit
RECEIVED BY
DATE
QUANTITY
2
2
2
2
2
PERSON IN CHARGE
units
units
units
units
units
Shift Supervisor S6
1 unit
2 pcs
1 unit
1 unit
2 units
Shift Supervisor S6
1
1
1
1
1
Shift Supervisor S6
unit
unit
unit
unit
unit
RECEIVED BY
DATE
FORM NO : QC-PCSECTION : POLISHING

NO
MACHINE / EQUIPMENT
1 POLISHING HEAD 1 TO 9
Check /Change if needed of bearing
Clean/ Change if needed of panel Contactor
Check/ Change if needed of Suction Hose
Check /Change if needed of Dust Guard
FREQUENCY
QUANTITY
2 Years
3 Months
3 Months
3 Months
2 pcs
3 units
1 unit
1 each
3 Months
Yearly
18 pcs
9 units
Weekly
6 Months
Yearly
Monthly
Monthly
Monthly
2 units
2 units
4 pcs
2 units
2 units
2 units
2 POLISHING IDLER 1 TO 5
Check /Change if needed of bearing
Check / Change if needed of Shaft Idler
3 CYCLONE MACHINE 1 & 2
Check
Check
Check
Check
Check
Check
/ Clean of Dust Collector

/ Clean of Ducting Hose
or Replace Bearing
Greasing
/ Clean of Filter Bag
Motor
ISSUED BY
DATE
:
:
RECEIVED BY
DATE
QUANTITY
PERSON IN CHARGE
2 pcs
3 units
1 unit
1 each
Shift Supervisor S7
18 pcs
9 units
Shift Supervisor S7
2 units
2 units
4 pcs
2 units
2 units
2 units
Shift Supervisor S7
RECEIVED BY
DATE
Page : 1 OF 2
FORM NO : QC-PC-023/09/RE
SECTION : PLATING
NO
MACHINE / EQUIPMENT
1 AUTO TRANSPORTERS 1 & 2
Checking / Replacement of Sensor
Check /Change if needed of Lifting Belt
Check / Change if needed of Roller
Change of Gear Box Oil
Check Brake Coil
Check and Maintain Transporter Rail
FREQUENCY
QUANTITY
6 Months
6 Months
Yearly
6 Months
Yearly
Yearly
20 pcs
4 pcs
28 pcs
2 litres
4 units
2 units
6 Months
Yearly
Yearly
6 Months
Yearly
8 pcs
2 pcs
4pcs
1 liter
1 unit
Weekly
Weekly
Weekly
6 Months
5 units
5 units
34 pcs
5 units
6 Months
6 Months
Yearly
1 unit
1 unit
1 unit
Yearly
Weekly
4 pcs
2 units
Yearly
6 Months
3 pcs
3 units
Weekly
6 Months
6 Months
6 Months
5 units
5 units
5 units
1 job
2 Weeks
3 Months
3 Months
Yearly
208 liter
2 pcs
6 pcs
1 unit
Monthly
Monthly
Monthly
1 unit
10 pcs
10 pcs
2 ABS TRANSPORTERS 1 & 2

Check Roller
Check Chain & Sprocket
Check Roller Shaft
Change of Gear Box Oil
Check and Maintain Transporters Rail
3 FILTER - CYANIDE COPPER, COPPER ACID, ABS & BRASS NICKEL
Cleaning Filter
Wash Filter Bag
Check / Change of Filter Cartridge & Bag
Check & Replace Seal
4 CHILLER MACHINE
Cleaning
Refilling of Gas
Painting Chiller Tank
5 AIR BLOWER 1& 2 (AIR AGITATION)
Check & Change Bearing
Cleaning Air Filter
6 EXHAUST 1 TO 4
Cleaning
7 RECTIFIER - BRASS & ABS CHROME, CYANIDE COPPER, ABS NICKEL,
COPPER ACID
Check
Check
Check
Check
Cable Lug Contact

& Cleaning PCB
& Replace Diodes if necessary
& Replace Wire if necessary
8 DEGREASING TANK
Renewal of Chemical
Check & Change of Seal
Check & Replace Heater
Painting Degreasing Tank
9 CONTROL PANEL AUTO LINE
Cleaning Panel
Check & Replace Contactor
Cleaning Contact Point
Page : 2 OF 2
FORM NO : QC-PC-023/09/RE
SECTION : PLATING
NO
10 V BLOCK
MACHINE / EQUIPMENT

Change if necessary
FREQUENCY
QUANTITY
Weekly
As Required
10 pcs
10 pcs
Weekly
As Required
10 pcs
10 pcs
Monthly
Yearly
6 Months
3 Months
6 Months
6 Months
1 job
5 units
14 pcs
1 unit
1 unit
1 unit
Monthly
Monthly
Monthly
1 unit
1 unit
1 unit
Weekly
Yearly
38 units
36 pcs
3 Months
1 job
3 Months
Weekly
1 unit
1 job
Weekly
Weekly
Weekly
3 Months
1 unit
1 job
1 job
1 job
11 FLIGHT BAR
Change if necessary
12 EFFLUENT PLANT
Cleaning Effluent Plant Area
Painting Effluent Plant Tank
Check & change of Seal
Checking Filter Press - Bag / Hydraulics
Change of Carbon
Change of Sand
13 HOIST - DEGREASING
Cleaning
Greasing
Painting
14 ABS AND BRASS PLATING TANK
Wash all water rinse tanks
Painting (Epoxy)
15 CARBON TREATMENT - CYANIDE COPPER, COPPER ACID, BRASS &
ABS NICKEL
Addition of Carbon
16 OVEN
Check / Replace Heater
Clean Blower Filter
17 GENERAL
Clean Main Water Supply Filter Cartridges
Check Water Supply Pipe
Check Air Agitation Pipe
Clean Sludge of Brass and ABS Chrome Tanks
ISSUED BY
DATE
:
:
RECEIVED BY
DATE
:
:
Page : 1 OF 2
PERSON IN CHARGE
Section Head S8 / Production

Assistant
Section Head S8
Section Head S8
Section Head S8
Section Head S8
Section Head S8

Assistant
Section Head S8

Assistant
Page : 2 OF 2
PERSON IN CHARGE
Section Head S8
Section Head S8
Section Head S8
Section Head S8
Section Head S8
Section Head S8
Section Head S8
Section Head S8
FORM NO : QC-PCSECTION : FINAL ASSEMBLY

NO
MACHINE / EQUIPMENT
1 WATER TESTING
Check & Clean Tanks
Check / Replace if needed of Seal
Check/Replace if needed of Motor and Pump
Check / Replace Pressure Gauge 1 & 2
FREQUENCY
QUANTITY
Daily
6 Months
6 Months
Daily
1 units
Daily
Yearly
1 unit
2 pcs
Yearly
2 pcs
3 Months
1 unit
3 Months
1 unit
3 Months
1 unit
2 units
2 BUFFING M/C
Check and Cleaning
Check/Replace of Bearing
3 DRILLING M/C
Check / Replace V- Belt
4 SCREW MOUNTING AIR TOOL
Check & Service
5 BONNET MOUNTING AIR TOOL
Check & Service
6 MONODE MARKER
Check & Service
ISSUED BY
DATE
:
:
RECEIVED BY
DATE
QUANTITY
PERSON IN CHARGE
1 units
Section Head S9
2 units
1 unit
2 pcs
Section Head S9
2 pcs
Section Head S9
1 unit
Section Head S9
1 unit
Section Head S9
1 unit
Section Head S9
RECEIVED BY
DATE
Page : 1 OF 2
SECTION : BUILDING AND EQUIPMENT
NO
MACHINE / EQUIPMENT
FREQUENCY
QUANTITY
1 FACTORY SSB 1
Cleaning
Check Joint Connection
Check Ampere For Incoming Cable
Check Fuse For Outgoing Supply
Check Earthing For SSB
Check/Replace Insulation For Outgoing Supply Cable
Monthly
Monthly
Monthly
Monthly
Monthly
Monthly
1
1
1
1
1
1
job
job
job
job
job
job
Monthly
Monthly
Monthly
Monthly
Monthly
1
1
1
1
1
job
job
job
job
job
2 CAPACITOR BANK
Cleaning
Check or Replace Cables, Connectors, Fuse
Check or Replace Power Factor Regulator
Check Ampere For Capacitor Bank
Check Earthing For Capacitor Bank Panel
3 ROOFING & WALLS
Check, Repair or Replace
Yearly
1 job
Yearly
1 job
Yearly
5 Years
1 job
1 job
3 months
Monthly
Monthly
Monthly
1 job
1 job
1 job
1 unit
Monthly
3 Years
Monthly
1 job
1 job
1 job
3 Months
1 job
Yearly
1 job
3 Years
Yearly
1 units
1 units
2 Months
3 Years
1 unit
1 unit
6 Months
Monthly
1 unit
1 unit
1 unit
1 unit
1 unit
1 unit
1 unit
1 unit
1 unit
2 units
2 Months
3 Years
1 unit
1 unit
4 AWNING
Check / Replace
5 FENCING
Check / Repair
Painting
6 GUARD HOUSE
Check
Check
Check
Check
/
/
/
/
Repair Basic Facility

Repair Lighting, Fan, and DB Box
Replace Insulation of Outgoing Cable
Replace Safety Alarm Panel Battery and Power Supply
7 TOILET
Check / Replace Water Hose
Painting
Check / Repair Lighting
8 CANTEEN
Check / Repair Basic Facility
9 PARAMETER DRAIN
Check, Clean or Repair
10 WATER STORAGE TANK
Painting
Check Condition of Tank Appearance / Piping
11 AIR STORAGE SUMP (RESERVOIR)
Cleaning
Painting
12 COMPRESSOR - INGERSOLL RAND 1 & 2
Cleaning
Check Ultra Coolant Level
Change Oil Filter
Clean Air Filter
Greasing
Change Separator Element
Check Ampere For Incoming Cable
Check Terminal Motor
Check / Clean Pre-Filter & After Filter
13 AIR DRYER
Cleaning
Refill Gas
Page : 2 OF 2
SECTION : BUILDING AND EQUIPMENT
NO
14 PALLET TRUCK
MACHINE / EQUIPMENT
Check & Relubricate

Check / Repair Roller Oil Seal & Shaft
FREQUENCY
QUANTITY
Monthly
Yearly
1 job
4 units
Monthly
Monthly
3 units
Monthly
Monthly
Monthly
Monthly
Monthly
1 job
1 unit
1 job
1 job
1 job
3 Months
1 job
1 job
1 job
2 Months
1 job
1 job
1 job
15 FIRE HYDRANT
Check and Inspect
Discharge water to release mud clog
16 PUMP HOUSE MOTOR
Check
Check
Check
Check
Check
Diesel Level
And Test Condition of Diesel Pump
Insulation For Cable (Manual & Auto)
Voltage For Battery
Alarm For Panel
17 FOGGING
18 SEPTIC TANK
Check / Repair Panel Motor
Check Ampere For Outgoing Cantractor
Check Earthing For Motor
19 TNB SUBSTATION
Check Earthing For Factory
Check / Replace MCCB For Production SSB
Check / Replace Earth Leakage Regulator Factory
ISSUED BY
DATE
:
:
RECEIVED BY
DATE
:
:
Page : 1 OF 2
PERSON IN CHARGE
Electrical Technician
Mechanical Technician (contractor)
Mechanical Technician
Electrical Technician (contractor)
Page : 2 OF 2
PERSON IN CHARGE
Mechanical Technician (Contractor)
PAGE : 1 OF 2
FORM NO : QC-IT-019/09/REV.0
DOE Industries Sdn. Bhd

Hull Cell Test Report
SAMPLE TAKEN ON :
TEST BATH
POSSIBLE DEFECTS
ANALYSIS RESULT
BLUR
ACID COPPER
HIGH CURRENT
LOW CURRENT
BLUR
CYANIDE COPPER
HIGH CURRENT
LOW CURRENT
CROMID ACID ABS AND BRASS
BRIGHT NICKEL ABS AND

BRASS
WHITISH PROBLEM
CONTAMINATION
PEELING
PITTING
RECOMMENDATIONS :
Legend : Analysis Column

= Result Good
x = Result Not Good
ANALYZED BY LAB
ASSISTANT :
VERIFIED BY CHEMICAL
ENGINEER :
PAGE : 2 OF 2
FORM NO : QC-IT-019/09
STANDARD OF HULL CELL TEST CHEMICALS

ACID COPPER
SAMPLE
Standard 1
Possible Cause
1. Bright
2. Dull
Corrective Action
Ok
Possible Cause
1. Bright
2. Dull
Corrective Action
Ok
Possible Cause
1. Fully Bright and
Good Leveling
Corrective Action
Ok
3 - 5 mm
CYANIDE COPPER
SAMPLE
Standard 1
3 - 5 mm
ABS AND BRASS BRIGHT NICKEL

SAMPLE
Standard 1
ABS AND BRASS CHROME

SAMPLE
Standard 1
60-70 mm
Corrective Action
Possible Cause
1. Ratio CrO3 : H2SO4 Ok
240:1
OF 2
O : QC-IT-019/09/REV.0
dn. Bhd
ACTION PLAN
PAGE : 2 OF 2
ICALS
Corrective Action
Corrective Action
Corrective Action
Corrective Action
PAGE : 2 OF 2
RESULTS
Dim. #
Standard
Sample
1
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
Note :
1) All dimensions in (mm) unless specified
2) Refer to the standard drawing during inspection.
Remarks :
Inspection Status
OF 2
: QC-IT-013/09/REV.5
Accept
Reject
PAGE : 2 OF 2
RESULTS
Dim. #
Standard
Sample
1
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
Note :
1) All dimensions in (mm) unless specified
2) Refer to the standard drawing during inspection.
Remarks :
Inspection Status
OF 2
: QC-IT-020/09/REV.0
Accept
Reject
FORM NO : MP-PC-016/09
DOE INDUSTRIES SDN BHD

TRAINING EVALUATION
Trainee Name
Position
Date Joined
Section/Type of Job Trained
Trainer Name
No.
DESCRIPTION OF TRAINING
Prepared BY
TRAINING EVALUATION
Note : Please (x) at the column be
DATE OF TRAINING
according to training evaluation
V.Good
Good
Approved By
FORM NO : MP-PC-016/09/REV.1
RAINING EVALUATION
ase (x) at the column below
to training evaluation
Average
Fail
Approved By
FORM NO :
S1 - PREVENTIVE MAINTENANCE SERVICE CHECKLIST
Date
Shift / Time
Maintenance / Operator :
SAND MIXER
CORE MACHINE NO:
1
Check
Cond.
Remark
2
Remark
Check
3
Remark
Check
Sliding Rail
Motor
Heaters
Wiring
Cleaning
Body
Sensors
Hopper
Temperature Controller
Air Regulator & Gauge
Panel Wiring
Valves
Hoses
Good Condition
a) Machine / part is running smooth
No unusual noise
b) Machine / part as good as original
c) Grease/oil still in validity period
CONDITION
* Maintenance Required
a) The machine is not running smoothly
Slight unusual sound heard
b) The part is slightly worn out
c) Grease / oil close to renewal time
x Need to Repair
a) The machine/part vibrates
Creates loud noise
b) The part is several worn out
c) Machine is potentially down
Checked By
Verified By
Shift Supervisor S1
Prod. Assistant / Prod. En
:
:
Shift / Time
4
Remark
Check
Remark
to Repair
Verified By
Prod. Assistant / Prod. Engineer/HOD Prod.
PREVENTIVE MAINTENANCE MONTHLY CHECK SHEET
SECTION : S2 DIE - CASTING
MONTH : YEAR
MACHINE
JOB / PROCEDURES
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
Cleaning Break Dross / Bottom

Check Secure Bolts & Nuts
FURNACE

Check / Change Cable Head
Check Coil and Change Gasket
Channel Cleaning
Check Timer
PANEL

Clean Contactors of Carbon Build Up
Check and Change Fuse
Check and Cleaning
Top Up of Oiling / Greasing
CASTING
MACHINE
Check / Change Hydraulic Fluid

Check /Change Sensor
Check /Change Rubber Coupling of Hydraulic Pum
Change of Dycote
Clean Sand In Vacuum Bag
SAND BLAST Clean Machine

MACHINE
Check / Change Blasting Nozzle
Cleaning Filter Bag
Check and Cleaning
CHIMNEY
Check Blower Motor

GENERAL
Top Up Dycote
Check Valves / Hose / Air Gun
Remark:
CONDITION
Good Condition
No unusual noise
x Need to Repair
Creates loud noise
DONE BY OPERATOR
DONE BY OPERATOR
DONE BY OPERATOR
CHECK BY SHIFT SUPERVISOR S2
27
VERIFIED BY PROD. Assistant / PROD. ENGINEER/HOD PROD.
28
29
31

DOUBLE CUT -OFF MACHINE

Cond.
CYCLONE DUST EXTRACTOR

Remark
Cond.
RUMBLING MAC
Remark
Cleaning
Dust Collector
Bearing
Check/Change bearing
Ducting Hose
Oil-Gear Box
Motor
Motor
Chain
Greasing
Painting
Sprocket
Check V-Belt
Motor
GRINDING MACHINE
Cond.
Remark
Check/Change bearing
Good Condition
No unusual noise
CONDITION
x Need to Repair
Creates loud noise
Checked By
Verified By
Section Head S3
Prod. Assistant / Prod. Engineer/HO
Date
Shift / Time
:
:
RUMBLING MACHINE
Cond.
Remark
Bearing
Oil-Gear Box
Chain
Sprocket
Motor
x Need to Repair
achine/part vibrates
rt is several worn out

e is potentially down

TOSCA MACHINE
TURBINE
RUNNERHEAD SABD/SHOT SEPERATOR
Check
Remark
Check
Cleaning
Check /Replace
Wear & Tear
Cleaning
ELEVATOR BUCKET
Check
SPINDLE HOUSING LUBRICATION
Remark
Check
VIBRATOR
Remark
Check
SLEEVE
Remark
Check
Check /Replace
Check /Repair
Check /Replace
Cleaning
Cleaning
Cleaning
FILTER BAG
Check
GEAR BOXES LUBRICANT LEVEL

Remark
Check /Cleaning
Check
Check
Check /Cleaning
Section Head S3
Remark
Check
ELEVATOR BELT
Remark
Check & Cleaning
Good Condition
No unusual noise
Checked By
Check
Check /Refill
FEED DUCT
Remark
Remark
PNEUMATIC ELECTROVALVES LUBRICATION
Remark
Check /Refill
HYDRAULIC PLANT PIPING
Remark
Check /Refill
Check
Remark
Check /Repair
CONDITION
x Need to Repair
Creates loud noise
Date
Shift / Time
:
:
ABRASIVE VALVE TILE

Check
Remark
Check /Replace
TRANSMISSION BELT & CHAINS STRETCHING

Check
Remark
Check /Cleaning
Tightening
LINING & BOLT

Check
Remark
Check /Replace
Verified By
Date
Shift / Time
JINFA - 1
Cond.
RIELLO - 1
Remark
RIELLO - 2
Cond.
Remark
Cleaning Panel
Grease
Grease
V - Belt
Brake Coil
Brake Coil
Motor
Hydraulic Fluid
Hydraulic Fluid
Limit Switch
Sensor
Sensor
Hydraulic Fluid
Limit Switch
Limit Switch
Unit Motor
Unit Motor
Timing Belt
Timing Belt
Accumulators
Accumulators
Hydraulic Pump & System
Hydraulic Pump & System
Cleaning Panel
Panel Contactors, Timers, Wiring
Panel Contactors, Timers, Wiring
V - Belt
Coolant
Coolant
JINFA - 2
Cond.
Remark
:
:
Motor
Limit Switch
Hydraulic Fluid
JINFA - 3
Cond.
BROACHING MACHINE
Remark
Cond.
Cleaning Panel
Motor
V - Belt
Press Button
Motor
Hydraulic Oil
Remark
Limit Switch
Hydraulic Fluid
Good Condition
No unusual noise
CONDITION
x Need to Repair
Creates loud noise
Checked By
Verified By
Section Head S4
NO : QC-PC-008/09/REV.2
-2
Cond.
Remark
FORM NO : QC-PCS5 - PREVENTIVE MAINTENANCE SERVICE CHECKLIST

Date
Shift / Time
INDUCTION BRAZING MACHINE

MAIN POWER SWITCH PANEL
Item
Cover Panel Fan
Condition
Good
Not Good
Check
Remark
Cleaning
Item
Water Tank
Check
Min
Condition
Normal
Max
Level
COIL
Item
Coil
Condition
Good
Not Good
Check
Remark
Cleaning
Item
Coil
Foot Switch
Condition
Good
Not Good
Check
Remark
Function
Connection
Check
Item
Connection
Condition
Good
Not Good
Check
Condition
Good
Not Good
Remark
Function
BRAZING TORCH
Remark
Function
Good Condition
No unusual noise
Condition
Not Good Change
COOLING WATER SYSTEM
CONNECTION
Item
Good
Function
FOOT SWITCH
Item
Check
Item
Brazing Nozzle
CONDITION
Check
Condition
Good
Not Good
Remark
Clean
x Need to Repair
Creates loud noise
Done By
Checked By
Verified By
Electrical Technician/Operator
Section Head S5
Prod. Assistant / Prod. Engineer/ HOD Prod.
Shift / Time
:
:
Remark
Remark
Remark
Remark
d to Repair
stant / Prod. Engineer/ HOD Prod.
FORM NO : QC-PCS6 - PREVENTIVE MAINTENANCE SERVICE CHECKLIST

Date
Shift / Time
AIR TESTING MACHINE NO.1
Cond.
AIR TESTING MACHINE NO.2

Remark
Air Cyclinder
Air Cyclinder
Pressure Gauge
Pressure Gauge
Limit Switch
Limit Switch
Testing Jig
Testing Jig
WATER TEST M/C PUMP

Cond.
WASHING MACHINE
Remark
Check & Cleaning
Check & Cleaning
Check / Replace Seal
Air Valves / Supply
Motor
Air Cyclinder
Pressure Gauge
Check Nuts & Bolts
Water Supply Control Valve
Water Supply Control Valves
Good Condition
No unusual noise
Checked By
CONDITION
x Need to Repair
Creates loud noise
Verified By
Shift Supervisor S6
Prod. Assistant / Prod. Engineer/ HOD Prod
:
:
Shift / Time
TESTING MACHINE NO.2

Cond.
Remark
WASHING MACHINE
Cond.
x Need to Repair
hine/part vibrates
loud noise
is several worn out
is potentially down
Remark
ant / Prod. Engineer/ HOD Prod.
Date
Shift / Time
:
:
POLISHING HEADS (BELTING)

1
Cond.
2
Remark
Cond.
3
Remark
Cond.
4
Remark
Cond.
Remark
Cond.
5
Remark
Cond.
Remark
Cond.
Remark
Bearing
Panel Contactor
Suction Hose
Dust Guard
IDLER
1
Cond.
2
Remark
Cond.
3
Remark
Cond.
5
Remark
Bearing
Shaft
POLISHING HEADS (MOPPING)
6
Cond.
7
Remark
Cond.
8
Remark
Cond.
9
Remark
Cond.
Remark
Bearing
Panel Contactor
Suction Hose
Dust Guard
CYCLONE / DUST EXTRACTOR - BELTING
Cond.
CYCLONE / DUST EXTRACTOR - MOPPING
Remark
Cond.
Dust Collector
Dust Collector
Ducting Hose
Ducting Hose
Motor
Motor
Bearing
Bearing
Filter Bag
Filter Bag
Good Condition
No unusual noise
CONDITION
Remark
x Need to Repair
Creates loud noise
Checked By
Verified By
Shift Supervisor S7
Prod. Assistant / Prod. Engineer/ HOD Prod.
S8 (ABS) - PREVENTIVE MAINTENANCE SERVICE CHECKLIST

MONTH :
Equipment Machine
YEAR :
Description of work to be done
Check
Week 1
Remarks/Comments
Check
Week 2
Remarks/Comments
Check
Week 3
Remarks/Comments
Week 4
Check
AIR BLOWER 1 (AIR Cleaning Air Filter

AGITATION)
ABS PLATING TANK
Operators :
Operators :
Operators :
Operators :
In-Charge by
Section Head S8 :
Verified by Prod.
Assistant /
Chemical
Engineer /HOD
Date :
In-Charge by
Section Head S8 :
Verified by Prod.
Assistant /
Chemical
Engineer /HOD
Date :
In-Charge by
Section Head S8 :
Verified by Prod.
Assistant /
Chemical
Engineer /HOD
Date :
In-Charge by
Section Head S8 :
Verified by Prod.
Assistant /
Chemical
Engineer /HOD
Date :
S8 (BRASS) - PREVENTIVE MAINTENANCE SERVICE CHECKLIST

MONTH :
Equipment Machine
YEAR :
Description of work to be done
CYANIDE COPPER
FILTER
Wash filter - 1 unit

Wash filter bag
Change filter bag and carbon cartridge
COPPER ACID
FILTER
Wash filter - 2 units

Wash filter bag
Check
Week 1
Remarks/Comments
Check
Week 2
Remarks/Comments
Check
Week 3
Remarks/Comments
Week 4
Check

Wash filter bag
ABS NICKEL FILTER Change filter bag and carbon cartridge
BRASS NICKEL
FILTER
DEGREASING TANK
BRASS CHROME
RECTIFIER
CYANIDE COPPER
RECTIFIER
COPPER ACID
RECTIFIER
ABS NICKEL
RECTIFIER
ABS CHROME
RECTIFIER

Wash filter bag
Renewal of chemical
Check cable lug contact
V BLOCK
Cleaning contact point

Change if necessary
FLIGHT BAR
Cleaning contact point

Change if necessary
BRASS PLATING Wash all water rinse tanks

TANK
AIR BLOWER 2 (AIR Cleaning Air Filter
AGITATION)
Cleaning Blower Filter
Oven
GENERAL
Clean main water supply filter cartridges

Check water supply pipe
Check air agitation pipe
Operators :
Operators :
Operators :
Operators :
1
2
3
4
1
2
3
4
1
2
3
4
1
2
3
4
In-Charge by
Section Head S8 :
Verified by Prod.
Assistant /
Chemical
Engineer /HOD
Date :
In-Charge by
Section Head S8 :
Verified by Prod.
Assistant /
Chemical
Engineer /HOD
Date :
In-Charge by
Section Head S8 :
Verified by Prod.
Assistant /
Chemical
Engineer /HOD
Date :
In-Charge by
Section Head S8 :
Verified by Prod.
Assistant /
Chemical
Engineer /HOD
Date :
PAGE : 1 OF 2
Week 4
Remarks/Comments
Operators :
1
2
3
4
In-Charge by
Section Head S8 :
Verified by Prod.
Assistant /
Chemical
Engineer /HOD
Date :
PAGE : 2 OF 2
Week 4
Remarks/Comments
Operators :
1
2
3
4
In-Charge by
Section Head S8 :
Verified by Prod.
Assistant /
Chemical
Engineer /HOD
Date :

BUFFING MACHINE
Cond.
DRILLING MACHINE
Remark
Check/Replace bearing
Cond.
MONODE MARKER
Remark
V-belt
Check & Service
WATER TESTING 1
Cond.
WATER TESTING 2
Remark
Cond.
Check/Replace Seal
Check/Replace Seal
Motor and Pump
Motor and Pump
SCREW MOUNTING (Air Tool)

Cond.
Remark
BONNET MOUNTING (Air Tool)

Remark
Check & Service
Cond.
Remark
Check & Service
Good Condition
No unusual noise
CONDITION
x Need to Repair
Creates loud noise
Checked By
Verified By
Section Head S9
Prod. Assistant / Prod. Engineer/H
Date
Shift / Time
:
:
MONODE MARKER
Cond.
Remark
Service
ed to Repair
Verified By

PREVENTIVE MAINTENANCE YEARLY MASTER SCHEDULE
SECTION : CORE SHOP
EQUIPMENT MACHINE
MONTH / WEEK
JOB/MAINTENANCE
1
JANUARY
2
3
4
FEBRUARY
7
8
9
MARCH
APRIL
MAY
JUNE
JULY
AUGUST
SEPTEMBER
OCTOBER
10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40
Check / Replace Sliding Rail
Cleaning
Check / Replace Sensor
Check / Repair Hopper

CORE MACHINE 1, 2, 3
&4
Check / Repair Temperature

Controller
Check / Replace Air Regulator
and Gauge
Check / Replace Panel Wiring
Check / Replace Valves
Check / Replace Hoses
Check / Replace Motor
SAND MIXER
Check / Replace Wiring
Check / Replace Body
Highlighted "C" denotes Preventive Maintenance Completed

Denotes PM postponed to new date
PM day - Saturday
Note : i) 1 day adjustment on delay fixed day
ii) PM Schedule circulated to Supervisor, Engineer, Manager
Legend :
W = Weekly
M = Monthly
Q = Quarterly
Y = Yearly
Prepared By :
Verified By :
Shift Supervisor S1
Prod. Assistant/Prod. Engine
YEAR :
OCTOBER
NOVEMBER
DECEMBER
41 42 43 44 45 46 47 48 49 50 51 52
ified By :
od. Assistant/Prod. Engineer / HOD Prod.

SECTION : CASTING
EQUIPMENT MACHINE
MONTH / WEEK
JOB/MAINTENANCE
1
JANUARY
2
3
4
FEBRUARY
7
8
9
MARCH
APRIL
MAY
JUNE
JULY
AUGUST
SEPTEMBER
OCTOBER
10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42
Cleaning Break Dross / Bottom
Check Securing Bolt and Nut

FURNACE
Check / Change Cable Head
Check Coil & Change Gasket
Channel Cleaning
Check Timer

CONTROL PANEL
Clean Contactors of Carbon
Build Up
Check / Change Fuse
Clean Sand In Vacuum Bag
Clean Machine
SAND BLASTING M/C
Check /Change Blasting
Nozzle
Cleaning of Filter Bag

PM day - Saturday
Legend :
W = Weekly
M = Monthly
Q = Quarterly
Y = Yearly
Prepared By :
Verified By :
Shift Supervisor S2
Prod. Assistant/Prod. Engineer /HO

SECTION : CASTING
EQUIPMENT MACHINE
MONTH / WEEK
JOB/MAINTENANCE
1
JANUARY
2
3
4
FEBRUARY
7
8
9
MARCH
APRIL
MAY
JUNE
JULY
AUGUST
SEPTEMBER
OCTOBER
10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42
Check & Cleaning
Top Up/ Check Oiling or

Greasing
Check / Change Hydraulic
Fluid
CASTING M/C
Check / Change Rubber

Coupling of Hydraulic Pump
Change of Dycote
Check and Cleaning
CHIMNEY
Check Blower Motor
Top Up Dycote
GENERAL
Check / Change Air Hoses and
Valves

PM day - Saturday
Legend :
W = Weekly
M = Monthly
Q = Quarterly
Y = Yearly
Prepared By :
Verified By :
Shift Supervisor S2
Prod. Assistant/Prod. Engineer /HO
TOBER
PAGE : 1 OF 2
YEAR :
NOVEMBER
DECEMBER
43 44 45 46 47 48 49 50 51 52
tant/Prod. Engineer /HOD Prod.

PAGE : 2 OF 2
TOBER
YEAR :
NOVEMBER
DECEMBER
43 44 45 46 47 48 49 50 51 52
tant/Prod. Engineer /HOD Prod.

SECTION : FETTLING
EQUIPMENT MACHINE
MONTH / WEEK
JOB/MAINTENANCE
JANUARY
3
4
FEBRUARY
7
8
9
10
MARCH
11 12
13
14
APRIL
15 16
17
18
19
MAY
20 21
22
23
JUNE
24 25
26
27
28
JULY
29 30
31
32
AUGUST
33 34
35
36
SEPTEMBER
37 38 39
40
OCTOBER
41 42
Cleaning
Check / Change Bearing
Double Cut- Off

Machine
Check / Replace V.Belt
Greasing
Check Motor
GRINDING M/C
Clean Dust Collector
Ducting Hose
CYCLONE MACHINE
Check Motor
Painting (Epoxy)
Change Oil Gear Box
RUMBLING MACHINE Check / Change Chain
Check / Change Sprocket
Check Motor
PM day - Saturday
Legend :
W = Weekly
M = Monthly
Q = Quarterly
Y = Yearly
Prepared By :
Verified By :
Section Head S3
Prod. Assistant/Prod. Engineer / H

SECTION : TOSCHA MACHINE
EQUIPMENT MACHINE
TURBINE
SPINDLE HOUSING
LUBRICATION
MONTH / WEEK
JOB/MAINTENANCE
1
JANUARY
2
3
4
FEBRUARY
7
8
9
MARCH
APRIL
MAY
JUNE
JULY
AUGUST
SEPTEMBER
OCTOBER
10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42
Visual Check - Wear & Tear

Cleanning
Check / Refill
TRANSMISSION BELT &

Check / Cleaning / Tightening
CHAIN STRETCHING
LINING & BOLT
FEED DUCT
Check / Replace
Check/ Cleanning
ABRASIVE VALVE TILE Check / Replace
GEAR BOXES
LUBRICANT LEVEL
Check / Refill
HYDRAULIC PLANT
PIPING
Check / Cleaning
Check / Replace
ELEVATOR BUCKET
Cleaning
FILTER BAG
PNEUMATIC
ELECTROVALVE
LUBRICATION
Check / Cleanning
Check / Refill
Cleaning
RUNNERHEAD SAND /
SHOT SEPARATOR
Check / Replace
ELEVATOR BELT
Check/Repair
Higlighted "C" denotes Preventive Maintenance Completed
PM day - Saturday
Legend :
W = Weekly
M = Monthly
Q = Quarterly
Y = Yearly
Prepared By :
Verified By :
Section Head S3

SECTION : TOSCHA MACHINE
EQUIPMENT MACHINE
MONTH / WEEK
JOB/MAINTENANCE
1
JANUARY
2
3
4
FEBRUARY
7
8
9
MARCH
APRIL
MAY
JUNE
JULY
AUGUST
SEPTEMBER
OCTOBER
10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42
Cleaning
VIBRATOR
Check / Repair
Check / Replace
SLEEVE
Cleaning

PM day - Saturday
Legend :
W = Weekly
M = Monthly
Q = Quarterly
Y = Yearly
Prepared By :
Verified By :
Section Head S3
Page : 1 OF 3
YEAR :
TOBER
43
44
NOVEMBER
45 46 47
48
49
DECEMBER
50 51 52
tant/Prod. Engineer / HOD Prod.
TOBER
Page : 2 OF 3
YEAR :
NOVEMBER
DECEMBER
43 44 45 46 47 48 49 50 51 52

Page : 3 OF 3
TOBER
YEAR :
NOVEMBER
DECEMBER
43 44 45 46 47 48 49 50 51 52
PAGE : 1 OF 2
FORM NO : QC-PC-02

SECTION : MACHINE SHOP
EQUIPMENT MACHINE
MONTH / WEEK
JOB/MAINTENANCE
1
JANUARY
2
3
4
FEBRUARY
7
8
9
MARCH
APRIL
MAY
JUNE
JULY
AUGUST
SEPTEMBER
OCTOBER
10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42
Topping Up Grease
Check Brake Coil
Check & Replace Sensor &

Limit Switch
RIELLO M/C 1
Check Motor, Timing Belt
Check Gas at Accumulator
Check Hydraulic Pump &

System
Check Panel Contactor, Timer,
Wiring
Top Up Coolant
JINN FA 1, 2 & 3
Check & Replace Limit Switch
Clean Electrical Panel

PM day - Saturday
Legend :
W = Weekly
M = Monthly
Q = Quarterly
Y = Yearly
Prepared By :
Verified By :
Section Head S4
PAGE : 2 OF 2
FORM NO : QC-PC-02

SECTION : MACHINE SHOP
EQUIPMENT MACHINE
MONTH / WEEK
JOB/MAINTENANCE
1
JANUARY
2
3
4
FEBRUARY
7
8
9
MARCH
APRIL
MAY
JUNE
JULY
AUGUST
SEPTEMBER
OCTOBER
10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42
Check Motor
BROACHING M/C
Check Press Button
Top Up Hydraulic Oil
Topping Up Grease
Check Brake Coil
Check & Replace Sensor &

Limit Switch
RIELLO M/C 2
Check Motor, Timing Belt
Check Gas at Accumulator
Check Hydraulic Pump &

System
Check Panel Contactor, Timer,
Welding
Top Up Coolant

PM day - Saturday
Legend :
W = Weekly
M = Monthly
Q = Quarterly
Y = Yearly
Prepared By :
Verified By :
Section Head S4
PAGE : 1 OF 2
TOBER
YEAR :
NOVEMBER
DECEMBER
43 44 45 46 47 48 49 50 51 52
PAGE : 2 OF 2
TOBER
YEAR :
NOVEMBER
DECEMBER
43 44 45 46 47 48 49 50 51 52
FORM

SECTION : BRAZING
EQUIPMENT MACHINE
MONTH / WEEK
JOB/MAINTENANCE
1
JANUARY
2
3
4
FEBRUARY
7
8
9
MARCH
APRIL
MAY
JUNE
JULY
AUGUST
SEPTEMBER
OCTOBER
10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42
Cleaning Cover Panel Fan

MAIN POWER SWITCH
PANEL
Check / Top Up Water
COIL
Check / Cleaning
FOOT SWITCH
Check / Replace
CONNECTION
Check
COOLING WATER
Check / Replace
SYSTEM CONNECTION
BRAZING NOZZEL
Clean / Replace

PM day - Saturday
Legend :
W = Weekly
M = Monthly
Q = Quarterly
Y = Yearly
Prepared By :
Verified By :
Section Head S5
Prod. Assistant/Prod. Engineer / HOD Prod.
TOBER
YEAR :
NOVEMBER
DECEMBER
43 44 45 46 47 48 49 50 51 52
. Engineer / HOD Prod.
PAGE : 1 OF 2
FORM NO : QC-PC-03

SECTION : SUB ASSEMBLY
EQUIPMENT MACHINE
MONTH / WEEK
JOB/MAINTENANCE
1
JANUARY
2
3
4
FEBRUARY
7
8
9
MARCH
APRIL
MAY
JUNE
JULY
AUGUST
SEPTEMBER
OCTOBER
10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42
Check & Service Air Cylinder
AIR TESTING MACHINE

NO.1
Check / Replace Pressure

Gauge
Check / Repair Testing Jig
Check & Service Air Cylinder
AIR TESTING MACHINE

NO.2

Gauge
Check / Repair Testing Jig
Check & Cleaning
Check & Replace Seal
WATER TESTING M/C

Check & Service Motor
PUMP
Gauge
Check / Replace Control
Valves
PM day - Saturday
Legend :
W = Weekly
M = Monthly
Q = Quarterly
Y = Yearly
Prepared By :
Verified By :
Shift Supervisor S6

EQUIPMENT MACHINE
MONTH / WEEK
JOB/MAINTENANCE
1
JANUARY
2
3
4
FEBRUARY
7
8
9
MARCH
APRIL
MAY
JUNE
JULY
AUGUST
SEPTEMBER
OCTOBER
10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42
Check & Cleaning
Service & Check Valves
WASHING MACHINE
Check / Replace Air Cylinders
Check Nuts & Bolts
Check / Replace Water Supply

Control Valve

PM day - Saturday
Legend :
W = Weekly
M = Monthly
Q = Quarterly
Y = Yearly
Prepared By :
Verified By :
Shift Supervisor S6
PAGE : 1 OF 2
TOBER
YEAR :
NOVEMBER
DECEMBER
43 44 45 46 47 48 49 50 51 52
TOBER
PAGE : 2 OF 2
YEAR :
NOVEMBER
DECEMBER
43 44 45 46 47 48 49 50 51 52
FORM

SECTION : POLISHING
EQUIPMENT MACHINE
MONTH / WEEK
JOB/MAINTENANCE
1
JANUARY
2
3
4
FEBRUARY
7
8
9
MARCH
APRIL
MAY
JUNE
JULY
AUGUST
SEPTEMBER
OCTOBER
10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42
Clean / Change Panel Contacto

POLISHING HEAD 1 TO 9
Check / Change Suction Hose
Check / Change Dust Guard

POLISHING IDLER 1 to
5
Check / Change Shaft Idler
Check / Cleaning Dust Collecto
Check / Cleaning Ducting Hose
Check / Replace Bearing

CYCLONE MACHINE 1
&2
Check Greasing
Check & Cleaning Filter Bag
Check Motor

PM day - Saturday
Legend :
W = Weekly
M = Monthly
Q = Quarterly
Y = Yearly
Prepared By :
Verified By :
Shift Supervisor S7
TOBER
YEAR :
NOVEMBER
DECEMBER
43 44 45 46 47 48 49 50 51 52

SECTION : PLATING (ABS)
EQUIPMENT MACHINE
MONTH / WEEK
JOB/MAINTENANCE
1
JANUARY
2
3
4
FEBRUARY
7
8
9
MARCH
APRIL
MAY
JUNE
JULY
AUGUST
SEPTEMBER
OCTOBER
10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42

ABS PLATING TANK
Painting

EXHAUST NO.1 AND
NO. 2
Cleaning
Check Roller

ABS TRANSPORTERS
Check Roller Shaft
NO.1
Change Gear Box Oil
Check / Maintain Transporters
Rail
Check Roller

ABS TRANSPORTERS
Check Roller Shaft
NO.2
Change Gear Box Oil
Rail
AIR BLOWER 1 (AIR
AGITATION)
Cleaning
PM day - Saturday
Legend :
W = Weekly
M = Monthly
Q = Quarterly
Y = Yearly
Prepared By :
Verified By :
Section Head S8

SECTION : PLATING (BRASS)
EQUIPMENT MACHINE
MONTH / WEEK
JOB/MAINTENANCE
1
JANUARY
2
3
4
FEBRUARY
7
8
9
MARCH
APRIL
MAY
JUNE
JULY
AUGUST
SEPTEMBER
OCTOBER
10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42

BRASS PLATING TANK
Painting
Change Lifting Belt
Change Roller
AUTO TRANSPORTERS
NO.1
Change Gear Box Oil
Check Break Coil

Rail
Change Lifting Belt
Change Roller
AUTO TRANSPORTERS
NO.2
Change Gear Box Oil
Check Break Oil

Rail
AIR BLOWER 2 (AIR
AGITATION)
Cleaning Air Filter
PM day - Saturday
Legend :
W = Weekly
M = Monthly
Q = Quarterly
Y = Yearly
Prepared By :
Verified By :
Section Head S8

EQUIPMENT MACHINE
MONTH / WEEK
JOB/MAINTENANCE
1
JANUARY
2
3
4
FEBRUARY
7
8
9
MARCH
APRIL
MAY
JUNE
JULY
AUGUST
SEPTEMBER
OCTOBER
10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42
Check Cable Lug Contact
CYANIDE COPPER
RECTIFIER
Cleaning & Check PCB

Check / Replace Diodes
Check / Replace Wire
COPPER ACID
RECTIFIER

ABS NICKEL RECTIFIER

ABS CHROME
RECTIFIER

BRASS CHROME
RECTIFIER

PM day - Saturday
Legend :
W = Weekly
M = Monthly
Q = Quarterly
Y = Yearly
Prepared By :
Verified By :
Section Head S8

EQUIPMENT MACHINE
MONTH / WEEK
JOB/MAINTENANCE
1
JANUARY
2
3
4
FEBRUARY
7
8
9
MARCH
APRIL
MAY
JUNE
JULY
AUGUST
SEPTEMBER
OCTOBER
10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42
Cleaning Filter
Wash Filter Bag

CYANIDE COPPER
FILTER
Check / Change Filter

Cartridge & Bag
Cleaning Filter
Wash Filter Bag

COPPER ACID FILTER
Cartridge & Bag
Cleaning Filter
Wash Filter Bag

ABS NICKEL FILTER
Cartridge & Bag
Cleaning Filter
Wash Filter Bag

BRASS NICKEL FILTER
Cartridge & Bag
PM day - Saturday
Legend :
W = Weekly
M = Monthly
Q = Quarterly
Y = Yearly
Prepared By :
Verified By :
Section Head S8

EQUIPMENT MACHINE
MONTH / WEEK
JOB/MAINTENANCE
1
JANUARY
2
3
4
FEBRUARY
7
8
9
MARCH
APRIL
MAY
JUNE
JULY
AUGUST
SEPTEMBER
OCTOBER
10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42

V BLOCK
Change if necessary
CYANIDE COPPER
Addition of Carbon
CARBON TREATMENT
COPPER ACID CARBON
Addition of Carbon
TREATMENT
BRASS NICKEL
Addition of Carbon
CARBON TREATMENT
ABS NICKEL CARBON
Addition of Carbon
TREATMENT
Cleaning Panel
CONTROL PANEL AUTO
Check / Replace Contactor
LINE
Renewal of Chemical
Check / Change Seal

DEGREASING TANK

FLIGHT BAR
Change if necessary

Oven
Clean Blower Filter
PM day - Saturday
Legend :
W = Weekly
M = Monthly
Q = Quarterly
Y = Yearly
Prepared By :
Verified By :
Section Head S8

SECTION : PLATING
EQUIPMENT MACHINE
MONTH / WEEK
JOB/MAINTENANCE
1
JANUARY
2
3
4
FEBRUARY
7
8
9
MARCH
APRIL
MAY
JUNE
JULY
AUGUST
SEPTEMBER
OCTOBER
10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42
Cleaning
CHILLER MACHINE
Refilling of Gas

EXHAUST NO.3 AND
NO.4
Cleaning
Cleaning
HOIST - DEGREASING Greasing
Painting
Clean Main Water Supply Filter
Cartridges
Check Water Supply Pipe
GENERAL
Check Air Agitation Pipe
Clean Sludge of ABS and Brass
Chrome Tanks

PM day - Saturday
Legend :
W = Weekly
M = Monthly
Q = Quarterly
Y = Yearly
Prepared By :
Verified By :
Section Head S8

SECTION : PLATING
EQUIPMENT MACHINE
MONTH / WEEK
JOB/MAINTENANCE
1
JANUARY
2
3
4
FEBRUARY
7
8
9
MARCH
APRIL
MAY
JUNE
JULY
AUGUST
SEPTEMBER
OCTOBER
10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42
Check/ Change Seal

EFFLUENT PLANT
Check Filter Press Bag/Hydraulics
Change Carbon
Change Sand

PM day - Saturday
Legend :
W = Weekly
M = Monthly
Q = Quarterly
Y = Yearly
Prepared By :
Verified By :
Section Head S8
PAGE : 1 OF 7
TOBER
YEAR :
NOVEMBER
DECEMBER
43 44 45 46 47 48 49 50 51 52
PAGE : 2 OF 7
TOBER
YEAR :
NOVEMBER
DECEMBER
43 44 45 46 47 48 49 50 51 52
PAGE : 3 OF 7
TOBER
YEAR :
NOVEMBER
DECEMBER
43 44 45 46 47 48 49 50 51 52
PAGE : 4 OF 7
TOBER
YEAR :
NOVEMBER
DECEMBER
43 44 45 46 47 48 49 50 51 52
PAGE : 5 OF 7
TOBER
YEAR :
NOVEMBER
DECEMBER
43 44 45 46 47 48 49 50 51 52
PAGE : 6 OF 7
TOBER
YEAR :
NOVEMBER
DECEMBER
43 44 45 46 47 48 49 50 51 52
PAGE : 7 OF 7
TOBER
YEAR :
NOVEMBER
DECEMBER
43 44 45 46 47 48 49 50 51 52
FORM

SECTION : FINAL ASSEMBLY
EQUIPMENT MACHINE
MONTH / WEEK
JOB/MAINTENANCE
1
JANUARY
2
3
4
FEBRUARY
7
8
9
MARCH
APRIL
MAY
JUNE
JULY
AUGUST
SEPTEMBER
OCTOBER
10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42

WATER TESTING
Check / Replace Motor and
Pump
BUFFING M/C
Check/ Replace Bearing

Condition
DRILLING M/C
SCREW MOUNTING AIR

Check & Service
TOOL
BONNET MOUNTING
Check & Service
AIR TOOL
MONODE MARKER
Check & Service

PM day - Saturday
Legend :
W = Weekly
M = Monthly
Q = Quarterly
Y = Yearly
Prepared By :
Verified By :
Section Head S9
TOBER
YEAR :
NOVEMBER
DECEMBER
43 44 45 46 47 48 49 50 51 52
PAGE : 1 OF 2
FORM NO : QC-PC-035/09

SECTION : BUILDING AND MAINTENANCE
EQUIPMENT MACHINE
MONTH / WEEK
JOB/MAINTENANCE
1
JANUARY
2
3
4
FEBRUARY
7
8
9
MARCH
APRIL
MAY
JUNE
JULY
AUGUST
SEPTEMBER
OCTOBER
10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42
Cleaning
FACTORY SSB 1
Check Joint Connection
Cleaning
CAPACITOR BANK
Check / Replace Cables,
Connectors, Fuse
Cleaning
Check Ultra Coolant Level
COMPRESSOR INGERSOLL RAND 1 &

2
Change Oil Filter
Clean Air Filter
Greasing
Change Separator Element
Cleaning
AIR DRYER
Refill Gas

PM day - Saturday
Legend :
W = Weekly
M = Monthly
Q = Quarterly
Y = Yearly
Prepared By :
Verified By :
PAGE : 2 OF 2
FORM NO : QC-PC-035/09

SECTION : BUILDING AND MAINTENANCE
EQUIPMENT MACHINE
ROOFING & WALLS
AWNING
MONTH / WEEK
JOB/MAINTENANCE
1
JANUARY
2
3
4
FEBRUARY
7
8
9
MARCH
APRIL
MAY
JUNE
JULY
AUGUST
SEPTEMBER
OCTOBER
10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42
Check, Repair / Replace
Check / Replace
Check/ Repair
FENCING
Painting
Check / Repair
GUARD HOUSE
Safety Alarm Panel
Painting
TOILET
Check, Clean / Repair
CANTEEN
PARAMETER DRAIN
Cleaning
WATER STORAGE TANK Painting
Check Structure Condition
Cleaning
AIR STORAGE SUMP
(RESERVOIR)
Painting
PALLET TRUCK
Check & Relubricate Roller &

Oil Seal
PM day - Saturday
Legend :
W = Weekly
M = Monthly
Q = Quarterly
Y = Yearly
Prepared By :
Verified By :
GE : 1 OF 2
ORM NO : QC-PC-035/09/REV.0
TOBER
YEAR :
NOVEMBER
DECEMBER
43 44 45 46 47 48 49 50 51 52
GE : 2 OF 2
ORM NO : QC-PC-035/09/REV.0
TOBER
YEAR :
NOVEMBER
DECEMBER
43 44 45 46 47 48 49 50 51 52
FORM NO : MP-PC-006
Hourly Inspection Sheet

Legend:
Machine No. /
Process
Product
No inspection
Inspected
Threading
Production
Period
Dimensions Specification Range
Seat
MD
SE
Reamed Size A
[mm]
Machine Down
Setting/Service
Reamed Size B
[mm]
Section : S
Date
:
Flange Size
[mm]
Hole Size
[mm]
RIELLO M/C 1
RIELLO M/C 2
JF 2 WAY 1
JF 2 WAY 2
JF 2 WAY 3
BROACHING
MANUAL CUT
Inspection methodology :
Inspected by
1) Use threaded, ring or plug gauges for Go and No Go ends
Name
Date
Name
Date
Setter
Checked by
Section Head S4
2) To record dimensions
Remarks: [to comment on non-inspection, if any]
3) Each box denotes per hour inspection
Tube Size
[mm]
TRIES SDN BHD
spection Sheet
Section : S4
Date
:
Bonnet Size
[mm]
4) Sample size: min. 2pcs
FORM NO : MP-PC-0
CORE SHOP (S1)
Checklist for Mixing Core Sand / Operating Parameters
Shift
Working Hours
Mixing Formula
Description
Silica Sand
20/60 (KG)
Silica Sand
30/60 (KG)
Resin HP
301 (ml)
Catalyst
Harter
AT7 (ml)
Quantity
Ammonium
(ml)
Silica
Std.
Mixing
Timer
Total Used
Resin
Catalyst
Ammonia
Record time for each as stated below:Machine
Mix No.
Start Mix
Stop Mix
Machine 1
Machine 2
To Hopper
1
2
3
4
5
6
7
8
9
10
11
12
Parameters
Machine 3
Product
Core Box Temperature
(260-450C)
Blowing Pressure (4 to 6 Bar)
Curing Time
(8 -40 sec.)
Note : All the mixing must be use within an hour after mixed it
Prepared By,
Operator
Checked By,
Shift Supervisor S1
Approved By,
Prod. Assistant/Prod. Engineer/HOD
ng Parameters
Date
Std.
Act.
1 min
2 min
1 min
1 min
Completed
Machine 3
Operator
Machine 4
Approved By,
Prod. Assistant/Prod. Engineer/HOD Prod.
CHECK LIST FOR CASTING
Shift
Date
NO
DESCRIPTION
STD
Temperature
9501070C
Furnace Brass Level
Dycote Top-Up & Level
Heating Up Laddies
Prepared By,
Operator
3/4 min
Full Bin
OK
NOT OK
:
FREQUENCY
Start - Up
Start - Up
Start - Up
(1st & 2nd Shift)
Start - Up
(1st & 2nd Shift)
REMARKS
Checked By,
Shift Supervisor S2
METAL CHARGING FORMAT
CHARGER
VERIFIED BY SHIFT
SUPERVISOR S2
:
TIME
INGOT
FURNACE
PCS
KGS
RUNNERS/
REJECTS ZINC KGS
KGS
DATE
SHIFT
ALUMINUM
KGS
AE
BE
REMARKS
MP-PC-007/09/REV.2
AE
BE
REMARKS
FORM NO : MP-PC-009/09/R
CHECK LIST FOR ELECTROPLATING (S8) - BRASS LINE
Date :
Check By
Working Hours :
Operator :
Verified By Section Head S8 :
At prestart level, to ensure that all switches are ON position

DESCRIPTION
ON
OFF
DEGREASER HEATER
TRANSPORTER MCB
MAIN WATER SUPPLY
RECTIFIER
AIR BLOWER
Frequency : Every 3 hours

REQUIRED TEMP
CHEMICAL
OP 283
(C)
40-65
CYANIDE COPPER
60-70
ACID COPPER
24-40
ABS NICKEL
49-60
BRASS NICKEL
49-60
ABS CHROME
45-55
BRASS CHROME
45-55
ACTUAL READING (C)

7:00/8:00 AM
10:00/11:00 AM
1:00/2:00 PM
4:00/5:00 PM

ACTUAL READING (pH)
CHEMICAL
STD pH
ABS NICKEL
4.0 - 4.5
BRASS NICKEL
4.0 - 4.5
7:00/8:00 AM
10:00/11:00 AM
7:00/8:00 AM
10:00/11:00 AM
7:00/8:00 AM
10:00/11:00 AM
1:00/2:00 PM
4:00/5:00 PM

BRASS
PRODUCT CATEGORY
STD Volts & Amp
SMALL
5~7
MEDIUM
5~7
500~800
BIG
6~8
600~1500
ACTUAL READING (Volts & Amp)

1:00/2:00 PM
4:00/5:00 PM
500~800

ABS
PRODUCT CATEGORY
STD Volts & Amp
SMALL
5~7
1500~3400
MEDIUM
6~8
2500~4000
ACTUAL READING (Volts & Amp)

1:00/2:00 PM
4:00/5:00 PM
NE
ING (C)
7:00/8:00PM
10:00/11:00 PM
7:00/8:00PM
10:00/11:00 PM
7:00/8:00PM
10:00/11:00 PM
7:00/8:00PM
10:00/11:00 PM
ING (pH)
Volts & Amp)
Volts & Amp)
BAR TRACKING FORM
OPERATOR NAME
SHIFT
Good
Reject
DATE
CHECKED BY SECTION HEAD S8 :
Good
Reject
Good
Reject
Good
Reject
Total Qty
Good
Reject
Good Qty
Good
Reject
Rej Qty
Good
Rej %
BRASS
Bars
pcs
pcs
pcs
ABS
Bars
pcs
pcs
pcs
TOTAL
Bars
pcs
pcs
pcs
Reject
DATE
TION HEAD S8 :
Reject
Good
Reject
FORM NO : MP-PC-014/
WASTE WATER TREATMENT RECORD
Section
: Effluent Treatment Plant
Date
Type :
Cyanide
Item
Type :
Qty
pH (Be)
pH (Af)
ORP (Be)
ORP (Af)
Chrome
Item
Caustic Soda (Kg)
Sulphuric Acid (Kg)
S. Hypochloride (Ltr)
S.Metabisulphate (Kg)
Sulphuric Acid (Kg)
Caustic Soda (Kg)
Polyfloc 10P (Kg)
Sulphuric Acid (Kg)
Polyfloc 20L (Ltr)
Polyfloc 10P (Kg)
Qty
pH (Be)
pH (Af)
pH (Be)
pH (Af)
Polyfloc 20L (Ltr)

Type :
Acid & Alkali (1st)

Item
Qty
Type :
pH (Be)
pH (Af)
Acid & Alkali (2nd)

Item
Qty
Caustic Soda (Kg)
Caustic Soda (Kg)
Sulphuric Acid (Kg)
Sulphuric Acid (Kg)
Polyfloc 10P (Kg)
Polyfloc 10P (Kg)
Polyfloc 20L (Ltr)
Polyfloc 20L (Ltr)
Note :
Be - Before dosing
Af - After dosing
Remark :
Recorded By,
Checked By,
Waste Water Treatment Plant Operator
Section Head S8
ORP (Be)
Checked By,
Section Head S8
ORP (Af)
FORM NO : MP-PCDOE INDUSTRIES SDN BHD

CHECK LIST FOR ELECTROPLATING (S8) - ABS LINE
Date :
Checked By Operator:
Working Hours :
Verified By Section Head S8 :

STD
(C)
CHEMICAL
Udyprep 110EC
40-50
Etching
65-70
Accelerator
35-40
ENP
40-50
7:00/8:00 AM
10:00/11:00 AM
ACTUAL READING (C)

1:00/2:00 PM
4:00/5:00 PM
7:00/8:00 AM
10:00/11:00 AM
ACTUAL READING (C)

1:00/2:00 PM
4:00/5:00 PM

CHEMICAL
ENP
Remarks:
STD pH
6-8
LINE
G (C)
7:00/8:00PM
10:00/11:00 PM
7:00/8:00PM
10:00/11:00 PM
G (C)
PREVENTIVE MAINTENANCE SERVICE REPORT

PERSON IN CHARGE
DATE :
TIME START :
EQUIPMENT
1.
&
2.
LOCATION :
3.
TIME FINISH :
WORK DONE :
1.
2.
3.
4.
5.
6.
FAULT :
1.
2.
3.
4.
PARTS CHANGED :
1.
2.
3.
REMARKS :
Prepared By,
Checked By,
Verified By,
Person In Charge
Prod. Assistant
Engineer /HOD Prod.
RM NO : QC-PC-013/09/REV.1
Verified By,
Engineer /HOD Prod.
S8 (ABS) - PREVENTIVE MAINTENANCE SERVICE CHECKLIST
1.
2.
ABS PLATING TANK

Cond.
EXHAUST NO.1
Time Start
Time End
Painting
Cond.
Time Start
Time Start
Time End
Cleaning
Cleaning
ABS TRANSPORTERS NO. 1

Cond.
EXHAUST NO.2
ABS TRANSPORTERS NO. 2

Time End
Cond.
Check Roller
Check Roller
Check Roller Shaft
Check Roller Shaft
Change Gear Box Oil

Rail
Change Gear Box Oil

Rail
Time Start
AIR BLOWER 1 (AIR AGI

Time End
Remarks:
Good Condition
No unusual noise
CONDITION
x Need to Repair
Creates loud noise
Checked By
Verified By
Section Head S8
1.
2.
BRASS PLATING TANK

Cond.
Time Start
EXHAUST NO.3
Time End
Painting
Cond.
Time Start
Time Start
Time End
Cleaning
Cleaning
AUTO TRANSPORTERS NO. 1

Cond.
EXHAUST NO.4
AUTO TRANSPORTERS NO. 2

Time End
Cond.
Time Start
CHILLER MACHIN
Time End
Cleaning
Check / Change Timing Belt
Check / Change Timing Belt
Refilling of Gas
Check / Change Roller
Check / Change Roller
Change Gear Box Oil
Change Gear Box Oil

Rail

Rail
AIR BLOWER 2 (AIR AGITATION)

Cond.
Time Start
CYANIDE COPPER FILTER

Time End
Cond.
Time Start
COPPER ACID FILT

Time End
Remarks:
Good Condition
No unusual noise
CONDITION
x Need to Repair
Creates loud noise
Checked By
Verified By
Section Head S8

1.
2.
ABS NICKEL FILTER

Cond.
BRASS NICKEL FILTER

Time Start
Time End
Cond.
Time Start
V BLOCK
Time End
BRASS CHROME RECTIFIER

Cond.
Time Start
Change if necessary
ABS CHROME RECTIFIER
Time End
Cond.
Time Start
CYANIDE COPPER REC

Time End
Check & Cleaning PCB
ABS NICKEL RECTIFIER

Cond.
Time Start
COPPER ACID RECTIFIER

Time End
Cond.
Time Start
DEREASING TANK
Time End
Check / Change Seal
Remarks:
Good Condition
No unusual noise
CONDITION
x Need to Repair
Creates loud noise
Checked By
Verified By
Section Head S8
1.
2.
CYANIDE COPPER CARBON TREARMENT

Cond.
Time Start
COPPER ACID CARBON TREARMENT

Time End
Addition of Carbon
Cond.
Time Start
BRASS NICKEL CARBON TR

Time End
Addition of Carbon
ABS NICKEL CARBON TREARMENT

Cond.
Time Start
Addition of Carbon
FLIGHT BAR
Time End
Addition of Carbon
Cond.
CONTROL PANEL AUTO

Time Start
Time End
Change if necessary
Cleaning Panel
Check / Replace Contactor
HOIST - DEGREASING
Cond.
Cleaning
Time Start
OVEN
Time End
Cond.
GENERAL
Time Start
Greasing
Time End
Clean Sluge of Brass & ABS
Chrome Tank
Painiting
Remarks:
Good Condition
No unusual noise
CONDITION
x Need to Repair
Creates loud noise
Checked By
Verified By
Section Head S8
1.
2.
EFFLUENT PLANT
Cond.
Time Start
Time End

Check / Change Seal
Check Filter Press - Bag / Hydraulics
Change Carbon
Change Sand
Remarks:
Good Condition
No unusual noise
CONDITION
x Need to Repair
Creates loud noise
Checked By
Verified By
Section Head S8
PAGE : 1 OF 5
Date :
EXHAUST NO.2
Cond.
Time Start
Time End
Change Bearing
AIR BLOWER 1 (AIR AGITATION)

Cond.
Time Start
Change Bearing
Verified By
Time End
PAGE : 2 OF 5
Date :
EXHAUST NO.4
Cond.
Time Start
Time End
Time Start
Time End
Time Start
Time End
Change Bearing
CHILLER MACHINE
Cond.
g
of Gas
COPPER ACID FILTER

Cond.
Replace Seal
Verified By
PAGE : 3 OF 5
Date :
V BLOCK
Cond.
Time Start
Time End
if necessary
CYANIDE COPPER RECTIFIER
Cond.
Time Start
Time End
Time Start
Time End
Cleaning PCB
Replace Diodes
Replace Wire
DEREASING TANK
Cond.
Change Seal
Replace Heater
Degreasing Tank
Verified By
PAGE : 4 OF 5
Date :
BRASS NICKEL CARBON TREARMENT

Cond.
Time Start
Time End
of Carbon
CONTROL PANEL AUTO LINE
Cond.
Time Start
Time End
Time Start
Time End
g Panel
Replace Contactor
g Contact Point
GENERAL
Cond.
n Sluge of Brass & ABS

Chrome Tank
Verified By
PAGE : 5 OF 5
Date :
Verified By
FORM NO

DAILY PREVENTIVE MAINTENANCE SERVICE CHECK SHEET
SECTION : CASTING
JOB / MAINTENANCE
YEAR :
EQUIPMENT
MACHINE
Month
Day
FURNACE
1
10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31
JANUARY
FEBRUARY
MARCH
APRIL
MAY
JUNE
DEGASSING
JULY
AUGUST
SEPTEMBER
OCTOBER
NOVEMBER
DECEMBER
Highlighted "" denotes Preventive Maintenance Completed

Highlighted "X" denotes Preventive Maintenance Incompleted
Note:
Degassing to be done end of 1st shift on daily basis.
Prepared by Shift
Supervisor S2
NDUSTRIES SDN BHD
AINTENANCE SERVICE CHECK SHEET
Verified by Prod. Assistant / Prod.

Engineer / HOD Prod.

SECTION : FETTLING
EQUIPMENT MACHINE
DAY
JOB/MAINTENANCE
10
11
12
13
14
MONTH :
15 16 17
18
19
20
21
22
23
Cleaning
GRINDING MACHINE
Check Grinding Stone

Prepared By,
Verified By,
Section Head S3
Prod. Assistant / Prod. Engin
YEAR :
24
25
26
27
28
29
rod. Assistant / Prod. Engineer / HOD Prod.
30
31

SECTION : MACHINING
EQUIPMENT MACHINE
DAY
JOB/MAINTENANCE
10
11
12
13
14
MONTH :
15 16 17
18
19
20
21
22
23
Cleaning
RIELLO - 1
Check Jaw/Reamer
Cleaning
RIELLO - 2
Check Jaw/Reamer
Lubricating Oil
BROACHING
Check Tool / Jaws

Cleaning

Prepared By,
Verified By,
Section Head S4
YEAR :
24
25
26
27
28
29
30
31

EQUIPMENT MACHINE
DAY
JOB/MAINTENANCE
AIR TESTING
MACHINE NO. 1
Check & Cleaning Tank
AIR TESTING
MACHINE NO. 2
Check & Cleaning Tank
10
11
12
13
14
MONTH :
15 16 17
18
19
20
21
22
23

Prepared By,
Verified By,
Shift Supervisor S6
YEAR :
24
25
26
27
28
29
30
31

SECTION : FINAL ASSEMBLY
EQUIPMENT MACHINE
DAY
JOB/MAINTENANCE
10
11
12
13
14
MONTH :
15 16 17
18
19
20
21
22
23
Check & Clean Tank

WATER TESTING
BUFFING M/C

1&2
Check & Cleaning

Prepared By,
Verified By,
Section Head S9
YEAR :
24
25
26
27
28
29
30
31
FORM NO:QC-IT-021/09/REV.0

Calibration of Thickness Tester Report
Brand / Model :
Calibration
Date
Calibration
Reading
Variance
Remarks
Calibrated By Lab Assitant
Note:
1. Calibrate before first use of this thickness tester
2. The calibration is considered failed if it not able to achieve 10.7m5%
RM NO:QC-IT-021/09/REV.0
Bhd
rt
Verified By Chemical
Engineer
FORM NO:QC-IT-022/09/REV.0

Condition of Hydrometer Report
Equitment No :
Date
SG Reading
Remarks
Calibrated By Lab Assitant
Note:
1. Check the condition of hydrometer once a year
2. The hydrometer is considered faulty if it not able to return back to SG 1000
RM NO:QC-IT-022/09/REV.0
Bhd
Verified By Chemical
Engineer

SECTION : LYK
EQUIPMENT MACHINE
DAY
JOB/MAINTENANCE
Check & Clean Tank

WATER TESTING
BUFFING M/C

1&2
Check & Cleaning

Prepared By,
LYK
10
11
12
13
14
MONTH :
15 16 17
18
19
20
21
22
23
YEAR :
24
25
26
27
28
29
Verified By,
Section Head S9
30
31

SECTION : LYK
EQUIPMENT MACHINE
MONTH / WEEK
JOB/MAINTENANCE
1
JANUARY
2
3
4
FEBRUARY
7
8
9

WATER TESTING
Check / Replace Motor and
Pump

PM day - Saturday
Legend :
W = Weekly
M = Monthly
Q = Quarterly
Y = Yearly
Prepared By :
LYK
MARCH
APRIL
MAY
JUNE
JULY
AUGUST
SEPTEMBER
OCTOBER
10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42
TOBER
YEAR :
NOVEMBER
DECEMBER
43 44 45 46 47 48 49 50 51 52
Verified By :
Section Head S9

Amendment Checklist &amp; Form 2

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Amendment Checklist &amp; Form 2

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FORM NO: QC-PCSECTION : CORE SHOP

SECTION PREVENTIVE MAINTENANCE PROGRAMME

2 SAND MIXER MACHINE

FORM NO: QC-PC-016/09/REV.0

Form NO: QC-PC-017

Cleaning - break dross / bottom

Form NO: QC-PC-017/09/REV. 0

b Spindle Housing Lubrication

c Transmission Belt Chain Stretching

d Lining & Bolt

h Hydraulic Plant Piping

k Pneumatic Electrovalves Lubrication

FORM NO : QC-PCSECTION : MACHINING

3 JINFA DM 1,2, AND 3

FORM NO : QC-PCSECTION : BRAZING

e Cooling Water System Connection

a Main Power Switch Panel

FORM NO : QC-PCSECTION : SUB ASSEMBLY

& Cleaning Tank

2 WATER TESTING M/C PUMP

FORM NO : QC-PCSECTION : POLISHING

/ Clean of Dust Collector

2 ABS TRANSPORTERS 1 & 2

Cable Lug Contact

Cleaning Contact Point

Section Head S8 / Production

Section Head S8 / Production

Section Head S8 / Production

FORM NO : QC-PCSECTION : FINAL ASSEMBLY

Repair Basic Facility

Check & Relubricate

Mechanical Technician (contractor)

Mechanical Technician (contractor)

Mechanical Technician (contractor)

DOE Industries Sdn. Bhd

CROMID ACID ABS AND BRASS

BRIGHT NICKEL ABS AND

Legend : Analysis Column

STANDARD OF HULL CELL TEST CHEMICALS

ABS AND BRASS BRIGHT NICKEL

ABS AND BRASS CHROME

DOE INDUSTRIES SDN BHD

Section/Type of Job Trained

CORE MACHINE NO:

Prod. Assistant / Prod. En

Prod. Assistant / Prod. Engineer/HOD Prod.

Cleaning Break Dross / Bottom

Check / Change Thermocouple

Clean Dust Accumulation

Check / Change Hydraulic Fluid

SAND BLAST Clean Machine

Check Blower Motor

CHECK BY SHIFT SUPERVISOR S2

VERIFIED BY PROD. Assistant / PROD. ENGINEER/HOD PROD.

S3 - PREVENTIVE MAINTENANCE SERVICE CHECKLIST

DOUBLE CUT -OFF MACHINE

CYCLONE DUST EXTRACTOR

Prod. Assistant / Prod. Engineer/HO

rt is several worn out

Prod. Assistant / Prod. Engineer/HOD Prod.

S3 - PREVENTIVE MAINTENANCE SERVICE CHECKLIST

RUNNERHEAD SABD/SHOT SEPERATOR

Wear & Tear

SPINDLE HOUSING LUBRICATION

Amendment Checklist & Form 2

Amendment Checklist & Form 2