Maintain machines and moulds

Maintenance keeps machines and moulds fit to run. The default roles are Maintenance (Zulkifli Hassan), the supervisor (Hafiz Rosli) who accepts handbacks, QC (Siti Rahmah) who checks the first part, and Quality (Jason Wong) who signs a revalidation. Open Maintenance.

Read the maintenance planCopy Anchor Link

Maintenance > Plan shows job orders and upcoming preventive maintenance (PM) on every machine. Switch between Data table, Swimlane, Calendar and Kanban in the toolbar. Dashed items are PM due from a PM plan with no job order raised yet. The tiles at the top show Open job orders, PM overdue, Open breakdowns and PM due · next 30 days.

On the kanban, columns are PM due, Planned, In progress, Handback & checks and Done.

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1. 1Tiles: open job orders, PM overdue, open breakdowns, PM due in 30 days.
2. 2Switch between table, swimlane, calendar and kanban.
3. 3Job orders and PM due on each machine.

Set up a PM planCopy Anchor Link

Maintenance > PM plans lists the plans. A plan covers one machine or one mould.

1. Choose Machine or Mould, enter Tasks and choose Interval basis: Days or Shots.
2. Enter Interval. A plan counted in days needs Last done. A plan counted in shots needs a mould, because only a mould has a shot count.
3. Next due is worked out for you. A plan that is overdue shows OVERDUE.

A plan is Active or Suspended. On an Active plan choose Raise PM job order to create the job order, or Suspend and type a reason. If an open PM job order on the same machine or mould already has the plan's tasks and belongs to no plan, Raise PM job order links that job order to the plan and opens it instead of raising a second one. Only a job order linked to its plan resets the plan. On a Suspended plan choose Reactivate and type a reason. You cannot suspend an overdue plan that holds an asset. Complete the PM first.

Run a job orderCopy Anchor Link

Open Maintenance > Job orders (or Plan) and open the job order, for example JO-2026-046.

%% title: Maintenance job order status flow
flowchart LR
  A[Planned] -->|Start job| B[In progress]
  B -->|Complete work · hand back| C[Handback]
  B -->|Modification| R[Revalidation required]
  C -->|Accept handback| D[First-part check]
  R -->|Revalidation done · first-part check| D
  D -->|Pass| E[Done]
  D -->|Fail| B

Job order types are Preventive (PM), Breakdown repair, Cleaning and Modification (needs revalidation).

A Modification (needs revalidation) job goes to Revalidation required instead of Handback, and its mould returns to Pending validation. Quality chooses Revalidation done · first-part check once an approved process validation dated on or after the handback exists in Engineering. Then the first-part check follows.

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1. 1Start job moves the order to In progress.
2. 2Machine, mould, type and isolation reference.
3. 3Work done and handback checks.

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1. 1Job order number and status.
2. 2Machine, type and work done.
3. 3Start job or the next step.

Checklists and NG findingsCopy Anchor Link

Maintenance > Checklists shows the daily, weekly and monthly checks for every machine, utility and area. Choose Fill, answer each item OK · good, NG · no good or N/A, add a remark for every NG item, then choose Submit and sign. For an NG item choose Raise maintenance job order, or enter the Corrective action and choose Close NG. At the end of the period the supervisor chooses Approve sheet once no NG finding is open.

Machines and mouldsCopy Anchor Link

Maintenance > Machines lists machines and their status: Active, Maintenance or Retired. The summary shows Active, In maintenance, PM due in 14 days and Validated moulds. Maintenance > Moulds shows each mould's shots against its life, next PM, and validation. A new mould starts as Pending validation; only an approved process validation makes it Validated. Use Adjust shots to correct a count. A decrease needs a request from Maintenance signed by Engineering.

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1. 1Machine summary tiles.
2. 2Machine and its status chip.
3. 3Next PM due.

How open maintenance stops a machine on the floorCopy Anchor Link

The floor cannot set up or run a machine or its mould while any of these is true:

• An Active PM plan of the machine or mould is overdue, by date or by shots.
• A checklist record of the machine or mould has an NG open.
• A Breakdown repair or Modification job order of the machine or mould has not been handed back.

The tablet then shows a message such as PM {plan} of {asset} is overdue (...). Complete the PM first. Clear the cause, and the machine is released. A production Request maintenance pause raises a Breakdown repair job order that holds the machine in the same way.

If the system refusesCopy Anchor Link

The messages are in Maintenance and EHS refusals. Signature authority, reasons and access are in Signatures and refusals.