# Maintain machines and moulds (/docs/maintenance-ehs/maintenance)

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 plan [#read-the-maintenance-plan]

**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**.

<GuideStep
  title="The maintenance plan"
  description="Job orders and PM due, by machine and date."
  src="/guide/maintenance/1.png"
  alt="Maintenance job orders on desktop with the tiles for open job orders, PM overdue and open breakdowns"
  width={1440}
  height={1000}
  callouts={[
    { x: 50, y: 18, caption: "Tiles: open job orders, PM overdue, open breakdowns, PM due in 30 days." },
    { x: 85, y: 12, caption: "Switch between table, swimlane, calendar and kanban." },
    { x: 50, y: 55, caption: "Job orders and PM due on each machine." },
  ]}
/>

## Set up a PM plan [#set-up-a-pm-plan]

**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 order [#run-a-job-order]

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

```mermaid
%% 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)**.

<Steps>
<Step>

**Planned**: a breakdown or modification job order needs its **Isolation / LOTO reference**. Enter
it, then choose **Start job** and sign.

</Step>
<Step>

**In progress**: do the work and record it in **Work done**. For a breakdown, also enter the order
that was running, the lots made since the last good check, and the QC disposition reference. Choose
**Complete work · hand back**: the dialog asks the four handback checks (area clean, guards and
interlocks, parameters restored, no contamination) with Yes or No, and you sign once. Anything other
than Yes on all four is refused before the signature.

</Step>
<Step>

**Handback**: the supervisor, not the technician, chooses **Accept handback** and signs. Anyone else, and the technician who did the work, sees the button greyed out with the reason beneath it.

</Step>
<Step>

**First-part check**: QC (who can open Maintenance to view the job order) chooses **Record
first-part check**, picks **Pass** or **Fail**, picks the **FAI / IPQC reference** from the first
article reports and in-process checks on record, and signs. **Pass** releases the machine, completes the job and resets
the PM plan. **Fail** sends the job back to maintenance with the handback cleared.

</Step>
</Steps>

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.

<GuideStep
  title="A planned job order on the desktop"
  description="The buttons depend on the status. Breakdown and modification jobs need the isolation reference."
  src="/guide/maintenance/2.png"
  alt="Job order JO-2026-046 on desktop showing status Planned with the Start job button"
  width={1440}
  height={1000}
  callouts={[
    { x: 80, y: 14, caption: "Start job moves the order to In progress." },
    { x: 50, y: 35, caption: "Machine, mould, type and isolation reference." },
    { x: 50, y: 62, caption: "Work done and handback checks." },
  ]}
/>

<GuideStep
  title="A job order on the phone"
  description="Technicians record work from the phone at the machine."
  src="/guide/maintenance/3.png"
  alt="Job order JO-2026-046 on mobile with its status and Start job button"
  width={375}
  height={812}
  callouts={[
    { x: 50, y: 10, caption: "Job order number and status." },
    { x: 50, y: 45, caption: "Machine, type and work done." },
    { x: 50, y: 92, caption: "Start job or the next step." },
  ]}
/>

## Checklists and NG findings [#checklists-and-ng-findings]

**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 moulds [#machines-and-moulds]

**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.

<GuideStep
  title="Machines"
  description="Status, PM due and the moulds fitted."
  src="/guide/maintenance/4.png"
  alt="Machines list on desktop with status chips and a machine summary"
  width={1440}
  height={1000}
  callouts={[
    { x: 50, y: 18, caption: "Machine summary tiles." },
    { x: 40, y: 45, caption: "Machine and its status chip." },
    { x: 70, y: 45, caption: "Next PM due." },
  ]}
/>

## How open maintenance stops a machine on the floor [#how-open-maintenance-stops-a-machine-on-the-floor]

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 refuses [#if-the-system-refuses]

The messages are in [Maintenance and EHS refusals](/docs/maintenance-ehs/refusals#maintenance).
Signature authority, reasons and access are in
[Signatures and refusals](/docs/get-started/signatures-and-refusals).

<NextSteps>

<NextStep href="/docs/maintenance-ehs/ehs" title="Safety and environment (EHS)" description="Incidents, permits to work and risk assessments." />

<NextStep href="/docs/maintenance-ehs/refusals" title="Maintenance and EHS refusals" description="Every message and what to do." />

</NextSteps>