Plant Machinery Management & Maintenance Procedure

This method is applicable for all  fixed, transportable and mobile machinery and equipment used in the building, construction and earthworks activities of the company.

Where plant resource is required on the projects, plant department will be contacted to provide equipment or services.

At each project site, project plant coordinator shall ensure that processes are in place on the project site to meet all minimum HSE requirements.

The project plant coordinator shall work cooperatively with the various section managers to establish a Zero Environmental Harm, Zero Accident and Zero Re-Work ethic relative to the Plant Management Program.

The Project Plant Coordinator shall also ensure that safe work methods are documented, communicated to all employees and enforced.

All equipment and plant maintenance activities shall comply with relevant HSE work method statements and standards.

Plant Management Responsibilities

The Project Plant Coordinator is responsible for:

• Managing and maintaining all plant and equipment on a site;
• Coordinating service and maintenance planning;
• supporting on technical issues to the Project;
• Managing project plant, equipment and costs.

Transport and Service Operations

Project Plant Coordinator is responsible for coordinating the necessary transport service support to the operations in the areas below:

• Managing plant transport issues;
• Management of light vehicles;
• Delivery of raw and potable water in tankers to the project site;
• Transportation and disposal of sewage from septic tanks at the project site.

Inspections and Certifications

The Project Plant Coordinator shall ensure that a process of thorough inspections and audits using detailed checklists is in place on the project.

These inspections shall include but shall not be limited to:

• Pre-start checks by the operators;
• Daily, weekly and monthly QHSE inspections of the workshops and facilities;
• Routine mechanical and safety inspections of all items of plant. These shall be as stipulated by the OEM or at least monthly for items of plant;
• 3rd party inspections as required by QHSE or by Statutory requirements

The Project Plant Coordinator shall ensure that all persons involved in these inspections are properly trained to undertake these inspections.

The results of all inspections shall be maintained on site.

The results of Certification inspections on such items as cranes and hoists, undertaken by a 3rd party, shall be retained with the Project. A copy may be sent to the supplier.

Plant Maintenance Procedure

The purpose of this procedure is to establish a set of guidelines to assist projects in establishing minimum maintenance standards for supplier of plant or equipment.

The maintenance philosophy behind this procedure is that plant  maintenance is an essential function, all plant shall be maintained in clean, safe and good working order, all plant shall be serviced when due and that operations  and maintenance  shall work cooperatively to meet the common good.

All plant maintenance activities shall follow the relevant HSE standards and work methods.

Planned Maintenance

To perform effective planned or preventative maintenance work, a detailed maintenance and service schedule shall be prepared by the project plant coordinator.

The plan shall be prepared in close cooperation with the Project Director and operations / engineering staff in order to maximize opportunities for maintenance whilst minimizing disruptions by allowing the operation / engineering staff to recognize plant planning needs early and build them into their own operational schedules.

The Key aspects required for Preventative maintenance are as follows:

• Daily Servicing Program;
• Scheduled Servicing Program;
• Inspections, including identification and recording;
• Backlogs

Daily Servicing

The Daily Service activity shall be carried out at set intervals in order to deliver fuel, grease, check critical component oil levels and coolant levels.

This is also combined with a ‘walk around’ inspection that may identify any equipment faults. The interval shall be every 12 hours or once every shift, for front line equipment.

Scheduled Servicing

Scheduled Servicing shall be carried out periodically and in accordance to the OEM requirements.

The Project Plant Coordinator shall ensure that checklists by equipment type and service interval are readily available and always used.

Backlogs

The ‘backlog sheet’ is a live document detailing up-coming maintenance and shall be used to effectively plan and undertake the required preventative maintenance.

Each Project shall operate a backlog system for all of its plant maintenance operations.

Safety Systems

Key safety components on equipment shall be tested and adjusted in accordance with the OEMs specification. For example, braking and steering systems require strict inspection.

These inspection processes shall be administered through the Mechanical Inspections conducted at each service interval or sooner as required under relevant Codes.

Tests shall be conducted to ensure the operating systems function according to the OEM specifications.

Repairs shall be conducted in accordance to the OEM instructions in Service.

Equipment reported faults shall be categorized and rated according to severity.

Any identified backlog item relating to safety shall be addressed immediately.

Break Down Repair

The Project Plant Coordinator shall establish a set of procedures and allocate resources to manage breakdown or unplanned maintenance. This shall address issues of priorities, parts, labor, transport and tooling to complete a break down repair in an effective and safe manner.

Plant Repair Priorities and Guidelines

Repair priority shall always be given to the primary production.

Secondary equipment such, as trucks, which are dependent on a primary production machine for loading, are to be repaired in order of severity and length of repair.

As a minimum, the following apply:

• If a diagnostic problem is not resolved on site within 4 hrs, the project plant coordinator shall advise the Project Director.
• All breakdowns exceeding 6 hours of downtime shall be communicated to the project director.

Model Faults

The Project Plant Coordinator shall establish clear guidelines on dealing with breakdown faults which may be inherent throughout a model type.

This may require that all other units of the same type be inspected to avert re-occurrence of the same breakdown on other equipment.

Manufacturer / OEM Support

The OEMs generally communicate product support information updates or product improvement. It is the responsibility of the Project Plant Coordinator to ensure critical items are attended to by the OEM in a controlled and planned manner.

The OEM may also provide Site Severity Surveys as requested by the Project

Plant Warranty Management

The purchase and operation of new equipment shall always be supported by the OEM’s warranty.

This warranty is an official agreement between the Dealer / Supplier and company which allows the company to claim for warranty when there is an issue with faulty parts or premature failure of major components systems.

The Project Plant Coordinator shall establish a clear set of guidelines to enable warranty issues to be handled quickly and, these guidelines shall cover the following areas as a minimum:

Identification of warranty issues;

• Action at Project Level;
• action at OEM Level.
• Mandatory Records

Following records shall be maintained.

Daily Servicing Program

Scheduled Servicing Program

Inspection check sheet

Maintenance backlog sheet

Handling warranty issues guideline

Breakdown faults and repair guideline

Equipment check sheets