Company Name: Document No.

NATIONAL ALCOHOL & LIQUOR FACTORY OF/NALF/016

Revision: 0 Document Title: Page 1 of 7

Bottling Overhaul Maintenance Plan
I. FILLER MACHINE
From: ____________to __________Total Maintenance Time: - 49hrs (12 working days)

No. Description Date Time Assigned

person
1. Cleaning 3hrs
1.1. Removing and cleaning of broken bottles sludge from the filler and 2hrs Operators
capping head machine.
1.2. Cleaning the machine area thoroughly. 1hrs Operators
2. Disassembling works 9hrs
2.1. Disassembling of all 50 filling valves from the machine. 3hrs Mechanic
& operator
2.2. Dismantling all the filling valves into parts 3hrs Mechanic
2.3. Dismounting all infeed and out feed star, worm screw both filler 1hrs >>
capping m/c.
2.4. Disassembling the capping head and revealing the revolving shaft 1hrs >>
cover
2.5. Dismantling pneumatic filter 30min Electrician
2.6. Disassembling cap sorter and cleaning it 30min Mechanic
3. Maintenance Works 34hrs
3.1. Vacuum Pump And Piping System Cleaning And Maintaining 2hrs Mechanic
3.2. Cleaning All The Filling Valve Parts 8hrs operators
3.3. Check Wear, Damages On All The Filling Valve Parts And Lubricate 4hrs Mechanic
3.4. Checking And Maintaining The Spring, Centering Guide And Seal 4hrs >>
Status
3.5. Checking Air Leakages And Lubricate Lifting Cylinders 4hrs >>
3.6. Checking Cardan Worm Screw And Lubricating 2hrs >>
3.7. Lubricating and Checking of Capping Heads Gears And Cam Of The 3hrs >>
Capper Heads.
3.8. Greasing and central lubrication for all the necessary parts 1hrs >>
3.9. Checking the level of oil on the side of the lubricant pan 30min >>
3.10. checking and maintaining vacuum pump Toothed wheel under 30min >>
machine table
3.11. Checking the status of the joints for wear and lubricating any 30min >>
damage If necessary lubricate or replace.
3.12. After completing the lubrication process, check that all points are 30min >>
sufficiently lubricated.
3.13. Checking the level of the gear motor oil and if needed top off. 30min >>
3.14. Product regulation valve (modulating valve) 30min >>
3.15. Checking machine safety system and cleaning electrical board 2hrs Electrician
3.16. Checking the Connections, piping, valves, cylinders, filters and 1hrs Mechanic
pressure gauges of Filler machine Air treatment unit
4. Assembling works 14hrs
4.1. Assembling all part and subpart of the filling valves’ 4hrs Mechanic
 Coordinators’:- Production Shift coordinators, Mesfin A., Nebiyu Z., Nega A., Taddele A.
 Electricians: Mulugeta T., Ayalow H., Tewabech T., and other shift electricians
 Mechanics: Kasaye G., Alemayeh K., Bealem T. and other shift mechanic
 Company Name: Document No.:

NATIONAL ALCOHOL & LIQUOR FACTORY OF/NALF/016

Revision: 0 Document Title: Page 2 of 7

Bottling Overhaul Maintenance Plan
4.2. Assembling all 50 filling valves on the machine 4hrs >>
4.3. Assembling all infeed and out feed star, worm screw for both filler 3hrs >>
capping machines
4.4. Assembling the capping head and the revolving shaft cover 2hrs >>
4.5. Assembling pneumatic Air filter 30min >>
4.6. Assembling cap sorter 30min >>
5. Checking and Tightening works 3hrs
5.1. Checking for correct tension, surface wear, or any damages for 30min >>
Transmission belts and chains
5.2. Checking product supply pump leakages and efficiency 30min >>
5.3. Checking and tightening of central distribution stars 30min >>
6. Checking for any air leakages on lifting cylinders and air treatment 30min >>
unit
7. Checking and adjusting of capping heads 1hrs >>
6. Testing 1hrs
6.1. Test running and checking both filler and capping machines 1hrs All

Any notices or remarks can be written here

 Coordinators’:- Production Shift coordinators, Mesfin A., Nebiyu Z., Nega A., Taddele A.
 Electricians: Mulugeta T., Ayalow H., Tewabech T., and other shift electricians
 Mechanics: Kasaye G., Alemayeh K., Bealem T. and other shift mechanic
 Company Name: Document No.:

NATIONAL ALCOHOL & LIQUOR FACTORY OF/NALF/016

Revision: 0 Document Title: Page 3 of 7

Bottling Overhaul Maintenance Plan
II. WASHING MACHINE
From: ____________to ________________Total maintenance time: - 34hrs (9 working days)

No. Description Date Time Assigned

person
1. Disassembling works 5hrs
1.1. Dismantling all spray pipes from the washing machine 1hrs operators
1.2. Dismantle bottle infeed chains 1hrs mechanic
1.3. Dismantling the bottle carrier basket seats as per necessary 1hrs Operators
1.4. Dismantling bottle infeed cams 2hrs mechanic
2. Cleaning works 10hrs
2.1. Cleaning all filters and water bathes 2hrs operators
2.2. Cleaning the machine area thoroughly. 1hrs >>
2.3. Removing and cleaning of broken bottles sludge from the washing 1hrs
>>
head machine.
2.4. Descaling and cleaning all bottle carrier basket seats and internal 6hrs
>>
machine bodies as per needed.
3. Maintenance work 31hrs
3.1. Cleaning and checking all Electrical safety and control devices’ 5hrs Electricians
cables thoroughly.
3.2. Checking and replacing if necessary all sensors and pneumatic 5hrs >>
solenoid valves
3.3. Replacing damaged bottle carrier basket if any 5hrs Mechanic
3.4. Replacing and filling of oils for gear boxes 5hrs >>
3.5. Lubricating all bottle basket carrier joints with mixture of benzene 2hrs >>
and food grade oil
3.6. Lubricating all parts with central lubrication system 1hrs >>
3.7. Dismantling and cleaning soda Pump 1hrs >>
3.8. Dismantling and cleaning 1st rinsing Pump 1hrs >>
3.9. Dismantling and cleaning 2nd rinsing Pump 1hrs >>
3.10. Dismantling and cleaning Circulation Pump 1hrs >>
3.11. Dismantling and cleaning bottle loading chain sprocket gears and 3hrs >>
chain, replacing if necessary.
3.12. Dismantling, cleaning and maintaining both infeed and out feed cam 1hrs >>
4. Assembling works 10hrs
4.1. Assembling the cleaned bottle carrier basket seats 2hrs Mechanic
4.2. Assembling the cleaned and maintained soda pump. 1hrs >>
4.3. Assembling the cleaned and maintained 1st rinsing Pump 1hrs >>
4.4. Assembling the cleaned and maintained 2nd rinsing Pump 1hrs >>
4.5. Assembling the cleaned and maintained Circulation Pump 1hrs >>
4.6. Assembling or replacing of bottle loading chain sprocket gear 3hrs >>
4.7. Assembling of infeed out feed cam 1hrs >>
 Coordinators’:- Production Shift coordinators, Mesfin A., Nebiyu Z., Nega A., Taddele A.
 Electricians: Mulugeta T., Ayalow H., Tewabech T., and other shift electricians
 Mechanics: Kasaye G., Alemayeh K., Bealem T. and other shift mechanic
 Company Name: Document No.:

NATIONAL ALCOHOL & LIQUOR FACTORY OF/NALF/016

Revision: 0 Document Title: Page 4 of 7

Bottling Overhaul Maintenance Plan
5 Testing and checking 1hrs
5.1. Test running and checking of the automation of the machine system 1hrs All

Any notices or remarks can be written here

III. LABELLING MACHINE

 Coordinators’:- Production Shift coordinators, Mesfin A., Nebiyu Z., Nega A., Taddele A.
 Electricians: Mulugeta T., Ayalow H., Tewabech T., and other shift electricians
 Mechanics: Kasaye G., Alemayeh K., Bealem T. and other shift mechanic
 Company Name: Document No.:

NATIONAL ALCOHOL & LIQUOR FACTORY OF/NALF/016

Revision: 0 Document Title: Page 5 of 7

Bottling Overhaul Maintenance Plan
From: ________to _________Total Maintenance Time: - 22hrs (6 working days)

No. Description Date Time Assigned

person
1. Cleaning works 2hrs
1.1. Cleaning all machine outer body and area 2hrs Operators
2. Disassembling works 12hrs
2.1. Detaching accessories label magazine, glue pump etc. 1hrs >>
2.2. Disassembling covers and safety guards 1hrs >>
2.3. Dismounting gripper drum, brushes, glue roller, infeed 1hrs >>
worm
2.4. Disassembling bottle distribution system, inlet and outlet 1hrs Mechanic
star, infeed screw, central distributer or counter star
2.5. Dismantling upper chariot labeling & sensor group 1hrs >>
2.6. Disassembling label hooks drum shaft & scroll unit 1hrs >>
2.7. Disassembling plate rest assembly 1hrs >>
2.8. Dismantling head jack 1hrs >>
2.9. Dismantling head cam plate 1hrs >>
2.10. Disassembling lower crank case 1hrs >>
2.11. Disassembling cardian system 1hrs >>
2.12. Dismantling all driving gears 1hrs >>
3. Maintenance works 18hrs
3.1. Checking and replacing of bottle plate rest if necessary 2hrs >>
3.2. Replace the brushes when the bristles are bent or have 1hrs >>
become too short, damaged
3.3. Check and replace centering bells 1hrs >>
3.4. Fix all the problem regarding with glue roller 2hrs >>
3.5. Retighten screw joints of the machine components. 1hrs >>
3.6. Check air hoses and replace if damaged 1hrs >>
3.7. Clean filter regulator; if required, change filter 1hrs >>
3.8. Cleaning of Electrical boards 2hrs Electrician
3.9. Cleaning and replacing safety sensors if necessary 4hrs >>
3.10. Tightening of any loosed connections of electric and 1hrs >>
sensors.

3.11. Check the central lubrication system (oil level and pump) 1hrs Mechanic
and fill it
3.12. Greasing and filling oil sumps 1hrs >>
4. Assembling works 5hrs
4.1. Assembling parts and sub components 5hrs >>
5. Testing works 2hrs
 Coordinators’:- Production Shift coordinators, Mesfin A., Nebiyu Z., Nega A., Taddele A.
 Electricians: Mulugeta T., Ayalow H., Tewabech T., and other shift electricians
 Mechanics: Kasaye G., Alemayeh K., Bealem T. and other shift mechanic
 Company Name: Document No.:

NATIONAL ALCOHOL & LIQUOR FACTORY OF/NALF/016

Revision: 0 Document Title: Page 6 of 7

Bottling Overhaul Maintenance Plan
5.1. Test running with bottles and without bottles 2hrs ALL

Any notices or remarks can be written here

IV. CONVEOR
From: __________to____________ Total Maintenance Time 8hrs (02 Working Days)
 Coordinators’:- Production Shift coordinators, Mesfin A., Nebiyu Z., Nega A., Taddele A.
 Electricians: Mulugeta T., Ayalow H., Tewabech T., and other shift electricians
 Mechanics: Kasaye G., Alemayeh K., Bealem T. and other shift mechanic
 Company Name: Document No.:

NATIONAL ALCOHOL & LIQUOR FACTORY OF/NALF/016

Revision: 0 Document Title: Page 7 of 7

Bottling Overhaul Maintenance Plan
No. Description Date Time Assigned
person
1. Cleaning works 4hrs
1.1. Cleaning all the conveyor and cable tray 3hrs production
1.2. Cleaning of electrical board 1hrs Electrician
2. Maintenance works 3hrs
2.1. Inspect all conveyor motors and Inverters 1hrs >>
2.2. Inspect and check the positioning of conveyor 1hrs >>
sensors
2.3. inspect and replace conveyor idler and sprocket 5hrs mechanic
gear
2.4. Lubricating and greasing all necessary parts of 3hrs >>
the conveyor
3. Testing works 30min
3.1. Test run with and without bottles 30min All

Any notices or remarks can be written here

 Coordinators’:- Production Shift coordinators, Mesfin A., Nebiyu Z., Nega A., Taddele A.
 Electricians: Mulugeta T., Ayalow H., Tewabech T., and other shift electricians
 Mechanics: Kasaye G., Alemayeh K., Bealem T. and other shift mechanic