A, equipment use, maintenance program development, modification and implementation
Equipment use, maintenance program is based on the use of equipment, maintenance instructions and production process requirements to guide the correct operation of the use and maintenance of equipment regulations. The plants, mines and companies belonging to the major companies must establish and improve the equipment use regulations and maintenance regulations.
Two, the development and modification of regulations
1. Plant (mine) first in accordance with the principles of the equipment management system, the correct division of equipment types, and in accordance with the status of the equipment in the production, structural complexity, and the use of the equipment, maintenance difficulties, the equipment will be divided into: important equipment, the main equipment, general equipment, the three levels, in order to facilitate the preparation of regulations and the hierarchical management of the equipment.
2. Where the installation of the equipment in use, must be done to achieve a complete set of use, maintenance procedures.
3. The new production of equipment, plant (mine) to be responsible for 30 days before the commissioning of the equipment to develop the use, maintenance procedures, and issued for implementation.
4. When the production is ready to adopt a new process, new technology, 10 days before the change in process, the production plant (mine) should be based on the new use of equipment, maintenance requirements of the original regulations to ensure the effectiveness of the regulations.
5. jobs in the implementation of the regulations, found that the regulations are not perfect to reflect the content of the regulations at each level in a timely manner, regulations management professionals should immediately go to the scene to verify the situation, the content of the regulations to add or modify.
6. Newly written or modified regulations should be approved according to the relevant provisions of the professional management contracting system.
7. The use of many years, the content of the regulations modified more, the third year through a combination of mass and professional management, by the plant (mine) organization to revise, reissue, and at the same time, notify the original regulations are invalid.
8. When serious defects occur in the equipment, and can not immediately shut down and repair, we must develop reliable measures and temporary use, maintenance procedures, by the plant (mine) approved the implementation. Defects eliminated after the temporary regulations are void.
Three, the use of equipment, maintenance procedures (a) the use of equipment regulations must include the content:
1. equipment technical performance and allowable limit parameters, such as the maximum load, pressure, temperature, voltage, current, etc.;
2. equipment handover provisions, two or three shifts of continuous operation of the equipment, the position of personnel must be handing over to the equipment operating conditions, including: equipment operation, temperature, voltage, current, etc.;
2. Handover of equipment, including: abnormalities in the operation of the equipment, changes in the original defects, changes in operating parameters, faults and handling, etc.;
3. Steps to operate the equipment, including the preparation and order of operation;
4. Emergency provisions;
5. Safety precautions in the use of the equipment, the operator of the non-job shall not be approved to operate the machine, and no one shall arbitrarily dismantle the machine. Operation of the machine, no one shall arbitrarily remove or relax the safety protection devices, etc.;
6. Troubleshooting in the operation of the equipment.
(ii) equipment maintenance procedures should include:
1. equipment transmission schematic and electrical schematic;
2. equipment lubrication "five" charts and requirements;
3. the provisions of the regular cleaning;
4. the use of equipment in the course of the inspection requirements, including routes, parts, and the use of the equipment. Inspection requirements, including routes, parts, content, standard condition parameters, cycle (time), inspector, etc.;
5. Troubleshooting methods for common failures in the operation;
6. Scrapping standards for major wearing parts of the equipment;
7. Safety precautions.
Four, the use of equipment, maintenance procedures for the implementation of
1. new equipment into use, by the plant (mine) professional leaders in charge of the layout of the implementation of equipment use, maintenance procedures, procedures to be issued to the relevant professional, post operators and maintenance inspectors manual, and to do the pile up does not leave the post.
2. Production units to organize equipment operators to study the regulations, equipment professionals to operators to explain the contents of the regulations and learning counseling.
3. Equipment operators shall be organized by the plant level regulations test and practical examination, qualified before taking up their duties.
4. Production units every week to organize the team to learn the regulations, workshop leaders and equipment management personnel, monthly production team to carry out spot checks on the study of regulations, found that the problem is resolved in a timely manner, the spot checks into the assessment.
Fifth, the management of the technical condition of the equipment
All the equipment according to the technical condition of the equipment, maintenance status and management status is divided into intact equipment and non-intact equipment, and to formulate specific assessment standards.
The production equipment of each unit must complete the technical condition indicators issued by the higher level, that is, the assessment of the comprehensive rate of equipment intact. Professional departments, respectively, to develop annual, quarterly, monthly equipment comprehensive rate of completion of the indicators, and layer by layer decomposition level by level to the post.
Six, equipment lubrication management (a) the requirements of equipment lubrication management:
1. Each unit of the motorized department set lubrication professional responsible for equipment lubrication professional and technical management; plant or workshop motorized section (group) set a full-time or part-time lubrication professional responsible for the unit lubrication professional and technical management; repair workshop (section) lubrication class or lubrication worker is responsible for the lubrication of the equipment.
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2. Each piece of equipment must be developed to improve the equipment lubrication "five" charts and requirements, and carefully implemented.
3. All factories and mines should seriously implement the equipment oil three clean (oil drums, oil, refueling points), to ensure that the lubricant (grease) clean and smooth oil, to prevent clogging.
4. For large, special, special equipment oil to adhere to the regular analysis and testing system.
5. Lubrication professionals to do a good job in promoting new lubrication technology and oil replacement.
6. Seriously do the waste oil recycling management.
(2) lubrication "five" chart development, implementation and revision.
1. Factory and mine production equipment lubrication "five" charts must be 'must be developed, and the use of maintenance procedures sent to the post at the same time.
2. Equipment lubrication "five" chart is:
fixed point: the lubrication part, name and refueling points;
qualitative: the provisions of each refueling point of the lubricating grease grade;
fixed time: the provisions of the time to add, change the oil;
quantitative: the provisions of the quantity of oil each time to add, change the oil;
quantitative: the number of each
Fixed quality: specify the lubricant grade of each refueling point;
Fixed time: specify the refueling time;
Fixed quantity: specify the quantity of each refueling point;
Fixed person: specify the responsible person of each refueling point.
3. Post operation and maintenance personnel to seriously implement the equipment lubrication "five" chart provisions, and make good operating records.
4. Lubrication professionals to regularly check and irregularly check the lubrication "five" chart implementation, found that the problem is handled in a timely manner.
5. Post operation and maintenance personnel must pay attention to the lubrication status of the equipment at all times, found that the problem of timely reporting and processing.
(C) the analysis of lubricating oil and grease management.
Equipment operation process, due to the machine itself and external dust, moisture, temperature and other factors, so that the lubricating grease deterioration, in order to ensure the quality of lubricating oil, need to be filtered regularly analyze and assay work on different equipment for different sampling and assay time. After testing the oil does not meet the requirements of use should be replaced in a timely manner lubricating grease. Each factory and mine on the equipment lubricating oil must do oil clean, smooth oil circuit.
(D) the application of new equipment lubrication technology and oil update management.
1. Factory and mine on the production of equipment lubricating oil running, bubbling, dripping, leakage, to organize research and study, and gradually solve the problem.
2. Oil renewal should be included in the annual equipment work plan of the plant and mine, and after the test, to ensure the safety of the implementation of the oil renewal must be before the oil tools, tanks, pipelines for cleaning.
Seven, the handling of equipment defects
1. equipment defects, post operation and maintenance personnel can be excluded should be excluded immediately, and detailed records in the log.
2. Post operators are unable to exclude equipment defects should be recorded in detail and reported to the next level, while careful operation, strengthen observation, pay attention to defects development.
3. Failure to timely remove the equipment defects, must be studied at the daily production scheduling meeting to decide how to deal with.
4. Before arranging to deal with each defect, there must be appropriate measures, clear specialists responsible for preventing defects from expanding.
Eight, equipment operation dynamic management
Equipment operation dynamic management, refers to certain means, so that all levels of maintenance and management personnel can firmly grasp the operation of the equipment, based on the condition of equipment operation to develop appropriate measures.
(a) the establishment of a sound system of equipment inspection standards
The plants and mines should be for each piece of equipment, based on its structure and mode of operation, set out to check the parts (inspection points), content (check what), the normal operation of the parameter standards (permissible values), and for the specific operating characteristics of the equipment, the equipment for each point of inspection, to determine a clear inspection cycle, generally divided into hours, classes, days, weeks, weeks, and so on. , class, day, week, ten days, monthly checkpoints.
(ii) the establishment of a sound inspection assurance system
Production post operators are responsible for the post use of equipment for all inspection points to check, professional maintenance personnel to contract the key equipment inspection tasks. All plants and mines should be based on the number and complexity of equipment to determine the number of people to set up full-time inspectors and candidates, full-time inspectors in addition to being responsible for contracting important inspection points, to fully grasp the dynamics of equipment operation.
(C) information transfer and feedback
Production post operator inspection, found that the equipment can not continue to operate the problem requires urgent treatment, to immediately notify the shift scheduling, by the person in charge of the duty to organize and deal with. General hidden dangers or defects, after inspection, log in the checklist, and pass it to the full-time inspector on time.
Equipment spot checks carried out by full-time maintenance personnel are to be recorded, and in addition to arranging for the group to deal with them, the information is to be passed to the full-time inspector for a unified summary.
Full-time inspectors in addition to completing the contracted inspection point task, but also responsible for all aspects of the inspection results, summarized and organized on a daily basis, and listed the key issues of the day to the plant and mine motorized section to pass.
The motorized section lists the main problems, in addition to registering the account, should also be entered into the computer in a timely manner to facilitate the comprehensive management of the motorized department of the parent company.
(D) the application of dynamic information
Inspection workers for the inspection of equipment defects found in the inspection, hidden trouble, proposed should be arranged for overhaul of the project, into the overhaul plan.
Equipment defects found in the inspection, must be dealt with immediately, by the production conductor of the shift immediately organized to deal with; the shift is unable to deal with, by the leadership of the plant and mine to determine the solution.
The major defects of important equipment shall be organized and studied by the plant leaders to determine the control plan and treatment plan.
(E) equipment weaknesses in the standing treatment.
All of the following are weak links in equipment:
1. operation of frequent breakdowns and downtime and repeated treatment of ineffective parts;
2. operation affects product quality and production of equipment, parts;
3. operation does not meet the requirements of the small repair cycle, often have to carry out unplanned overhaul of the parts (or equipment);
4. The existence of unsafe hazards (personal and equipment safety), and routine maintenance and simple repairs can not be resolved parts or equipment.
(F) management of weak links
Mobile Division of the major companies should be based on dynamic information, listed in the weak links of the equipment, on time to organize hearings, to determine the current projects that should be resolved, do a good job in solving the equipment problem of the plan or put forward the improvement program;
Plant and mine should organize the relevant personnel to consider the improvement program, validation included in the overhaul plan.