Cleaning and on-site inspection
Many enterprises are carrying out 5S activities, aiming at creating a clean and tidy workplace. 5S activities are also important for equipment management. On the one hand, it is impossible to have high-level equipment management in a dirty environment, and well-maintained equipment is spotless; On the other hand, the process of cleaning is the process of spot check, that is, we often say that "cleaning is spot check". Cleaning equipment carefully is a process of "close contact" with equipment. In this process, it is easy to find some bad phenomena of the equipment, such as oil dripping, loose screws, yellow wires and so on. It is very necessary to deal with these bad phenomena in time. Based on this understanding, we have changed the practice that operators and maintenance personnel are responsible for 5S and maintenance of equipment respectively, requiring operators to participate in equipment maintenance.
Independent improvement of defects
On-site improvement emphasizes activating the site, mobilizing the enthusiasm of employees and constantly improving the work. In equipment management, it is also necessary to stimulate employees' awareness of problems and enthusiasm for improvement. We mainly do the following two aspects: first, encourage employees to actively find the problems and imperfections of equipment and facilities and improve them themselves; Secondly, pay attention to the treatment of the source. Source refers to the source of pollutants on the equipment, such as dust, liquid, cutting waste, etc. The pollutants produced by equipment not only cause environmental pollution, but also are the source of equipment deterioration, which must be solved. The solution is to eliminate the source of occurrence, or reduce the amount of occurrence, or limit the pollutants to a small range.
It is the key to do well in these two aspects, stimulate employees' enthusiasm for improvement and give full play to their intelligence. By combining the company's "personal proposal" reward system with the "excellent improvement case presentation" system, the enthusiasm of employees has been well mobilized, and many creative small improvements and inventions have emerged.
Extensive implementation of visual management
Visual management is to make management visible and clear at a glance. Implementing visual management on site can expose problems and improve management efficiency. It can be considered that the implementation level of visual management is an important indicator to measure the level of field management.
In the equipment management work, we pay attention to the application of visual management technology, focusing on improving the equipment management situation from the following three aspects, and achieved the effect of improving the equipment management level.
First, fully reveal the normal and abnormal state and parameters of the equipment, such as the normal and abnormal range of the instrument, the normal and abnormal position of the switch, the open and close state of the valve, the upper and lower limits of the liquid level and so on. This not only makes the staff know whether the equipment is running normally at a glance, but also improves the work efficiency. Through the visual management of the generator room, the positive and abnormal ranges of various instruments are marked, and the spot check operation channel is set up, so that the meter reading operation time for recording generator operation parameters is shortened from the original 10 minute to 2 minutes.
The second is to reveal the matters needing attention, play the role of prompt and supervision, and avoid work mistakes caused by negligence. Good equipment management requires timely maintenance of equipment. It often happens that equipment fails to carry out necessary maintenance on time, which leads to equipment failure. Our approach is to reveal the work content of field equipment maintenance as much as possible. For example, for the replacement of consumables such as lubricating oil, filters and belts of machinery and equipment, a sign was set up beside the equipment, which indicated the model, quantity, replacement standard, last replacement time and next expected replacement time of consumables to be replaced. In this way, if the replacement of consumables is not completed on time, then everyone can see it.
The third is to simplify homework. The startup, shutdown, switching and other processes of many devices are very complicated, and misoperation will cause equipment damage. Using visual management to identify the complex operation steps of equipment can simplify the operation of equipment and reduce the occurrence of errors.
Although a good equipment management system is complicated, even through some simple field improvements, enterprises can improve the management level and overall efficiency of equipment.