People [2011] 0013 No. Issued by:
1, in order to the general health of the staff, to create a good and orderly working environment, the formulation of these rules and regulations;
2, without the company's training on the job or supervisor authorization permits the personnel, shall not operate any machinery and equipment;
3, machine operators should pay strict attention to personal clothing, is strictly prohibited to carry earrings, jewelry, pets, etc. into the operating room;
4, machine and equipment operators must be proficient in operating procedures and and according to the requirements of the operation, is strictly prohibited to operate in violation of the rules;
5, machine and equipment operators in the production before and after the production of equipment, strict inspection of the equipment whether there is a leakage of oil, leakage, etc., and to report the phenomenon.
6, equipment operation should always pay attention to the operation of the process, not doze, leave the post; such as found abnormal, should be promptly reported to the repair;
7, machine and equipment operators are strictly prohibited from drinking alcohol before the shift, in order to prevent accidents and injuries. Special types of work must be licensed;
8, machine and equipment cleaning and cleaning work should first cut off the power supply;
9, it is strictly prohibited to flush water to the motor and control system part of the equipment; it is strictly prohibited to use water to wash the power supply equipment, electrical circuit systems, power switches, electric control boxes, electric control cabinets, exhaust fans and other electrical installations, and it is strictly prohibited to do the work of cleaning and sanitation of the machine and equipment under the operating conditions;
10, non-equipment maintenance personnel are strictly prohibited from disassembling, modifying machinery and equipment and electrical systems;
11, shift handover and leave the machine at the end of the day, the equipment operator and the director of the workshop, the foreman of the staff at the end of the day to check whether the equipment, circuit systems, water supply systems, locks of the workshop doors, warehouse door locks, etc., is closed;
12, the workshops, warehouses must be equipped with the appropriate Fire fighting facilities. No fire, it is strictly prohibited to use and damage the fire fighting facilities;
13, equipment operators should be molds, operating tools, etc. to do spot positioning;
14, equipment operators clean up the raw materials, finished products, tools, operating tables on time;
15, active learning, mutual improvement, respect for workshop masters, leaders, respect into colleagues;
16, Other regulations in the work process at any time to supplement;
17, the provisions of this regulation since the date of enactment of the day shall come into force;
●●●●**** company equipment management system
People [2011] 0012 No. Issued by:
In order to ensure that the company's equipment and facilities are in a good state to ensure that the equipment and facilities are safe and good operation, maintenance of the production order, and to ensure that equipment and facilities maintenance costs are at the lowest level, we have to ensure that equipment and facilities maintenance costs are at the lowest level. Facility maintenance costs at the lowest level, the development of this system:
1 Equipment Management Responsibilities
1.1 R & D, Quality Assurance, Production Department and other departments are responsible for organizing the company's leadership, other relevant personnel according to the requirements of the product process and quality of the planning of the equipment capacity, the demand for equipment capacity, the selection of equipment models.
1.2 Purchasing and supply department is responsible for organizing the relevant personnel to confirm and conclude the equipment contract, as well as payment applications.
1.3 Equipment Department is responsible for organizing equipment acceptance, installation, commissioning and other preliminary work.
1.4 Equipment Department is responsible for organizing the preparation of the company's equipment ledger, equipment files, equipment data registration form, equipment use and maintenance procedures and other management documents.
1.5 The Production Department is responsible for organizing the acceptance of the capacity of the equipment before it is formally put into use.
1.6 The production department is responsible for the use of equipment and the use of routine maintenance, abnormal repair work, the safe use of equipment.
1.7 Equipment Department is responsible for organizing the maintenance of equipment, primary maintenance, secondary maintenance, repair work.
1.8 The Mechanical Department is responsible for regularly organizing the evaluation of the ability of the equipment in use.
1.9 The Equipment Department is responsible for the safety management of the equipment.
2 Equipment data management
2.1 The establishment of basic equipment data
2.1.1 After the arrival of the new equipment, the Equipment Department organizes the acceptance of the equipment using units, the Purchasing Department and other relevant departments, and counts the equipment and accessories, tools, etc. according to the purchasing contract, the equipment manufacturer's random list of information and check the surface condition of the equipment, and the acceptance of the equipment, the Equipment Department collects all the acceptance data and establishes the "Equipment Data Management". Upon completion of the acceptance, the Equipment Department collects all the acceptance information and establishes the "Equipment Information Registration Form".
2.1.2 After the installation and commissioning, the equipment department in accordance with the equipment specifications and other information to supplement the "equipment data registry", and the relevant instructions, drawings and other information into the equipment file management.
2.1.3 Equipment such as improvement, replacement and other changes in the situation, the leading unit should be based on the actual state of change to amend the information into the equipment file.
2.1.4 Equipment files should include:
Equipment important parts
Installation and commissioning conditions
Spare parts details
Integrity standards
Lubrication standards
Equipment failure analysis and countermeasure programs, the past important changes.
2.2 Development of equipment integrity standards
After the completion of the equipment installation and commissioning, the Equipment Department should be based on the characteristics of the equipment drawings, maintenance instructions, operating conditions and other information, the preparation of the equipment inspection items, inspection methods, requirements and judgment standards, inspection cycles, inspectors and other items, the formation of the "Equipment Integrity Standards Table".
3 equipment use and maintenance program development
3.1 General requirements
Equipment use and maintenance program is based on the use of equipment, maintenance instructions and production process requirements developed to guide the correct operation of the use and maintenance of equipment regulations, the use of equipment must comply with the use of equipment units and maintenance programs.
3.2 Formulation and modification
3.2.1 Equipment Department in accordance with the value of equipment, the status of production, structural complexity, and the difficulty of the use and maintenance of the equipment will be divided into: important equipment (Class A), the main equipment (Class B), general equipment and utensils (Class C) three levels, the formation of the "Equipment Classification and Management List," in order to facilitate the preparation of the regulations and the classification and management of equipment. Classification management.
3.2.2 All A, B class equipment installed in use, must be done to achieve a complete set of use and maintenance procedures.
3.2.3 on the new production and use of equipment, equipment department is responsible for the equipment formally put into use within one week before the development of the use and maintenance of the draft regulations, and released for implementation.
3.2.4 Equipment use department according to the draft use and maintenance procedures, combined with the occurrence of actual use and problems found in the equipment into use one month later, put forward the draft use and modification of the views of the Department of equipment led by the organization of the Department of Mechanical Engineering, R & D Department and the Ministry of Production countersign the use and maintenance of equipment and regulations, the formation of an official document, and implementation.
3.2.5 When adopting new process and technology, after the process and technology are confirmed, the equipment department should complete the modification, countersigning and releasing of the new regulations within one week to ensure the effectiveness of the regulations.
3.2.6 In the implementation of the regulations, the site personnel found that the content of the regulations is not perfect directly feedback to the workshop director, the workshop director to contact the equipment professionals at the scene to verify and confirm the content of the regulations for additions or modifications, countersigning and publishing process in accordance with the implementation of 2.2.5.
3.2.7 Newly written or modified regulations shall be approved by the vice president in charge and come into effect according to the principle of professional management.
3.2.8 on the short-term multiple revisions lead to more substantive changes in the regulations, the regulations have not been revised and reviewed within one year, the Equipment Department annually to organize the re-revision, countersigning, approval and release, and at the same time, the recovery of the original nullification of the regulations.
3.2.9 When serious defects occur in the equipment, and can not immediately stop production to repair, the equipment department and the relevant technical departments to develop a reliable temporary use of measures, approved by the deputy general manager in charge of the implementation of the defects elimination of temporary measures immediately void.
3.3 The main content of the regulations
3.3.1 Equipment use regulations
The technical performance of the equipment and allowable limit parameters, such as the maximum load, pressure, temperature, voltage, current, etc.;
Equipment handover and use of the provisions of the equipment, two shifts or three shifts of continuous operation of the equipment, the job personnel must be handed over to the equipment operation when handing over the shift, including: abnormal conditions of equipment operation, the temperature, the voltage, current, etc. Including: the abnormal situation of equipment operation, the original defect changes, changes in operating parameters, faults and treatment, etc.;
Steps to operate the equipment, including preparations for operation and the order of operation;
Emergency handling provisions;
Safety precautions in the use of the equipment, the non-job operators are not allowed to operate the machine without authorization, no one may not Remove or relax the safety protection devices at will;
Troubleshooting in the operation of the equipment.
3.3.2 Equipment Maintenance Regulations:
Equipment transmission schematic and electrical schematic;
Equipment lubrication "five" chart and requirements;
Timed cleaning regulations;
Equipment use of the process of the inspection requirements, including routes, parts,
The inspection requirements during the use of the equipment, including the route, parts, standard condition parameters, cycle (time), inspector, etc.;
The troubleshooting methods of common failures in operation;
The scrapping standards of the equipment's main wearing parts;
Safety precautions.
4 Equipment lubrication management
4.1 Equipment lubrication standard development
4.1.1 Equipment Department of the existing equipment, based on the equipment data, lubrication instructions, operating conditions, etc., the establishment of the lubrication parts of the equipment, the use of grease, inspection cycle, oil change benchmarks, etc., the formation of the "equipment lubrication benchmarks table".
4.1.2 Equipment Department for each piece of equipment, respectively, to develop a perfect equipment lubrication "five" chart, and issued for implementation.
4.2 Requirements
Equipment Department set up lubrication professionals (part-time), responsible for equipment lubrication professional and technical work; equipment use workshop (group) designated specialists responsible for equipment lubrication implementation.
Execution of equipment oil three clean (oil drums, oil tools, refueling points), to ensure that the lubricant (grease) clean and smooth oil circuit to prevent clogging.
Lubrication specialists to do a good job of equipment lubrication new technology promotion and oil replacement work.
Seriously do the waste oil recycling management.
4.3 Lubrication "five" chart development and implementation
Production equipment lubrication "five" charts must be developed one by one (or as an annex to the use of maintenance procedures), and the use of maintenance procedures issued at the same time.
Equipment lubrication "five" chart of the content:
- fixed point: the lubrication part, name and refueling points;
- quality: each refueling point of the lubricating grease grades;
- timed: the provisions of the addition, oil time;
- quantitative: the number of each addition, oil change;
- quantitative: the provision of Each time to add, change the number of oil;
- fixed: the person in charge of each oil point to add, change the person in charge.
Lubrication specialists should regularly check the lubrication "five" chart implementation, and irregular audit, found that the problem is dealt with in a timely manner.
Job operators and maintenance personnel must pay attention to the lubrication status of the equipment at all times, and found that the problem of timely reporting and processing.
4.4 Quality management of lubricating oil and grease During the operation of the equipment, the lubricating oil and grease will deteriorate due to the influence of the machine itself and external dust, water, temperature and other factors. In order to ensure the quality of lubricating oil, it needs to be replaced regularly, and the Equipment Department will set different replacement cycles according to different equipments and arrange for the implementation, and the oil must be cleaned before the oil replacement for the oil tools, tanks and pipelines.
5 daily inspection of equipment operation
5.1 General purpose Through certain means, so that the maintenance and management personnel at all levels can firmly control the operation of the equipment, according to the status of equipment operation to develop appropriate measures, some of which can be combined with the actual situation of three-level maintenance at the same time.
5.2 The establishment of equipment inspection standards Equipment Department based on the structure of each piece of equipment and mode of operation, set out to check the parts (inspection points), content (check what), the normal operation of the parameter standards (permissible values), the implementation of the person, and for the specific characteristics of the equipment, each point of inspection of the equipment, to determine a clear cycle of inspection, which can be divided into hours, shifts, days, weeks, days, months, etc., the formation of "equipment inspection form". Formation of "equipment point inspection table".
5.3 Inspection of the operation and audit
The executive is responsible for the implementation of the standard set in accordance with the inspection, the equipment department has a plan to arrange for personnel to audit the implementation of the inspection status, in order to comprehensively grasp the dynamics of the equipment operation, and at any time to review the problems in the operation of the equipment.
5.4 Feedback and application of inspection information
All the information found in the inspection, regardless of whether the scene is dealt with, must form a record.
The Equipment Department is responsible for the weekly summary of the classification and summary of inspection issues, and the formation of a fixed format of electronic documents for analysis, use and integrated management.
All inspection problems (faults, hidden dangers, etc.), should be included in the next phase of the maintenance program.
Major defects and failures are immediately reported to the Vice President of Production in order to determine control and treatment programs.
6 Equipment Maintenance and Maintenance
6.1 Division of Equipment Maintenance - "Three Levels" of Maintenance
Daily Maintenance: Daily maintenance of equipment is the responsibility of the operator, before and after the shift by the operators to carefully check and wipe the equipment. All parts of the equipment or injection of oil maintenance, so that the equipment to maintain lubrication, clean. Equipment failure in the shift, to timely exclude or repair, and carefully do a good job of the shift handover records.
The first level of maintenance: operator-based, maintenance workers to participate in the local disassembly and inspection of the equipment, cleaning the prescribed parts, dredge the oil circuit, adjusting the equipment parts with the gap, tighten the equipment parts and so on. Equipment running 600 hours, to carry out a level of maintenance.
Second-level maintenance: maintenance workers mainly, operating workers to participate in the partial disassembly of equipment, inspection and repair, replacement and repair of worn parts, partial restoration of precision, lubrication system cleaning, oil change, gas and electricity system inspection and repair. Equipment running 3000 hours to carry out a secondary maintenance.
6.2 Specific requirements for daily maintenance of equipment
Check the equipment carefully before the shift, do a good job in accordance with the provisions of the inspection, lubrication and refueling according to regulations.
Obeying the operating procedures of the equipment during the shift and using the equipment correctly.
Discovered hidden problems during the shift, timely elimination, can not be resolved should immediately notify the repair personnel to deal with.
After the shift, do a good job of equipment cleaning, lubrication work, class B equipment for 15-30 minutes, class A equipment should be extended appropriately. Oil line, oil holes and other parts of the adherence to a weekly thorough cleaning, pressure head, cutter and other parts of the adherence to a daily thorough cleaning.
Do a good job of handing over the work, the day's equipment operation will be recorded in detail on the handover record.
Insist on a small sweep every day, a big sweep on weekends, and a thorough sweep at the end of the month before the festival. Weekend B class equipment cleaning about 1 hour, A class equipment about 2 hours; end of the month B class equipment cleaning 1-2 hours, A class equipment 2-4 hours; holiday maintenance in accordance with the required maintenance standards.
6.3 Equipment Maintenance
Equipment maintenance includes improved maintenance, potential failure repair maintenance and preventive maintenance, in order to improve the operating efficiency of equipment, extend the service life, reduce the time of sudden failure for the purpose of the actual project can be combined with the three levels of maintenance of the equipment, led by the Department of Equipment, the specific to the submission of the schedule to the production plan supervisors, the two sides after confirmation Arrangements for implementation.
6.4 Equipment maintenance and maintenance of the plan and implementation
6.4.1 primary maintenance, secondary maintenance and routine maintenance are carried out in accordance with the planning, confirmation, implementation of the mode of operation, routine maintenance in accordance with the contents of the determined, primary maintenance, secondary maintenance to fill out the "equipment repair and maintenance records".
6.4.2 Equipment Department to the annual cycle for the report of the second level of maintenance plan, to the monthly cycle for the report of the first level of maintenance, routine maintenance plan, confirmed by the production plan supervisor, the company's leadership approval to enter the plan implementation link.
6.4.3 Equipment Department according to the plan to develop maintenance, maintenance of spare parts, materials and other needs, in the procurement cycle before the plan and implementation of the matters and departments that need to cooperate.
6.4.4 Inform the related departments, especially focusing on the production plan and its changes.
6.4.5 Maintenance program execution, maintenance summary and records, and problem analysis.
8 Equipment Fault Repair
3.3.1 In the event of a minor equipment fault, the operator should immediately remove the fault if he/she is able to do so, and record it in detail in the operating record of the shift.
3.3.2 For the inability to remove the equipment failure, the post operator should strengthen observation, pay attention to the fault development process, and at the same time detailed feedback to the shift director, the director notifies the equipment maintenance personnel to immediately repair. Maintenance personnel to record in detail the maintenance process, causes of failure and solution measures and other information, the formation of "equipment repair and maintenance records".
3.3.3 For equipment failures that cannot be eliminated in time, feedback must be given to the person in charge of the production plan and the director of the production plant within 2 hours in order to decide on treatment measures.
3.3.4 Before dealing with each fault, the maintenance personnel must have the appropriate analysis and solution measures to maximize the prevention of fault expansion.
9 Spare parts management
9.1 Control of inventory parts
Where production equipment requires spare parts, the unit or combination of the unit price of more than 200 yuan, or need to be purchased from the manufacturer, or need to be specially manufactured, or can not be purchased within the county, are required to prepare the appropriate amount of inventory, through the setting of a safety stock level as a means of control.
9.2 Unit of Control
The unit of control for all inventory parts is the Facilities Department and the unit of claim is the user department.
9.3 Safety Stock Setting
Maintenance engineers of the Equipment Department set the minimum stock level of each controlled part according to the use of parts, life, procurement cycle, safety stock, batch purchasing and other factors, forming the "Safety Stock Table of Parts", and immediately requisitioning according to the purchasing process when the actual stock is lower than the safety stock level.
9.4 Regular Review The Equipment Department reviews the reasonableness of the Parts Safety Stock List quarterly according to the inventory situation and utilization, and declares the amendments.
10 equipment to improve the project and processing
10.1 All of the following are within the scope of the equipment to improve, you can set up a special project to improve:
Operation of frequent failures and downtime and repeated treatment of ineffective parts;
Operation affects the quality of the product, production, efficiency of equipment, parts;
Operation does not meet the requirements of the small repair cycle, often to unplanned maintenance. Requirements, often have to carry out unplanned maintenance parts (or equipment);
There are unsafe hidden dangers (personal and equipment safety), and routine maintenance and simple repairs can not be resolved parts or equipment.
Can improve the current level of quality, production, efficiency and management of other new programs
10.2 Improvement of the case and implementation
All personnel can be proposed to improve the program, the program can be submitted directly to the direct superiors or submitted to the company's administrative department of the way to propose.
The items in 10.1 are ex-officio elements of the proposal.
The company's vice president (including) or above can decide to file and execute the program according to the corresponding responsibility and authority.
After the successful implementation of the program, the corresponding decision-maker of the program to propose measures of commendation.
The program (whether successful or not) of the project, the process and the implementation of the results of the corresponding information must be documented. For equipment improvements, this information is also recorded in the equipment file.
11 Related Forms
Equipment Data Registration Form
Equipment Completeness Standard Form
Equipment Sub-control List
Equipment Lubrication Baseline Form
Equipment Inspection Form
Equipment Repair and Maintenance Record
Safety Inventory Level of Spare Parts Form
●●●**** Company Production Department Job responsibilities
People [2011] No. 0011 Issued by:
I. Management authority
Exercise the management authority over the production process of the product, and assume the obligation to implement the company's rules and regulations, management procedures and work instructions.
Second, the management function
Rational organization of the company's products production process, a comprehensive balance of production capacity, scientifically formulate and implement the production plan, strengthen the training and education of workers to improve production efficiency and save manufacturing costs.
Three, the main responsibilities
1, the strict implementation of the company's rules and regulations, to fulfill their work responsibilities.
2, the organization of production, equipment, safety, environmental protection and other system development, inspection, supervision, control and implementation.
3, responsible for the preparation of annual, quarterly and monthly production operation plan and equipment maintenance plan.
4, closely cooperate with the marketing department to ensure product contract fulfillment.
5, responsible for the preparation of technical management standards, production process flow, equipment operation manuals and operating instructions.
6, responsible for production safety education, strengthen production safety control, strict implementation of production operating procedures, timely supervision and inspection. Ensure safe production. Eliminate safety accidents.
7, responsible for organizing the production site management, to ensure that the production site is neat and orderly.
8, timely preparation of annual, quarterly and monthly production reports, regular statistical analysis of production, and constantly improve the production accounting work, saving money, reduce costs.
9, responsible for production equipment, measuring instruments, maintenance and repair work, rationalize the production equipment, measuring instruments plan to ensure the normal use of equipment.
10, do a good job of production management personnel training and business guidance, and regularly carry out work ability inspection, assessment and evaluation.
11, with the quality control department, and constantly product quality and management quality improvement.
Four, divided into duties
1, production plant manager: according to the sales plan (sales department submission, general manager for approval, the General Manager's Office transfer) and the inventory situation to develop production plans, and reasonable organization of workshop production; daily checking of raw material inventory statements, the development of raw materials need to purchase a single; daily check of the production workshop production safety, the director of the workshop, the mechanic, the production of workers training, supervision, management; organization and arrangement of personnel machine maintenance, electrical circuitry, and the training, supervision, and management. Organization and arrangement of personnel machine maintenance, maintenance of circuit facilities; arrangements, convene the morning meeting of the production workshop, regular meetings;
2, workshop director: according to the production director of the arrangements for the workshop site management, leading the workers to safety production; supervision and management of the workshop matters, arrangements for internal workshop affairs, for should be praised and disciplined personnel for the first time to educate and criticize the staff need to be promoted or dismissal of personnel Timely report, recommendations;
3, production workers: comply with the workshop production system, initiative, safety, efficient completion of the tasks assigned by the Ministry of Production; timely maintenance of the machine; regularly do a good job in the workshop cleaning; continuous learning, reasonable innovation.