1, the basic knowledge of equipment management
1, operating equipment
1.1 employees in the independent use of equipment, must be after the structure of the equipment, performance, safe operation, maintenance requirements and other aspects of the basic technical knowledge of the education and safety operation of the theoretical and practical training, such as operators in the training period of the operation of the machine, there must be a master, the shift manager to give on-site guidance.
1.2 For special types of work and special equipment operators must be qualified by the relevant state ministries of training, issued by the Labor Bureau of special types of work permits to operate, this work is declared by the workshop, the Ministry of Human Resources for the organization of training.
2, equipment handover, inspection system
2.1 "equipment inspection, maintenance benchmarks"
Role: on the one hand, it plays a role in guiding the operator's equipment inspection, maintenance, on the other hand, it plays a role in the handover of equipment. Operators in the operation of the machine tool before the "equipment inspection, maintenance benchmarks" requirements of the machine tool inspection, found that the problem is resolved in a timely manner, for the problem can not be dealt with on their own, should be timely feedback to the maintenance staff to solve. The operator shall record in detail the operation of the equipment in this shift, the problems found in the operation, the fault repair situation, etc.; the personnel of the two-shift system or multi-shift production shall do a good job of handing over the work and signing the approval, and fill in the point inspection and maintenance records carefully.
2.2 equipment inspection, maintenance record sheet
Keep clean, complete, not allowed to tear, altered and lost, the operator must be handed over to the department of equipment management personnel, and then submitted to the Ministry of Engineering and Technology, to the old for the new. Maintenance personnel based on equipment inspection, maintenance record sheet records, found that the problem is solved in a timely manner, troubleshooting, and from which to analyze the technical state of the equipment, equipment management and maintenance to provide information, violation of the provisions of the equipment inspection, maintenance, strictly in accordance with the rules for the implementation of the assessment.
3 equipment maintenance
3.1 equipment maintenance of the "four requirements"
a, neat: tools, workpieces, accessories placed neatly, equipment parts and safety guards are complete, lines, pipes intact;
b, clean: equipment inside and outside clean, no parts of the oil, water, gas leakage. Oil leakage, water leakage, gas leakage (steam), leakage phenomenon, no dust and garbage;
c, lubrication: on time, according to the quality, according to the amount of fuel, oil, keep the oil circuit is smooth, reasonable lubrication;
d, safety: in accordance with the relevant provisions of the rational use of equipment, careful maintenance, monitoring of anomalies, and no accidents.
3.2 Categories and requirements of equipment maintenance
Equipment maintenance is also called maintenance, most of the current enterprise routine maintenance, first-class maintenance, preventive maintenance, predictive maintenance.
3.2.1 Daily Maintenance
The daily maintenance of equipment includes two kinds of maintenance every shift and weekend, which is carried out by the operator.
3.2.1.1Shift maintenance
Shift maintenance requires the operator to check and lubricate the equipment before, during and after the shift; use the equipment correctly in accordance with the equipment operation and maintenance procedures during the shift; check and maintain the equipment in accordance with the equipment inspection and maintenance benchmarks, and deal with the anomalies in a timely manner. The main production equipment, its operators should also be required to fill out the "equipment inspection, maintenance records", before leaving work on the equipment for serious cleaning and scrubbing, and the necessary oil removal.
3.2.2 First-level maintenance
Equipment in the cumulative operation of the specified hours later, the operator mainly, maintenance workers as a supplement, according to the model specified content and requirements, specific maintenance requirements detailed in the equipment operation and maintenance procedures and inspection, maintenance benchmarks, maintenance records, should be filled out in detail in the equipment inspection, maintenance record sheet.
"A guarantee" of the main contents include:
a, according to the use of equipment, some parts of the disassembly, cleaning.
b, part of the equipment fit clearance for appropriate adjustment.
c, remove the yellow robe, oil on the surface of the equipment.
d, check, adjust the lubricating oil road, keep smooth, no leakage, cleaning linoleum, oil line and oil filter.
e, wipe the distribution cabinet surface dust.
f, cleaning dust, chip-proof device, safety guards tightened.
g, cleaning accessories and cooling devices.
"A guarantee" the main purpose:
a, so that the operator is gradually familiar with the structure of the equipment, performance, mastery of the "three good", "four will".
b, to reduce wear and tear of the equipment, to extend the service life.
c, troubleshooting equipment in general.
d, to create conditions for the completion of the next month's production tasks.
3.2.3 Preventive Maintenance
Preventive maintenance of equipment, it is the operator as a supplement, maintenance workers mainly for the maintenance work, the use of equipment and equipment departments responsible for workshop equipment management technicians, maintenance team leader should be based on equipment inspection, maintenance records, maintenance records and other dynamic statistical data, analysis and reflection of the equipment operating conditions and the production task schedule, the development of equipment Regular maintenance program, engineering and technical personnel declared to the equipment manager, after the unified balance of the Engineering and Technology Department, the equipment manager to develop a monthly regular maintenance program for the Division. At the same time, according to the equipment instruction manual maintenance requirements and equipment census results, the development of annual equipment maintenance program.
The periodic maintenance cycle can be formulated according to the equipment manual and the use of equipment, and its operational reference time according to each repair complex parameters 0.3-0.5 hours. The main contents of regular maintenance of equipment are as follows (specific maintenance content see each machine tool equipment maintenance details):
a, disassemble part of the equipment components, box cover and shield, etc., thoroughly clean, wipe the equipment inside and outside.
b, check, adjust the parts of the fit gap, tighten the loose parts, replace individual wearing parts.
c, dredging oil to add oil, cleaning oil filters, linoleum, oil line, oil markers, etc., replacement of coolant and cleaning coolant tank.
d, cleaning guide and sliding surface, remove burrs and scratches.
e, cleaning, checking, adjusting electrical wiring and devices (by the maintenance electrician).
Equipment through regular maintenance must be achieved: inside and outside the clean color, smooth oil, bright oil, flexible operation, normal operation, the accuracy of the standard requirements (such as precision is too large, can not be adjusted can be declared to carry out large and medium-sized project repair). Regular maintenance of equipment and its time schedule as far as possible with the equipment program maintenance comprehensive, maintenance personnel to do the corresponding maintenance records.
3.2.4 Predictive maintenance
In order to improve the efficiency of the production equipment and ensure its effectiveness, the need for some of the key, key equipment for predictive maintenance. First of all, the establishment of predictive maintenance system, the system mainly consists of equipment using department operators, engineering and technical department of engineering and technical personnel and maintenance personnel, equipment management team to organize and carry out the work.
3.2.4.1 Determination of predictive maintenance items
Equipment predictive maintenance items are mainly composed of engineers and technicians according to the equipment instruction manuals, equipment failure maintenance records, equipment operation records and other relevant information, statistics, accumulation of relevant data, identification of equipment parts and components replacement cycle and other predictive maintenance items, the equipment management team is responsible for the compilation of a complete set of equipment The equipment management team is responsible for organizing a complete set of equipment predictive maintenance list.
3.2.4.2 Implementation of Predictive Maintenance Programs
After the equipment predictive maintenance programs are compiled, they will be issued by the technicians to the maintenance team for implementation. The implementation of the equipment predictive maintenance program is mainly divided into two parts, one part is implemented by the maintenance staff of the Engineering and Technology Department, and the maintenance items, cycles and records are mainly reflected in the Equipment Maintenance List; the other part is implemented by the equipment operators, and the maintenance items, cycles and records are mainly reflected in the Equipment Inspection and Maintenance Table. The actual running time of the equipment is mainly reflected from the equipment management information statistical table, and the feedback is made by the relevant maintenance personnel, and the maintenance team leader and the relevant personnel of the workshop will arrange for the implementation; the maintenance personnel and the operators must fill in the details of the inspection phenomenon and the implementation results in the implementation of the predictive maintenance work, such as in the stipulated cycle, the inspection items are in perfect condition, and in order to avoid waste, no need to carry out the replacement, the maintenance personnel need to increase the frequency of inspection according to the The current state to increase the frequency of inspection, inspection cycle according to this maintenance project cycle of one-third to one-tenth of the time for inspection, the maintenance team leader of the group need to check the frequency of cycle identification, signature recognition. Similarly, the inspection results should be recorded in the equipment maintenance checklist and equipment inspection, maintenance record sheet, technicians should collect data for the next step in the revision of the predictive project ready; workshop in the implementation of predictive maintenance to do a good job of checking, tracking, feedback and so on, and at the same time, to do a good job of recording.
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