By wiping, cleaning, lubrication, adjustment and other general methods of care of equipment to maintain and protect the performance and technical condition of the equipment, known as equipment maintenance. There are four main requirements for equipment maintenance:
(1) clean equipment inside and outside the neat, sliding surfaces, screws, racks, gear boxes, oil holes, etc., no oil, no oil leakage of various parts, no air leakage, equipment around the chips, debris, dirt to be swept clean;
(2) neat tools, accessories, workpieces (products) to be placed neatly, pipelines, lines to be organized;
(3) good lubrication Timely refueling or oil change, no oil, no dry friction phenomenon, oil pressure is normal, the oil label is bright, the oil circuit is smooth, the oil quality is in line with the requirements of the oil gun, oil cups, linoleum is clean;
(4) safety Comply with the safety regulations, do not overloaded use of the equipment, the equipment's safety guards complete and reliable, and timely elimination of insecure factors.
The maintenance of equipment generally includes routine maintenance, regular maintenance, periodic inspection and accuracy checks, equipment lubrication and cooling system maintenance is also an important element of equipment maintenance.
The routine maintenance of equipment is the basic work of equipment maintenance, must be institutionalized and standardized. Regular maintenance of equipment to develop work quotas and material consumption quotas, and according to the quota assessment, regular maintenance of equipment should be included in the workshop contract responsibility system assessment. Regular inspection of equipment is a planned preventive inspection, the means of inspection in addition to human senses, but also a certain inspection tools and instruments, according to the implementation of the regular inspection card, regular inspection of some people also known as regular inspection. Mechanical equipment should also be carried out precision checks to determine the actual accuracy of the equipment to the extent of the advantages and disadvantages.
Equipment maintenance should be carried out in accordance with the maintenance program. Equipment maintenance program is the daily maintenance of equipment requirements and regulations, adhere to the implementation of equipment maintenance program, you can extend the service life of the equipment to ensure a safe and comfortable working environment. Its main content should include:
(1) equipment to achieve neat, clean, strong, lubrication, corrosion, safety, etc., the content of the work, the method of operation, the use of tools and materials, to achieve the standards and precautions;
(2) daily inspection and maintenance and periodic inspection of the parts, methods and standards;
(3) check and assess the degree of maintenance of equipment by the operating workers (3) The contents and methods of checking and evaluating the degree of maintenance of the equipment by the operators, etc.
Second, the three-tier maintenance system of equipment
The three-tier maintenance system is China's 20th century, starting in the mid-1960s, in the former Soviet Union to summarize the system of planned pre-maintenance in China on the basis of the practice of gradual improvement and development of a maintenance and repair system, which reflects China's equipment maintenance and management of the center of gravity by the repair of the maintenance of the change, reflecting China's progress in the management of equipment maintenance and maintenance management and to prevent the main focus of more clearly defined maintenance management policy. The maintenance management policy is more clear. Three-tier maintenance system includes: routine maintenance of equipment, maintenance and secondary maintenance. Three-tier maintenance system is the operator-oriented equipment to ensure that the main maintenance system, warranty and mandatory maintenance system. The three-tier maintenance system is to rely on the masses, give full play to the enthusiasm of the masses, the implementation of group management group repair, specializing in the combination of groups, to improve the maintenance of equipment and effective methods.
(a) the daily maintenance of equipment
The daily maintenance of equipment, general maintenance and weekly maintenance, also known as daily and weekly routine insurance.
1. Day routine insurance
Day routine insurance by the equipment operator workers on duty, seriously do four things before the shift, five attention in the class and four things after the shift.
(1) four things before the shift Digesting drawing information, check the shift records. Wipe the equipment, according to the provisions of the lubrication and refueling. Check the handle position and manual operation parts are correct, flexible, safety devices are reliable. Low-speed operation to check whether the transmission is normal, lubrication, cooling is smooth.
(2) five attention in the shift Note the sound of operation, equipment temperature, pressure, level, electrical, hydraulic, pneumatic system, instrumentation signal, safety insurance is normal.
(3) Four things after the shift Close the switch, all the handles to the zero position. Remove iron filings, dirt, wipe the equipment rail surface and sliding surface of the oil, and refueling. Clean up the workplace, organize accessories and tools. Fill in the shift handover records and running time records, and go through the shift handover procedures.
2. Weekly routine maintenance
Weekly routine maintenance is carried out by the equipment operators at the end of each week, the maintenance time is: general equipment 2h, fine, large and rare equipment 4h.
(1) Appearance Wipe clean the equipment guide rail, the transmission parts and the exposed parts, clean the workplace. To achieve internal and external cleanliness without dead ends, no corrosion, the surrounding environment is clean.
(2) maneuvering transmission Check the technical condition of each part, tighten the loose parts, adjust the fit gap. Check interlock, insurance device. To achieve normal transmission sound, safe and reliable.
(3) Hydraulic lubrication Clean the oil line, dust felt, oil filter, oil tank add oil or oil change. Check the hydraulic system to achieve clean oil, smooth oil circuit, no leakage, no research injury.
(4) Electrical system Wipe the surface of motor, snake skin tube, check insulation, grounding, to achieve complete, clean and reliable.
(2) the first level of maintenance
The first level of maintenance is based on the operation of the workers, maintenance workers to assist, according to the plan of the local disassembly and inspection of the equipment, cleaning of the prescribed parts, dredging of the oil circuit, piping, replacement or cleaning of the oil line, felt, oil filter, adjusting the gap between the various parts of the equipment, tightening of all parts of the equipment. The time used for the first level of maintenance is 4-8h, and after the completion of the first guarantee, records should be made and defects that have not been removed should be indicated, and acceptance should be organized by the workshop mechanic. The scope of a guarantee should be all the equipment in use, the key equipment should be strictly enforced. The main purpose of a guarantee is to reduce the wear and tear of equipment, eliminate hidden problems, extend the service life of the equipment, for the completion of the next guarantee period of production tasks in the equipment to provide protection.
(C) the second level of maintenance
The second level of maintenance is based on maintenance workers, operating workers to participate in the completion. The second level of maintenance is included in the overhaul program of the equipment, part of the equipment dismantling inspection and repair, replacement or repair of wear parts, cleaning, oil change, inspection and repair of electrical parts, so that the technical condition of the equipment to achieve the full range of equipment to meet the requirements of the standard of integrity. The time used for secondary maintenance is about 7 days.
After the completion of the second maintenance, maintenance workers should fill out the maintenance records in detail, by the workshop mechanic and operator acceptance, acceptance sheet to the equipment power section archives. The main purpose of the second guarantee is to make the equipment to reach the standard of integrity, improve and consolidate the equipment integrity rate, and extend the overhaul cycle.
The implementation of the "three-tier maintenance system", must make the operator of the equipment to do "three good", "four will", "four requirements " and comply with the "five disciplines". Three-tier maintenance system highlights the maintenance in the equipment management and planned maintenance work in the status of the operators of the workers "three good", "four will" requirements more specific, improve the operators to maintain the knowledge and skills of the equipment. The three-tier maintenance system breaks through the former Soviet plan to repair the relevant provisions of the system, improve the plan to repair some of the shortcomings of the system, more practical. In the implementation of the three-tier maintenance system also learned and absorbed some of the practices of the military management of weapons, and emphasized the group management and group repair. Three maintenance system in our enterprise has achieved good results and experience, due to the implementation of the three maintenance system, effectively improve the integrity of the enterprise equipment, reduce the equipment accident rate, extend the equipment overhaul cycle, reduce the equipment overhaul costs, and achieved a better technical and economic results.
Third, fine, large, rare equipment, the use of maintenance requirements
(a) four work
(1) the use of personnel. According to the fixed person fixed machine system, fine, large, dilute equipment operators should choose the type of work in a strong sense of responsibility, high level of technical and practical experience, and as far as possible to maintain a relatively long period of relative stability;
(2) fixed maintenance personnel. Fine, large, dilute equipment more enterprises, according to the conditions of the enterprise, can organize fine, large, dilute equipment professional maintenance or repair group, specifically responsible for the fine, large, dilute equipment inspection, precision adjustment, maintenance, repair;
(3) fixed operating procedures. Precision, large, rare equipment should be divided into models and prepare operating procedures, to show and strictly enforced;
(4) fixed spare parts. According to the role of various fine, large, rare equipment in the production of enterprises and the source of spare parts, to determine the reserve quota, and prioritize the solution.
(ii) precision equipment use and maintenance requirements
(1) must be strictly in accordance with the provisions of the manual to install the equipment;
(2) to the environment has special requirements of the equipment (constant temperature, constant humidity, shockproof, dust-proof) enterprises should take appropriate measures to ensure that the accuracy of the equipment performance:
(3) equipment in the daily maintenance of the maintenance, not allowed to dismantle the parts and components, found abnormalities immediately stop, do not allow the equipment precision performance:
(3) equipment in routine maintenance, not allowed to dismantle the parts and components. Abnormalities found immediately stop, not allowed to operate with disease;
(4) Strict implementation of the cutting specifications specified in the equipment specification, only allowed to carry out parts finishing according to the direct use. The machining allowance should be as small as possible. Processing of castings, the blank surface should be pre-blasted or painted;
(5) non-working hours should be added to the shield, a long period of time off, should be regularly wiped, lubrication, idling;
(6) accessories and special tools should be special cabinets and shelves shelves to keep clean, to prevent research injuries, and shall not be lent.
Fourth, the use of power equipment maintenance requirements
Power equipment is the key equipment in the enterprise, in the operation of high temperature, high pressure, flammable, toxic and other hazardous factors, is to ensure the safety of the production of key parts, in order to achieve a safe and continuous and stable supply of production of kinetic energy, the use of power equipment maintenance should be a special requirement:
(1) operation of the operator Must be pre-trained and passed the examination;
(2) There must be complete technical data, safe operation technical regulations and operation records;
(3) The operating personnel should be on duty at any time to carry out inspections, and shall not leave their posts at will;
(4) In case of irregularities during operation, the personnel on duty should be dealt with in an emergency according to the operation procedures and report to their superiors in a timely manner;
(5) The power equipment should be used and maintained in a safe, continuous and stable manner in order to achieve a safe, continuous and stable supply of kinetic energy for production. And report to the superior in time;
(5) Ensure that all kinds of indicating instruments and safety devices are sensitive and accurate, and calibrated regularly. Standby equipment is complete and reliable;
(6) Power equipment shall not be operated with disease, and any malfunction must be eliminated in time;
(7) Preventive tests and seasonal inspections are carried out regularly;
(8) Safety education is often given to the duty personnel, and the safety and security system is strictly enforced.
V. Regional maintenance of equipment
Regional maintenance of equipment is also known as the maintenance worker package mechanism. Maintenance workers to undertake a certain production area of equipment maintenance work, and production workers *** with the production operation to do routine maintenance, inspection tours, regular maintenance, scheduled repairs and troubleshooting work, and is responsible for the completion of the equipment within the area of the completion rate, the failure of the downtime rate and other assessment indicators. Regional maintenance responsibility system is to strengthen the maintenance of equipment for production services, mobilize the enthusiasm of maintenance workers and production workers to take the initiative to care about equipment maintenance and repair work in a good form.
The main organizational form of professional equipment maintenance is the regional maintenance group. Regional maintenance group is fully responsible for the production of regional equipment maintenance and emergency repair work, its tasks are:
(1) responsible for the maintenance and repair of equipment in the region, to ensure the completion of the equipment completion rate, failure downtime rate and other indicators;
(2) the implementation of the equipment regular inspection and regional inspection system, guidance and supervision of operators to do a good job of routine maintenance and regular maintenance
(3) Participate in equipment condition survey, accuracy check, adjustment, leakage treatment, fault analysis and condition monitoring under the guidance of workshop mechanics.
The advantages of this form of equipment maintenance organization of regional maintenance groups are: a high degree of mobility in the completion of emergency repairs, so that the shortest possible downtime for equipment repair, and on-duty clampers in the absence of a call, you can complete the preventive operations and participate in the planned repairs.
Equipment maintenance area should take into account the distribution of production equipment, equipment condition, technical complexity, production needs and repair the technical level of the clampers and other factors. Workshop equipment can be divided into a number of regions according to the above factors, but also according to the type of equipment divided into regional maintenance group. Flow production line equipment should be divided by line maintenance area.
The regional maintenance group should prepare a regular inspection and precision inspection program, and set out the time for routine inspection of equipment on each shift. In order to make these tasks do not affect the production, the planned inspection of equipment to be arranged in the plant on non-working days, and the routine inspection of each shift to be arranged in the production workers' lunch break.
Six, improve the level of equipment maintenance measures
In order to improve the level of equipment maintenance should be made to maintain the work of the basic to achieve the three, that is, standardization, process, institutionalization.
Standardization is to make the maintenance content uniform, which parts of the cleaning, which parts should be adjusted, which device should be checked, according to the situation of each enterprise in accordance with the objective law to be considered and stipulated in a unified manner.
Technologization is based on different equipment to develop the maintenance process procedures, according to the procedures for maintenance.
Institutionalization is based on different working conditions of different equipment, different maintenance cycles and maintenance time, and strictly enforced.
Regular maintenance work, to develop a quota of working hours and material consumption quota and to be assessed according to the quota.
Equipment maintenance work should be combined with the enterprise production economic contract responsibility system for assessment. At the same time, the enterprise should also mobilize the masses to carry out a combination of specialized groups of equipment maintenance work, self-inspection, mutual inspection, to carry out equipment inspection.