The use of equipment failure in enterprise equipment management

With the development of modern equipment to large-scale, refined, automation, complexity, high-speed operation, the links and opportunities for equipment failures are also more and more difficult to diagnose and analyze failures. As an important part of enterprise equipment management equipment failure analysis, how to innovate management, enterprise resource allocation and application of continuous optimization, which is our enterprise equipment management personnel should think y about the reasons. Only by constantly learning and mastering advanced management concepts and strategies, theory and practice, and strive to innovate, bold practice, in order to find their own equipment management strategy, in order to lay a solid foundation for the long-term development of the enterprise equipment management.

1 Overview

Equipment failure analysis is through the equipment failure before (after) the diagnosis, maintenance, overhaul and other data for statistical analysis, the use of statistical analysis, step-by-step analysis and fault tree analysis method of equipment failure analysis, in order to find the law of the occurrence of failures, and to take appropriate measures to avoid or reduce the failure of the purpose. The purpose of the failure is to avoid or minimize the failure.

Equipment failure analysis is an active, spontaneous work, in the work process must follow the principle of PDCA, timely analysis of the results of the equipment maintenance and overhaul plan to adjust. The role of equipment failure analysis is not only to prevent and restrict the occurrence of failures, through the analysis of equipment failure, we can also continue to improve the efficiency of the equipment, save equipment maintenance costs, improve maintenance technology, rational allocation of maintenance human resources.

2 The main content of the work of equipment failure analysis

2.2 Analysis of equipment failure information data ① equipment manager according to the equipment ledger will be classified, according to the key equipment, the main equipment, the general equipment statistics within the enterprise the number of various equipment. ② of the same type of equipment failure statistical classification, equipment failure according to the type of failure can be divided into emergency failure, major failure, general failure; according to the failure state can be divided into sudden failure, gradual failure; according to the reasons for the failure can be divided into the design reasons, manufacturing reasons, reasons for the installation, the reasons for the natural wear and tear reasons, repair reasons, maintenance reasons, reasons for unauthorized operation, lubrication reasons, and so on. ③ of the same kind of equipment for the same kind of failure statistics, the main statistical failure frequency, failure reasons, fault handling measures. (iv) Statistics on the replacement of spare parts for the same type of equipment failure, including spare parts replacement time, replacement quantity, inventory balance, procurement cycle, and so on. ⑤ Statistics on the cost of equipment maintenance, mainly divided into daily maintenance costs, equipment renovation costs and equipment overhaul costs. ⑥ For the equipment failure caused by the loss of large or large impact on the production process failure should be prioritized for analysis, by the equipment division of the technical staff to coordinate the relevant process operators, maintenance personnel to carry out thematic analysis, the development of fault handling programs and organize training for relevant personnel. (7) equipment failure analysis strategy has a variety of reasons, such as simple statistical analysis for a single equipment failure, for the reliability of the equipment during the use of MTBF analysis, for a single device fault tree analysis and for improving the economy of the equipment for the typical failure analysis. In short, failure analysis should be based on the actual needs of the enterprise, targeted selection.

3 The use of equipment failure analysis results

3.1 According to the results of equipment failure analysis to adjust the equipment operating procedures Good, standardized equipment operation can effectively improve the service life of the equipment to reduce the occurrence of equipment failure. According to the equipment failure analysis, selective identification of general equipment failure and treatment measures written into the equipment operating procedures, the post operator to carry out fault handling, because 80% of the equipment failure is the first time found by the post operator, and 80% of these faults are the post operator can be effectively resolved or temporary treatment, the first time to deal with equipment failure can effectively reduce equipment failure. The first time to deal with equipment failure can effectively reduce the loss of equipment failure, to ensure continuous production, to avoid the expansion of failure losses. Strengthen the position of the operator to understand the equipment, but also to promote the improvement of the operator's equipment operating skills, enhance the position of the operator's sense of responsibility for the management.

3.2 According to the results of equipment failure analysis to adjust the equipment overhaul program Equipment overhaul program is the main basis for equipment maintenance personnel to deal with equipment failures, according to the results of equipment failure analysis, equipment overhaul program can be constantly on the fault of the reasons for the failure and the treatment of measures to supplement the perfect, and then effectively improve the efficiency of the equipment overhaul. Through the continuous improvement of the equipment maintenance program, can improve the maintenance personnel on the equipment, so that the maintenance personnel in the equipment fault handling can be based on the description of the post operator in the shortest possible time to find the reasons for equipment failure and effective treatment. Through the combination of equipment maintenance procedures arranged maintenance skills practical training can effectively improve the maintenance staff's practical experience, training maintenance personnel observation and judgment, improve the maintenance staff's ability to deal with the problem.

3.3 According to the results of equipment failure analysis to adjust the equipment maintenance plan and overhaul plan

3.3.1 Equipment maintenance plan is based on the results of equipment failure analysis, the development of regular maintenance projects (such as equipment cleaning, equipment lubrication, wearing parts replacement, etc.). According to the equipment failure analysis, can be due to equipment cleaning is not timely, poor equipment lubrication, wearing parts wear and tear caused by serious reasons such as failure cycle for reasonable judgment, through the equipment maintenance plan for early treatment, prevent equipment failure. Equipment maintenance plan by the post operator and maintenance personnel *** with the implementation of the post operator-based maintenance personnel mainly with the post operator to confirm the results of maintenance. 3.3.2 Equipment maintenance plan is divided into two categories of temporary maintenance plan and regular maintenance plan, the temporary maintenance plan is mainly for sudden emergency failure or does not affect the production of general failures, need to be combined with the production of Scheduled maintenance plan is based on equipment failure analysis and equipment maintenance standards determined by the regular maintenance of equipment, generally including equipment repair, repair, overhaul, different equipment maintenance cycle is not the same, equipment management personnel should be determined in accordance with the analysis of the 'equipment maintenance cycle to prepare the equipment maintenance plan for the regular maintenance cycle is generally fine-tuned to the maintenance cycle to the beginning of each year to issue the 12 months of the year Monthly maintenance plan for the current year issued at the beginning of each year. Equipment regular maintenance program must be strictly enforced after the development of this work must be supported by the production line process operators, not because of the rush to arrange production and neglect equipment maintenance work, neglect equipment maintenance caused by equipment failure will often cause a longer production stoppage, the loss is not worth it.

3.4 According to the results of the equipment failure analysis to adjust the equipment spare parts management Equipment spare parts management is an important part of the economic management of equipment, is a professional, technical work, the number of spare parts inventory to ensure that the operation of the equipment is a reasonable need and can not be too much storage, aggravate the workload of the storage personnel, both to ensure equipment performance and try to reduce costs. Through the equipment failure analysis, first we can use all kinds of equipment and spare parts for a reasonable prediction of the number and cycle, the establishment of warehouses, maintenance team inventory management system at two levels, reasonable arrangements for all levels of warehouses spare parts inventory quantities (maintenance team inventory of spare parts is mainly to deal with emergency, critical failures and general faults in the day-to-day production of the use of fault handling, aimed at improving efficiency, the number of strict constraints); Secondly, the number of spare parts in stock should not only ensure the reasonable needs of equipment operation, but also not overstore the workload of warehouse personnel, both to ensure equipment performance and minimize costs. constraints); secondly, we can arrange for the planned localization of spare parts test, through the localization of spare parts, not only can reduce maintenance costs, but also shorten the procurement cycle, improve work efficiency.

3.5 Improve the utilization of human resources according to the results of equipment failure analysis Because our company is a continuous production enterprise, the production line is running 24 hours a day, how to reasonably arrange the maintenance personnel is always troubled by our problems. When the production line first began to operate, equipment failures occur frequently, maintenance personnel not only the number of people, and often have to work overtime, many workers are unable to eat. Through our adherence to the implementation of equipment failure analysis, and the establishment of a good equipment inspection and maintenance system, the frequency of equipment failure has been greatly reduced, and many daily equipment failure processing is also reasonably arranged to the post operator to carry out maintenance personnel can focus on the main equipment inspection, maintenance and technical research and development, and greatly improve the efficiency of human resources utilization.

4 Conclusion

My company by insisting on the implementation of equipment failure analysis, and according to the results of the analysis of reasonable equipment operating procedures, maintenance procedures, maintenance plans and overhaul plans to improve the adjustment, the equipment failure rate has been significantly reduced; through the daily operation of the position of the operator and the maintenance of the staff to carry out practical training to improve the work skills of the staff and enhance the staff's ability to work. Employee's work skills and enhance the sense of responsibility of the staff management; through the optimization of spare parts inventory and the promotion of localization of spare parts, the company's annual maintenance costs have been gradually reduced. In short, by insisting on the implementation of equipment failure analysis and utilization, the company's cohesion is further enhanced, the economic benefits have been significantly improved.

References:

[1]Lu Feng. Introduction to equipment failure analysis strategy [M]. Metallurgical Automation, 2009(S1): 298-299.

[2]Ma Xinguo. Encyclopedia of modern enterprise equipment management [M]. Harbin Map Press, 2006.

[3]Xia Hong, Liu Yongkuo, Xie Chunli, Equipment Fault Diagnosis Technology [M]. Harbin Institute of Technology Press, 2010.