1. Good imported equipment, the preliminary management, due to technological constraints and product requirements for the function of the equipment, some of our equipment and spare parts have to be imported from developed countries, and most of these equipment are expensive, the pressure on the cost of our pressure to constitute a direct pressure, but we also have to do so, the question is how do we go to do a good job. The author believes that the first thing is to imported equipment and spare parts to do a good job of research, selection, especially for some of the computer and microelectronics control equipment, whether or not it can match the existing equipment, whether or not it has the advanced nature of a serious review. We must not be purchased back after the equipment because it can not be adapted to the needs of the product, can not be integrated with the totality of the equipment to let it sleep in the library, in the past some of our enterprises in this regard is relatively blind, which is a waste of resources, but also make the enterprise to carry a heavy burden of costs, and the management of the objectives of the contrary. To this end, we need to strengthen management and cooperation with suppliers to maximize the implementation of zero inventory management of equipment spare parts. Let these "virtual" enterprise for my service.
2. According to the equipment life cycle, the preparation of equipment spare parts renewal and procurement plan. Any kind of equipment has a life cycle, including maintenance cycle and replacement cycle of two periods. With the construction and operation of the equipment information construction project, the equipment life cycle information will be displayed in front of us through the computer, the equipment life cycle table, the preparation of equipment spare parts program provides a strong support, can greatly improve the accuracy and timeliness of the spare parts program, thereby reducing the pressure caused by opportunity costs.
3. The use of equipment diagnostic technology, timely diagnosis and elimination of sudden accidents caused by equipment deterioration. Equipment accidents caused by economic losses is huge, especially some sudden accidents can cause both personal injury, but also cause economic loss of property. In practice, to eliminate the phenomenon of man-made deterioration of equipment operation, but also must use equipment diagnostic technology, as early as possible to find the abnormal state of the equipment, the development of abnormalities in the treatment plan. The application of diagnostic technology is not only to eliminate potential accidents, but also to reduce the huge economic losses caused by equipment accidents. Spare parts repair is an effective way to reduce the cost of spare parts, in the repair of spare parts in the repair of imported spare parts is the focus of spare parts repair. Imported spare parts due to the blockade of foreign technology and provide information on the disabilities, often failures and damages, it is difficult to dispose of a moment, resulting in great losses. Therefore, the imported spare parts, first, we must dare to use new technologies, independent innovation, to break the monopoly of foreign technology, to master the core technology, through the repair to restore the original technical performance, continue to play the utility of the equipment function. Secondly, as the team should pay great attention to the establishment of incentives to encourage employees to carry out technical research, and provide the necessary financial support and technical support.
Five stages
The development process of equipment maintenance system can be divided into five stages: after-the-fact repair, preventive maintenance, production maintenance, maintenance prevention and comprehensive equipment management.
1. repair after the fact
Repair after the fact refers to equipment failure, and then repair. This repair method does not know in advance when the failure occurs, the lack of repair before the preparation, therefore, the repair of longer downtime. In addition, because the repair is unplanned, often disrupting the production schedule, affecting the delivery date. Repair after the fact is a relatively primitive equipment maintenance system. In addition to small, unimportant equipment, has been replaced by other equipment maintenance system.
2. Preventive maintenance
The Second World War period, the military production is very busy, but equipment failures often damage production. In order to strengthen equipment maintenance, reduce equipment downtime repair time, the emergence of equipment preventive maintenance system. This system requires equipment maintenance to prevention-oriented, in the process of equipment maintenance work, strengthen the daily inspection and regular inspection, according to the law of wear and tear of parts and inspection results in the equipment before the failure of the planned repairs. As a result of strengthening the routine maintenance work. So that the effective life of the equipment to extend, and because of the planned repair, easy to do before the repair of the preparatory work, so that the equipment to repair the downtime greatly shortened, and improve the effective utilization of equipment.
3. Production maintenance
Preventive maintenance has the above advantages, but sometimes increase the maintenance workload, resulting in excessive maintenance. For this reason, in 1954 and the emergence of production maintenance. Production maintenance requirements to improve the economic results of enterprise production for the purpose of organizing equipment maintenance. It is characterized by the importance of equipment according to the choice of maintenance methods, the key equipment using preventive maintenance, the production of general equipment with little impact on the use of post-event repairs. In this way, on the one hand, we can concentrate on the maintenance of important equipment, but also can save maintenance costs.
4. Maintenance prevention
People in the maintenance of equipment found that, although the maintenance of equipment, maintenance, repair work carried out good or bad on the failure rate of equipment and effective utilization rate has a great impact, but the quality of the equipment itself how the use of equipment and repairs tend to have a decisive role. The inherent inadequacy of the equipment is often the main aspect that makes it difficult to carry out repair work. As a result, the concept of maintenance prevention emerged in 1960. This refers to the design of equipment, manufacturing stage on the consideration of maintenance issues, improve the reliability of equipment and easy to repair, so that in the future use, minimize or do not occur equipment failure, once the failure occurs, but also to make the maintenance work smoothly. Maintenance prevention is a major breakthrough in equipment maintenance system.
5. equipment integrated management
Public equipment maintenance on the basis of prevention. From the point of view of behavioral science, systems theory, in the early 1970s, and the formation of the concept of integrated equipment management. Equipment integrated engineering, or equipment integrated management. The original name in English is Terotechnology, which is an important way to implement comprehensive management of equipment. 1970 was first created in the United Kingdom, and then spread in European countries. It is a revolution in equipment management. Japan in the process of introduction, learning, combined with the practical experience of production and maintenance, created a comprehensive production and maintenance system, which is the Japanese style of comprehensive management of equipment.
With the development of the application of computer technology in the enterprise. The field of equipment maintenance has also undergone significant changes, the emergence of state-based maintenance (Condition-basicmaintenance) and intelligent maintenance (Intelligentmaintenance) and other new methods.
Condition-based maintenance was used on production systems with the advent of programmable logic controllers (PLCs), which are capable of continuously monitoring equipment and processing parameters. With condition-based maintenance, the PLC is connected directly to an on-line computer that monitors the status of the equipment in real time, and will automatically issue an alarm (or repair order) if there is any deviation from the standard normal tolerance range. This type of maintenance system can be expensive to install, but can greatly improve the level of equipment utilization.
Intelligent maintenance, or self-maintenance, includes automatic diagnostics of electronic systems and modular replacement devices that will provide sensor data from remote facilities or machines continuously to a centralized workstation. Through this workstation, maintenance specialists can be supported by the intelligence of expert systems and neural networks for decision-making tasks. Commands will then be issued to the remote site to begin maintenance routines that may involve adjusting alarm parameter values, activating test vibration devices on the machine, and actuating backup systems or subsystems. The Federal Aviation Administration (FAA) is developing the Remote Maintenance Monitoring System (RMMS). It is an example of the future direction of maintenance automation. In some examples, robotic technology can be used to perform remote module replacement.
Maintenance costs
I. Emphasis on equipment procurement management
Equipment procurement is extremely important in the selection of the type, if it is highly reliable, maintainability is good, the equipment will reduce the cost of maintenance of the latter part of the cost of a lot.
Additionally, to choose a unified model, not only to facilitate the reserve of spare parts, general interchangeability, but also to facilitate the organization of maintenance, saving inventory costs. Equipment selection is good or bad, determines the number of equipment life cycle costs.
Two, choose the appropriate maintenance
How to correct the relationship between production and market, production and maintenance of the relationship is critical. Do not pay attention to maintenance, production discretionary, in the organization, funds, time can not give the most basic conditions of equipment management and maintenance of the guarantee will inevitably lead to equipment repair, equipment, equipment, the decline in the state of good condition, which in turn affects the effectiveness of the equipment to play, resulting in an increase in the cost of equipment maintenance. Improvement of the past has been the long-term use of equipment, three-level maintenance, large and medium repair and other traditional practices. Should be a person, the organization of a reasonable time for maintenance, for large and medium-sized repair plans such as pre-maintenance system, it is changed to a flexible item repair, maintenance to replace.
Three, improve the effective operation rate of equipment
Equipment performance is not good, inefficient, and idle too much, but also an intangible waste of equipment assets, resulting in higher costs. To this end, the importance of improving the effective operation rate of equipment, the implementation of "responsibility and maintenance", "maintenance personnel annual evaluation system" and other management systems, to strengthen the construction of equipment management incentives and maintenance personnel to build self-restraint mechanism. The company has organized a number of activities such as equipment integrity management, "five leaks" rectification and elimination of "seven harmful behaviors" in operation and maintenance. The improvement of the effective operation rate of the equipment significantly reduces the unit maintenance cost.
Four, careful repair and maintenance of equipment
Careful maintenance of equipment, correct operation, rational use, careful maintenance, can prevent abnormal wear and tear of equipment parts and damage to extend the repair interval, reduce maintenance costs. There are two main forms of maintenance waste: one is equipment out of repair. This is due to equipment inspection omission, inaccurate prediction or due to insufficient funds, the lack of attention to equipment, spell equipment and equipment repair phenomenon. Second, excess maintenance. This is due to excessive maintenance arrangements for equipment, as well as excessive pursuit of equipment performance intact, such as the requirement to repair the old as new, etc., requiring excess functionality caused by the waste of maintenance.
Fifth, improve the rules and regulations
Improve, scientific and reasonable equipment management system and regulations, have a great impact on the cost. Cost management is the core of enterprise management, but also the focus of equipment management. In order to put an end to and reduce the equipment management and maintenance work in the existence of management loopholes, accounts do not match, maintenance is not in place, equipment with disease operation, unauthorized operation, as well as poor lubrication and other forms of waste, to improve the conscientiousness of the whole staff. The company's equipment management department according to the actual situation of statistical maintenance costs, has formulated the maintenance cost management regulations, abnormal damage to parts and equipment accident reporting and processing system, on the old parts of the repair of the appraisal and reward provisions of the management system, safe operating procedures, maintenance specifications, inspection and maintenance records, to strengthen the system construction of equipment management.
Sixth, the development of scientific, advanced technical and economic indicators
1. Indicators is to guide, check, evaluate the business, technical, economic activities and their economic effects of the basis. Indicators can be divided into a single technical and economic indicators and comprehensive indicators, can also be divided into quantitative and qualitative indicators of the main role of the indicators are: quantitative evaluation of the performance of the management work; in the management process to play a supervisory, regulatory and guiding role in the management process; the role of incentives and promotion.
2. The technical and economic indicators of equipment management is a set of interlinked, mutual constraints, can be a comprehensive evaluation of the effectiveness and efficiency of the management of no equipment indicators. Technical indicators of equipment management is an important part of the equipment management objectives. Equipment management involves funds, materials, labor organization, technology, economy, production and management objectives and other aspects, to test and measure the management level of each link and equipment assets management effect, must establish and improve the technical and economic indicators of equipment management system.
Maintenance quotas for a comprehensive measure of the maintenance of labor organization, material, technical equipment, repair technology level has value, should continue to use. But the development of maintenance quota coefficients, with the increasing content of the equipment section, need to be revised and supplemented, while the development of scientific maintenance indicators.
Equipment completion rate as the main assessment of the technical status of the equipment is effective, can continue to use. However, in the specific operation, the qualitative provisions of the standard should be improved to improve the integrity of the study, and strive to reduce the impact of subjective factors; or to improve the calculation of indicators to ensure the accuracy of the indicators.
Seven, strengthen the cost management education
1. In order to control the expenditure of maintenance costs, specifically set up by the engineers to participate in the maintenance of the replacement of the gatekeeper group, and on the spare parts receiving procedures, the identification of non-normal damage to the pieces of the identification and treatment of the development of special regulations.
2. In order to adapt to the market situation, the maintenance personnel actively participate in and cooperate with the plant to optimize the allocation of raw and auxiliary materials, and actively adjust the equipment to adapt to the various raw and auxiliary materials without increasing the cost, so that the optimization of the work can be carried out smoothly.
3. Vigorously carry out cost education activities. In order to improve cost management, the cost of holding special meetings, research and analysis, agreed on a variety of countermeasures, in the holiday overhaul, the daily production meeting is often carried out on the topic of instructions and requirements, and combined with the repairman assessment of the special training, so that the cost management work can be deepened.
Eight, promote the repair of old, energy saving
1. In order to reduce maintenance costs, give full play to and mobilize the enthusiasm of maintenance personnel, on the repair of old parts, parts of the damage to the development of special identification procedures and rewards and penalties for dealing with the provisions.
2. Reduce consumption, reduce production costs is the main content of equipment management. Most of the consumption of raw materials is realized in the equipment. Equipment in poor condition will increase the consumption of raw materials; in energy consumption, equipment accounted for a greater proportion. Strengthen equipment management, improve equipment operating efficiency, reduce energy consumption is an important means of saving energy. In the process of equipment operation, in order to maintain the normal operation of the equipment, itself also requires a certain amount of material consumption. Equipment generally have standing parts, wearing parts, such as parts consumption, equipment maintenance costs are high.
Nine, strengthen the technical improvement work
Technical improvements to improve equipment performance, reduce maintenance costs, has a particularly important significance. Vigorously carry out technical research activities, small reforms, to eliminate the inherent defects in the equipment, improve the stability and efficiency of the system work, greatly reducing the workload of inspection and maintenance, can save a lot of maintenance costs each year.
Ten, the establishment of a monitoring system, highlighting the economic management of equipment
The past analysis of maintenance costs, mostly at the end of the period, is an ex post facto analysis, has been unable to adapt to the requirements of the market economy. At present, the enterprise should not simply engage in ex post facto analysis, but to strengthen the promotion of cost prediction analysis, that is, the plan analysis, prediction analysis and ex post facto analysis of the combination of performance, set up a complete analysis, budget system.
Three major trends
1. Establishment and application of AME maintenance model
China's AME availability of enterprises on the low side, the cost of maintenance and repair is too high, the research applicable to the AME maintenance model is still far from enough. Therefore, the establishment of an applicable model to assist on-site maintenance engineers to make quantitative maintenance decisions in order to determine the reasonable timing of maintenance is one of the most important elements of maintenance management. Theoretically, the basis for establishing maintenance optimization model is a large amount of effective maintenance data, and often the maintenance data is unavailable, so in the case of incomplete maintenance data, how to use subjective data to establish maintenance optimization model will become the development trend of AME maintenance modeling. That is, by virtue of the empirical data given by maintenance engineers about maintenance, the fault distribution function of the equipment is estimated, and the established model is fitted and tested. Finally, according to the objective function to determine a reasonable maintenance interval, so that the total downtime per unit of time is minimized; to establish a reasonable cost model, to determine a reasonable timing of maintenance, so that the expected value of equipment maintenance costs per unit of time is minimized.
2. Maintenance of the network and the establishment of a decision support system
Compared with foreign countries, China's maintenance management status quo is unsatisfactory, one of the very important reason is that the enterprise does not pay attention to the maintenance and management of the equipment, a variety of original records, such as the failure history of the equipment, the accumulation of diagnosis and maintenance experience and theoretical summarization of most of the work stored in some of the technicians and maintenance workers. Mind, not formed a systematic information, maintenance work of poorer science. So in the maintenance management must be introduced into the computer information management, will be the existing fault diagnosis and maintenance of information on the collation and generalization.
Along with the intensification of the importance of AME in the enterprise, for the maintenance time, accuracy, precision requirements are increasingly high. Many managers find it difficult to control maintenance costs due to inadequate or excessive maintenance. With the intensification of information technology, the maintenance management information system is no longer a few enterprises to win the treasure taunt. Maintenance of the network and the establishment of decision support systems will become an inevitable trend of development. With the development of computer networks, network management came into being, the two promote each other, *** with the development. Network management is a complex control process for controlling and managing computer network equipment connection, system operation and resource allocation, so that it has a higher operating efficiency, in order to seek to maximize network availability, improve network equipment utilization, network performance, quality of service and system security, simplify the multi-vendor equipment composed of mixed network environment operation and management, control the network operating costs, and for the network development to provide a basis for long-term planning. The purpose of establishing a network management and decision support system in maintenance is to use software means on a certain hardware basis to monitor and control network operation, reduce the probability of failure, and quickly find problems and solve problems, monitor and analyze network performance, as well as optimize network configuration.
3. Maintenance of socialization, specialization
With the development of technical specialization, AME equipment maintenance work should be separated from the enterprise. That is, in accordance with the different aspects of production purposes, types of equipment, regional division, the establishment of professional maintenance plants or regional maintenance centers. Specialized maintenance factories provide paid services to enterprises by means of economic contracts, gradually forming a socialized maintenance system. These maintenance specialized organizations will be for advanced manufacturing equipment performance indicators, the accumulation of basic data, the establishment of equipment failure library and model library, through computer-aided equipment for maintenance decisions. This will enable the rational allocation of resources, not only is conducive to the production enterprises to focus on the main business, streamline the main body, reduce the burden on enterprises, improve efficiency and enhance vitality, but also conducive to the further division of labor in the social sector, the further enhancement of social productivity. The state can through laws and regulations to cultivate and regulate the equipment maintenance market, enter the market for equipment maintenance enterprise qualification, maintenance quality and price as well as mediation of maintenance transaction disputes and other standardized management, for enterprises to change the "big", "small", "small" equipment maintenance system to create a "big", "small", "small". "equipment maintenance system to create a favorable external environment. The author foresees the rise of professional maintenance enterprises, will be like a third-party logistics as the vigorous development.