1. Equipment inspection list inspection and motivation
Equipment inspection is one of the contents of 5S. 5S activities are relatively easy to carry out, can be in various forms, and achieve results in a short time. Obviously, but most companies always start but end, and there are very few companies that can persevere. The company should add weekly spot inspections by squad leaders and monthly inspections by equipment managers to the inspection form.
The inspection form should be specific to every point of the on-site equipment, and the specifications should be formulated in detail and written into the responsibilities of each position. All employees must strictly abide by it, so that every employee knows the specific content of the equipment inspection. Know what needs to be done, where to do it, when to do it, who to do it, how to do it and to what extent. At the same time, the completion of the inspection form must be included in the employee assessment items.
On the other hand, through positive incentives, on-site operators are mobilized to participate in equipment inspections, and operators are trained to develop the habit of equipment inspections. Let the operator truly feel the effect of careful inspection on the equipment. Provide material and spiritual rewards to outstanding operators who participate in equipment inspections. Regularly update the inspection form, extend the inspection cycle for data that does not change frequently during equipment inspection, and add new content that needs inspection to ensure that the equipment inspection work is constantly updated and improved. Equipment inspection work should be changed from passive implementation to proactive action.
The inspection and evaluation process begins with superiors inspecting subordinates, gradually transitions to the stage of mutual inspection and self-inspection, and changes from supervision and inspection to forms such as competitions and competitions.
Use the above two methods to solve the problem of operators not carefully checking equipment. The above methods ensure that the operator's inspection data is true and reliable, and provide a reliable data guarantee for understanding the status of the equipment.
2. Strengthen equipment training for operators
According to the TPM management method, employees are a key link in TPM management. How can we do a good job in TPM? For enterprises, reasonable and effective training is an important means to improve the quality of employees. The company has never lacked employee training, but although it invests a lot of money every year, it does not achieve the desired results. The fundamental reason is that theoretical things are not really used in practice, and practical things are not developed in conjunction with theory. It was discovered that the operator's improper use of equipment caused equipment failure, and it was learned that the operator had too little knowledge about the equipment. Companies need to carry out equipment-related training to help operators recognize and understand the equipment. The training content can be roughly divided into several aspects:
1) Factory equipment operation training, so that operators can understand the operation methods and precautions of the equipment.
2) Equipment inspection training, training operators on equipment inspection locations, methods and means.
3) Independent equipment maintenance training, training operators on the correct method of maintaining equipment.
Through the above three aspects of training, operators can have a deeper understanding of the equipment and be able to operate and use the equipment more rationally in the future.
3. Improve independent maintenance
In the management thinking of TPM, an important idea is "full participation", and a key content of equipment management in which operators participate is Self-preservation. To carry out independent security well, we need to solve some problems. 1 The operator completes the content of autonomous maintenance. The operator must understand and understand what needs to be carried out independently. Through autonomous security training, operators can master the knowledge of autonomous security. 2. Tools used in self-maintenance. When carrying out self-maintenance, appropriate cleaning tools must be used to achieve twice the result with half the effort. 3. Establish a complete set of independent maintenance standards. Operators perform equipment maintenance according to the independent maintenance standards. The maintenance standards provide the location of equipment maintenance, required maintenance tools, maintenance methods and maintenance frequency in the form of pictures. In this way, operators can perform maintenance according to maintenance standards, which not only improves work efficiency but also ensures the correctness of maintenance methods. 4Autonomous maintenance requires timely updates based on the status of the equipment. Because the equipment is in different states at different times, the parts that need maintenance are naturally different. According to the PDC cycle in on-site management, remove items that do not require maintenance and add maintenance items that need to be added. Ensure that autonomous security is always updated.
After the independent maintenance activities are carried out, the operators' independent maintenance should be evaluated, and a reward and punishment mechanism should be established to reward operators who have performed good maintenance, and to criticize and educate operators who have performed poor maintenance. , allowing operators to fully realize the importance of independent maintenance.
4. Establish a professional inspection mechanism
The professional inspection system is a set of relatively complete scientific management methods that are institutionalized. Its essence is based on preventive maintenance. Maintenance method with spot inspection as the core, professional spot inspection is one of the key tasks to find out equipment problems, and it is the focus of condition maintenance. The company's professional inspection department has eleven initial stages. The inspection content only stops at checking whether the equipment oil has deteriorated and whether the protection is intact. These inspection contents are relatively simple and cannot serve the purpose of checking the status of the equipment. In order to scientifically formulate professional inspections, according to the structure of the equipment, it is necessary to formulate detailed inspection locations, inspection items, inspection cycles, inspection methods, inspection divisions and judgment standards. Therefore, all inspection points must be fixed. , determine the law, determine the period, determine the person, and determine the target.
The following is a detailed analysis of how to develop these standards. 1. Fixed point means to determine the location of equipment inspection. 2. Establish methods and use standard operating methods to develop detection methods. 3. Regularly and reasonably develop inspection cycles for different parts. 4. Appoint people and divide equipment responsibilities. Let each maintenance personnel conduct professional inspections of the equipment they are responsible for. 5. Calibration, using data to determine the quality of equipment status, avoiding human subjective judgment.
In addition, there must be clear instructions on the testing tools and the number of people to be inspected. This ensures the accuracy of professional inspections.
The content of professional equipment inspection mainly includes:
. Regular inspection of equipment without disassembly
b. Equipment disassembly inspection
c. Deterioration tendency inspection
d. Equipment accuracy test
e. System accuracy inspection and adjustment
f. Parts replacement
5. Properly scrap and update equipment
According to the equipment life cycle theory, equipment has two lifespans, namely technical life, management life and economic life. When the manpower required to maintain the equipment and the capital invested in replacing spare parts are greater than the profits created by the equipment, it is no longer economical to use the equipment at this time, so it is necessary to consider scrapping the equipment at this time. At the same time, if the production capacity of the equipment is too low and the accuracy of the equipment is reduced, it must be improved and transformed through technical means to improve the efficiency and accuracy of the equipment. When the equipment cannot be modified through technical means, the equipment must also be scrapped.
Scientific analysis of equipment status, reasonable equipment scrapping plans, and resolute abandonment of equipment with high energy consumption and low productivity. At the same time, for those equipment that are still experiencing occasional failures, the service life of the equipment can be extended through technological innovation and other methods to increase economic benefits for the enterprise.
6. Properly reserve original spare parts
According to the company's spare parts consumption patterns and failure occurrence patterns, reasonably establish a safety inventory of spare parts.
For emergency spare parts, reserve some important spare parts with long purchase cycle. Spare parts reserves cannot be too high, which will cause a backlog of company funds, and they cannot be too low, which will lead to insufficient spare parts reserves and affect production. While stocking original spare parts, we should also consider the selection of local spare parts. The purchasing department needs to find some better quality spare parts manufacturers to provide spare parts. For some imported spare parts, although they are not critical spare parts, the procurement cycle is very long, so you can also consider localizing them. This will not only shorten the spare parts procurement time, but also reduce the cost of purchasing imported spare parts.
7. Establish a reasonable planned maintenance
In order to establish a scientific and reasonable planned maintenance, you must first understand the status of all equipment. There are two ways to understand the status of the equipment: 1. Problems found during equipment inspection. Through the equipment inspection table, you can see the trend changes of various indicators of the equipment, and then analyze possible problems with the equipment. 2. Professional equipment inspection. Professional equipment inspection is to diagnose equipment problems through professional inspection. 3. Fault statistics. Many fault problems can often be found in fault statistics. After identifying the hidden faults of the equipment, it is necessary to carry out planned maintenance of the equipment reasonably. For ten small hidden faults, maintenance personnel will solve them through weekly planned maintenance. For ten large hidden faults, the maintenance team will repair them through holiday inspections.
8. Continuously improve and improve
1) Improve equipment defects
Through fault statistics, summarize frequent equipment faults and find out from them Failure caused by equipment defects.
Set up a special team to formulate countermeasures to eliminate design hazards, carry out equipment transformation in a planned manner, track the modified equipment, and gradually establish good equipment status.
2) Improvement of vulnerable spare parts
Replacement of some vulnerable spare parts can be considered, replacing poor quality spare parts with good quality spare parts, or replacing equipment that is not suitable for the equipment. Replace the spare parts used with spare parts suitable for the on-site use environment to extend the service life of the spare parts and reduce the occurrence of equipment failures.
3) Improve the TPM management system. Continuously improve the equipment management system, and timely update equipment inspection, independent maintenance, professional inspection and planned maintenance. Ensure that these management systems meet the needs of the current equipment status.