Reducing the maintenance cost of forklift equipment in enterprises, as an important part of reducing production costs, has become the focus of the majority of equipment managers. For small and medium-sized production enterprises with increasingly aging forklift equipment, the reduction of forklift maintenance costs has a particularly important impact on production costs.
1. Factors affecting the maintenance cost of forklift equipment
First, internal factors
(1) For enterprises engaged in production, due to the extension of the service life of forklift equipment, the aging degree of the equipment is gradually aggravated, and the maintenance cost of forklift equipment increases with the extension of the service life of the equipment, resulting in an increase in production costs, a decrease in profits and a decrease in benefits.
(2) The upgrading of forklift equipment is slow, and the continued use of scrapped machinery and worn machinery greatly increases the failure rate, thus the maintenance cost keeps rising, and finally the embarrassing situation of "it is a pity to abandon it, but it is expensive to use it" is formed.
(c) Insufficient understanding of the importance of forklift management in enterprise production and construction projects, resulting in high maintenance cost of forklift machinery and equipment;
1) In the whole enterprise production and construction industry, the importance and necessity of forklift equipment management are high, but the real understanding of forklift equipment management by managers is still insufficient.
The intensity of specific implementation is obviously insufficient; There is no effective and perfect mechanical equipment management system; Failure to formulate an efficient and reasonable forklift maintenance plan with a pragmatic attitude will often lead to the phenomenon of backlog and waste of forklift maintenance parts, high maintenance costs and inefficient use of machinery.
2) Relevant systems for forklift maintenance and procurement. Although there is a system, it is not detailed and quantified, with vague responsibilities and poor implementation. The professional quality of forklift equipment management personnel, maintenance personnel and procurement personnel is low.
Forklift equipment management personnel failed to supervise in place in a series of maintenance links; In the process of purchasing and processing spare parts, the phenomenon of wrong purchase, overbought or purchasing high-quality and low-priced products occurs from time to time.
Processing can not be completed at one time, which leads to secondary purchase and repeated processing, which increases the cost; In the process of forklift maintenance, maintenance personnel have a weak sense of responsibility and waste materials seriously. Some human factors are meaningless, and she has increased the expenditure of manpower and material resources.
B, external factors
There are many spare parts for forklift equipment, but the quality of spare parts is uneven. If the maintenance personnel are not responsible enough and use poor quality spare parts, the maintenance cost of forklift trucks will increase.
2. Measures to reduce the maintenance cost of forklift equipment.
Based on the above internal and external factors that lead to the high maintenance cost of forklift equipment, especially for small and medium-sized production enterprises with aging equipment, Snooko, combined with years of experience in forklift equipment management, believes that taking the following measures is conducive to reducing the maintenance cost of forklift equipment:
First, pay attention to the upgrading of forklift equipment
Accelerate the upgrading of forklift machinery and equipment. Generally speaking, many companies have some forklift machinery and equipment in an extended service state, and the equipment's innovation coefficient is quite low. The worn-out machinery still participates in the construction work and has to rely on the maintenance of forklift equipment at all levels to support it. Expensive manpower and material resources are likely to exceed the value created by themselves. We managers should treat such problems from the perspective of economics and don't waste them. This has a great effect on revitalizing the enterprise economy and enhancing the competitiveness of enterprises.
B, strengthen the maintenance of forklift equipment, prevent false insurance, put an end to leakage.
Improper maintenance of forklift trucks is the main cause of equipment failure, and maintenance work must be strengthened. Forklift truck operators should make an effective maintenance plan according to the mechanical maintenance instruction, and make technical disclosure with the driver to check the implementation of supervision and maintenance at any time. Strengthen the operator's sense of responsibility, do a good job of maintenance, ensure the normal operation of equipment, prolong the service life of equipment, reduce the number of failures, reduce the scale of failures, and save forklift maintenance costs. Maintenance work should start from the source, to prevent repair with repair.
C, improve the technical level of forklift operators, strengthen the inspection of equipment.
(1) Operators are not familiar with the performance and principle of forklift equipment, which is often one of the causes of mechanical accidents. Therefore, in order to reduce the maintenance cost of forklift trucks, we must first strengthen the skills training for operators, so that they can master the structure, performance and working principle of the equipment.
(2) The daily inspection of forklift trucks is essential. The inspection results should be recorded in detail, including not only the previous forklift maintenance records and replacement records, but also the daily use and workload records. So as to analyze and judge mechanical faults and eliminate hidden dangers timely and accurately.
Improve the quality of forklift maintenance and the quality of maintenance team.
Nowadays, with the extension of the service life of forklift equipment, it is a fact that no one can change the aging of equipment. Improving the quality of machinery maintenance by improving the quality of maintenance team is also an important measure to reduce the maintenance cost of forklift equipment. Because the quality of mechanical repair is not up to standard, the cost of forklift maintenance remains high, and the waste of secondary repair and repair materials and working hours is widespread in various maintenance enterprises.
For the maintenance of large forklift equipment, we should try to reduce the maintenance cost through the marketization of maintenance. By improving the technical level and sense of responsibility of mechanical maintenance personnel, conducting business training and assessment, a fighting mechanical maintenance team is established. For the internal maintenance of small machinery, it is necessary to standardize the maintenance, introduce and explore new maintenance technologies, and put an end to waste and delay.
E, improve the quality of forklift equipment management personnel.
In enterprise engineering projects, forklift equipment managers should play a strong role of contact and supervision. They are the link between the engineering production department and the mechanical department of an enterprise. They should know the situation in time, understand the overall situation, make a reasonable and detailed maintenance plan for the mechanical forklift, and guide and supervise the forklift maintenance and procurement activities to avoid unnecessary maintenance and cost waste.
F, further improve the forklift machinery and equipment management system.
At present, various construction enterprises have strengthened equipment management year by year and established some mechanical equipment management systems. However, the related systems of mechanical maintenance are relatively few or insufficient, which brings great difficulties to mechanical management. Snooko suggested that relevant systems should be further established and improved, and the role of maintenance and management should be emphasized; Improve the data statistics system and file forklift failures; Clear rewards and punishments for pilots and maintenance management personnel, and clear responsibilities; Strengthen the supervision of spare parts procurement and processing.
G, overcome the concept of "big family"
Some forklift maintenance personnel and even some equipment managers think that the spare parts I replaced are worthless and have little impact on the cost. Actually, it's not. As the saying goes, "a levee of a thousand miles is destroyed by an ant nest." If it is not accumulated bit by bit, it is impossible to achieve good results. Equipment managers and maintenance personnel should regularly carry out maintenance cost analysis meetings, find loopholes, analyze problems and start with details. Only when equipment managers and maintenance personnel implement the saving system can the established goal of reducing forklift maintenance cost be achieved.
H, strengthen the communication and coordination between all units and departments of enterprise engineering production.
In the actual production process, the phenomenon of "emphasizing use over management" is still quite serious, and engineering managers generally know little about mechanical properties. They think that as long as mechanical energy works, it should run at full capacity, even 24 hours a day, without giving time for rest and maintenance.
Shutdown maintenance is considered to be a waste of time, delay the construction progress and reduce production efficiency. Doing so will lay a hidden danger for mechanical failure. I don't know that the time and money spent on a major mechanical failure is far greater than the usual maintenance time and cost. Therefore, as one of the effective ways to reduce the maintenance cost, the equipment management department should strengthen the contact and communication with the production department of the enterprise.