Everyone wants equipment to be highly efficient. As far as equipment is concerned, its efficiency involves two parties, one is the production and use of personnel, and the other is the maintenance and repair personnel. If the two sides of the personnel are viewed as their own isolated party, we are the producers only to use, you are the maintenance of maintenance, equipment, good or bad by your responsibility, so of course, will not produce any good results. Should see, production and use and maintenance is a whole of the two aspects, which is like a bicycle with two wheels, only the two are ready to cooperate with each other, in order to give full play to the effectiveness of the equipment. Production and use of the department is not only in charge of production and use is enough, it should also assume the basic work of equipment maintenance, that is, "to prevent the deterioration of the activities". Only the production and use of the department to do a good job of "preventing the deterioration of the activities", the maintenance department can play out its assumption of full-time maintenance of the real power of the means in order to make the equipment to get really effective maintenance.
We production and use of the department to "prevent equipment deterioration" as the center of maintenance activities called "all staff to participate in the independent maintenance activities", usually referred to as independent maintenance.
In the case of autonomous maintenance activities. In order to fully utilize the capabilities of the equipment, it is necessary to implement "their own equipment by their own management", to be a person who can control the equipment. Therefore, in addition to the ability to manufacture products, operators must also have the following four aspects of the ability:
1, the ability to find abnormalities
The ability to find abnormalities in the equipment "abnormality discovery ability" is not simply to have produced a failure or produce poorly when the abnormality is found, but when it seems to be occurring, it seems to produce poorly, but when it seems to be occurring, it seems to have a failure, it seems to produce poorly, it seems to produce poorly. But when there seems to be a malfunction, seems to produce defects, the cause of these malfunctions and other abnormalities can be seen at a glance, only then can be called a real "abnormality discovery ability.
2, the ability to correctly and quickly deal with anomalies (processing recovery ability)
For the anomalies that have been found, only to restore it to the original state of correctness, in order to give play to the original function of the equipment, and should also be able to decide whether to report to the superiors and the maintenance department according to the degree of anomalies, and how to deal with it.
3, the ability to set the conditions
The ability to find anomalies often depends on the level and experience of each person, due to the level and experience of the different, may affect the discovery of anomalies. In order to prevent this phenomenon, it should be decided on a definite amount to judge whether the equipment is normal or not. The benchmark for judgment should be quantitative, for example, temperature, which should be quantitatively determined as "below XX degrees" rather than vaguely described as "there should be no abnormal heat generation". It should be emphasized that, rather than focusing on the correctness of the judgment benchmark and delayed implementation, it is better to set a temporary benchmark, and then amended several times in order to set a more appropriate benchmark, this approach is more realistic.
4. Maintenance management capability
It is better to repair equipment after it breaks down than to prevent it from breaking down in the first place, and for this reason, it is necessary to comply with the established standards, such as the "cleaning and refueling standards" and the "self-inspection standards", and so on.
How the ability to form, it mainly depends on the work of continuous learning and accumulation, so the work itself is a kind of learning, due to the continuous improvement of the ability to achieve more results, they are interdependent and mutually reinforcing relationship between the three.
To train operators to master the equipment, to form an independent maintenance system, on the one hand, we must focus on the training of personnel, on the other hand, according to its actual ability to work on the practical improvement to achieve real results, that is, this effect can be maintained. When carrying out autonomous maintenance, it is important not to expect many problems to be solved all at once, and for this reason, we have organized the objectives and contents into seven steps, which is called "step-by-step autonomous maintenance. The ideal approach is to do each step thoroughly, and then move on to the next step when you have reached a certain level.
The seven steps of autonomous maintenance are:
Step 1: Initial cleaning
Initial cleaning is a thorough cleaning of dust, garbage, etc., centered on the equipment. We want to change the cleaning inspection, inspection can find problems, find potential defects in equipment, and deal with them in a timely manner. At the same time through the cleaning can help operators to produce equipment care heart.
The second step: the source of occurrence, difficult parts of the countermeasures
In order to maintain and improve the results of the first phase of the initial cleaning, it is necessary to eliminate the source of dust, contamination, etc. (source of occurrence), which can be eliminated, or cover, sealing, and other countermeasures. For parts that are difficult to maintain, such as refueling, cleaning, and decontamination, effective countermeasures should also be taken to improve the maintainability of the equipment.
Step 3: Prepare cleaning and refueling benchmarks
Based on the experience gained from the activities in steps 1 and 2, prepare a temporary benchmark to maintain the equipment under your control, such as cleaning, refueling, and fastening, and other basic conditions.
Step 4: Comprehensive Inspection
In order to give full play to the inherent functions of the equipment, it is necessary to learn the structure, function, and judgmental benchmarks of the equipment, inspect the appearance of each major part of the equipment, find defects in the equipment and restore them, and at the same time, equip yourself with the necessary inspection skills. Furthermore, the previously prepared benchmarks can be considered for continuous improvement for inspection.
Step 5: independent inspection
In the third step of the preparation of cleaning benchmarks, refueling benchmarks, inspection benchmarks on the basis of the fourth step of the content, and fully comply with the implementation of the contents, which is the independent inspection benchmarks. In the process of learning and implementation, but also continue to learn and familiarize with the operation of the equipment and action, quality and equipment, etc. correlation, with the correct operation of the equipment and the ability to early detection of abnormalities.
Step 6: Organize and reorganize
We will expand the scope of our activities from the existing equipment-centered activities to the peripheral equipment and the entire plant, and based on the ability to master the above five steps, we will develop the ability to realize and maintain the image that the entire plant deserves.
In this step, we specify the jigs, semi-finished products, defective products, etc. in the workshop, and set up the management standards, and reduce the objects of management such as things, and simplify them as much as possible.
The so-called should be thorough rectification is to comply with (maintain) that is, the benchmark and gradually improve, so that operators can easily comply. Workshop visual management and management standardization.
The seventh step: the thoroughness of self-management
Through the activities of the previous six steps, has obtained a lot of results, the staff has also been a great exercise, so the seventh step should be to establish a sense of continuous improvement, and constantly carry out the PDCA cycle, combined with the company's policy, objectives, to formulate their own new group activities suitable for their goals, to achieve the thoroughness of self-management.