Basic work content of equipment management
Voucher management, data management, quota management, archives management and rules and regulations management.
Device Credential Management
1. Meaning: In the technical management and economic management of equipment, a written certificate used to record equipment management and technical activities, as well as economic accounting, and clarify the responsibilities of all management parties, is the equipment management voucher. 2. Principles of voucher setting (basis for activities, guarantee function): (1) Principle of meeting needs; (2) Principle of concise application; (3) Principle of scientific standardization. 3. Voucher setting requirements (1) are generally set in a table format. A form has fixed columns and columns that need to be filled in each time. The fixed columns include titles, table headers, various grids and text descriptions, etc. The title must have clear meaning and concise language. ; To fill in the columns, the data source must be reliable and easy to collect, and the maximum possible value must be considered, leaving enough room for spaces. (2) The voucher is passed along with the flow of equipment logistics and value flow. During the transfer process, some links need to be retained as a basis, so the voucher pages must be designed reasonably, and the department to which the voucher is deposited must be indicated on each page. (3) Once the voucher format is determined, it must remain relatively stable. 4. Specific management requirements for vouchers (1) Clarify the management department (section, group) of the voucher; (2) Clarify the setting unit and setting procedure of the voucher; (3) Clarify the methods for enabling, inspecting and supervising the voucher; (4) Clarify the filling in and use of the voucher. Departments and personnel; (5) Clarify the review of vouchers (6) Clarify the delivery and storage methods of vouchers. 5． Equipment certificate reference (Appendix 2-1-26) 1. Early equipment management vouchers (1) Equipment purchase (update) voucher ① Equipment purchase (update) declaration form ② Annual equipment purchase (update) plan project details (2) Equipment ordering voucher ① Equipment ordering contract ② Equipment unpacking inspection acceptance form ③ Equipment entry (exit) warehouse receipt (3) Equipment installation and commissioning acceptance voucher ① Installation and commissioning record ② Mechanical equipment accuracy inspection record form ③ Equipment asset transfer and handover acceptance form 2. Equipment life management voucher (1) Equipment status handover record (2) Key equipment inspection card (3) Maintenance inspection record ① Equipment first-level maintenance record card ② Equipment second-level maintenance registration form ③ Periodic accuracy and performance test records (4 ) Precision sealing point leakage inspection record (5) Lubricating oil change record (6) Equipment maintenance management voucher ① Maintenance notice ② Repair record sheet ⑧ Equipment repair test run record sheet ④ Repair quality inspection sheet ⑤ Repair cost accounting sheet (7) Equipment Accident report sheet (8) Special equipment safety appraisal certificate (generally authenticated by the Labor Bureau) ① Pressure vessel inspection product safety and quality supervision and inspection certificate ② Special equipment use certificate. (9) Equipment technical transformation voucher ① Production equipment sealing application form ② Equipment technical transformation acceptance form (10) Equipment asset management voucher ① Production equipment sealing application form ② Production equipment unsealing application form ③ Equipment rental contract ④ Equipment scrapping form
Device data management
1. Meaning: Data management refers to the collection, processing and interpretation of data to turn it into information useful for management decision-making (some information is still represented by data). It includes the entire process of data collection, classification, sorting, retrieval, modification, storage, transmission, calculation, and output (reports or graphics). Equipment data mainly refers to data generated in the field of equipment management and maintenance.
2. The role of equipment data management
(1) Through the management of material movement forms, ensure the normal operation of equipment management and maintenance, ensure that the equipment is in good condition, and complete production and operations for the enterprise The task is guaranteed to be reliable. (2) Through data management of the value stream (equipment purchase, maintenance, etc. expenses), personnel at all levels can timely understand the occurrence and flow of various equipment expenses, and conduct cost control; at the same time, by checking the data on the voucher with the physical objects, Avoid asset loss. (3) Through statistics and analysis, calculate and output various data values ??and compare them with target values, take measures to control excessive indicators, and provide a basis for the management department to formulate equipment management goals, work plans, maintenance decisions, etc.
3. Methods for determining data management content (1) Use system thinking for data management (2) Determine the scope of data management (3) Determine output data (4) Determine data processing logic (5) Optimize the data management system (6) Pay attention to data collection Management 4. Data management program (1) Data collection (2) Data storage (3) Data transmission (4) Data processing (5) Data output 5. Data summary - establishment of accounts, cards, charts, and registers Data summary refers to the classification and accumulation of data that occurs in the equipment management process, and the calculation of the total number. Commonly used data summary charts and methods are listed below. l. Equipment ledger and equipment card: After the equipment is accepted and handed over to production, both the enterprise's equipment management department and the finance department should establish a fixed asset ledger and card for a single piece of equipment. The data mainly comes from equipment order contracts, operating instructions and installation handover acceptance forms. (1) Equipment ledger: divided into main production equipment (F≥5) and non-main production equipment ((F<5)), see Table 2-27. There are three general equipment ledgers: ① Equipment serial number account ② Equipment ledger ③ points Workshop (User Unit) Account (2) Equipment Card: In addition to establishing a complete ledger, equipment asset management also needs to create a card book in the order of the user unit (workshop, department, etc.) as the equipment is mobilized, transferred, and scrapped. , the position of the long film can be adjusted in the card book, transferred or withdrawn for cancellation. In order to facilitate verification and ensure that the accounts and items are consistent, the equipment card should be in two sets (one set for each equipment management and use department). Available at the ledger store (see Table 2-28 for the format) (3) Equipment classification and asset number When filling in the equipment ledger and card, the equipment asset number must be involved, and the asset number is related to the equipment classification and must be unified. Division and numbering. In addition, in order to facilitate equipment management and computer data processing, enterprises should scientifically code equipment so that it can be easily identified and facilitated statistical summary by computer. ① Equipment classification (see the unified classification and numbering catalog of equipment. ) (used in the first paragraph of the asset number) ② Equipment asset number The number of the asset equipment consists of three segments, with a horizontal line between each two segments. One segment indicates the equipment category; the second segment indicates the unit using the equipment (including branch factory, workshop, etc.). Department) code; the three segments represent the sequence number of similar equipment. The representation method is shown in Figure 2-1. 2. Summary of equipment operation management data ① Main production equipment lubrication card (see Table 2-30) ② Incomplete equipment register (see table). 2-31) ③ Equipment accident register (see Table 2-32) 3. Equipment spare parts ledger (see Table 2-33) 4. Equipment asset change data summary ① Equipment purchase (self-made) transferred to the register (Table 2- 34) ② Equipment sealing (unsealing) register (Table 2-35) ③ Idle equipment register (Table 2-36) ④ Equipment transfer register (Table 2-37) ⑤ Equipment scrapping register (Table 2-38) 5 ．Main production equipment operation certificate issuance register (Table 2-39) 6. Data statistics 1. Equipment asset status statistics, including the following three aspects: (1) Equipment ownership and classified ownership (divided into three levels) ① All equipment : Refers to all equipment that has a useful life of more than one year and a value above the industry prescribed limit and is a fixed asset. ② Production equipment: refers to equipment that directly or indirectly participates in the production process. It is an important part of the company's fixed assets. The management scope and management catalog shall be stipulated by the competent industry authorities. ③Main production equipment: refers to the production equipment whose equipment repair complexity coefficient is above the prescribed limit and is the main component of all production equipment, production equipment and important production equipment. The quantity and classified ownership data are collected and tabulated by the statistician of the equipment management department on a regular basis based on the equipment ledger (see Table 2-40) (2) The original value, net value and newness coefficient of equipment assets. This statistics reflects the annual equipment of the enterprise. Asset scale and aging level. The equipment newness coefficient is the ratio of the net asset value of the equipment to the original value of the equipment assets. It is a statistical indicator that reflects the newness of the enterprise's equipment during the reporting period from a value perspective. Through statistical analysis of this indicator, it provides a basis for enterprises to formulate equipment update plans. The original value and net value data of equipment assets are provided by the financial department of the enterprise, and are collected and filled in the form by the fixed asset management personnel of the equipment management department.
See table (2-41) (3) Depreciation rate and annual depreciation amount of fixed assets production equipment 2. Equipment technical status statistics (1) Main production equipment intactness rate: In the formula, the total number of units should include all important production equipment that the enterprise is using, standby, sealed, and under maintenance, but does not include equipment that has not yet been installed and used. (2) Main equipment leakage rate. Leakage point statistics are not limited to static sealing joints. One leak is considered a leakage point. Whether it is a static sealing point, or leakage caused by weld cracks, blisters and other reasons, it is counted as a leakage point. 3. Equipment operation status statistics (1) Main production equipment unit time utilization rate This rate is one of the indicators that reflects the degree of equipment time utilization. The basis for calculating the equipment hour utilization rate: ① The actual operating hours of the main production equipment during the reporting period are summarized in the equipment system hour utilization summary table (see Table 2-42). The data in the table are compiled from production operation records ② The reporting period When the main production equipment system workbench is installed, it is calculated based on the working hours of the enterprise's first, second, and third shift system. (2) Actual equipment utilization rate Actual equipment utilization rate mainly indicates the degree of utilization of production equipment in terms of quantity, time, capacity, etc. It comprehensively reflects the potential of idle equipment, unusable equipment, spare equipment, and shutdown equipment. Its calculation formula is: 4. Equipment maintenance status statistics ① Accident (fault) shutdown rate ② Equipment repair complexity coefficient statistics ③ Equipment major (item) repair plan completion rate ④ Total annual maintenance costs.
Equipment quota management
1. The meaning and basic form of quota management. Enterprise quota is a quantitative standard consumed in the product production process. It refers to the materialized labor and living labor specified in order to complete the unit's qualified products or tasks within a certain period of time and under certain production technology and organizational conditions. consumption. There are two basic forms of enterprise labor quotas: ①Working hour quota ②Output quota 2. In enterprise equipment management and maintenance, the main quota contents are (1) equipment daily maintenance time quota (2) equipment maintenance time quota (3) equipment repair downtime quota (4) equipment maintenance material consumption quota (5) equipment maintenance cost quota (6 ) Equipment parts reserve quota (the calculation of the quota content is introduced in equipment repair and parts management).
Equipment file and data management
1. The meaning and distinction of files and data. Equipment technical files refer to the drawings, charts, text descriptions, calculation data, photos, videos, audio tapes and other scientific and technological documents and data that are formed during the entire process of equipment management and should be archived and saved. Continuously collect, organize, identify and archive the equipment files established. Equipment information refers to product samples, drawings, procedures, technical standards, technical manuals required for equipment selection, installation, commissioning, use, maintenance, repair and modification, as well as equipment management regulations, methods and work systems, etc. Equipment files and information are a form of information for equipment manufacturing, use, repair, etc., and are indispensable basic information in the management and repair process. The difference between equipment archives and data is: ① archives have exclusive characteristics, while data have universal characteristics; ② archives are original materials accumulated and collected from actual work, and have the characteristics of being lost and irretrievable; data are processed and refined Formed, it is often formally promulgated and published. Equipment files are also a kind of data, which are special data. The management of equipment files and data refers to the management of equipment files and data collection, storage, storage, transfer, modification and update, etc. 2. File and data management content (1) Equipment file content Equipment files generally include two parts: the early stage and the late stage of equipment. The early stage files include materials for ordering, random supply and installation acceptance; the later stage files include materials for various management and repairs after use. ① Preliminary equipment file details A. Ordering contract B. Packing list, instructions and information, accessories, tool details (original) C. Factory certificate, factory accuracy (performance) inspection record (original) D. Unpacking acceptance form E . Relevant descriptions, drawings and information of self-made equipment F. Equipment foundation and hidden engineering drawings G. Power pipeline drawings H. Installation and debugging test receipts I. Relevant original materials for purchased second-hand equipment.
②Equipment later file details A. Record of initial use of equipment B. Regular maintenance record C. Regular inspection and monitoring record D. Equipment failure analysis report E. Equipment maintenance record F. Equipment storage (activation) sheet G. Equipment lubrication card H. Overhaul mission statement and completion acceptance report I. Technical transformation application form and project technical and economic demonstration report J. Technical transformation instructions and drawings and trial effect appraisal K. Equipment accident report sheet L. Equipment scrap sheet. (2) Equipment information content Equipment management information includes laws, regulations, procedures, standards and other information formulated or compiled by equipment management departments and enterprises at all levels to strengthen equipment management. Generally include: ①Details of comprehensive equipment management information A. National, industry and local relevant equipment management documents B. Enterprise equipment management policy objectives C. Annual work plan and work summary D. Enterprise equipment asset management rules and regulations E. Annual report on equipment asset management status F. Special requests, reports and approvals ② Equipment asset management and technical management information details A. Equipment classification and number catalog B. Standards for large, heavy, rare, and high-precision equipment C. Equipment integrity standards D. Equipment operation, maintenance, and overhaul procedures E .Equipment lubrication manual (including comparison table between imported oil products and domestic oil products) F. Equipment repair technical standards G. Equipment repair complexity coefficient H. Special equipment preventive test procedures I. Mechanical repair manual J. Electrical repair manual K. Mechanical equipment spare parts Accessories manual L. General equipment wearing parts catalog M. Electrical components manual (including comparison table of imported equipment components and domestic components) N. Mechanical design manual O. Product samples P. Professional journals Q. Translation reference book
< p>Equipment rules and regulations managementEquipment management rules and regulations refer to various regulations that guide and inspect equipment management work. They are the basis and inspection standards for the implementation of equipment management, use, and repair work. Equipment management rules and regulations can be divided into two categories: management and technology. The management category includes management systems and methods; the technical category includes technical standards, work procedures and work quotas. The management of rules and regulations refers to the formulation, modification and implementation of rules and regulations. 1. Formulation of rules and regulations (1) Principles of formulation ① Policy-based: implement relevant national equipment management guidelines and policies, comply with the requirements of the "Regulations" ② Be inheritable ③ Be advanced ④ Be coordinated ⑤ Be feasible ⑥ Be normative (2) Content composition of rules and regulations ① Scope of application: According to the business scope of each department, the equipment life is scientifically divided into segments, the management scope and management objects of each segment are determined, and corresponding rules and regulations are compiled. ② Management functions: Determine the responsibilities and authorities of relevant functional departments, such as equipment, supply, finance and other departments in this management. ③ Management business content: Generally, according to the flow direction or management work procedures of equipment logistics and value stream, the management work content, methods, means, corresponding vouchers and voucher delivery routes of each functional department are stipulated, and the required information, etc. are also required. Develop business connection, coordination and restriction methods between relevant departments. ④Inspection and assessment: stipulates the standards and requirements that should be met by management business, as well as the assessment content, assessment time, assessment methods, rewards and punishments for relevant management personnel, etc. (3) Procedures for formulating rules and regulations ① Determination of tasks: According to the needs of management work, the equipment management department puts forward opinions on formulating the system, and the drafting department is determined with the consent of the person in charge ② Preparation of draft: The drafter conducts investigation and research, collects information, and writes A draft is produced and sent to the relevant departments for comments, and then revised to form a draft for review. ③ Countersigning and approval: The draft for review is countersigned by the relevant departments, important systems are reviewed at the meeting, and then sent to the person in charge of the equipment for review and approval, and the factory department issues it in the form of a document. implementation. 2. Implementation of rules and regulations Rules and regulations can only exert their due effectiveness if they are carefully implemented in corporate practice. At the same time, the implementation is also a comprehensive verification of the rules and regulations. The parts that are not scientific enough or unrealistic will be discovered and organized. After the revision, the child regulation system is more complete. (1) Procedures for implementing rules and regulations ① Develop measures to implement rules and regulations: A. Develop implementation plans B. Develop inspection and assessment methods. ②Organize reading and training. It is necessary to implement equipment management rules and regulations to leaders, business cadres and front-line workers of various departments involved in equipment asset management, and organize study and discussion. (2) Implement the requirements of rules and regulations ① Carry out coordination work.
During the implementation of various rules and regulations, there will be some problems that were not anticipated when they were formulated. If they are not properly resolved, they will affect the implementation of the rules and regulations. Therefore, measures should always be taken to deal with problems that arise, and organizations should coordinate to resolve them. The solution is to carefully record the problems exposed during the trial period, and the competent authorities should investigate clearly the causes of the problems. If it is indeed a problem with the rules and regulations themselves, they can be revised according to regulations. ②Funding guarantee. In the process of implementing rules and regulations, some additional forms and documents must be printed; in the inspection and assessment of implementing rules and regulations, there must be rewards, etc., which all require some expenses. Therefore, this cost should be considered in the plan for implementing regulations and included in the company's financial budget. 3. Modification of rules and regulations (1) A trial period for various rules and regulations should be specified in advance according to the specific circumstances. After the trial period expires, based on the problems exposed during the trial, focus on research, comprehensive balance, and unified revision. (2) After the rules and regulations are officially promulgated and implemented, they must remain relatively stable at a stage. Generally, they should be the equipment management guidelines and policies of the country or industry. When there are major changes, or there are major changes in the enterprise's production scale or management organization, and the original rules and regulations are no longer applicable, modifications shall be made; if a certain system is not suitable, individual modifications may also be made (3) The modification of rules and regulations must be based on Regarding the implementation of rules and regulations, retain those applicable parts, fully investigate and demonstrate new parts, and solicit opinions from relevant personnel. The modification procedure is the same as the formulation procedure. (4) Modifications of rules and regulations must be approved, and the approval level and The approval process is the same as the formulation of rules and regulations. 4. Enterprise equipment management rules and regulations (introduction) (1) Preliminary management methods or systems for equipment (2) Equipment use and maintenance management methods or systems (3) Equipment lubrication management methods or systems (4) Equipment maintenance management methods or systems (5) Equipment Spare parts management methods or systems (6) Equipment technical transformation management methods or systems (7) Equipment accident management methods or systems (8) Equipment asset disposal management methods or systems (9) Equipment archives management methods or systems (10) Equipment statistics management methods Or system (11) Equipment management and technical personnel training management methods or systems (12) Equipment work assessment and reward and punishment methods or systems.
Management of mechanical equipment
On-site safety management
Strengthen on-site safety management, continue to highlight key points, and strengthen "one communication and three defenses" as the top priority Special rectification work, continue to focus on roofing, mechanical and electrical, transportation, water prevention and control, the "three preventions" in the rainy season and the "three preventions" of public security, strengthen the rectification of self-made processing and special equipment management, and continue to increase the rectification of "non-standard" issues intensity; at the same time, we must strengthen prevention and real-time monitoring of major hazardous sources, dangerous goods, key departments, and transportation to eliminate hidden dangers and prevent accidents; continue to implement and study major accident prevention and emergency rescue plans, and conduct accident prevention drills in a timely manner to achieve When called upon, he will come, he who comes will be able to fight, and he who fights will be able to win. Strengthen the implementation and study of accident prevention plans for each job type, so as to memorize and master them and respond with ease. We must have flood prevention awareness and focus on strengthening special inspections and key prevention in subsidence areas, waste rock mountains, coal piles, along railway lines, power supply lines, highway bridges, dams, and dangerous buildings. 1. Pay attention to the impact of high temperature weather on equipment. If high temperatures persist and equipment operates efficiently, attention should be paid to the problem of excessive temperature to prevent equipment from burning and being damaged. 2. Pay attention to the impact of rain on equipment. In the rainy season, the air is humid and there is a lot of rain. Diligent, rain-proof and moisture-proof equipment should be put on the agenda. Third, pay attention to the impact of continuous work on the equipment. In field engineering projects, everyone is competing for time, speed, and continuous operations. The equipment is also at full capacity or even overloaded. This situation is understandable, but equipment maintenance and upkeep must keep up. 4. Pay attention to the condition of the equipment. The equipment operates efficiently. It is inevitable that it will be damaged or not work in the normal state due to "fatigue". You must not "don't wash the mud when the carrot is too fast". Working while sick will inevitably cause big losses. 5. Pay attention to the training of “novices”. During busy production seasons, it is inevitable to hire some temporary workers. Some college and technical secondary school graduates are also coming to report one after another. Their enthusiasm for work should be encouraged, but the performance of the equipment, operating procedures, and protective measures used must be clearly explained to them. After the assessment, they are sure to master these technologies. , before you can take up the job, otherwise, you will never be given the green light.
6. Pay attention to strengthen the study of the equipment management system. There are strict regulations on the use of equipment and must be studied regularly. Otherwise, veteran employees will forget and do not use equipment according to the regulations. It will be difficult to implement the equipment management system. There will be May cause damage to the equipment and personal injury to the user. Therefore, it is necessary to constantly study the equipment management system and carry out work under the constraints of the system. 7. Pay attention to rectifying equipment hidden dangers. "A sharpened knife will never make a mistake in chopping firewood". For all known equipment hazards, such as incomplete protective equipment for drilling rigs, oil and electricity leakage from machines, inflexible switches, inaccurate meter scales, etc., it is necessary to check and verify them one by one, correct and complete them, and ensure that the equipment Integrity rate. In short, the busier the work, the more attention must be paid to safety. The higher the equipment usage rate, the more intensive maintenance must be done. Any negligence or luck will lead to unsafe disasters.