In order to ensure the normal operation of equipment, leaders attach great importance to the management of spare parts. In the preparation and early stage of production, a spare parts research group headed by the equipment factory director was set up to organize relevant engineers and technicians to intervene in advance, familiarize themselves with the equipment, understand its technical parameters and principle structure, transform and prepare spare parts drawings, put forward spare parts plans in time, and actively organize supply. In the normal production stage, according to the operation and transformation of equipment, equipment meetings are held regularly to organize and coordinate spare parts management.

2. Improve the equipment spare parts account and grasp the core of spare parts management.

According to the actual situation of the equipment, the spare parts account of four categories of equipment shall be established for each equipment, including mechanical special parts, mechanical general parts, power general parts and electrical spare parts, and spare parts information such as spare parts name, drawing number, test size, standard, model specification, main technical parameters, schematic diagram, maximum and minimum reserve quota, actual inventory, inventory location, reference price, etc. shall be specified in detail and revised gradually.

3. Actively manage spare parts technology.

There are some German, Dutch and British equipment drawings, some German and American standards, some only have assembly drawings without parts drawings, some have no drawings at all, some standard parts are not standardized, and the spare parts of the same equipment are not unified. The following measures have been taken to solve these problems.

(1) Unified drawing number. A spare part has a unique drawing number in the form of HB *-*-*-*, which runs through the whole life of the spare part. HB stands for medium and heavy plate factory, and the four * s reflect the order of professional category, equipment, parts and spare parts in turn.

(2) Adhere to the standardization, generalization and serialization of spare parts.

All adopt national standards and ministerial standards to select, design and manufacture spare parts, and try to reduce the variety of spare parts; A large number of different and similar equipment spare parts, such as crown block, reducer, synchronous shaft, straightener slide, hydraulic cylinder, etc. , are gradually close to each other by modifying the design, so that spare parts are unified and interchangeable; According to the same design standard, parts with the same structure, the same function, different sizes and different technical parameters, such as gear coupling, reducer and single-drive roller table, are arranged according to certain rules to form a series of parts.

(3) Actively localize spare parts. As 2/3 of the equipment in the whole plant is old equipment, a large number of spare parts are needed, such as straightening roller of thermal straightener, main reducer, reducer of cold bed drawing, reducer of turnover mechanism, eccentric shaft of longitudinal shear, gear, main transmission box of transverse shear, etc. These spare parts are all foreign language drawings, and ordering foreign spare parts is expensive and has a long cycle, which is inconvenient to supply. Therefore, we should actively do a good job in the translation of foreign drawings and the localization design and manufacturing of parts.

(4) Actively adopt new technologies, new processes and new materials to improve the service life of spare parts. For example, wear-resistant copper slide plate is used in practical work to improve the life of universal sleeve slide plate of four-high roughing mill; Repairing seriously worn shaft by surfacing technology: the cutting edge is treated by laser surface treatment technology for repeated use.

(5) Actively develop spare parts. For spare parts that have no drawings or the drawings are unclear and not detailed, use the time of daily maintenance and major repairs to carry out surveying and mapping, develop spare parts and draw drawings.

(6) Strengthen the maintenance and utilization of spare parts through incentives and assessment measures. Due to the shortage of spare parts, according to the equipment operation, spare parts such as motor, reducer, universal coupling sleeve, etc. If it is not timely and urgently needed, it will be actively reused through welding repair, repair and processing, which not only ensures the operation of the equipment, but also reduces the consumption of spare parts.

(7) Do a good job in drawing management. Make a spare parts drawing unique and consistent; Spare parts drawings shall be distributed to workshops and teams in time as the technical basis for spare parts use and equipment maintenance; Equipment and spare parts are scrapped and drawings must be destroyed; The archive room shall be provided with a dedicated spare parts drawing cabinet. Blueprints and base maps must be kept, and common spare parts will always be put together with blueprints.

4. Strengthen spare parts planning and statistical analysis management.

Spare parts planning is the basic basis for organizing spare parts production and supply. In practical application, there are many forms, such as monthly plan, supplementary plan, annual plan, large and medium-sized repair plan, etc., with the emphasis on the management of monthly spare parts plan.

In order to ensure the rationality and accuracy of spare parts plan, ensure the timely supply of spare parts as planned, rationally use spare parts funds and speed up the turnover of spare parts inventory funds, two points should be paid attention to when preparing spare parts plan:

(1) Fully understand the operation and maintenance of the equipment.

(2) Master spare parts consumption quota and reserve quota, order carry-over quantity, spare parts inventory and spare parts ordering cycle.

At the same time, dynamically track the spare parts plan and keep abreast of the processing and supply of spare parts.

In order to strengthen spare parts management and reduce costs, statistics of spare parts inventory index, consumption index and repair index should be actively carried out to provide decision-making basis for spare parts management and reference basis for making spare parts work plan.

5. Strengthen the inventory management of spare parts

In order to strengthen spare parts inventory management, the following measures have been taken:

(1) According to the requirements of ISO9002 standard, the account cards must be consistent, and there must be something in the card, something in the card and something in the account.

(2) The storage of spare parts must be checked and accepted by spare parts clerks, regional technicians and warehouse administrators, and spare parts must be stored in designated areas, and cards and account books should be established.

(3) Spare parts shall be distributed according to the limited supply system, and shall be collected from the warehouse with the requisition form.

(4) Timely clearance.

6. Strengthen the quota and fund management of spare parts.

In order to reduce the capital occupation of mobile examination, reduce the production cost and accelerate the capital turnover, according to the operation of equipment, scientific and reasonable methods are adopted to formulate and revise the spare parts quota in time:

(1) According to spare parts manufacturing cycle, optimal processing cycle, spare parts occupation, service life, correction factor, etc. , reasonably formulate spare parts reserve quota, control spare parts inventory, and prevent over-storage.

(2) Based on the principle of meeting production needs and on the basis of output, equipment condition, spare parts life and actual consumption level over the years, the spare parts consumption quota is reasonably formulated.

Accurately formulate the quota of spare parts funds and strengthen the management of spare parts funds.