Equipment spot check is one of the contents of 5S. 5S activities are relatively easy to carry out, and can take various forms and achieve obvious results in a short time, but most enterprises are always anticlimactic, and few enterprises can persevere. The company should add the weekly sampling inspection of the squad leader and the monthly inspection system of equipment manager to the inspection list.

The spot check list should be specific to every point of the field equipment, and each post has detailed specifications and responsibilities, which all employees are required to strictly abide by, so that every employee can know the specific content of the spot check of the equipment, know what to do, where to do it, when to do it, who to do it, how to do it and to what extent. At the same time, it is also necessary to include the filling of the checklist in the employee assessment items.

On the other hand, through positive incentives, field operators are mobilized to participate in equipment inspection, and operators are trained to develop the habit of equipment inspection. Let the operator really feel the effect of careful inspection of the equipment. Give material and spiritual rewards to outstanding operators who participate in equipment inspection. Regularly update the routine inspection table, extend the routine inspection period for the data that does not change frequently in the routine inspection of the top ten equipment, and add new contents that need routine inspection, so as to ensure that the routine inspection of equipment is constantly updated and improved. Passive implementation of equipment spot check strain is active action.

The process of inspection and evaluation is from superior to subordinate, gradually to the stage of mutual inspection and self-inspection, and from supervision and inspection to competition.

Through the above two ways, the problem of careless inspection of equipment by operators can be solved. Through the above methods, the authenticity and reliability of the operator's spot check data are ensured, and reliable data guarantee is provided for understanding the equipment state.

2. Strengthen the equipment training of operators.

According to TPM management method, employees are the key link of TPM management. How to do TPM well? For the top ten enterprises, reasonable and effective training is an important means to improve the quality of employees. The company never lacks staff training. Although it invests a lot of money every year, the effect is not satisfactory. The fundamental reason is that theoretical things are not really used in practice, and practical things are not combined with theory. Improper use of equipment by operators leads to equipment failure, and it is known that operators know too little about equipment-related knowledge. The company needs to carry out equipment-related training to help operators know and understand the equipment. Training content can be roughly divided into several aspects:

1) Operation training for incoming equipment, so that operators can understand the operation methods and precautions of the equipment.

2) Training on routine inspection of equipment, and training the operators on the parts, methods and means of routine inspection of equipment.

3) Equipment independent maintenance training, training operators in correct equipment maintenance methods.

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 reasonably in the future.

3. Improve independent preservation

In the management thought of TPM, an important idea is "full participation", and an important content of equipment management in which operators participate is autonomous safety. To carry out independent guarantee, we must solve the problem. 1 The content saved independently by the operator is perfect. Operators should understand and clarify the contents that need to be preserved independently. Operators can master the knowledge of self-preservation through self-preservation training. 2 For the tools used for self-preservation, when self-preservation, we should make good use of appropriate cleaning tools to achieve twice the result with half the effort. 3. Establish a set of perfect independent maintenance standards, and the operators shall maintain the equipment according to the independent maintenance standards. Maintenance standards provide the location of equipment, required maintenance tools, maintenance methods and maintenance frequency in the form of pictures. In this way, the operator can carry out maintenance according to the maintenance standard, which not only improves the work efficiency, but also ensures the correctness of the maintenance method. 4 autonomous security needs to be updated in time according to the state of the equipment. Due to the different status of equipment in different periods, the parts that need maintenance are naturally different. According to PDC cycle in site management, delete those items that don't need maintenance and add maintenance items that need to be added. Ensure that independent security is always in a state of ten updates.

After the independent preservation activities are carried out, it is necessary to evaluate the independent preservation of operators, establish a reward and punishment mechanism, reward operators who have maintained well, and criticize and educate operators who have not maintained well, so that operators can fully realize the importance of independent preservation.

4. Establish a professional inspection mechanism.

Professional spot check system is a set of institutionalized and relatively perfect scientific management methods. Its essence is a maintenance method based on preventive maintenance and taking spot inspection as the core. Professional spot check is one of the key tasks to find equipment problems and the focus of condition maintenance. In the eleven initial stages of the company's professional spot check, the content of the spot check is only to check whether the equipment oil is deteriorated and whether the protection is in good condition. The contents of these spot checks are relatively simple and cannot be used to check the status of equipment. In order to scientifically formulate the professional spot check, it is necessary to formulate the spot check position, spot check items, spot check period, spot check method, spot check division of labor and judgment benchmark in detail according to the structure of the equipment. So all the detection points have been fixed, fixed, fixed, fixed and calibrated.

Then analyze in detail how to formulate these standards. 1, the fixed point is to determine the location of equipment inspection. 2. Methodologically, the standard operation method is adopted to develop detection means. 3, according to different parts on a regular basis, make a reasonable inspection cycle. 4, a person, equipment responsibility partition. Let each maintenance personnel have professional inspection equipment. 5, calibration, using data to determine the state of the equipment, to avoid artificial subjective judgment.

In addition, there must be a clear description of the test tools and the number of people inspected. This can ensure the accuracy of professional spot checks.

The contents of equipment professional spot check mainly include:

Regular inspection of equipment without disassembly

B. Equipment disintegration inspection

C. Deterioration trend inspection

D. Equipment accuracy test

E. Accuracy check and adjustment of the system

F. Replacement of spare parts

5. Reasonably scrap and update equipment.

According to the theory of equipment life cycle, equipment has two lifetimes, namely, technical life, management life and economic life. When the manpower required for equipment maintenance and the investment in replacing spare parts are greater than the profit created by the equipment, it is not economical to reuse the equipment at this time, so it is necessary to consider scrapping the equipment. At the same time, if the production capacity of the equipment is too low, which reduces the accuracy of the equipment, technical measures should be taken to improve the efficiency and accuracy of the equipment. When the equipment cannot be modified by technical means, the equipment should also be scrapped.

Scientifically analyze the status of equipment, formulate a reasonable plan for scrapping equipment, and resolutely give up those equipment with high energy consumption and low production capacity. At the same time, for the equipment that is still in the fault period of ten times, the service life of the equipment can be extended through technological innovation and other methods to increase economic benefits for enterprises.

6. Reasonable reserve of original spare parts

According to the company's spare parts consumption law and! Rule of fault occurrence, and reasonably establish safety stock of spare parts.

Ten emergency spare parts, and reserve some more important spare parts with long procurement cycle. Spare parts reserve should not be too high, which will cause the company's capital backlog, nor too low, which will lead to insufficient spare parts reserve and affect production. While retaining the original spare parts, we should also consider the screening of local spare parts. The purchasing department needs to find some spare parts manufacturers with better quality to provide spare parts. For some imported spare parts, although they are not key spare parts, the procurement cycle is very long, and localization can also be considered. This can not only shorten the procurement time of spare parts, but also reduce the cost of purchasing imported spare parts.

7. Establish a reasonable maintenance plan.

In order to make a scientific and reasonable maintenance plan, we must first know all the equipment status. There are two ways to know the equipment status: 1. Problems found in routine inspection of equipment. Through the equipment checklist, we can see the trend changes of various indicators of the equipment, and then we can analyze the possible problems of the equipment. 2. Equipment professional spot check. Equipment professional spot check is to diagnose equipment problems through professional spot check. 3, fault statistics, fault statistics can often find many problems in the fault. After finding out the hidden trouble of the equipment, it is necessary to carry out planned maintenance of the equipment reasonably. Ten minor hidden dangers are solved by weekly planned maintenance, and ten major hidden dangers are repaired by the maintenance team through holiday maintenance.

8. Continuous improvement.

1) to improve equipment defects.

Through fault statistics, the common faults of equipment are summarized and the faults caused by equipment defects are found out.

Set up a special team, formulate countermeasures to eliminate design hidden dangers, carry out equipment transformation in a planned way, track the transformed equipment, and gradually establish a good equipment state.

2) Improvement of vulnerable spare parts

For some vulnerable spare parts, we can consider replacing them with good quality spare parts, or replacing spare parts that are not suitable for equipment use with spare parts that are suitable for on-site use environment, so as to prolong the service life of spare parts and reduce the occurrence of equipment failures.

3) Improve TPM management system, continuously improve equipment management system, and update equipment spot check, independent maintenance, professional spot check and planned maintenance in time. Ensure that these management systems are suitable for the needs of the current equipment state.