Factory management system

(1) general principles

Article 1 This system is formulated to strengthen the management of the company's production, transportation, lifting and office equipment, and correctly and safely use and maintain the equipment.

Article 2 According to the equipment use and maintenance instructions and production process requirements, the equipment use and maintenance procedures are formulated to guide the correct operation, use and maintenance of the equipment. All departments of the company must establish and improve equipment use procedures and maintenance procedures.

(2) Formulation and revision of rules and regulations

Article 3 All departments should first correctly classify equipment types according to the principles stipulated in this system, and classify equipment into three levels: important equipment, main equipment and general equipment according to its position in production and operation, complexity of structure and difficulty in use and maintenance, so as to facilitate the system formulation and hierarchical management of equipment.

Article 4 All equipment installed and used must have complete use and maintenance procedures.

Article 5 For the newly put into production equipment, the Technical Equipment Department shall formulate the use and maintenance regulations 30 days before the equipment is put into production, and issue them for implementation.

Article 6 When the production is ready to adopt new processes and technologies, the Technical Equipment Department shall modify the original regulations according to the new requirements for the use and maintenance of equipment 10 days before changing the process to ensure the effectiveness of the regulations.

Article 7 In the process of implementing the regulations, when a post finds that the contents of the regulations are imperfect or defective, it shall promptly report them step by step. Discipline management professionals should immediately go to the scene to verify the situation and supplement or modify the discipline content.

Article 8 The newly written or revised procedures shall be submitted to the competent deputy general manager for examination and approval respectively in accordance with the relevant provisions of professional management.

Article 9 When the equipment has serious defects and cannot be stopped immediately for repair, reliable measures and temporary use and maintenance procedures must be formulated and approved by the competent deputy general manager. After the defects are eliminated, the interim provisions shall become invalid.

(3) Contents of laws and regulations

Tenth equipment use system must include the following contents:

1, equipment technical performance and allowable limit parameters, such as maximum load, pressure, temperature, speed, voltage and current.

2. Provisions on the transfer and use of equipment. For the equipment running in two or three shifts continuously, the post personnel must hand over the operation of the equipment when handing over, including: abnormal operation of the equipment, lubrication, changes in original defects, changes in operating parameters, failures and treatment.

3. Steps to operate the equipment, including the preparation work before operation and the operation sequence;

4. Emergency treatment regulations;

5, safety precautions in the use of equipment, this post operator shall not operate the machine without approval, no one shall arbitrarily remove or relax the safety protection device, etc. ;

6, equipment operation fault query and elimination.

Eleventh equipment maintenance procedures should include:

1. Equipment transmission schematic diagram, hydraulic schematic diagram, pneumatic schematic diagram, steam schematic diagram and electrical schematic diagram;

2. "Five Fixed" charts and requirements for equipment lubrication;

3, the provisions of regular cleaning;

4. Inspection requirements in the process of equipment use, including route, location, content, standard condition parameters, cycle (time), inspectors, etc. ;

5. Troubleshooting methods for common faults in operation;

6. Scrapping standards for main wearing parts of equipment;

7. Safety precautions.

(4) Detailed rules for implementation

Article 12 Before new equipment is put into use, the deputy general manager in charge of technical equipment department shall organize the implementation of equipment use and maintenance procedures. Rules should be sent to relevant professionals, post operators and maintenance personnel, and no one can leave his post.

Article 13 The production department shall organize the equipment operators to study this regulation seriously, and the equipment professionals shall explain and learn the contents of this regulation to the operators.

Article 14 Equipment operators must pass the discipline examination and practical operation examination organized by the company, and can only take up their posts after passing the examination.

Article 15 The production department organizes teams to learn the rules every month, and the workshop supervisor and equipment management personnel conduct regular or irregular spot checks on the learning situation of the rules of the production teams every year, and solve the problems in time when they are found, and the spot checks will be included in the assessment.

(5) Equipment technical condition management

Article 16 According to the technical status, maintenance status and management status of equipment, equipment is divided into intact equipment and non-intact equipment, and specific evaluation standards are formulated respectively.

Seventeenth departments producing equipment must complete the technical indicators issued by the superior, that is, to assess the comprehensive intact rate of equipment. Professional departments should formulate the annual, quarterly and monthly comprehensive intact rate index of equipment, and decompose it layer by layer and implement it step by step.

(6) Equipment lubrication management

Article 18 Equipment Lubrication Management Requirements

1. All departments should set up full-time lubricators to be responsible for equipment lubrication.

2. Each equipment must formulate a complete chart and requirements of "five determinations" for equipment lubrication, and earnestly implement it.

3, all departments should conscientiously implement the equipment oil three clean (oil drums, oil tools, gas stations), to ensure the cleanliness of lubricating oil (grease) and oil flow, to prevent congestion.

4, for large, special, special equipment oil to adhere to the system of regular analysis and testing.

5, lubrication professionals should do a good job of equipment lubrication new technology promotion and oil upgrading.

6. Carefully manage the recycling of waste oil.

Article 19 Formulation, implementation and modification of lubrication "Five Fixed" chart

1. The "Five Definitions" diagram of production equipment lubrication in each department must be worked out one by one and sent to the post at the same time as the operation and maintenance regulations.

2. The contents of the "Five Definitions" chart of equipment lubrication are as follows:

(1) Fixed point: Specify the lubrication position, name and refueling point.

(2) Quality judgment: specify the brand of grease at each refueling point.

(3) Timing: specify the refueling and oil change time.

(4) Quantification: specify the amount of oil to be added and replaced each time.

(5) Designated person: Designate the person in charge of each refueling and oil changing point.

3. The post operation and maintenance personnel should conscientiously implement the "five-fixed" diagram of equipment lubrication and make branch records.

4. Lubrication professionals should conduct regular and irregular spot checks on the implementation of the lubrication "five-fixed" diagram, and handle problems in time when found.

5, post operation and maintenance personnel must always pay attention to the lubrication of various parts of the equipment, report and handle problems in time.

Article 20 Management of Grease Analysis and Testing

In the process of equipment operation, lubricating oil is easy to deteriorate due to the influence of dust, moisture, temperature and other factors. In order to ensure the quality of lubricating oil, filtration and analysis tests must be carried out regularly, and different sampling and test times should be stipulated for different equipment. When the test oil does not meet the use requirements, the grease should be replaced in time.

Article 21 Application of new equipment lubrication technology and oil change management

1. All departments should organize research and tackle key problems and solve them step by step.

2. The upgrading of oil products should be included in the company's annual equipment work plan, and can only be implemented after testing to ensure safety. Before updating oil products, oil tools, oil tanks and pipelines must be cleaned.

(7) Treatment of equipment defects

Article 22 Any equipment defect that can be eliminated by post operation and maintenance personnel shall be eliminated immediately and recorded in the log in detail.

Article 23 Equipment defects that cannot be eliminated by post operators shall be recorded in detail and reported step by step. At the same time, we should operate carefully, strengthen observation and pay attention to the development of defects.

Twenty-fourth equipment defects that cannot be eliminated in time must be studied and decided at the daily production scheduling meeting.

Twenty-fifth before arranging to deal with each defect, there must be corresponding measures to clarify the responsible person and prevent the defect from expanding.

(8) Dynamic management of equipment operation

Twenty-sixth dynamic management of equipment operation refers to the maintenance and management personnel at all levels firmly grasp the operation of equipment through certain means, and formulate corresponding measures according to the operation of equipment.

Twenty-seventh establish and improve the equipment inspection standard system.

Each department should determine the normal operation position (checkpoint), content (what to check) and parameter standard (allowable value) for each equipment according to the structure and operation mode of the equipment, and determine a clear inspection period for each checkpoint of the equipment according to the specific operation characteristics of the equipment, which can generally be divided into hourly, shift, daily, weekly, ten-day, monthly, quarterly and annual inspections.

Article 28 Establish and improve the inspection and guarantee system.

Operators in production posts are responsible for checking all checkpoints of the equipment used in this post, and professional maintenance personnel should contract the inspection of key equipment. Each department shall determine the number and candidates of full-time inspectors according to the quantity and complexity of equipment. Full-time inspectors are responsible for contracting important checkpoints and fully grasping the equipment operation dynamics.

Article 29 Information transmission and feedback

When the operators of production posts patrol, they find that the equipment cannot continue to run and need emergency treatment, they should immediately notify the personnel on duty, who will organize the treatment. General hidden dangers or defects, after inspection, log in the checklist and pass it to full-time inspectors on time.

Full-time maintenance personnel should make a good record of equipment inspection, and in addition to arranging processing, they should also pass the information to full-time inspection personnel for unified summary.

In addition to completing the inspection tasks stipulated in the contract, the full-time inspectors are also responsible for summarizing and sorting out the inspection results in all aspects every day, listing the key problems of the day and reporting them to the Technical Equipment Department.

The technical equipment department should list the main problems, besides registering the ledger and inputting it into the computer, it should also be further checked and implemented for comprehensive management.

Article 30 Application of dynamic data

According to the equipment defects and hidden dangers found in the inspection, the inspector puts forward the items that should be arranged for maintenance and incorporated into the maintenance plan. If the equipment defects found in the inspection must be dealt with immediately, the duty officer will immediately organize the treatment; If the class can't handle it, the technical equipment department will determine the solution. Major defects of important equipment shall be studied by the competent deputy general manager to determine the control scheme and treatment scheme.

Article 31 Weak links in equipment project processing

The following conditions are the weak links of the equipment:

1, frequent failures in operation, and repeated treatment of invalid parts;

2. Equipment or parts that affect product quality and output in operation;

3, the operation can not meet the requirements of minor repair cycle, and the equipment or parts are often unplanned maintenance;

4. Equipment or components that are unsafe (personal and equipment safety) and cannot be solved by routine maintenance and simple repair.

Article 32 Management of weak links

According to the dynamic data, the technical equipment department of our company lists the weak links of the equipment, organizes the trial production on time, determines the projects that should be solved at present, and puts forward the improvement plan. The competent deputy general manager is responsible for organizing relevant personnel to review the improvement plan and incorporate it into the maintenance plan after approval.

After the improvement of weak links of equipment is implemented, it is necessary to check the effect and put forward evaluation opinions, which will be reviewed by the deputy general manager in charge and stored in the equipment file.

-Daily management of equipment

Daily management of equipment

1 Use and maintenance of equipment

The service period of equipment is the main stage of equipment life cycle, and it is also an important period for equipment operation to play a role and produce benefits. Therefore, the management of equipment operation period is very important, and the maintenance and operation in equipment operation has become an important link to keep the equipment in good technical condition, prevent and reduce abnormal wear and sudden failure, and improve the economic benefits of enterprises. According to the previous statistical data, the equipment failures caused by improper use or misoperation in T company and H company account for 20% ~ 35% of the total failures.

1. 1 Daily maintenance contents of equipment

Daily maintenance of equipment is the responsibility of equipment maintenance personnel or operators. The current development trend is that equipment operators are responsible for the daily maintenance of equipment and train equipment operators into multi-skilled workers. For the equipment of automobile production line, due to the complexity of the equipment, the daily maintenance requirements of the equipment are higher, so the quality and ability of the equipment operators are also higher. At present, the equipment maintenance work of T Company and H Company is basically completed by professional equipment maintenance personnel. Operators should be able to use production equipment correctly and check, lubricate, clean and fasten the equipment at the same time. These four aspects of work are carried out at the same time when the operator checks the equipment.

(1) check. Operators should check the operation conditions, operation parameters, lubrication, vibration, sound, temperature, whether there is peculiar smell, etc. Check the equipment with the feeling of using people or with simple testing instruments.

(2) lubrication. First, check the lubrication of the equipment, the temperature, pressure and liquid level of the lubricating grease, whether the lubricating oil has deteriorated and whether the oil circuit is unblocked. Regularly detect the lubricant in use and replace or replenish the grease of the equipment.

(3) clean. Clean the equipment and ancillary equipment and the surrounding environment, keep its original appearance and luster, and leave no dead ends. All items on the production site should be fixed and positioned according to the frequency of use and visualization standards, and arranged reasonably and neatly.

(4) fastening. If the fastening bolts of the non-rotating parts of the equipment are found loose during the inspection, they should be tightened and fixed in time.

1.2 Daily maintenance of equipment

The daily maintenance of equipment is standardized and programmed according to fixed point, timing, quantification, standards, personnel, records and routes. Designated personnel refer to trained operators or full-time equipment maintenance personnel with certain practical experience, who are responsible for the daily maintenance and maintenance of equipment management; Fixed point refers to determining the inspection parts and contents of key parts and common fault points according to the structure and operation characteristics of equipment; According to the maintenance technical standards, the deterioration trend of equipment wear, corrosion, deformation and thinning is determined quantitatively to decide whether to maintain or not; Determine the inspection and maintenance time of operators on a regular basis according to the operating conditions, changing characteristics and production requirements of the equipment; Determine the route according to the layout of production technology and equipment, and specify the inspection and maintenance route; Standard formulation refers to the formulation of standards for judging the deterioration of equipment according to different operating periods, and the formulation of corresponding inspection and maintenance methods, means and operating procedures; Make a unified, simple and clear form for easy inspection and maintenance. Operators or full-time maintenance personnel will fill in the form truthfully, especially the abnormal phenomena of equipment, which should be recorded completely and accurately, and the relevant operators should sign for confirmation.

1.3 Establish an independent enterprise equipment management system.

After the following seven steps, the independent management system of the enterprise is gradually formed: through preliminary cleaning (cleaning and spot check); Solve the root cause of equipment problems; A preliminary compilation of standards and specifications; Spot check practice; Self-inspection; Rectify and standardize; Continuous improvement of independent management.

2 Equipment inspection system

2. 1 System function of the spot check system

Equipment spot check system is an equipment management system centered on equipment spot check, and it is also the basis of TPM. For the equipment of automobile production line, the spot inspection system can effectively reduce the equipment failure rate, improve the maintenance efficiency, improve the production quality and reduce the maintenance cost, thus bringing remarkable economic benefits to enterprises. Full-time spot check personnel are responsible for equipment spot check and equipment management, which is the bridge and core between operation and maintenance. The spot inspector shall take full responsibility for the equipment in his management area, strictly abide by the spot inspection standards, formulate maintenance standards, prepare spot inspection plans and maintenance plans, manage maintenance projects, and prepare material plans and maintenance cost budgets. The spot check system consists of five aspects: the daily spot check of post operators; Regular inspection by professional inspectors; Accurate spot checks by professional and technical personnel; Expert technical diagnosis and trend diagnosis; Accuracy test and inspection by technical experts, etc. Under the same goal, the equipment inspection is coordinated by operators, professional inspection personnel, professional technicians and maintenance technicians in different professions and stages, so that people at all levels of these professions and technologies can cooperate and coordinate with each other to form a perfect and effective equipment management system.

2.2 business spot check system

The routine inspection of equipment shall be carried out according to the division of equipment area, routine inspection road map and specified business process. Enterprises shall, according to the characteristics of their own equipment, formulate corresponding spot check plans and standards, and track and evaluate the spot check results. Specifically, it is "eight decisions".

(1) Fixed personnel. The core of spot check operation is the spot check of full-time spot check personnel, not patrol inspection, but a fixed spot check area, so that the location, personnel and projects are fixed and personnel are not easily changed.

(2) fixed position. Pre-set the routine inspection plan of the equipment, including defining the routine inspection parts, items and contents of the equipment, so that the routine inspection personnel can carry out the routine inspection with purpose and direction.

(3) Determination method. Different spot-checking methods are used for different acupoints, which are often called "five senses", that is, listening, seeing, smelling, touching and tasting.

(4) fixed period. The location, project and content of the fault point have a clear preset period, and through the improvement of the quality of inspection personnel and the accumulation of experience, they are constantly revised and improved, and the best inspection period is explored.

(5) setting standards. Routine inspection standard is the basis to measure or judge whether the routine inspection parts are normal or not, and it is also the yardstick to judge whether the parts are deteriorated or not.

(6) fixed table type. The routine check schedule (or routine check operation card) is a guide for routine check personnel to carry out routine check operations, and it is also a blueprint for independent management in the minds of routine check personnel.

(7) record. Spot check performance records have a fixed format, including operation records, abnormal records, fault records and trend records. These complete records provide valuable raw data for the information transmission of daily inspection business.

(8) Fixed-point inspection of business processes.

2.3 Professional Tally Clerk

There is a high demand for professional inspectors, who have considerable professional knowledge and practical work experience, master various technical and management standards, formulate maintenance plans, material plans and capital budgets, analyze faults and handle opinions, and put forward countermeasures to improve equipment.

2.4 check the plan and operation card

Make routine check operation card, weekly routine check plan card, long-term routine check schedule, etc. Make routine inspection a standard operation.

3 equipment fault management

Equipment fault management is the basic work of equipment management and one of the basic tools for enterprises to master the equipment status. Analyzing and sorting out the equipment faults can not only understand the state of the equipment, but also take targeted improvement measures to avoid repeated mistakes, and also improve the technical level of maintenance personnel and improve maintenance efficiency. In addition, the fault information of equipment is also very valuable information for equipment design and manufacturing units, and it is one of the bases for equipment upgrading. Equipment fault analysis is a very complicated work, involving a wide range of technical fields. As far as metal failure analysis is concerned, it is a professional technology. At present, there are three forms of fault analysis:

(1) comprehensive statistical method. This is a failure probability analysis for the whole equipment of the factory. Such as the failure probability of all kinds of equipment; Failure probability classified according to failure phenomena or causes; Classification probability of fault types of a class of heavy equipment. In view of the high probability of equipment failure, technical or management measures are formulated to find and implement methods to reduce replanted equipment failure.

(2) Typical failure analysis methods. For some important equipment or components with defects and faults, or frequent failure modes, it is necessary to find out their internal reasons. Therefore, it needs to be solved by technical analysis and professional analytical instruments, which is the metal failure analysis technology. The general steps of metal failure analysis technology are as follows: typical failure parts sampling-macro analysis of fracture failure-micro analysis of fracture failure-material analysis-failure type and mechanism-failure reason judgment. Environmental damage analysis: analyze the medium, temperature, pressure, harmful substances and corrosion products in the working environment of equipment, or analyze the atmosphere and surrounding conditions. Simulation analysis: simulate the working conditions of failed components to verify the conclusion of failure analysis.

Metal failure analysis is not only a professional technology, but also a comprehensive analysis method. It needs to use various technologies, from structural design to material selection. Processing and manufacturing, assembly adjustment, use and maintenance, technological process, human factors, environmental pollution, etc. , has become a systematic project of comprehensive correlation analysis.

(3) Fault diagnosis and analysis. Monitoring and diagnosis instruments are used to monitor and diagnose the running equipment, so as to understand the state and trend of the occurrence, development and change of faults. The general steps are as follows: equipment running state monitoring → fault diagnosis and analysis → trend prediction. When the equipment stops, check and detect the fault of the faulty equipment, and verify and compare the fault conclusion with the diagnostic analysis. Its methods include corrosion monitoring, vibration monitoring, temperature monitoring, sound monitoring, lubrication monitoring and so on.

4. Training equipment operation and maintenance personnel and professional spot check personnel.

In order to become qualified employees, equipment operators and maintenance personnel and professional spot-check personnel must undergo professional training and education in daily maintenance or spot-check operation of equipment, so that all employees can establish the concept of "independent" maintenance. On the one hand, it is one of the basic tasks of TPM to understand the performance structure of equipment, master the equipment maintenance technology, diagnose the common faults of equipment, and know the troubleshooting methods or emergency treatment methods, so as to establish the "independent maintenance" system for enterprise employees.

To do a good job in the training of equipment operation and maintenance personnel and professional spot check personnel, we must do a good job in the following aspects: defining the training purpose, making long-term and short-term training plans according to the actual objectives, and the corresponding training contents; Organize employees to participate in training at different levels; Evaluate the training results of employees; Summarize the training results and employee training assessment, and constantly study and improve the training plan and training content in combination with the changes of enterprise equipment operation and failure and equipment update. In order to combine theory with practice and continuously improve the technical skills and quality of employees through training.