This system is specially formulated in order to strengthen the skills training of employees, continuously improve the operating skills of operators in each position, and ensure the safe operation of equipment and normal process indicators:
1. On-the-job training is based on job responsibilities, with the principles of what to do, what to learn, what to lack and what to make up, taking the form of combining theory with practice and combining production with training, taking production projects as training projects, and improving operational skills through on-the-job training.
Second, practice basic skills, that is, practice the basic actions and skills of practical operation and the ability to analyze and judge various situations. Really "four understandings" (understanding the structure, principle, performance and use of equipment); "Three skills" (use, maintenance, troubleshooting ability) can be used freely.
Third, the training forms are flexible and diverse. You can use the training card, or write it on the blackboard or notebook, or ask the technician or shift supervisor to give questions or everyone will take turns to give questions.
Fourth, on-the-job training activities are mainly based on mutual teaching and learning, supplemented by on-site guidance and explanation by technicians, and insist on learning the contents of training projects every day, and employees ask questions and ask for records.
Five, seriously implement the system of post operators holding certificates, new workers and job-changing personnel must pass the safety technical assessment, and those with an assessment score of less than 80 points must learn from the new assessment, otherwise they are not allowed to work.
Six, often organize operators, learning post operation procedures and methods, professional and technical education.
Seven, a quarterly technical education and training, and examination, examination results will be included in the assessment of operators.
Eight, implement the principle of "strict training, strict requirements", strict and meticulous, starting from reality. Carry out on-the-job training with help and education.
Nine, organize an emergency drill every quarter to improve the ability of employees to deal with emergencies.
Process management system
This system is specially formulated to ensure the safe and stable operation of the equipment and meet the production requirements:
A, each post personnel in accordance with the requirements of "operating rules" and production process indicators, strict process operation, strict control of process indicators to meet production requirements, and timely, complete and accurate records of various process indicators. Eliminate illegal operation.
Second, for the abnormal process indicators in the production process, it is necessary to find out the reasons for exceeding the standard in time, report and deal with them in time, and make records so that the process indicators can return to normal as soon as possible.
Three, where the technical indicators exceed the standard due to equipment reasons, reverse the car as soon as possible, report to the shift supervisor, and contact the maintenance personnel for maintenance.
Fourth, strengthen patrol inspection, fully understand and master the control of various process indicators, and timely analyze and deal with abnormal situations.
Five, each post personnel must be familiar with the technological process, technical operation procedures, start-stop methods, fault diagnosis and treatment and other necessary operational skills and business knowledge.
Six, the factory regularly organize process inspection, assessment of illegal operators.
Seven, the implementation of equipment maintenance and regular switching system.
Eight, timely analysis of changes in production technology, reasonable process indicators, timely according to the actual production, adjust the process indicators.
Nine, according to the actual production, timely put forward the system technical transformation plan.
. rotation/relay system
A, succession management is a clear succession responsibility, an important system to ensure safety in production, each post personnel should consciously abide by this system, do a good job of succession, put an end to abnormal or accidents due to unclear handover.
Second, the operation personnel must be in accordance with the provisions, shift, time shift.
Three, 30 minutes before the succession, after the succession 15 minutes generally do not carry out major operations. During the occurrence and handling of major accidents or major operations, shifts are not allowed. If the successor agrees to take over, the consequences will be borne by the successor.
Fourth, it is forbidden to go to work after drinking.
Verb (abbreviation for verb) inherits content:
(a), half an hour before the succession, check whether the public information, running logs and records of the class are complete, detailed and orderly. Check whether all tools and articles to be handed over are in good condition.
(2), do a good job of cleaning the workplace and mechanical equipment before the succession.
(3), before the succession, the team's production situation, the implementation of process indicators, the operation of mechanical and electrical equipment and instruments, spare cars, equipment maintenance and commissioning, leakage, accidents and handling, etc. , as well as the instructions of the leader, should be recorded in detail in the production duty diary and handed over to the next shift.
(4) 20 minutes before the succession, report to the shift supervisor the production situation of the shift. Attend the after-work meeting and summarize the production situation and experience and lessons of Class One. When there is no succession, stick to your post and report to the shift supervisor. You can't leave your job until someone takes over.
Six, succession content:
(a), the successor must attend the succession meeting on time, listen to the shift supervisor to introduce the production situation, work to be done after work and matters needing attention, and accept the assignment of the shift supervisor. Then conduct on-site inspection according to their respective job responsibilities.
(2), the successor to deal with post fire, telecommunications equipment and other instruments, post health inspection. If you find a project that does not meet the requirements of succession, you can temporarily not take over. In case of emergency after the succession, it can be handled together with the successor, who must obey the command of the person on duty.
(3), post situation after the succession, the successor should sign and report on the production duty diary.
Provisions on labor discipline
First, employees must wear factory clothes, famous brands and safety helmets when entering production posts.
2. Employees are not allowed to sleep, leave their posts, leave their posts, gather people to chat, play, make noise or do things unrelated to their jobs during their work. Employees who violate the regulations will be fined 50 yuan every time they are verified.
Thirdly, employees must follow the principle of "subordinates obey superiors", obey the reasonable work arrangement of managers and complete various production tasks according to the work arrangement.
Smoking, eating snacks and wearing high heels are strictly prohibited in the factory. Employees are prohibited from going to work after drinking.
5. During working hours, whether for personal reasons or official reasons, you must apply for the Employee Outgoing Voucher before you can go out.
Six, employees without the consent of the long-term value or factory leaders, it is forbidden to find someone to replace or shift.
Seven, employees change jobs or leave, should be timely clear handover procedures.
Eight, employees steal property, or take the property of the company and others for themselves or exchange money, once found, immediately recover the illegal income, and hell to pay.
Nine, it is forbidden to conceal the accident, it is forbidden to pass the buck for the mistakes made.
Ten, in violation of the above provisions, depending on the seriousness of the case, each time a fine of 50- 10 yuan, serious cases to the company.
Equipment periodic test and switching system
I. General rules:
Regular maintenance, testing and switching of equipment is an important measure to ensure that standby equipment, electrical and thermal automation devices, protection devices and signal devices can play their roles correctly. Operators must regularly maintain, test and switch the equipment as required, and make records.
Second, the regular maintenance of equipment testing content
(1) Periodic test of automatic device, protection device and signal device.
(2) Regular switching or trial operation of standby equipment.
(3) Regular and regular maintenance of equipment.
Three. Rules and requirements
(a) found in the daily work of equipment defects should immediately report to the value of long, make records, requirements to eliminate defects quickly. If defects cannot be eliminated in a short time, operators should strengthen monitoring, take necessary safety measures and make accident prediction.
(2) If the test results are significantly different from the last time, analyze the reasons, report the situation to the technicians, and contact the personnel of relevant departments for inspection and handling.
(three) in case of special circumstances, the test switching project can not be carried out as scheduled, and can be postponed with the consent of the long-term value or special workers, but the reasons should be indicated.
(4) No matter any test, records shall be made, and regular work shall be counted by special personnel at the end of the month according to the duty records.
(5) After major repairs and before starting, the unit shall be tested as required, and the unit can be started only after it is qualified.
(six) there are important visits or other arrangements at the production site, and the regular work involving the safety of the unit shall be approved by the relevant leaders before it can be carried out.
Factory management system
First, the content of equipment management
Management of technical conditions of equipment According to the technical conditions, maintenance conditions and management conditions of equipment, all equipment is divided into intact equipment and non-intact equipment, and specific assessment standards are formulated respectively.
The production equipment of each post must complete the technical condition index issued by the superior, that is, the comprehensive intact rate of inspection equipment. Professional departments should work out the annual, quarterly and monthly comprehensive intact rate index of equipment, and decompose it layer by layer and implement it step by step.
2. Equipment lubrication management
(1) Equipment lubrication management requirements:
1. There are lubrication professionals in this department who are responsible for the technical management of equipment lubrication in each position. Each team should have the main person in charge, responsible for temporary refueling and lubrication during the shift.
2. Each equipment must formulate a complete chart and requirements of "five determinations" for equipment lubrication, and earnestly implement it.
3. Each post should conscientiously implement the "Three Cleaning and Oil Washing of Equipment" (cleaning oil drums, oil tools and oil filling points) to ensure the cleanliness of grease and the smooth flow of oil channels to prevent blockage.
Lubrication professionals are responsible for adhering to the regular oil analysis and testing system for large, special and special equipment.
5. Lubrication professionals should do a good job in popularizing new equipment lubrication technology and upgrading oil products.
Carefully manage the recovery of waste oil.
(2) Formulation, implementation and modification of the lubrication "five-fixed" diagram.
1. The "Five Definitions" diagram for lubrication of production equipment must be worked out one by one and sent to the post.
2. The contents of the "five definitions" chart of equipment lubrication are:
Fixed point: specify the lubrication position, name and refueling point;
Qualitative determination: specify the brand of grease for each refueling point;
Timing: specify the refueling and oil change time;
Quantification: specify the amount of oil added and replaced each time;
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 operation records.
4. Lubrication professionals should regularly and irregularly check the implementation of the lubrication "five-fixed" diagram, and handle problems in time when found.
5. Post operators and maintenance personnel must always pay attention to the lubrication of various parts of the equipment, and report and handle problems in time when found.
(3) Lubricating oil analysis and test management.
During the operation of the equipment, the lubricating oil deteriorated due to the influence of the parts themselves and external factors such as dust, moisture and temperature. In order to ensure the quality of lubricating oil, filtration analysis and testing must be carried out regularly, and different sampling and testing time of different equipment should be stipulated. When the test oil does not meet the requirements, replace the grease in time. Each post must clean up the lubricating oil of the equipment and keep the oil circuit unblocked.
(4). The application of new equipment lubrication technology and oil product renewal management.
1. The main person in charge of the equipment should organize research and solve it step by step.
2. The upgrading of oil products should be included in the annual equipment work plan of this department, and can only be implemented after testing to ensure safety. Before upgrading petroleum products, petroleum equipment, oil tanks and pipelines must be cleaned.
Three. Treatment of equipment defects
1. Equipment defects that can be eliminated by post operators and maintenance personnel shall be eliminated immediately and recorded in the log in detail.
2. Equipment defects that cannot be eliminated by post operators should 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.
3. Equipment defects that cannot be eliminated in time must be studied and decided at the daily production scheduling meeting.
4. Before arranging to deal with each defect, there must be corresponding measures to designate the person in charge to prevent the defect from expanding.
Four. Dynamic management of equipment operation
Dynamic management of equipment operation means that maintenance managers at all levels firmly grasp the operation of equipment through certain means and formulate corresponding measures according to the operation of equipment.
1. Establish and improve the equipment inspection standard of the system.
The person in charge of equipment specialty should determine the checkpoint, inspection content and allowable values of normal operation parameter standards of 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, per shift, daily, weekly, every ten days and monthly checkpoints.
2. Establish and improve the inspection and guarantee system.
Operators in production posts are responsible for checking all checkpoints of equipment used in this post, and the inspection tasks of key equipment are contracted by professional maintenance personnel. According to the number and complexity of equipment, determine the number and candidates of full-time inspectors. In addition to contracting important inspection points, full-time inspection workers should also fully grasp the equipment operation dynamics.
3. Information transmission and feedback
(1) When the operators in the production post patrol, they found that the equipment could not continue to run and needed urgent treatment. They should immediately notify the dispatcher on duty, and the person in charge on duty will organize the handling. General hidden dangers or defects, after inspection, log in the checklist and pass it to full-time inspectors on time.
(2) Full-time maintenance personnel should make a record of equipment spot check, and in addition to arranging the processing of this group, they should also pass the information to full-time inspection workers for unified summary.
(3) In addition to completing the contracted inspection tasks, full-time inspectors should also be responsible for collecting and sorting out all aspects of inspection results every day, and list the key issues of the day and pass them on to superiors.
(4) Be responsible for listing the main problems existing in this department. In addition to registering the household registration, it is also necessary to enter the computer in time to facilitate the comprehensive management of the mobile department of the superior large company.
4. Application of dynamic data
According to the equipment defects and hidden dangers found in the inspection, the inspection workers put 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 production duty commander shall immediately organize the treatment; If the class can't handle it, the responsible department should determine the solution.
The major defects of important equipment should be studied and determined by the factory-level leaders to determine the control scheme and treatment scheme.
5. Project treatment of weak links of equipment
1. The following conditions are the weak links of the equipment:
(1) Frequent breakdowns occurred during operation, and invalid parts were repeatedly processed;
(2) Equipment and parts that affect product quality and output during operation;
(3) Parts (or equipment) that cannot meet the requirements of minor repair cycle and often need unplanned maintenance;
(4) There are hidden dangers (personal and equipment safety), which require routine maintenance and simple repair.
An insoluble part or device.
2. Management of weak links
Formulate management measures and assign special personnel to be responsible.
Equipment maintenance system
A, the implementation of special plane, regional responsibility system, so that Taiwan equipment, pipelines, valves, meters are responsible.
Second, the operator should be careful to maintain and use the equipment correctly. Patrol inspection on time, do a good job in cleaning, lubricating, fastening, adjusting and anticorrosion of equipment, and maintain the equipment.
Three, the equipment of this position should be "four understanding" (structure, principle, performance, use) and "three will" (operation, maintenance, troubleshooting).
Four, the parking and normal operation of equipment, should be carried out in strict accordance with the post law and safety production technical regulations, strictly control the process indicators. Do "four no overload", that is, no overtemperature, no overpressure, no overspeed and no overload.
Five, patrol inspection equipment to carry "three treasures" (tools, listening sticks, rags), the implementation of the "five-character operation method" (listening, touching, watching, smelling and checking). Equipment maintenance should adopt "cross-operation method" (cleaning, lubrication, fastening, adjustment and corrosion prevention). Master the distribution of static and dynamic sealing points in this area, and timely stop the leakage, with the leakage rate not higher than 0.2‰. Eliminate the dirt, defects and corrosion of equipment, and the equipment integrity rate shall not be lower than 98%.
Six, equipment lubrication should be "five fixed" (fixed person, fixed point, fixed quality, fixed time, quantitative) and "three-level filtration" (oil drum, oil pot, oiler).
Seven, standby equipment should be regularly turning, switching and make records, and achieve "four prevention", that is, moisture, frost, dust and corrosion.
Eight, do a good job of equipment, pipelines, instrument panels, the ground clean and sanitary. Eliminate leakage in time and realize civilized production.
Nine, found that the equipment hidden dangers and failures should immediately find the reason, timely report to the shift supervisor and shift supervisor, emergency decisive processing.
Ten, equipment lubrication, turning, start-up, switch, stop and fault handling records should be complete and accurate (turning marked).
Eleven, professional maintenance personnel to patrol inspection on time in charge of the equipment, take the initiative to understand the operation status of the equipment to the operator, timely handle the hidden dangers and failures of the equipment, and fill in the inspection records.
Twelve, strict succession system, completes the equipment operation and maintenance records. The treated and untreated defects shall be clearly recorded.
Civilized production management system
This system is specially formulated to further strengthen the management of production operations and create a good working environment for the company's safe production.
A, the operator's dress should comply with the provisions of the "safety regulations" and the company's relevant standards and requirements.
Two, the production site should be "five noes" (no dust, no water, no oil, no sundries, no sanitary corner) and "four noes" (complete safety cover, complete trench cover, complete equipment signs, complete lighting facilities), and the production site work is orderly.
Third, the health responsibility area is clean. The internal and external passages and roads of the workshop are unblocked, and all sanitary areas should be kept free of sundries, cigarette butts, dust and water.
Fourth, the class looks clean and tidy. Studio and dressing room must be "five cleanness" (doors and windows, tables and chairs, filing cabinets, walls and lockers) and "five neatness" (tables and chairs, information tools, desktop articles, charts hanging on the wall, items on the counter table).
Five, equipment, pipelines, valves should achieve no oil leakage, no water leakage, no steam leakage, no powder leakage, surface insulation, paint integrity. Platforms, railings, stairs and baffles are intact and clean.
Six, on-site use of programs, logs, record books, telephones, analysis, laboratory equipment and other items should be neatly arranged and kept clean.
Seven, on-site tableware, tea sets, work clothes, shoes and hats, health cleaning equipment according to the specified location. It is strictly forbidden to place it at will.
Eight, safety production facilities, warning signs, safety warning lines, equipment signs are complete. All kinds of pipelines have clear color rings and clear medium flow direction.
Nine, it is strictly prohibited to be on duty after drinking, not to take off the post, not to string posts, not to sleep, not to swear, not to talk loudly, and to use civilized and standardized terms. The personnel on duty should sit upright, pay attention, don't laugh and frolic, and don't do things unrelated to work.
Ten, within the jurisdiction of the water supply facilities damage should be reported in a timely manner.
Patrol inspection system
In order to strengthen the inspection management, find out the problems and abnormal operation of the equipment system in time, and ensure the safe and stable operation of the equipment, this system is specially formulated:
First, patrol inspection is an essential and important measure to keep abreast of the status of operating equipment, find equipment anomalies, eliminate equipment hidden dangers, prevent equipment accidents and ensure the safe and economic operation of equipment.
2. Inspection contents: implementation of process indicators, lubrication operation of equipment and safety in production.
Third, inspection tools: patrol inspection of three treasures: rags, listening sticks and tools.
Fourth, the inspection method:
(1) Judge the situation by listening, watching, touching and smelling, and find problems.
(two), to be timed, fixed, fixed route, fixed content.
(3) General parts should be inspected once every hour, and key parts and defective parts should be inspected frequently.
(four), found that the problem should be reported in a timely manner and recorded in detail.
Five, inspectors should be in accordance with the requirements of the relevant provisions of the inspection items, content, time, route, number of inspections.
Six, patrol inspection is divided into regular patrol inspection and key patrol inspection.
(1) Regular patrol inspection refers to the regular patrol inspection conducted by operators at the specified time, once every 1 hour.
(2) The key patrol inspection is to inspect the characteristics, operation mode and load of the equipment to ensure that the inspection contents are not omitted.
Seven, inspection, inspection personnel should concentrate on inspection, using the correct inspection method, found that the abnormal equipment should be reported in time, and handled correctly.
Eight, it is forbidden to touch the rotating parts and running parts of the equipment. If necessary, contact the shift supervisor to switch the standby auxiliary machine and check.
Nine, patrol inspection, recorded in accordance with the provisions. If any abnormality or doubt is found in the equipment, the monitoring should be strengthened, the reasons should be analyzed, and the case should be reported to the shift supervisor in time and handled as instructed.
Ten, the abnormal situation and abnormal handling found in the inspection, must be clear in succession, and confirmed by the successor.
Eleven, equipment or system maintenance, inspection personnel should understand the maintenance progress.
Twelve, in case of the following circumstances, inspectors should focus on inspection:
(1) Commissioning after overhaul.
(2) The new equipment is put into trial operation.
(3) The operating equipment is defective or the equipment fails frequently.
(four) the abnormal situation or matters needing attention of the equipment on duty.
13. If the equipment is found to endanger the safety of personal equipment during the inspection, the necessary treatment shall be carried out immediately, and then the report shall be made to the shift supervisor.
Original record management system
In order to do a good job in the management of original records and promote the standardization and standardization of production management, this system is specially formulated.
First, the original post record is an important part of production management. Through careful and detailed records, the inspection quality of operators can be further improved, various hidden dangers and problems can be found and judged in time, and accurate basis can be provided for analyzing and evaluating the running state of equipment. The original post records generally include daily post operation reports, handover records, inspection records, maintenance records and other record forms and ledgers, which are the first-hand information that truly reflects the production and operation.
Second, the daily report of post operation should be recorded by meter reading on time (before and after 10 minutes), and other record forms should be recorded in time after the work of recording content is completed.
Three, post personnel should check on time according to the post operation procedures, and fill in the equipment operation status and various parameters according to the inspection content. Fill in the content should be consistent with the real situation of production and operation, and shall not be omitted, estimated, concealed or modified afterwards to ensure the accuracy and completeness of the records.
Four, the record content must be true, the font is neat, clear, imitation of Song Dynasty, filled in with a carbon pen, and the recording paper should be kept clean and intact, and it is not allowed to arbitrarily alter, roll pages, tear pages, lack pages or scribble.
Five, meter reading or inspection process, found abnormal data or equipment operation, should analyze the reasons, timely report processing, and make records and shift work.
Six, all kinds of original records and statements issued by the comprehensive administrator. If it is lost or damaged, postal personnel should ask for it in time. Put an end to the phenomenon that it is impossible to record normally due to the lack of watch paper. All kinds of records should be properly kept and submitted to the comprehensive administrator for filing at the end of each month.
Seven, in violation of the above terms, depending on the seriousness of the case, every time found, the responsible person shall be fined 20- 10 yuan.