The maintenance of equipment is the key to ensuring its continuous and stable operation. Through daily wiping, cleaning, lubrication, and adjustment operations, we can effectively maintain and protect the performance and technical status of equipment, ensuring its long-term stable operation. To further improve the quality of equipment maintenance, we should strive to achieve standardization, craftsmanship, and institutionalization of maintenance work, ensuring that every step of operation meets standards and every link is carefully taken care of.
1, Maintenance and upkeep of equipment
(1) Clean and keep the inside and outside of the equipment clean, remove oil stains from sliding surfaces, screws, racks, gearboxes, oil holes, etc., and ensure that there are no chips, debris, or dirt around the equipment.
(2) Neat tools, accessories, and workpieces (products) should be placed neatly, and pipes and lines should be organized clearly.
(3) Lubricate well, regularly add or change oil, keep the oil circuit unobstructed, ensure the oil quality meets the requirements, keep the oil gun, oil cup, and oil felt clean, without any dry friction, and maintain normal oil pressure and oil gauge.
(4) Adhere to safety operating procedures, avoid overloading of equipment, ensure the integrity and reliability of safety protection devices, and promptly eliminate safety hazards.
2, Three level maintenance system for equipment
The three-level maintenance system covers the daily maintenance, first level maintenance, and second level maintenance of equipment. It is a mandatory system with the operator as the main body, emphasizing prevention as the main focus and balancing maintenance and repair. Through the participation of all staff, group management and maintenance, and the combination of specialized groups, the good maintenance and upkeep of equipment can be effectively ensured.
(1) Daily maintenance and upkeep of equipment
Daily insurance
Daily maintenance is a daily task that equipment operators must perform, including three stages: pre shift, during shift, and post shift. Before the shift, the operator needs to digest the drawing materials, check the handover records, and prepare for equipment wiping, lubrication, and refueling. In class, they should closely monitor the operation of equipment, including various indicators such as sound, temperature, pressure, liquid level, etc., to ensure the reliability of safety devices. After the shift, the operator needs to turn off the equipment switch, clean the work site, and fill out the handover record and operation table time record, and handle the handover procedures.
Zhou Zuobao
Zhou Jianbao is a more comprehensive inspection of equipment, covering multiple aspects such as appearance, operation and transmission, hydraulic lubrication, and electrical systems.
(2) First level maintenance
The first level maintenance is mainly carried out by operators, with the assistance of maintenance workers, to partially disassemble and inspect the equipment. The maintenance includes cleaning designated areas, unclogging oil circuits and pipelines, replacing or cleaning oil lines, felt, oil filters, etc. At the same time, it is necessary to adjust the clearance between various parts of the equipment and tighten each component. The time for first level maintenance is usually 4-8 hours, and it should be inspected and recorded after completion.
(3) Secondary maintenance
The second level maintenance is mainly carried out by maintenance engineers, with the participation of operators. It is included in the equipment maintenance plan, conducting partial disassembly inspection and repair of the equipment. The maintenance involves replacing or repairing worn parts, cleaning and changing oil, as well as inspecting and repairing electrical components. The goal of secondary maintenance is to ensure that the technical condition of the equipment fully meets the prescribed standards.
3, Requirements for the use and maintenance of precision, large, and rare equipment
(1) Four fixed jobs
The use and maintenance of precision, large, and rare equipment must follow the "four determinations" principle, which includes determining the user, maintenance personnel, operating procedures, and spare parts. This is the foundation for ensuring the efficient and safe operation of equipment.
(2) Requirements for the use and maintenance of precision equipment
The use and maintenance of precision equipment require special caution. Firstly, it is necessary to strictly follow the equipment manual for installation to ensure that all technical parameters are accurate and error free. Secondly, for equipment with special environmental requirements such as constant temperature, humidity, shock resistance, or dust prevention, enterprises should take corresponding measures to ensure the accuracy and performance of the equipment. In daily maintenance, it is strictly prohibited to disassemble the components of precision equipment. Once any abnormal situation is found, the equipment should be stopped immediately for inspection, and it is never allowed to operate with problems. In addition, it is necessary to strictly follow the cutting specifications specified in the equipment manual, only allow precision machining of parts according to the direct use of the equipment, and minimize machining allowances as much as possible. During non working hours, equipment should be equipped with protective covers and regularly wiped, lubricated, and air operated to maintain its good working condition. At the same time, accessories and specialized tools of the equipment should be stored in dedicated cabinets, kept clean and protected from scratches, and borrowing is strictly prohibited.
4, Requirements for the use and maintenance of power equipment
(1) Operators must undergo professional training and pass the examination before they can take up their posts.
(2) It is necessary to ensure the completeness of technical data, clear technical regulations for safe operation, and establish comprehensive operation records.
(3) Operators should continue to conduct patrol inspections during their duty period and are strictly prohibited from leaving their posts without authorization.
(4) When encountering abnormal operation, the on duty personnel need to handle it urgently according to the operating procedures and report it immediately.
(5) Ensure the sensitivity and accuracy of various indicator instruments and safety devices, and conduct regular calibration. Meanwhile, backup equipment must be kept in good condition and reliable.
(6) Power equipment is strictly prohibited from operating with faults, and any malfunctions must be promptly resolved.
(7) Regularly conduct preventive tests and seasonal inspections to ensure the stability and safety of the equipment.
(8) Strengthen safety education for on duty personnel and strictly implement security measures.
5, Regional maintenance of equipment
Regional maintenance of equipment, also known as the maintenance package mechanism, is an important method of equipment maintenance. In this mode, maintenance workers are responsible for equipment maintenance in specific production areas, collaborating with production operators to complete tasks such as daily maintenance, patrol inspections, regular maintenance, planned repairs, and troubleshooting. At the same time, they also bear the responsibility of achieving assessment indicators such as equipment integrity rate and downtime rate within their jurisdiction. This regional maintenance responsibility system not only strengthens the concept of equipment maintenance serving production, but also stimulates the enthusiasm of maintenance workers, prompting them to be more proactive in caring for equipment maintenance and repair.
The main organizational form for equipment professional maintenance is the regional maintenance team. These regional maintenance teams are fully responsible for equipment maintenance and emergency repair work in their production areas, with high mobility to ensure that equipment is repaired in the shortest possible time, while also completing various preventive operations and participating in planned repairs without being called upon.
When dividing equipment maintenance areas, it is necessary to comprehensively consider multiple factors such as the distribution of production equipment, equipment condition, technical complexity, production demand, and the technical level of repair fitters. Based on these factors, workshop equipment can be divided into several areas, or maintenance groups can be divided according to equipment types. For equipment on the assembly line, maintenance areas should be divided according to the production line to ensure that each device can receive timely and effective maintenance.
6, Measures to strengthen equipment maintenance level
To further improve the level of equipment maintenance, it is necessary to ensure that maintenance work follows the principles of standardization, craftsmanship, and institutionalization. Standardization requires unified maintenance content, clarifying the parts and cycles of cleaning, adjustment, and inspection to ensure that all maintenance activities are carried out in an orderly manner. Craftsmanship refers to the development of specialized maintenance procedures for different equipment, guiding maintenance personnel to operate according to the procedures. Institutionalization specifies maintenance cycles and times for different equipment and operating conditions to ensure strict compliance. In addition, for regular maintenance work, it is necessary to establish quotas for working hours and material consumption, and assess them based on the quotas to motivate maintenance personnel to improve work efficiency and quality.
Equipment maintenance work should be included in the assessment system of the enterprise's production economic contracting responsibility system. Enterprises should actively promote the participation of all employees, combine professional and mass forces, jointly carry out equipment maintenance activities, including self inspection, mutual inspection, and regularly organize equipment inspections.