How to achieve zero failure of enterprise compressor equipment

How to achieve zero failure of enterprise compressor equipment

At this stage, companies have repeatedly advocated zero-fault management of equipment, requiring all equipment-related personnel to change their concepts, from the point of view that equipment always fails to the point of not allowing equipment failures to be reduced to zero. Then, What is zero failure of equipment?

Compressors and other equipment are the necessary conditions and strength support for the operation of modern industrial enterprises. With the continuous progress and rapid development of science and technology, their updating and intelligent upgrading are gradually accelerating, which puts forward a higher level of equipment management for enterprises. Requirements. Whether the compressor equipment is functioning well will directly affect various factors such as enterprise output, quality, cost, delivery time, safety and morale. Therefore, the previous maintenance system and the concept of maintenance activities must be upgraded to be able to cope with future changes.

As a new management concept, "zero failure" management of compressor equipment has been promoted in many companies. This article will further discuss the characteristics of management, causes of equipment failures, and management measures.

What is equipment "zero failure" management

Compressor equipment "zero failure" is a kind of zero concept, not an absolute value of zero. "Zero failure" management is implemented with the goal of "zero" to prevent equipment failures and maintain an efficient and stable production order. The series management process, although its management goal is the zero concept, it is not the target effect management but the process management. It is through a series of effective process management to advance to the zero concept, after continuous spiraling, until the equipment failure can be reduced to Close to "zero" level.

The core of equipment "zero failure" management is to eliminate emergency maintenance and unplanned maintenance. The losses caused by unplanned maintenance and emergency maintenance are huge, and the consequences are also very serious. The maximization of enterprise benefits is not only the starting point of the "zero failure" management of compressor equipment, but also its fundamental goal.

The "zero failure" management of compressor equipment is a systematic management method. It is not difficult for a single compressor or unit to achieve phased zero failure operation, but how to minimize its impact on the entire company's production chain, then It is a complex issue and must be considered comprehensively.

Features of equipment "zero failure" management

　(1) Adhere to the policy of focusing on prevention. Its guiding ideology is to "prevention" as the mainstay, changing the traditional thinking of repairing as the mainstay in the past, in order to minimize accidents and failures.

(2) Implement full-staff management. Every employee participating in the production process is required to care about and participate in the maintenance of the equipment, so that the production personnel and the equipment personnel are integrated and become the basis of the equipment management for all employees.

(3) Highlight the concept of serving production. Each process of the entire equipment management (including operation and maintenance) is implemented in accordance with "all specifications and standard everything", which not only guarantees the normal execution of the production plan, but also meets the maintenance requirements, reflecting the unity and coordination of production and equipment Sex.

(4) Tendency management. Determine the overhaul time and content based on the equipment status to prevent over- or long-term maintenance. The essence lies in the inspection and diagnosis of the equipment to discover the deterioration tendency problems, so as to predict the life cycle of equipment parts, determine the maintenance items, and propose improvements Measures to keep the equipment in an efficient and stable operating state

(5) Concentration of management objectives. One is to reduce equipment failures, and the other is to reduce maintenance costs.

(6) Standardize everything. From the perspective of "regulating everything, all standards", a relatively complete standard system has been established and strictly implemented. The emphasis is on the inspection standards. The equipment inspection is to set a number of points where the equipment may deteriorate and malfunction, and implement fixed points, calibrations, regular, fixed methods, fixed inspection standards, maintenance technical standards, and grease standards. And maintenance standards.

(7) Adopt PDCA working method. Equipment management departments at all levels should hold regular performance analysis meetings, provide information level by level, use data and charts to analyze failure conditions, overhaul implementation and maintenance cost usage, and propose improvement countermeasures and implementation measures.

(8) Maintain the versatility of workers. Due to the increasing development of equipment modernization and maintenance technology, the requirements for the quality of maintenance personnel are getting higher and higher. They must have considerable practical experience, a certain level of basic theory and strong management capabilities. Advocating the spirit of corporate culture of continuous learning from the perspective of changing the mental outlook and improving work skills.

(9) With the development of technology and the improvement of equipment design and manufacturing level, it is possible for some equipment to achieve lifetime without major repair, and it is completely possible to achieve zero life cycle maintenance.

Causes of equipment failure

There are many reasons for equipment failure, which can be simply divided into two categories: congenital failure and service failure.

　Congenital failure: failure caused by inherent defects of equipment caused by improper design and manufacturing.

Strictly speaking, the congenital failure of the equipment is not only subject to the phased constraints of the development of science and technology, but the level of the designer and manufacturer, the sense of responsibility, the operation and daily management of the equipment after operation are all human factors, which means that these can be passed Human behavior is controlled.

Usability failures: failures caused by factors such as installation and maintenance, operation and natural deterioration of equipment can be further divided into: misoperation, improper maintenance and disrepair.

Measures to promote equipment "zero failure" management

Establish a corporate culture suitable for equipment zero-fault management

First of all, equipment "zero failure" management is a management method based on a full-staff equipment management system. It is necessary to cultivate a corporate culture that adapts to equipment "zero failure" management, including: creating a learning atmosphere and creating learning conditions to form a learning team; correct Work attitude, recognize the difference in ability, but ask to make the best of oneself; cultivate enterprise talents, pay attention to the future of employees; require every employee to work according to standards and so on.

Start by strengthening basic equipment maintenance

The so-called basic maintenance refers to correct adjustment, cleaning, oiling, tightening, etc. Failures are caused by equipment deterioration. As long as equipment operation and maintenance are strengthened and the equipment runs in a good condition, the service life and life of the equipment will increase steadily.

Strictly observe the equipment use conditions

The conditions of use are predetermined when the equipment is designed. Equipment designed according to the conditions of use, if these conditions of use are strictly met, failures are rarely caused. For example, load, speed, installation conditions and temperature are all determined according to the characteristics of the equipment. Blindly operating or consolidating equipment may increase output in a short period of time, but in the long run it will only be counterproductive, and the gain will outweigh the loss. To achieve zero failure of the equipment, it is necessary to strictly observe the conditions of use of the equipment itself.

Strengthen preventive maintenance and restore equipment to normal

All equipment, even if the basic conditions and usage conditions are strictly adhered to, the equipment will deteriorate and cause malfunctions. Therefore, to make the deterioration of hidden dangers obvious and restore them to the normal state is a necessary condition to prevent failures before they happen. This means that inspections should be performed correctly to restore the equipment to normal preventive repairs.

Analyze how the failure occurred, because we did not notice the seed defect of the failure before the failure occurred. In this way, the failure seeds that we have not paid attention to are called latent defects. According to the principle of zero failure, these "potential defects" should be made obvious, and attention should be paid before failures occur. In this way, these defects can be dealt with before they become failures and failures can be avoided. Therefore, the emphasis on preventive maintenance is an important guarantee for achieving zero failure.

Improve the shortcomings in the design

　Some failures cannot be removed even after the above-mentioned countermeasures are taken, and sometimes these failures increase production costs. Most of this type of equipment has shortcomings such as insufficient technical force or errors in the design or construction stage. Therefore, failures should be carefully analyzed to improve these shortcomings. Only by constantly improving the factors that restrict the safe operation of equipment can zero failures be achieved.

Improve employee business skills

The realization of zero-fault management lies in people. The biggest problem is that even if countermeasures are taken, there will be operational errors and repair errors. In order to prevent such failures, only the professional skills of operators and security personnel must be improved. How to deal with failures

After the equipment failure accident occurs, it is necessary to quickly organize rush repair or treatment, resume production as soon as possible, and handle it according to the company's accident management methods, and insist that the cause and responsibility of the failure accident are not clear; the person responsible for the failure accident and the relevant personnel should not be truly educated. Let it go; if the measures to prevent and deal with failures are not implemented, let it go

After the equipment (system) function, accuracy or output (speed) of the equipment (system) is proficiency verification after the equipment (system) fails in the event of a failure accident.

　Strengthen the management of repeated failure accidents. Professional inspectors are directly responsible for repeated failures and are also responsible for implementing corrective measures. 　To sum up, if the zero-fault management of equipment can be carried out in a firm and effective manner in the enterprise and achieve results, it will definitely provide stronger and more effective support for the company's production and operation.