Mechanical equipment inspection management
Air compressors are the most used power resource in the 21st century, and are basically needed in all walks of life. Therefore, the normal operation of air compressors is the key to protecting the interests of users. For this reason, equipment inspection is extremely important. Doing a good job in the spot inspection and management of air compressor equipment will reduce the incidence of equipment failure and greatly reduce equipment maintenance costs.
1 Equipment inspection management
1.1 Contents of equipment inspection management
Equipment inspection management is the use of human senses and simple instrumentation tools, or precision testing equipment and instruments, in accordance with pre-established technical standards, locating people, locating, quantifying, calibrating, locating routes, deciding cycles, deciding methods, deciding check Record and implement dynamic inspection of operating equipment throughout the entire process. It is a serious scientific management method to grasp the operation status of equipment in time and guide the maintenance of equipment status.
To achieve status maintenance, it is essential to understand and grasp the various status of the equipment in real time, accurately and comprehensively. The inspection system was originally developed from the preventive maintenance system introduced by Japan from the United States, and it has now become a basic task for realizing condition inspection. The application of this management mode will effectively grasp the various states of equipment, prevent "over-maintenance" and "under-maintenance", reduce the incidence of equipment failures, and greatly reduce equipment maintenance costs. Therefore, this management mode is widely used in equipment management in the world.
Inspection management can usually be divided into two types: daily inspection and precision inspection.
Daily inspection refers to the continuous routine inspection of equipment in daily work, and the completion of the collection and analysis of status data, which is the basis for the development of precise inspection work. The development of daily inspection work constitutes the basic framework of inspection work.
Precision inspection is the detailed investigation, measurement and analysis of equipment that has problems. It is an extension of daily inspection work and is used to professionally find the cause of equipment failure.
Daily inspection and precision inspection shall not be neglected. To realize the equipment inspection system, each enterprise needs to plan the corresponding organizational management, technical management and application programs according to their own characteristics.
1.2 Significance of equipment inspection
Ensure the safe and stable operation of the equipment system;
Extend the service life of the equipment;
Achieve "zero failure" of equipment;
Reduce maintenance costs.
2 The relationship between operators and post inspection
Post inspection is a method to find hidden equipment safety hazards, one of the basis for equipment maintenance, and an important link in the equipment maintenance management system with spot inspection as the core. It consists of two parts. One is the job inspection task composed of operators, who are mainly responsible for the daily inspection of equipment, and the other is maintenance personnel who are responsible for the daily professional inspection of equipment. It embodies the characteristics of equipment maintenance management for all employees.
The operator must be familiar with the structure of the production process equipment, master the basic knowledge of the relevant equipment, have a strong sense of responsibility and observation, and be able to observe and analyze the characterization phenomenon of the equipment with his own intuition, feeling and experience, and judge the abnormality of the equipment Happening.
Equipment maintenance personnel conduct professional inspections on the equipment in the jurisdiction every day, which plays the role of the bottom line of protection. If you are negligent and fail to check the failures in time, the next process will not be performed normally and the loss will be very large.
3 The relationship between job inspection and professional inspection
3. 1 Organically integrate operation inspection to strengthen communication between the two
At present, most factories implement the system of fixed personnel and fixed machines. Each operator is fixed to guard a certain number of mechanical equipment, but the fixed personnel maintenance system is ignored, and the various rules and regulations of mechanical equipment maintenance are not clearly implemented to individuals. Because of this, the operators often just "include service but not repair", and the maintenance personnel are also sloppy. Whenever the mechanical equipment fails, the operators and maintenance personnel often shirk each other's responsibilities. This not only affects the output and quality, but also increases maintenance costs, operating costs and reduces the service life of the equipment.
It requires a reasonable division of labor between job inspection and professional inspection, and an organic combination. Equipment management is a comprehensive project, that is, professional management with a reasonable division of labor, and post inspection management with the active participation of employees. The two complement each other to achieve good results.
3. 2 Spot inspection is the first line of defense for equipment abnormality discovery
Post inspection is the first line of defense for equipment safety hazards (abnormal), the basic basis for equipment maintenance, and the basic link in equipment maintenance management. To ensure that the job inspection plays its due role, the operator must be familiar with the inspection standards, formulate "inspection cards" and "equipment lubrication accounts" according to the standards, and record the situation in the card; be familiar with the principle of equipment structure and process operation procedures, and do To use and operate the equipment properly. Operators should also have the work quality of self-management; have the basic skills of maintaining equipment, maintaining equipment, and inspecting equipment, including correct use of tools, correct addition of lubricating oil, simple adjustment and replacement, troubleshooting, etc.
3. 3 The role and requirements of maintenance personnel and professional technicians
Maintenance personnel and professional technicians are at the core of spot inspection and maintenance, and are the responsible and manager of equipment maintenance.
In terms of professional technology: Have the basic knowledge of maintenance, master the relevant technical drawings and materials of the equipment, formulate inspection standards, determine the maintenance content, and combine the diagnostic technology of the instrument to quantitatively manage the main wear parts. In the stage of new equipment installation and commissioning, technicians actively participate and are familiar with each key link. After commissioning, manufacturers or suppliers are required to train relevant operators.
Special positions must not only have a certificate, but also have regular annual inspections.
In terms of management business: on the basis of carrying out inspection work, prepare various maintenance plan budgets, such as equipment maintenance plan, maintenance spare parts material plan, maintenance cost plan and various plans for inspection business, and make original records and information transmission , Arrangement and analysis of actual data, and continuously improve the management level of equipment inspection and maintenance.
In terms of handling business relations: correctly handle and coordinate the business relations between spot inspection, production and overhaul. Complete the coordination of each maintenance work and guide the post inspection work.
In terms of work style: Have a high sense of responsibility, do not shirk each other, and keep improving the inspection business.
4 Prerequisites for job inspection
4. 1 Change ideas to meet the requirements of new forms
As the company becomes stronger and bigger, operators need to have multiple jobs, not just operations, but more importantly, post inspection. The focus of work has changed and operators must change this concept.
4.2 Clarify responsibilities and improve post inspection responsibility system
Post inspection is one of the contents of equipment management, so it is necessary to establish a complete post inspection system and clarify corresponding responsibilities. When there is responsibility, there is pressure, and when there is pressure, motivation will be generated. Only when there is motivation, post inspection can be carried out smoothly. Secondly, it is necessary to formulate the necessary incentive mechanism, reward the good and punish the bad, inspire the enthusiasm of the operators, so that the post inspection can continue to develop.
4. 3 Strengthen training and exchange of experience
In order to effectively promote the job inspection, enable the operators to master the skills of the inspection work, be familiar with the inspection business procedures, and be able to independently complete the inspection work, it is necessary to do business training for the operators and maintenance workers. Secondly, do a good job of communication between posts, teams and workshops, and learn from each other. The equipment department organizes a post inspection exchange meeting every year to further improve the quality of post inspection and make equipment management a new platform.
4. 4 Two "improvements" must be achieved
Improve the "points" of the check points set by the existing equipment system, re-determine its scope, and further refine it to be as dense as possible, and the finer the better, without leaving any omissions.
Improve the existing inspection methods and require the inspectors to do the "three fines" when inspecting the equipment, that is, the inspection equipment is "careful", the inspection method is "fine", and the equipment operation status is judged to be "precise" . To achieve the "three fines", it is necessary to make a real effort and hard work to improve the ideological quality and professional skills of the inspectors.
4. 5 Do a good job in equipment maintenance
The so-called "overhaul" means inspection and repair. In the past, most of the maintenance projects were focused on repairs. Whenever there was a failure, the repair was done, and the inspection, that is, the spot inspection of the equipment, was ignored. As a result, it is easy to rush repairs, disrupt the continuity of production and cause passive phenomena. Every piece of equipment has its service life, and its service life is closely related to the environment, frequency of use, methods, and daily maintenance. At the same time, the appearance of equipment failure has some precursors, such as temperature, sound, vibration, and related monitoring data. Equipment inspection is to determine the condition of the equipment through the operation phenomenon of these equipment and related technical data. To do a good job in equipment inspection, the following aspects must be grasped:
Understand and master the operating rules and characteristics of equipment, and understand the production process.
Full-time inspection, three-shift inspection, and post operator inspection are responsible for three parties. Although each has its own focus, they complement each other and supervise each other. The inspection status is recorded in real-time on the equipment post inspection book and signed by the three parties.
The continuity of inspection. The equipment is always running, no matter what the situation, someone must check the equipment. At the same time, it is necessary to grasp the operation law of equipment, equipment inspection records should be tracked for a long time, and statistical summary analysis should be performed regularly.
Periodic inspection of equipment static. The static state of the equipment cannot be provided to the equipment manager at any time, so a scientific and reasonable overall plan must be implemented and implemented as planned.