In order to make the preventive maintenance, routine maintenance, spare parts management and maintenance performance operation of the company's production equipment have rules to follow, so as to maintain the normal operation of production equipment, reduce the failure rate and improve productivity, this method is specially formulated.
Scope of Article 2
The maintenance of all production machinery, gas meters and public equipment shall be handled in accordance with the provisions of these Measures, including:
1 Division of responsibilities and responsibilities of the handling unit.
2. Establishment of equipment reference data.
3. Establish a maintenance and lubrication plan.
4. Implementation and inspection of maintenance and lubrication plan.
Please repair the fault.
6 spare parts application and management.
7 Electric welding and gas welding operation management.
8. Review of maintenance performance.
Article 3 Name and functions of the organization
First, the names of departments and related personnel mentioned in these Measures are compiled according to the existing institutions.
Second, when the organizational structure is adjusted, the general manager's office will convene relevant personnel for review and discussion.
Article 4 Division of powers and responsibilities of handling units
I. Processing unit
(1) Management Department: The accounting department is the management department of the company's equipment.
(2) maintenance department.
1. The maintenance unit of the production department (divided into mechanical unit and motor unit due to work needs) is responsible for the maintenance of construction equipment, mechanical equipment, storage equipment, electrical instrumentation equipment and miscellaneous equipment related to production business.
2. General Affairs Unit of Administration Department: responsible for other equipment maintenance of public engineering units in non-production departments.
3. User department: responsible for the maintenance and repair of the equipment used. Where the user departments are indistinguishable, the management department is the user department.
Second, the responsibilities of relevant departments
(a) management department:
1. Establishment and classification of equipment account.
2. Cooperate with the maintenance department to establish various equipment maintenance operation specifications.
3. Supervise all user departments to perform maintenance work according to the specifications.
4. The equipment used shall be counted by the department using the formal contract, and its operation mode shall be handled according to the Company's Equipment Inventory Management Operation.
5. Check whether the name, specification and quantity contained in the equipment registration card are consistent with the actual situation at any time.
6. Label the equipment to facilitate the keeper and inventory.
(2) Maintenance Department
1. Assist in the installation, debugging and acceptance of newly purchased equipment.
2. Execution of fault repair.
3. Formulation and implementation of regular maintenance plan.
4. Abnormal reaction of equipment use and failure cause analysis.
5. Application, supervision and acceptance of external repairs.
6. Implementation and tracking of energy-saving plan.
7. Check the lubrication maintenance and lubrication implementation of the user department.
8. The establishment of equipment files.
9. Suggestions on updating or scrapping idle equipment.
10. Follow up the implementation of work improvement and equipment improvement plan.
1 1. Use control and audit of spare parts.
12. Other matters assigned by superiors.
(2) Equipment using department
1. Assist in the installation, debugging and acceptance of newly purchased equipment.
2. Clean and tidy the equipment and keep the surrounding environment clean and tidy.
3. Maintain the equipment according to the maintenance and lubrication standards.
4. Assist in regular maintenance and troubleshooting of equipment.
5. Put forward suggestions for equipment improvement.
6. Other matters assigned by superiors.
Article 5 Establishment of basic data of equipment
First, establish basic equipment information
(1) After the installation and debugging of new equipment is completed, the owner and customer of the maintenance unit are responsible for establishing the original equipment registration form (table 1) according to the equipment specifications and other materials, and the relevant specifications and drawings are classified into the equipment maintenance file management.
(2) If there are any equipment changes such as improvement and replacement, the director of the public works unit shall correct the data according to the actual changes.
(3) The contents of equipment maintenance files shall include:
1. Important elements of the equipment.
2. Installation and debugging status.
3. Spare parts list.
4. Check the benchmark.
5. Lubrication benchmark.
6. Maintain records.
7. Lubrication records.
8. Cause analysis and countermeasures of equipment failure.
Second, the conclusion of the equipment inspection benchmark
1. After the completion of equipment installation and trial operation, the supervisor of the engineering unit shall prepare the equipment inspection matrix (Table 2) including equipment inspection items, inspection methods, judgment standards, treatment methods, inspection cycle, inspectors and other items according to the characteristics of equipment drawings, maintenance instructions and operating conditions.
2. After the Equipment Inspection Matrix is completed, the manager of the production department will call the owner of the user to overturn the audit and submit it to the general manager for approval, promulgation and implementation.
Third, establish the equipment lubrication benchmark.
1. The director of the public works unit shall formulate the equipment lubrication reference table for the existing equipment according to the equipment data, lubrication instructions and operating conditions, and other data, such as lubricating parts, grease used, inspection period, oil change reference and the person in charge of each equipment (Appendix 3).
2. After the Equipment Inspection Matrix is completed, the manager of the production department will call the owner of the user to overturn the audit and submit it to the general manager for approval, promulgation and implementation.
Article 6 inspection and maintenance of lubrication plan
First, the annual inspection and maintenance lubrication plan
The supervisor of the maintenance unit shall draw up the annual regular maintenance schedule (Annex 4) for the next year according to the "Inspection of Lubrication Benchmark" and the equipment operation in June 5438+February every year, and submit it to the General Manager for approval in coordination with the setting of production and sales targets, with one copy for self-storage, one for the production department office, one for the user and one for the general manager's office for future reference.
Second, the monthly inspection and maintenance of lubrication plan
1. Before 25th of each month, the supervisor of the maintenance unit shall draw up a monthly inspection and maintenance plan (Annex 5) and a monthly lubrication plan (Annex 6) in quadruplicate according to the annual regular maintenance plan and referring to the actual maintenance status, production and sales targets and spare parts of the equipment in the current month, and submit them to the general manager for approval, one for self-storage, one for the survival department office, one for the user and one for the user.
Article 7 Inspection, maintenance and lubrication operation implementation
I. Daily inspection and maintenance of lubrication
Maintenance units and equipment users shall carry out daily maintenance and lubrication operations in accordance with the provisions of "maintenance benchmark" and "lubrication benchmark".
(1) Assign lubrication personnel for daily inspection and maintenance.
1. Equipment operators are lubrication personnel for daily inspection and maintenance.
2. The supervisor of the equipment user can assign relevant personnel to assist according to the working conditions.
3. The daily inspection and maintenance personnel of the public engineering unit shall be conducted by the person in charge of the public engineering unit.
(2) Carry out daily inspection and maintenance lubrication.
1. Maintenance and lubrication personnel in each shift shall be included in the independent inspection items of equipment at all levels, and shall be inspected item by item.
2. The daily maintenance of lubrication shall be checked item by item by the person in charge of the early shift at work that day.
3. If it is a weekly routine maintenance and lubrication, the supervisor of the user unit will assign a special person to check it item by item after completion.
4. The above-mentioned inspectors shall fill in and compile the Equipment Maintenance Checklist (Annex 7), and fill in two copies after being reviewed by the unit supervisor and reported to the production manager for instructions, one for self-storage and the other for filing and management in the production office.
Five, regular downtime for maintenance.
The maintenance unit should refer to the Maintenance Request Form (Table 8) in addition to the friend inspection and maintenance schedule and the friend lubrication schedule, and call the person in charge of the equipment use department to review the practice of shutdown and maintenance and the cooperation of personnel before regular shutdown and maintenance.
Article 8. Please repair the fault.
I. Abnormal reaction
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Second, the factory maintenance
1. When the supervisor of the maintenance unit goes to work every day, he should put forward maintenance requirements according to the items that were not maintained before yesterday. Regular maintenance plan and daily check the workload of operation, assign the maintenance work of subordinates and arrange maintenance work.
2. When the supervisor of the public works unit receives the "Emergency Repair Request Form", he should send someone to carry out emergency repair as soon as possible according to the severity of the fault and the working conditions of the personnel, so as to strive for timely repair.
3. "Maintenance Application Form" in triplicate. After completion, the maintenance unit records the maintenance process, determines the cause of the failure, and is accepted by the supervisor of the maintenance requesting unit. After verification by the production manager, one copy of the repair application unit will be included in the mechanical file, one copy will be kept by itself, and the other copy will be transferred to the repair application unit.
Third, entrust external repair.
1. When the repair of equipment needs to be entrusted for external repair due to the factory's lack of technical ability, timeliness or repair tools, the person in charge of the maintenance unit is responsible for the repair arrangement and cost estimation. After consulting the price of the appropriate manufacturer, drawing up the name and place of the entrusted manufacturer, filling in the "Requisition Form" and "Ex-factory Certificate Form" and submitting them to the manager of the production department for approval, the purchasing department is entrusted to handle the external repair manually.
2. When entrusting external repair, the maintenance unit shall grasp the implementation situation and provide information, maintenance acceptance and other matters.
3. After entrusting the outsourcing maintenance, the maintenance unit shall indicate the maintenance manufacturer and contractor on the "Maintenance Application Form" and submit it to the production manager for verification before closing the case (the process is the same as Article 8, paragraphs 2 and 3).
Article 9 Management of Inventory Parts
I. Definition of name
1. Control spare parts in stock
All spare parts required for production equipment, whose unit or combined unit price exceeds that of 500 yuan, or need to be imported from abroad or specially manufactured, and the delivery time exceeds three days, need to prepare an appropriate amount of inventory, and set an inventory benchmark to control important parts.
2. General spare parts in stock
Spare parts required for production equipment, whose unit price or combined unit price is lower than that of common parts in 500 yuan, should be purchased from nearby markets at any time and used frequently.
Second, the management unit
1. The control unit of "Control Inventory Parts" is the production department and the collecting unit is the maintenance unit.
2. The control unit of "General Stock Parts" is the maintenance unit.
Third, the basic quantity benchmark setting
(A) the project and setting method
1. on-hand inventory: it depends on the most suitable inventory quantity at present.
2. Minimum inventory: it depends on the amount needed from application to factory entry.
3. Maximum inventory: set in consideration of supply location, traffic restrictions, parts nature, quantity and other factors.
4. Set monthly consumption: set according to previous collection records and annual production variation factors.
5. Purchase cycle: consider the purchase cycle plus the number of days of factory acceptance.
(b) Control method of "spare parts control in stock"
1. The office of the production department shall establish a "controlled inventory parts matrix".
2. When the existing inventory is lower than the minimum inventory, the production department office shall issue the Supplementary Notice of Controlled Inventory Parts (attachment 10) to inform the maintenance unit, and issue a purchase requisition accordingly.
3. When the actual annual consumption exceeds the annual consumption, the production department and office should open a "Control Parts Variance Reflection Sheet" to reflect to the maintenance unit, explain the reasons or suggest to put forward the revised consumption, and after the approval of the production department manager, the production department and office should sign back to correct the "Control Inventory Parts Inventory Benchmark Setting Sheet".
4. When receiving the inventory controlled object, fill in the "Receiving Form" (table 1 1) and get it from the production department office.
(3) Control method of general inventory parts
1. The maintenance unit shall establish a "General Inventory Parts Inventory Table".
2. The maintenance unit shall list the monthly inventory status and consumption status of common parts, submit them to the production manager for approval, and then issue a purchase requisition accordingly.
Fourth, review regularly.
(1) "Spare parts under control in stock"
1. The accounting department will make a comparison chart at the end of each quarter and submit a report to the management meeting of the company to understand the implementation performance. If there is any difference, the general manager's office will make a follow-up report.
2. At the end of each quarter, the production department calls relevant units to review the operation of spare parts in stock, and whether it is reasonable to set the benchmark at (1); (2) Whether the supply of spare parts with appropriate quality, quantity and time has been realized, so as to reasonably reduce the inventory.
(2) "Common stock parts"
Every month, the manager of the production department will find out whether there is waste, waste, abnormal use, etc. on the consumption statistics table of common parts, so as to reduce the consumption amount.
Article 10 Management of electric welding and gas welding operations
First, the preparation work before construction
The use of units or maintenance units to deal with the following matters after inspection, can be allowed to construction.
(1) Fire fighting measures: Appropriate fire extinguishers and water should be prepared at the construction site, and the operators should know the location and usage of fire fighting equipment.
(2) Safety measures: protective masks and gloves. Wear safety helmet and safety belt when working at height.
(3) On-site safety measures: whether the machinery used has stopped, whether the pressure and liquid in the pipeline or storage tank have been completely eliminated, and whether the steel cylinder pressure valve and pipeline joint are leaking electricity, etc.
Second, the matters needing attention in the construction
At least one maintenance unit personnel shall be present to supervise the electric welding and gas welding operations, and pay attention to the following matters:
(a) when working near factories or inflammable and explosive places, fireworks should be strictly prohibited.
(2) It is forbidden to put the covered electrode of electric welding and gas welding in a red state.
(3) Sparks generated by electric welding and gas welding should be prevented from splashing around.
(four) whether the gas cylinder is firmly placed and whether the pressure valve is normal.
(5) Flammable and explosive articles shall be removed, and the outlet valve of steel cylinder shall not be stained with oil.
(6) Dust on the job site should be removed.
(seven) the use of machinery should be confirmed to stop.
(eight) shall not be connected to the power supply without authorization, and the person in charge shall apply to the motor unit for connection.
(nine) the use and repair of electrical equipment should be supervised by an electrician.
Three, after the construction before leaving should do the following:
(a) Clean up the site residues, sparks, ironware and covered electrode, etc.
(2) The tools and equipment used shall be removed from the site.
(3) welding and cutting site, the upper and lower floors should be guarded by personnel, and they can leave only after confirming safety.
Article 1 1 Maintenance Performance Review
A, regular maintenance lubrication progress review:
(1) Before the 5th day of each month, the supervisor of the maintenance unit should immediately fill in the actual progress of the Monthly Periodic Maintenance Plan and the Monthly Lubrication Plan Implementation Form according to the actual maintenance and lubrication overhaul work last month, and submit them to the production manager for instructions, one for filing and one for the general manager's office.
(2) If the project is not implemented as planned, the reasons shall be explained, and the makeup date shall be drawn up. After the approval of the production manager, it will be arranged to be implemented in the schedule of next month.
(three) the inspection responsibility of each user unit (called first-class maintenance) shall be borne by the maintenance unit.
Second, the maintenance performance statistics:
(1) Before the 5th day of each month, the supervisor of the maintenance unit shall report the maintenance performance statistics in triplicate according to the maintenance application form, shift work log and monthly regular maintenance (lubrication) schedule, and submit them to the manager of the production department for review, one for self-storage, one for the production department office and one for the general manager's office for future reference.
Article 20 Implementation and revision
These Measures shall be implemented after being approved by the General Manager, and the revision time shall be changed.