I. Equipment Management Department and Staffing
1. Set up the equipment management department. The staffing should meet the needs of enterprise equipment management and maintenance, and all work should be managed and kept relatively stable.
2. There are factory leaders in charge of equipment work. The person in charge of the equipment management department should have a college education or above (or have a technical title above the intermediate level), be qualified through on-the-job training and have practical work experience.
3. Equipment management departments and departments related to equipment management have clear functions and responsibilities for equipment management.
4. Equipment management networks at all levels (factories, workshops and teams) are sound and their activities are normal.
5. The equipment maintenance organization is sound.
Second, the equipment management rules and regulations
According to national regulations and industry regulations, formulate and revise equipment management rules and regulations in a timely manner;
(1). Management system of special equipment [including boilers, pressure vessels (including gas cylinders), pressure pipes, lifting machinery and special motor vehicles in the factory];
2. Equipment pre-management (including equipment procurement and bidding management) system;
(3). Equipment asset management system;
(4) Equipment use and maintenance system;
5]. Equipment maintenance management system;
[6]. Equipment spare parts management system and so on.
Three. Determination of equipment management regulations and standards
All kinds of work standards, technical standards, safety operation procedures, maintenance procedures, overhaul procedures, work processes and technical documents for equipment management and maintenance are complete, correct and standardized.
Four. Technical and economic data statistics
Fill in the statistical report of equipment management on time and accurately, and make analysis and summary. The technical and economic indicators of equipment management should meet the requirements of the industry or relevant departments. Technical and economic indicators (see Appendix for statistical methods) include:
1. Safe operation of equipment:
(1). Regular inspection rate of special equipment;
(2) Frequency of equipment accidents;
(3). Equipment accident downtime;
(4) Equipment accident statistics.
2. Equipment technical indicators:
(1). The intact rate of main equipment and all equipment;
(2) Utilization ratio of major equipment and all equipment;
(3) Comprehensive efficiency of equipment;
(4) Leakage rate of dynamic and static sealing points;
(5) Completion rate of equipment overhaul plan;
(6) Instrument "three rates": intact rate, control rate and sample;
(7). Idle rate of equipment.
Verb (abbreviation of verb) equipment pre-management
1. The Equipment Management Department is responsible for or participates in the planning and bidding of equipment renewal, technical transformation, new projects, expansion projects, self-made equipment and sporadic equipment procurement.
2. The equipment management department should participate in the equipment selection, installation, commissioning and completion acceptance. Key equipment should participate in its technical and economic analysis and demonstration.
3. The equipment management department should participate in the research and approval of the self-made equipment design scheme.
4. The equipment management department is responsible for or involved in equipment selection, and puts forward requirements for spare parts, lubricating oil, equipment installation, debugging and maintenance.
5. The equipment management department should promptly feed back the defects in quality, function and efficiency found in the initial use of new equipment to the manufacturing unit, so as to urge the manufacturing unit to formulate and implement rectification measures to ensure that the quality, function and efficiency of the equipment meet the standards.
6. When purchasing equipment, it is necessary to master the qualifications and performance of manufacturing and sales units. When purchasing special equipment, according to the requirements of the Regulations on Safety Supervision of Special Equipment, the design qualification, production qualification and documents that the bidder should have at the corresponding level should be clearly specified in the bidding documents, and the products should be provided when leaving the factory. Don't buy illegal products.
7. It is strictly forbidden to purchase and use the process equipment that endangers production safety and is explicitly eliminated and prohibited by the state.
Technical basic management of intransitive verb equipment
1. Equipment technical files are complete. The custody of technical data conforms to the Technical Archives Management Regulations.
2. Equipment drawings, technical documents and completion data are complete and accurate; The technical documents, drawings and data required for special equipment shall be collected completely in accordance with the Regulations on Safety Supervision of Special Equipment.
3. The equipment spare parts catalogue is complete and the classification is clear; Spare parts have procurement (manufacturing) plan and reserve quota; The warehousing procedures for spare parts in stock are clear, the vouchers are complete, and the accounts, cards and materials are consistent; The warehouse should be clean, spare parts should be free from corrosion and damage, and should be properly kept.
4. Formulate equipment safety operation procedures for special equipment and general equipment, regularly train and assess the operators' equipment operation knowledge, and keep complete records.
5. The laws, regulations and provisions related to special equipment promulgated by national and local technical supervision departments are complete, and the equipment managers and operators are often publicized. Their operators should have operation certificates issued by relevant technical supervision departments and hold relevant certificates.
6. Special equipment shall be subject to the safety supervision of the technical supervision department, registered, and tested regularly, preventively and online according to regulations, so as to eliminate hidden dangers in time and ensure the use of special equipment within the validity period of inspection.
7. Special equipment should be managed by special personnel. According to the "Regulations on Safety Supervision of Special Equipment", special files are established, special safety operation procedures are formulated, and regular maintenance, maintenance and online detection are carried out in accordance with relevant national and provincial regulations, and records are made to ensure its normal operation.
8. The safety valve, explosion-proof module (membrane) and safety interlock device of the equipment shall be set up with ledgers, managed by special personnel, and regularly checked and calibrated online. Inspection and calibration records shall be filed.
9. The equipment accident should be unclear according to the cause of the accident; Accident prevention measures are not implemented; The person responsible for the accident has not been dealt with; The cadres and workers who have not received education shall be dealt with in accordance with the relevant provisions of the Regulations on Reporting, Investigation and Handling of Production Safety Accidents or the Regulations on Safety Supervision of Special Equipment.
Seven, equipment modernization management
1. Equipment ledgers, files, spare parts, equipment status, lubrication management, technical and economic indicators, reports, data and preparation of major repair plans are all managed by computers.
2. Strengthen the construction of equipment inspection system, adopt equipment condition monitoring and fault diagnosis technology, and gradually implement preventive maintenance mode based on condition maintenance.
3. Strengthen information management, keep abreast of the status of equipment in the same industry, adopt new materials, new processes and new technologies in equipment manufacturing, renovation and maintenance, and improve the output of equipment and devices.
4. Using scientific and advanced methods to monitor the state of various lubricating oils (including hydraulic oil) or using on-site rapid analysis methods to master the oil quality can be used as the basis for making a good lubrication plan.
Eight, equipment economic management
1. Pay attention to economic benefits in the whole process of equipment management. Technical and economic analysis and demonstration should be carried out for the purchase of new equipment and major transformation of equipment.
2 in accordance with the provisions of the full depreciation, depreciation expenses are mainly used for enterprise equipment renovation.
3. When preparing the equipment maintenance plan, the equipment maintenance cost budget plan should be prepared at the same time. Maintenance costs can only enter the production cost after accounting and implementation.
4. The financial department of the enterprise shall, jointly with the equipment management department, assess and statistically manage the equipment maintenance costs, and review and analyze the maintenance costs.
5. Carry out equipment operation efficiency analysis and kinetic energy economic accounting, improve equipment operation efficiency, reduce energy consumption level, and do a good job in kinetic energy control and energy saving.
6. Scrapping and configuration of equipment shall comply with relevant regulations, and assets shall be handed over according to relevant regulations.
7. The classification and numbering of equipment assets conform to industry standards, the equipment ledger and original data are complete and correct, and the accounts are consistent.
8. The acceptance, handover, relocation, deactivation, modification, renewal and scrapping of equipment assets are in compliance with regulations, and the documents are complete.
9. After the technical transformation of the equipment, the equipment value-added procedures shall be handled in accordance with the regulations.
10. Establish an idle equipment ledger, and do a good job in the declaration and adjustment of idle equipment.
Nine, equipment use and maintenance, maintenance
1. Operators shall be trained and assessed, and only after obtaining the post operation certificate can they hold relevant certificates.
2. Operators should master "four understandings (structure, principle, performance and use)" and "three meetings (use, maintenance and troubleshooting)", and implement post responsibility system, and implement monitoring responsibility system for equipment operated by many people.
3. Operators should strictly implement the equipment safety operation procedures, and the equipment operation parameters should meet the specified indicators (temperature, pressure, flow, current, etc.). ), the operation record should be clear, complete and true.
4. Operators should adhere to the daily maintenance and regular maintenance of equipment, and participate in equipment inspection. Equipment maintenance should meet the standards of neatness, cleanliness, lubrication and safety, and meet the requirements of clean and civilized production.
5. Assign personnel, machines and responsibilities to key and major production equipment; Implement the shift change system and maintain the equipment correctly.
6. Equipment maintenance personnel should implement the regional maintenance responsibility system, conduct regular inspection and maintenance, and the inspection and maintenance records are clear, complete and true.
7. The safety valve, explosion-proof module (membrane) and safety interlock device of the equipment shall be regularly maintained, checked online and calibrated. Inspection and calibration are recorded, and the records are true and complete.
8. Standby equipment should establish a regular trial system.
9. Idle equipment should be maintained regularly according to regulations.
X. Equipment Maintenance, Modification and Update
1. Equipment maintenance plan has basis and adjustment procedures. Equipment overhaul plan should be incorporated into the production plan of the enterprise and issued at the same time, organized and implemented by the equipment management department of the enterprise, and completed, summarized and assessed on schedule; Minor repairs or troubleshooting of equipment shall be arranged, inspected, summarized and evaluated by the workshop without affecting production; External repair equipment shall be implemented according to enterprise regulations.
2 large and medium-sized equipment repair should be issued a task book, including technical preparation, production preparation, safety precautions, working hours, spare parts, materials to be replaced, repair costs, etc.
3. When special equipment is overhauled, the overhaul unit must provide corresponding maintenance qualification certificates and special operation personnel qualification certificates for overhaul. In the maintenance task book, the qualification grade requirements for maintenance units and special operations personnel must be clearly put forward.
4. The maintenance of special equipment must be carried out at the same time as the regular inspection items of equipment. Testing work must be undertaken by qualified units, and the qualification requirements for testing units must be clearly defined in the maintenance task book. Those who fail the test must be stopped and replaced.
5. After the maintenance project is completed, it shall be inspected according to the quality standards stipulated in the equipment maintenance regulations, and the technical data and equipment handover procedures shall be handled.
6. There must be examination and approval procedures for technical transformation or update of in-use equipment. The technical scheme of renovation and update shall be demonstrated by the equipment management department, and implemented after being signed by the main leaders of the company and the responsible department is defined.
7. After the technical transformation or updating of the equipment is completed, the completion acceptance, asset appreciation and scrapping procedures of the updated equipment must be handled.
Eleven, do a good job of on-site management of equipment.
1. The workshop decomposes the equipment management objectives into teams and groups, with clear objectives and clear indicators, and conducts regular assessment and evaluation.
2. There are various equipment ledgers in the workshop, and the safety, technical and economic indicators and maintenance of equipment in the workshop have statistical data and original records. According to the requirements of classified management of enterprises, do a good job in the management of data and statements.
3. The production site operation room has equipment site management system (succession system, inspection system, lubrication management system, equipment maintenance system, etc. ), can be seriously implemented.
4. Regularly carry out the inspection of equipment in good condition and civilized production, with inspection and assessment methods and reward and punishment measures. The equipment production site is clean and civilized, and the equipment maintenance site has obvious regional signs and safety signs.
5. Do the daily maintenance of the equipment, and there is no obvious phenomenon of "running, running, dripping and leaking".
6. The operation parameters of the field equipment meet the specified indexes, and all kinds of original operation records and hand-over records are complete, filled in carefully and truly standardized.
7. Equipped with full-time (part-time) lubrication management personnel and lubrication workers, fully implement the "five-fixed" work of equipment lubrication (personnel, fixed point, timing, quality and quantity), carry out oil quality testing at lubrication stations and lubrication points, change oil on time, complete equipment lubrication records and good lubrication conditions.
8. All kinds of pipes, valves and pipe fittings shall be firmly supported, the pipelines shall be neatly arranged, the color code shall conform to the industry regulations, and the corrosion protection, heat preservation and insulation shall be good, without obvious "running, leaking, dripping and leaking" phenomenon. There are examination and approval procedures for temporary connection and distribution pipelines, and there are modification records after pipeline changes.
9. The running equipment has no vibration and noise exceeding the allowable limit, the equipment foundation and pipe rack are stable, and the anchor bolts are not loose.
10. Operators of special equipment shall hold relevant certificates, and the certificates shall be neat, effective and properly kept.