I. Equipment maintenance

Equipment maintenance refers to the maintenance of equipment by wiping, cleaning, lubricating and adjusting, so as to maintain and protect the performance and technical condition of the equipment. There are four main requirements for equipment maintenance:

(1) Clean the inside and outside of the equipment, and the sliding surfaces, screws, racks, gear boxes and oil holes of all parts are free of oil, oil and gas leakage, and the debris, sundries and dirt around the equipment should be cleaned up;

(2) Tools, accessories and workpieces (products) should be placed neatly, and pipes and lines should be organized;

(3) Good lubrication, timely refueling or oil change, no dry friction. The oil pressure is normal, the oil mark is bright, the oil path is smooth, the oil quality meets the requirements, and the oil gun, oil cup and linoleum are clean;

(4) Abide by the safety operation rules, do not overload the equipment, complete and reliable equipment safety protection devices, and eliminate unsafe factors in time.

Equipment maintenance generally includes daily maintenance, regular maintenance, regular inspection and precision inspection, and the maintenance of equipment lubrication and cooling system is also an important part of equipment maintenance.

Daily maintenance of equipment is the basic work of equipment maintenance, which must be institutionalized and standardized. Regular maintenance of equipment should establish labor quota and material consumption quota, and conduct assessment according to the quota. Regular maintenance of equipment should be included in the assessment of workshop contract responsibility system. Regular inspection of equipment is a planned preventive inspection. In addition to human senses, there must be certain inspection tools and instruments, which are carried out in the checklist regularly. Regular inspection is also called regular spot check. The accuracy of mechanical equipment should also be checked to determine the actual accuracy of the equipment.

Equipment maintenance should be carried out according to the maintenance procedures. Equipment maintenance procedures are the requirements and regulations for daily maintenance of equipment. Compliance with these requirements can prolong the service life of the equipment and ensure a safe and comfortable working environment. Its main contents should include:

(1) The equipment shall be neat, clean, firm, lubricated, anti-corrosive, safe and other operation contents, operation methods, tools and materials used, standards and precautions;

(2) the parts, methods and standards of daily inspection, maintenance and regular inspection;

(3) Check and evaluate the contents and methods of the operator's degree of equipment maintenance.

Second, the three-level maintenance system of equipment

Three-level maintenance system is a kind of maintenance system that has been gradually improved and developed in China since the mid-1960s, on the basis of summarizing the practice of planned pre-maintenance system in the former Soviet Union. It reflects the change of the focus of equipment maintenance management in China from repair to maintenance, the progress of equipment maintenance management in China and the clearer maintenance management policy of prevention first. The three-level maintenance system includes daily maintenance, first-level maintenance and second-level maintenance of equipment. Three-level maintenance system is a mandatory maintenance system with operator as the center and equal emphasis on equipment maintenance. Three-level maintenance system is an effective way to rely on the masses, give full play to their enthusiasm, implement group management and group maintenance, and combine special groups to do a good job in equipment maintenance.

(1) Daily maintenance of equipment

The daily maintenance of equipment generally includes daily maintenance and weekly maintenance, also known as daily routine maintenance and weekly routine maintenance.

1. Daily insurance

The equipment operator on duty shall perform daily work, and do four things before class, five things during class and four things after class.

(1) Arrange the pattern data of four things before the shift change, and check the shift change records. Wipe the equipment, and lubricate and add oil as needed. Check whether the handle position and manual operation position are correct and flexible and whether the safety device is reliable. Check whether the transmission is normal and whether the lubrication and cooling are smooth when running at low speed.

(2) Pay attention to operating sound, equipment temperature, pressure, liquid level, electrical, hydraulic and pneumatic systems, instrument signals and safety insurance.

(3) Turn off the four-object switch after work, and set all handles to zero. Remove iron filings and dirt, clean the oil stains on the guide rail surface and sliding surface of the equipment, and refuel. Clean up the work site, arrange accessories and tools. Fill in the handover record and operation time record, and go through the handover procedures.

2. Weekly guarantee

Weekly maintenance is conducted by equipment operators every weekend. The general maintenance time of equipment is 2h, and the maintenance time of fine, large and rare equipment is 4h.

(1) Externally clean the guide rail, transmission parts and exposed parts of the equipment, and clean the work site. Achieve cleanliness inside and outside, no dead ends and no rust, and the surrounding environment is clean and tidy.

(2) Control the transmission to check the technical condition of each component, tighten loose components and adjust the fit clearance. Check interlocking and safety devices. Transmission sound is normal, safe and reliable.

(3) Hydraulic lubrication cleans the oil circuit, dust cover and oil filter, and adds oil or changes oil in the oil tank. Check the hydraulic system to ensure that the oil quality is clean, the oil circuit is smooth, there is no leakage and no wear.

(4) The electrical system should wipe the surface of the motor and the snake skin tube, and check the insulation and grounding to achieve completeness, cleanliness and reliability.

(2) Primary maintenance

The first-level maintenance is given priority to operators, supplemented by maintenance workers. The equipment is partially disassembled and inspected as planned, the designated parts are cleaned, the oil lines and pipelines are dredged, the oil lines, linoleum and oil filters are replaced or cleaned, the fit clearance of each part of the equipment is adjusted, and each part of the equipment is fastened. The first-class maintenance time is 4-8 hours. After the first-level maintenance is completed, records shall be made and the uncleared defects shall be indicated, and the workshop mechanic shall organize the acceptance. The scope of the first insurance should be all the equipment in use of the enterprise, and the key equipment should be strictly implemented. The main purpose of the first warranty is to reduce the wear and tear of equipment, eliminate hidden dangers, prolong the service life of equipment and provide guarantee for the completion of production tasks until the next first warranty period.

(III) Secondary maintenance

Secondary maintenance is mainly completed by maintenance workers and operators. Incorporate the secondary maintenance into the equipment maintenance plan, partially disassemble, inspect and repair the equipment, replace or repair worn parts, and clean, change oil, inspect and repair electrical parts, so that the technical condition of the equipment can fully meet the requirements of the specified equipment integrity standards. The second maintenance takes about 7 days.

After the second guarantee is completed, the repairman should fill in the maintenance records in detail, which will be accepted by the workshop mechanics and operators, and the acceptance sheet will be submitted to the equipment power department for filing. The main purpose of the second maintenance is to make the equipment reach the intact standard, improve and consolidate the intact rate of the equipment, and extend the overhaul period.

To implement the "three-level maintenance system", operators must achieve "three good", "four meetings" and "four essentials" and abide by "five disciplines". Three-level maintenance system highlights the position of maintenance in equipment management and planned maintenance, which makes the requirements of "three good" and "four meetings" for operators more specific and improves the knowledge and skills of operators in equipment maintenance. The three-level maintenance system breaks through the relevant provisions of the planned pre-repair system in the former Soviet Union, improves some shortcomings in the planned pre-repair system, and is more practical. In the implementation of the three-level maintenance system, we also learned and absorbed some practices of the military in managing weapons, emphasizing group management and group repair. The three-level maintenance system has achieved good results and experience in China enterprises. Due to the implementation of the three-level maintenance system, the equipment integrity rate of enterprises has been effectively improved, the equipment accident rate has been reduced, the equipment overhaul cycle has been extended, and the equipment overhaul cost has been reduced, and good technical and economic effects have been achieved.

Three, fine, large and fine equipment use and maintenance requirements

Four jobs

(1) Specify the user. According to the system of "person-to-person, machine-to-machine", the operators of fine, large and rare equipment should choose people with strong sense of responsibility, high technical level and rich practical experience in their own jobs, and keep relatively stable for as long as possible;

(2) Fixed maintenance personnel. Enterprises with more refined, large and rare equipment can organize professional maintenance or repair teams of refined, large and rare equipment according to their own conditions, and be responsible for the inspection, precision adjustment, maintenance and repair of refined, large and rare equipment;

(3) Set the operating procedures. Fine, large and thin equipment should be compiled, displayed and strictly implemented by machine;

(4) Order spare parts. According to the function of various fine, large and rare equipment in enterprise production and the source of spare parts, the reserve quota is determined and given priority.

(2) Requirements for the use and maintenance of precision equipment

(1) The equipment must be installed in strict accordance with the instructions;

(2) Enterprises that have special requirements for the environment (constant temperature and humidity, earthquake prevention and dust prevention) should take corresponding measures to ensure the accuracy and performance of the equipment:

(3) During the daily maintenance of the equipment, it is not allowed to disassemble the parts. If any abnormality is found, stop the machine immediately, and work with illness is not allowed;

(4) Strictly implement the cutting specifications specified in the equipment manual, and only allow the parts to be used directly after processing. The machining allowance should be as small as possible. When processing castings, the surface of the blank should be sandblasted or painted in advance;

(5) The protective cover should be added during non-working hours, and it should be wiped, lubricated and idling regularly when it is stopped for a long time;

(6) Accessories and special tools should be put in a special cabinet, kept clean to prevent abrasion, and shall not be checked out.

Four, the use and maintenance requirements of power equipment

Power equipment is the key equipment of enterprises, and there are high temperature, high pressure, flammability, toxicity and other dangerous factors in operation, which is the key part to ensure safe production. In order to ensure the safe, continuous and stable supply of kinetic energy needed for production, there should be special requirements for the use and maintenance of power equipment:

(1) Operators must be trained in advance and pass the exam;

(2) There must be complete technical data, technical regulations for safe operation and operation records;

(3) Operators shall patrol and inspect at any time during the duty, and shall not leave their posts at will;

(4) If any abnormal situation is found in the operation, the personnel on duty shall make emergency treatment according to the operation procedures and report to the superior in time;

(5) Ensure that all kinds of indicating instruments and safety devices are sensitive and accurate, and check them regularly. The standby equipment is complete and reliable;

(6) Power equipment shall not be operated in spite of illness, and faults must be eliminated in time;

(7) Regular preventive tests and seasonal inspections;

(8) Conduct regular safety education for the personnel on duty and strictly implement the security system.

Verb (abbreviation of verb) regional maintenance of equipment

Regional maintenance of equipment is also called maintenance package mechanism. The repairman undertakes the maintenance of equipment in a certain production area, completes the daily maintenance, patrol inspection, regular maintenance, planned maintenance and troubleshooting together with the production operators, and is responsible for completing the assessment indicators such as the equipment intact rate and fault shutdown rate in the area. Regional maintenance responsibility system is a good form to strengthen the maintenance of production equipment, mobilize the enthusiasm of maintenance workers and make production workers take the initiative to care about equipment maintenance.

The main organization form of equipment professional maintenance is regional maintenance group. The regional maintenance team is fully responsible for equipment maintenance and emergency repair in the production area, and its tasks are:

(1) Be responsible for the maintenance and repair of equipment in this area, and ensure the completion of equipment integrity rate, failure rate and other indicators;

(2) Seriously implement the system of regular spot inspection and regional inspection of equipment, and guide and urge operators to do daily maintenance and regular maintenance;

(3) Under the guidance of workshop mechanics, participate in equipment condition investigation, precision inspection, adjustment, leakage control, and conduct fault analysis and condition monitoring.

As an organizational form of equipment maintenance, the regional maintenance team has the advantages of high mobility when completing emergency repair, which can minimize the downtime of equipment maintenance, and the locksmith on duty can complete various preventive operations and participate in planned maintenance without being called.

The division of equipment maintenance area should consider the distribution of production equipment, equipment status, technical complexity, production needs and the technical level of assemblers. Workshop equipment can be divided into several areas according to the above factors, and regional maintenance groups can also be divided according to equipment types. The equipment of the assembly line should be divided into maintenance areas according to the production line.

The regional maintenance team shall make a plan for regular inspection and accuracy inspection, and specify the time for routine inspection of equipment in each shift. In order to make these work not affect the production, the planned inspection of the equipment should be arranged in the non-working days of the factory, and the routine inspection of each shift should be arranged during the lunch break of the production workers.

Six, measures to improve the level of equipment maintenance

In order to improve the level of equipment maintenance, the maintenance work should be basically standardized, technical and institutionalized.

Standardization is to unify the maintenance content, which parts should be cleaned, which parts should be adjusted and which equipment should be inspected, which should be considered and stipulated according to the situation of each enterprise and objective laws.

Technicalization is to formulate various maintenance procedures according to different equipment and carry out maintenance according to the procedures.

Institutionalization is to stipulate different maintenance periods and times according to different working conditions of different equipment and strictly implement them.

For regular maintenance work, man-hour quota and material consumption quota should be formulated and assessed according to the quota.

Equipment maintenance work should be assessed in combination with the enterprise production economic contract responsibility system. At the same time, enterprises should also mobilize the masses to carry out equipment maintenance work combining special groups, conduct self-inspection and mutual inspection, and carry out equipment inspection.