●●●****Company Safety Production Management System

Renzi [2011] No. 0013 Issuer:

1. For the health of all employees Healthy and create a good and orderly working environment, these rules and regulations are specially formulated;

2. Personnel who have not been trained by the company or authorized by the supervisor are not allowed to operate any machinery and equipment;

3 , Machine operators should strictly pay attention to personal clothing, and it is strictly prohibited to bring earrings, jewelry, pets, etc. into the operating room;

4. Machinery and equipment operators must be proficient in operating procedures and operate as required, and illegal operations are strictly prohibited. ;

5. Machinery and equipment operators should strictly check whether there are oil leaks, electricity leaks, etc. before and after production, and report them.

6. During the operation of the equipment, you should always pay attention to the operating conditions, and do not doze off or leave your job; if any abnormalities are found, you should report for repair in time;

7. Machinery and equipment operators are strictly prohibited from working before work Drink alcohol to prevent accidental injuries. Special types of work must hold a certificate;

8. When cleaning and cleaning machinery and equipment, the power supply should be cut off first;

9. It is strictly forbidden to flush water into the motor and control of the equipment. System part; It is strictly prohibited to use water to flush power supply equipment, circuit systems, power switches, electrical control boxes, electrical control cabinets, exhaust fans and other electrical facilities, and it is strictly prohibited to do cleaning and sanitation work when the machinery and equipment are running;

10 Non-equipment maintenance personnel are strictly prohibited from dismantling or modifying machinery, equipment and power systems without permission;

11. When handing over a shift and leaving the machine after work, equipment operators, workshop directors and foremen should inspect equipment, circuit systems, Whether the water supply system, workshop door locks, warehouse door locks, etc. are closed;

12. Each workshop and warehouse must be equipped with corresponding fire protection facilities. When there is no fire, it is strictly prohibited to use or damage fire-fighting facilities;

13. Equipment operators should position molds, operating tools, etc. at fixed points;

14. Equipment operators should clean up on time Raw materials, finished products, tools, operating tables;

15. Actively learn, improve each other, respect workshop masters, leaders, and colleagues;

16. Other regulations are added at any time during the work process ;

17. These regulations will come into effect from the date of enactment;

●●●****Company Equipment Management System

Renzi [2011] Issuer No. 0012:

In order to ensure that the company's equipment and facilities are in good condition, ensure the safe and good operation of the equipment and facilities, maintain production order, and ensure that the maintenance costs of the equipment and facilities are at the lowest level, this system is specially formulated:

1 Equipment management responsibilities

1.1 The R&D department, quality inspection department, production department and other departments are responsible for organizing company leaders and other relevant personnel to plan equipment capabilities and propose equipment capability requirements based on product process and quality requirements. Select device model.

1.2 The Procurement and Supply Department is responsible for organizing relevant personnel to confirm, conclude equipment contracts, and apply for payment.

1.3 The Equipment Department is responsible for organizing preliminary work such as equipment acceptance, installation, and debugging.

1.4 The Equipment Department is responsible for organizing the preparation of company equipment ledgers, equipment files, equipment data registration forms, equipment use and maintenance procedures and other management documents.

1.5 The production department is responsible for organizing the capability acceptance work before the equipment is officially put into use.

1.6 The production department is responsible for the use of equipment and daily maintenance during use, abnormal repair work, and safe use of equipment.

1.7 The Equipment Department is responsible for organizing equipment maintenance, primary maintenance, secondary maintenance, emergency repair and other work.

1.8 The Mechanical Maintenance Department is responsible for organizing regular assessments of the capabilities of the equipment in use.

1.9 The Equipment Department is responsible for the safety management of equipment.

2 Equipment data management

2.1 Establishment of basic equipment data

2.1.1 After the newly purchased equipment arrives at the factory, the equipment department organizes the equipment using units and the purchasing department to Wait for the acceptance by relevant departments, inventory the equipment, accessories, tools, etc. according to the purchase contract, equipment manufacturer's random list, etc., and check the surface condition of the equipment. After the acceptance is completed, the equipment department collects all acceptance data and establishes the "Equipment Information Registration Form".

2.1.2 After the installation and debugging are completed, the equipment department will supplement the "Equipment Information Registration Form" according to the equipment instructions and other information, and include relevant instructions, drawings and other information into equipment file management.

2.1.3 When equipment changes such as improvement or replacement, the leading unit should submit correction data according to the actual change situation and enter it into the equipment file.

2.1.4 The equipment file content should include:

Important parts of the equipment

Installation and commissioning status

Spare parts details

Integrity standards

Lubrication standards

Equipment failure causes analysis and countermeasures, previous important changes, etc.

2.2 Establishment of equipment integrity standards

After the equipment installation and commissioning is completed, the equipment department should prepare inspection items for the equipment based on equipment drawing characteristics, maintenance instructions, operating conditions and other information. Inspection methods, requirements and judgment standards, inspection cycles, inspection personnel and other items form the "Equipment Integrity Standard Table".

3 Formulation of equipment use and maintenance procedures

3.1 General requirements

Equipment use and maintenance procedures are formulated based on equipment use, maintenance instructions and production process requirements , regulations used to guide the correct operation, use and maintenance of equipment. Each equipment user must comply with the equipment usage and maintenance procedures.

3.2 Formulation and modification

3.2.1 The equipment department divides equipment into: important equipment ( Three levels: Category A), main equipment (Category B), and general equipment and tools (Category C) form the "Equipment Classification Management List" to facilitate the preparation of procedures and hierarchical management of equipment.

3.2.2 All Class A and B equipment installed and in use must have complete usage and maintenance procedures.

3.2.3 For newly put into production equipment, the equipment department shall be responsible for formulating a draft usage and maintenance procedure within one week before the equipment is officially put into use, and issue and implement it.

3.2.4 Based on the draft of the use and maintenance procedures, the equipment usage department will put forward opinions on the use and modification of the draft one month after the equipment is put into use, and the equipment will be responsible for the actual use and problems discovered. Under the leadership of the department, organize the machine maintenance department, R&D department and production department to counter-sign the equipment use and maintenance procedures, form a formal document, and implement it.

3.2.5 When new processes and technologies are adopted, after the process and technology are confirmed, the equipment department must complete the modification, countersigning and release of the new procedures within one week to ensure the effectiveness of the procedures.

3.2.6 During the implementation of the procedures, if the on-site personnel find that the content of the procedures is incomplete, they will directly report it to the workshop director. The workshop director will contact the equipment professionals to verify and confirm on-site, and add or modify the content of the procedures. , the countersigning and publishing process shall be carried out in accordance with 2.2.5.

3.2.7 Newly written or revised procedures must be in accordance with the principles of professional management and take effect after being approved by the vice president in charge.

3.2.8 For procedures that have been revised many times in a short period of time, resulting in substantial changes in substantive content, and procedures that have not been revised and reviewed within one year, the Equipment Department will organize re-revision, countersigning, approval and release every year, and recycle them at the same time. The original regulations are invalidated.

3.2.9 When a serious defect occurs in the equipment and it cannot be stopped immediately for repair, the equipment department and relevant technical departments shall formulate reliable temporary use measures, which shall be implemented after approval by the deputy general manager in charge. The temporary measures shall be taken after the defect is eliminated. Immediately void.

The main contents of 3.3 regulations

3.3.1 Equipment usage regulations

Equipment technical performance and allowable limit parameters, such as maximum load, pressure, temperature, voltage , current, etc.;

Regulations on the handover and use of equipment. For equipment that operates continuously in two or three shifts, the personnel at the post must hand over the operating status of the equipment when handing over the shift. The content includes: abnormal conditions in the operation of the equipment, the original Changes in defects, changes in operating parameters, faults and handling conditions, etc.;

Steps to operate the equipment, including preparations before operation and operating sequence;

Emergency handling regulations;

Safety precautions when using the equipment. Operators other than those in this position are not allowed to operate the machine without approval. No one is allowed to remove or relax safety protection devices at will;

Equipment operation Troubleshooting.

3.3.2 Equipment maintenance procedures:

Equipment transmission schematic diagram and electrical schematic diagram;

Equipment lubrication "five fixed" diagrams and requirements;

Regulations on regular cleaning;

Various inspection requirements during the use of equipment, including route, location, content, standard condition parameters, cycle (time), inspector, etc.;

Scrap standards for main wearing parts of equipment;

Safety precautions.

4 Equipment lubrication management

4.1 Establishment of equipment lubrication standards

4.1.1 The equipment department shall review existing equipment based on equipment data, lubrication instructions, and operating conditions. etc., establish the lubrication parts, grease used, inspection intervals, oil change standards, etc. of each equipment to form the "Equipment Lubrication Standard Table".

4.1.2 The Equipment Department formulates a complete "Five Certainty" charts for equipment lubrication for each piece of equipment, and publishes and implements them.

4.2 Requirements

The equipment department has a lubrication specialist (part-time) who is responsible for the professional and technical work of equipment lubrication; the equipment usage workshop (team) designates specialized personnel to be responsible for the lubrication of the equipment.

Carry out the three types of oil cleaning for equipment (oil barrels, oil utensils, and refueling points) to ensure that the lubricating oil (grease) is clean and the oil circuit is smooth to prevent clogging.

Lubrication professionals should do a good job in promoting new equipment lubrication technologies and upgrading oil products.

Conscientiously implement the recycling and management of waste oil.

4.3 Formulation and implementation of the "Five Certainties" chart for lubrication

The "Five Certainty" charts for lubrication of production equipment must be drawn up one by one (or as an attachment to the use and maintenance procedures), and used and maintained Regulations are released at the same time.

Contents of the "five fixed points" chart for equipment lubrication:

- Fixed points: stipulates the lubrication position, name and number of refueling points;

- Fixed points: stipulates each The grade of lubricating grease at the refueling point;

-Timing: stipulates the time for adding and changing oil;

-Quantitative: stipulates the quantity of oil added and changed each time;

- Designate: Specify the person in charge of each oil filling and changing point.

Lubrication professionals should regularly check the implementation of the "Five Certainty" charts for lubrication, conduct irregular audits, and deal with problems in a timely manner if problems are found.

Position operation and maintenance personnel must pay attention to the lubrication status of each part of the equipment at all times, and report and handle problems in a timely manner if problems are found.

4.4 Quality management of lubricating grease During the operation of the equipment, the lubricating grease will deteriorate due to the influence of the machine parts themselves and external dust, moisture, temperature and other factors. In order to ensure the quality of lubricating oil, it needs to be replaced regularly. The equipment department stipulates different replacement cycles according to different equipment and arranges their execution. Oil fittings, fuel tanks and pipelines must be cleaned before oil replacement.

5 Daily inspection of equipment operation

5.1 Overall purpose: Through certain means, maintenance and management personnel at all levels can firmly control the operation of the equipment. Develop corresponding measures, some of which can be implemented simultaneously with the three-level maintenance depending on the actual situation.

5.2 Establishment of equipment inspection standards. Based on the structure and operation mode of each piece of equipment, the equipment department determines the inspection parts (inspection points), content (what to inspect), and normal operation parameter standards (allowable value), executor, and based on the specific characteristics of the equipment, determine a clear inspection cycle for each inspection point of the equipment, which can generally be divided into hours, shifts, days, weeks, ten days, months, etc., forming the "Equipment Inspection surface".

5.3 Operation and audit of spot inspections

Each executor is responsible for setting up and executing spot inspections in accordance with the standards. The equipment department has plans to arrange personnel to audit the execution status of spot inspections in order to fully understand Equipment operation dynamics, and review problems that arise during equipment operation at any time.

5.4 Feedback and application of inspection information

All information found during inspections must be recorded, regardless of whether it is handled on site.

The Equipment Department is responsible for classifying and summarizing inspection problems on a weekly basis and forming electronic documents in a fixed format for analysis, use and comprehensive management.

All inspection problems (faults, hidden dangers, etc.) should be included in the next maintenance plan.

Significant defects and failures should be reported immediately to the Vice President of Production in order to determine control and treatment plans.

6 Equipment care and maintenance

6.1 Division of equipment maintenance - "three-level" maintenance

Daily maintenance: The operator is responsible for the daily maintenance of the equipment. Before and after work, operators will carefully inspect, wipe every part of the equipment or add oil for maintenance to keep the equipment lubricated and clean. If equipment malfunction occurs during the shift, it must be promptly eliminated or reported for repair, and records of shift handover must be carefully made.

First-level maintenance: Operators are the main ones, maintenance workers participate, and the equipment is partially disassembled and inspected, cleaning specified parts, clearing the oil lines, adjusting the matching clearance of various parts of the equipment, fastening various parts of the equipment, etc. . After the equipment has been running for 600 hours, it needs to undergo a first-level maintenance.

Second-level maintenance: Mainly maintained by maintenance workers, with the participation of operating workers, partial disassembly of equipment, inspection and repair, replacement and repair of worn parts, partial restoration of accuracy, cleaning of lubrication system, oil change, gas and electrical system Inspection and repair etc. Secondary maintenance is required after the equipment has been in operation for 3,000 hours.

6.2 Specific requirements for daily maintenance of equipment

Check the equipment carefully before work, perform inspections as required, and perform lubrication and refueling as required.

Comply with equipment operating procedures and use equipment correctly during the class.

If hidden dangers are found in the class, they should be eliminated in time. If they cannot be solved by themselves, they should immediately notify the maintenance personnel to deal with them.

After work, clean and lubricate equipment. For Class B equipment, 15-30 minutes should be extended appropriately for Class A equipment. Oil lines, oil holes and other parts must be thoroughly cleaned once a week, and parts such as the pressure head and cutter must be thoroughly cleaned once a day.

Do a good job in shift handover and record the day's equipment operation in detail in the shift record.

Insist on a small sweep every day, a big sweep on weekends, and a thorough sweep before the end of the month and the holidays. Class B equipment is cleaned for about 1 hour on weekends, and Class A equipment is cleaned for about 2 hours; at the end of the month, Class B equipment is cleaned for 1-2 hours, and Class A equipment is cleaned for 2-4 hours; holiday maintenance is performed according to prescribed maintenance standards.

6.3 Equipment maintenance

Equipment maintenance includes improved maintenance, potential fault repair maintenance and preventive maintenance to improve equipment operating efficiency, extend service life and reduce sudden failure time For this purpose, the actual project can be carried out in conjunction with the third-level maintenance of the equipment, led by the equipment department. Specifically, the plan should be submitted to the production planning supervisor, and implementation will be arranged after confirmation by both parties.

6.4 Planning and execution of equipment maintenance and maintenance

6.4.1 First-level maintenance, second-level maintenance and daily maintenance are all carried out in accordance with the operation mode of planning, confirmation and execution. Daily maintenance Carry out according to the determined content, fill in the "Equipment Maintenance Record" after the first-level maintenance and second-level maintenance are completed.

6.4.2 The equipment department submits the second-level maintenance plan on an annual basis and the first-level maintenance and daily maintenance plans on a monthly basis. The plan will be entered into the plan after confirmation by the production planning supervisor and approval by the company leader. execution link.

6.4.3 The Equipment Department shall formulate the requirements for spare parts, materials, etc. for maintenance and maintenance according to the plan, and the matters and departments that need to be coordinated during planning and execution before the procurement cycle.

6.4.4 Notify relevant information to relevant departments, paying special attention to production plans and changes.

6.4.5 Maintenance plan execution, maintenance summary and records, and problem analysis.

8 Emergency repair of equipment faults

3.3.1 When a minor fault occurs in the equipment, the operator on the job should eliminate it immediately and record it in detail in the shift operation record.

3.3.2 For equipment faults that cannot be eliminated, the operators on the job should strengthen observation, pay attention to the development process of the fault, and provide detailed feedback to the supervisor on duty, who will notify the equipment maintenance personnel to repair it immediately. Maintenance personnel record the maintenance process, fault causes, solutions and other information in detail to form an "Equipment Maintenance Record".

3.3.3 For equipment faults that cannot be eliminated in time, feedback must be given to the person in charge of the production plan and the production director within 2 hours in order to decide on treatment measures.

3.3.4 Before handling each fault, maintenance personnel must take corresponding analysis and solution measures to prevent the expansion of the fault to the greatest extent.

9 Spare parts management

9.1 Control of inventory parts

Any spare parts required for production equipment whose unit or combination unit price exceeds 200 yuan may need to be purchased by yourself If the manufacturer purchases, or needs to be specially manufactured, or cannot be purchased within the county, it is necessary to prepare an appropriate amount of inventory, and set a safety stock amount as a means of control.

9.2 Management unit

The control unit of all inventory parts is the equipment department, and the receiving unit is the user department.

9.3 Safety stock setting

The maintenance engineer of the equipment department sets each item based on factors such as the usage, lifespan, procurement cycle, safety stock, and batch purchase volume of parts. The minimum inventory of parts is controlled and a "Parts Safety Stock Scale" is formed. When the actual stock is lower than the safety stock, purchase will be made immediately according to the procurement process.

9.4 Regular review The Equipment Department will review the rationality of the "Parts Safety Stock Scale" of parts on a quarterly basis based on inventory and usage, and report for revision.

10 Project establishment and processing of equipment improvement

10.1 All the following situations fall within the scope of equipment improvement and can be initiated as a project for improvement:

Faults often occur during operation Stopping the machine and repeatedly processing ineffective parts;

Equipment and parts that affect product quality, output, and efficiency during operation;

The operation cannot meet the minor repair cycle requirements, and unplanned maintenance is often required. Parts (or equipment);

Parts or equipment that have potential safety hazards (personal and equipment safety) and cannot be solved by routine maintenance and simple repairs.

Other new plans that can improve the current quality, output, efficiency and management level

10.2 Establishment and implementation of improvements

All personnel can propose improvement plans. The proposal can be submitted directly to the immediate superior or submitted to the company's administrative department.

The items in 10.1 are part of the proposal.

The company’s vice president (inclusive) and above can decide on the filing and implementation of the plan according to their corresponding responsibilities and authorities.

After the plan is successfully implemented, the corresponding decision-maker of the plan will propose reward measures.

Corresponding information on the project establishment, process and execution results of the plan (whether successful or not) must be documented for future reference. For equipment improvements, this information is also recorded in the equipment file.

11 Related forms

Equipment information registration form

Equipment integrity standard form

Equipment management list

Equipment Lubrication benchmark table

Equipment inspection table

Equipment repair and maintenance record

Parts safety inventory scale

●●●** **Work Responsibilities of the Company's Production Department

Issued by Renzi [2011] No. 0011:

1. Management authority

Exercise management of the product production process authority, and assume the obligation to implement the company's rules, regulations, management procedures and work instructions.

2. Management functions

Reasonably organize the production process of the company's products, comprehensively balance production capabilities, scientifically formulate and implement production operation plans, strengthen employee training and education, and improve production efficiency. Save manufacturing costs.

3. Main Responsibilities

1. Strictly implement the company's rules and regulations and perform work responsibilities.

2. Organize the formulation, inspection, supervision, control and implementation of production, equipment, safety, environmental protection and other systems.

3. Responsible for preparing annual, quarterly and monthly production operation plans and equipment maintenance plans.

4. Closely cooperate with the marketing department to ensure the fulfillment of product contracts.

5. Responsible for the preparation of technical management standards, production process flow, equipment operation manuals and work instructions.

6. Responsible for safety production education, strengthen safety production control, strictly implement production operating procedures, and conduct timely supervision and inspection. Ensure safe production. Prevent safety accidents.

7. Responsible for organizing production site management to ensure that the production site is clean and orderly.

8. Prepare annual, quarterly and monthly production reports in a timely manner, conduct regular production statistical analysis, continuously improve production accounting work, save expenses and reduce costs.

9. Responsible for the maintenance and repair of production equipment and measuring instruments, and make reasonable arrangements for production equipment and measuring instruments to ensure normal use of equipment.

10. Provide training and business guidance for production management personnel, and conduct regular inspections, assessments and evaluations of work abilities.

11. Cooperate with the quality control department to continuously improve product quality and management quality.

4. Division of responsibilities

1. Production director: Develop production plans based on the sales plan (submitted by the sales department, approved by the general manager, and handed over by the general manager office) and inventory conditions, and Properly organize workshop production; daily check raw material inventory reports, formulate raw material purchase orders; daily check production safety conditions in the production workshop, train, supervise, and manage workshop directors, mechanics, and production workers; organize and arrange personnel, machine maintenance, and circuit facilities Maintenance; arrange and hold morning meetings and regular meetings in the production workshop;

2. Workshop director: According to the arrangement of the production director, manage the workshop site and lead workers to carry out safe production; supervise and manage affairs in the workshop, arrange Regarding internal affairs of the workshop, conduct initial education and criticism for those who deserve praise and punishment, and promptly report and recommend those who need to be promoted or fired;

3. Production workers: abide by the workshop production system, be proactive, safe, and Efficiently complete various tasks assigned by the production department; perform machine maintenance in a timely manner; clean the workshop regularly; continue to learn and innovate rationally.