In the past 10 years, the feed industry has developed rapidly in China. Many multinational companies and large domestic group companies have built or purchased a large number of large and medium-sized feed automation production lines in various provinces. The maintenance and management of the feed automation production line has gradually moved from passive maintenance management to modern equipment management. In the past, equipment management personnel were the core and relied too much on the knowledge and experience of management. In the equipment management mode, equipment management errors were often caused by outdated management personnel and one-sided experience. Modern equipment management was developed by many experts. Based on the equipment management system, the factory has the equipment management personnel to learn and use the system, and can improve and innovate according to the characteristics of the equipment of the factory, so that the equipment management can reach new levels and levels. The following is a brief introduction to the application practice of modern equipment management with our company as an example.
1 Advanced equipment and how to keep the equipment long-term and advanced to keep the products manufactured in the forefront of the market, always in the forefront of the market, to produce products that are constantly changing in the market, stable in performance and advanced equipment. First of all, when we purchase equipment, we should purchase equipment with more mature and new technology as much as possible, and we must be able to foresee that the purchased equipment will be advanced in the next few years, and it has its own characteristics. Then, to maintain the advanced nature of the equipment, it mainly relies on equipment management personnel and maintenance personnel and equipment operators. If the equipment manager has a strict and practical attitude. Strongly innovative spirit, courageous and forward-looking. Then they can work hard to improve the old equipment, continue and create new life according to the ever-changing product demand. If the equipment maintenance staff loves the maintenance work, is willing to solve the difficulties, is helpful, and is good at making the owner of the machine instead of the slave, the stability of the equipment will be greatly improved. If the equipment operator is proficient in the principle and performance of the equipment, good at the daily maintenance of the equipment and efforts to overcome the weakness of the equipment in the production process, and to play the advantages of the equipment, it will be able to produce a good product. This will show that the device is always advanced during its life cycle.
2 Scientific equipment management is unbeaten in order to compete in the fierce market. In terms of device management, the device must be used to its fullest extent. With the latest concept, we constantly pursue zero failure rate and low maintenance costs. At the same time, it is necessary to establish a series of equipment management systems and methods. The Dad Group Company is jointly developed by the Group's equipment management experts or by a number of factory equipment management personnel. It has the content to check the time, frequency and analysis of equipment; the cycle and time of equipment lubrication; the cycle and time of equipment cleaning; equipment maintenance and adjustment, the core of which is based on preventive maintenance, emergency maintenance To complement the principle. Figure 1 shows the basic process of device management.
2.1 Equipment Cleaning, Cleaning and Inspection Equipment cleaning refers to the work of each employee who is engaged in production, and the equipment and floor surface related to his work are cleaned before work. There must be a cleaning record card in the conspicuous area of ​​the cleaning area, indicating the cleaning requirements, cleaning cycle and cleaning personnel. The cleaning time must be recorded and signed each time. The goal is to get timely access to external information on the operating equipment and to maintain a good working environment. A good working environment will enhance the enthusiasm of employees and promote the safety of the factory. The equipment must be cleaned up within the specified period. The equipment should be cleaned internally. It is better to have a cleaning record card on each equipment. The clearing record card should indicate the responsible person, cleaning method, cleaning requirements and period. The cleaning time and related content should be recorded in time for each cleaning and reported to the equipment or production supervisor. Different devices are cleaned up in different cycles. For example, when the cooler is changed to different varieties, it needs to be cleaned, and the mixer is cleaned by the operator every week. The granulator has to be cleaned up every ten shifts, and most of the equipment is cleaned up every month. The purpose of the cleaning equipment is to ensure the stability of the feed quality and to obtain information on the internal wear of the equipment.
Equipment inspections include daily equipment inspections and monthly equipment inspections. Daily equipment inspection means checking from outside the equipment. The inspector must go to each device nearby to see, monitor, and touch the condition of the device and record it in time. It is usually done by maintenance personnel or equipment management personnel. Each time, different maintenance or management personnel can be executed to obtain different key information. Each inspection time depends on the size of the factory, and it is about 0.5 to 2.5 people per day.
The monthly equipment inspection refers to the equipment management personnel to develop the inspection items for each equipment of the factory according to the characteristics of the equipment of the factory and the system for each equipment. The main contents of it include: the standard of each project and the requirements of the project, the inspection time of each project and the inspection cycle. This work is generally performed by the equipment manager to instruct the maintenance personnel to perform. The monthly equipment inspection time can be controlled at 20 to 70 person/month depending on the size of the factory.
2.2 Daily maintenance work record The daily maintenance work record refers to the maintenance personnel's accurate and timely record of the work content and the accessories used in the maintenance, and the nature of the work is classified. It can be divided into preventive maintenance and emergency maintenance that affects production. Every day, equipment management personnel must summarize the information obtained and enter the equipment management manual for later analysis and monthly statistical analysis of production and equipment management, and provide information for the maintenance plan on the second day. In addition, equipment information is provided for weekly equipment production.
2.3 Lubrication and adjustment Lubrication can be divided into regular lubrication and special lubrication after equipment inspection. Regular lubrication is based on the requirements of the equipment manual, equipment expert advice and the strength of the plant equipment and the manager's work experience. Annual lubrication and quarterly lubrication are available. After daily and monthly inspections, due to the high degree of wear of some equipment or the serious heat of the equipment, the equipment manager requires special lubrication and necessary equipment parts adjustment according to work experience. To prevent the degree of equipment degradation from accelerating. Some high temperature or heavy equipment must be specially lubricated. For example, the granulator has a pressure roller bearing, which must be lubricated once per shift. The spindle bearing is preferably lubricated once a week, and the general industrial base grease is used. The pulverizer main shaft bearing is best lubricated once every 2 weeks.
2.4 Production Equipment Analysis Production and equipment management personnel must analyze and summarize the production and equipment status on a weekly or monthly basis. Summarize the completion of the work plan last week or last month and explain the reasons for the unfinished plan. Formulate the specific work direction and maintenance and preservation plan for the next week or next month. Participants must come up with their own views and let different perspectives collide so that the manager can finally determine the best solution. Regardless of whether the participant's point of view differs from the decision, the determined plan must be strictly enforced. Of course, each manager must submit a weekly or monthly work report to the department manager, and also to other relevant department managers and captain managers or leaders. The goal is to promote the correct rate of work and ensure the smooth flow of information.
2.5 Spare parts management and support Maintenance equipment managers should timely obtain safety stocks from daily maintenance records and maintenance morning meetings, daily walking equipment inspections, weekly and monthly production equipment meetings, and spare parts. Accessories have information. Prepare the plan in time to ensure that all kinds of work are completed in time.
2.5. l Spare parts inventory principle 1 Commonly used spare parts, wearing parts and spare parts with long purchase period and foreign imported parts must have a safe inventory. Purchase plans and applications for parts that are below the safe stock quantity on a monthly or weekly basis. Early replenishment, avoiding the long-term stoppage due to the lack of accessories to repair; 2 not commonly used, the price is lower, can be purchased to get accessories. Can also be used for a small amount of inventory; 3 is not commonly used at higher prices, but can be purchased in time to get accessories, you can contact a number of dealers, so that when needed, timely delivery.
2.5.2 Spare parts classification and purchase of spare parts are divided into bearing, electrical, electronic, hardware, machinery, computer, machine sieve, ring mold, pressure roller, belt, nylon bucket plastic products, seam Accessories category. Mechanical processing plant, equipment production group company category.壹-like accessories can be purchased by category, and it is best to have two suppliers for each category so that prices can be compared at any time. In the case of regular cooperation, suppliers can pay after delivery and the quality of accessories is stable. However, the supplier selected, we have the best access every time to check the price and quality of the accessories provided. In the case of a small amount of parts purchased, it is possible for the company to use group purchases to ensure the quality and price of the parts. For small quantities, the price is not very high, and the quality is the most important. In the process of negotiating the purchase of accessories, after negotiating with a large number of manufacturers, it is possible to know that the accessories are generally produced and sold at a price. This is very helpful for the mass purchase of ring molds, press rolls, crushing rolls, sieves and hammers. For the group company, the spare parts have to be procured, and each factory is best to exchange information every month and copy it to the corresponding leaders, so that each factory can get the best price, rich information and the most stable quality. Products, and can increase the transparency of work, and promote mutual work.
2.6 Maintenance actions have sufficient information, adequate accessories and a comprehensive preventive maintenance program. We have laid a solid foundation for maintenance and preservation operations next week and next month. Preventive maintenance should be arranged as far as possible during non-production hours. This can improve the efficiency and personal safety of maintenance personnel. After the repair is completed, try to run the repaired equipment as much as possible to ensure that there are no problems in the formal production and that the normal production is not affected. In the production time, it is necessary to stop production and maintenance, the maintenance plan must be comprehensive, and the production and maintenance must be closely coordinated. Before the maintenance, the repair parts and related personnel must be in place, cut off the power switch and lock, hang the repair card, and guarantee Under the premise of quality and personnel safety, repair time should be as short as possible. At the end of the repair, it is best for the relevant personnel to be on site to test the equipment. After the equipment is in normal production, the maintenance will be completed. This allows the device to be improved and restored before it deteriorates.
2.7 Good operational skills to ensure the normal operation of the equipment is the guarantee for the good operation of good products and equipment. In order to produce high-quality products, it is necessary to have operators who are diligent and pragmatic and who like to follow the rules and regulations. Training for operators is not just months of training when entering the factory but training for life. Production and equipment managers should turn 80% of the orders into training, let them know not only to master the knowledge and technology of production and equipment in practice, but also to theoretically master the relevant production and equipment knowledge, and let them Constantly from practice to theory, and then from theory to practice. In order to make the production department employees continue to improve, it is very necessary to carry out cross-training. Post-cross training can make employees feel pressured, promote employees' internal motivation, and stimulate employees to generate innovation. Every production employee is here. A variety of operational skills can be mastered in the process. At the same time, managers must create a good working environment for them. Let them continue to pursue high quality, high efficiency production; let them dare to challenge quality, production and equipment maintenance every day! Managers must also make policies that make them progress and succeed. In this way, our equipment will reflect the true value.
2.8 Appraisal of the maintenance department In order to promote the efficiency of maintenance work and ensure the good operation of the equipment, the maintenance department must conduct necessary assessment. The assessment mainly consists of three aspects: 1 The ratio of production time to the total production time is interrupted due to sudden equipment failure every month. The equipment is in good condition and the management is better. The factory is 4% to 8%. The size of small and medium-sized factories is 9% to 15%. The purpose is to ensure the continuous operation of the equipment; 2 the monthly maintenance department's preventive maintenance hours and the maintenance department's total hours of maintenance work. The factory with good management should be around 70% (the maintenance plan must be handed over to the first-level leadership department on the 1st of each month), and the purpose is to ensure the long-term stable operation of the equipment; 3 the maintenance parts must be controlled in the monthly maintenance work. Cost and maintenance personnel efficiency (except equipment renovation costs). It is normal for the direct cost of maintenance to account for about 10% of the total production cost. These aspects can be linked to the salary and honors of maintenance personnel to facilitate work. Every month, the content of the assessment and the other factories of the Group must be assessed and reported to the Shangyu class. The goal is to keep the maintenance department moving forward.
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