Maintenance workshops are the most important workplaces for factory-level maintenance where maintenance personnel maintain and repair off-line equipment or prepare for maintenance during plant operations. Many equipment managers pay more attention to the on-site operation of the equipment. They spend a lot of time on the equipment operation site to observe the operation status of the equipment, understand the development of reliability technology, and improve the equipment management strategy. But sometimes these methods are not very effective. Equipment managers can only be attributed to poor equipment quality, low quality of workers, and unstable parts quality. Perhaps the poor management of the repair room is the root cause of this dilemma. The improvement of maintenance workshops can not only directly and effectively improve maintenance quality and reduce maintenance, but also be of critical importance to the quality improvement of maintenance personnel, thereby improving the skills of maintenance personnel, improving on-site operation, and improving the quality of inspections. The key role of substitution. Equipment overhaul 1, maintenance room FAQ a) The layout of the repair room is incorrect In many cases, due to the limited factory area, the maintenance workshop is small in size, there is no reasonable partition, and tools and maintenance equipment are mixed. This is not an ideal situation. Even if the maintenance space is small, it still needs to consider some basic functional areas. For example, to be repaired area, maintenance area, maintenance temporary storage area, shipping area, common consumable parts storage area, maintenance tool storage area, waste storage area, etc. When planning and arranging the maintenance room, it is necessary to fully consider the transportation route of the materials and reduce the pollution or miscellaneous or damage during transportation of the equipment. b) Insufficient basic hardware The most basic configuration of the inspection room is hardened floor, ergonomic maintenance worktable, electric hoist and hydraulic vehicle used for equipment transportation or transportation, and good lighting. These items may seem insignificant, but they are essential to improving the quality of the repairs. In many cases, the assembly of a moving equipment such as a pump or a blower itself is required to be very precise. However, due to the above-mentioned conditions, foreign matter may enter the equipment, the collision of the sealing surface may be impaired, and the internal components may not be inspected properly. c) The maintenance tools are not in place Maintenance tools are the first pass to guarantee the quality of inspections. The equipment manager must set the cycle, check the tools to repair the staff, from screwdrivers, wrenches, to bearing heaters, hydraulic wrenches, torque wrenches... neglect of inspection tools will not only reduce inspection efficiency, but also often result in maintenance quality. In many cases, such as excessive torque or looseness, etc., are caused by the inaccurate torque of a torque wrench or torque wrench. d) Common Consumables Management Issues Frequently used consumables in the inspection room include bolts, nuts, gaskets, and water and air fittings. Many times when employees or equipment managers overhaul their equipment, they think that they can all be reused indefinitely. Based on this idea, we often see that various bolts and nuts are flooded around the maintenance cabinets or parts storage cabinets, and some of them have been rusted and rusted. Some of them have worn out their teeth and the integrity of their parts is seriously insufficient. It is of course good to make good use of old products. However, it is necessary to set controls on the old part of the spare parts, so that old ones will not be used. In DuPont's work practices, gaskets, O-rings and other sliding seals are not recommended for repeated use; flanged fastening bolts (except special provisions) are also consumables. Usually involves equipment overhaul work of the above types of parts, repair time at least 2 people 3 hours, component failure caused by equipment damage or parking or production fluctuations, as well as potential safety impact is very large, so the "conservation" on these consumables The author thinks it is worth the candle. e) Lack of 5S management Since the maintenance room is usually a place where the equipment is disassembled and assembled, there are many occasions where the grease, materials and parts are scattered. This is also an excuse for many maintenance personnel not to perform 5S management. In fact, it is precisely because of the above situation, equipment maintenance personnel should organize, rectify, clean, clean and repair rooms, and on this basis form a lean maintenance literacy. The 5S management of maintenance workshops insists that, firstly, equipment managers need to make certain investments to upgrade and upgrade the problems mentioned in the previous chapter, and secondly, equipment managers must also arrange regular finishing activities. For example, the organization of the responsibility area after the daily work; the monthly arrangement of public utilities, etc. At the same time, it is recommended to implement visualized management in the maintenance room, including the best practice of regional marking and staffing. Overhaul 2, improvement of the inspection room a) Pay attention to maintenance staff The improvement of the maintenance room needs to pay attention to hardware issues, but more importantly, it is concerned with the software problems that the maintenance personnel manage. Equipment managers need to pay attention and care to the day-to-day activities and working conditions of maintenance personnel. Whether the work clothes are clean and tidy, whether the issuance is sufficient, whether it is convenient to clean their hands near the maintenance room, and whether the rest area is clean and comfortable, these soft strengths also make the maintenance personnel more willing to manage their own repair rooms. b) Standardization of inspection operations For maintenance workshop equipment maintenance managers need to develop related operating procedures, in particular frequent maintenance work, such as the replacement of the bearing, the disassembly and assembly of the pump. Regulating the relevant steps, using tools, manipulating manpower, identifying maintenance quality control points, etc., will effectively avoid overhaul and improve the quality of inspections. c) "Terrestrial Management" and "Sensed Leadership" According to the DuPont Sustainability Division (DSS) experience, improving and improving the maintenance staff’s thinking and behavioral patterns is the most important aspect of maintenance workshop management. The necessary means to improve the maintenance staff's thinking and behavioral model is "relationship management" and "sensible leadership" of management personnel. Determine the person responsible for the relevant area, reduce the "commons" and let everyone manage their own territory. “Sensed leadershipâ€, equipment managers need to allow employees to truly sense the management requirements of equipment managers in the maintenance room. It is a good practice to regularly or irregularly confirm the status of the maintenance room, raise standards, improve unreasonable or unsatisfactory settings and arrangements, and communicate with employees. 3, review The maintenance room is of vital importance to improve the quality of equipment maintenance, promote the safe and reliable operation of equipment, and improve the quality of inspection and maintenance personnel. When an enterprise encounters repeated device failures and frequent maintenance failures, it is necessary to first check and confirm whether there is a problem with the maintenance room management. As a result of the inspection, the author encountered a complex project in which safety and reliability of a chemical plant were upgraded. The company encountered low quality of personnel, unstable equipment operation, frequent frequent shutdowns, repeated maintenance, and unreliable preparation machines. . The author first adopted the strategy of upgrading from the maintenance room management, and through the standardization activities of the maintenance room, the average monthly failure rate of the moving equipment of the chemical plant decreased by 30% in half a year, which greatly solved the low quality of maintenance and " "The machine is not ready" situation. At the same time, the reduction of on-site maintenance activities also avoids a large number of potential exposures, with significant results. Single Screw SGP-VD Standard Nipple Single Screw Thread Nipple,Single Screw Nipple Fitting,Vd Standard Nipple,External Screw Thread Nipples SHAOXING OGAWA PIPE CO.,LTD. , https://www.sxogawapipe.com
