Equipment daily maintenance strategy, no longer afraid of yellow robe!


Release time:

2020-06-03

The correct use and maintenance of equipment is an important part of equipment management, by the operators and maintenance personnel according to the equipment maintenance rules to carry out a series of maintenance work on the equipment, but also the objective requirements of the movement of the equipment itself.
Equipment maintenance work includes: daily maintenance (first guarantee), equipment lubrication and regular oil change, preventive test, regular adjustment of accuracy and equipment 2. three-level maintenance. The quality of maintenance will directly affect the operation of the equipment, the quality of the product and the production efficiency of the enterprise.
Inspection of (I) equipment
Equipment inspection is an effective means to timely grasp the technical status of equipment and implement equipment condition monitoring and maintenance. It is the basic work of maintenance. Through inspection, it is an important work to discover and eliminate equipment hidden dangers in time and prevent sudden failures and accidents.
1. Daily inspection
Daily inspection is to check the technical condition of each part of the equipment according to the prescribed standards, mainly with facial senses, so as to find out the trouble in time, take countermeasures and minimize the loss of failure and shutdown. For key equipment, each shift or a certain period of time by the operator according to the equipment inspection card item by item inspection records. During the patrol inspection, the maintenance personnel shall timely and effectively eliminate the abnormalities recorded in the spot inspection card to ensure that the equipment is in good working condition.
2. Periodic inspection
According to the specified inspection cycle, the maintenance worker will conduct a comprehensive inspection and measurement of the equipment performance and amateurism. In addition to the problems found at that time, the inspection results will be carefully recorded as the basis for future decision-making on the equipment maintenance plan.
3. Accuracy inspection
This is the determination, analysis and adjustment of the geometric accuracy, machining accuracy and installation level of the equipment. This work is carried out by full-time inspectors as planned, with the purpose of determining the actual refinement of the equipment and providing a reference basis for equipment adjustment, repair, acceptance and scrapping.
Checking the equipment and accurately recording the status information of the equipment can provide a reliable basis for future maintenance and maintenance costs.
Daily maintenance of (II)
The daily maintenance of the equipment can be summarized into eight words-neat, clean, lubricated and safe.
1. Tidiness: tools, workpieces and accessories are placed neatly; safety protection articles are complete; the pipeline is safe and complete.
2. Cleaning: The inside and outside of the equipment are clean. All sliding surfaces, screw rods, racks, gears, handle handwheels and other grease stains are free from damage. All parts shall not leak oil or water, and iron filings and garbage shall be cleaned.
3. Lubrication: Regularly and quantitatively add oil and change the oil. The oil quality meets the requirements. The oil pot, oil gun and oil cup are complete. Keep the oil label, oil line and oil scraper clean and the oil road unblocked.
4. Safety: Implement the system of fixed personnel, fixed machine, certificate operation and shift change; Familiar with the equipment structure, abide by the operation rules, use reasonably, maintain carefully, and be safe and accident-free.
(III) secondary maintenance
This level of maintenance is mainly based on operation work, and maintenance work is coordinated. The maintenance period can be determined according to the working environment and working conditions of the equipment. For example, the gold cutting machine can be set to run for 400~600 hours, and the rest time and maintenance hours can be calculated according to the 0.5 leaflet of each complex coefficient of the equipment.
1. Secondary maintenance content
(1) according to the use of equipment, some parts of the disassembly, cleaning, adjustment, replacement of individual wearing parts, the specific cleaning process can click
(2) Thoroughly clean the inside and outside of the equipment to remove "yellow robes" and dirt;
(3) Check and clean the lubricating oil circuit, clean the oil scraper, oil line and oil filter, add lubricating oil appropriately, and check the oiling condition of the sliding surface;
(4) Appropriate adjustment of the fit clearance of each moving surface of the equipment;
(5) Clean the electrical box (electrician's cooperation) and electrical devices, and ensure that the lines are fixed and tidy and the safety protection is firm;
(6) Cleaning equipment accessories and cooling system;
2. Maintenance standard
After secondary maintenance, the equipment shall be clean inside and outside, showing its natural color; the oil road shall be smooth, the oil mark shall be bright, and the oil level shall be clearly visible; the operation shall be flexible and normal. After the maintenance is completed, a special person shall be responsible for acceptance and fill in the maintenance completion record form carefully.
Repair of 2. equipment
In the process of using the equipment, due to the default of wear, corrosion, burning and deformation of some parts, the accuracy, performance and production efficiency of the equipment are affected. Correct operation and careful maintenance can reduce damage and prolong the service life of the equipment, but the equipment will be worn and damaged after all, which is an objective law. Therefore, in addition to proper use and maintenance, it is also necessary to replace, repair or improve worn parts and arrange necessary maintenance plans to restore the accuracy and performance of the equipment, preserve the quality of processed products and give full play to the due efficiency of the equipment.
(I) equipment maintenance methods
1. Preventive maintenance: maintenance activities carried out according to the pre-specified plan and technical conditions in order to prevent equipment performance deterioration or reduce the probability of equipment failure. It is from the standpoint of preventing "medical treatment", according to the regular inspection records or operation of the equipment, there are abnormal signs of the main quality and production efficiency, and preventive repair and improvement should be carried out before the equipment fails. Preventive maintenance is usually planned according to the actual operation of the equipment.
2, fault maintenance: equipment failure or performance reduction to take non-planned maintenance, also known as after-the-fact maintenance.
3, production maintenance: from the economic benefits to improve the efficiency of equipment production maintenance methods, it is treated according to the impact of equipment on production. After-the-fact maintenance is adopted for unimportant equipment, while preventive maintenance is carried out for key equipment.
4. Predictive maintenance: According to the information provided by condition monitoring and diagnosis technology, necessary and appropriate maintenance is carried out before the failure occurs, also known as condition monitoring maintenance.
In addition to the above several maintenance methods, there are also ways to improve maintenance, regular maintenance and no maintenance design.
The significance of (II) preventive maintenance
The planned preventive maintenance of the equipment is an important guarantee to maintain the normal operation of the equipment and maximize its function by mastering the wear law of the equipment and carrying out periodic maintenance in a planned way.
Planned preventive maintenance is an important link in equipment management and an integral part of the enterprise's production, technology and financial plans. A correct and realistic pre-repair plan can uniformly arrange manpower and material resources to prepare for repair as early as possible, shorten equipment downtime and reduce repair costs. It can not only repair equipment on time, but also arrange production in a planned and rhythmic manner, so as to achieve two errors in production and maintenance.
Main categories of (II) repairs
Level 3 maintenance (also known as minor repairs)
The minor repair is the regular maintenance work in which the maintenance workers mainly participate. The equipment shall be partially disassembled, cleaned and overhauled, and severely worn parts shall be replaced or repaired to restore part of the accuracy of the equipment to meet the process requirements.
The maintenance interval of metal cutting equipment is generally 2500~3000 running hours, the main contents are:
(1) Replace some parts of the equipment with fast wear, corrosion and burning;
(2) Use professional parts grease cleaning agent to clean equipment parts;
(3) Fasten the card wedges and screws in the machine parts;
(4) Replace the lubricating grease according to the specified period;
(5) Measure and record the main accuracy of the equipment and the wear, burning, deformation and corrosion of some parts.
2. Targeted repair (also known as item repair)
According to the structure and use characteristics and existing problems of the equipment, under the premise of meeting the process requirements, partial repair of one or several items of the equipment. Its workload is equivalent to 20% to 70% of the equipment overhaul.
3. Overall overhaul
This is one of the most extensive repairs to be made. Overhaul all equipment, repair benchmark parts, replace or repair all damaged parts, completely remove defects, restore the original accuracy, performance and efficiency, and meet the factory standards or meet the standards required by the process. When the equipment is overhauled, it should also be combined with technical transformation as far as possible to improve the accuracy and performance of the original equipment.
In addition to the above types of maintenance, there are regular, pre-repair pre-inspection and power running equipment and preventive testing, seasonal technical maintenance and other maintenance methods to ensure the normal operation of different types of equipment.
4. Acceptance criteria
The acceptance criteria for overhaul can be divided into three categories: acceptance accuracy, relevant accuracy and irrelevant accuracy. The acceptance accuracy is the accuracy of the recovered parts in the repair, which must meet the factory standard. Relevant accuracy requires not less than pre-repair accuracy. Irrelevant accuracy can be checked.
In modern industrial enterprises, equipment reflects the degree of enterprise modernization and the level of science and technology, and occupies an increasingly important position in the process of enterprise production and operation. It plays an extremely important role in the quality, output, production cost, delivery time, energy consumption and human-machine environment. With the rapid development of science and technology, the production technology and equipment of enterprises are constantly updated, and the degree of automation and continuity of product production is getting higher and higher. Therefore, equipment for the survival and development of enterprises and market competitiveness has occupied a pivotal position, good equipment management determines the production efficiency of enterprises, whether large enterprises, or small and medium-sized enterprises, are not to be ignored, should cause the attention of leaders and management departments at all levels, especially the current enterprise equipment is constantly updated, high-precision, high-efficiency, automation equipment is increasing, it also shows the importance of equipment maintenance and repair work.