In field management, equipment can be divided into "pollution source, cleaning difficulty source, fault source, waste source, defect source and hazard source" (hereinafter referred to as "6 sources"). Therefore, 6S management is an important aspect. To carry out equipment management, it is necessary to standardize the working environment of equipment, prevent and eliminate "six sources", standardize the daily maintenance of equipment on site, establish and improve the standardized equipment management system, improve the quality of employees and establish an assessment system.
First, standardize the working environment of the equipment.
According to the characteristics and use requirements of the equipment, establish or prepare the environmental facilities required for the special process conditions of the equipment to meet the requirements of temperature and cleanliness, sort out and rectify the working environment and equipment accessories of the equipment, and carefully distinguish the necessary and unnecessary items in the workplace. By handling unnecessary items, the production site and workplace are transparent, the workspace is enlarged, the collision accidents are reduced and the work efficiency is improved. And set and locate the useful things left behind, and arrange them reasonably according to the frequency of use and visualization standards, so as to achieve standardization, color standardization and setting.
Second, find the "six sources" related to the equipment.
(1) Check the pollution source. Pollution sources refer to dust, oil pollution, waste, processing sawdust, etc. Caused by equipment, it further includes harmful gas, toxic liquid, electromagnetic radiation, optical radiation and noise pollution. After searching and collecting the information of these pollution sources, we can solve them by source control and taking protective measures.
(2) Check the source of cleaning difficulties. The source of difficulty in cleaning refers to the parts of the equipment that are difficult to clean, including the parts with small space and no operation, and the parts inside the equipment where cleaning tools cannot be used; Parts that are often contaminated and cannot be cleaned at any time; Areas inaccessible to personnel, such as high altitude, high temperature and high-speed operation of equipment.
(3) Check the hazards. Hazard source refers to the source of safety accidents related to equipment. Due to the large-scale and continuous development of equipment, once an accident occurs, it may bring harm to enterprises and even society. Safety work must be based on "prevention first, nip in the bud, nip in the bud", and accidents and signs that may be caused by equipment must be eliminated. We should actively look for potential safety hazards and formulate countermeasures, such as checking whether all kinds of safety devices of equipment are complete and reliable, whether the components used in the equipment meet the relevant provisions of the state, and whether the specifications for the use, maintenance and repair of equipment meet the safety requirements. Power transmission and transformation equipment, pressure vessels and other special equipment should be inspected and maintained regularly by qualified units in strict accordance with relevant national regulations and technical standards.
(4) Check the source of waste. Waste source refers to all kinds of energy waste related to equipment. The first kind of waste is "running, running, dripping and leaking", including water leakage, oil leakage, electricity leakage, gas leakage (steam) and leakage of various production media (these leaks will also pollute the environment); The second is the waste of "switch", such as the light is still on when people walk, the machine is idling, and the energy of air conditioner, hot air and fan is wasted. It is necessary to take various technical measures to do a good job of leakage prevention and plugging, and put an end to waste through the tips at the switch and the good habits of employees.
(5) Check the fault source. The fault source refers to the fault of the equipment itself. Through daily statistical analysis, gradually understand the causes and laws of equipment failures, formulate corresponding measures, extend the normal operation time of equipment, and take measures to strengthen and transform the lubrication system for failures caused by poor lubrication; Faults caused by high temperature and poor heat dissipation can be realized by strengthening air coolers or cooling water.
(6) Check the source of defects. The source of defects refers to the aspects that the existing equipment can't meet the product quality requirements. Focus on ensuring and improving product quality, find out the processing links that affect product quality, and realize it through technical transformation and updating existing equipment.
By taking corresponding measures to classify the "six sources", we can eliminate, reduce and prevent the "six sources".
Third, establish a perfect field work standard.
When compiling daily work specifications, we should organize technical backbones, including equipment departments, workshops, maintenance teams and front-line production technical backbones, select typical machines, production lines and typical management processes to tackle key problems, investigate and study, find out laws, conduct experiments, and formulate equipment operation and cleaning suitable for current equipment conditions through "selecting people, selecting points, selecting schemes, selecting time, selecting tenders, selecting methods, selecting shifts and selecting roads".
(1) Personnel selection: define the responsibilities, define the responsible person of each equipment (including power pipeline) on the production site, including the responsibilities of operators, patrol inspectors and maintenance teams, and ensure the management of the platform equipment on site;
(2) Point selection: determine the items (points) that need attention on the equipment, that is, the points that need cleaning, inspection, lubrication and maintenance;
(3) Option: According to the characteristics of the selected "points", select several necessary items from the four items of cleaning, spot inspection, lubrication and maintenance;
(4) Timing: according to the characteristics and operation instructions of the equipment, determine a certain interval between cleaning and spot inspection, and conduct operation inspection according to a certain period and time;
(5) Bidding selection: for each job content of each point, the corresponding target state or standard is formulated;
(6) Selection method: clear tools, methods and auxiliary materials should be available for each operation;
(7) Shift selection: determine the responsible shift. For example, in the production site with multi-shift operation, white shift operation is the most, middle shift is the second and night shift is the least;
(8) Route selection: According to the structure of the equipment, especially the production line, power distribution room, refrigeration station, etc. With the position of the operator as the reference, a shorter, easier and more labor-saving operation route is optimized for the selected operation point according to the principle of from low to high, from inside to outside, from near to far, so as to avoid confusion and leakage.
The field management of equipment reflects the level of equipment management, and the level of field work of equipment is closely related to whether the equipment system is sound and standardized. Therefore, in the equipment management work, apart from standardizing the on-site management of equipment, we should also standardize the equipment maintenance, early management of equipment, spare parts management of equipment, technical transformation of equipment and professional management of equipment. In the whole process of production management, the behavior of each link should be standardized, the process should be closed-loop, the control should be strict, and the management should be meticulous, so as to ensure that every link has rules to follow, "laws" can be followed, and "techniques" can be implemented, so as to avoid the fluctuation of equipment management level after personnel adjustment due to "one person, one working method, one leader and one idea".
Fourth, improve the quality of employees.
By improving the quality of employees, I mean thinking and skills. In addition to standardizing the daily work of equipment, we should also do a good job in equipment management and improve the quality of personnel from ideological and technical training. Workers' ideology should first get rid of the idea that operators only care about operation, regardless of maintenance; Repairmen only care about maintenance, regardless of operating habits. Operators should take the initiative to clean equipment hygiene, participate in equipment troubleshooting, combine equipment inspection, maintenance and lubrication, and actively check and maintain equipment to improve equipment conditions. Equipment maintenance and repair personnel carefully supervise, inspect and guide users to use and maintain equipment correctly.
Personnel training, special equipment is trained by qualified national labor departments, so that each equipment operator can truly achieve "three good and four meetings" (three good-manage, use and repair well; Four know how to use, how to maintain, how to check and how to troubleshoot).
Five, the quantitative assessment of equipment management.
In order to ensure that the work of improving employees' technical quality, improving employees' mental outlook, improving enterprise working environment and equipment management can be effectively carried out in 6S management, it is necessary to rely on organizational management, rules and regulations, and continuous and effective inspection, evaluation and assessment to ensure that the benefits generated before and after 6S are compared and counted, and to set higher goals at each stage. It is necessary for enterprise operators and employees to see the changes and benefits, really mobilize the enthusiasm of cadres and employees, and change "I want to carry out 6S management" and "I want to carry out 6S management" to effectively avoid the phenomenon of "one tight, two loose and three collapsed". Statistical comparison should pay attention to productivity, quality, cost, safety environment and labor sentiment.
Statistical indicators of equipment assessment mainly include standardized operation, energy consumption, spare parts consumption, accident rate, failure rate, maintenance cost, equipment-related rejection rate, etc. According to the statistical data, we will constantly set new development goals and implement target management in a one-year cycle. It is necessary to establish an inspection and assessment system in which equipment departments, workshops, workshop teams, maintenance teams, operators and other links assist each other and cross. The assessment results should be combined with the rewards, incentives and promotion of employees. "