One, the characteristics and requirements of automatic production line
1, automated production line equipment complex, high degree of automation, maintenance is not a simple mechanical maintenance, but mechanical and electrical integration of maintenance, this requires maintenance organization is a mechanical, electrical, automation and instrumentation professionals integrated group, so the high requirement of technology of maintenance personnel quality;
2, any process problems will influence the whole production, so the requirement of the fault timely maintenance is very important, and maintenance of information transmission and maintenance decision required to establish a unified coordination management institutions, to prevent failure, to the greatest extent possible to ensure production line is not due to a process all production, maintenance system mainly adopt preventive maintenance mode;
Shutdown time is short, troubleshoot quickly and accurately.
3, due to the characteristics of water supply enterprises, need to shift more production, maintenance personnel shift more cooperate with production, set up units of machines & other;
Total preventive maintenance & throughout;
System, to effective unified maintenance main body.
2, the content of total preventive maintenance
1, maintenance organization
our company first to highlight the maintenance personnel composed of maintenance and technical personnel and production personnel to attend, at the same time, the mechanical, electrical, automation and instrumentation, dispatchers are incorporated into the production department management, to form a rapid response system maintenance information and activities.
On the other hand, due to our company practice & other
Class four three operation & throughout;
System of continuous operation, to avoid each class staff responsibility is not clear, perfunctory, we will equipment breakdown to each class operators and maintenance personnel, the personnel responsibilities in clear, detailed feasible fault report, processing and recording procedures, while handing over to work should be the equipment clear together, so that operators and maintenance personnel responsibilities and activities vertically organic connection, formed a complete set of equipment maintenance organization.
2, the content of the preventive maintenance
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1)
Predicting maintenance
can not only avoid the sudden failure, and can prevent the unnecessary excess maintenance.
Especially for automatic production line, used to predict repair to reduce faults and stop losses, is more significant.
My company constantly improve the level of fault diagnosis and equipment, with high efficiency, high precision testing instrument and means, and equipment maintenance team.
Has been equipped with vibration detector, rotating electrode fault diagnosis system, oscilloscope and advanced tools such as electric power analyzer, to carry out the on-line nondestructive testing device, made it possible to predict the maintenance, and can provide reliable basis for equipment renewal and reconstruction, decision, sudden fault decrease greatly, produced good economic benefit in practice.
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2)
Daily maintenance and check management
due to the continuous production of automatic production lines, to stop check, so we daily check for each device made the project record, a record of a request inspection, until the complete all items in a flight, so as to provide the necessary original basis for maintenance, to help arrange maintenance, equipment situation analysis.
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3)
Maintenance cycle and planning control
a, preventive maintenance
outage maintenance plan of automatic production lines and downtime must be reasonable arrangement, our company generally arranged in December to April the following year, to avoid the peak period of production.
Can state detection finds the problems, don't need to immediately stop the processing, can be together in the overhaul of processing or use of production clearance, to good equipment, the operation state can postpone or cancel the maintenance plan, greatly saves manpower and material resources, reduce the excess maintenance and downtime losses.
b, personnel training,
participation is key of the success of preventive maintenance personnel quality, so the staff training is very important.
Our company insist on continuous training programs, each open classes, lectures by technicians, basic knowledge, knowledge training and so on equipment maintenance management, technical personnel communicate with each other, go out learning, greatly improving the level of equipment maintenance related personnel.
3, the management of spare parts,
types of automation equipment, accessories and complex, and imported equipment, the price is more expensive, delivery cycle is long.
So to determine the reasonable spare parts to reduce capital takes up rate, ensure the production, improve business efficiency has the effect that cannot ignore.
The beginning of my company from using automated equipment, statistical summary of all kinds of spare parts consumption law and adopt different methods of inventory management.
To consume more frequent spare parts, determine the upper limit and lower limit of inventory, high value, long spare parts consumption cycle, zero inventory management;
Purchasing and suppliers to establish long-term cooperation relations, usually do not make reserve;
For spare parts that need to be imported from abroad, to determine the reasonable time and quantity of the order.
Attaches great importance to the quality of spare parts at the same time, ensure the key spare parts of the percent of pass is 100%, in the procurement, select high-profile, high qualification of the manufacturer.
4, the advantages of the preventive maintenance
through years of practice.
We believe that the automatic production line to production as the main body of total preventive maintenance has the following advantages:
a, due to the maintenance plan, organize and implement basic on the production, thus can rapid response to maintenance, adapted to the continuity between production automation production process and equipment characteristics of monolithic.
b, emphasize the equipment condition monitoring and management, can effectively prevent the fault predicting maintenance way, reduce downtime losses.
c, maintenance organization on the basis of production operators, maintenance technicians, factory leadership direct supervision, and using the maintenance quality and timeliness as the evaluation index, greatly to mobilize the initiative of maintenance personnel preventive maintenance and motivation.