Equipment maintenance An important part of a modern enterprise, the purpose of equipment maintenance is to make the equipment run reliably and to ensure that the company's production will continue smoothly for a long time. Since the beginning of the 1990s, newspaper printing companies have become very popular, equipment has been constantly updated, and production has grown rapidly. However, due to the lack of equipment maintenance management, the delay in newspaper printing time, the quality of newspapers, and the waste of printed materials from people are frequent. I tried to talk about personal understanding, experience, and opinions on how to do a good job in the maintenance of printing equipment.
First, the importance of press maintenance management The characteristics of the existing equipment of newspaper printing enterprises There are many types of printing equipment in newspapers, which are complicated in structure, high in automation, and expensive. Most of them are the most imported equipment from abroad. These devices have a high technological content and have integrated multi-disciplinary technologies such as mechanics, electronics, optics, hydraulics, pneumatics, microcomputers, and chemicals and light industry. The operation of the equipment is relatively convenient, and the maintenance of the equipment is difficult. There is no certain theoretical basis and rich repair experience is incompetent.
2. Economic Significance of Equipment Maintenance Management Equipment maintenance does not seem to produce direct economic benefits, but it has a tremendous role to play in extending the useful life of equipment and giving full play to the potential of equipment. For example, the sauna offset press of our factory was originally approved as scrapped by the State-owned Assets Administration Bureau in 1995, but it has been used for nearly 3 years since it was overhauled in 1996. The printing quality is still highly praised by various users, and the aircraft can be extended for at least 5-8 years. Life expectancy. In 1995, if we purchased a North man machine with the same combination, we needed RMB 2 million, and our factory only spent more than RMB 100,000 to fully restore the industry and various functions of the machine. It can be seen that the economic value of equipment maintenance is huge. Another example is that a certain newspaper company purchased three Roland rotary offset presses and its active spiral gear was damaged. It was purchased from Roland manufacturers. The price was as low as RMB 50,000. Maintenance managers were asked to design and manufacture in the local area, which cost less than 2,000 yuan. Yuan processed the same teeth and saved a lot of money. There are countless examples.
3. Social influence of equipment maintenance and management The Party newspaper is the mouthpiece of the Party and the government. Once the equipment is out and the quantity cannot keep up, the machine will stop production, and its social impact can be imagined. A printing press of a newspaper company had to go to Nanchang printing from more than 100 kilometers due to equipment failure, and then pulled back the printed newspapers. The newspapers ceased publication for almost a day, causing a bad social impact.
Some people say that the competition of modern enterprises is the competition between equipment and technology. In a sense, it is very important that equipment maintenance concerns the survival of enterprises. In order to make è work state, equipment maintenance management should be regarded as a system engineering. In the entire process of equipment inspection, introduction, installation, commissioning, and use, attention must be paid to maintenance management.
Second, the introduction of the site must consider the introduction of maintenance management equipment to combine the actual needs of the company's work, according to the market potential demand, with a certain sense of advance, in the inspection, argumentation and negotiation process, we must consider the following factors: 1. Overall technical level of the machine; 2. The degree of automation and reliability of the electrical control of the machine; 3. Mechanical wear, lubrication conditions; 4. The degree of difficulty in purchasing spare parts and spare parts; 5. Technical information is complete and easy to understand (Chinese is required) 6. Excellent and poor after-sales service. The above points have an important influence on the maintenance management after the equipment is introduced.
Third, the transformation of production equipment must pay attention to the maintenance of testing equipment updates 1. The status quo of repair and inspection equipment must repair the worn parts so that they can recover the dimensional accuracy. Therefore, there must be higher-precision maintenance equipment. At present, most press printing companies have obsolete repair and inspection equipment. The main surfaces are: 1) Long use time, small quantity; 2) Few repairs, sick work; 3) Low precision and no detection effect; 4) The detection method is backward, and lack of testing equipment during the maintenance process. The detection means is backward and the malfunction is judged by intuitive feelings such as hand touch and ear hearing. Therefore, the repair quality is often poor and even repeated repairs.
2. Emphasis on maintenance and testing equipment renewal With the booming development of the newspaper industry, various advanced equipments have been introduced into newspaper printing companies. However, many printing companies only pay attention to the transformation of production equipment, neglecting the maintenance of repair and inspection equipment, and maintaining equipment. Can not produce economic benefits. However, the most advanced equipment will wear out, and it will be necessary to repair it. The precision of the parts of advanced equipment is high, and the maintenance and inspection equipment with high precision is required during the maintenance process. Therefore, the renovation of production equipment and the maintenance of maintenance and testing equipment must not be neglected.
Fourth, training high-level maintenance personnel The quality of maintenance personnel First, many people recruited and replaced in the 1980s. These people are not well-educated, lack technical training, lack professional theoretical knowledge, and have slow repairs. Most people are unable to work alone for many years. Analyze and deal with difficult faults. Second, there are few high-level maintenance personnel, and the complex repair work mainly depends on one or two people, which brings great difficulties to maintenance management. Third, there are few young people in their 20s and they are not willing to learn repair techniques and have poor maintenance.
2. Should pay attention to the introduction of talent to change the high level of maintenance personnel, there is no backup status, talent must be introduced as soon as possible. 1) Introduced in secondary school graduates. They have high levels of education and certain professional theories. As long as they are trained, they can quickly improve the maintenance level. These people have the potential and hope to become high-level maintenance personnel. 2) Recruitment of maintenance personnel in the community. Such people generally have basic maintenance and experience. As long as they are familiar with the process of printing equipment, they can quickly understand, familiarize themselves with and master the printing equipment repair technology.
3. To do a good job in technical training and improve the printing equipment with advanced technical staff of maintenance personnel, we have integrated multiple disciplines and the staff constantly learn to adapt to the rapid development of technology. Therefore, doing a good job of technical training plays a key role in improving the technical level of maintenance personnel. 1) Do a good job of technical training. Use spare time to organize maintenance personnel to learn the basic knowledge of electrical engineering and mechanics, and ask high-level maintenance personnel to bring drawings to the machine to explain the problem on site and to simulate failure phenomena. The theoretical knowledge of hydrogen is applied to practice. 2) Send maintenance personnel to participate in the technical training organized by the machine manufacturer, and take off the production to study professional theoretical knowledge. 3) During the introduction of equipment, management personnel should promptly organize equipment drawings and data, organize maintenance personnel to read, and gradually digest. When installing the equipment, the maintenance personnel must work with the manufacturer's installation personnel to do more and more questions, to master the performance of the machine faster and better, and lay a solid foundation for the maintenance of the equipment.
V. Establish equipment files and implement active repairs. Establishing equipment files Establishing equipment files is an important basic work for equipment management in printing companies. It has important significance for equipment maintenance.
From the signing of the purchase contract, the equipment will begin to set up equipment files. The purchase contract, technical data, instructions for use of the machine, checklists, and related drawing receipts are filed in the archives, and at any time during the use of the equipment, the equipment malfunctions, causes, methods of elimination, and normal maintenance procedures The troubles discovered, etc. are recorded in detail in the equipment file. This will have a more comprehensive understanding of the working conditions of the equipment, which is conducive to the type of cycle and type of occurrence of the failure of the sheep and the preparation of spare parts for repair as soon as possible.
2. Take various forms to ensure the timely supply of spare parts. As the saying goes, it is difficult for a clever woman to be without rice, repair technology is no better, there is no replacement of spare parts, can only wait. Therefore, spare parts should be prepared in time according to equipment file information and maintenance experience.
1) During the purchase of equipment, it is necessary to configure random accessories as much as possible and comprehensively according to the maintenance experience.
2) When the machine is used for a period of time and the spare part is not enough, it can be purchased by mail order from the machine manufacturer. This ensures the quality of spare parts.
3) In the case of drawings, it can be processed according to the drawings; when there are no drawings, the parts can be mapped and processed, and the quality of the spare parts must be guaranteed. Many spare parts must be heat-treated in order to meet quality requirements. Therefore, it is sometimes preferable to send large-scale machine factories for processing, and do not save money, time, and trouble. Replace parts that do not meet the quality requirements, which inevitably results in repeated repairs.
4) For the electrical spare parts of imported equipment, it often takes several tens of thousands of dollars to buy a circuit board from foreign companies. To solve this problem, we must take the road of localization and adopt economic and technological cooperation methods. The unit that uses the equipment puts forward specific technical requirements for scientific research institutes, provides necessary funds, and signs economic contracts. After the successful development, it will Industry promotion. In this way, the cost of repairs can be greatly reduced.
5) At present, there is almost no competition among newspaper printing enterprises in different places. As long as they strengthen contact in peacetime and know their equipment and spare parts, once the spare parts are not enough, they can communicate with each other in the printing industry.
6) The establishment of a spare parts store shall be managed by a special person and supplemented in a timely manner to ensure that the spare parts for repair can be supplied in a timely manner.
3. Implementing active repairs Since newspapers are published every day, it is generally difficult to arrange for a longer period of downtime. In the past, most of the machines were malfunctioned and then re-analyzed and eliminated. In order to resume production as soon as possible, maintenance personnel are under pressure. This is a passive repair method.
To implement aggressive repairs, first the machine operators must do their daily maintenance work conscientiously and responsibly. In particular, they must strictly follow the requirements of the user's manual and do a good job of lubrication of the machine parts, because most of the failures are Due to the poor lubrication of the machine, it is necessary to promptly inform the maintenance management department of abnormalities and avoid failures as soon as possible. Secondly, maintenance personnel cannot wait for the machine to go out of trouble and repair it. They should frequently inspect and inspect, detect hidden troubles early, and take decisive measures. The stoppage must be stopped immediately, and the hidden trouble should not become a failure due to fear of influencing production. Third, we must repair it in time. If you discover hidden troubles and wear out machine parts, do not develop them. The replacement parts must be replaced as soon as possible. Do not think that the project is large, afraid of trouble, etc., making the hidden troubles become faults, so that the general failure becomes a bad failure. As a result, shutdowns were discontinued, causing serious consequences.
In short, to do a good job in printing equipment maintenance management, first, strengthen leadership, attach great importance to mobilize the enthusiasm of maintenance managers; second is to improve the quality of maintenance management personnel, improve maintenance management level; third is to make repairs and maintenance of spare parts material preparation. Only in this way can we ensure long-term reliable operation of printing equipment.
First, the importance of press maintenance management The characteristics of the existing equipment of newspaper printing enterprises There are many types of printing equipment in newspapers, which are complicated in structure, high in automation, and expensive. Most of them are the most imported equipment from abroad. These devices have a high technological content and have integrated multi-disciplinary technologies such as mechanics, electronics, optics, hydraulics, pneumatics, microcomputers, and chemicals and light industry. The operation of the equipment is relatively convenient, and the maintenance of the equipment is difficult. There is no certain theoretical basis and rich repair experience is incompetent.
2. Economic Significance of Equipment Maintenance Management Equipment maintenance does not seem to produce direct economic benefits, but it has a tremendous role to play in extending the useful life of equipment and giving full play to the potential of equipment. For example, the sauna offset press of our factory was originally approved as scrapped by the State-owned Assets Administration Bureau in 1995, but it has been used for nearly 3 years since it was overhauled in 1996. The printing quality is still highly praised by various users, and the aircraft can be extended for at least 5-8 years. Life expectancy. In 1995, if we purchased a North man machine with the same combination, we needed RMB 2 million, and our factory only spent more than RMB 100,000 to fully restore the industry and various functions of the machine. It can be seen that the economic value of equipment maintenance is huge. Another example is that a certain newspaper company purchased three Roland rotary offset presses and its active spiral gear was damaged. It was purchased from Roland manufacturers. The price was as low as RMB 50,000. Maintenance managers were asked to design and manufacture in the local area, which cost less than 2,000 yuan. Yuan processed the same teeth and saved a lot of money. There are countless examples.
3. Social influence of equipment maintenance and management The Party newspaper is the mouthpiece of the Party and the government. Once the equipment is out and the quantity cannot keep up, the machine will stop production, and its social impact can be imagined. A printing press of a newspaper company had to go to Nanchang printing from more than 100 kilometers due to equipment failure, and then pulled back the printed newspapers. The newspapers ceased publication for almost a day, causing a bad social impact.
Some people say that the competition of modern enterprises is the competition between equipment and technology. In a sense, it is very important that equipment maintenance concerns the survival of enterprises. In order to make è work state, equipment maintenance management should be regarded as a system engineering. In the entire process of equipment inspection, introduction, installation, commissioning, and use, attention must be paid to maintenance management.
Second, the introduction of the site must consider the introduction of maintenance management equipment to combine the actual needs of the company's work, according to the market potential demand, with a certain sense of advance, in the inspection, argumentation and negotiation process, we must consider the following factors: 1. Overall technical level of the machine; 2. The degree of automation and reliability of the electrical control of the machine; 3. Mechanical wear, lubrication conditions; 4. The degree of difficulty in purchasing spare parts and spare parts; 5. Technical information is complete and easy to understand (Chinese is required) 6. Excellent and poor after-sales service. The above points have an important influence on the maintenance management after the equipment is introduced.
Third, the transformation of production equipment must pay attention to the maintenance of testing equipment updates 1. The status quo of repair and inspection equipment must repair the worn parts so that they can recover the dimensional accuracy. Therefore, there must be higher-precision maintenance equipment. At present, most press printing companies have obsolete repair and inspection equipment. The main surfaces are: 1) Long use time, small quantity; 2) Few repairs, sick work; 3) Low precision and no detection effect; 4) The detection method is backward, and lack of testing equipment during the maintenance process. The detection means is backward and the malfunction is judged by intuitive feelings such as hand touch and ear hearing. Therefore, the repair quality is often poor and even repeated repairs.
2. Emphasis on maintenance and testing equipment renewal With the booming development of the newspaper industry, various advanced equipments have been introduced into newspaper printing companies. However, many printing companies only pay attention to the transformation of production equipment, neglecting the maintenance of repair and inspection equipment, and maintaining equipment. Can not produce economic benefits. However, the most advanced equipment will wear out, and it will be necessary to repair it. The precision of the parts of advanced equipment is high, and the maintenance and inspection equipment with high precision is required during the maintenance process. Therefore, the renovation of production equipment and the maintenance of maintenance and testing equipment must not be neglected.
Fourth, training high-level maintenance personnel The quality of maintenance personnel First, many people recruited and replaced in the 1980s. These people are not well-educated, lack technical training, lack professional theoretical knowledge, and have slow repairs. Most people are unable to work alone for many years. Analyze and deal with difficult faults. Second, there are few high-level maintenance personnel, and the complex repair work mainly depends on one or two people, which brings great difficulties to maintenance management. Third, there are few young people in their 20s and they are not willing to learn repair techniques and have poor maintenance.
2. Should pay attention to the introduction of talent to change the high level of maintenance personnel, there is no backup status, talent must be introduced as soon as possible. 1) Introduced in secondary school graduates. They have high levels of education and certain professional theories. As long as they are trained, they can quickly improve the maintenance level. These people have the potential and hope to become high-level maintenance personnel. 2) Recruitment of maintenance personnel in the community. Such people generally have basic maintenance and experience. As long as they are familiar with the process of printing equipment, they can quickly understand, familiarize themselves with and master the printing equipment repair technology.
3. To do a good job in technical training and improve the printing equipment with advanced technical staff of maintenance personnel, we have integrated multiple disciplines and the staff constantly learn to adapt to the rapid development of technology. Therefore, doing a good job of technical training plays a key role in improving the technical level of maintenance personnel. 1) Do a good job of technical training. Use spare time to organize maintenance personnel to learn the basic knowledge of electrical engineering and mechanics, and ask high-level maintenance personnel to bring drawings to the machine to explain the problem on site and to simulate failure phenomena. The theoretical knowledge of hydrogen is applied to practice. 2) Send maintenance personnel to participate in the technical training organized by the machine manufacturer, and take off the production to study professional theoretical knowledge. 3) During the introduction of equipment, management personnel should promptly organize equipment drawings and data, organize maintenance personnel to read, and gradually digest. When installing the equipment, the maintenance personnel must work with the manufacturer's installation personnel to do more and more questions, to master the performance of the machine faster and better, and lay a solid foundation for the maintenance of the equipment.
V. Establish equipment files and implement active repairs. Establishing equipment files Establishing equipment files is an important basic work for equipment management in printing companies. It has important significance for equipment maintenance.
From the signing of the purchase contract, the equipment will begin to set up equipment files. The purchase contract, technical data, instructions for use of the machine, checklists, and related drawing receipts are filed in the archives, and at any time during the use of the equipment, the equipment malfunctions, causes, methods of elimination, and normal maintenance procedures The troubles discovered, etc. are recorded in detail in the equipment file. This will have a more comprehensive understanding of the working conditions of the equipment, which is conducive to the type of cycle and type of occurrence of the failure of the sheep and the preparation of spare parts for repair as soon as possible.
2. Take various forms to ensure the timely supply of spare parts. As the saying goes, it is difficult for a clever woman to be without rice, repair technology is no better, there is no replacement of spare parts, can only wait. Therefore, spare parts should be prepared in time according to equipment file information and maintenance experience.
1) During the purchase of equipment, it is necessary to configure random accessories as much as possible and comprehensively according to the maintenance experience.
2) When the machine is used for a period of time and the spare part is not enough, it can be purchased by mail order from the machine manufacturer. This ensures the quality of spare parts.
3) In the case of drawings, it can be processed according to the drawings; when there are no drawings, the parts can be mapped and processed, and the quality of the spare parts must be guaranteed. Many spare parts must be heat-treated in order to meet quality requirements. Therefore, it is sometimes preferable to send large-scale machine factories for processing, and do not save money, time, and trouble. Replace parts that do not meet the quality requirements, which inevitably results in repeated repairs.
4) For the electrical spare parts of imported equipment, it often takes several tens of thousands of dollars to buy a circuit board from foreign companies. To solve this problem, we must take the road of localization and adopt economic and technological cooperation methods. The unit that uses the equipment puts forward specific technical requirements for scientific research institutes, provides necessary funds, and signs economic contracts. After the successful development, it will Industry promotion. In this way, the cost of repairs can be greatly reduced.
5) At present, there is almost no competition among newspaper printing enterprises in different places. As long as they strengthen contact in peacetime and know their equipment and spare parts, once the spare parts are not enough, they can communicate with each other in the printing industry.
6) The establishment of a spare parts store shall be managed by a special person and supplemented in a timely manner to ensure that the spare parts for repair can be supplied in a timely manner.
3. Implementing active repairs Since newspapers are published every day, it is generally difficult to arrange for a longer period of downtime. In the past, most of the machines were malfunctioned and then re-analyzed and eliminated. In order to resume production as soon as possible, maintenance personnel are under pressure. This is a passive repair method.
To implement aggressive repairs, first the machine operators must do their daily maintenance work conscientiously and responsibly. In particular, they must strictly follow the requirements of the user's manual and do a good job of lubrication of the machine parts, because most of the failures are Due to the poor lubrication of the machine, it is necessary to promptly inform the maintenance management department of abnormalities and avoid failures as soon as possible. Secondly, maintenance personnel cannot wait for the machine to go out of trouble and repair it. They should frequently inspect and inspect, detect hidden troubles early, and take decisive measures. The stoppage must be stopped immediately, and the hidden trouble should not become a failure due to fear of influencing production. Third, we must repair it in time. If you discover hidden troubles and wear out machine parts, do not develop them. The replacement parts must be replaced as soon as possible. Do not think that the project is large, afraid of trouble, etc., making the hidden troubles become faults, so that the general failure becomes a bad failure. As a result, shutdowns were discontinued, causing serious consequences.
In short, to do a good job in printing equipment maintenance management, first, strengthen leadership, attach great importance to mobilize the enthusiasm of maintenance managers; second is to improve the quality of maintenance management personnel, improve maintenance management level; third is to make repairs and maintenance of spare parts material preparation. Only in this way can we ensure long-term reliable operation of printing equipment.
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