Is it important to manage equipment through classification and grading?

It’s very important to follow the standards.

It’s probably to control costs and effort, focusing on the most important things.

If there is a management unit at the higher level and reports on operations need to be submitted to that unit, then such devices are classified as Type A; we refer to them as key devices internally. The rest can be classified as regular devices. If there are branch offices at the lower level and the management unit needs to have information about them, then those devices are classified as Type B. Devices managed by workshops or branch offices are classified as Type C

Due to the different roles that various types of equipment play in the production process, as well as differences in working conditions, operating time, structural performance, and other factors, the importance and safety level of these devices also vary. Therefore, with limited resources such as manpower and materials available for maintenance, assessing and classifying equipment based on its safety level allows for the planning of routine maintenance and repair tasks. This not only helps to allocate resources efficiently and ensure smooth production, but also reduces maintenance and management costs effectively. 6.2 The grading of equipment into categories A, B, and C shall follow the following principles: 6.2.1 It shall be able to reflect the main characteristics of the equipment. 6.2.2 It possesses quantifiability and universality. 6.2.3 It must be comparable. 6.2.4 Quantitative analysis. 6.3 Methods for Classifying Equipment into ABC Categories 6.3.1 The formula for calculating the ABC classification of equipment is as follows: C = C1 + C2 + C3. C1 = A * 50%, C2 = B * 20%, and C3 = (Major repairs J*D + Minor repairs J*D + Routine repairs J*D) * 30%. 6.3.2 The criteria for ABC classification, based on the value of C, are shown in the table below: Grade Category C Requirements for Management and Maintenance Requirements for Spare Parts Stock A A++ 0.95–1.00 Requires careful maintenance and focused management; a complete equipment BOM must be maintained, with sufficient spare parts in stock. A+ 0.90-0.94 Requires careful maintenance and focused management. A device BOM must be established, with sufficient spare parts in stock. A 0.85-0.89 requires regular monitoring and maintenance in accordance with regulations. 100% of Equipment BOMs have been established, with sufficient spare parts in stock. B B++ 0.80-0.84 Requires regular monitoring and maintenance in accordance with regulations. Schedule regular maintenance and plan for spare parts, maintaining an appropriate inventory of wear-prone components. B+ 0.75-0.79: Routine inspections, maintenance as scheduled; moderate stock of wear parts.
B 0.70-0.74: Routine inspections, maintenance as scheduled; moderate stock of wear parts.
C: C ≤0.69: Routine inspections; maintenance carried out in case of failures; low or no stock of wear parts.
6.3.4 Criteria for determining values of C1, C2, and C3
Weight of the equipment in the production process (C1): Degree of impact of equipment failures on production.
Level | Weight (A) | Remarks
--- | --- | ---
Directly causes shutdown of the facility | I | 100%
Has a significant impact on product quality and output | II | 80%
Has a minor impact on product quality and output | III | 60%
The impact on production can be mitigated through measures in the short term | IV | 40%
6.3.5 Weight of the equipment’s age in the evaluation (C2)
Equipment age | Weight (B) | Remarks
Less than 2 years | 30%
2–5 years | 50%
5–10 years | 80%
More than 10 years | 100%
6.3.6 Weight of the number of inspections and repairs on the equipment in the evaluation (C3)
Type of repair and its weight (D): Number of repairs | Weight (J) | Remarks
Major repair (50%): Less than 2 repairs | 60%; 2–5 repairs | 80%; 5+ repairs | 100%
Medium repair (30%): Less than 2 repairs | 60%; 3–5 repairs | 80%; 6+ repairs | 100%
Minor repair (20%): Less than 2 repairs | 60%; 3–5 repairs | 80%; 6+ repairs | 100%
6.4 Exceptional principles for grading equipment
This evaluation method is applicable to the grading of the company’s main equipment, including various pumps, compressors, air-cooled fans, and all other process-related equipment. In actual operation, in addition to the evaluation carried out using the methods mentioned above, there are also the following additional principles: 6.4.1 Imported equipment may not be subject to evaluation and can be directly classified as Class A equipment. Imported equipment is superior to domestic equipment in terms of precision, material quality, and technical sophistication; moreover, spare parts are difficult to obtain. In the event of a malfunction, it is necessary for domestic agents to send personnel for repairs, which requires careful maintenance. 6.4.2 All types of units are considered special-care equipment, and can also be directly classified as Class A equipment. The unit is composed of multiple devices, with a relatively complex structure; in addition to the main equipment, there are also auxiliary devices such as lubrication and cooling systems. Due to the high technical complexity of these units, as well as the complexity associated with their maintenance and repair, they hold a significant role in production facilities. Therefore, units that do not have any backup units are classified as A++, while those that do have backup units can be classified as A+ grade equipment. 6.4.3 If the equipment is imported, it can be directly classified as A++ category equipment. 6.4.4 Some equipment, due to their own characteristics, such as reactors and towers that are large in size and weight ； Boilers and heating furnaces with complex structures and components ； Medium-pressure steam drum belonging to category III pressure vessels ； Pumps with high flow rates and head can be considered separately and upgraded as appropriate.