The method of having designated personnel conduct inspections on equipment and the key points for such operations

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Image 1: Inspection based on identified issues. Image. During routine inspections at the workstations, many equipment problems are inevitably detected, but neither the operators nor the team leaders are able to identify and address them accurately. When such equipment problems occur, it is necessary to have the company’s specialized maintenance personnel conduct inspections and diagnostics on the equipment. 1. Job Responsibilities: When conducting inspections based on the issues identified for each position, the cooperation of professional inspectors, operators, and team leaders is necessary. The job responsibilities of employees in each position are as follows. Image 2. Duties of the inspection officer. Relying on their knowledge, skills, experience, and logical thinking, inspection officers identify problems with equipment at the production site and determine the root causes of those problems. The specific duties are as follows. 1 Equipment inspection. Inspection personnel use precision instruments or online monitoring methods to conduct comprehensive inspection, testing, and diagnosis of both online and offline equipment. They measure certain physical parameters of the equipment, thereby keeping track of the operating conditions and any defects in the equipment and its components. This allows them to determine quantitatively the technical condition of the equipment, the degree of degradation, and the trends in such degradation, as well as to assess the necessity for repairs and adjustments. 2 Identify the root cause of the problem. Through equipment inspections, unstable factors are identified among those that are stable, and signs of abnormalities are detected in equipment that is operating normally ； Detect the degradation of the equipment and closely monitor its progression to identify patterns. At the same time, it is necessary to detect and address equipment degradation anomalies early, preventing them from escalating into equipment failures. 3. Inspection process for identifying problems: By examining and assessing the equipment, inspectors eliminate faulty factors, thereby determining the scope and details of repairs needed. They also prepare accurate and reasonable plans for supplying spare parts as well as for equipment maintenance. The specific inspection process is as follows. 1 The specialized inspection personnel collect the technical standards, inspection criteria, and equipment operation status for the areas where issues are identified during routine inspections, and submit a detailed inspection plan for precise inspections to the equipment management department. 2 The equipment management department compiles the detailed inspection plans for each area, conducts an overall balance, and then issues the implementation plans for these inspections to the respective areas. 3. The inspection area fills out the inspection assignment form according to the implementation plan and submits it to the personnel in charge of precise inspections; these personnel then pass the form on to the units responsible for carrying out the precise inspections. 4 The implementing unit discusses the specific date, requirements, and related technical issues with the regional inspection personnel, carries out the detailed inspections as planned, and submits the results of these inspections to the equipment management department. 5 The equipment management department will make copies of the test results for archiving, submit the original copies to the technical department, and provide technical analysis opinions at the same time. 6 The technical department delivers the test reports and analysis results to the personnel in the inspection area. The inspectors use these reports and results to assess the actual technical condition of the equipment and take appropriate actions. Image Image II. Inspection during operation Image Image When equipment operators detect any abnormal conditions in the equipment during production or operation, they need to stop the equipment at the end of that production cycle in order to conduct an inspection. The focus of this type of inspection work is to ensure speed and accuracy, in order to identify issues within the equipment as efficiently as possible and avoid delaying production progress. 1. Inspection tools: Simple and efficient measuring tools are required for inspections during operation. In addition to tools such as flashlights and voltage testers, inspectors often use two other types of tools: inspection hammers and listening rods. 1. The inspection hammer is a small hammer with a conical end and a circular end, along with a long handle; inspectors can utilize the different shapes of these two ends to apply it flexibly to the equipment being inspected, depending on the requirements of the situation. The inspection hammer covers a wide range of equipment inspections, and it can quickly and accurately determine whether the components of the equipment being inspected are functioning properly. 2 A listening rod is a metal rod with a spherical shape at both its tip and end, and it can fit tightly against the ear canal. By using a listening rod and making contact with the surface of the equipment being inspected, inspectors can detect various faint sounds generated during the operation of the equipment – sounds that cannot be heard with the ear in normal daily work. During routine inspections, inspectors can use listening rods to check the operating condition of equipment components such as bearings and gears. 2. Grading of inspectors: During operation, inspections are unexpected events, and there is often no pre-established plan for dealing with them; therefore, inspectors need to identify and resolve equipment issues as quickly as possible. The inspection skills and experience of the inspector affect the efficiency and accuracy of equipment inspection. To improve equipment management, some companies implement a hierarchical system for inspectors, assigning higher-ranked inspectors to handle critical equipment issues. The grading criteria for inspectors are as follows. Classification criteria for inspectors – Images, Images, Images. III. Inspection at maximum load – Images, Images. Many types of equipment, such as electrical and mechanical devices, typically have a maximum load value; failures are likely to occur when the machine operates at or near this maximum load. To prevent production accidents and ensure the safety of people and property, enterprise managers should conduct inspections of equipment under maximum load conditions. 1. Key inspection areas: The equipment itself has, by design, certain parts and areas that are vulnerable and subject to high stress, such as wear-prone parts, areas prone to thermal fatigue, and connection points. Inspection personnel should pay special attention to checking these areas during inspections, especially under maximum load conditions. The key areas for inspection are as follows. Key inspection areas of the equipment under maximum load – Image 2. Inspection techniques: When the equipment is operating at its maximum load, inspectors may need to use various specialized inspection techniques; the common ones are as follows. Temperature monitoring technology, surface non-destructive monitoring technology, oil monitoring and analysis technology, non-destructive testing technology, vibration and noise diagnosis, electrical equipment monitoring technology, stress and strain monitoring technology. Images. Images. IV. Routine inspections during downtime. Images. Images. To avoid delaying production progress, inspectors may need to carry out inspections when the equipment is not in operation, that is, during downtime. This type of inspection work requires the inspector to make thorough preparations. During production pauses, team leaders must cooperate with the inspection staff in conducting equipment inspections and must not prevent such inspections. To ensure that inspection tasks can be completed during the breaks in production, so that inspections are finished before production resumes, equipment managers can divide the inspection areas and carry out area-specific inspections. This facilitates equipment inspection, reduces maintenance time, and helps plan the volume of maintenance work. After completing the inspections, the inspectors in each area must fill out the area inspection form, which is detailed below. Regional Inspection Form: Inspection Area: Inspection Date: Year Month Day. Images: The person in charge of the inspection work should compile and organize the equipment issues identified by the inspectors in each area, and fill out the Equipment Inspection Issues Summary Table as shown below. Equipment Inspection Issues Summary Table Fill-in person: Date of filling: Year Month Day