Management processes, management systems, and implementation plans for equipment use and maintenance

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Equipment Use Management System Chapter 1 General Provisions Article 1 Purpose This system is established to ensure the proper use of equipment, prevent abnormal wear or damage to it, avoid accidents involving personnel or equipment, and extend the equipment’s service life and maintenance intervals. Article 2 Scope of Application This applies appropriately to tasks such as equipment operation, maintenance, and equipment documentation management. Article 3 Responsibility Allocation The responsibilities and specific duties of the departments involved in equipment usage management are as follows. 1. Team leaders in production and equipment management should assist the equipment department manager in establishing and improving the systems related to equipment operation, and oversee the compliance with various rules and regulations during the use of the equipment. 2. The Equipment Department shall strictly comply with the provisions set out in this system to strengthen the use and management of equipment at the production site, implement and supervise the equipment usage regulations during production activities, and carry out proper management of equipment before, during, and after its use. Chapter 2: Equipment Operating Procedures. Article 5: Basis for the formulation of equipment operating procedures. The company’s equipment operating procedures are regulations that equipment operators must comply with; they are crucial for ensuring the safe operation of equipment. Therefore, these procedures must be formulated based on the performance parameters of the equipment and the requirements imposed by the production process. Article 6: Division of responsibilities for preparing equipment operation procedures Before each piece of equipment is handed over to the production team for use, the company must prepare complete operation procedures for that equipment. The process operation details in the equipment specifications are written by the company’s process technology personnel; the safety operation section is written by safety personnel. The Equipment Department Manager is responsible for compiling and finalizing the document. Article 7: Contents of equipment operation specifications. Equipment operation specifications must include the following four aspects. 1. Preparatory work before starting work. 2. Parameters and performance of the equipment. 3. Measures to take in case of an emergency with the equipment. 4. Provisions for the daily maintenance of equipment. Article 8 Approval and implementation of equipment operating procedures: Once approved by the Technical Department Manager and the Deputy General Manager in charge, the equipment operating procedures are issued to various production units for implementation. Article 9 Changes to Equipment Operation Specifications: When there are changes in the production process, or when the performance or operation methods of equipment change as a result of technical modifications, the operation specifications for that equipment must also be adjusted accordingly. Chapter 3: Preparatory Work Before Equipment Use Article 10: Qualifications for Operating Equipment Before operating equipment, operators must receive training in accordance with the equipment operation guidelines. The Human Resources Department is responsible for conducting assessments; upon passing these assessments, the Equipment Comprehensive Management Office issues a certification allowing the operator to work with the equipment. Only equipment operators with valid certificates may operate the equipment. Article 10 Preparations before Starting the Equipment Before starting the equipment, the operator must conduct a thorough inspection of it according to the specifications for using the equipment. Article 12: Management of Equipment Operated by Multiple Persons. For equipment that requires multiple persons to control or is located on a production line, it is necessary that the operators be familiar with and understand the procedures and details related to starting up the equipment, in order to prevent accidents. Article 13: Observation before starting the equipment. When the equipment operator performs necessary test operations on the equipment, it is necessary to check whether there are any people working or objects placed in the upstream and downstream processes as well as within the equipment area. Article 14: Warning signal before starting the equipment. Before starting the equipment, the operator must first issue a warning signal to indicate that the equipment is about to be started, and then proceed according to the procedures specified in the equipment’s operating instructions. During the startup and operation of the equipment, it is necessary to check for any abnormal conditions. Chapter 4: Regulations for Equipment Use Article 15: The “Four Fixed Principles” for Equipment Use The use of company equipment is to be assigned to specific individuals and governed by established procedures; unauthorized persons are prohibited from operating such equipment, otherwise they shall bear the consequences. Article 16 Management of Equipment Safety Devices: No one shall, without approval, arbitrarily cut or weld on equipment, alter its structure, or modify or remove its safety devices. Article 17: Operating requirements for critical equipment. For key positions (such as main step-down substations, transformer stations, etc.), a two-person operation and verification system must be implemented; that is, one person performs the operation while another supervises it, thereby preventing operational errors that could lead to serious personal injuries or equipment accidents. Article 18: Handling of Equipment Abnormalities During operation, the equipment operator shall monitor the surrounding environment, pay attention to the coordination between preceding and subsequent processes, and keep an eye on changes in instrument readings. Upon detecting any abnormal condition in the equipment, stop it immediately and report it to higher authorities. Chapter 5: Shift Handover for Equipment Operation Article 19: Equipment Operation Records Before leaving work, the equipment operator must complete the equipment operation records and carry out any necessary maintenance and lubrication of the equipment. Article 20: Cleaning of the equipment area. Equipment operators shall maintain cleanliness and order in the equipment area; they should wipe the equipment and clean the area before leaving work, in order to keep the equipment and the area tidy. Article 21 Requirements for Equipment Handover: If a fault is detected in the equipment during operation, any issue that can be resolved by the current shift should not be passed on to the next shift. If the current shift is unable to resolve the issue completely, the remaining parts can be handed over to the next shift, which must then continue to work on it and conduct a thorough inspection. The equipment can only be turned on once everything is normal. Article 22: Careful review by handover personnel. After arriving at their posts, incoming personnel must carefully examine the operating records of the equipment from the previous shift, especially any records of malfunctions. They must have a clear understanding of these details to prevent accidents. Article 23: Determining the status of equipment handover. When the person taking over the shift has doubts regarding the equipment’s operation records, they should promptly consult the on-duty manager to determine the actual status of the equipment. Chapter 6: Management of Documents and Information During Equipment Use Article 24: Contents of Equipment Usage Records Equipment operators are required to record the operating conditions of the equipment, and the information recorded should reflect the actual technical condition of the equipment. The contents that equipment operators need to record include the following 6 aspects. 1. During operation, the equipment itself may exhibit abnormal phenomena such as unstable operation, vibration and noise, abnormal data readings from the monitoring devices, local temperature rises exceeding specified limits, abnormal wear or deformation of components, axial movement, corrosion, as well as unusual odors, sparks, or smoke. 2. Data on sudden changes and abnormal fluctuations in the equipment control system, such as frequent power failure protections. 3. Changes in the electromagnetic performance parameters of electrical equipment, such as parameters related to insulation, rectification, grounding, electronically controlled excitation, frequency conversion, as well as changes in voltage, current, resistance, capacitance, etc. 4. Power supply parameters, such as changes in steam, compressed air, industrial water pressure, flow rate, velocity, temperature, etc. 5. Equipment lubrication parameters, such as the pressure, flow rate, and temperature of the centralized lubricating oil, as well as changes in the quality of the grease; abnormal conditions such as pipeline leaks and blockages. 6. The entire process of an accident or malfunction of the equipment (including time, phenomena, causes, characteristics, and consequences), as well as any abnormal signs prior to its occurrence, etc. Article 25 Requirements for equipment records: When the above conditions occur with the equipment, the operator must record them at all times, and the data recorded must be accurate, clear, and complete. Article 26 Submission of equipment records: The equipment operation records shall be compiled by the production unit in chronological order by shift, day, and month, and submitted regularly to the relevant personnel at the Equipment Comprehensive Management Office. Article 27: Equipment Record Keeping and Statistics. The staff of the company’s Comprehensive Equipment Management Office shall periodically check the records of equipment operation status. Should it be discovered that equipment operators fail to record the operation status of the equipment, or intentionally omit or misrecord such information, the company will take severe action against them. Article 28: Establishment of equipment records. The Equipment Department shall establish equipment management records, which should include original technical documents such as equipment user manuals, handover registers, operation logs, inspection records, records of inspections and corrective actions, maintenance records, accident analyses, and information regarding technical modifications. Production teams must promptly report any changes related to the equipment to the Equipment Department. Chapter 7 Supplementary Provisions Article 29 This system is formulated by the Equipment Department, which holds the authority to interpret and amend it. Article 30: This system shall come into effect as of the date of issuance, following approval by the General Manager’s Office meeting. Images, Equipment Department, Images, Equipment Maintenance Management System, Chapter 1: General Provisions, Article 1: Purpose. This system is established to standardize the company’s equipment maintenance management, ensure the long-term stable operation of the equipment, and extend its service life. Article 2 Scope of application. This system applies to the daily and regular maintenance of equipment in production workshops. Chapter 2: Responsibilities for Equipment Maintenance Article 3: The main personnel involved in the maintenance of the company’s equipment are production team leaders, equipment maintenance staff, and equipment operators. Article 4 The duties of production team leaders are as follows. 1. Develop an equipment maintenance plan based on relevant materials. 2. Train equipment operators on knowledge related to equipment maintenance. 3 Supervise the implementation and execution of the equipment maintenance plan. 4. Regularly inspect the equipment’s maintenance work and conduct evaluations. Article 5 The responsibilities of equipment maintenance personnel are as follows. 1. Understand the operating status of the equipment. 2. Responsible for the secondary maintenance of equipment. 3. Supervise the equipment maintenance work carried out by the equipment operators. 4. Check the equipment’s maintenance records, and regularly collect, organize, and analyze them. 5. Responsible for the maintenance of backup equipment. Article 6 The responsibilities of equipment operators are as follows. 1. Strictly follow the operating procedures for the equipment, and keep proper records of its maintenance. 2. Responsible for the cleaning and upkeep of equipment. 3. Monitor the operation of the equipment, and report any issues found in a timely manner. Chapter 3: Preparatory Work for Equipment Maintenance Article 6: The production team leader shall prepare a maintenance plan, assign specific personnel to carry out the equipment maintenance tasks, and establish corresponding assessment procedures. Article 7: Equipment maintenance personnel shall prepare in advance various forms for recording equipment maintenance tasks, as well as the tools and supplies needed for equipment upkeep. Article 8: Equipment maintenance personnel shall establish maintenance boards around the equipment, on which the basic principles of equipment maintenance as well as schematic diagrams of the maintenance procedures should be displayed. Article 9: Production shift leaders shall provide technical training to operators before they start working, so that they understand the structure, performance, operation procedures, and maintenance requirements of the equipment. They must meet the requirements of “three understandings” (understanding the structure, understanding the principles, understanding the performance) and “four skills” (being able to use the equipment, conduct inspections, perform maintenance, and troubleshoot faults). Article 10: Before using the equipment, the equipment maintenance personnel shall, together with the equipment repair staff and relevant personnel from the technical department, conduct a comprehensive inspection and verification of the equipment’s accuracy, performance, safety, and control systems. It may only be used after it has been confirmed to be in good condition. Article 11: Equipment operators must obtain a qualification certificate before taking up their posts. Once a position is assigned, the equipment to be operated must also be determined, and there shall be no arbitrary changes to it. Chapter 4: Implementation of Equipment Maintenance Article 12: The daily maintenance of equipment is the responsibility of the equipment operators, who must carry out maintenance tasks in accordance with the established maintenance procedures for that equipment. Article 13: Before ending work each day, the equipment operators shall fill out a detailed record of the equipment’s maintenance, describing its operating condition; this record is then checked by the equipment maintenance staff. Article 14: Equipment maintenance personnel shall regularly collect equipment maintenance data, organize and analyze it, and prepare reports on equipment repair and maintenance. Article 15: Production team leaders shall carefully review equipment maintenance reports and check the maintenance records of the equipment. Based on these records, they should modify the equipment maintenance procedures as necessary to make the maintenance process more efficient. Chapter 5: Standards for Equipment Maintenance Article 16: Equipment maintenance is divided into three levels: daily maintenance, level-1 maintenance, and level-2 maintenance. Daily maintenance is further divided into shift-based maintenance and maintenance during holidays. Article 17: Specifications for daily maintenance of equipment. 1. Equipment operators should conduct a pre-shift inspection of the equipment to check for any abnormalities and review the equipment operation records from the previous shift. 2. The equipment operator should lubricate the equipment in accordance with the specifications indicated on the equipment’s lubrication icons before starting it up. 3. After ensuring that the equipment is in good condition, the operator shall run the equipment without a load; work can begin only after all its components are functioning properly. 4. Equipment operators must conduct regular inspections during the operation of the equipment; if any abnormalities are detected, they should stop the equipment immediately and notify the equipment maintenance staff promptly. 5. Before leaving work each day, the equipment operator should check whether the equipment operation records have been completed, and spend about 20 minutes cleaning the equipment, turning off the power supply, and tidying up the work area to ensure that the equipment is clean and tidy. Article 18: On company holidays, equipment operators shall spend approximately one and a half hours thoroughly cleaning the equipment, removing oil stains, performing lubrication, and tidying up the surrounding area; this work must then be inspected by equipment maintenance personnel. Article 19: Standards for first-level maintenance of equipment. 1. In principle, the first-level maintenance of equipment should be carried out every three months; for equipment used in dry grinding operations where dust is generated, it should be done monthly. 2. The primary maintenance of the equipment is carried out mainly by the operators, with the assistance of equipment maintenance staff. 3. The key points for performing first-level maintenance on equipment are as follows. (1) Remove the specified components, lid, dust cover, etc., and clean them thoroughly. (2) Clear the oil passages, clean the filters, and replace the oil lines, oil felt, oil filters, lubricant, etc. (3) Replace components such as handles, handballs, screws, nuts, and oil nozzles to maintain the integrity of the equipment. (4) Tighten any loose parts of the equipment, adjust the clearance between its components, and replace individual wear-prone parts and seals. (5) Clean the guide rails and all sliding surfaces, removing burrs and scratches. Article 20 The specifications for the secondary maintenance of equipment are as follows. 1. The secondary maintenance of the equipment is generally carried out once every six months, or it can also be done during the off-peak production period. 2. The secondary maintenance of production equipment is primarily carried out by equipment maintenance staff, with operators playing a supporting role. 3. The key points for the secondary maintenance of production equipment are as follows. (1) Disassemble certain components of the equipment for inspection and maintenance, and replace or repair the worn parts. (2) Replace the mechanical oil in the equipment. (3) Clean, inspect, and adjust electrical circuits and devices. Chapter 6: Maintenance of Special Equipment Article 21: The company’s special equipment refers primarily to its “precision, large-scale, and rare” equipment. Article 22: In daily operations, equipment maintenance personnel are required to guide the operators of the equipment in continuously maintaining the environment in which the company’s special equipment is located, so that the operating conditions meet the requirements for the proper functioning of such equipment. Article 23: Operators of special equipment must strictly adhere to the equipment maintenance specifications during routine maintenance, and shall not remove components at will, especially precision components. Article 24: Lubricants, cleaning materials, and detergents used in the maintenance of special equipment must be used in accordance with the specifications provided in the equipment’s operating instructions; they shall not be replaced arbitrarily. Article 25: In the event of any abnormal phenomena during the operation of special equipment, it must be stopped immediately, and the situation should be reported to the equipment maintenance personnel; operation with defects is not permitted. Article 26: When special equipment is not in use, the entire unit or its key components should be covered with guards. If it is not used for an extended period of time, it must still be wiped down, lubricated, and run idle regularly to prevent corrosion and damage to its components. Article 27: Special attachments and maintenance tools shall be kept in designated cabinets, where they are to be properly stored by the equipment operators and kept clean to prevent loss and rust. Article 28: The “four fixations” for the maintenance of special equipment. 1. Determine the users. Personnel responsible for operating special equipment should be individuals with high technical skills and a strong sense of responsibility, and these positions should remain stable; there should be no changes without proper reason. 2. Assign maintenance personnel. The personnel responsible for maintaining special equipment should be fixed, so that they can become familiar with it and gain experience in maintaining such equipment, thereby enabling them to address issues quickly and accurately. 3. Establish operating and maintenance regulations. The production team leader, together with relevant personnel from the technical department, formulates maintenance specifications for each piece of equipment based on its specific characteristics, and these specifications are strictly followed. 4. Establish maintenance plans and spare parts. The production shift leader determines the maintenance plan and methods for each piece of equipment based on its impact on production, to ensure timely supply of spare parts during equipment repairs. Chapter 7 Supplementary Provisions Article 29 These provisions are formulated by the Equipment Department, which holds the authority to interpret and amend them.