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Operation of field equipment – inspections, checks, and defect supervision and management

2024-01-11View Original

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Dynamic monitoring of equipment operation refers to the use of certain methods to enable maintenance personnel and managers at all levels to keep track of the equipment’s operating conditions, so that appropriate measures can be taken based on those conditions. 1. Establish and improve equipment inspection standards. Enterprises should determine, based on the structure and operating mode of each piece of equipment, the areas to be inspected (inspection points), the contents of the inspections, and the parameter standards for normal operation. Additionally, taking into account the specific operating characteristics of the equipment, they should set out the inspection frequency for each inspection point; these frequencies can generally be categorized as hourly, shift-based, daily, weekly, ten-day, or monthly inspections. 2. Establish and improve the inspection assurance system. Operators at production posts are responsible for checking all inspection points of the equipment used in their respective posts, while specialized maintenance personnel should undertake the inspection of key equipment. Enterprises should determine the number and selection of full-time inspection personnel based on the quantity and complexity of their equipment. In addition to being responsible for inspecting key pieces of equipment, these full-time inspectors must also have a comprehensive understanding of the equipment’s operational status. 3. Improve information transmission and feedback (1) Operator inspection: When operators at the production site check the equipment and find that it cannot continue to operate, they must immediately inform the on-duty dispatcher, who will then organize the necessary actions to address the issue. As for general hazards or defects, they should be recorded in the inspection checklist after inspection. For certain devices that require regular inspection, the inspection records can be attached to the surface of the device. (2) Dedicated personnel conduct equipment inspections. ① When carrying out equipment inspections, dedicated personnel must keep proper records; in addition to assigning tasks to members of their own team, they should also pass on the relevant information to the dedicated inspection staff so that it can be compiled together. ②In addition to carrying out the inspections at their assigned locations, these full-time staff are also responsible for compiling and summarizing the inspection results from various areas on a daily basis, identifying the key issues of the day, and then reporting them to the equipment management department. ③The equipment management department shall maintain a register of reported issues. 4. Timely handling of equipment defects (1) Inspectors identify equipment defects and potential hazards discovered during inspections, propose items that require maintenance, and include them in the maintenance plan. (2) Equipment defects identified during inspections that require immediate attention must be addressed right away, with the production supervisor on duty organizing the necessary actions promptly ; For issues that this shift is unable to handle, the enterprise leadership shall determine a solution. (3) Major defects in important equipment shall be studied by plant-level leaders, who will determine the control and handling plans. 5. Handling of weak links (1) Identification of weak links Equipment can be identified as having weak links if it falls under any of the following conditions. ①During operation, malfunctions frequently occur, causing shutdowns; repeatedly addressing the ineffective parts proves futile. ②Equipment and components that affect product quality and output during operation. ③Parts whose operation does not meet the requirements of the minor repair cycle and often require unscheduled maintenance. ④Parts or equipment that pose safety hazards and cannot be resolved through routine maintenance or simple repairs. (2) Requirements for managing weak links: ① The equipment management department should, based on dynamic data, identify the weak links in the equipment, organize reviews on a timely basis, determine the issues that need to be addressed immediately, and propose improvement plans. ②Organize relevant personnel to review the improvement plan; upon approval, it shall be included in the maintenance schedule. ③After implementing improvement measures for the weak points of equipment, an evaluation of the effectiveness must be conducted, and evaluation comments should be provided. These comments, after being reviewed by relevant supervisors, shall be filed in the equipment records. 6. Equipment inspection markings: When conducting equipment inspections, records should be kept, and appropriate markings should be made; if the inspection shows normal operation, mark it as “Operating normally”, and if a fault is detected, mark it as “Machine fault”, etc.

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