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1 Scope This standard specifies the management requirements for the inspection of equipment and tools. This standard applies to online tooling for equipment and production lines where high requirements are placed on operational reliability, as well as to the preventive maintenance management of utility power equipment; it does not apply to household equipment and public facilities. 2 Terms and Definitions The following terms and definitions apply to this document: ① Professional inspection – Equipment inspection activities carried out primarily by maintenance workers; these inspections involve more in-depth checks of the equipment and tools, and require specific professional skills and specialized tools to be conducted. ②Self-inspection refers to equipment inspection activities carried out primarily by operators; these inspections cover the condition of the equipment and tools, operational safety, as well as key quality-related aspects. They can be conducted without the need for specialized maintenance skills or tools. ③5W2H are the basic elements for formulating basic work standards. 5W specifies the task content (What), location (Where), frequency (When), responsible person (Who), reason (i.e., the choice of task content) (Why), quantitative standard (How much), and method (How). 3 Classification of inspections 1 Self-inspection ① Self-inspection is carried out primarily by the operators. ②The contents of self-inspection mainly involve the detection and elimination of defects and issues related to the equipment’s exterior and environmental conditions (such as its appearance, safety, quality, etc.); it is not permissible to disassemble the equipment or carry out work on live circuits. ③The contents of self-inspection should be guided and confirmed by maintenance personnel. ④Based on the operator’s proficiency in self-inspection, the level of such inspections can be gradually increased, but this does not apply to tasks that require special qualifications. 2 Professional inspection ①Professional inspection is carried out primarily by maintenance personnel. ②Professional inspections involve comprehensive and thorough checks as well as repairs for defects and issues in both the external and internal conditions of the equipment. ③The items to be inspected and the technical methods used by maintenance personnel are guided and confirmed by the equipment technician. 4 Preparation of inspection documents 1 Classification of equipment inspection documents a) Inspection standard cards: Define the inspection areas, contents, frequency, criteria for judgment, and methods for inspecting equipment and tools. b) Inspection record form: Records the actual contents of the inspection work and the inspection results. c) Operation manual: Guides inspectors in carrying out complex inspection tasks. 2 Assignment Content ① Source of assignment content a) Items recommended in the equipment manual ； b) Defects in the equipment itself or in the environment that can lead to equipment deterioration, identified during equipment maintenance ； c) Weak points that need special attention as exposed by equipment failures ； d) Items that require attention based on accumulated maintenance experience ； e) Items that require regular inspection in accordance with regulations. ②The content of the tasks should focus on: a) potential hazards related to personal safety and equipment safety ； b) Dynamic defects and hidden risks that arise during dynamic processes and can lead to sudden shutdowns ； c) Inspection of the equipment’s static appearance for integrity and defects ； d) Measurement of the internal conditions and parameters of equipment that are important both in dynamic and static states, are variable, and require daily control and monitoring ； e) Check the condition of vulnerable components ； f) Check the lubrication condition ； g) Other areas and issues that require daily monitoring. ③Items for which the inspection cycle should be kept at 1 month (exclusive) or less. 3 Document Preparation Standards ① Inspection Standard Card 1.1 The \"Inspection Standard Card\" should be prepared in accordance with the 5W2H principle and must include the following essential elements: a) Task content: A description of the tasks to be carried out ； b) Location: The location on the equipment or tool where the work is carried out ； c) Responsible person: Person in charge of the operation ； d) Operation cycle: the fixed interval between two consecutive operation times ； e) Control criteria: Criteria for determining the desired state of operations ； f) Method: Work procedures, precautions, etc. 1.2 The contents of the “Inspection Standard Card” focus on professional inspections, while also including elements related to self-inspections. 1.3 The “Inspection Standard Card” should use text, diagrams, etc. to clearly explain the relevant requirements, making it easy for workers to understand. 1.4 The extent of the inspection items can be determined based on the actual operational resources available in the workshop, but it is advisable to cover key aspects such as safety, quality, defects that can lead to rapid deterioration of the equipment, and other issues of significance. 1.5 The inspection requirements cover all operational equipment and in-use tooling. 1.6 The items included in the inspection should be targeted at common faults and deteriorations, be preventive in nature, and practical to implement. 1.7 The energy quantified for operational standards should be expressed in numerical terms. 1.8 The “Inspection Standard Card” should include fields for compilation, review, and approval. 1.9 No restrictions are imposed on the format of the \"Inspection Standard Card\" form; each unit may develop it according to its own needs. For details, please refer to Informative Appendix A. ②Inspection Record Form 2.1: The \"Inspection Record Form\" corresponds one-to-one with the \"Inspection Standard Card\", and it serves as a record of the work that has been carried out. 2.2 The document should record the details of the task, the personnel performing it, and the inspection results (mark √ or ○ for normal conditions, and × for abnormal conditions); when × is marked, the issue and the actions taken to address it should be described. 2.3 When the inspection result is marked with ×, if it can be addressed on-site immediately, it should be dealt with right away; if it cannot be handled promptly, it should be included in a targeted repair plan, and the results of the handling should be recorded. The inspection records, the targeted plan, the corrective actions taken, and the work records must all be consistent with each other. 2.4 For measurement points involving quantification, data should be recorded; for those with large volumes of data, specialized data recording sheets are advisable. 2.5 The “Inspection Record Form” shall include a three-level confirmation section for signatures by the operator, team leader, and maintenance technician. 2.6 No specific requirements are set for the format of the \"Inspection Record Form\" and the accompanying data recording forms; each unit may develop them according to its own needs. For details, please refer to Informative Appendix B. ③Operation Instructions 3.1 For relatively complex inspection processes where operators are prone to making operational errors or creating quality and safety hazards, it is necessary to prepare \"Operation Instructions\". 3.2 The \"Operation Instructions\" define the specifics of a particular operation: a) Operation preparation: tools and materials that need to be prepared; b) Operation sequence: a description of the steps involved in carrying out the operation; c) Operation methods: manual tasks and how to use tools; d) Control standards: criteria for determining whether the operation has been completed successfully; e) Precautions: safety and quality-related considerations; f) Sorting and organization: requirements for cleaning up and organizing the work area after the operation. These cover all the elements necessary to complete an operation properly. 3.3 The text of the 《Operation Instructions》 shall meet the following grammatical requirements: a) The wording must be accurate and free of ambiguity ； b) The narrative is simple, with clear and easy-to-understand meaning ； c) For areas where value specifications are required, quantitative control standards should be established ； d) When understanding is difficult, graphical explanations such as photos, block diagrams, and flowcharts should be provided. 3.4 The grassroots operation units shall organize single-point training in accordance with the Operation Instructions to ensure that operators master them proficiently. 3.5 No restrictive regulations are set for the format of the «Work Instructions Book», and each unit may prepare it according to its own needs. 4 Dynamic Maintenance ① The workshop should conduct regular dynamic maintenance of relevant documents based on the following changes, in order to implement a PDCA cycle for continuous improvement: a) Changes in the maintenance requirements resulting from alterations or improvements to equipment and tools, which lead to changes in their structure or operating principles ； b) Items that need to be inspected, as determined through fault analysis following a malfunction of equipment or tools ； c) Defects or potential hazards discovered during equipment maintenance that lead to equipment deterioration; items that should be controlled through inspections ； d) Optimized inspection items based on the trend changes in the data records accumulated during the inspection process ； e) Projects for which the preventive effect is not evident based on observations of actual operational results, or those that are discontinued due to an inability to sustain support in terms of human and material resources. ②Through dynamic maintenance, three alignments are achieved: alignment between inspection items and issues serta defects that require attention, alignment between operational tasks and the \"Inspection Standards\", and alignment between operation records and the operational tasks. ③All Inspection Standard Cards and work records that require written approval must be archived in written form in addition to electronic versions; other documents can be archived in electronic form. ④Dynamic documents such as the Inspection Standard Cards and Inspection Record Forms shall be archived for a period of not less than 3 years; the retention period for data records should be determined based on actual analysis requirements, while the Operation Instructions shall be archived permanently until the equipment is scrapped. 5 Process Management of Operations 1 Operation Organization 5.1.1 Professional inspections and self-inspections are organized respectively by the maintenance team leader and the production team leader, with the maintenance staff and operators carrying out the tasks. 5.1.2 The “Inspection Record Form” and the “Inspection Data Record Form” should be hung at the equipment location, so that maintenance workers can access them and make records during inspections. 5.1.3 The department responsible for inspections shall, based on the production environment of its assigned area, implement the \"Eight-Defined Inspection Method\" where conditions permit: a) Define the inspection locations: Determine the areas to be inspected using the \"Inspection Standard Cards\". b) Determination of content: The specific tasks for inspection are determined through the \"Inspection Standard Card\". c) Establish standards: Determine the normal judgment criteria for inspections through the \"Inspection Standard Card\". d) Determination method: Determine the inspection tools, procedures, and precautions through the “Inspection Standard Card” and “Operating Instructions”. e) Assign personnel: Determine the person responsible for the task. f) Define zones: Assign personnel to specific equipment responsibility zones. g) Determine the route: When conducting inspections of large areas such as entire plant facilities or outdoor sites using public power systems, the route to be followed during the inspection should be fixed. h) Fixed time: When conducting inspections of large areas such as the entire plant or outdoor sites using public power systems, the inspection time should be fixed. 5.1.4 During inspection, the inspection form should be taken out, and each item on the form should be checked one by one; records should be made as the inspection is carried out to ensure nothing is overlooked. 5.1.5 In accordance with the actual parts and contents to be inspected, for each inspection item, one must be physically present, observe carefully, and perform the necessary actions. Over time, these actions should be standardized and institutionalized in the workflow to ensure the authenticity of the inspections. 2 Work Record 5.2.1 After each inspection item is completed, it is necessary to record on the spot whether the inspected item is normal or abnormal. If an anomaly is detected and resolved on-site, it may not need to be recorded as an anomaly. When an abnormality is recorded, the details of the abnormality should be indicated on the Inspection Record Form. After recording, it is signed by the operator. 5.2.2 For measurement-related items or items with accuracy requirements that can be quantitatively recorded, the quantified recorded data shall be filled in. 5.2.3 The contents of the records related to inspections must correspond one-to-one with the \"Inspection Standard Card\". 5.2.4 The maintenance team leader shall regularly (e.g., weekly) confirm and sign the team’s ‘Inspection Record Form’. 5.2.5 Technicians or other designated managers shall regularly (e.g., monthly) confirm and sign the recovered inspection sheets. 5.2.6 Relevant records and signature confirmations should be carried out in real time, and should not be filled in retrospectively. 3 Application of inspection results 5.3.1 For problems identified during inspections, those that can be addressed promptly in accordance with safety regulations and for which the conditions for handling are available should be dealt with immediately; those that cannot be handled right away should be recorded accurately as abnormalities and included in a targeted repair plan. 5.3.2 The problems identified through inspections can be used as a basis for planning the following maintenance activities: a) Regular and scheduled maintenance plans; b) Targeted repair plans; c) Annual project plans. 5.3.3 Status data records must be analyzed regularly to identify trends in deterioration, and these analyses should be used to guide the content of inspections as well as the maintenance outlined in regular and scheduled maintenance plans. 6 Confirmation and Evaluation ①Implement a three-level confirmation system involving team leaders, equipment technicians, and workshops (grassroots departments). ②In addition to verifying signatures, the team leader should conduct practical spot checks on the inspections performed by team members, reproducing the actual inspection process to confirm whether the employees’ results are accurate and correct. ③Workshops (front-line departments) should regularly organize inspections to observe on-site performance, actually watch and record how employees carry out inspections, and provide guidance, evaluation, and corrective actions. ④To ensure the authenticity of inspections and the identification of issues, it is advisable to establish indicators such as the number of issues detected and the issue resolution rate, and include them in the performance evaluation of workshops (grassroots departments).