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1. What basic elements should equipment operation procedures include? Equipment operating procedures are the technical specifications that enable operators to properly master operational skills. Its content consists of the matters that operators must adhere to throughout their entire operation process, based on the structure and operating characteristics of the equipment, as well as requirements for safe operation. Generally includes: --- The tasks and requirements for cleaning the site and checking the equipment status before operating it ； --- Tools that must be used to operate the equipment ； --- Main process parameters for equipment operation ； --- Causes and solutions for common faults ； --- Driving procedures and precautions ； --- Lubrication methods and requirements ； --- Specific requirements for inspection and maintenance ； --- Procedures and precautions for parking ； --- Requirements for the use and adjustment of safety protection devices ； --- The specific tasks and record-keeping details for handover and takeover. 2. What basic elements should the equipment operation procedures include? Equipment operating procedures are regulations for using the equipment, based on its characteristics and structural features. Its contents generally include: --- the operating range and process requirements for using the equipment ； --- Basic qualities and skills required of users ； --- User’s job responsibilities ； --- Various systems that users must comply with, such as assigning specific personnel to specific machines, operating based on permits, shift handovers, maintenance, and accident reporting systems ； --- Procedures essential for users, such as operating procedures and maintenance procedures ； --- Technical standards that users must master, such as lubrication cards, inspection and periodic check cards, etc ； --- Tools necessary for operation or inspection ； --- Discipline and safety precautions that users must follow ； --- The contents and standards for examining and evaluating users. 3. What basic elements should equipment maintenance procedures include? Equipment maintenance procedures are the requirements and regulations regarding the daily maintenance of equipment. Adhering to equipment maintenance procedures can extend the lifespan of the equipment and maintain a safe and comfortable working environment. Its main contents should include: — operational tasks, methods, tools and materials used, standards to be met, and precautions regarding keeping the equipment neat, clean, sturdy, lubricated, corrosion-resistant, and safe ； --- Daily inspections and the locations, methods, and standards for such inspections ； --- Inspect and evaluate the content and methods regarding the extent to which operators maintain the equipment. 4. What basic elements should be included in the equipment post responsibility system? Enterprises should establish post responsibility systems for the management of equipment, including its operation, use, maintenance, repair, and storage. Its content is to clarify the responsibilities of all personnel at various levels and in different positions related to the equipment within the company, with regard to the use, maintenance, repair, and management of the equipment. For operators, a system of designated personnel responsible for equipment operation and maintenance should be established, along with a routine inspection system and a shift-handover system. For maintenance personnel, a system of regional responsibility, regular inspection systems, and scheduled inspections for key equipment should be established. Appropriate responsibility systems should be established for equipment management personnel, including those from departments such as equipment, finance, corporate management, labor safety, education, and quality. At the same time, the post responsibility system and economic responsibility system for equipment are closely integrated, linking the quality of equipment use, maintenance, and management to the individual economic interests of employees, thereby facilitating the long-term implementation of the equipment post system. 5. Why is it necessary to use equipment correctly? The process in which a device operates under load and performs its designated functions is known as the usage process. During use, due to various forces and chemical effects, as well as factors such as the method of use, operating specifications, and duration of operation, the technical condition of the equipment changes, resulting in a gradual decline in its performance. To control the changes in the technical condition during this period and slow down the decline in the equipment’s operational capacity, it is necessary to understand the patterns of degradation based on factors such as the operating conditions and structural properties of the equipment ； Create environmental conditions suitable for the operation of the equipment, adhere to proper and reasonable usage methods and permitted operating specifications, and control the load and continuous operating time of the equipment ； Maintain the equipment carefully. All these measures must be carried out by the operator. Only when operators use the equipment correctly can its good operating performance be maintained, its efficiency fully utilized, and its service life extended. Only when the operator uses the equipment correctly can sudden failures be reduced and avoided. 6. Why is it necessary to strengthen the maintenance of equipment? The maintenance of equipment is an objective requirement for its operation. Marx said, “Machines must be cleaned regularly.” What is mentioned here is a type of additional work; without this additional work, the machine will become unusable. ”(Volume 24 of the Marx-Engels Collected Works, page 194) During use, due to the physical operations and chemical reactions associated with the equipment, there are inevitable changes in its technical condition as well as various abnormal phenomena; in addition, wear and tear caused by human factors such as loosening, dry friction, and corrosion also occur. This is a hidden hazard of the equipment; if not addressed promptly, it will lead to premature wear of the equipment and may even result in serious accidents. By ensuring the proper operating conditions of the equipment, potential problems can be prevented, avoiding unnecessary losses. Practice has shown that the lifespan of equipment depends to a large extent on the level of maintenance. Therefore, the maintenance of the equipment must be carried out compulsorily, with strict supervision and inspection. Both workshop equipment operators and maintenance staff should focus their efforts on maintenance, emphasizing \"prevention first and maintenance as the foundation.\" 7. Why is it necessary to inspect equipment? Equipment inspection involves checking and verifying the equipment’s operating conditions, performance, and degree of wear. Inspection is an important part of equipment maintenance, and it can also be considered the essence of preventive maintenance. Through inspection, it is possible to gain a comprehensive understanding of the changes in the technical condition and wear of the equipment. Any potential issues identified during inspections can always be promptly identified and resolved ； Guide the proper use and maintenance of the equipment ； Propose measures to improve maintenance ； Purposefully carry out all preparatory work before repairs to improve repair quality, reduce repair time, and lower the costs associated with each phase of the repair process. 8. What are the basic key points of total production maintenance? Total Productive Maintenance can be summarized into four basic points: --- Guiding principles. It refers to the “three comprehensives”, namely full efficiency, full system, and all employees. Total efficiency refers to comprehensive efficiency. It involves six aspects—output, quality, cost, safety, lead time for defective products, and employee morale—as well as life cycle costs. System-wide management refers to the systematic management of a device’s entire life cycle. And integrate all the operational tasks related to the lifetime management of equipment and the departments involved into an organic management system. All personnel, from managers to workers, from those involved in design to those responsible for operation, are involved in production and maintenance management, each assuming and fulfilling their respective responsibilities. --- Ways and methods of maintenance. In terms of equipment maintenance, daily inspections, regular inspections and special inspections are carried out, along with preventive testing and condition monitoring, as well as fault diagnosis. In terms of maintenance, driven by economic considerations and with the aim of improving equipment efficiency, different approaches are adopted based on the impact of the equipment on production, including corrective maintenance, preventive maintenance, improvement maintenance, and predictive maintenance. --- Production and maintenance objectives. Maintain the equipment in its optimal technical condition at the lowest possible maintenance costs ； Achieve the maximum utilization time for the equipment with the lowest failure downtime rate ； Aiming to achieve the highest efficiency of the equipment through the best maintenance methods and approaches, the direction of production maintenance work and the specific standards to be met are determined. --- Maintenance records and analysis. Regular scientific analysis is conducted on the information provided by the original records, statistical data, and outcome data, in order to reflect the distribution and degree of variation throughout the equipment maintenance process. Based on this, key issues are identified, patterns are understood, priority areas are determined, and decisions are made. Establish a reasonable, effective, and civilized production and work order. 9. What are the main contents of the “three goods” and “four skills” that operators should master? Mihoshi: To take care of it, use it well, and maintain it properly. --- Manage equipment properly: Operators are responsible for taking care of the equipment they use, and it is not allowed for others to operate it without permission. Attachments, spare parts, tools, and technical documents must be kept clean and must not be lost. --- Make good use of the equipment: strictly follow the operating procedures, use it correctly, and apply lubrication appropriately. Keep proper shift handover records and fill in the required documents carefully. --- Repair equipment: Strictly follow maintenance procedures, understand the performance and operating principles of the equipment, and promptly troubleshoot any issues ； Assist maintenance personnel in equipment maintenance and participate in commissioning and acceptance work. Four skills: namely, knowing how to use it, know how to maintain it, know how to inspect it, and know how to troubleshoot faults. --- Will be able to use: be familiar with the performance, structure, and working principles of the equipment, learn and master the operating procedures, and perform operations skillfully and accurately. --- Proper maintenance: Learn and follow the requirements for maintenance and lubrication, carry out cleaning and wiping as specified, to keep the equipment and the surrounding area clean. --- Inspections will include: becoming familiar with the equipment’s structure and performance, understanding the process standards and inspection items, and assessing the technical condition of various parts of the equipment in accordance with the requirements of routine inspections ； It can identify abnormal phenomena in equipment and their locations, and determine the causes ； It is able to assess the technical condition of equipment based on the standard of intact equipment. --- Faults will be eliminated: When a device malfunctions, measures are taken promptly to prevent the fault from spreading ； It can perform general adjustments and simple troubleshooting. 10. How should operators implement the shift handover system? Before leaving, the person handing over the shift must, in addition to carrying out routine maintenance tasks, carefully record in the \"Shift Handover Log\" details such as the operation status of the equipment during their shift, any problems encountered during operation, repairs carried out for faults, and matters that need attention by the next shift. They should also provide a detailed overview to the person taking over, conduct a thorough inspection, and sign the log accordingly. If face-to-face handover is not possible, the person in charge of the handover can carry out routine maintenance to keep the equipment in a safe condition, fill out the handover report, and submit it to the relevant responsible person for signature. If the successor detects any abnormalities in the equipment or finds that the records are incomplete, and the equipment is not maintained as required due to unclear conditions, they may refuse to take over the shift. If problems occur with the equipment after the handover due to the handover process, the person taking over is responsible. Equipment management and maintenance personnel should regularly check the implementation of the shift handover system, review the shift handover records at any time, analyze the technical condition of the equipment from these records, and use this information for condition management and maintenance purposes. 11. What does equipment maintenance include? Caring for equipment through general methods such as wiping, cleaning, lubrication, and adjustment in order to maintain and preserve its performance and technical condition is known as equipment maintenance. There are mainly four requirements for equipment maintenance: --- Cleaning. The inside and outside of the equipment should be kept clean; there should be no oil residue on various sliding surfaces, screw rods, racks, gearboxes, oil holes, etc. No oil or air leakage should occur in any part of the equipment, and debris, waste materials, and dirt around the equipment must be removed ； --- Neatness: Tools, accessories, and workpieces (products) should be placed neatly, and pipes and wiring should be organized properly. --- Good lubrication: Oil should be added or changed on time; there should be no lack of oil, no dry friction, normal oil pressure, a clear oil level indicator, unobstructed oil pathways, and oil of acceptable quality. Oil guns, oil cups, and oil seals should also be kept clean ； --- Safety: Comply with safety operating procedures, avoid overloading the equipment, ensure that the equipment’s safety protection devices are complete and reliable, and promptly eliminate any unsafe factors. The maintenance tasks for equipment generally include routine maintenance, periodic maintenance, regular inspections, and accuracy checks. The maintenance of the equipment’s lubrication and cooling systems is also an important part of its upkeep. 12. What does the three-level maintenance system include? The three-level maintenance system includes: daily maintenance of the equipment, as well as level 1 and level 2 maintenance. The three-level maintenance system is a mandatory maintenance regime that focuses on equipment care and repair, with the operator playing a key role in it. The three-level maintenance system is an effective approach to equipment maintenance, one that relies on the workforce, fully leverages their enthusiasm, implements collective management and repair, and combines specialized efforts with those of the workforce. I. Daily maintenance of equipment The daily maintenance of equipment generally includes daily tasks and weekly tasks, also known as routine daily maintenance and routine weekly maintenance. 1. Daily maintenance: This is carried out by the equipment operators during their shift, with careful attention to the four tasks before starting work, the five things to be mindful of during the shift, and the four tasks after finishing work. --- Four things before starting work: digest the pattern documents and check the shift handover records. Wipe the equipment and lubricate it as specified. Check whether the handle position and manual operation parts are correct and flexible, and whether the safety devices are reliable. Check during low-speed operation whether the transmission is functioning properly, and whether lubrication and cooling are unobstructed. --- In the class, pay attention to the operating sounds, as well as the temperature, pressure, and liquid level of the equipment. Also pay attention to the electrical, hydraulic, and pneumatic systems, the instrument signals, and whether the safety mechanisms are functioning properly. --- Four things to do after the shift: turn off the switches and set all levers to the zero position. Remove iron filings and dirt, clean the oil from the surfaces of the equipment’s guides and sliding parts, and apply lubricant. Clean the work area and organize attachments and tools. Fill out the shift handover record and the control panel log, and complete the shift handover procedures. 2. Weekly maintenance: This is carried out by the equipment operators at the end of each week. The maintenance time required is 2 hours for ordinary equipment, and 4 hours for precision, large-scale, and special equipment. --- Appearance: Wipe clean the equipment guides, all moving parts, and exposed areas, and clean the work area. It should be completely clean inside and out, without any dead corners or rust, with a tidy surrounding environment. --- Operate the transmission: check the technical condition of all components, tighten any loose parts, and adjust the clearance gaps. Check the interlocks and safety devices. Achieve normal transmission sound, as well as safety and reliability. --- Hydraulic lubrication: Clean the oil lines, dust seals, and oil filters; add oil to the tank or change the oil. Inspect the hydraulic system to ensure the oil is clean, the oil passages are unobstructed, and there are no leaks or pressure damage. --- Electrical system: Wipe the surfaces of the motors and flexibles, and check the insulation and grounding to ensure they are intact, clean, and reliable. II. Level 1 Maintenance: Level 1 maintenance is carried out primarily by operators, with the assistance of maintenance workers. It involves systematically disassembling and inspecting certain parts of the equipment as per a plan, cleaning the specified areas, clearing oil circuits and pipes, replacing or cleaning oil lines, felts, and filters, adjusting the clearance between various parts of the equipment, and tightening all components of the equipment. The time required for level 1 maintenance is 4–8 hours. After this maintenance is completed, records should be kept, indicating any defects that have not been resolved, and the workshop’s mechanical staff shall organize an inspection. The scope of protection should cover all equipment in use within the enterprise, with strict enforcement applied to key equipment. The main purpose of the first maintenance is to reduce equipment wear and tear, eliminate potential hazards, extend the equipment’s service life, and ensure that the equipment is in good condition to meet the production requirements until the next maintenance period. III. Level II maintenance: Level II maintenance is carried out primarily by maintenance workers, with the assistance of operators. Secondary maintenance is included in the equipment’s maintenance schedule; it involves partial disassembly and inspection of the equipment, replacement or repair of worn parts, cleaning, oil change, and inspection and repair of the electrical components, so that the technical condition of the equipment meets all the requirements specified for an equipment in good condition. The time required for level 2 maintenance is about 7 days. After the secondary maintenance is completed, the maintenance workers should fill out a detailed maintenance record, which is then inspected by the workshop’s mechanical staff and operators; the inspection form is submitted to the Equipment Power Department for archiving. The main purpose of secondary maintenance is to bring the equipment up to standard condition, improve and maintain its operational readiness, and extend the interval between major overhauls. 13. What is the system for equipment inspection? The equipment inspection system is an equipment management system centered on equipment inspections. Full-time inspection personnel are responsible for inspecting the equipment as well as managing it; they serve as a bridge and a core link between operation and maintenance. The inspection system consists of five aspects: the daily inspections carried out by the operators at their posts ； Regular inspections by qualified inspection personnel ； Precise inspection by technical professionals ； Experts’ technical diagnosis and probabilistic diagnosis ； Accuracy test inspection by technical experts. By coordinating different specialties and stages toward a common goal, it enables people at various levels of these different technical specialties to work together and in harmony, thus creating a comprehensive and effective equipment management system. 14. What are the basic elements of the equipment inspection system? A equipment maintenance management system that involves checking specified components of the equipment using defined methods at predetermined times and by designated personnel, and assessing the technical condition of the equipment based on standards to determine what maintenance work is necessary, is known as the scheduled inspection system. The basic elements of the inspection system include: --- Implementing management involving all employees, with production workers particularly required to participate in inspections and maintenance tasks within their capabilities. --- There should be dedicated inspectors to manage the equipment by zone. --- Inspection personnel are not merely responsible for checking equipment; they must also have management functions and be granted appropriate authority in accordance with their responsibilities. The management functions of inspection officers mainly include: monitoring and assessing the condition of equipment, managing and analyzing accidents, formulating repair plans, and preparing plans for maintenance materials as well as cost budgets. --- There must be a set of scientific inspection standards, records, cards, and systems. --- Strengthen dynamic management by implementing three levels of inspections, namely production inspections, specialized inspections, and precision inspections.