Equipment Inspection and Management System

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I. General Provisions 1. Equipment inspection, maintenance, and repair shall follow the principle of combining professional management with collective management. By integrating daily inspections, routine inspections, professional inspections, and precise inspections, it is possible to improve the performance of equipment, prevent accidents, extend the lifespan of components, reduce downtime, enhance the efficiency of equipment operation, ensure smooth production, and lower maintenance costs. Its core is \"prevention first and predictive maintenance.\" 2. The company implements a inspection and maintenance system for equipment management. The inspection tasks are carried out by the equipment department of the manufacturing plant, as well as by the operators and maintenance staff at various positions in the workshops. Purpose 2: 1. Inspection: It involves examining and diagnosing equipment in order to identify defective areas as early as possible, analyzing the trend of equipment degradation, and thus determining the timing, scope, and details of equipment maintenance and repairs. This helps in formulating maintenance plans and supply plans for spare parts. 2. Scheduled maintenance: It is a basic form of organizing planned maintenance for production equipment, and it is a maintenance management system developed based on the technical condition of the equipment. The goal is to carry out predictive maintenance in a safe, economical, high-quality, and efficient manner, in order to prevent further deterioration of the equipment and avoid significant losses. Inspections at fixed intervals: 1. Routine inspections: Before and during equipment operation, the operators use their five senses (sight, hearing, smell, taste, touch) or simple tools to examine the appearance of the equipment, in order to detect any abnormalities such as vibration, unusual noises, overheating, looseness, corrosion, strange odors, leaks, etc. This helps to prevent the equipment from operating in an abnormal condition. 2. Professional inspection: To predict the internal operating condition of equipment, inspectors use their senses or simple tools and instruments to conduct detailed static or dynamic visual inspections as well as internal inspections of key parts of the equipment. The results of these inspections are recorded and analyzed to understand the trend of equipment degradation, thereby enabling the formulation of more appropriate maintenance plans. 3. Precision inspection: Comprehensive testing and examination of equipment are carried out using precision instruments and meters, or diagnostic techniques are employed without disassembling the equipment. In this approach, special instruments, tools, or methods are used to measure physical parameters such as vibration, stress, temperature rise, current, and voltage. By analyzing and comparing the obtained data, it is possible to determine the technical condition of the equipment as well as the degree of its degradation, thereby assessing the necessity for repair or adjustment. Unscheduled inspections: 1. Conducting disassembly inspections or detailed inspections on the equipment promptly when abnormal conditions in its operation are detected (such as vibration or unusual noises). Implementation of the four types of inspections: 1. Inspection tasks carried out by operators at their posts (routine inspections): 1.1 Fill out the inspection forms in accordance with the inspection standards and lubrication standards. 1.2 Inspections shall be carried out within the scope and responsibility areas determined by the \"Equipment Charter Inspection Labeling\" system; inspections must be conducted according to the options specified on the inspection card at the scheduled times during the shift, with careful recording of all findings. 1.3 If any abnormalities are detected in the equipment, it is necessary to inform the shift supervisor promptly and record this in the operator’s inspection card. 1.4 During shift handover, the details of inspections carried out during the shift must be clearly communicated, and both parties involved in the handover should check the inspection cards. If anything is unclear, further clarification should be sought. 2. Inspection tasks for routine maintenance work at the position (professional inspections): 2.1 Fill out the inspection form according to the inspection standards and the lubrication requirements. 2.2 Inspections shall be carried out within the scope and responsibility areas determined by the \"Equipment Charter Inspection Labeling\" system; inspections must be conducted according to the options specified on the inspection sheet at the scheduled times during working hours, with careful recording of the results. 2.3 When any abnormality in the equipment is detected or becomes known, the cause must be identified and resolved, the relevant party must be informed promptly, and this must be recorded on the inspection sheet. 2.4 During shift handover, the inspection results for the current shift must be clearly transferred; both parties involved in the handover should check the inspection sheets, and any unclear points should be clarified. 3. Inspection tasks carried out by full-time inspection staff in the Equipment Department (precision inspections): 3.1 Each unit formulates and improves the five criteria for equipment inspections based on the specific conditions of the equipment (designated personnel, designated locations, designated times, designated standards, and designated inspection routes). 3.2 Develop regular and long-term inspection plans. 3.3 Carry out inspection tasks carefully as planned, inspecting the operators and maintenance staff on duty. Those in charge of maintenance guidance have the authority to supervise and inspect these activities. Check the inspection task sheets and relevant records daily; identify any issues and address them promptly. If necessary, assign maintenance personnel to handle the problems or include them in the maintenance plan for subsequent treatment. Detailed records of the issues and the actions taken to resolve them must be kept. 3.4 Prepare maintenance plans and carry out proper management of maintenance work. 3.5 Review the requirements plan for maintenance materials (spare parts, main materials) in accordance with the seasonal (annual) spare parts plan and maintenance schedule. 3.6 Collect information on equipment status, prepare registers for recording potential equipment issues, carry out trend analysis of equipment performance, and conduct quantitative analyses to determine the degree of component degradation; responsible for providing daily updates on potential equipment issues to the Equipment Department. 3.7 Participate in accident analysis and handling, and propose repair and preventive measures. 3.8 Provide maintenance records to conduct analyses on faults, repairs, costs, etc., and offer suggestions for improving the equipment. 3.9 Formulate a plan for a thorough inspection of areas where nothing can be done, and assign it to qualified professional teams to carry out. 4. Management of inspection tasks by professional engineers in the Equipment Department: 4.1 The Equipment Department is fully responsible for managing equipment inspections across the entire company. It provides guidance to various departments, oversees and inspects the standards used for inspections in those departments, continuously improves the inspection management system, and offers feedback on the implementation of these standards. The department is also tasked with exploring and promoting new methods for inspection, monitoring, and fault diagnosis, recommending advanced inspection instruments, organizing regular training for inspection personnel, and constantly enhancing the equipment management framework in order to improve the company’s overall equipment management level. 4.2 The professional engineers at the equipment site are responsible for compiling and analyzing the daily inspection reports, and organizing relevant units to address the identified issues. 4.3 The Equipment Department holds a equipment meeting once a month. The meeting is organized by the Equipment Department, with the company’s relevant management officials in attendance, as well as the heads of the equipment departments from each production plant and the company’s chief dispatcher. Each production plant reports on its operational status for the month as well as any potential problems that exist. Address the issues existing in the inspection and operation work of various units, exchange various work-related information, and put forward work requirements. 5. Supervision mechanism: 5.1 The Equipment Department is responsible for overseeing the inspection work carried out by various production units. 5.2 The equipment supervisors in each production unit are responsible for supervising the inspection work performed by the maintenance staff and operators at their respective posts. 6. Rules for rewards and penalties: 6.1 In accordance with the content and requirements of the inspection work, the Equipment Department conducts a monthly evaluation of the inspection efforts carried out by each production plant. 6.2 Economic penalties will be imposed in any of the following situations: 6.2.1 If equipment accidents occur or repeated failures of the equipment happen due to careless inspection, in addition to enforcing the \"Equipment Management Regulations,\" a fine of 50–100 yuan will be imposed on the inspector responsible, and a fine of 50 yuan will be imposed on the person in charge of supervision; 6.2.2 If the inspection forms are incomplete or not filled out carefully, if production workers or maintenance staff fail to carry out inspections properly, or if they engage in illegal or reckless practices or fail to address potential hazards in a timely manner, economic penalties of 100–300 yuan will be imposed on the person responsible for the inspection and on those directly involved. At the same time, a fine of 50-100 yuan is imposed on the person responsible for supervision. 6.3 Units and individuals that achieve outstanding results in inspection work will be recognized and rewarded. 6.3.1 During the inspection of major production equipment, any significant potential hazards related to the equipment are identified, and early preventive measures are taken to avoid equipment failures. 6.3.2 Those who can consistently carry out professional inspections of key and critical equipment over the long term, identify and control trends in equipment degradation, maximize the efficiency of such equipment, and thereby save on maintenance costs. 6.3.3 Those who actively explore new approaches to inspection work, implement such inspection practices, and achieve significant results. 5. The inspection, maintenance, and management of other equipment are included in the company’s economic responsibility assessment system, with the Enterprise Management Department responsible for overseeing its implementation.