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Compilation of Equipment Use and Maintenance Knowledge 1. What basic elements should an equipment operation procedure include? Equipment operation procedures are technical specifications that help sales staff properly master operating skills. Its content consists of the matters that operators must follow throughout the entire operation process, based on the structure and operating characteristics of the equipment, as well as requirements for safe operation. These generally include: (1) the tasks and requirements for cleaning the work area and checking the condition of the equipment before operating it ； ⑵Tools that must be used to operate the equipment ； ⑶、Main process parameters for equipment operation ； ⑷, causes of common faults and queueing methods ； ⑸, driving procedures and precautions ； ⑹, methods and requirements for lubrication ； ⑺Specific requirements for inspection, maintenance ； ⑻, procedures and precautions for parking ； ⑼Requirements for the use and adjustment of safety protection devices ； ⑽The specific tasks and record-keeping details for handover and takeover. 2. What basic elements should the equipment usage procedures include? Equipment operating procedures are regulations established for using the equipment, based on its characteristics and structural features. Its content generally includes: (1) the operating range and process requirements for using the equipment ； ⑵Basic qualities and skills that users should possess ； ⑶User’s job responsibilities ； ⑷Various 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 ； ⑸Essential procedures for users, such as operating procedures and maintenance procedures ； ⑹Technical standards that users must master, such as lubrication cards, inspection, and routine maintenance cards, etc ； ⑺Tools necessary for operation or inspection ； ⑻Discipline and safety precautions that users must follow ； ⑼The contents and standards for examining and assessing users. 3. What basic elements should equipment maintenance procedures include? Equipment maintenance procedures are the requirements and regulations for 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: ⑴ The requirements regarding equipment to be neat, clean, sturdy, properly lubricated, corrosion-resistant, and safe; the working methods; the tools and materials to be used; the standards to be met; and the precautions to take ； ⑵Daily inspections and the locations, methods, and standards for such inspections ； ⑶Inspect and evaluate the content and methods regarding the extent to which operators maintain the equipment. 4. What basic elements should a equipment post responsibility system include? 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. A system of assigning specific personnel responsible for equipment operation and maintenance should be established for operators, along with a routine inspection system and a shift-handover system. For maintenance personnel, a system of regional responsibility, a routine inspection system, and a scheduled inspection system 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, occupational 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 important to use equipment correctly? The process in which the equipment operates under load and performs its designated functions is known as the usage process. During use, due to various mechanical 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 equipment to operate in, follow proper and reasonable usage methods and allowable operating specifications, and control the equipment’s load and continuous operation time ； Maintain the equipment carefully. All of these measures must be carried out by the operator. Only when the operator uses the equipment correctly can it maintain good performance, achieve optimal efficiency, and have a longer service life. Only by having the operator use 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 wiped clean regularly.” What is mentioned here is a type of additional work; without this additional work, the machine will become unusable. “(Volume 24 of the Complete Works of Marx and Engels, 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 risk for 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, thus 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 inspections, 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 stage of the repair process. 8. What are the basic key points of total productive maintenance? Total Productive Maintenance can be summarized into four basic points: (1) Guiding principle. It refers to the “three comprehensives”, namely full efficiency, full system, and all employees. Overall efficiency is 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 lifecycle. And integrate all the operational tasks related to the lifetime management of equipment, as well as the departments involved, into an organic management system. All personnel, from managers to workers, from those involved in design to those responsible for operation, participate in production and maintenance management, each assuming and fulfilling their respective responsibilities. (2) Methods and approaches for maintenance. In terms of equipment maintenance, daily inspections, regular inspections and special inspections, preventive tests and condition monitoring, as well as fault diagnosis are carried out. 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. (3) Production and maintenance objectives. Maintain the equipment in its optimal technical condition at the lowest possible maintenance costs ； Achieve the longest equipment uptime with the lowest failure downtime rate ； Aiming to achieve the highest efficiency of the equipment through the optimal maintenance methods and approaches, the direction of production maintenance work and the specific standards to be met are determined. (4) 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 change in the equipment maintenance process over time and space. 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 order 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. ⑴Manage 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. ⑵Make good use of the equipment: strictly follow the operating procedures, use it correctly, and apply lubrication properly. Keep proper shift handover records and fill in the required documents carefully. ⑶Fix equipment: Strictly follow maintenance procedures, understand the performance and operating principles of the equipment, and address faults promptly ； 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. ⑴Skills required: Familiarity with the equipment’s performance, structure, and working principles; learning and mastering the operating procedures; skilled and accurate operation. ⑵It involves carrying out maintenance by learning the relevant procedures and fulfilling requirements for lubrication; it also includes cleaning and scrubbing as specified, to keep the equipment and the surrounding area clean. ⑶Inspections 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 conditions in the equipment and their locations, as well as determine the causes ； It is able to assess the technical condition of equipment based on the standard of its integrity. ⑷Faults will be eliminated: When a device fails, measures will be 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 duty 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 any matters that need attention by the person taking over. They should also provide a detailed briefing to the successor, conduct a thorough inspection, and sign the log. If an in-person handover is not possible, the person responsible for 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 supervisor for signature. If the successor detects any abnormal conditions in the equipment, finds that the records are incomplete, or observes that the equipment has not been maintained as required, they may refuse to take over the shift. If problems occur with the equipment after it is taken over as part of the shift handover, the person who takes 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 them, and provide information for condition management and maintenance. 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: (1) Cleaning – Keep the inside and outside of the equipment clean; ensure that there is no oil residue on various sliding surfaces, screw rods, racks, gearboxes, oil holes, etc. There should be no leaks of oil or air in any part of the equipment, and debris, waste materials, and dirt around the equipment must be removed ； (2) Neatness: Tools, accessories, and workpieces (products) should be placed neatly, and pipes and wires should be organized in an orderly manner ； (3) Good lubrication: Oil is added or changed on time; there is no interruption in oil supply, no dry friction, normal oil pressure, a clear oil level indicator, unobstructed oil passages, oil of satisfactory quality, and clean oil guns, oil cups, and oil felts ； (4) 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. The three-level maintenance system is an effective approach to equipment maintenance that relies on the workforce, fully leverages their enthusiasm, implements collective management and repair, and combines specialized efforts with those of the workforce. (1) 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 is carried out by the equipment operators during their shift, with careful attention to the four tasks before starting work, the five precautions during work, and the four tasks after finishing work. (1) Four tasks before starting work: digest pattern data 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. During low-speed operation, check whether the transmission is functioning properly, as well as whether lubrication and cooling are adequate. (2) Five points of attention in the class: pay attention to the operating sounds, the temperature and pressure of the equipment, the liquid level, the electrical, hydraulic, and pneumatic systems, the instrument signals, and whether the safety devices are functioning properly. (3) Four things after class: Turn off the switches and set all levers to the zero position. Remove iron filings and dirt, clean the oil from the guide surfaces and sliding surfaces of the equipment, and apply oil. Clean the work area and organize attachments and tools. Fill out the shift handover record and the console log, and complete the shift handover procedures. 2. Weekly maintenance: Weekly maintenance 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. (1) Appearance: Wipe clean the equipment guides, all transmission parts, and exposed areas, and clean the work area. Achieve a clean interior and exterior without any dead corners or rust, with a tidy surrounding environment. (2) Transmission operation: Check the technical condition of all components, tighten any loose parts, and adjust the clearance fits. Check the interlocks and safety devices. Achieve normal transmission sound, as well as safety and reliability. (3) Hydraulic lubrication: Clean the oil lines, dust seals, and oil filters; add oil to or replace the oil in the tank. Inspect the hydraulic system to ensure the oil is clean, the oil passages are unobstructed, and there are no leaks or abrasions. (4) Electrical system: Wipe the surfaces of the motors and flexible hoses, 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 planned, cleaning the specified areas, clearing oil passages and pipes, replacing or cleaning oil lines, felts, and filters, adjusting the clearance between various components of the equipment, and tightening all parts of it. 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 mechanic 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 demands until the next maintenance period. (III) Secondary maintenance: Secondary maintenance is carried out mainly 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 inspection report, which is then checked by the workshop mechanic and the operator; 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 reliability, 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 operators at their posts ； Regular inspections by qualified inspection personnel ； Precise inspection by technical professionals ； Experts’ technical diagnosis and presumptive diagnosis ； The precision test checks by technical experts are shown in the table below. Table 1-1 Inspection System: Name, Method, Person in Charge, Tools Used. Routine inspection: Scheduled within 24 hours; carried out by operators and on-duty maintenance staff; relies on knowledge of equipment structure, senses, and experience. Periodic inspection: Conducted during the day shift on a scheduled basis; performed by specialized inspectors with general knowledge of mechanics, electricity, instrumentation, hydraulics, etc., as well as tools, instruments, and experience. Precision inspection: Performed during the day shift according to a planned schedule; carried out by specialized inspectors and maintenance staff, using professional knowledge, experience, precision instruments, and theoretical analysis. Technical diagnosis and trend analysis: Conducted on a scheduled basis per item; done by inspectors and maintenance technicians with comprehensive knowledge of mechanics, electricity, instrumentation, hydraulics, etc., along with diagnostic instruments and analysis skills. Accuracy testing: Performed regularly; carried out by inspectors and professional technical personnel, utilizing knowledge of equipment, experience, precision instruments, and analytical judgment capabilities. Equipment inspection relies on the efforts of operators, specialized inspectors, professional technicians, and maintenance technicians – all working together toward a common goal. This coordination among professionals at various levels enables the creation of 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 parts of the equipment using defined methods at specified times by designated personnel, assessing the technical condition of the equipment based on standards, and determining the necessary maintenance tasks, is known as the scheduled inspection system. The basic elements of the inspection system include: (1) implementing full-staff management, with production workers particularly required to participate in inspections and maintenance tasks within their capabilities. ⑵There should be dedicated inspectors to manage the equipment by zone. ⑶Inspectors 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. ⑷There must be a set of scientific inspection standards, records, cards, and systems. ⑸Strengthen dynamic management by implementing three levels of inspections, namely production inspections, specialized inspections, and precise inspections.