Steps for inspecting TPM devices

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　　Overview by Huatianmou TPM consulting expert: Inspection work is an important measure and method in equipment maintenance. The preventive and proactive equipment inspection process is the core of equipment operation management. The inspection system plays an important role in both equipment condition management and equipment technical management as well as equipment asset management. Equipment inspection is carried out to maintain the specified performance of the equipment, following established standards; therefore, companies need to have complete procedures for conducting such inspections. Next, I will share how enterprises carry out TPM inspections 　　The equipment design department should prepare three technical documents as part of the maintenance management design: 1) The \"Equipment Installation Guidelines\" to assist with the installation of the equipment; 2) The \"Equipment Operation Manual\" to guide the use of the equipment; 3) The \"Equipment Maintenance Standards\" to provide guidance on equipment inspections. Specific requirements for these inspections should be outlined, as these documents constitute important technical materials provided by the design department for equipment maintenance management. 　　Accuracy: Accuracy is a metric that affects equipment performance and product quality. 　　Accuracy parameters include clearance, vibration levels, temperature rise, noise, and other data with quantitative standards. The precision point values are not absolute numbers, but rather precision ranges, such as the ideal value, allowable value, warning value, degraded value, and degradation limit. 　　Exceeding the allowable value is referred to as degradation (it must not exceed the warning limit). If the precision exceeds the threshold value, repairs must be carried out. 　　Precision point detection is relatively complex; in some devices, it is the overall precision that determines the product quality and device performance. Precision testing must be carried out systematically and comprehensively; generally, it should be performed once a year or every six months or so, with a comprehensive evaluation conducted, and measures taken promptly to address any issues that are identified. 　　Performance: Performance is an evaluation indicator for the functions of a device, such as the required accuracy, pressure, temperature, vibration, noise, production capacity, and safety. 　　Performance evaluation focuses on the direct impact on key equipment and critical components. The scope of management should be reduced to the most reasonable level. 　　Accuracy testing cannot replace performance evaluation; accuracy testing does not include the assessment of the equipment’s overall production performance. 　　2. Basis for equipment inspection standards The \"Equipment Maintenance Work Standards\" serve as an important technical basis for equipment maintenance inspections. They include equipment maintenance technical standards, inspection criteria, lubrication guidelines, repair work standards, as well as various inspection schedules – all of which are essential materials for carrying out proper equipment inspections. 　　These standards form the system of maintenance technical regulations required for implementing the equipment inspection system. 　　The four major maintenance standards (inspection standards, lubrication standards, maintenance operation standards, and maintenance technical standards) – of which the technical standards form the foundation and serve as the basis for formulating the other three standards – mainly include: (1) key equipment and devices; the performance and structure of components (simplified diagrams), materials, etc. 　　(2) Main equipment and installations. Components’ maintenance characteristics (tendency to degrade, occurrence of specific phenomena). 　　(3) Technical management values for the maintenance of main equipment and components. Such as drawing dimensions and installation clearance. Allowable values, inspection methods, and frequency, etc. The allowable values include not only wear amount but also temperature, pressure, flow rate, current, voltage, and vibration. 　　3. Preparation for equipment inspection 　In the inspection standards, based on the structural characteristics of various components, the inspection locations, items to be inspected, inspection intervals, inspection methods, responsibilities for carrying out inspections, and criteria for evaluation are specified in detail. As a result, all inspection points have defined locations, items, methods, intervals, responsible persons, and standards. 　　Before carrying out inspection tasks, the following preparatory steps must be carefully taken: 1. Implementing the \"five fixings\" for equipment. Fixing the location – It is necessary to clearly define the areas, items, and aspects of the equipment that need to be inspected, so as to carry out the inspections in a targeted and purposeful manner. Fixing the methods – Clear inspection methods should be established for each item to be checked; these methods may involve using the senses for assessment, or employing simple tools and instruments. 　　Scaling – that is, establishing standards to serve as a basis for measuring and determining whether the examined area is normal. 　　Regularly — establish inspection cycles, taking into account the importance of the equipment and whether certain parts require focused attention. 　　1. Assign personnel – Determine the individuals responsible for carrying out the inspection tasks (production staff, inspectors, technical specialists, production workers*** persons, full-time inspectors*** persons).
2. Develop an inspection plan – To ensure a balanced workload and avoid any omissions in the inspection tasks, it is necessary to create an inspection plan that specifies who will carry out each task. 　　In addition, a inspection schedule to be followed by the operators should also be prepared, requiring them to carry out the inspections diligently as planned. 　　3. Planning the inspection route 　　Since professional inspectors are responsible for large areas that need to be inspected, to avoid repeating the same routes, it is necessary to plan the paths to be taken during inspections in advance, thereby saving time spent on travel. 　　4. Prepare inspection checklists. The main purpose is to record the results of inspections, which serve as an important basis for formulating maintenance plans. 　　4. Equipment inspection plan 　After listing the inspection items for various parts of all equipment along with their respective inspection intervals, it is necessary to summarize and balance these items in order to create an inspection plan that ensures a relatively even distribution of workloads throughout the day. 　　Inspection plans are divided into daily inspection plans, regular inspection plans, and long-term inspection plans. 　　Inspection plan formulation and inspection route maps 1. The operating shift should prepare inspection route maps corresponding to each operating shift. 　　2. The inspector formulates an inspection plan for the equipment under his/her responsibility, in accordance with the inspection standards, while adhering to the principles of convenience in work, the most efficient route, and consideration of the workload. 　　Then, prepare a inspection route map based on the daily inspection plan to ensure accurate, reasonable, time-efficient, and effective operations. 　　To optimize the route and develop a weekly plan, devices that are similar should be included in the same daily inspection schedule. 　　To balance the workload of inspections, equipment that is inspected once a week is distributed evenly across Monday to Thursday, while equipment that requires monthly inspections is checked on Fridays. Generally, each inspector is assigned 5 to 6 inspection routes. 　　3. Prepare a regular inspection plan based on the inspection standards. 　　Prepare inspection plans. An inspection plan is a implementation plan for inspection tasks carried out by dedicated inspectors; it is prepared by these inspectors in advance, based on the inspection standards, and serves as the standardized procedure for daily and regular inspections. 　　After determining the inspection intervals for each item to be inspected on the equipment under their responsibility, the full-time inspectors must summarize these intervals and conduct a comprehensive balance to create an inspection plan that ensures a relatively even distribution of daily workload. 　　In the inspection plan, clear specifications should be provided for the inspection areas of the equipment, the items to be inspected, the inspection frequency, and the inspection methods. 　　The inspection plan should be adjusted in a timely manner as the condition of the equipment changes; the contents, frequency, methods of inspections, as well as their level of importance, also need to be adjusted accordingly. 　　Full-time inspection personnel should regularly modify and improve the inspection plan based on the actual conditions of the equipment, and promptly adjust the inspection intervals as well as the intervals for managing various items. 　　Inspection activity models: Work models (inspection route maps, operational process flows), planning models (inspection work sheets, regular inspection schedules, long-term inspection plans). TPM weekly inspection sheets. Performance management and analysis: Maintenance record management, identification of abnormalities found during inspections, analysis sessions held by teams or specialists along with team leaders to determine the causes of faults and develop countermeasures. 　　The PDCA seven-step method for inspectors: Investigating the current situation, identifying problems, formulating plans, ensuring implementation of measures, managing the process, analyzing results, and strengthening improvements. 5. Inspection plan models: Classification of inspection plans: (1) Inspection work sheets; (2) Regular inspection schedule; (3) Long-term inspection schedule. 　　1. The inspection work sheet is a schedule that operators use to carry out daily inspections. 　　The work cards are prepared by the inspectors and assigned according to roles, and are divided into two types: daily inspection work cards and weekly inspection work cards. 　　2. The regular inspection schedule lists the tasks that must be completed next month, and it represents a summary of the monthly plan. Determine the inspection date based on the device at the host. 　　3. The long-term inspection plan, also known as the periodic management table, is formulated based on years of experience with disassembly inspections, routine maintenance inspections, and cross-checking precision inspections. 　　6. Inspection Routes Inspection Route Maps Routine inspections are carried out by the operators at their respective posts, and each dedicated inspector has their own inspection route map. The inspection personnel prepare the shortest inspection route map based on the range of equipment under their responsibility. 　　Prepare inspection route maps. Each inspection area has its own distinct inspection route map, and the dedicated inspectors must, based on the distribution of the equipment they are responsible for, as well as the specific inspection locations and tasks, create the shortest possible inspection routes. They then carry out inspections along these routes every day, in order to ensure safety, efficiency, and to prevent any missed inspections. 　　The principle for drawing up the inspection route chart is as follows: Without omitting any items, all inspection tasks related to the equipment in the area under the responsibility of the dedicated inspectors must be included in the inspection route. The route chosen should be the shortest possible to save time, repeated sections of the route should be avoided as much as possible, and attention must be paid to the safety of the inspection activities. 　　7. Design of inspection sheets Equipment inspection sheets Equipment inspection sheets are record-based documents in which operators conduct preliminary checks on the equipment they use during each shift; they reflect the specific condition of the equipment. These sheets serve as an important basis for guiding equipment repairs, and they represent a key step in shifting from reactive repair to proactive prevention. 　　Production steps: 1. Identify the problem (define it); 2. Conduct a preliminary analysis of causes; 3. Break down the process (common methods include brainstorming, the 5 Whys technique, and matrix tables); 4. Determine improvement methods; 5. Implement the changes and summarize the results; 6. Roll out the improvements and ensure control. 　　Instructions for Filling in the Inspection Standard Form Basis for Preparation 1. Maintenance technical standards; 2. Performance data of similar equipment; 3. Equipment operation manuals and technical drawings; 4. Practical experience. 　　Key points for preparing tables: 1. In accordance with the equipment maintenance and technical management regulations, equipment classified as levels A, B, and C must all be included in the records; 2. The equipment name should be entered as a 6-digit code identifying the specific device, while the equipment number should also be a 6-digit value; 3. Enter the sequence number of the inspection items; 4. Enter the 9-digit code for the sub-components of that equipment; 5. List the areas where deterioration may occur in that component. Inspection areas can include: a. sliding parts, b. rotating parts, c. transmission parts, d. parts in contact with raw materials, e. load-bearing parts, f. parts subject to corrosion from fluids, g. electrical components, including insulation, precision control of motor parameters, and stability of monitoring systems; 6. List the inspection items related to deterioration in that component, such as bearings in rotating parts, gears or racks in transmission parts, or inspections requiring disassembly; 7. Identify the ten key factors for diagnosing deterioration in that component: pressure, flow rate, temperature, leaks, abnormal noises, vibrations, oiling conditions, wear, looseness, cracks (corrosion), etc.; 8. Determine the regular inspection schedules for maintenance personnel, operational staff, and production teams in accordance with the assigned responsibilities. For the regular inspection cycle, a initial value can be set, which can then be adjusted and refined over time; 9. Clearly distinguish projects, contents, and attributes in accordance with the division of responsibilities, and specify under what conditions inspections should be carried out for each project or content; 10. Identify the inspection methods applicable to each project or content – mark “√” or enter “0” in the corresponding field if there is a change; 11. Enter qualitative or quantitative data in the inspection standard field: absence of damage constitutes qualitative data, while a temperature of ≤75°C represents quantitative data; 12. The inspection standards are prepared and signed by the dedicated inspector; 13. They are then reviewed and signed by the person in charge of inspection tasks. 　　Standard Classification This table is suitable for use in the routine inspection of mechanical, electrical, and instrumentation equipment. It can be divided into: a. General inspection standards, which are applicable to items such as belt conveyors, pumps, DC motors, AC motors, transformers, switches, etc. These standards are further subdivided into more specific categories; for example, belt conveyors can be classified based on differences in belt width, drive mechanism, weight distribution method, and belt type. The details filled in the table should be as precise as possible. 　　b. **The statutory inspection equipment required, such as pressure vessels, safety valves, lifting equipment, etc.,** shall be prepared in accordance with the provisions of relevant laws and regulations. 　　c. The inspection standards for specialized equipment shall be filled in according to the guidelines for preparing tables. 　　Other requirements: 1. It is required that the values entered be correct, the names complete, and the handwriting clear; 2. When preparing the document, first list the items related to the inspection of that component using the five senses. Next is the formulation of the content for the cycle management tasks, which include cleaning, tightening, adjustment, disassembly inspection, replacement parts, and refurbished components. 　　3. Develop detailed inspection procedures for tasks such as vibration measurement and flaw detection; a complete set of procedures includes three aspects. 4. For newly added equipment or equipment that has undergone technical upgrades, inspection standards should be established promptly, taking into account that similar equipment may require different inspection standards depending on their operating environment. 5. The inspection standards should be continuously revised and improved through annual P-D-C-A cycle reviews.