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Equipment management model and characteristics

2019-12-14View Original

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Currently, there are mainly three models for equipment management in large state-owned enterprises. (1) A comprehensive management system based on the principle of life-cycle management. That is, through certain technical, economic, and organizational measures, comprehensive scientific management is carried out across the entire life cycle of equipment – from planning, design, manufacturing, selection, acquisition, installation, use, maintenance, repair, renovation, and upgrading to eventual disposal. This model is what is commonly referred to as the comprehensive equipment management approach. Most discrete manufacturing enterprises use this model for equipment management. (2) A equipment maintenance management system centered on preventive maintenance. The inspection-based maintenance management model is a maintenance approach that, under the conditions of an inspection system and preventive maintenance, reduces maintenance workload to the minimum, focuses on minimizing downtime due to maintenance, and achieves a predictable and balanced distribution of maintenance tasks. This management model is currently widely adopted in process industry enterprises, especially those in the metallurgy sector. The scheduled maintenance mode involves managing the relationship between scheduled maintenance and preventive maintenance; scheduled maintenance focuses on balancing the maintenance workload, while preventive maintenance emphasizes proactive prevention based on reasonable maintenance intervals. Prevention comes at two costs: first, repairs have to be carried out on a periodic basis, which may result in a high maintenance load; second, the downtime caused by repairs can be significant. Preventive maintenance is only economical when the timing of those repairs is based on sound principles. In general, for process-oriented enterprises, the continuous operation nature of their production processes makes it very difficult to implement preventive maintenance. Therefore, it is desirable to carry out repairs on all the affected equipment (process systems or production lines) at the same time during a single scheduled shutdown, in order to minimize the impact that frequent shutdowns have on production. This is why scheduled maintenance is understood as pursuing a predictable and balanced maintenance workload on the basis of the inspection system and preventive maintenance. In fact, what is determined in scheduled maintenance is the time period, which, due to the characteristics of production in process-oriented enterprises, is limited by the service life of critical replacement parts. Therefore, it is hoped to utilize the downtime caused by replacing parts to carry out maintenance work on related equipment; both the replacement operations and the maintenance work are considered part of the scheduled maintenance. In actual work, it is impossible for it to happen that just when components need to be replaced and the machine is shut down, other equipment happens to require maintenance at that time. The maintenance carried out while the machine is shut down to replace components is, similar to preventive maintenance, likely to be a form of precautionary maintenance; it may also lead to excessive maintenance of those devices whose components have not been replaced. Moreover, those devices that are not maintained may still develop problems before the next component replacement. To address this new issue, frequent inspections and monitoring are necessary to ensure the proper operation of the equipment. If monitoring and inspection (known as routine checks) can ensure that defects or problems in components other than those that need to be replaced are detected in a timely manner, repairs or adjustments must still be carried out; otherwise, the equipment either continues to operate with defects or is shut down for repair. Currently, this issue is one of the main challenges in the maintenance activities of process-oriented enterprises. (3) A equipment management model led by TPM, combined with routine inspection and maintenance as well as comprehensive management. The main problem with this management model is the effectiveness of TPM implementation. In those companies that implement TPM management effectively, this approach is primarily based on the basic methods of TPM management. In general, regardless of the primary equipment management approach adopted by Chinese enterprises, it is essentially the result of integrating various management methods and techniques. The management model pursued by enterprises is a combination or variation of the basic model consisting of life-cycle management + preventive maintenance (PM) + scheduled maintenance + TPM management. Based on this, the equipment management model with Chinese characteristics can be described as one that follows the principle of life-cycle management, takes inspection and preventive maintenance as its core, and relies on TPM as the foundation for standardized management, in order to implement standardized and comprehensive management of equipment. In the process of establishing an equipment management model with Chinese characteristics, many enterprises have made active efforts and explorations, but they have also encountered some difficulties. The main reason is that the rapid development of the Chinese economy and enterprises has put enterprise management in an unstable state; management organizations and systems are still in the process of development, and equipment management is no exception ; Advanced management concepts and methods, through study, introduction, and experimentation, have achieved certain management results; however, they are still in the process of integrating with existing management systems and ways of thinking. It is necessary to adapt and innovate them in light of the actual conditions of Chinese enterprises ; Due to the complex production processes, a wide variety of equipment in large enterprises, large quantities of such equipment, as well as significant differences in their age and technical level, it is very difficult to determine how to implement management measures in practice.

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