2. 1 self-maintenance branch will establish self-maintenance education and training courses:
2.2 The self-maintenance branch will establish a self-maintenance introductory training schedule;
2.3 The Education and Training Department will implement the basic theory course training of independent maintenance.
3. 1 Through the training of self-maintenance training materials, make personnel understand the implementation purpose;
Objective: In order to carry out independent maintenance smoothly and prevent accidental injuries in each step of activities, it is necessary to stipulate the preparation items before implementation.
3.2 On-site equipment operators will cooperate with the independent maintenance branch to expand the equipment function and understand that the equipment can deteriorate;
The independent maintenance division will be responsible for improving the necessary skills of field personnel (such as the correct methods of cleaning, oiling and locking, the use of tools, and the methods of finding micro-defects);
Independent maintenance department officials investigate the occurrence of faults, defects and short-term shutdowns;
3.3. The self-study branch will publicize the safety of on-site personnel, and provide safety education and countermeasures for unsafe situations and unsafe predictions.
(1) Independent Maintenance Concept Education
Demonstration equipment stage
The TPM Implementation Bureau and the Education and Training Sub-committee should jointly organize an education on the concept of self-maintenance, targeting the supervisors and members of the demonstration line activity circle.
? Horizontal expansion stage
Before the implementation of self-maintenance, each person in charge shall educate the operators on the concept of self-maintenance.
? Educational content
Concept education should include the following contents
A. Why should independent maintenance be implemented?
B. Basic idea of independent maintenance
3.3.2 Independent Maintenance Safety Education
? Demonstration equipment stage
A. Self-maintenance safety education should be jointly organized by the safety group and the education and training sub-committee, and the education targets are inspectors, leaders and members of the demonstration line activity group.
? Horizontal expansion stage
A. Before implementing independent maintenance, each responsible person shall conduct independent maintenance safety education for the operators.
? Educational content
Safety education should include the following contents
A. Personal dress and appearance
B. Safety protection equipment
C. hazard prediction training (KYT)
D. Implement safety measures before independent maintenance.
data collection
The person in charge of each activity circle should send someone to collect the following information:
? The number of sudden failures? Total efficiency of the equipment? Six major losses analysis
3.3.4 Treatment of major pollution sources
If there is a major pollution source for the activity object, it should be dealt with first.
3.3.5 Preparation of Tools and Instruments
A the tools and instruments to be prepared before the implementation of each stage shall be prepared by the leaders of each activity circle.
3.3.6 Matters needing to be confirmed before independent maintenance.
A. Before implementing independent maintenance in each stage, the group leader of each activity circle should confirm the following items, and then conduct independent maintenance activities after everything is normal.
A. Prepare tools and appliances
B. Turn off the power supply
C. Hanging safety warning signs
D. insert safety pins at necessary positions.
E. Turn off the pressure source switch (steam, air pressure ...) and release the pressure to 0.
F. Contents of concern
4. 1 The purpose of independent maintenance in each step:
Objective: This method is formulated to clean the equipment and restore the original appearance of the equipment with the concept of "cleaning is spot inspection".
4.2 Independent maintenance department will carry out "initial cleaning" activities.
4.3 Noun explanation
4.3. 1. Defects: The so-called defects refer to the abnormal phenomena such as dust, oil stain, corrosion, relaxation, abnormal sound, heat, vibration, corrosion, wear, crack, breakage, deformation, wiring confusion, failure and unsafe sources of the equipment.
4.3.2. Unsafe sources: The so-called unsafe sources refer to accidents such as involvement, electrification, falling, slipping, scalding, fire, collision, collapse, cutting, clamping and functional failure caused by the defects of the equipment itself.
4.4 Implementation process: selecting activity objects → forming activity groups → making activity plans → education → implementing initial cleaning → problem discovery and recording → problem review → regular inspection → steps 1 application for review.
4.5. Implementation method:
4.5. 1 Active Object Selection
? Demonstration stage
Selection of demonstration objects (equipment)
(a) Take each manufacturing room under the production department as the demonstration object, and select the demonstration equipment according to the manufacturing process and the following conditions:
A. Equipment related to production efficiency
B. Bottlenecks or important machines.
C. one of the following:
(1). The top 3 non-performing rates.
(b) The maximum number of faulty parts is the top three.
(c) Up to the first 3 failures.
(b) Use form: "Filling Line Shutdown Record Form"
? Horizontal expansion stage
A. Selection of active objects (equipment)
4.5.2 Composition of activity groups
? Demonstration stage
A. First-line time: the section chief serves as the team leader, and all team leaders and demonstration equipment in the section are designated as the squad leader and operators. The counselor is the direct director; The equipment department shall designate one person as the technical director.
? Horizontal expansion stage
A the timing of horizontal deployment shall be initiated by the TPM implementation bureau according to the reporting level of actual deployment status.
B. Composition method of activity groups in horizontal expansion:
A. Manufacturing various disciplines and production lines: the team leader is the team leader, and all the staff in the class are designated as members, and the counselors are directly under the section chief or branch members.
B other units: the team leader directly under the equipment is the team leader, and the squad leader and the personnel designated by the section chief in the designated team are the team members. Counselors are appointed by the section chief or the chairman of the branch Committee.
4.5.3 Activity Plan
? Demonstration stage
A the team leader shall call the team members to review the progress according to the company's independent medium-term maintenance plan.
? Horizontal expansion stage
A. Each equipment department makes an undergraduate activity plan according to the company's independent maintenance medium-term plan.
A. Attend every activity class: All equipment must be planned according to the deployment plan of the seventh stage.
? The activity schedule shall include the following items:
A. cleaning plan B. calculation of equipment productivity and efficiency C.6 big loss analysis D. hazard prediction education
education
? Demonstration stage
A.TPM implementation bureau shall arrange implementation briefing before initial cleaning.
B. The safety team shall cooperate with the implementation of independent maintenance, and conduct education on pre-operation hazard prediction and improvement of unsafe sources of equipment.
? Production line demonstration and horizontal development stage
A the section chief shall hold a briefing before the initial cleaning and arrange it for the members of the on-site education activity team.
? Problems in the implementation results should be made into "single point education" courseware when necessary.
The key points of making "single-point education" shall be implemented according to the "Implementation Measures for Single-point Education Textbooks".
Regular cleaning
? Regular cleaning should be carried out with the concept of "cleaning is spot inspection".
? The period and time of regular cleaning shall be decided by the activity group meeting.
? Before implementation, safety should be confirmed before initial cleaning, and dangerous reserved items should be confirmed by identification and calling.
4.5.6 Problem discovery and record
? After regular cleaning, the sources of defects and insecurity should be recorded in the "Non-conformity Point List".
Problem review
? For the problems found after cleaning, the "non-conformity accusation form" should be filled in, and the team leader should hold a review meeting to improve the countermeasures, and record the contents of the meeting in the "Meeting Minutes".
? During the activity, micro-defects, pollution sources and unsafe factors that cannot be maintained after several cleanings are given priority, and items such as cleaning difficulties, oiling difficulties and inspection difficulties are filled in the "Initial Cleaning Defect Record Form".
? When the problems found in the process of independent maintenance activities are considered necessary by the team review, they should be mastered and submitted to their supervisors to form a separate improvement team to implement the improvement activities:
A. Problems in each stage of independent maintenance:
A. difficulties at each stage:
(a) difficulty in cleaning; (b) difficulty in refueling; (c) inspection difficulties.
B. Source of the incident:
(a) Pollution source (b) Unsafe source.
C.6 heavy losses
(a) Failure loss (b) Line changing adjustment loss (c) Idling and small stop loss (d) Deceleration loss (e) Correcting bad loss (f) Starting production bad loss.
4.5.8 Regular inspection
? Regarding the implementation of "Independent Maintenance Activity Schedule", the team leader should check it once a month and revise the activity plan if necessary.
? self-assessment
A. Each team leader should complete most of the micro-defects, master the problems involved in the second-stage improvement, conduct self-inspection and evaluation according to the "first-step diagnosis", and urge the missing parts to be reviewed and improved.
4.5.9 The first step is to apply for advanced diagnosis.
? If the self-diagnosis score reaches 90 points, you can apply for the first step of high-level diagnosis, and activists and field operators will restore and improve the unconnected points;
4.6 Implementation process
5. 1 The purpose of independent maintenance every two steps:
Objective: This method is formulated in order to improve pollution sources and unsafe sources, shorten the time of cleaning, oiling and inspection of equipment, improve safety, and thus enhance the ability of field personnel to improve equipment.
5.2. Scope of application: This method is applicable to all self-sustaining activity circles.
5.3. Definition of terms:
5.3. 1 Source: It can be divided into pollution source and unsafe source.
? Pollution source: the so-called pollution source refers to the scattering and leakage of dust, solid, liquid and gas, which hinders the maintenance of the initial clean state.
? Unsafe occurrence source: The so-called unsafe occurrence source refers to accidents such as being involved, charged, falling, slipping, scalding, fire, impact, collapse, cutting, pinching and functional failure caused by the defects of the equipment itself.
5.3.2 Difficulties: The so-called difficulties refer to the parts that are difficult to clean, refuel, check and lock.
5.4. Implementation process: Step 1: Grasp the residual problems → Review the problems → Improve the scheme → Implement countermeasures → Independent diagnosis → Department-level diagnosis → High-level diagnosis.
5.5. Implementation method:
5.5. 1. The first step is to grasp the residual problem.
? The activity circle should grasp the problems left over from the first stage;
A. Pollution sources and unsafe sources
B Difficulties are divided into cleaning difficulties, oiling difficulties, inspection difficulties and locking difficulties.
? In view of the above problems, it should be recorded on the bulletin board of the activity circle.
5.5.2. Review of problems
? For the problems found, the team leader should hold a review meeting to improve the countermeasures, and invite the equipment department to participate if necessary.
5.5.3. Completion of improvement plan
? The improvement plan after meeting review shall fill in the Summary of Occurrence Sources and Difficulties, submit it for approval and release.
5.5.4. Countermeasures implementation
? The circle leader should set an example, actively promote the implementation of the source and difficult countermeasures, and when necessary,
Report improvement activities to personal improvement team.
? Major problems that cannot be solved independently by this department shall be reported to the independent maintenance branch Committee for deliberation and handling.
? The composition and activities of individual improvement teams will be formulated separately.
? The parts that have been improved well should be standardized and developed horizontally.
? If it is found that the unsafe matters cannot be improved in a short time, or cannot be improved due to operational reasons, a danger warning sticker or a notice board should be posted in a conspicuous place next to the part.
? In order to maintain the safety of operators, the safety team should organize equipment early warning danger training (KYT) and call recognition education, and all units should carry out education and implement it at their own level.
? For improvement projects (including safety) with good countermeasures, the supervisor should fill in "single point education" and report the implementation of education or level development.
? The key points of making "single-point education" shall be implemented according to the "Implementation Measures for Single-point Education Textbooks".
5.5.5. Regular inspection
? Regarding the implementation of the "Source of Occurrence and Difficulties Countermeasures Plan", a branch meeting was held once a week to review the progress of the solution.
? self-assessment
A. After most of the sources and difficulties have been improved, the team leader should make independent diagnosis and evaluation according to the "two-step diagnosis" and urge the missing parts to be reviewed and improved.
B. The reasons for the failure to improve the completed project should be properly explained and how to deal with it.
5.5.6. Application review in the second stage
? If the department-level diagnosis reaches 85 points, you can apply for a second review.
6. 1. Purpose: To gain experience from the activities of initial cleaning, taking countermeasures at the source and difficulties, so as to cultivate their correct understanding of the basic conditions of equipment, establish the operating benchmark of cleaning, inspection and refueling, and define the inspection parts necessary for safety, and the methods are specially formulated.
6.2. Scope of application: This method is applicable to all self-maintenance activity circles.
6.3. Definition of terms:
Cleaning and refueling benchmark: refers to the management benchmark for daily cleaning, maintenance inspection and lubrication and oil change of mechanical equipment.
They are as follows:
6.3. 1. Cleaning benchmark: refers to the cleaning management benchmark to keep the equipment in a "dust-free, dust-free" state.
6.3.2. Inspection benchmark: refers to the management benchmark that should be checked in daily maintenance to maintain the normal operation of equipment.
6.3.3. Refueling benchmark: refers to the management benchmark of lubrication and oil change to maintain the normal operation of equipment.
6.4. Implementation process: as shown in the attached figure.
6.5. Implementation method:
6.5. 1. Make an implementation plan
Regarding the daily cleaning, inspection, refueling benchmark and implementation form of the equipment, the team leader should call the team members to review together, fill in the "activity plan" and announce the implementation.
6.5.2. Establishment of provisional benchmarks
? Revise (formulate) and formulate the "provisional benchmark for cleaning, inspection and refueling" with reference to the following matters.
A.※ Structural drawing
A. Draw the equipment structure diagram of cleaning part, inspection part and oil filling part.
B the above parts shall be indicated by symbols and implementation sequence numbers.
C. symbols are distinguished as follows:
It means cleaning.
□ indicates inspection.
○ means refueling
D. The date of modification should be filled in the lower right corner of the structure chart.
B. content of the interim benchmark:
It should include no. As well as the location of marking, distinguishing, cleaning, checking and oiling, implementation method, judgment standard, tools (devices) used, required time, cycle (daily, weekly and monthly) and implementation opportunity (shutdown and operation).
C. the implementation time should be clearly stated.
? After the provisional benchmark is established, it should be published or posted in a prominent position of the machine.
6.5.2. Revision of the Implementation Form
? Revision of Implementation Table for Daily Maintenance Inspection and Lubrication and Oil Change
A. The activity group shall carry out independent maintenance work according to the "Provisional Standard Book for Cleaning, Inspection and Refueling". ※.
B. The activity group shall review and revise the "Provisional Benchmark for Cleaning, Inspection and Refueling" according to the actual cleaning situation.
6.5.3. Color management of parts
A. Lubricating parts
A. In order to promote the implementation of equipment lubrication and oil change, the management method of grease color should be formulated. "Grease color management" shall be stipulated separately.
B. clean and inspect the site. ※
◇ indicates the cleaning part, □ indicates the inspection part, and the cycle is distinguished by color as follows:
Yellow means every day, green means every week and orange means every month.
C. The above-mentioned color management label (specified separately) shall be pasted in a conspicuous position for equipment cleaning and inspection, and the number shall be indicated below the label. ※.
Education and implementation
? After the completion of the implementation form, the members of the activity circle should be educated and delivered for implementation.
※ ? In order to shorten the cleaning, inspection and oiling time and improve the operation efficiency of the equipment, the activity circle should devote itself to improving this shortened time, compare the time before and after the improvement, and fill in the "transition diagram before and after the improvement of cleaning, inspection and oiling time"
? In order to ensure the safety of operation and equipment maintenance and reduce accidents, all activity circles should really carry out activities to predict hazards and identify calls.
? If the content has been successfully implemented, the leaders of the activity circle should fill in "single point education" and report the implementation level to start education.
? The key points of making "single-point education" shall be implemented according to the "Implementation Measures for Single-point Education Textbooks".
6.5.5. Department-level diagnosis
? After formulating the cleaning, inspection and oiling standards and delivering them for implementation, the team leader will implement the department-level diagnosis according to the "third-step diagnosis certificate" and urge the missing parts to be reviewed and improved.
6.5.6. Step 3, apply for advanced diagnosis.
If the department-level diagnosis score is above 85, you can apply for the third step of advanced diagnosis.
6.6 Steps 1 to 3 shall be carried out in a continuous cycle.