What are the methods and contents of routine inspection of equipment?

Point inspection and repair is gradually initiated by some large enterprises in China by introducing TPM and the concept of "point inspection and repair" from Japan. The so-called spot check is a management method that arranges specialized personnel to use people's five senses and simple instruments and tools to check the parts of equipment according to certain periods and standards, judge whether they are normal, find hidden dangers, and master the initial information of faults so as to take countermeasures in time and eliminate faults in the bud. And planned maintenance is planned maintenance and regular maintenance. \x0d\ In the factory, according to the classification of participants, there are routine inspection mainly by operators, professional inspection by full-time inspection, precise inspection by technicians, special care inspection by maintenance workers, and manager inspection arranged by leaders, etc. According to the professional division of labor, there are also four directions of inspection: organic, electrical, instrument and operation. In petrochemical and other enterprises, due to the large device and wide area, the inspection of the device is like a patrol, so it is called patrol inspection. \x0d\ According to the equipment status during routine inspection, there are running routine inspection, shutdown routine inspection, disassembly routine inspection and non-disassembly routine inspection. Preparations for routine inspections include the following: \x0d\? Fixed point: set the inspection place; \x0d\？ Determine: determine the inspection items and contents; \x0d\？ Determine: determine the inspection method; \x0d\？ Calibration: determine the criteria for judging whether it is normal; \x0d\？ Periodically: set the inspection interval; \x0d\？ Personnel: determine the personnel who will implement the inspection items; \x0d\？ Form determination: determine the form format and record requirements; \x0d\？ Determine the process: determine the interface and workflow of routine inspection and maintenance; \x0d\？ Closed loop: implement the work step by step to form closed loop management. \x0d\ We call it "eight to ten". Head and tail are the most important. \x0d\ Fixed point refers to the determined inspection position, which covers a wide range, such as equipment parameter display instruments (including temperature, pressure, speed, vacuum, flow, electrical parameters, liquid level, etc. ), cooling system (air cooling, water cooling, oil cooling, etc. ), transmission system (chain transmission, gear transmission, belt transmission, etc. ) and electrical control system (sensor and related servo) lubrication system (oil filler, oil circuit, oil cup, etc. ), safety alarm and protection parts, sealing and leakage parts, corrosion parts, mechanical wear parts, impact fatigue parts, alternating hot and cold parts (thermal fatigue), contact, connection, welding parts, fastening parts, filter screen, filter element parts, product (service) quality-related parts, etc. \x0d\ into a closed loop is to design the interface between daily inspection information and maintenance to form a management closed loop. The routine inspection and maintenance in many factories are two pieces of leather, which are not connected with each other, so the function and role of routine inspection are greatly reduced. Therefore, the abnormal routine check information must be transmitted, and a closed loop can only be formed if there are maintenance and processing actions with the maintenance interface or the maintenance interface. \x0d\ Routine inspections in many factories are often a mere formality, and the "check mark" on the routine inspection list may not be true. Some people didn't do it seriously and filled in the check box in a hurry when they were about to receive the checklist. This is called "writing a memoir". Some people are happy to fill in the list for next week in order to save trouble. This is called "future tense". In the past, a chemical plant told the author that in order to see if employees climbed up the reaction device several stories high for spot check, some holes were made for inserting flags. The day shift inspection personnel climbed the equipment with the red flag for inspection and inserted the red flag. The leaders in charge below know whether they are in place by counting the flags, and change them into white flags at night. The night shift inspectors pulled down the red flag and planted the white flag. Some employees planted flags in a hurry, found a warm corner, spread cotton-padded clothes and slept until dawn. \x0d\ Later, some enterprises changed the spot check cycle to every two hours, and installed a spot check clock that can move the watch hands at the parts where the equipment needs spot check. When the tally inspector arrives, he will allocate time and put the tally sheet next to the parts that need to be checked at the equipment site. When the manager checks, he will know whether the inspector is in place in time and conduct a careful spot check. \x0d\ \x0d\ Now, we scan the QR code through the Lean Guardian mobile APP. When employees arrive at the checkpoint and scan the QR code with APP, the information will be automatically recorded and directly transmitted to the cloud server through the wireless network. The competent leader can know the inspection in place at any time through the lean guard mobile APP or PC browser, and count the overall implementation progress of a department and a team in real time, who did not check on time and who did not check on time. \x0d\ In the knowledge transfer of routine inspection of equipment, most of the traditional paper documents only contain routine inspection items and contents, but they can't tell employees what methods and standards to use for inspection. However, methods and standards are a process of continuous optimization and improvement, which makes the routine inspection work unable to be standardized and quantified. If new people perform or replace equipment, it will be different, resulting in all inspections being carried out in accordance with unified methods and standards. Through lean guard, you can intuitively and conveniently display the operation methods and standards, and implement them according to the standards to ensure the inspection effect to the greatest extent. \x0d\ If the routine check is good or bad, the equipment is normal, and the routine check personnel tick √, it means that the routine check table has been checked; If there is deterioration, but it does not affect production for the time being, then fight! Number, which is equivalent to the precautions on the checklist; If you hit ×, the phone interface will slide out three options, namely, "Handle by yourself", "Abnormal feedback" and "Pending repair". Self-handling and abnormal feedback require inspection personnel to fill in equipment abnormal information or take photos, which will be immediately transmitted to the cloud server according to the existing management process of the enterprise and pushed to the mobile phones of the corresponding personnel. \x0d\ After the other party receives it, it can choose whether to handle it by itself or continue to feed back to the actual person in charge according to the existing management process of the enterprise; Or the leader directly assigns the task to the corresponding person in charge to deal with it. No matter who handles it, you can accurately record the exception handling in the form of text+pictures. \x0d\ The result of exception handling will be automatically fed back to the initiator of the exception or the leader who assigned the task at the first time. \x0d\ \x0d\ With the application of the above technical means, will the spot check be completed? \x0d\ The answer is no, it should be said that although the above-mentioned technical means will make it difficult for the spot-checking staff to miss or not reach the designated position, if they arrive at the spot-checking post, there will still be the phenomenon of not actually doing spot-checking or even carefully doing spot-checking. \x0d\ So how to solve this problem? This requires comprehensive management. \x0d\ Corporate culture and corporate cohesion are very important! An enterprise that doesn't let employees linger, an enterprise without cohesion and centripetal force, don't expect employees to work hard. \x0d\ Staff training and professional quality education are also very important, which is a long-term and subtle work. \x0d\ Therefore, Lean Guard provides a mechanism for managers to score and evaluate the results of employee spot checks on mobile phones and automatically rank them, which provides a reference for performance appraisal. \x0d\ At the same time, Lean Guardian has also opened a learning channel for collective training of enterprise teams, and the learning materials are automatically pushed to everyone through the functional module of work circle; Employees can also share their good ideas and experiences through mobile phones, learn from each other and praise each other, which is much more convenient than brushing WeChat friends circle. \x0d\ In the design of incentive mechanism, the running state of equipment can also be linked to employee bonus. This can stimulate the work motivation of employees from the source. Large production vehicle is an important production equipment of iron ore. It was always impossible to ask everyone to check carefully before. Some employees even hope that the car breaks down and the mechanic can have a rest while repairing the car. Later, the target contract responsibility system was implemented, and the tons and kilometers of ore transportation completed by cars were linked to bonuses. A maintenance man is in charge of several cars, and the total tons and kilometers completed by these cars are also linked to the maintenance man's bonus. So both the driver and the maintenance personnel took the responsibility. The author even saw this scene in the mine. When employees go home, they make a "sleeve" with mask cloth and put it on the hydraulic column of the dumper to prevent dust from polluting the column and causing the column to wear quickly. As for all the spot checks stipulated in the mine, it is naturally taken seriously. Parking loss caused by any fault will directly affect the bonus income of employees. This is a typical case of management from "source" and "motivation". \x0d\ By encouraging employees to find hidden dangers in routine inspections, preventing troubles by eliminating hidden dangers and giving rewards, employees' enthusiasm for routine inspections can also be positively motivated. \x0d\ For this reason, Lean Guardian provides lean Kanban function module, which makes intelligent real-time statistical analysis on abnormal quantity, early warning quantity, self-disposal/abnormal feedback/non-disposal. How many hidden dangers are eliminated by employees themselves, how many are upward feedback, who will deal with them, how the results are, how many hidden dangers have not been dealt with, and how many need to be repaired can be displayed directly on the mobile phone in the form of charts. Managers can directly motivate employees with practical actions in evaluation and scoring by looking at employees' abnormal self-disposal, and can also complete the reference for material incentives of enterprises. \x0d\ Everything has advantages and disadvantages. There is a subtle difference between true and false, and paradox always exists in it. \x0d\ Even if encouraged from the source, some employees will be eager for quick success and instant benefit, ignoring some necessary routine inspections, so that some routine inspections are not in place. There are also problems that cannot be found out because of technical ability problems. No panacea can cure all diseases. \x0d\ The author has asked about the spot checks of European and American enterprises, and the spot checks of China enterprises are not in place from time to time. There are even American companies that hire students who have nothing to do with employees to supervise the equipment inspection. \x0d\ Based on the actual management needs in reality, Lean Guard specially designed the "special inspection" function from the management dimension. Managers can inspect and supervise the implementation of employee spot checks through special inspections. If they find anything inconsistent with the actual situation, they can not only directly reflect the attitude of the management, but also directly take photos of the scene through abnormal feedback and send them to the relevant responsible personnel, so that they can know what they have done badly, so that the next improvement is meaningful. \x0d\ Appropriate negative reinforcement incentives are also necessary. If you don't do the prescribed actions, after being discovered by managers, you should not only educate employees, but also give appropriate performance penalties, and even demote and change posts will have a certain promotion effect. \x0d\ In short, putting spot checks in place is a long-term systematic project and a comprehensive management problem.