How to manage the equipment?

At present, many enterprises have adopted modern equipment management theory and method-total equipment management. Integrated equipment management is to take a series of technical, economic and organizational measures from a long-term, comprehensive and systematic point of view to strive for the most economical equipment life cycle cost and the highest comprehensive efficiency, so as to obtain the best economic benefits. The characteristics of integrated equipment management: first, the whole process (life) management; Second, all staff participate in management (from enterprise leaders to production workers); The third is value management. Whole process management is the foundation, full participation is the means, and value management is the purpose.

To do a good job in equipment management, we must act in accordance with the laws and regulations promulgated by the state, ministries and commissions and the head office. Adhere to the combination of specialized management and group management; Combination of technical management and economic management; Combining equipment management with production; Combination of design, manufacture and use; Combination of equipment maintenance and planned maintenance; Combination of equipment maintenance and technical transformation; Equipment management is combined with technical development and intellectual development; Ideological and political work should be combined with material rewards. The above principles are as follows.

1. Combination of specialized management and group management

Each enterprise shall, according to the provisions of the higher authorities and the production scale and actual needs of its own unit, establish a strong special equipment management system. Establish an optimized organization and professional equipment management team, and formulate a practical management system. Company managers, factory directors and other leading cadres should put equipment management on the main agenda and decide the principles and objectives of equipment management. There should be a deputy manager (deputy director) in charge of equipment work, and at the same time, according to the needs, there should be a motor section chief or a mechanic section chief and a power section chief respectively. The chief mechanic and chief power engineer are responsible for the technical management of equipment under the leadership of the competent manager (factory director) and chief engineer. The workshop is in charge of equipment by a deputy director and equipped with full-time engineers and technicians to manage the equipment; Workshops and teams also have part-time equipment members; Form a device management network. And establish the corresponding management system and regulations, so that the work has rules to follow.

In factories and enterprises, it is the vast number of production workers and maintenance workers who directly manipulate and maintain equipment. They are most familiar with the performance, working state and existing problems of the equipment. They are the owners of the equipment and are responsible for the daily maintenance of the equipment they control. Therefore, we should give full play to their enthusiasm in managing equipment. In equipment management, we should attach importance to human factors and fully mobilize the enthusiasm of production workers and maintenance workers.

In the Equipment Technical Management System (Trial) formulated by sinopec group, it is required that equipment maintenance should be carried out by special plane or package mechanism. Someone is required to be responsible for equipment, pipes, valves and partition tables. Operators should understand the "four things" (structure, principle, performance and use) and "three things" (operation, maintenance and troubleshooting) of the equipment used. Do a good job in equipment lubrication, adhere to the "five settings" and "three-level filtration" (that is, personnel, fixed points, quality, quantity and timing; "Three-stage filtration" means from oil receiving barrel to rear oil storage barrel, from rear oil storage barrel to oil tank, and from oil tank to oil filling point). Operators should keep the equipment, pipes, instrument panel, paint and insulation in good condition and the ground clean. We should strengthen the management of static sealing points, put an end to running, running, dripping and leaking, and strive to reduce the leakage rate. We should do a good job in environmental sanitation and achieve civilized production. 1April, 1990, sinopec group inspected the circulating water pump house of a petrochemical complex: 14 pump, and the platform was in good condition; 14 lubrication points shall be well lubricated in time; Of the 7692 static sealing points, only one is obviously leaking, and the leakage rate is only 0. 13%.； 37 lamps are in good condition; 774 pieces of glass, the pieces are bright and complete; Toolbox tools should be placed neatly, and people should be seated accordingly; The standby equipment runs in turn, and the backrest wheel is marked. The pump body screw glows, and the valve root screw sees light. They really achieved "consistency inside and outside, consistency in altitude and ground, consistency in backyard and front yard, consistency in systems and devices".

2. Combination of technical management and economic management

Comprehensive equipment management is equipment management in a broad sense, that is, comprehensive technical and economic management of equipment, which should be advanced in technology and reasonable in economy. Equipment management is essentially the management of equipment movement process. There are two forms of equipment movement: one is the material movement of equipment, including equipment research, design, trial production, production, purchase, installation, use, maintenance, transformation, renewal and even scrapping; The second is the value movement form of equipment, including equipment investment, depreciation, maintenance cost and accounting, fund raising for renovation and economic effect analysis. The former is called technical management, while the latter is called economic management. They are governed by the laws of technology and economy respectively. Accordingly, equipment management will ultimately achieve two effects: technical effect and economic effect. That is, on the one hand, it is required to keep the equipment in good technical condition, on the other hand, it is required to save the cost of equipment maintenance and management. Technical management and economic management must be closely combined to obtain the lowest equipment life cycle cost and the highest equipment comprehensive efficiency.

From planning to design and manufacture, the cost of equipment is getting higher and higher; After the installation stage, the cost began to decline; The cost of the operation stage is generally stable and lasts for a long time; Finally, the cost rises again, indicating that the equipment has reached the stage where it should be repaired, modified or updated. For users, when purchasing new equipment, they should not only consider the purchase cost (i.e. production cost) at the time of purchase, but also consider the use cost (or maintenance cost) of the equipment in the operation stage.

The task of comprehensive equipment management in economic management is to take various measures to minimize the equipment consumption cost of enterprises. It not only pays attention to a certain stage of equipment, but the whole process of equipment planning, design, manufacturing, procurement, installation, use, maintenance, transformation, renewal and scrapping is the most economical, that is, the whole life cycle cost of equipment is the most economical. Life cycle cost includes production cost and use cost of equipment. Production cost refers to the expenses paid for research, design, trial production, manufacturing, storage and transportation. Before the equipment is constituted, it is generally the sales price of the product. Operating expenses (also called maintenance expenses) are the expenses paid by the equipment in the use stage, including kinetic energy, wages, maintenance, depreciation, insurance, training and other expenses. In the design stage, we should not only reduce the manufacturing cost, but also ignore the reliability, durability and energy saving of the equipment. We should estimate the management and maintenance costs in the operation stage from a long-term perspective. In the use stage, we should not only emphasize the good technical condition of the equipment, but also compare the spent manpower, material resources and financial resources with the obtained production results in order to obtain the best economic benefits.

Traditional equipment management pays more attention to technical management of equipment. In the evaluation index of equipment management, the technical index of equipment is also highlighted, which is satisfied with managing, using and repairing equipment well, but not paying much attention to economic benefits. Using the concept of equipment cycle cost, we can overcome the problem of only looking at technical achievements and ignoring cost consumption in equipment management. In the use of equipment, only the process needs are emphasized, and the phenomenon of rational use and full play of equipment potential is not mentioned.

In order to judge the economic benefit in equipment management, the economic benefit index should be appropriately increased. Because enterprises generally assess equipment maintenance costs and other items, a lot of maintenance costs are saved.

3. Combination of equipment management and production

In modern chemical enterprises, equipment is the material and technical basis of production and the means to complete production tasks. The level of equipment management and equipment condition are closely related to the successful completion of production tasks.

Equipment management must adapt to the change of enterprise management direction and serve production. With the changes of product structure, market demand and user requirements in different periods, the business direction of enterprises will have different emphases in different periods. When the business direction of an enterprise changes, the equipment management of the enterprise should also be adjusted, improved and improved in time to meet the requirements of the changed business direction for equipment management. It is necessary to establish the idea of attaching importance to equipment management and strengthening equipment management to serve production. The key equipment should be determined according to the production task, variety and quality of the enterprise and the difficulty of equipment repair. Give priority to the maintenance, repair, spare parts supply, transformation and update of key equipment to ensure the completion of production tasks of enterprises.

4. Combination of design, manufacture and use

The design and manufacturing process of equipment is managed by the design and manufacturing department; The use process of the equipment is managed by the user. The two should be closely combined to meet each other's information. Design and manufacturing departments can't just focus on reducing equipment costs and ignore the reliability, durability, maintainability, environmental protection, safety and energy saving of equipment. It is necessary to be familiar with the user's process requirements and use conditions, and also to consider the management and maintenance costs of the equipment in the operation stage, so that the developed equipment can meet the user's requirements. After the equipment is manufactured, the developers should participate in the installation, debugging and use of the equipment, and do a good job in technical service. Users should feed back the problems found in installation, debugging and use to the design and manufacturing departments in time, so as to improve the design of equipment.

5. Combination of equipment maintenance and planned maintenance.

Production practice has proved that equipment management should implement the principle of "maintenance first, maintenance second". Without proper maintenance, it is impossible to have a thorough overhaul plan.

There are often some contradictions between equipment maintenance and planned maintenance. If the planned maintenance only pays attention to the progress and ignores the quality of maintenance, it will increase the workload of maintenance. On the other hand, if the maintenance is not careful, the problems are not handled in time, and the operators do not strictly enforce the rules and regulations, it will not only bring about "small holes are not repaired, but also increase the maintenance workload, disrupt the normal plan and even cause serious consequences."

6. Combination of equipment maintenance and technical transformation.

For a long time to come, it is required to concentrate on equipment renewal and technical transformation of existing enterprises. Only by upgrading the equipment can we overcome the disadvantages of high consumption, high energy consumption and poor quality in existing enterprises. In addition, the renovation of equipment is also an objective requirement for the rapid development of science and technology.

In equipment management, it is undoubtedly correct to prolong the service life and keep the equipment in good condition. However, we can't extend our "life" indefinitely, nor can we maintain a good technical state at the expense of our work. This is because the equipment has been used for a long time, the technical performance is getting more and more backward, the consumption of energy and raw materials is gradually increasing, the maintenance cost is higher every time, and the maintenance cycle is getting shorter and shorter. According to statistics, if the depreciation cycle of an ordinary lathe is calculated as 22 years, the operating cost spent in 22 years is 6 times the value of the equipment. Therefore, in equipment maintenance, we should correctly handle the relationship between equipment maintenance and transformation through technical and economic analysis, and combine maintenance and transformation. On the one hand, take advantage of the opportunity of maintenance, adopt new technologies, new materials and new processes, and replace equipment and parts with backward technology, high energy consumption and low efficiency. On the one hand, obsolete and backward equipment with no further maintenance value will be scrapped and replaced with advanced equipment according to procedures.

7. Equipment management is combined with technical development and intellectual development.

Equipment is the crystallization of scientific and technological development. With the progress of modern science and technology, the modernization level of production equipment is constantly improving, and the equipment is developing towards the characteristics of large-scale, high-speed, electromechanical integration and complicated structure. In order to manage modern equipment well, it is required that equipment managers and maintenance personnel must master professional scientific and technical knowledge and modern management theories and methods. Modern equipment management is essentially a combination of modern equipment and modern management theories and methods.

Faced with modern production equipment and complex equipment, operators should have "four understandings" and "three skills" about the equipment used. The equipment management personnel shall comprehensively manage the whole process of the equipment. As engineers and technicians, they should not only carry out technical transformation on the original equipment, but also carry out technical development on the basis of learning, digesting and absorbing imported advanced foreign equipment. In order to achieve these goals, we must carry out organized, planned, long-term, multi-level, multi-channel and various forms of technical education, train professional technology and management knowledge, and carry out continuing education.

In order to do a good job in equipment management, we should strengthen the study and research on modern equipment management theories and methods, and actively organize technical experience exchanges at home and abroad and between our department and other departments. Investigate, learn, introduce, transplant, summarize and popularize foreign advanced technology, equipment and management experience, so that the technical equipment level and equipment management level of enterprises can gradually reach the international advanced level.

All enterprises must carry out equipment research. For key equipment research projects or projects with wide application value, it is necessary to organize the equipment research strength of various enterprises or cooperate with scientific research units and universities to concentrate on tackling key problems together. Technical achievements should be popularized and applied in time.

8. Combination of ideological and political work and material rewards.

In the 1960s, workers and engineers in Daqing won Daqing Oilfield for the country in a short time with the iron man spirit of not being afraid of hardship and death under the conditions of backward production equipment and extremely difficult production and living conditions, and made great contributions to China's socialist construction and set up a glorious banner of industrial Daqing. Over the past 30 years, Daqing Oilfield has achieved stable and high production, reaching the world advanced level. The equipment management in Daqing Oilfield is also excellent. In the production struggle, Daqing people have honed the good ideas, good styles and good experiences of "three elders" (honesty, telling the truth and doing practical things) and "four strictness" (strict organization, strict discipline, strict requirements and strict style of work), which are all very valuable assets. What are the main reasons why Daqing people worked hard to create miracles under such difficult conditions at that time? The conclusion is clear: they rely on the correct leadership of the China Party and the Party's ideological and political work.

Compared with the 1960s, great changes have indeed taken place today. Under the new situation, the * * * production party of China proposed to strengthen ideological and political work, do a good job in the construction of two civilizations, carry forward the spirit of Lei Feng and learn from the experience of Daqing. In equipment management, we must first do a good job in ideological and political work and human work. No matter how advanced the equipment is, it is artificial, and no matter how complicated the structure is, it is operated, maintained and managed by people. However, people's ideological consciousness level and technical level have a great relationship with equipment management. It is necessary to educate the workers to care for the equipment in the factory. Of course, ideological work is not everything. Only by combining ideological education with material rewards can we fully mobilize the enthusiasm of all employees. Only by doing a good job in equipment management for a long time can we achieve the expected management objectives.

In a word, equipment management is a systematic project, and comprehensive equipment management is related to many factors. According to many excellent units that have made achievements in equipment management reform and equipment management, the attention of leaders is an important prerequisite and guarantee for doing a good job in equipment management, which is a successful experience.