维修工作流程图及说明.doc

维修工作流程Maintenance Work Flow 机械设备部 MECH 2014年07月 July, 2014维修流程介绍 Introduction of Maintenance Process维修业务工作流程Maintenance business work flow： l 年/季/月（1+3）计划维修工作流程Work flow for annual /quarterly/monthly (1+3) planned maintenancel 日常故障维修工作流程 Daily failure maintenance work flowl 非计划维修工作流程 Unplanned maintenance work flowFREP所有维修工作都是按照这三个工作流程开展的。 All maintenance works of FREP are carried out according to these three work flows.Work Flow Diagram for Annual/Quarterly/Monthly Planned Maintenance Application for project changeBTM MCL Develop thelist for annuallarge-scalemaintenanceprojectsOperation reliability analysis MCL Equipment strategyMaintenance plan supervisorMaintenance plan supervisorMLTMaintenance plannerMCLSummarize draft of annual maintenance plan submitting to FREPl Organize review and finalizationl Submit toBOD for Review /approvalDevelop (1+3) four-week planReview/Communicate 3- month maintenance planl Develop 3 month maintenance planl Plant-wide resources managementl Rolling management of delayed plan MCLEquipmentimprovement List for highfailurerate equipment MCL Adjust the project/budgetMaintenance Work Flow DiagramQuarterly/monthly/weekly maintenance planMaintenance plan supervisor/PlanerMaintenance plannerMaintenance plannerMaintenance Team leadMaintenance planner MCLField operatorsMCLPCLFailure notification fills in ERP WorkClosurel Safety managementl Management interface coordinationl Work execution supervisionl Implementation performance report development for relative complex projectl Feed back the work plan improvement points to the maintenance planer and the engineersl Develop job packagel Coordinate work preparation l Develop work procedure l Develop weekly/daily resources allocation planApprove procurement requisition(DOAG)l Screening notificationsl Check reasons for workl Screen alternativesl Communicate selection results, give instructionsl Confirm best work scope l Inspect best work timel Root cause failure analysis Handle notification (DOAG)l Confirm on site and prepare specific work scopel Develop materials/machines/tools/resource needl Work is required to be entered into ERPl Cost estimationl Plan effectiveness confirmationApprove(budget/constructionperiod)Delay/declineStandard jobpackagedatabase maintenanceRecommendation: narrow down scope/adjust budgetCommunicationcycleNote: 1. for general equipment, it is not necessary to indicate the deliverable construction period, but the planner needs to prioritize them according to SDD and resource availability.2. When calculating the cost and preparing resource requirements for construction, the maintenance planner shall as per relevant contracts and relevant regulations.Emergency matters(Critical equipment failure)Overrun of budgetPreparation for maintenance:Switch equipment outConfirm safety measuresIssue noticeConfirm work scopeInspect the best work timeApprove(DOAG)Inspect continuous work is required or notNOFill in ERP work orderInspect/ApproveEnter implementation process of for maintenanceEnter plan/ Implementation processInspect work reasonsCompare other selectionsFailure notice for key equipmentMaintenance PlannerOperatorsMaintenance LeadYes工作流程说明Explanation on Work Process一、 年度/月度计划维修工作流程Annual/Quarterly/Monthly Planned Maintenance Work Process1. 年度维修计划由年度大型维修项目及常规预防性维修项目、改良性项目、大修项目等组成。MCL组织各专业工程师根据五年规划要求、设备策略、运行设备可靠性分析及高故障率设备清单等编制年度大型维修项目清单，BTM组织业务团队内部讨论（MCL、PCL、TCL、安全工程师参加）筛选后，报机械设备部维修计划主管汇总。Annual Maintenance Plan is composed of annual large-scale maintenance program, routine maintenance program, improvement program, overhaul program and etc. MCL shall organize each discipline engineer to develop annual large-scale maintenance program according to the five-year plan requirements, equipment maintenance strategy, equipment reliability analysis and high failure equipment list and etc., and BTM shall organize business teams for internal discussion (MCL, PCL, TCL and safety engineers participate) and selection, which shall be submitted to the planning supervisor of Mechanical Department for summary.2. 机械设备部维修计划组参照历年同类装置维修费用使用、设备运行趋势进行费用综合测算（包括业界对比适时情况、公司下一年度维修预算展望），双方并就工作单优化及年度初步预算达成一致于每年8月中旬前完成公司年度维修计划初稿上报MLT审查。Maintenance Plan Group of Mechanical Dept. shall develop comprehensive expense budgeting according to year-on-year maintenance expenses and equipment running conditions over the years (including applicable benchmarking data and the next-year maintenance budget outlook); and reach an agreement with BTs on optimization of work lists and preliminary annual budget. Maintenance Plan Group of Mechanical Dept. develops draft of Annual Maintenance Plan for the Company by the middle of August and submits it to the MLT.3. MLT组织相关职能部门讨论定稿后上报公司董事会（BOD）审批执行，如MLT对年度计划项目或概算有调整则需返回业务团队重新优化后报批。MLT organize discussions among relevant functional departments, finalize the draft and submit to BOD of the company for approval and implementation, if MLT has any adjustment towards annual planned project or budgets, then the draft shall be returned back to business teams for optimization and then submit for approval.4. 机械设备部维修计划主管根据年度业务计划编制三月维修计划展望（包括成本估算、执行时间建议），该计划要结合全厂资源管理，计划工作延迟管理等情况进行滚动编制，每月更新一次。Maintenance Plan Group Supervisor of Mechanical Dept. develops outlook for quarterly plan (including cost estimation, suggestions of execution time). The plan shall be developed in a rolling way by combining the Plant-wide Resource Management and plan work postponement management, which shall be updated on a monthly basis.5. 业务团队MCL根据月、季度成本/预算对计划进行审核、沟通，优化计划执行，如需对批准的项目变更、替代或追加项目或申请预备金等则需由MCL申请，由MLT审批后方可执行。Business Team MCL shall review, communicate and optimize the implementation of the plan as per monthly/quarterly cost/budget, if it is necessary to change, replace or additional project or apply reserve fund for the approved project, MCL shall submit the application, and will be put into implementation after the approval by MLT.二、维修工作流程Maintenance Work Process1计划协调：维修计划员根据各项工作准备（包括材料交货时间/资源情况），编制（1+3）周工作计划排序，在周四维修计划会提交讨论，已总结上周计划完成情况及安排下周工作安排，滚动更新（1+3）并于每周五发布执行。Coordination of plan: maintenance planner shall develop work plan order of (1+3) weeks according to all preparations (including delivery time of materials/enterprise resource); completion status of plan for the last week and work arrangement for the next week shall be submitted and discussed at the maintenance meeting held on Thursday; it shall be updated (1+3) in a rolling manner and issued for implementation on Friday.2. 工作申报：外操人员在ERP系统录入故障通知单（计划通知单由计划员录入）。Request of work: Maintenance Planner issues weekly planned maintenance notification sheet (unplanned failure is notified by operator).3. 工作筛选：PCL对工作通知进行筛选，检视作业理由及比较其他选择，确定工作选择；MCL确定工作范围及最佳工作时间。PCL与MCL之间将就工作选 择不断沟通协调优化，同时要对故障进行根本性原因分析，MCL在ERP上对通知单进行处理，处理意见有：延期/拒绝/批准。Selection of work: PCL screens the work notification, inspects work reasons and compares other selections to determine work; MCL confirms work scope and best work time; PLC and MCL make continuous coordination and optimization for work selection through communication, and analyze the root reasons of failure, MCL shall handle the notification in ERP system based on the following opinions: propones/ refuse/ approve.4工作审批：MCL（根据授权）对需要执行的通知单进行工作清单审批（包括概算、可接受的交付时间要求），一般设备不必注明可交付工期，由计划员根据SDD及资源情况进行排序。Approval of work: MCL (based on DOAG) needs to approve the work list in respect of the work order to be implemented (including budgetary estimate and acceptable time request); for general equipment, it is not necessary to indicate the deliverable construction period, but the planner needs to prioritize them according to SDD and resource availability.”6. 工作编制：Development of work: 计划员根据审批的工作清单以及季/月/周计划进行现场确认，编制具体工作范围描述、成本测算，制定具体的施工材料、施工机具及资源需求并录入ERP；施工资源需求按照合同履行，成本测算按照相关定额进行，需求策略维修计划组负责统筹询价采购申请并安排。如果超概算则由计划员提出相关建议：如缩小范围、调整概算等，返回MCL重新审定。符合概算由维修计划员/维修计划主管（DOAG）批准进行采购申请（包括材料采购及服务采购）。Planner make confirmation on site based on work list approved, prepares description of specific work scope and cost estimation, and develops specific construction materials, construction machines & tools and resources demand which shall be entered into ERP; the resource requirement for construction shall be implemented as per the contract, and the cost calculation shall be conducted as per relevant quota; Demand Strategy Maintenance Planning Team shall summarize the inquiries, purchase request and make arrangements. In case of over-budget, planner shall provide relevant suggestions: such as narrowing down scope, adjusting budget and etc., which shall be returned to MCL for re-check. If the job complies with budget, Maintenance Planner or Maintenance Plan Supervisor will approve the procurement request (including material purchase and service purchase). 维修计划员编制工作包，协调工作前准备，编制周/日资源分配计划及工作排序。按照月计划编排好最新第一周排序（包括故障维修计划）并释放，维修班长安排实施（其中第一周的工作已完全安排好并包含其中工作的每日时间表），四周时间表还提供第2至4周的综合工作时间表，以便及时为这些工作做好必要的准备，另对标准工作包数据库进行维护。Maintenance planner shall prepare the work package and coordinate the preparations before work, prepare weekly/daily resources distribution program and work orders. Prepare the orders of the first week(including maintenance plan of failures) based on the monthly plan and its assignments. Shift lead of maintenance team shall be responsible for the implementation (among which, the jobs of the first week have already been arranged, and include the time schedule of each day), provide work schedules of the four weeks and the comprehensive work schedule form week 2 to week 4 so as to make the necessary preparation work timely, and be responsible for the maintenance work for standard work data package.7. 工作执行：维修班长将每项工作安排到执行班组，进入作业票办理。Execution of work: shift lead of maintenance team shall arrange every job to the responsible shift, and enter into the process of work permit. 按照日计划安排，作业人员于前一天下午通知作业票协调员开具作业票（包括动火、用电等），发出作业需求。According to the schedule of work permit, the operators shall inform work permit coordinator to issue work permit (including hot work and electricity permit) on the afternoon before work, deliver the requirement to work. 作业票协调员根据作业内容进行作业票填写签发，操作人员根据作业票详细要求进行逐项落实确认于作业当天上午8点前完成该项工作。 Work permit coordinator shall fill in and issue the work permit as per the working content, and the operators shall confirm item by item according to the detailed requirements of work permit, and such confirm shall be complete before 8clock on the date of work permit. 维修人员施工前对作业票确认签字后开始实施作业，项目作业完成后由维修班长及倒班班长共同对作业票进行签字确认关闭。Maintenance works shall sign on the work permit before work, maintenance lead and shift lead shall sign and close the work on work permit after the work is complete. 维修班长要进行安全管理、管理界面协调，协调安排工作、监督工作执行，工作量确认（不超计划量，如超计划必须及时沟通计划员）及较复杂项目完成执行报告，关键工单拖延/提前应及时与维修计划员协调，对于工作提升建议需反馈维修计划和可靠性工程师。Maintenance lead shall perform safety management, management interface coordination, job coordination and supervise the work implementation, confirm the work quantity (do not exceed the scheduled quantity, and shall communicate with the planers timely if it exceed the scheduled quantity), and prepare implementation report for complicated work items, coordinate with the planner timely if key work order is postponed or brought forward, and shall feed back the work improvement suggestions to maintenance planning and reliability engineers. 维修计划员在ERP上对工单完工确认并关闭。Maintenance planner shall confirm and close work order in ERP system.注：按照授权指引分别授权给MCL和BTM进行ERP工单审批，费用超过（按授权指引）需提交MLT讨论批准（线外书面审批），由MCL在ERP上完成审批流程。Note: Approval authority of ERP work order is delegated to MCL and BTL based on DOAG. For work orders with extremely large cost (to be determined), they shall be submitted to MLT for discussion and approval (offline approval in writing) and MCL goes through approval procedure in ERP.三、 非计划维修工作流程Unplanned Maintenance Work Process1. 因功能故障而需进行的非计划检修，应该仅适用于事先确定的关键设备/紧急事件，一旦发生由操作人员发出通知单报告PCL/MCL/生产总调。Unplanned repair due to functional failures shall only apply to key equipment/emergency events w