设备管理程序EquipmentManagementProcedure

1、注意！attention ！除签字批准的原版外，只有在公司内部网上的文件才是有效文件，打印出的文件只能作为参考。this document is controlled by the database on company server. print-outs are for reference only. 无锡荣鑫金属涂装有限公司wuxi rongxin metal coating co., ltd.文件名称 procedure name : 设备管理程序equipment management procedure文件编号 document id : rx-qp-16 文件版本 documen

2、t version : a/0 发放号 issue no ：编制：prepared by颜伟光日期date：2014-4-28 审核：reviewed by日期date：批准：approved by日期date：发布日期：issue date :实施日期：implement date 会签栏countersignature row 部门department 人事部hr 生产部production 质量部quality 采购部purchasing 签核人countersign 部门department 物流部logistic 财务部finance 工程部engineering 业务部busine

3、ss 签核人countersign 设备管理程序equipment management procedure文 件 编 号document id ：rx-qp-16版次 version ： a/0修改日期 revision date：页次 page ：1 /12 1、目的1. purpose确保各生产单元设备安全、稳定、连续运行，以满足加工设备对产品质量技术特性的需求。it aims to ensure safety, stability and continuous running of the production equipments so as to meet the requirem

4、ent of the processing equipments for product quality technical features. 2、适用范围2. scope 适用于各类动力设备及辅助生产设备的维修和日常维护保养，包括设备技术和备品备件的管理。it applies to repairing and routine maintenance of all kinds of power equipments and auxiliary production equipments, including equipment technique and spare parts manage

5、ment. 3、定义3. definition3.1 关键设备：喷粉线为公司的主要装置， 而装置是由各设备组成， 装置中的任何一台设备发生故障，都将对整体生产产生重大的影响。所以公司用于生产的任何设备都属于关键设备。3.1 key equipments: powder coating is the main devices of the company; the device is made up of equipments and equipment failure in the device will impose great influence on production, so any

6、 equipment used for production belongs to key equipment.4. 职责4. responsibilities为对设备维修和保养进行科学的管理，首先应明确设备使用部门和设备维修部门的职责，然后细分其职责并落实到每个使用和维修管理人员身上。for scientific management of equipment maintenance, define the responsibilities of the departments using and maintaining the equipment at first, and then de

7、fine the responsibilities in details and devolve out into individual administrative staff using and maintaining the equipment. 设备管理程序equipment management procedure文 件 编 号document id ：rx-qp-16版次 version ： a/0修改日期 revision date：页次 page ：2 /12 4.1 生产部负责设备的统筹管理，其包括设备的配置、验收、建档、检修、维护、巡检、报废。4.1 the product

8、ion department shall be responsible for overall management of the equipments, including layout, inspection and acceptance, filing, overhaul, maintenance, in-process check and scrapping. 4.2 生产部门负责设备的运行操作和日常设备维护保养。4.2 the production department shall be responsible for running and operation and routin

9、e maintenance of the equipments.5、程序5. procedure5.1 设备的申购和验证5.1 equipment purchase application and verification在生产设备和辅助设备采购过程中，设备的申购和验证环节是决定设备投资成败的关键，必须引起重视。in the purchasing process of the production and auxiliary equipments, equipment purchasing application and verification makes all the differenc

10、e between success and failure, so it needs to attach importance to it. 5.1.1申购5.1.1 purchase application新设备的添置是根据公司实际业务的发展和产品质量以及技术更新的需求而提出的。设备的购置先由需求部门提出申购，然后由工程部汇同各相关部门对申购设备进行可行性的综合分析，如：设备加工能力、精度、尺寸、价格和生产加工工艺要求等。propose to buy new equipments according to actual business development of the company

11、and the requirement for product quality and technological updating. the department of demand shall apply to buy the equipment at first, and then the engineering department jointly with relevant departments shall perform comprehensive analysis of the feasibility of the equipment applied to be bought,

12、 such as the equipment working capacity, precision, dimension, price and production and processing technological requirements. 设备管理程序equipment management procedure文 件 编 号document id ：rx-qp-16版次 version ： a/0修改日期 revision date：页次 page ：3 /12 5.1.2验证5.1.2 verification 购置后的任何设备，必须由生产部按新设备验收程序进行验收，验收合格方

13、能投入使用。申购设备的具体验收程序为：any equipment purchased shall be inspected and accepted by the production department according to the new equipment inspection and acceptance procedure; it can be using after proven to be qualified through inspection. the specific inspection and acceptance procedure of the equipme

14、nt purchased is: a. 设备运抵公司后，先开箱对设备的外观和数量进行检验。a. after the equipment is transported to the company, open the box the check the appearance and quantity of the equipment at first. b. 设备在安装期间由生产部专人负责监理，发现问题及时与设备安装施工单位沟通并解决。b. the specially-assigned person of the production department shall supervise ins

15、tallation of the equipment, communicate with the unit in charge of equipment installation and solve it timely if a problem is found. c.设备安装调试后， 监理要对设备试运行过程中出现的问题和情况进行跟踪，以便在最终验收时无遗漏项。c. after the equipment is installed and debugged, the supervisor shall trace the problems and conditions occur in the

16、trial operation process so as to ensure that there are no missing items during final acceptance.d. 最终验收是根据设备的具体情况由负责机械，电器或程序的工程师分别实施验收确认，当三方验收都合格时，设备方能移交使用。d. as to final acceptance, engineers responsible for machinery, electrical equipments or programs shall confirm acceptance according to specific

17、 condition of the equipment; if it is proven to be qualified after inspection and acceptance of the three parties, the equipment can be transferred to the user. e. 验收合格后按要求填写“设备验收单”备档。设备管理程序equipment management procedure文 件 编 号document id ：rx-qp-16版次 version ： a/0修改日期 revision date：页次 page ：4 /12 e.

18、 after acceptance, fill out the “equipment acceptance certificate” according to requirement.5.2 设备建档5.2 equipment filing 设备建挡是设备管理过程中一项最基本的管理工作，它的好与否将直接影响到设备管理的结果，因此，必须按部就班地认真做好此项工作。equipment filing is the most essential management work in the equipment management process, which influences the equip

19、ment management results directly, so it has to be done conscientiously and conventionally. 5.2.1 设备台帐5.2.1 equipment account 设备台帐“设备统计表”是设备管理工作的基础，其统计内容包括：设备名称，制造厂商，制造年月，主要技术参数等，除此之外，每台设备还附有相应的照片供方便查寻。the equipment account “equipment statistical table ” is the base for equipment management, and its

20、statistical content includes: equipment name, manufacturer, manufacturing date and main technical parameters; in addition, every equipment shall be attached with corresponding picture for looking up. 5.2.2设备档案5.2.2 equipment archives设备档案完整性对设备维修起着关键性的作用，为做好设备档案的管理，其具体的管理措施为：the completeness of the e

21、quipment archives plays a key role in equipment maintenance; to manage the equipment archives well, the specific management measures are: a. 以单元为整体分门别类对设备建档。a. file equipment by category by taking unit as whole.b. 建立设备资料登记制度。b. establish equipment data registration system.c.建立设备档案借用登记制度。c. establish

22、 equipment archives borrowing registration system.d. 重要设备档案和图纸进行复制备份。设备管理程序equipment management procedure文 件 编 号document id ：rx-qp-16版次 version ： a/0修改日期 revision date：页次 page ：5 /12 d. duplicate and back up importance equipment archives and drawings. 5.2.3 关键设备的管理5.2.3 key equipment management为提高设备

23、的完好率，关键设备采取定时定人的管理方法是切实可行的，具体措施办法：to improve equipment perfectness ratio, it is feasible to adopt the management measure fixed time and person to the key equipment, with the specific measures as follows: a. 每班操作工对其使用的设备进行日巡检，发现问题及时向维修人员汇报。a. operator per shift shall perform daily in-process check to

24、 the equipment used and report to the maintenance personnel timely if finding problems. b. 维修人员按周、月、旬和年对其管辖的机器设备定时进行检查和维护保养。b. the maintenance personnel shall inspect and maintain the machine equipment regularly according to week, month, ten-day and year. c.除设备故障时，要求尽可能地从根源上解决问题。c. except equipment

25、failure, try to deal with the root of the problem.d. 生产部门对同一设备的故障进行统计和预防分析“设备故障和预防措施汇总表”。d. the production department shall perform statistical and preventive analysis of the failure of the same equipment according to the “equipment failure and preventive measures summary sheet ”.5.3 设备的使用和日常维护5.3 e

26、quipment operation and routine maintenance为确保生产设备的安全，持续和高效运行，正确操作使用设备和定期维护保养是关键。to ensure safe, continuous and efficient running of the production equipment, it is essential to operate and use the equipment correctly and maintain it regularly. 5.3.1使用要求5.3.1 operating requirement 每一个操作工在操作使用生产设备时，必须

27、严格按照使用规程进行操作，尤其在设备启动、停机、故障和紧急状态下的操作处理。设备管理程序equipment management procedure文 件 编 号document id ：rx-qp-16版次 version ： a/0修改日期 revision date：页次 page ：6 /12 when operating and using the production equipment, each operator shall operate it strictly according to the operating regulations, especially for eq

28、uipment starting-up, stopping and disposal under failure and emergency state. 5.3.2日常维护5.3.2 routine maintenance 操作工在接班前要对其管辖的生产设备按日巡检项目进行点检，并填写巡检记录“操作工设备日常巡检表”，发现设备异常现象立刻通知设备维修人员，以便及时排除故障。before taking his turn on duty, the operator shall perform point inspection to the production equipment accordi

29、ng to the daily in-process check items and fill the inspection result in the “operator equipment daily inspection form” and inform the equipment maintenance personnel immediately to remove the failure timely if finding abnormal phenomenon of the equipment. 5.4 设备维护和保养5.4 equipment maintenance设备的维护和保

30、养主要分预防性维保养和预测性维护保养,设备维修人员根据“设备保养表”进行设备维护保养。equipment maintenance mainly divided into preventive and predicative maintenance; the equipment maintenance personnel shall maintain the equipment according to the “equipment maintenance form”. 5.4.1预防性保养5.4.1 preventive maintenance 设备维修人员不仅按周、月、季度和年度计划定时定点

31、对所管辖的设备进行维护巡检，而且还针对性地按“设备保养表”对设备实行有计划的预防性保养。the equipment maintenance personnel shall not only maintain and inspect the equipment at fixed time and point according to the weekly, monthly, quarterly and annual plans, but also perform planned preventive maintenance to the equipment with a clear aim ac

32、cording to the “equipment maintenance form”. 5.4.2预测性维护5.4.2 predicative maintenance 设备管理程序equipment management procedure文 件 编 号document id ：rx-qp-16版次 version ： a/0修改日期 revision date：页次 page ：7 /12 设备维修人员除做好预防性维护工作外，还应根据经验和设备的特性进行预测性维护，如：当外部环境温度，湿度和压力等发生较大变化时，设备的工况条件也将随之发生改变，所以要提前做好预测性的维护工作和预防措施。be

33、sides preventive maintenance, the equipment maintenance personnel shall perform predicative maintenance according to the experience and equipment features. for example, when greater change happens to the temperature, humidity and pressure of the external environment, the equipment working conditions

34、 change along with it, so it is necessary to perform predicative maintenance and take preventive measures. 5.4.3维护监督5.4.3 maintenance supervision生产部经理要对维修人员的保养和维护工作内容进行检查确认, 并对周、月、季度和年度设备保养维护点检表进行抽检并确认“维修人员设备巡检确认表”。the production department manager shall inspect and confirm the job content of the ma

35、intenance personnel, perform causal inspection to the weakly, monthly, quarterly and annual equipment maintenance point inspection form and confi rm the “maintenance personnel equipment in-process checkconfirmation form”. 5.5 设备维修5.5 equipment maintenance5.5.1操作工在操作和巡检中发现设备异常现象或发生故障报警时，必须及时通知设备维修人员，

36、设备维修人员接到通知后，必须及时赶到现场处理排除。5.5.1 when finding abnormal phenomenon of the equipment or failure warning occurring in the operation and in-process check, the operator shall inform the equipment maintenance personnel timely, who shall rush to the spot to deal with it in time after receiving the notice.5.5

37、.2设备维修人员到达现场时，将首先对故障现象进行分析和诊断，确定其初步原因。5.5.2 the equipment maintenance personnel shall analyze and diagnose the failure first and determine the cause preliminarily after arriving at the spot.5.5.3在初步确定故障原因后，先查明是否有备品备件，如果没有要立刻填写“采购申请单”紧急采购，只有在被备品备件有保障或可用其它方法取代的情况下，才能实施维修。5.5.3 after determining the ca

38、use for failure preliminarily, find out if spare parts available; if no, fill out the “purchase application form” immediately for emergency procurement; maintain the equipment in the condition that the spare parts are assured or other method can be used to 设备管理程序equipment management procedure文 件 编 号

39、document id ：rx-qp-16版次 version ： a/0修改日期 revision date：页次 page ：8 /12 replace it.5.5.4维修过程中备品备件更换必须按规定进行登记，在库存低于最小库存量时，要及时填写“采购申请单”。5.5.4 changes of spare parts in the maintenance process shall be registered; when the inventory is lower than the minimum quantity, fill out the “purchase application

40、form” timely. 5.5.5故障排除后要及时填写设备维修记录备案，以便故障排除的经验供他人查阅和参考。5.5.5 after the failure is removed, fill the equipment maintenance record for reference to failure removal experience for others. 5.5.6生产部经理每月将根据设备维修记录，整理填写“设备故障和预防措施汇总表”进行分析，以便采取相应的预防措施，避免类似的设备故障发生。5.5.6 the production manager shall sort out a

41、nd fill out the “equipment failure and preventive measures summary sheet” and analyze every month according to the equipment maintenance record, so as to take corresponding preventive measurer and avoid similar equipment failure from occurring.5.5.7设备维修完毕维修人员要登记维修时间。5.5.7 after the equipment is main

42、tained, the maintenance personnel shall register the maintenance time. 5.5 设备备品备件管理5.5 equipment spare parts management设备备品备件的管理是确保设备在故障情况下能否得到及时维修和保养的关键，它是设备正常运行的基础。equipment spare parts management is the key to timely maintenance in the condition of equipment failure and is the base for normal run

43、ning of the equipment. 5.6.1备品备件申请5.6.1 spare parts application备品备件应根据各设备的具体情况和已有的经验适时适量地申请储备，在确保安全库存的前提下要尽可能地减少库存量。申请备品备件应遵守如下三个原则：apply to store spare parts timely and adequately according to the specific condition of the equipments and the existing experience and try to reduce inventory on the pr

44、emise of safety stock. spare parts application shall observe the following three principles: a能通用的备品备件尽可能通用。设备管理程序equipment management procedure文 件 编 号document id ：rx-qp-16版次 version ： a/0修改日期 revision date：页次 page ：9 /12 a. try to use universal spare parts. b根据经验在满足最小库存量的前提下申请备品备件。b. apply for spar

45、e parts on the premise of meeting minimum inventory and according to experience. c采购周期长且重要的备品备件要适当多备，采购时间短且不重要的备品备件可少备或不备。c. store more spare parts with longer purchase period and importance adequately, and store less or do not store spare part with shorter purchase period and without importance.5.6

46、.2备品备件保存5.6.2 spare parts preservation备品备件应根据安全易找的原则进行存放，具体应遵守如下四个原则：the spare parts shall be stored according to the principle of safety and ease for finding, and the following four principles shall be observed specifically: a. 精度高和贵重的备品备件要做好防潮防尘保护措施。a. take moisture-proof and dustproof protective

47、measures to spare parts with high accuracy and great value.b. 备品备件按轻上重下和电上机下的原则存放在货架上。b. keep the spare parts on the shelf according to the principle of “light up and heavy down, electrical up and machinery down”. c.按生产设备的单元和设备重要性划分备品备件货架。c. divide spare parts shelf according to the unit of the prod

48、uction equipment and the equipment importance.d. 领后不用的备品备件必须按何取何归的原则及时摆放到货架原处。d. put the spare parts not used after getting them back to the original place on the shelf according to the principle of “put back to where getting them”.5.6.3备品备件领用5.6.3 spare parts getting 设备管理程序equipment management proc

49、edure文 件 编 号document id ：rx-qp-16版次 version ： a/0修改日期 revision date：页次 page ：10 /12 能否按规定领用备品备件是保证库存正确性的关键，具体应遵守如下四个原则：to get the spare parts according to regulations is the key to inventory correctness and the following four principles shall be observed specifically: a. 备品备件领用，应按规定和要求先填写“备品备件领用登记单”

50、，紧急情况下可先领用后补单。a. when getting spare parts, fill out the “spare parts getting registration sheet” according to regulations and requirements; get the spare parts first and fill out the registration sheet later in emergencies. b. 领用数量一定要和领用登记单上的一致。b. the amount got shall be in conformity with the amoun

51、t on the registration sheet.c.由专人定时更改系统库存“备品备件库存表”，低于安全库存的备品备件，应及时填写申请进行采购c. specially- assigned person shall alter the system inventory “spare parts inventory statement ” regularly; fill application timely for purchasing spare parts lower than the safety stock.d. 定期进行库存盘点，防止漏填造成库存不准。d. perform inve

52、ntory verification regularly and prevent from missing out the inventory statement and causing inaccurate inventory.5.6.4备件报废5.6.4 spare parts scraping更换下来的备品备件不能随便丢弃，要按规定摆放到备品备件报废货架上妥善管理，其作用为：do not abandon the replaced spare parts casually, put them on the scraping shelf according to regulations an

53、d manage them properly; and their functions are: a如有可能进行修复。a. repair them if possible.b更换下的备品备件上的某些部件可再利用。设备管理程序equipment management procedure文 件 编 号document id ：rx-qp-16版次 version ： a/0修改日期 revision date：页次 page ：11 /12 b. some parts of the replaced spare parts can be reused.c 有些机器和备品备件还在保修期内，可得到厂家补偿或更换。c. some machine and spare parts are under warranty, so you can get compensation from the manufacturer or the manufacturer can change them. d作为分析设备故障的证据。d. take it as the evidence to analyze equipment failure