设备管理程序EquipmentManagementProcedure

./WORD格式可编辑XX荣鑫金属涂装有限公司WuxiRongxinmetalcoatingCo.,Ltd.文件名称ProcedureName:设备管理程序EquipmentManagementProcedure文件编号DocumentID:RX-QP-16文件版本DocumentVersion:A/0发放号IssueNo：编制：Preparedby颜伟光日期Date：201审核：Reviewedby日期Date：批准：Approvedby日期Date：发布日期：Issuedate:实施日期：Implementdate会签栏

CountersignatureRow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

Business签核人

Countersign.WORD格式可编辑.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。Itaimstoensuresafety,stabilityandcontinuousrunningoftheproductionequipmentssoastomeettherequirementoftheprocessingequipmentsforproductqualitytechnicalfeatures.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。Itappliestorepairingandroutinemaintenanceofallkindsofpowerequipmentsandauxiliaryproductionequipments,includingequipmenttechniqueandsparepartsmanagement.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。3.1Keyequipments:Powdercoatingisthemaindevicesofthecompany;thedeviceismadeupofequipmentsandequipmentfailureinthedevicewillimposegreatinfluenceonproduction,soanyequipmentusedforproductionbelongstokeyequipment.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。Forscientificmanagementofequipmentmaintenance,definetheresponsibilitiesofthedepartmentsusingandmaintainingtheequipmentatfirst,andthendefinetheresponsibilitiesindetailsanddevolveoutintoindividualadministrativestaffusingandmaintainingtheequipment.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。4.1Theproductiondepartmentshallberesponsibleforoverallmanagementoftheequipments,includinglayout,inspectionandacceptance,filing,overhaul,maintenance,in-processcheckandscrapping.4.2生产部门负责设备的运行操作和日常设备维护保养。4.2Theproductiondepartmentshallberesponsibleforrunningandoperationandroutinemaintenanceoftheequipments.5、程序5.Procedure5.1设备的申购和验证5.1Equipmentpurchaseapplicationandverification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。Inthepurchasingprocessoftheproductionandauxiliaryequipments,equipmentpurchasingapplicationandverificationmakesallthedifferencebetweensuccessandfailure,soitneedstoattachimportancetoit.申购Purchaseapplication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。Proposetobuynewequipmentsaccordingtoactualbusinessdevelopmentofthecompanyandtherequirementforproductqualityandtechnologicalupdating.Thedepartmentofdemandshallapplytobuytheequipmentatfirst,andthentheengineeringdepartmentjointlywithrelevantdepartmentsshallperformcomprehensiveanalysisofthefeasibilityoftheequipmentappliedtobebought,suchastheequipmentworkingcapacity,precision,dimension,priceandproductionandprocessingtechnologicalrequirements.验证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,验收合格方能投入使用。申购设备的具体验收程序为：Anyequipmentpurchasedshallbeinspectedandacceptedbytheproductiondepartmentaccordingtothenewequipmentinspectionandacceptanceprocedure;itcanbeusingafterproventobequalifiedthroughinspection.Thespecificinspectionandacceptanceprocedureoftheequipmentpurchasedis:设备运抵公司后,先开箱对设备的外观和数量进行检验。a.Aftertheequipmentistransportedtothecompany,opentheboxthechecktheappearanceandquantityoftheequipmentatfirst.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.Thespecially-assignedpersonoftheproductiondepartmentshallsuperviseinstallationoftheequipment,communicatewiththeunitinchargeofequipmentinstallationandsolveittimelyifaproblemisfound.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.Aftertheequipmentisinstalledanddebugged,thesupervisorshalltracetheproblemsandconditionsoccurinthetrialoperationprocesssoastoensurethattherearenomissingitemsduringfinalacceptance.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.Astofinalacceptance,engineersresponsibleformachinery,electricalequipmentsorprogramsshallconfirmacceptanceaccordingtospecificconditionoftheequipment;ifitisproventobequalifiedafterinspectionandacceptanceofthethreeparties,theequipmentcanbetransferredtotheuser.e.验收合格后按要求填写"设备验收单"备档。e.Afteracceptance,filloutthe"equipmentacceptancecertificate"accordingtorequirement.5.2设备建档5.2Equipmentfiling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。Equipmentfilingisthemostessentialmanagementworkintheequipmentmanagementprocess,whichinfluencestheequipmentmanagementresultsdirectly,soithastobedoneconscientiouslyandconventionally.设备台帐Equipmentaccount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。Theequipmentaccount"equipmentstatisticaltable"isthebaseforequipmentmanagement,anditsstatisticalcontentincludes:equipmentname,manufacturer,manufacturingdateandmaintechnicalparameters;inaddition,everyequipmentshallbeattachedwithcorrespondingpictureforlookingup.设备档案Equipmentarchives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：Thecompletenessoftheequipmentarchivesplaysakeyroleinequipmentmaintenance;tomanagetheequipmentarchiveswell,thespecificmanagementmeasuresare:以单元为整体分门别类对设备建档。a.Fileequipmentbycategorybytakingunitaswhole.建立设备资料登记制度。b.Establishequipmentdataregistrationsystem.建立设备档案借用登记制度。c.Establishequipmentarchivesborrowingregistrationsystem.重要设备档案和图纸进行复制备份。d.Duplicateandbackupimportanceequipmentarchivesanddrawings.关键设备的管理Keyequipmentmanagement为提高设备的完好率,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：Toimproveequipmentperfectnessratio,itisfeasibletoadoptthemanagementmeasurefixedtimeandpersontothekeyequipment,withthespecificmeasuresasfollows: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.Operatorpershiftshallperformdailyin-processchecktotheequipmentusedandreporttothemaintenancepersonneltimelyiffindingproblems.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.Themaintenancepersonnelshallinspectandmaintainthemachineequipmentregularlyaccordingtoweek,month,ten-dayandyear.除设备故障时,要求尽可能地从根源上解决问题。c.Exceptequipmentfailure,trytodealwiththerootoftheproblem.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.Theproductiondepartmentshallperformstatisticalandpreventiveanalysisofthefailureofthesameequipmentaccordingtothe"equipmentfailureandpreventivemeasuressummarysheet".设备的使用和日常维护5.3Equipmentoperationandroutinemaintenance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。Toensuresafe,continuousandefficientrunningoftheproductionequipment,itisessentialtooperateandusetheequipmentcorrectlyandmaintainitregularly.使用要求Operatingrequirement每一个操作工在操作使用生产设备时,必须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。Whenoperatingandusingtheproductionequipment,eachoperatorshalloperateitstrictlyaccordingtotheoperatingregulations,especiallyforequipmentstarting-up,stoppinganddisposalunderfailureandemergencystate.日常维护Routinemaintenance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。Beforetakinghisturnonduty,theoperatorshallperformpointinspectiontotheproductionequipmentaccordingtothedailyin-processcheckitemsandfilltheinspectionresultinthe"operatorequipmentdailyinspectionform"andinformtheequipmentmaintenancepersonnelimmediatelytoremovethefailuretimelyiffindingabnormalphenomenonoftheequipment.设备维护和保养5.4Equipmentmaintenance设备的维护和保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。Equipmentmaintenancemainlydividedintopreventiveandpredicativemaintenance;theequipmentmaintenancepersonnelshallmaintaintheequipmentaccordingtothe"equipmentmaintenanceform".预防性保养Preventivemaintenance设备维修人员不仅按周、月、季度和年度计划定时定点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。Theequipmentmaintenancepersonnelshallnotonlymaintainandinspecttheequipmentatfixedtimeandpointaccordingtotheweekly,monthly,quarterlyandannualplans,butalsoperformplannedpreventivemaintenancetotheequipmentwithaclearaimaccordingtothe"equipmentmaintenanceform".预测性维护Predicativemaintenance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。Besidespreventivemaintenance,theequipmentmaintenancepersonnelshallperformpredicativemaintenanceaccordingtotheexperienceandequipmentfeatures.Forexample,whengreaterchangehappenstothetemperature,humidityandpressureoftheexternalenvironment,theequipmentworkingconditionschangealongwithit,soitisnecessarytoperformpredicativemaintenanceandtakepreventivemeasures.维护监督Maintenancesupervision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"。Theproductiondepartmentmanagershallinspectandconfirmthejobcontentofthemaintenancepersonnel,performcausalinspectiontotheweakly,monthly,quarterlyandannualequipmentmaintenancepointinspectionformandconfirmthe"maintenancepersonnelequipmentin-processcheckconfirmationform".5.5设备维修5.5Equipmentmaintenance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,设备维修人员接到通知后,必须及时赶到现场处理排除。Whenfindingabnormalphenomenonoftheequipmentorfailurewarningoccurringintheoperationandin-processcheck,theoperatorshallinformtheequipmentmaintenancepersonneltimely,whoshallrushtothespottodealwithitintimeafterreceivingthenotice.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。Theequipmentmaintenancepersonnelshallanalyzeanddiagnosethefailurefirstanddeterminethecausepreliminarilyafterarrivingatthespot.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。Afterdeterminingthecauseforfailurepreliminarily,findoutifsparepartsavailable;ifno,filloutthe"purchaseapplicationform"immediatelyforemergencyprocurement;maintaintheequipmentintheconditionthatthesparepartsareassuredorothermethodcanbeusedtoreplaceit.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"。Changesofsparepartsinthemaintenanceprocessshallberegistered;whentheinventoryislowerthantheminimumquantity,filloutthe"purchaseapplicationform"timely.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。Afterthefailureisremoved,filltheequipmentmaintenancerecordforreferencetofailureremovalexperienceforothers.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。Theproductionmanagershallsortoutandfilloutthe"equipmentfailureandpreventivemeasuressummarysheet"andanalyzeeverymonthaccordingtotheequipmentmaintenancerecord,soastotakecorrespondingpreventivemeasurerandavoidsimilarequipmentfailurefromoccurring.设备维修完毕维修人员要登记维修时间。Aftertheequipmentismaintained,themaintenancepersonnelshallregisterthemaintenancetime.设备备品备件管理5.5Equipmentsparepartsmanagement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。Equipmentsparepartsmanagementisthekeytotimelymaintenanceintheconditionofequipmentfailureandisthebasefornormalrunningoftheequipment.备品备件申请Sparepartsapplication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：Applytostoresparepartstimelyandadequatelyaccordingtothespecificconditionoftheequipmentsandtheexistingexperienceandtrytoreduceinventoryonthepremiseofsafetystock.Sparepartsapplicationshallobservethefollowingthreeprinciples:能通用的备品备件尽可能通用。a.Trytouseuniversalspareparts.根据经验在满足最小库存量的前提下申请备品备件。b.Applyforsparepartsonthepremiseofmeetingminimuminventoryandaccordingtoexperience.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.Storemoresparepartswithlongerpurchaseperiodandimportanceadequately,andstorelessordonotstoresparepartwithshorterpurchaseperiodandwithoutimportance.备品备件保存Sparepartspreservation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：Thesparepartsshallbestoredaccordingtotheprincipleofsafetyandeaseforfinding,andthefollowingfourprinciplesshallbeobservedspecifically:精度高和贵重的备品备件要做好防潮防尘保护措施。a.Takemoisture-proofanddustproofprotectivemeasurestosparepartswithhighaccuracyandgreatvalue.备品备件按轻上重下和电上机下的原则存放在货架上。b.Keepthesparepartsontheshelfaccordingtotheprincipleof"lightupandheavydown,electricalupandmachinerydown".按生产设备的单元和设备重要性划分备品备件货架。c.Dividesparepartsshelfaccordingtotheunitoftheproductionequipmentandtheequipmentimportance.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.Putthesparepartsnotusedaftergettingthembacktotheoriginalplaceontheshelfaccordingtotheprincipleof"putbacktowheregettingthem".备品备件领用Sparepartsgetting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：Togetthesparepartsaccordingtoregulationsisthekeytoinventorycorrectnessandthefollowingfourprinciplesshallbeobservedspecifically: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",紧急情况下可先领用后补单。a.Whengettingspareparts,filloutthe"sparepartsgettingregistrationsheet"accordingtoregulationsandrequirements;getthesparepartsfirstandfillouttheregistrationsheetlaterinemergencies.领用数量一定要和领用登记单上的一致。b.Theamountgotshallbeinconformitywiththeamountontheregistrationsheet.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-assignedpersonshallalterthesysteminventory"sparepartsinventorystatement"regularly;fillapplicationtimelyforpurchasingsparepartslowerthanthesafetystock.定期进行库存盘点,防止漏填造成库存不准。d.Performinventoryverificationregularlyandpreventfrommissingouttheinventorystatementandcausinginaccurateinventory.备件报废Sparepartsscraping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：Donotabandonthereplacedsparepartscasually,putthemonthescrapingshelfaccordingtoregulationsandmanagethemproperly;andtheirfunctionsare:如有可能进行修复。a.Repairthemifpossible.更换下的备品备件上的某些部件可再利用。b.Some