設(shè)備管理程序EquipmentManagementProcedure

./WORD格式可編輯XX榮鑫金屬涂裝有限公司W(wǎng)uxiRongxinmetalcoatingCo.,Ltd.文件名稱ProcedureName:設(shè)備管理程序EquipmentManagementProcedure文件編號(hào)DocumentID:RX-QP-16文件版本DocumentVersion:A/0發(fā)放號(hào)IssueNo：編制：Preparedby顏偉光日期Date：201審核：Reviewedby日期Date：批準(zhǔn)：Approvedby日期Date：發(fā)布日期：Issuedate:實(shí)施日期：Implementdate會(huì)簽欄

CountersignatureRow部門

Department人事部

HR生產(chǎn)部

Production質(zhì)量部

Quality采購(gòu)部

Purchasing簽核人

Countersign部門

Department物流部

Logistic財(cái)務(wù)部

Finance工程部

Engineering業(yè)務(wù)部

Business簽核人

Countersign.WORD格式可編輯.目的1.Purpose確保各生產(chǎn)單元設(shè)備安全、穩(wěn)定、連續(xù)運(yùn)行,以滿足加工設(shè)備對(duì)產(chǎn)品質(zhì)量技術(shù)特性的需求。Itaimstoensuresafety,stabilityandcontinuousrunningoftheproductionequipmentssoastomeettherequirementoftheprocessingequipmentsforproductqualitytechnicalfeatures.適用范圍2.Scope適用于各類動(dòng)力設(shè)備及輔助生產(chǎn)設(shè)備的維修和日常維護(hù)保養(yǎng),包括設(shè)備技術(shù)和備品備件的管理。Itappliestorepairingandroutinemaintenanceofallkindsofpowerequipmentsandauxiliaryproductionequipments,includingequipmenttechniqueandsparepartsmanagement.3、定義3.Definition3.1關(guān)鍵設(shè)備：噴粉線為公司的主要裝置,而裝置是由各設(shè)備組成,裝置中的任何一臺(tái)設(shè)備發(fā)生故障,都將對(duì)整體生產(chǎn)產(chǎn)生重大的影響。所以公司用于生產(chǎn)的任何設(shè)備都屬于關(guān)鍵設(shè)備。3.1Keyequipments:Powdercoatingisthemaindevicesofthecompany;thedeviceismadeupofequipmentsandequipmentfailureinthedevicewillimposegreatinfluenceonproduction,soanyequipmentusedforproductionbelongstokeyequipment.4.職責(zé)4.Responsibilities為對(duì)設(shè)備維修和保養(yǎng)進(jìn)行科學(xué)的管理,首先應(yīng)明確設(shè)備使用部門和設(shè)備維修部門的職責(zé),然后細(xì)分其職責(zé)并落實(shí)到每個(gè)使用和維修管理人員身上。Forscientificmanagementofequipmentmaintenance,definetheresponsibilitiesofthedepartmentsusingandmaintainingtheequipmentatfirst,andthendefinetheresponsibilitiesindetailsanddevolveoutintoindividualadministrativestaffusingandmaintainingtheequipment.4.1生產(chǎn)部負(fù)責(zé)設(shè)備的統(tǒng)籌管理,其包括設(shè)備的配置、驗(yàn)收、建檔、檢修、維護(hù)、巡檢、報(bào)廢。4.1Theproductiondepartmentshallberesponsibleforoverallmanagementoftheequipments,includinglayout,inspectionandacceptance,filing,overhaul,maintenance,in-processcheckandscrapping.4.2生產(chǎn)部門負(fù)責(zé)設(shè)備的運(yùn)行操作和日常設(shè)備維護(hù)保養(yǎng)。4.2Theproductiondepartmentshallberesponsibleforrunningandoperationandroutinemaintenanceoftheequipments.5、程序5.Procedure5.1設(shè)備的申購(gòu)和驗(yàn)證5.1Equipmentpurchaseapplicationandverification在生產(chǎn)設(shè)備和輔助設(shè)備采購(gòu)過程中,設(shè)備的申購(gòu)和驗(yàn)證環(huán)節(jié)是決定設(shè)備投資成敗的關(guān)鍵,必須引起重視。Inthepurchasingprocessoftheproductionandauxiliaryequipments,equipmentpurchasingapplicationandverificationmakesallthedifferencebetweensuccessandfailure,soitneedstoattachimportancetoit.申購(gòu)Purchaseapplication新設(shè)備的添置是根據(jù)公司實(shí)際業(yè)務(wù)的發(fā)展和產(chǎn)品質(zhì)量以及技術(shù)更新的需求而提出的。設(shè)備的購(gòu)置先由需求部門提出申購(gòu),然后由工程部匯同各相關(guān)部門對(duì)申購(gòu)設(shè)備進(jìn)行可行性的綜合分析,如：設(shè)備加工能力、精度、尺寸、價(jià)格和生產(chǎn)加工工藝要求等。Proposetobuynewequipmentsaccordingtoactualbusinessdevelopmentofthecompanyandtherequirementforproductqualityandtechnologicalupdating.Thedepartmentofdemandshallapplytobuytheequipmentatfirst,andthentheengineeringdepartmentjointlywithrelevantdepartmentsshallperformcomprehensiveanalysisofthefeasibilityoftheequipmentappliedtobebought,suchastheequipmentworkingcapacity,precision,dimension,priceandproductionandprocessingtechnologicalrequirements.驗(yàn)證Verification購(gòu)置后的任何設(shè)備,必須由生產(chǎn)部按新設(shè)備驗(yàn)收程序進(jìn)行驗(yàn)收,驗(yàn)收合格方能投入使用。申購(gòu)設(shè)備的具體驗(yàn)收程序?yàn)椋篈nyequipmentpurchasedshallbeinspectedandacceptedbytheproductiondepartmentaccordingtothenewequipmentinspectionandacceptanceprocedure;itcanbeusingafterproventobequalifiedthroughinspection.Thespecificinspectionandacceptanceprocedureoftheequipmentpurchasedis:設(shè)備運(yùn)抵公司后,先開箱對(duì)設(shè)備的外觀和數(shù)量進(jìn)行檢驗(yàn)。a.Aftertheequipmentistransportedtothecompany,opentheboxthechecktheappearanceandquantityoftheequipmentatfirst.設(shè)備在安裝期間由生產(chǎn)部專人負(fù)責(zé)監(jiān)理,發(fā)現(xiàn)問題及時(shí)與設(shè)備安裝施工單位溝通并解決。b.Thespecially-assignedpersonoftheproductiondepartmentshallsuperviseinstallationoftheequipment,communicatewiththeunitinchargeofequipmentinstallationandsolveittimelyifaproblemisfound.設(shè)備安裝調(diào)試后,監(jiān)理要對(duì)設(shè)備試運(yùn)行過程中出現(xiàn)的問題和情況進(jìn)行跟蹤,以便在最終驗(yàn)收時(shí)無遺漏項(xiàng)。c.Aftertheequipmentisinstalledanddebugged,thesupervisorshalltracetheproblemsandconditionsoccurinthetrialoperationprocesssoastoensurethattherearenomissingitemsduringfinalacceptance.最終驗(yàn)收是根據(jù)設(shè)備的具體情況由負(fù)責(zé)機(jī)械,電器或程序的工程師分別實(shí)施驗(yàn)收確認(rèn),當(dāng)三方驗(yàn)收都合格時(shí),設(shè)備方能移交使用。d.Astofinalacceptance,engineersresponsibleformachinery,electricalequipmentsorprogramsshallconfirmacceptanceaccordingtospecificconditionoftheequipment;ifitisproventobequalifiedafterinspectionandacceptanceofthethreeparties,theequipmentcanbetransferredtotheuser.e.驗(yàn)收合格后按要求填寫"設(shè)備驗(yàn)收單"備檔。e.Afteracceptance,filloutthe"equipmentacceptancecertificate"accordingtorequirement.5.2設(shè)備建檔5.2Equipmentfiling設(shè)備建擋是設(shè)備管理過程中一項(xiàng)最基本的管理工作,它的好與否將直接影響到設(shè)備管理的結(jié)果,因此,必須按部就班地認(rèn)真做好此項(xiàng)工作。Equipmentfilingisthemostessentialmanagementworkintheequipmentmanagementprocess,whichinfluencestheequipmentmanagementresultsdirectly,soithastobedoneconscientiouslyandconventionally.設(shè)備臺(tái)帳Equipmentaccount設(shè)備臺(tái)帳"設(shè)備統(tǒng)計(jì)表"是設(shè)備管理工作的基礎(chǔ),其統(tǒng)計(jì)內(nèi)容包括：設(shè)備名稱,制造廠商,制造年月,主要技術(shù)參數(shù)等,除此之外,每臺(tái)設(shè)備還附有相應(yīng)的照片供方便查尋。Theequipmentaccount"equipmentstatisticaltable"isthebaseforequipmentmanagement,anditsstatisticalcontentincludes:equipmentname,manufacturer,manufacturingdateandmaintechnicalparameters;inaddition,everyequipmentshallbeattachedwithcorrespondingpictureforlookingup.設(shè)備檔案Equipmentarchives設(shè)備檔案完整性對(duì)設(shè)備維修起著關(guān)鍵性的作用,為做好設(shè)備檔案的管理,其具體的管理措施為：Thecompletenessoftheequipmentarchivesplaysakeyroleinequipmentmaintenance;tomanagetheequipmentarchiveswell,thespecificmanagementmeasuresare:以單元為整體分門別類對(duì)設(shè)備建檔。a.Fileequipmentbycategorybytakingunitaswhole.建立設(shè)備資料登記制度。b.Establishequipmentdataregistrationsystem.建立設(shè)備檔案借用登記制度。c.Establishequipmentarchivesborrowingregistrationsystem.重要設(shè)備檔案和圖紙進(jìn)行復(fù)制備份。d.Duplicateandbackupimportanceequipmentarchivesanddrawings.關(guān)鍵設(shè)備的管理Keyequipmentmanagement為提高設(shè)備的完好率,關(guān)鍵設(shè)備采取定時(shí)定人的管理方法是切實(shí)可行的,具體措施辦法：Toimproveequipmentperfectnessratio,itisfeasibletoadoptthemanagementmeasurefixedtimeandpersontothekeyequipment,withthespecificmeasuresasfollows:每班操作工對(duì)其使用的設(shè)備進(jìn)行日巡檢,發(fā)現(xiàn)問題及時(shí)向維修人員匯報(bào)。a.Operatorpershiftshallperformdailyin-processchecktotheequipmentusedandreporttothemaintenancepersonneltimelyiffindingproblems.維修人員按周、月、旬和年對(duì)其管轄的機(jī)器設(shè)備定時(shí)進(jìn)行檢查和維護(hù)保養(yǎng)。b.Themaintenancepersonnelshallinspectandmaintainthemachineequipmentregularlyaccordingtoweek,month,ten-dayandyear.除設(shè)備故障時(shí),要求盡可能地從根源上解決問題。c.Exceptequipmentfailure,trytodealwiththerootoftheproblem.生產(chǎn)部門對(duì)同一設(shè)備的故障進(jìn)行統(tǒng)計(jì)和預(yù)防分析"設(shè)備故障和預(yù)防措施匯總表"。d.Theproductiondepartmentshallperformstatisticalandpreventiveanalysisofthefailureofthesameequipmentaccordingtothe"equipmentfailureandpreventivemeasuressummarysheet".設(shè)備的使用和日常維護(hù)5.3Equipmentoperationandroutinemaintenance為確保生產(chǎn)設(shè)備的安全,持續(xù)和高效運(yùn)行,正確操作使用設(shè)備和定期維護(hù)保養(yǎng)是關(guān)鍵。Toensuresafe,continuousandefficientrunningoftheproductionequipment,itisessentialtooperateandusetheequipmentcorrectlyandmaintainitregularly.使用要求Operatingrequirement每一個(gè)操作工在操作使用生產(chǎn)設(shè)備時(shí),必須嚴(yán)格按照使用規(guī)程進(jìn)行操作,尤其在設(shè)備啟動(dòng)、停機(jī)、故障和緊急狀態(tài)下的操作處理。Whenoperatingandusingtheproductionequipment,eachoperatorshalloperateitstrictlyaccordingtotheoperatingregulations,especiallyforequipmentstarting-up,stoppinganddisposalunderfailureandemergencystate.日常維護(hù)Routinemaintenance操作工在接班前要對(duì)其管轄的生產(chǎn)設(shè)備按日巡檢項(xiàng)目進(jìn)行點(diǎn)檢,并填寫巡檢記錄"操作工設(shè)備日常巡檢表",發(fā)現(xiàn)設(shè)備異?，F(xiàn)象立刻通知設(shè)備維修人員,以便及時(shí)排除故障。Beforetakinghisturnonduty,theoperatorshallperformpointinspectiontotheproductionequipmentaccordingtothedailyin-processcheckitemsandfilltheinspectionresultinthe"operatorequipmentdailyinspectionform"andinformtheequipmentmaintenancepersonnelimmediatelytoremovethefailuretimelyiffindingabnormalphenomenonoftheequipment.設(shè)備維護(hù)和保養(yǎng)5.4Equipmentmaintenance設(shè)備的維護(hù)和保養(yǎng)主要分預(yù)防性維保養(yǎng)和預(yù)測(cè)性維護(hù)保養(yǎng),設(shè)備維修人員根據(jù)"設(shè)備保養(yǎng)表"進(jìn)行設(shè)備維護(hù)保養(yǎng)。Equipmentmaintenancemainlydividedintopreventiveandpredicativemaintenance;theequipmentmaintenancepersonnelshallmaintaintheequipmentaccordingtothe"equipmentmaintenanceform".預(yù)防性保養(yǎng)Preventivemaintenance設(shè)備維修人員不僅按周、月、季度和年度計(jì)劃定時(shí)定點(diǎn)對(duì)所管轄的設(shè)備進(jìn)行維護(hù)巡檢,而且還針對(duì)性地按"設(shè)備保養(yǎng)表"對(duì)設(shè)備實(shí)行有計(jì)劃的預(yù)防性保養(yǎng)。Theequipmentmaintenancepersonnelshallnotonlymaintainandinspecttheequipmentatfixedtimeandpointaccordingtotheweekly,monthly,quarterlyandannualplans,butalsoperformplannedpreventivemaintenancetotheequipmentwithaclearaimaccordingtothe"equipmentmaintenanceform".預(yù)測(cè)性維護(hù)Predicativemaintenance設(shè)備維修人員除做好預(yù)防性維護(hù)工作外,還應(yīng)根據(jù)經(jīng)驗(yàn)和設(shè)備的特性進(jìn)行預(yù)測(cè)性維護(hù),如：當(dāng)外部環(huán)境溫度,濕度和壓力等發(fā)生較大變化時(shí),設(shè)備的工況條件也將隨之發(fā)生改變,所以要提前做好預(yù)測(cè)性的維護(hù)工作和預(yù)防措施。Besidespreventivemaintenance,theequipmentmaintenancepersonnelshallperformpredicativemaintenanceaccordingtotheexperienceandequipmentfeatures.Forexample,whengreaterchangehappenstothetemperature,humidityandpressureoftheexternalenvironment,theequipmentworkingconditionschangealongwithit,soitisnecessarytoperformpredicativemaintenanceandtakepreventivemeasures.維護(hù)監(jiān)督Maintenancesupervision生產(chǎn)部經(jīng)理要對(duì)維修人員的保養(yǎng)和維護(hù)工作內(nèi)容進(jìn)行檢查確認(rèn),并對(duì)周、月、季度和年度設(shè)備保養(yǎng)維護(hù)點(diǎn)檢表進(jìn)行抽檢并確認(rèn)"維修人員設(shè)備巡檢確認(rèn)表"。Theproductiondepartmentmanagershallinspectandconfirmthejobcontentofthemaintenancepersonnel,performcausalinspectiontotheweakly,monthly,quarterlyandannualequipmentmaintenancepointinspectionformandconfirmthe"maintenancepersonnelequipmentin-processcheckconfirmationform".5.5設(shè)備維修5.5Equipmentmaintenance操作工在操作和巡檢中發(fā)現(xiàn)設(shè)備異常現(xiàn)象或發(fā)生故障報(bào)警時(shí),必須及時(shí)通知設(shè)備維修人員,設(shè)備維修人員接到通知后,必須及時(shí)趕到現(xiàn)場(chǎng)處理排除。Whenfindingabnormalphenomenonoftheequipmentorfailurewarningoccurringintheoperationandin-processcheck,theoperatorshallinformtheequipmentmaintenancepersonneltimely,whoshallrushtothespottodealwithitintimeafterreceivingthenotice.設(shè)備維修人員到達(dá)現(xiàn)場(chǎng)時(shí),將首先對(duì)故障現(xiàn)象進(jìn)行分析和診斷,確定其初步原因。Theequipmentmaintenancepersonnelshallanalyzeanddiagnosethefailurefirstanddeterminethecausepreliminarilyafterarrivingatthespot.在初步確定故障原因后,先查明是否有備品備件,如果沒有要立刻填寫"采購(gòu)申請(qǐng)單"緊急采購(gòu),只有在被備品備件有保障或可用其它方法取代的情況下,才能實(shí)施維修。Afterdeterminingthecauseforfailurepreliminarily,findoutifsparepartsavailable;ifno,filloutthe"purchaseapplicationform"immediatelyforemergencyprocurement;maintaintheequipmentintheconditionthatthesparepartsareassuredorothermethodcanbeusedtoreplaceit.維修過程中備品備件更換必須按規(guī)定進(jìn)行登記,在庫(kù)存低于最小庫(kù)存量時(shí),要及時(shí)填寫"采購(gòu)申請(qǐng)單"。Changesofsparepartsinthemaintenanceprocessshallberegistered;whentheinventoryislowerthantheminimumquantity,filloutthe"purchaseapplicationform"timely.故障排除后要及時(shí)填寫設(shè)備維修記錄備案,以便故障排除的經(jīng)驗(yàn)供他人查閱和參考。Afterthefailureisremoved,filltheequipmentmaintenancerecordforreferencetofailureremovalexperienceforothers.生產(chǎn)部經(jīng)理每月將根據(jù)設(shè)備維修記錄,整理填寫"設(shè)備故障和預(yù)防措施匯總表"進(jìn)行分析,以便采取相應(yīng)的預(yù)防措施,避免類似的設(shè)備故障發(fā)生。Theproductionmanagershallsortoutandfilloutthe"equipmentfailureandpreventivemeasuressummarysheet"andanalyzeeverymonthaccordingtotheequipmentmaintenancerecord,soastotakecorrespondingpreventivemeasurerandavoidsimilarequipmentfailurefromoccurring.設(shè)備維修完畢維修人員要登記維修時(shí)間。Aftertheequipmentismaintained,themaintenancepersonnelshallregisterthemaintenancetime.設(shè)備備品備件管理5.5Equipmentsparepartsmanagement設(shè)備備品備件的管理是確保設(shè)備在故障情況下能否得到及時(shí)維修和保養(yǎng)的關(guān)鍵,它是設(shè)備正常運(yùn)行的基礎(chǔ)。Equipmentsparepartsmanagementisthekeytotimelymaintenanceintheconditionofequipmentfailureandisthebasefornormalrunningoftheequipment.備品備件申請(qǐng)Sparepartsapplication備品備件應(yīng)根據(jù)各設(shè)備的具體情況和已有的經(jīng)驗(yàn)適時(shí)適量地申請(qǐng)儲(chǔ)備,在確保安全庫(kù)存的前提下要盡可能地減少庫(kù)存量。申請(qǐng)備品備件應(yīng)遵守如下三個(gè)原則：Applytostoresparepartstimelyandadequatelyaccordingtothespecificconditionoftheequipmentsandtheexistingexperienceandtrytoreduceinventoryonthepremiseofsafetystock.Sparepartsapplicationshallobservethefollowingthreeprinciples:能通用的備品備件盡可能通用。a.Trytouseuniversalspareparts.根據(jù)經(jīng)驗(yàn)在滿足最小庫(kù)存量的前提下申請(qǐng)備品備件。b.Applyforsparepartsonthepremiseofmeetingminimuminventoryandaccordingtoexperience.采購(gòu)周期長(zhǎng)且重要的備品備件要適當(dāng)多備,采購(gòu)時(shí)間短且不重要的備品備件可少備或不備。c.Storemoresparepartswithlongerpurchaseperiodandimportanceadequately,andstorelessordonotstoresparepartwithshorterpurchaseperiodandwithoutimportance.備品備件保存Sparepartspreservation備品備件應(yīng)根據(jù)安全易找的原則進(jìn)行存放,具體應(yīng)遵守如下四個(gè)原則：Thesparepartsshallbestoredaccordingtotheprincipleofsafetyandeaseforfinding,andthefollowingfourprinciplesshallbeobservedspecifically:精度高和貴重的備品備件要做好防潮防塵保護(hù)措施。a.Takemoisture-proofanddustproofprotectivemeasurestosparepartswithhighaccuracyandgreatvalue.備品備件按輕上重下和電上機(jī)下的原則存放在貨架上。b.Keepthesparepartsontheshelfaccordingtotheprincipleof"lightupandheavydown,electricalupandmachinerydown".按生產(chǎn)設(shè)備的單元和設(shè)備重要性劃分備品備件貨架。c.Dividesparepartsshelfaccordingtotheunitoftheproductionequipmentandtheequipmentimportance.領(lǐng)后不用的備品備件必須按何取何歸的原則及時(shí)擺放到貨架原處。d.Putthesparepartsnotusedaftergettingthembacktotheoriginalplaceontheshelfaccordingtotheprincipleof"putbacktowheregettingthem".備品備件領(lǐng)用Sparepartsgetting能否按規(guī)定領(lǐng)用備品備件是保證庫(kù)存正確性的關(guān)鍵,具體應(yīng)遵守如下四個(gè)原則：Togetthesparepartsaccordingtoregulationsisthekeytoinventorycorrectnessandthefollowingfourprinciplesshallbeobservedspecifically:備品備件領(lǐng)用,應(yīng)按規(guī)定和要求先填寫"備品備件領(lǐng)用登記單",緊急情況下可先領(lǐng)用后補(bǔ)單。a.Whengettingspareparts,filloutthe"sparepartsgettingregistrationsheet"accordingtoregulationsandrequirements;getthesparepartsfirstandfillouttheregistrationsheetlaterinemergencies.領(lǐng)用數(shù)量一定要和領(lǐng)用登記單上的一致。b.Theamountgotshallbeinconformitywiththeamountontheregistrationsheet.由專人定時(shí)更改系統(tǒng)庫(kù)存"備品備件庫(kù)存表",低于安全庫(kù)存的備品備件,應(yīng)及時(shí)填寫申請(qǐng)進(jìn)行采購(gòu)c.Specially-assignedpersonshallalterthesysteminventory"sparepartsinventorystatement"regularly;fillapplicationtimelyforpurchasingsparepartslowerthanthesafetystock.定期進(jìn)行庫(kù)存盤點(diǎn),防止漏填造成庫(kù)存不準(zhǔn)。d.Performinventoryverificationregularlyandpreventfrommissingouttheinventorystatementandcausinginaccurateinventory.備件報(bào)廢Sparepartsscraping更換下來的備品備件不能隨便丟棄,要按規(guī)定擺放到備品備件報(bào)廢貨架上妥善管理,其作用為：Donotabandonthereplacedsparepartscasually,putthemonthescrapingshelfaccordingtoregulationsandmanagethemproperly;andtheirfunctionsare:如有可能進(jìn)行修復(fù)。a.Repairthemifpossible.更換下的備品備件上的某些部件可再利用。b.Some