Keeping npr. Preventive maintenance and its role in production
It is known that the operation of the machine and the duration of operation are influenced by maintenance carried out on time and with high quality, as well as repairs. Even in the USSR, a PPR system (scheduled preventive maintenance and repair) was introduced. It regulates the scope of the proposed work, the timing of their implementation, as a result of which the reasons for possible machine malfunctions are eliminated. Thus, scheduled preventive maintenance prolongs the mechanisms and improves their quality of work.
Preventive maintenance of machinery and construction equipment
The operation of mechanisms involves the implementation of complex works, which constitute the PPR system, the purpose of which is to prevent breakdowns due to wear of parts. Special events that ensure the maintenance of each machine are necessarily planned in advance, and their preparation is carried out.
When the machines are in use, scheduled preventive maintenance is carried out either monthly or according to an approved plan. Maintenance carried out on a monthly basis is performed during the work shift, at the beginning or at the end. The maintenance carried out according to the plan is carried out in accordance with the requirements of the mechanism manufacturer. And also distinguish between maintenance carried out seasonally twice a year, when the machines are prepared for the winter or summer period of operation. During storage of machines or their transportation, scheduled preventive maintenance takes place in accordance with the documentation and requirements for observing operating rules.
Drivers or crew members can independently carry out daily repairs to the vehicle that is assigned to them. However, if scheduled repairs are not included in their duties, then the machine is sent for maintenance centralized to the preventive maintenance departments, where specialists are engaged in it. Work on the daily maintenance of the mechanisms is not planned, as they are mandatory. During the maintenance of construction and road machines, technical diagnostics, cleaning, lubrication, inspection, regulation, refueling are carried out.
Scheduled preventive maintenance of electrical equipment
At large industrial enterprises, the current scheduled preventive maintenance is carried out by the forces of the shop personnel. Only major repairs are a task that skilled workers undertake under the guidance of a foreman. The task force formed in this way, headed by the shift supervisor, supervises the electrical equipment in the shops and is responsible for its minor scheduled repairs. In power plants, electrical department personnel are responsible for inspecting tunnels, canals and mines. The work is proceeding according to the schedule. During inspection, the detected defects are recorded in the log, they are eliminated when the opportunity arises.
Types of preventive maintenance
As a system, preventive maintenance of equipment contains such types of maintenance, care and supervision of the repair and operation of mechanisms as:
- routine preventive maintenance of equipment
- scheduled checks and inspections
- scheduled repairs, medium and small
- major planned repairs
The repair cycle is called the period that passes between 2, which includes several inspections and repairs of smaller ones. Minor repairs are called preventive maintenance, in which the unit is completely disassembled. The average includes scheduled repairs, during which the mechanism is partially disassembled, individual units are subject to major repairs. During a major overhaul, units and parts are replaced that are badly worn, the unit is completely disassembled, the basic parts are repaired and adjusted.
In order to prevent damage, it is necessary to follow the instructions for the care and rules for the operation of the equipment.
The main stages of PPR equipment
Well-designed preventive repairs provide for:
Planning;
Preparation of electrical equipment for scheduled repairs;
Carrying out scheduled repairs;
Carrying out activities related to scheduled maintenance and repair.
The system of preventive maintenance of equipment includes a couple of stages:
1. Stage between overhauls
It is carried out without disrupting the operation of the equipment. Includes: systematic cleaning; systematic lubrication; systematic examination; systematic adjustment of the operation of electrical equipment; replacement of parts that have a short service life; elimination of small malfunctions.
In other words, this is prevention, which includes daily inspection and maintenance, while it must be properly organized in order to maximize the life of the equipment, maintain high-quality work, and reduce the cost of scheduled repairs.
The main work performed at the overhaul stage:
Tracking the status of equipment;
Conduct by employees of the rules of appropriate use;
Daily cleaning and lubrication;
Timely elimination of minor breakdowns and adjustment of mechanisms.
2. Current stage
Preventive maintenance of electrical equipment is most often carried out without disassembling the equipment, only its work stops. It includes the elimination of breakdowns that occurred during the period of work. At the current stage, measurements and tests are carried out, with the help of which equipment flaws are identified at an early stage.
The decision on the suitability of electrical equipment is made by the repairers. This decree is based on a comparison of the test findings during routine maintenance. In addition to scheduled repairs, to eliminate defects in the equipment, work is performed outside the plan. They are carried out after the exhaustion of the entire resource of the equipment.
3. Stage middle
It is carried out for the complete or partial restoration of old equipment. Includes disassembly of assemblies intended for viewing, cleaning mechanisms and eliminating identified defects, replacing some quickly wearing parts. The middle stage is carried out no more than 1 time per year.
The system at the middle stage of scheduled preventive maintenance of equipment includes the installation of the cyclicality, volume and sequence of work in accordance with the normative and technical documentation. The middle stage affects the maintenance of the equipment in good condition.
4. Overhaul
It is carried out by opening the electrical equipment, checking it completely with inspection of all parts. Includes tests, measurements, elimination of identified malfunctions, as a result of which the modernization of electrical equipment is carried out. As a result of the overhaul, the technical parameters of the devices are completely restored.
Overhaul is possible only after the overhaul stage. To carry it out, you must do the following:
Draw up work production schedules;
Conduct a preliminary inspection and check;
Prepare documents;
Prepare tools and necessary replacement parts;
Carry out fire-fighting measures.
Overhaul includes:
Replacement or restoration of worn-out mechanisms;
Modernization of any mechanisms;
Performing preventive checks and measurements;
Carrying out work related to the elimination of minor damage.
Malfunctions discovered during the equipment check are eliminated during subsequent repairs. And breakdowns of an emergency nature are eliminated immediately.
PPR systems and its basic concepts
The system of preventive maintenance of power equipment (hereinafter referred to as the PPREO System) is a set of guidelines, norms and standards designed to ensure the effective organization, planning and performance of maintenance (MOT) and repair of power equipment. The recommendations given in this PPR EO System can be used at enterprises of any type of activity and ownership, using similar equipment, taking into account the specific conditions of their work.
The planned preventive nature of the PPR EO System is implemented: by carrying out equipment repairs with a given frequency, the timing and material and technical support of which are planned in advance; carrying out maintenance operations and monitoring the technical condition aimed at preventing equipment failures and maintaining its serviceability and operability in the intervals between repairs.
The PPR EO system was created taking into account new economic and legal conditions, and in technical terms, with maximum use of: the possibilities and advantages of the aggregate repair method; the whole range of strategies, forms and methods of maintenance and repair, including new means and methods of technical diagnostics; modern computing technology and computer technologies for collecting, accumulating and processing information about the state of equipment, planning repair and preventive actions and their material and technical support.
The action of the PPR EO System applies to all equipment of power and technological shops of enterprises, regardless of the place of its use.
All equipment operated at enterprises is subdivided into basic and non-basic. The main equipment is equipment, with the direct participation of which the main energy and technological processes of obtaining a product (final or intermediate) are carried out, and the failure of which leads to the termination or sharp reduction in the output of products (energy). The non-core equipment ensures the full flow of energy and technological processes and the operation of the main equipment.
Depending on the production significance and functions performed in energy and technological processes, equipment of the same type and name can be classified as both primary and non-primary.
The PPR EO system provides that the need for equipment for repair and prophylactic actions is satisfied by a combination of various types of maintenance and scheduled equipment repairs, differing in the frequency and scope of work. Depending on the production significance of the equipment, the impact of its failures on the safety of personnel and the stability of energy technological processes, repair effects are implemented in the form of regulated repairs, repairs based on operating time, repairs based on technical conditions, or in the form of a combination of these.
Table 5 - number of repairs in 12 months
Table 6 - Planned balance of working time for the year
Payroll coefficient
- 1. For continuous production = 1.8
- 2. For continuous production = 1.6
AUTONOMOUS NON-PROFIT RESTRICTION
HIGHER PROFESSIONAL EDUCATION
EASTERN EUROPEAN INSTITUTE OF ECONOMY, GOVERNANCE AND LAW
DEPARTMENT OF ECONOMY
CONTROL AND COURSE WORK
FOR THE DISCIPLINE "MANAGEMENT OF THE ORGANIZATION"
Completed by student gr. FC 101 v Kuznetsov M.V.
Checked by D.E. D., professor Mikhaleva E.P.
1. Introduction
2. Main part
3. Conclusions
Applications
1. Introduction
One of the stages of technical preparation is the technological preparation of production. It is she who ensures the full readiness of the enterprise for the release of new products with a given quality, which, as a rule, can be implemented on technological equipment that has a high technical level, ensuring minimal labor and material costs. Technological preparation of production is carried out in accordance with the requirements of the standards of the Unified System for Technological Preparation of Production (ESTPP, GOST 14.001-73) and provides for the solution of the following tasks:
ensuring high manufacturability of structures, which is achieved by a thorough analysis of the manufacturing technology of each part and a technical and economic assessment of possible manufacturing options;
design of technological processes, including the development of traditional (basic for this type of production) processing, and individual technological processes, the development of technical specifications for special rigging and special technological equipment (the design of technological equipment is carried out in the manner adopted for the design preparation of production);
structural analysis of the product and, on its basis, the preparation of interdepartmental technological routes for processing parts and assembling products;
technological assessment of the workshop capabilities, based on the calculation of production capacity, throughput, etc.
development of technological standards for labor intensity, consumption rates of materials, operating modes of equipment;
equipment maintenance and repair planning;
manufacturing of technological equipment;
scheduled preventive maintenance deterioration
debugging of the technological complex (performed on the installation series of products) - the technological process, tooling and equipment;
development of forms and methods of organizing the production process;
development of technical control methods.
Consider in more detail the aspect of the organization of equipment repair at the enterprise.
2. Main part
2.1 The role of preventive maintenance (PM) in improving the use of fixed assets
Repair production is created at the enterprise in order to ensure the rational operation of its main production assets with minimal costs. The main tasks of the repair production are: maintenance and repair of fixed assets; installation of newly purchased or manufactured by the enterprise itself equipment; modernization of operated equipment; production of spare parts and assemblies (including for equipment modernization), organization of their storage; planning of all works on maintenance and repair, as well as the development of measures to increase their efficiency.
The leading form of the system of technical maintenance and repair of equipment at industrial enterprises is the system of scheduled preventive maintenance of equipment (PPR). The PPR system is understood as a set of planned measures for the maintenance, supervision and repair of equipment. Maintenance and repair of equipment under the PPR system include: maintenance of equipment, overhaul maintenance, periodic repair operations. Maintenance of equipment consists in observing the rules of technical operation, maintaining order at the workplace, cleaning and lubricating working surfaces. It is carried out directly by production workers serving the units under the supervision of production foremen. Overhaul maintenance consists in monitoring the condition of the equipment, observing the working rules of operation, in the timely regulation of mechanisms, and eliminating minor malfunctions. It is carried out by duty workers of the repair service without equipment downtime - during lunch breaks, non-working shifts, etc. In industries with a continuous production process, this amount of work when current repairs (or next repairs) occur, or the equipment stops for unscheduled repairs to eliminate the identified defects (this conclusion is made by the equipment repair technician). The backup equipment is switched on or the production is unloaded. Periodic maintenance operations include flushing equipment, changing oil in lubrication systems, checking equipment for accuracy, inspections and scheduled repairs - current, average (current increased) and overhaul. These operations are carried out by the repair personnel of the enterprise according to a pre-developed schedule. Not all equipment is subjected to flushing as an independent operation, but only that which operates in conditions of high dustiness and pollution, for example, foundry equipment, equipment for the production of food products. Oil change is carried out in all lubrication systems with centralized and other lubrication systems according to a special schedule linked to the scheduled maintenance schedule. The oil change intervals are specified in the equipment specifications. It is allowed to change the oil according to the results of the analysis by the laboratory for the compliance of the quality indicators of the oil with the requirements of regulatory documents (GOST). All equipment is checked for accuracy after the next scheduled repair. All precision equipment is periodically checked separately according to a special schedule. Accuracy check consists in identifying the correspondence of the actual capabilities of the unit to the required accuracy of its operation. This operation is carried out by the quality control department controller with the help of a repair mechanic. All equipment is periodically inspected. Their task is to identify the degree of wear of parts, regulate individual mechanisms, eliminate minor faults, replace worn out or lost fasteners. When inspecting the equipment, the scope of the upcoming repair and the timing of its implementation are also specified. Routine repair is the smallest type of scheduled repair carried out to ensure or restore the unit's operability. It consists in partial disassembly of the machine, replacement or restoration of its individual units and parts, repair of irreplaceable parts; also, all identified comments reflected in the defect list (compiled by the shop mechanic) are eliminated.
Medium repair differs from the current one in a large amount of work and in the number of worn out parts that need to be replaced.
Overhaul - full or close to full restoration of the unit resource with the replacement (restoration) of any of its parts, including the base ones. Consequently, the task of overhaul is to bring the unit into a condition that fully meets its purpose, accuracy and performance class. Progressive repair systems are based on the implementation of only two types of planned repairs during the repair cycle - current and major, i.e. no medium repairs. At the same time, overhaul is often accompanied by the modernization of equipment. Depending on the degree of centralization of repair work, three forms of their organization are distinguished: centralized, decentralized and mixed. Centralized repair provides that all types of repairs and overhaul services are carried out by the forces of the mechanical repair shop subordinate to the chief mechanic of the enterprise, decentralized - by the shop repair services under the guidance of the shop mechanic. The mixed form of organization of repairs is based on various combinations of centralized and decentralized forms. In many cases, the mixed form provides for the implementation of all types of repair operations and overhaul services, except overhaul, by workshop repair services, as is the case with a decentralized system. Overhaul is carried out by a mechanical repair shop.
In addition to various forms of in-plant repairs, specialized equipment overhaul has been organized outside the factory. Along with scheduled preventive repairs, which form the basis of maintenance and repair of fixed assets, unscheduled (emergency) and restoration repairs can also take place at enterprises. The need for emergency repairs can arise as a result of unexpected equipment failure. Refurbishment has as its object those elements of fixed assets, the further operation of which is no longer possible.
2.2 Characteristics of equipment at the enterprise according to the degree of deterioration
Depreciation in the economic sense means the loss of the value of an object during its operation. Loss of value can occur for various reasons. If the cost has decreased due to the aging of the object and the partial loss of its performance, then they speak of physical wear and tear. If the cost has decreased due to the fact that the object has lost its competitiveness in the market in comparison with other similar objects and began to be in less demand, then they speak of obsolescence. Both types of wear develop independently of each other. This means that a completely new product can lose value before its use due to obsolescence. Even when calculating the full replacement cost by direct comparison with an analogue, such adjustments are made to the price of an analogue, which in one way or another take into account obsolescence.
Physical deterioration is such a loss of value that is caused by a decrease in the performance of an object as a result of both natural physical aging and wear of structural elements during operation, and the influence of external unfavorable factors (accidents, shocks, overloads, etc.), the consequences of which were eliminated by repairs.
How do you find this loss in value? In many methods of assessing wear, they do not start from the cost itself, but from the external manifestations of wear: deterioration of characteristics (accuracy, speed, performance, power consumption, etc.), the onset of frequent breakdowns, the appearance of noise, knocking and other negative effects. It is believed that the index of decline in consumer qualities is at the same time an index of decline in value. In reality, the connection here is not as straightforward as it seems.
The physical wear and tear of the equipment depends on how long it serves, how much work is done with it, and how well its maintenance is organized. The amount of work done would be the best wear factor. A more easily measurable factor is the age of a piece of equipment. The year of manufacture of the product is recorded in the passport and even stamped on the nameplate.
At the time of purchase of the equipment, the company does not know what its actual service life will be. Therefore, in real practice, it is necessary to plan the service life. Since a certain share of its original cost is consumed annually over the life of the equipment, this share refers to the costs of the corresponding year.
The most difficult issue is the classification and description of equipment, its solution will require significant time and effort.
Firstly, it is very difficult to use the existing (accounting) databases of fixed assets accounting, because they are compiled according to completely different principles (there is no description hierarchy, no reference to technical locations, etc.).
Secondly, during the reconstruction and modernization of equipment, its technical was often changed. circuit, device, etc. Moreover, such changes were not always made in the technological documentation and equipment passports. In practice, this leads to the fact that when describing equipment, it is not enough to use only technological documentation and equipment passports. It is necessary to look at the equipment "live" - of course, this leads to an increase in time costs.
Thirdly, there are no standard requirements for the manufacturer to fill out equipment passports by the manufacturer. In this regard, different manufacturers do not always indicate a detailed diagram of the equipment device. Sometimes such passports are lost altogether. Accordingly, there is simply not enough information to describe the structure of a specific piece of equipment.
This is one of the most serious questions that arise in the process of describing equipment. The only way to solve this problem is to combine (in time) the overhaul of the equipment and its description.
In addition to technical issues, in the process of describing equipment, important methodological issues arise. First of all, they relate to the principles of equipment classification. There are various approaches. It can be classified by types of equipment, divided into main and auxiliary, etc., etc. It is much more important to define the equipment hierarchy.
The uppermost level should represent a set of technological objects (elements of the technological chain) through which the production of products is carried out. Further, individual pieces of equipment are determined, as well as components and assemblies of which it consists.
Thus, we distinguish the following three levels of the equipment hierarchy:
Level I: Technological facility (part of the technological chain).
Level II: Individual pieces of equipment
Level III: Components and assemblies.
This approach will create the necessary prerequisites for the correct determination of equipment wear, tracking its technical condition, making investment decisions and much more. Thus, detailing components and assemblies to the level of details will optimize logistics systems, and linking the types and volumes of repair work to individual pieces of equipment will increase planning accuracy. The accumulation of reliable factual information about the operating modes of the equipment, failures, repair work performed, replacement of individual pieces of equipment will make it possible to most effectively manage the process of equipment maintenance and repair.
Principles for determining physical wear and tear of equipment
The developed mechanism consists of the following six steps:
Classification and description of the equipment in the process chain of the workshop:
Development of key indicators characterizing the state of the performance capabilities of a single piece of equipment.
Determination of weights for calculating the integral indicator of physical wear and tear of a single piece of equipment. The weights of the indicators are determined by the method of expert assessments.
Determination of the current values of key indicators, comparison with reference values. Determination of the wear of a single piece of equipment.
Depreciation calculation for groups of the same type of equipment. The same type is understood as the equipment on which the production of the same products (technological operations) is carried out.
Depreciation for a group of equipment of the same type is determined as the weighted average value of wear for each piece of equipment. Weighing is carried out in relation to the actual load of the equipment.
The calculation of the technological chain wear is carried out on the basis of the actual wear data for the equipment groups. The calculation of the process chain wear is based on the following principle: the process chain wear is taken as the maximum wear value (critical point) calculated for groups of the same type of equipment.
The implementation of these principles allows:
Predict the physical deterioration of equipment and identify "bottlenecks" in the technological chain;
Effectively allocate funds for equipment repair and replacement;
Reduce the number of production incidents and failures.
It should be noted that, despite the obvious positive effect, the developed mechanism also has a number of disadvantages:
First, the determination of the wear of the technological chain at the critical point in the case when the degree of influence of the physical state of various groups of equipment on the productive capabilities of the chain as a whole is not the same can lead to erroneous conclusions. Secondly, the high labor intensity of the implementation and maintenance of the equipment databases in an up-to-date state.
Thirdly, the effective functioning of the physical deterioration monitoring system based on the indicated principles is impossible without an appropriate information system.
Nevertheless, these problems, one way or another, can be solved. For example, the use of equipment. Weights of the correction factors, taking into account the degree of influence of the physical state of the same type of equipment groups on the productive capabilities of the technological chain, stage-by-stage development and implementation of the system: first of all, put the system for limiting and especially important equipment.
Thus, the determination of the actual wear and tear of equipment leads not only to the effective use of the repair fund, but is also a prerequisite for the effective management of production facilities.
The depreciation of fixed assets in certain industries reaches 80%, and the dynamics of the renewal of these assets does not exceed 11%.
Compared to 1970, the average age of equipment in the domestic industry has almost doubled: in 1970, 40.8% of industrial equipment was up to five years old, today it is only 9.6%.
Almost half of Russian enterprises are experiencing difficulties with equipment, while domestic manufacturers do not have sufficient capabilities to provide Russian enterprises with high-tech high-quality equipment.
A significant share of equipment and components is imported.
2.3 The structure of the repair service of the enterprise, functions and system of work of its individual divisions
Repair of equipment at the enterprise is carried out by auxiliary shops.
Auxiliary production and maintenance in an enterprise can employ up to 50% of all workers. Of the total volume of auxiliary and maintenance work, transport and storage accounts for approximately 33%, repair and maintenance of fixed assets - 30, instrumental maintenance - 27, energy maintenance - 8 and other works - 12. Thus, repair, energy, instrumental, transport and storage services account for approximately 88% of the total volume of these works. Improving the efficiency of technical maintenance of production as a whole depends to the greatest extent on their correct organization and further improvement. The repair service of the enterprise includes: the department of the chief mechanic, repair production, repair and mechanical workshop, electrical workshop, workshop of instrumentation and equipment. Equipment repairs are carried out in accordance with the schedule of each service provider.
2.4 Planning of repair work: the composition of repair standards and their definition, drawing up long-term, annual and operational plans for repair work
The introduction of the PPR system requires a number of preliminary preparatory work. These include: classification and certification of equipment; drawing up specifications of replaceable and spare parts and establishing standards for the stock of the latter; development of drawing albums for each standard size of equipment; organization of storage of spare parts and assemblies; development of instructions for production and repair personnel for the maintenance of equipment and technological documentation for its repair. The classification of equipment is aimed at a certain grouping of it according to the features of the same type to determine the number of replaceable parts of the same name, draw up instructions for the maintenance of equipment, develop a standard technology for repair work, etc.
The purpose of certification is to have a complete technical specification of all the tools of labor used at the enterprise. The passport is entered for each unit of plant equipment. It records its technical data and their changes, operating modes, permissible loads, results of inspections and repairs. The equipment passport is the initial document in the organization and planning of its repair and maintenance. Drawing up specifications of replacement and spare parts, drawing albums is necessary for their timely production and development of repair technology. Replaceable parts are machine parts that are subject to wear and tear and must be replaced during repair. Their service life does not exceed the duration of the repair cycle. Replacement parts that need to be kept in a constantly renewing stock are called spare parts. For the storage of spare parts, a general plant warehouse of spare parts and assemblies is created, and, if necessary, storerooms in production workshops.
The development of instructions for production and maintenance personnel, as well as the technology of repair work, is aimed at increasing the organizational and technical level of routine maintenance and repair of equipment and thereby contributing to its more efficient use at the enterprise.
The organization and planning of equipment repair in the PPR system are based on certain standards that allow planning the scope of repair work, their sequence, timing, both for groups of homogeneous machines, and for the enterprise as a whole and its individual divisions. The system of these standards includes: categories of repair complexity, repair units, duration and structure of repair cycles, duration of overhaul and inter-inspection periods, duration of the repair period. They are also adjoined by standards for overhaul of equipment, rates of consumption of materials, spare parts and stocks of wearing parts. The method for calculating the standards and their specific values for different types of equipment and conditions of its operation are determined by the Unified PPR system. Each piece of production equipment is assigned a corresponding category of repair complexity. The more complex the unit, the higher it is, and vice versa.
With regard to a repair unit, they are developed by methods of technical regulation of norms for the cost of working time by types of repair operations and the nature of work. Table 1 shows the corresponding norms for one repair unit (in man-hours).
Table 1. Norms of work with one repair unit
Name Locksmith work Machine work Other work Total Flushing as an independent operation 0.35--0.35 Checking for accuracy as an independent operation 0.4--0.4 Inspection before overhaul 1.00.1-1.1 Inspection 0.750.1-0.85 Current repairs 4.02.00.16.1 Overhaul 23.010. 02.035.0
Using the above standards, you can calculate the laboriousness of repairing equipment in a shop, enterprise, etc. Determination of the scope of work on overhaul services is carried out according to service standards. For example, for locksmiths, lubricants and machine operators on duty, the following service standards are set for one worker per shift in repair units: locksmiths - 500, lubricators - 1000 and machine operators - 1500.
For each type of equipment, the standard duration of the repair cycle is established. The repair cycle is the smallest repetitive period of equipment operation, during which all the established types of maintenance and repair are carried out in a certain sequence. Since all of them are carried out in the period from the beginning of the operation of the equipment to its first overhaul or between two subsequent overhauls, the repair cycle is also defined as the period of operation of the equipment between two consecutive overhauls.
The overhaul period is the period of equipment operation between two next scheduled repairs. The inter-inspection period is the period of operation of the equipment between two regular inspections or between the next scheduled repair and inspection. The repair period is the downtime of the equipment being repaired. Currently, the following standards for equipment downtime in repair are accepted per one repair unit (see Table 2).
Table 2. Standards for repair work
Type of repair in one shift (days) in two shifts (days) in three shifts (days) Current 0.250.140.1 Capital 1.00.540.41
In the general case, the duration of the equipment being repaired Trem can be determined by the formula
Three = trem * r / b * tcm * Kcm * Kn,
where t rem - the norm of time for locksmith work per one repair unit of this type of repair; r - group of equipment repair complexity; b - the number of simultaneously working locksmiths per shift; tcm is the duration of the shift; Ksm - coefficient of shift work of repair workers; Кн - coefficient of fulfillment of norms by repair workers.
The duration of the repair cycle depends on the design features of the equipment, its operating conditions and other factors. For different types of equipment, it can differ significantly. For example, for metal-cutting equipment it is 26,000 hours, for forging machines and press-forging machines - 11,700 hours, for foundry and molding conveyors - 9500 hours, etc.
The number and sequence of repair operations included in the repair cycle form its structure. Each group of equipment has its own structure of the repair cycle. For example, the structure of the repair cycle for turning, milling and other metal-cutting machines with a mass of 10 to 100 tons includes: one major, five current repairs and 12 inspections, and for the same machines with a mass of over 100 tons - one major, six current repairs and 21 inspections.
Based on the repair standards and the results of the technical inspection of the equipment, annual, quarterly and monthly plans and schedules of repair work are drawn up. The plans determine the types of maintenance and repair work, their labor intensity, planned downtime for each type of equipment, the amount of repair work for each workshop and the enterprise as a whole. At the same time, the number and cost of spare parts and materials for the repair of equipment, the number of repair personnel by category are determined. The planning of repair work is carried out by the production planning bureau (PPB) of the chief mechanic's department. Planning begins with workshop annual repair schedules covering all equipment in each workshop. On the basis of the annual and quarterly plans, updated monthly plans and schedules are drawn up, taking into account the data of previous examinations and inspections. They are the operational task of the shop for the production of repair work.
Organization of repair work
Reducing the cost of repair work is one of the goals of effective housekeeping. Therefore, the implementation of repair work is preceded by technical, material and organizational preparation.
Technical training is characterized by the implementation of design work on disassembly and subsequent assembly of equipment, drawing up a list of defects, breakdowns and malfunctions. Their elimination requires an appropriate study of restoration work and operations. In turn, the material preparation for the implementation of repair work is reduced to the compilation of a bill of materials, component parts, tools and fixtures. Material preparation presupposes the availability of a sufficient and necessary stock of replaceable parts, assemblies, as well as transport and lifting equipment. Organizational preparation for repair work can be performed using one of the following methods: centralized, decentralized and mixed. The centralized method is characterized by the fact that all types of repair work are carried out by the forces of the factory mechanical repair shop. In the event that they are performed by the shop repair service, the method is called decentralized. It should be noted that these methods have obvious drawbacks in the form of a complex and expensive system for organizing work. As for the mixed method, it makes it possible to carry out repair work with lower costs and is characterized by the fact that all types of maintenance and repairs, with the exception of capital, are performed by the workshop service of the repair economy, and major repairs are performed by the mechanical repair workshop. At the same time, you can successfully use the methods of nodal replacement of worn-out blocks by removing and repairing them at a recovery base, or you can perform repair work during technological and inter-shift equipment downtime.
2.5 Organization and remuneration of repair crews
The considered tariff system, differentiating the wages of workers by category, takes into account mainly the quality side of labor and stimulates the qualification growth of workers whose wages depend on their qualification category or position. By itself, it does not create a direct interest of workers in increasing labor productivity and improving product quality. The leading role in stimulating labor activity belongs to the forms and syntheses of remuneration, which, interacting with the tariff system and labor rationing, make it possible to apply to each group and category of workers a certain procedure for calculating wages by establishing a functional relationship between the measure of labor and its payment in order to more accurately take into account the quantity and quality of labor invested in production, and its final results.
Labor remuneration in accordance with Article 131 of the Labor Code of the Russian Federation comes in two forms - monetary and non-monetary. Payment for labor in non-cash form can be made only if it is provided for by the collective or labor agreement and in the presence of a written application from the employee. Legislatively, the share of non-monetary wages is limited to 20% of the total amount of wages.
The remuneration system is understood as the method of calculating remuneration payable to employees in accordance with the costs they have incurred, and in some cases with its results. Most enterprises use only two forms of remuneration: piece-rate and time-based. The choice of a remuneration system depends on the characteristics of the technological process, forms of labor organization, requirements for the quality of products or work performed, the state of labor rationing and accounting for labor costs. With piece-rate pay, the measure of labor is the output produced by the worker, and the amount of payment directly depends on the quantity and quality of the output produced in the existing organizational and technical conditions of production. With time-based wages, the measure of labor is the time worked, and the worker's wages are calculated in accordance with his wage rate or salary for actually worked time.
Both piece-rate and time-based wage systems can be supplemented by bonuses, which are combined with them and allows you to establish more specific relationships between labor results and the size of wages.
The piecework wage system is advisable to apply in the following cases when:
accurate quantitative accounting of the volume of work and an assessment of their dependence on the specific conditions of the worker are possible;
technically justified time norms have been established for the works and the correct tariffication of works has been carried out in strict accordance with the tariff and qualification reference book;
the worker has a real opportunity to increase the output or the volume of work performed while increasing his own labor costs;
an increase in production will not lead to a deterioration in product quality and a violation of technology.
The piece-rate system of remuneration has the following varieties: direct piece-rate pay, piece-bonus, piece-rate progressive, indirect piece-rate, lump-sum.
Direct piecework wages are the simplest, since the size of the worker's earnings changes in direct proportion to his output. The calculation of earnings is based on the piece rate (P sd ), defined by one of the following formulas:
Where C i - hourly wage rate of the category of work performed.
Based on the assessment and the volume of work performed, the amount of wages is calculated
Where N i - the actual volume of work performed for the i-th type per month;
n is the number of types of work performed by the worker.
This system of remuneration is advisable where, according to production conditions, it is possible and justified to perform work by one performer. In conditions of multi-station service, when the time norms are set for each of the machines, the piece rate is calculated according to the formula
Where n is the number of machines established by the service rate.
If a worker works on several machines with different productivity or with a different nature of work, then piece rates are determined for each machine separately, and the calculation of the price is made according to the formula
Where H rip out - the production rate established when working on the i-th machine.
The piece-bonus system provides for the payment to the worker, in addition to piece-rate wages, calculated according to the rates, bonuses for achieving the established individual or collective quantitative and (or) qualitative indicators. The bonus position usually includes two or three bonus indicators, one of which is the main one and characterizes the quantitative fulfillment of the established production rate, others - additional, taking into account the qualitative aspect of labor and the cost of raw materials, energy resources and materials.
Piece-piece-progressive system of remuneration provides for the calculation of the wages of a worker within the limits of the fulfillment of production rates at direct piece-rate rates, and when working out in excess of the original rates - at increased rates. Thus, piece rates are differentiated depending on the achieved level of compliance with the norms.
The limit for meeting production standards, in excess of which work is paid at higher rates, is set, as a rule, at the level of actual fulfillment of the norms for the last three months, but not lower than the current norms.
With a piece-rate-progressive system of remuneration, the growth of workers' earnings outstrips the growth of their labor productivity. This circumstance excludes the possibility of mass and constant use of this system. It is usually introduced for a limited time in narrow areas of production, for a limited range of works, where for some reason there is an unfavorable situation with the implementation of the plan.
Indirect piecework wages are used to pay for the work of a part of auxiliary workers who are not directly engaged in the production of products, but their activities significantly affect the results of the work of the main workers they serve. These workers include adjusters, repairmen, transport workers, and some others. Under this system, the size of the wages of auxiliary workers depends on the output of the serviced piecework workers. The rate for indirect piecework wages is determined by the formula
Where C Art. days - the daily rate of an indirectly paid worker,
N ext. main - shiftable production rate of the main employee being served.
The wages of an auxiliary worker under an indirect piecework system are calculated by the formula
Where P To - indirect piece rate,
N f - the actual production of the serviced worker for the billing period,
n - the number of serving workers piece-workers
The lump-sum wage system is a kind of piece-rate system in which the piece rate is set for the amount of work without setting norms and prices for its individual elements. The piecework assignment indicates the amount of earnings, the amount of the bonus and the deadline for completing the assignment.
The brigade wage system, which is used at many enterprises in Russia, is based on the association of workers into production brigades. Such a system presupposes the appropriate organization of labor of workers, united by a single production task and incentives for the general results of labor. It is advisable to use the brigade system in cases where coordinated joint efforts and interaction of a group of workers are required when performing a production task.
The brigade wage system allows for a more rational use of working time and production resources, increasing output and ensuring high-quality output, which ultimately has a positive effect on the overall performance of the entire enterprise and increasing its competitiveness. Providing the necessary conditions for the effective functioning of teams creates a favorable psychological climate, decreases staff turnover, actively masters related professions, develops creative initiative and democratic principles in team management, and increases the general interest in collective labor results.
The brigade wage system is widely used in construction, coal and mining industries, logging, and repair work in transport. It is advisable to use it for collective servicing of large units, apparatuses and mechanisms, and in other cases.
In the brigade organization of labor, both a time-based and piece-rate system of remuneration are used.
With a time-based brigade wage system, total earnings are formed in accordance with the staffing table, drawn up on the basis of headcount standards, service standards, tariff rates (salaries) and the provision on bonuses for collective labor results.
Thus, the collective earnings under the time-based brigade wage system include:
time-based wages at established tariff rates (salaries) for hours worked;
savings in the wage fund, resulting from the temporary absence of any of the team members, as well as in the presence of vacancies;
a bonus for the collective results of the work of the brigade in accordance with the regulations on bonuses;
remuneration for labor contribution to the overall results of the work of the structural unit and (or) the enterprise.
When distributing collective earnings in the brigade, all members of the brigade should be guaranteed a tariff rate for fulfilling the labor standard, taking into account the hours worked. The savings in the tariff fund and the accrued bonus for collective labor results are distributed according to the labor participation rate (KTU). One or two KTUs can be used. In the first case, the entire above-tariff part is distributed to KTU. In the second case, the economy of the wage tariff fund is distributed over the first KTU, the amount of which depends on the availability of vacancies in the brigade and absenteeism of individual workers. The savings are aimed at stimulating those workers who performed the work duties of the absent team members. For the second KTU, the collective bonus is distributed among the members of the brigade, depending on the fulfillment of the established indicators by each of them.
The brigade piece-rate system of remuneration has become widespread, and it is used, like the time-based one, in combination with bonuses for collective labor results.
For calculating wages under the brigade piecework system, a complex price per unit of output is calculated
The distribution of total earnings among the members of the piecework brigade is carried out in the same way as it is done under the brigade-based time-based wage system. It is also possible that the distribution of the variable part of earnings, which includes extra earnings and bonuses, takes into account not the tariff rates, but the individual piecework earnings of workers.
If the brigade consists of piecework workers, time workers and specialists, then the total salary of the brigade is formed from the earnings of pieceworkers at piecework rates, the earnings of time workers according to the sum of their tariff rates, specialists according to the amount of their official salaries and bonuses accrued to the brigade according to the current regulation on bonuses for the collective results of labor.
The members of the brigade can be assigned personal payments, as well as individual additional payments for overtime and night work, on holidays and some others, which are not included in the total earnings of the brigade. The specific conditions for the application of a particular payment system are determined by what tasks the employer sets for himself. For example, if its goal is to increase production volumes and ensure high quantitative achievements in labor, then direct piece-rate and piece-bonus systems are most rational. In the case when it is important to stimulate the employee to improve his qualifications and to fully work out the working hours provided for in the schedule, it is advisable to use a time-bonus system of remuneration.
Where T ci - tariff rates of the category of work performed by members of the team, T PC. - the time norm set per unit of work performed, n is the number of team members. The salary of the entire team is calculated using the formula
Where N f - the actual production of products by the team for the billing period,
m - number of work items
Time-based wages include a simple time-based and time-based bonus wage system.
In a simple time-based system, wages are calculated at the established tariff rate (salary) for the hours actually worked. Under the conditions of the administrative-command system, the wage rate was set according to the category of the worker. In some enterprises, this procedure has been retained. At the same time, at enterprises that charge work with a deviation from the ETKS, the wage rates of a worker can be set according to the category of work.
According to the method of calculating wages, a simple time-based system is subdivided into three types:
hourly;
daily;
monthly.
The calculation of wages under this wage system is carried out at hourly, daily tariff rates and monthly salaries
With hourly wages, wages are calculated based on the hourly wage rate set for the employee and the actual number of hours worked by him for the billing period:
Z pov = T h × V h ,
where: Z pov - the total earnings of the time worker for the billing period;
T h - hourly wage rate set for the employee;
V h - actually worked time in the billing period, hour.
With daily wages, earnings are calculated based on the daily wage rate and the actual number of days worked:
Z pov = T d × V day ,
where: T d - daily tariff rate;
V day - the number of days actually worked.
With a monthly payment, earnings are calculated based on the established monthly salary (rate), the number of working days according to the schedule and actually worked in a given month.
A simple time-based wage system encourages the employee to improve their skills and work out to the full extent of the scheduled working hours. However, it has limited application, since it does little to interest the employee in the individual results of labor.
Time-bonus system of remuneration. Traditionally, widespread use at enterprises, both foreign countries and Russia, is time-based wages, supplemented by bonus payments for fulfilling the plan for the volume and quality of products, respect for equipment and tools, economical use of raw materials, etc. The effectiveness of the time-bonus system is ensured not only by bonus payments, but also by the establishment of normalized tasks for time workers. To establish standardized tasks at the enterprise, technically sound labor standards must be developed. The time-bonus wage system is used to pay managers, specialists, other employees, as well as a significant number of workers.
The use of a time-bonus system in combination with standardized tasks allows solving the following tasks:
fulfillment of production tasks for each workplace and production unit as a whole;
improving the organization of labor and reducing the labor intensity of products;
rational use of material resources, increasing labor productivity and product quality;
deployment of collective forms of labor organization;
improving the professional skills of workers and, on this basis, the transition to a wide combination of professions and multi-station service;
strengthening labor, production and technological discipline, stabilizing the staff;
differentiation of wages, taking into account the qualifications and complexity of the work performed, as well as individual labor results.
2.6 Technical and economic indicators of the repair service of the enterprise and ways to improve them
The main technical and economic indicators characterizing the work of the enterprise's repair service are: labor intensity and cost of maintenance and repair of each type of equipment, the proportion of repair personnel in the total number of employees, the percentage of equipment downtime in repair in relation to the operating time fund, the consumption of auxiliary materials per unit of equipment.
3. Conclusions
The growing importance of effective maintenance and repair of equipment for the smooth functioning of production requires their further improvement. The most important ways of this improvement are:
timely provision of the enterprise with spare parts and fasteners, strengthening of discipline in compliance with supply contracts between industrial enterprises and enterprises producing components for their equipment;
development of a system of branches for technical maintenance on the part of equipment manufacturers;
application of advanced methods and technologies for carrying out repair work;
improvement of the system of organization of labor of repair personnel, advanced training of repair personnel, close cooperation in the supply of technical information with equipment manufacturers.
But at the moment, at most enterprises, the PPR system is practically inactive, and only routine repairs are carried out as the equipment fails. This in no way contributes to the normal operation of the equipment in the enterprise. But since during the period of economic disintegration, first of all, communications between enterprises in different regions were broken, the system of supplying components practically ceased to exist.
4. List of used literature
1. # "center"> Applications
Annex 1
Appendix 2
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2. System for preventive maintenance of equipment
The planned preventive form of organizing the repair of technological equipment throughout the world is recognized as the most effective and is most widely used. The development of a system for preventive maintenance of equipment began in the USSR in 1923. At present, various versions of the PM system are the basis for organizing maintenance and repair of equipment at enterprises in most branches of the sphere of material production and service.
System for preventive maintenance of equipment is a set of planned organizational and technical measures for the care, supervision of equipment, its maintenance and repair. The purpose of these measures is to prevent progressively increasing wear, prevent accidents and keep equipment in constant readiness for operation. The PPR system involves the implementation of preventive measures for the maintenance and scheduled repair of equipment after a certain number of hours of its operation, while the alternation and frequency of measures are determined by the characteristics of the equipment and the conditions of its operation.
PPR system includes
Maintenance
and scheduled equipment repair.
Maintenance- is a set of operations to maintain the performance of equipment when using it for its intended purpose, during storage and transportation. Maintenance includes
routine overhaul
and periodic preventive maintenance operations.
Routine overhaul service consists in the daily monitoring of the condition of the equipment and compliance with the rules of its operation, the timely regulation of mechanisms and the elimination of minor malfunctions that arise. These works are performed by the main workers and maintenance personnel on duty (locksmiths, lubricators, electricians), as a rule, without equipment downtime. Periodic preventive maintenance operations are regulated and carried out by repair personnel according to a pre-developed schedule without equipment downtime. These operations include
inspections carried out to identify defects that must be eliminated immediately or at the next scheduled repair;
flushing and oil change, provided for equipment with a centralized and crankcase lubrication system;
accuracy check carried out by the technical control staff and the chief mechanic.
Planned repairs includes
Maintenance
and major repairs.
Maintenance is carried out during the operation of the equipment in order to ensure its operability until the next scheduled repair (the next current or major). Routine repair consists in replacing or restoring individual parts (parts, assembly units) of equipment and adjusting its mechanisms. Overhaul carried out in order to restore the full or close to full service life of the equipment (accuracy, power, productivity). Overhaul, as a rule, requires repair work in stationary conditions and the use of special technological equipment. Therefore, it is usually required to remove equipment from the foundation at the site of operation and deliver it to a specialized department where overhaul is carried out. During a major overhaul, the equipment is completely disassembled with checking all its parts, replacing and restoring worn parts, reconciling coordinates, etc.
The repair and maintenance system, depending on the nature and operating conditions of the equipment, can function in different organizational forms:
in the form of a post-examination system,
periodic maintenance systems
or a standard repair system.
Post inspection system involves carrying out inspections of the equipment according to a pre-developed schedule, during which its condition is established and a list of defects is drawn up. Based on the inspection data, the timing and content of the upcoming repair are determined. This system is applicable to some types of equipment operating under stable conditions.
Periodic repair system involves planning the timing and scope of repair work of all types on the basis of a developed regulatory framework. The actual scope of work is adjusted relative to the normative according to the results of the inspection. This system is most common in mechanical engineering.
Standard repair system involves planning the scope and content of repair work on the basis of precisely established standards and strict adherence to repair plans, regardless of the actual condition of the equipment. This system applies to equipment, the unplanned stop of which is unacceptable or dangerous (for example, lifting and transporting devices).
The effectiveness of the PM system is largely determined by the development of its regulatory framework and the accuracy of the established standards. The standards of the PPR system of the enterprise are differentiated by equipment groups. Main repair standards are
repair cycles and their structure,
labor intensity and material consumption of repair work,
inventory for repair needs.
Repair cycle- this is the period of time from the moment the equipment is put into operation until the first overhaul or between two successive overhauls. The repair cycle is the smallest repetitive period of equipment operation, during which all types of maintenance and repair are carried out in the established sequence in accordance with the structure of the repair cycle. The structure of the repair cycle establishes the list, quantity and sequence of equipment repairs during the repair cycle. For example, a repair cycle structure might include the following repair sequence:
K - T 1 - T 2 - T 3 - TO,
where T 1 , T 2 and T 3 - respectively, the first, second and third current repairs;
TO- overhaul (only one overhaul is included in the repair cycle).
The content of work performed as part of each of the current repairs is regulated and may differ significantly from others present in the repair cycle. In the structure of the repair cycle, a small ( M) and average ( WITH) repair: for example, T 2 = C; T 1 = T 3 = M.
Similarly, the structure of the maintenance cycle can be presented, establishing the list, number and sequence of overhaul maintenance work (shift inspection, partial inspection, lubrication replenishment, lubricant change, preventive adjustment, etc.). It is possible to include maintenance work ( THEN) into the structure of the repair cycle, for example:
WHO 1 - T 1 - THEN 2 - T 2 - THEN 3 - T 3 - THEN 4 - TO.
The repair cycle is measured by the operational time of the equipment, the downtime in repair is not included in the cycle. The duration of the repair cycle is determined by the service life of the main mechanisms and parts, the replacement or repair of which can be carried out during the complete disassembly of the equipment. Wear of main parts depends on many factors, the main of which are
the type of production on which the intensity of the use of equipment depends;
physical and mechanical properties of the processed material, on which the intensity of wear of equipment and its parts depends;
operating conditions, such as high humidity, dustiness and gas pollution;
equipment accuracy class, which determines the level of requirements for monitoring the technical condition of equipment;
Duration of the repair cycle T is determined in the worked machine-hours by a calculation method according to empirical dependencies, taking into account the influence of many factors, including those listed above:
where T n- standard repair cycle, hours (for example, for certain metal-cutting machines T n= 16 800 hours);
ß P , ß m , ß at , ß T , ß R- coefficients, taking into account the type of production, type of processed material, operating conditions, accuracy and dimensions of the equipment, respectively.
The values of the coefficients and the standard duration of the repair cycle are determined on the basis of generalization and analysis of the actual data of the enterprise or are taken according to reference data.
Overhaul period T mr and maintenance intervals T then are also expressed by the number of hours worked:
,
(104)
,
(105)
where n T and n THEN- respectively, the number of current repairs and maintenance work per one repair cycle.
The duration of the repair cycle, the overhaul period and the frequency of maintenance can be expressed in years or months, if the shift of the equipment is known. Proper care of equipment during its operation, organizational and technical measures that extend the service life of parts and parts of equipment, contribute to a change in the actual duration of the repair cycle and overhaul periods in comparison with the standard. The service life of wearing parts and equipment parts is shorter than the overhaul period. Therefore, it is advisable to replace them as they wear out during the overhaul period. At the same time, the complexity of the repair is reduced, the volume of work on overhaul maintenance increases.
Labor intensity and material consumption of equipment repair and maintenance depend on its design features. The more complex the equipment, the larger its dimensions and the higher the processing accuracy, the higher the complexity of its repair and maintenance, the higher the labor intensity and material consumption of these works. According to the complexity of the repair, the equipment is divided into categories of repair complexity. The labor intensity of repair work separately for the mechanical and electrical parts of the equipment is determined through the labor intensity of the unit of complexity of repair.
Repair complexity category (TO) is the degree of complexity of equipment repair. The category of equipment repair complexity is determined by the number of units of repair complexity assigned to a given group of equipment by comparing it with the accepted standard - conventional equipment. At domestic machine-building enterprises, the repair complexity of conventional equipment is traditionally taken as a unit of repair complexity of a mechanical part, the laboriousness of the overhaul of which is 50 hours, for a unit of repair complexity of its electrical part - 12.5 hours (1/11 of the laboriousness of the overhaul of a screw-cutting lathe 1K62, which was assigned the 11th category of repair complexity).
Repair unit (R. e.) is the labor intensity of the corresponding type of equipment repair of the first category of repair complexity. Labor intensity rates for one repair unit are set by type of repair work (flushing, checking, inspection, current and overhaul repairs) separately for locksmith, machine tools and other works. The labor intensity of each type of repair work is determined by multiplying the time norms for a given type of work for one repair unit by the number of repair units of the category of complexity of repair of the corresponding equipment.
Total labor intensity of repair work (Q) in the planning period is calculated by the formula:
q K , q T and q THEN- norms of labor intensity of capital and current repairs, technical maintenance per one repair unit, hours;
n TO , n T , n THEN- the number of major and current repairs, maintenance work in the planned period.
Today, preventive maintenance is the simplest, but at the same time, reliable method of performing work. As for the resumption of the functioning of the equipment, the list of the main conditions ensuring it includes the following:
The units have already worked out a specific number of hours and a new periodic working cycle is coming, which must be preceded by scheduled preventive maintenance.
The normal level of repair work is clearly indicated by determining the optimal intervals between scheduled periodic maintenance.
Organization of approved works. Control over them is based on a standard scope of work. Their responsible implementation ensures the further full functioning of the existing units.
Preventive maintenance of electrical equipment is carried out to the extent necessary in order to effectively eliminate all existing defects. It is also carried out to ensure the natural operation of the equipment before subsequent repairs. Typically, a scheduled preventive maintenance schedule is drawn up based on specified periods.
In the intervals between scheduled repair work, electrical equipment is also subject to pre-scheduled inspections and a series of checks, which are, in fact, preventive.
Repair work of electrical equipment
The alternation, the frequency of scheduled repairs of the units depend both on their purpose and on their design features, operating conditions, and dimensions. The basis for preparing for this work is the clarification of defects, the selection of spare parts and spare parts, which will need to be replaced in the future. An algorithm for performing this type of manipulation is specially developed, due to which the uninterrupted operation of equipment (machines) during repairs is possible. Correct preparation of such a plan of action makes it possible to carry out a complete resumption of the functioning of all devices without disrupting the usual operating mode of production.
Organization of the process
Competent scheduled preventive maintenance includes the following sequence:
1. Planning.
2. Preparing units for repair.
3. Carrying out repair work.
4. Implementation of measures related to repair and scheduled maintenance.
The considered system of preventive maintenance of equipment has stages: overhaul, current. They can be examined in more detail.
Overhaul stage
The overhaul stage allows you to repair the equipment without disrupting the production process. It includes systematic cleaning, lubrication, inspection, adjustment of units. This also includes the elimination of minor malfunctions, replacement of parts with a short service life. In other words, this is prevention, which is not complete without daily examination and care. It must be properly organized in order to maximize the life of the existing equipment.
A serious approach to this issue can significantly reduce the cost of future repairs and contributes to a better and more efficient performance of the tasks set by the enterprise. The main work that is carried out during the overhaul stage is daily lubrication and cleaning of units, compliance by all employees with the rules for using devices, monitoring the current state of equipment, adjusting mechanisms and timely elimination of minor breakdowns.
Current stage
This stage of preventive maintenance of electrical equipment often does not provide for the disassembly of devices, but it includes the prompt elimination and elimination of all breakdowns that have arisen during the period of operation. In this case, only the units are stopped. During the current stage, tests and measurements are carried out, thanks to which equipment flaws are detected even at an early stage, and this is very important.
The decision about whether the electrical equipment is suitable is made by the repair specialists. This is within their competence. They base their decision on a comparison of the available conclusions obtained during the tests during the implementation of scheduled routine repairs.
Elimination of defects in the functioning of units can be carried out not only during scheduled repairs, but also outside of it. This usually occurs after the equipment has completely exhausted its resource.
Preventive maintenance: middle stage
Allows you to partially or completely restore already worn-out units. This stage includes disassembling the necessary units for viewing them, eliminating the identified defects, cleaning the mechanisms and replacing some quickly wearing parts and parts. It is carried out annually.
The system of scheduled preventive maintenance at the middle stage includes the installation of the volume, cycle and sequence of the works indicated here in strict accordance with all regulatory and technical documents. Thanks to this, normal operation of the equipment occurs.
Overhaul and its prerequisites
It is carried out after opening the equipment, its full inspection with examination for defects in all parts. This stage includes measurements, tests, elimination of identified malfunctions, due to which it is necessary to modernize the units. Here, one hundred percent restoration of the technical parameters of the devices under consideration takes place.
When is the overhaul of electrical equipment carried out?
Such manipulations are possible only after the completion of the overhaul stage. The following conditions must also be met:
The work schedule has been drawn up.
A preliminary check and inspection has been carried out.
All the necessary documents have been prepared.
Replacement parts and tools provided.
Fire-fighting measures were taken.
What does the overhaul include?
The process of repairing electrical equipment in this case consists of:
1. Replacement / restoration of worn-out mechanisms.
2. Upgrading devices requiring it.
3. Carrying out measurements and preventive checks.
4. Carrying out works to eliminate minor damage.
Malfunctions and defects that are discovered during checks of equipment (machines) are eliminated during subsequent repair. Breakdowns classified as emergency are eliminated immediately. Equipment of different types has its own frequency of activities related to repair work, which is regulated by the rules of technical operation. All manipulations carried out are reflected in the documentation, the strictest records of the presence of units and their condition are kept.
According to the approved plan for the year, a nomenclature plan is created, in which the current / major repairs are recorded. Before proceeding with them, the date of stopping electrical equipment (machines) for repair must be specified.
The scheduled preventive maintenance schedule is the official basis for drawing up a budget plan for a year, developed twice over a specified period. The total amount of the plan-estimate is distributed by months, quarters, taking into account the period of capital repair work.
Peculiarities
Today, the preventive maintenance system provides for the use of microprocessor and computer technology (stands, structures, test and diagnostic facilities). This prevents wear and tear on the equipment and reduces the cost of rebuilding. All this also contributes to an increase in operational efficiency, and therefore, the profit of enterprises.
Preventive maintenance: drawing up a schedule for the year
Consider how the schedule for the year is drawn up. Preventive maintenance of buildings or electrical equipment is a full-fledged complex of organizational and technical measures closely related to supervision and maintenance. It concerns all types of repairs and is carried out periodically according to a previously drawn up plan. This helps to prevent premature partial or complete wear and tear of equipment, accidents. All fire protection systems are in constant readiness.
Preventive maintenance is organized according to a system that includes such types of maintenance as:
Weekly technical fix.
Monthly repairs.
Annual pre-scheduled preventive maintenance.
The developed regulation on scheduled preventive maintenance is approved by sectoral ministries and departments. The document is obligatory for the enterprises of the industry.
Preventive maintenance is always carried out in strict accordance with the existing annual work schedule, which includes each mechanism subject to current or major repairs. When drawing up this schedule, the standards for the frequency of equipment maintenance are used. They are taken from the passport data of the units prepared by the manufacturer. All available mechanisms, devices are entered into a schedule, where brief information about them is indicated: quantity, resource standards, labor intensity of one current or major overhaul. It also records information about the last ongoing ongoing and major repairs.
Additional Information
The regulation on scheduled preventive maintenance contains information about in-shift maintenance (supervision, maintenance) and preventive inspection of the existing equipment. It is usually assigned to the operating and duty personnel. It also contains information on the implementation of the planned work.
The advantages of preventive maintenance systems include:
Fixing downtime of units, equipment, machines.
Control over the duration of overhaul periods of operation of devices.
Forecasting the costs of repairing equipment, mechanisms, components.
Accounting for the number of personnel involved in the activity, which depends on the complexity of the repair.
Analysis of the causes of equipment failure.
Disadvantages of preventive maintenance systems:
The complexity of the calculation of labor costs.
Lack of convenient and suitable tools for planning (implementing) repair activities.
Difficulty accounting for a parameter / indicator.
The complexity of the operational adjustment of the planned work.
Each preventive maintenance system has a trouble-free model of operation / repair of units, but in the event of accidents or as a result of deterioration, unscheduled work can also be carried out related to the full resumption of the operation of the devices.
The frequency of equipment operation stops for major or current repairs is determined by the service life of the wearing mechanisms, parts, and assemblies. And their duration is determined by the time it takes to perform the most laborious manipulations.
Hoisting machines (units), in addition to a routine inspection, are also subject to technical inspection. It is carried out by the specialists responsible for the supervision of this equipment.
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