First, TPM management model innovation-man-machine combination
China Resources Snow Beer (Anshan) Co., Ltd. has been introducing TPM management mode for many years, and has always adhered to its management system, organizational form and group activities. In the highly competitive beer industry, beer production equipment has become more and more complex, precise and large-scale, and the key equipment is still mainly imported. The beer packaging production line, CIP system and saccharification and fermentation system all adopt PLC automatic control. Saccharification-fermentation-wine filtration-canning-storage, etc. The automation degree of flow production is getting higher and higher. There are dozens of processes and thousands of process control points from the input of raw materials to the output of finished wine. The equipment failure at any control point will affect the physical and chemical process indexes of wine, and in serious cases, it will lead to the shutdown of the whole factory, causing serious losses and quality accidents, which is not allowed. Therefore, on the basis of TPM management mode, the company explored the man-machine combination management mode in practice and integrated it into TPM management mode, organically combined people and equipment, fully exerted human factors, realized the maximum comprehensive efficiency of equipment, and enriched and innovated the content of TPM management mode.
1. Fixed aircraft and personnel, charter maintenance
The three production lines (A, B and C) used by our company for bottled wine packaging are all joint operations, from bottle unloading, bottle washing, canning, sterilization, labeling, bottling and palletizing, among which the palletizing of line C is manual operation, which runs continuously for 24 hours in peak season. The equipment failure in any process will lead to the production line stop, and the filling and capping machine is the core of the whole production line and the key to ensure the normal operation of the production line.
Under the guidance of TPM management consulting experts, the workshop conducts group assessment on machinists, electricians and operators. Each group manages a production line, with a highly skilled master as the team leader, and signs a letter of responsibility with the TPM coordinator (equipment member) of the workshop and equipment department, and conducts performance assessment linked with the production efficiency, failure rate, maintenance cost, intact rate and energy consumption of the equipment, so as to establish a long-term incentive mechanism to organically combine people and equipment. Under the leadership of the workshop equipment supervisor and the TPM coordinator of the equipment department, each team will carry out the daily maintenance and management of the contracted equipment to ensure the completion of all indicators.
(1) Strengthen the examination of equipment downtime.
There are two kinds of equipment downtime, one is caused by improper human operation, and the responsibility is borne by the operator; Second, the fault caused by improper maintenance or normal damage of equipment shall be borne by the contractor's mechanic. After troubleshooting, the equipment maintenance report should be filled out in time, and the causes or phenomena of equipment failure, maintenance process and replaced parts should be recorded. According to the contents of the equipment maintenance report, the person in charge of workshop equipment establishes the equipment information file and reports it to the equipment department as the basis for analyzing the monthly and annual equipment status and assessing the maintenance level and quality of maintenance personnel.
(2) Strengthen the statistics of equipment information.
In the daily equipment inspection, every mechanic will record the equipment defects or faults and hidden dangers that cannot be solved immediately, report them to the person in charge of the workshop equipment, and record them in the electronic information file of the equipment status, so as to know the equipment running status in time.
(3) Strengthen the maintenance and supervision of equipment.
Machinists and operators on the production line should carry out daily maintenance, weekly maintenance, monthly maintenance and lubrication of equipment in strict accordance with the equipment maintenance card and lubrication table. The mechanic is responsible for supervising and guiding the operator's equipment maintenance; The person in charge of workshop equipment is responsible for supervising the work quality of technicians. For the problems found in the maintenance process, the person in charge of workshop equipment should fill in the equipment maintenance card and work out the solutions in time. For unqualified equipment maintenance projects, it is necessary to publicly criticize and make corrections within a time limit.
(4) Regular maintenance according to the situation.
The person in charge of workshop equipment puts forward the maintenance plan according to the defects recorded in the equipment electronic information file. In principle, 8 hours of downtime should be arranged every month. Equipment maintenance is generally arranged in the off-season of production. After the steam heat exchanger of bottle washer and sterilizer works 1200h, it should be disassembled and cleaned at least once, and the equipment status and maintenance should be reported to the equipment department and recorded in the equipment file.
(5) Strengthen technical transformation of equipment.
The equipment on the packaging production line is a complete set of equipment. According to the service life and the development level of equipment technology at home and abroad, the structure or device that affects the efficiency and technology of equipment is technically reformed. Make the equipment maintain the advanced technical level and produce greater economic benefits. The technical transformation results should be reported to the equipment department and recorded in the equipment file.
Since the man-machine combination was implemented in the packaging workshop, the equipment failure rate and equipment maintenance cost have been obviously reduced, and the equipment production efficiency has been greatly improved.
2. Create jobs and personnel and maintain the area.
Regional maintenance, also known as machine maintenance package mechanism, belongs to the form of equipment maintenance combining man and machine. The mechanic is responsible for the equipment maintenance in the production area, and works with the operators to do the daily maintenance, patrol inspection, regular maintenance, predictive maintenance and troubleshooting of the equipment, so as to ensure the completion of the assessment indicators such as equipment integrity rate and failure rate in the area under his jurisdiction. Regional maintenance responsibility system organically combines people and equipment, strengthens equipment maintenance, fully mobilizes the enthusiasm and initiative of mechanics and operators, and makes them more concerned about equipment maintenance and maintenance.
According to the characteristics of a large number of equipment and wide distribution area, the company's brewing workshop has established a number of equipment regional maintenance groups by means of fixed posts and fixed personnel and regional maintenance, effectively combining mechanics with the equipment in its jurisdiction, and achieved good results. Since regional maintenance, there has not been an equipment accident caused by improper equipment maintenance, and the equipment failure rate has also dropped to the lowest level in history.
3. Advantages of regional maintenance team
It has a high degree of flexibility in the emergency repair task of equipment, which shortens the time of emergency repair of equipment. The mechanic on duty can consciously complete the repair plan of various preventive operations.
4. Matters needing attention when establishing regional maintenance group
When dividing the equipment maintenance area, we should fully consider the factors such as equipment distribution, equipment condition, technical complexity, production needs and technical level of mechanics, and divide the equipment into several areas reasonably; Regional maintenance groups can also be divided by equipment type (for example, pipeline equipment by line). The regional maintenance team shall make a maintenance plan and specify the time for routine maintenance of each shift of equipment. In order not to affect production, the planned maintenance of equipment should be arranged on non-working days, and the routine maintenance of each shift should be arranged during the lunch break of production workers.
Second, man-machine combination is the guarantee of energy saving and consumption reduction in production.
Because the overall equipment level of the packaging production line is not high, the technical conditions of new and old equipment are uneven, and the failure rate of bottle washing machine is high, which is the weak link of the company's production. Facing the situation that the energy consumption index continues to rise, the company further deepens equipment management and technical transformation to tap the potential of equipment. Through man-machine management, the packaging workshop puts the responsibility of equipment maintenance on people, continuously reduces the downtime rate of equipment and improves the production efficiency of equipment; Strengthen the ability of maintenance diagnosis, and change passive maintenance into active maintenance, predictive maintenance, planned maintenance and controlled maintenance; Actively control the running state of the equipment, so that the equipment is always in the best working state. Man-machine combination urges machinists to establish the concept of "zero failure" of equipment, and expand it on the platform of TPM management mode to explore the mode of lifelong inspection-free equipment. Practice has proved that man-machine combination has improved the production capacity of beer canning line in packaging workshop.
The power workshop is a big consumer of electricity in the company. The long running time and high power consumption of air compressors and refrigeration units have always been the main problems that affect the completion of the company's energy-saving and consumption-reducing indicators. When the air compressor and refrigeration unit are started, the torque is large, the starting current is large, and the equipment and components are greatly impacted, which not only consumes electricity, but also directly affects the service life of the unit. In order to solve these problems, the power workshop actively monitors the operation parameters of the equipment, analyzes the proportion of electricity consumption per unit time, and reduces the power consumption of the equipment by starting and stopping the air compressor unit and the refrigeration unit according to the production load. Perform predictive maintenance according to equipment inspection records to reduce the downtime of factory equipment. At the same time, the starting system of high-power motor is technically reformed. Firstly, the soft start technology combining PLC and computer is adopted to replace the traditional start-up mode. After the transformation, the starting current is stable, the equipment starts smoothly, the impact force is small, and the starting current is reduced. Second, a frequency conversion control device is added to the equipment control system, which can automatically perform frequency conversion speed regulation according to the operating load, thus achieving the purpose of saving energy and reducing consumption.
The successful practice of man-machine combination of TPM management has been recognized by leaders at all levels. Man-machine combination is more intelligent, more efficient and more guaranteed in quality. Can play a greater role in continuous improvement. How to improve the man-machine combination mode will continue to work hard.