The story of Bian Que's cure
During the Warring States period, King Wen of Wei once asked the famous doctor Bian Que: "The three brothers in your family are all good at medicine. Which one is the best?"
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King Wen asked, "Then why are you the most famous?"
Bian Que replied: "My eldest brother treats the disease before the disease breaks out. Because most people don't know that he can eradicate the disease beforehand, so his reputation cannot be spread. Only our family knows.
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My second brother treats illnesses at the onset of illnesses; most people think that he can only treat minor ailments, so his reputation only extends to the local people.
And when I treat diseases, I treat them when they are serious. Most people see me putting needles on the meridians to let blood, applying medicine on the skin and other treatment measures, so they think that my medical skills are superb, and my reputation spreads all over the country. "
King Wen said, "You speak very well."
Equipment is like people. If the equipment is well maintained, it will not break down. We need to reflect on the causes of failures and take measures to prevent them. In the process of equipment use, to achieve zero failure of equipment is the goal pursued by maintenance technicians.
Equipment maintenance is the same as treating diseases and saving lives. It needs to focus on prevention and be good at treating "preventive diseases". Equipment maintenance should be done well to avoid failures and achieve zero failures of equipment. Zero failures are the highest pursuit of maintenance practitioners.
The zero failure of the equipment does not mean that the equipment does not fail, but that the equipment does not fail during the production time, and the maintenance technicians eliminate the failure of the equipment in the bud during the non-production time through technical means.
For example, the aircraft cannot break down during the flight; another example is that in the key power production, if the production is stopped for a long time due to the failure, it will cause huge losses. Therefore, for this type of equipment, it is necessary to overhaul it during non-production hours to eliminate hidden troubles and ensure zero failures.
It is precisely because our production site management has seriously neglected the equipment that the equipment often has "symptoms"!
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Where are we?
The difference lies in the understanding of modern management, the implementation of the management system, and the use of the most advanced equipment with backward concepts.
The production of modern teams is increasingly inseparable from various processing and auxiliary equipment. Without stable operation of equipment, there will be no normal survival basis for teams.
On the other hand, the equipment around us frequently violates our wishes, frequent failures, energy interruptions, oil leaks, defective spare parts, loss of functions, etc. These problems caused by equipment always interfere with the normal work, and the production site organizes activities accordingly. Always in interrupted state. Over time, the team leader changed from a "combat elite" who organizes production to a "fire-fighting elite" who organizes emergency repairs and reports.
Similarly, in the face of frequent equipment failures, the equipment management department and professional maintenance personnel are struggling to deal with it. They rush around and fight fires everywhere, but they still cannot get rid of the bad luck of being complained by the front-line personnel. In the end, the front-line squad leader and equipment maintenance personnel simultaneously Exhausted, helpless.
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How to achieve zero failure?
Someone may ask, according to the point of view of zero failure, can the equipment be used forever? Here we need to distinguish two different concepts: natural aging and forced deterioration.
The so-called natural aging means that although the method of use is correct, as time goes by, the equipment undergoes physical and chemical changes, and the initial performance gradually declines.
The so-called forced deterioration refers to the failure to operate in the proper way, which artificially promotes deterioration. For example, there is no refueling at the place where refueling should be done, or the amount of refueling is too small or the cycle is too long. There is also failure to perform due equipment cleaning, etc., that is, failure to do what should be done will cause the equipment to deteriorate.
In this way, the service life of the equipment is lower than its expected life, which is much shorter than the life of natural aging. Therefore, the significance of the zero-fault viewpoint is to guide us to correctly understand faults, do what we should do to avoid forced deterioration, and delay natural aging.
So far, the reason why there are still many faults is that the real cause of the fault is often not grasped. There are usually some tiny, hidden flaws that precede failures. If we pay attention to this unobtrusive potential defect that eventually leads to failure before the failure occurs, and improve it in time, the failure can be eliminated. It can be seen that the obvious treatment of potential defects is the principle of "no failure".
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In order to actually advance this work, we have derived five countermeasures to achieve zero failures based on the possible causes of failures:
1. Have the basic conditions The so-called basic conditions refer to cleaning, refueling, fastening and so on. The failure is caused by the deterioration of the equipment, but most of the deterioration is caused by the lack of the three elements of the basic conditions.
2. Strictly abide by the conditions of use The conditions of use are determined when the machinery and equipment are designed. If used in strict accordance with the conditions of use, the equipment will rarely fail. Such as voltage, speed, temperature and installation conditions, etc., are determined according to the characteristics of the equipment.
3. Make the equipment return to normal A piece of equipment, even if it has the basic conditions and guarantees the conditions of use, it is difficult to be perfect, so the equipment will still deteriorate and malfunction. So make the implicit deterioration apparent and restore it to normal. This means that we should regularly carry out proper inspections and preventive repairs on equipment.
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4. Improve design deficiencies. Some faults cannot be eliminated even after the above three countermeasures are taken. They are often caused by deficiencies or errors in the design, manufacture, and installation of equipment. Such faults should be carefully analyzed and these defects should be improved.
5. Improve the quality of people All countermeasures must be implemented by people, and people are the most fundamental in the process of realizing zero failure. First of all, everyone must have a serious attitude and professionalism, secondly, have a correct understanding of faults, and finally, improve the professional skills of operators and maintenance personnel. the
In general, we should do the following work well in our daily work: activities to prevent deterioration: correct operation, preparation, adjustment, cleaning, refueling, fastening, etc.; Do daily and regular inspections of equipment to find hidden troubles as soon as possible; activities to restore deterioration: eliminate hidden dangers and deterioration in time, so that the equipment can return to a normal state.
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Use step-by-step methods to carry out self-maintenance
Everyone wants equipment to have high efficiency. As far as equipment is concerned, the level of its efficiency involves two people, one is the production and use personnel, and the other is the maintenance and repair personnel. If the two parties regard themselves as isolated parties, we are the producers and only use it, and you are the maintainers, and you are responsible for the quality of the equipment, which of course will not produce any good results.
It should be noted that production, use and maintenance are two aspects of a whole, which are like the two wheels of a bicycle. Only when the two are fully coordinated can the effectiveness of the equipment be fully exerted. The production and use department is not only concerned with production and use, it should also undertake the basic work of equipment maintenance, that is, "activities to prevent deterioration". Only when the production and use department has done a good job of "prevention of deterioration", the maintenance department can exert the real power of the full-time maintenance means it undertakes, and the equipment can be truly and effectively maintained.
We call the maintenance activities centered on "prevention of equipment deterioration" carried out by the production and use department "independent maintenance activities participated by all employees", which is usually called independent maintenance. in self-maintenance activities. In order to give full play to the capabilities of the equipment, it is necessary to implement "manage your own equipment by yourself" and be a person who can control the equipment. Therefore, in addition to the ability to manufacture products, the operator must also have the following four abilities:
1. The ability to detect abnormalities The "abnormality detection ability" that can detect abnormalities in equipment is not simply to discover abnormalities when a fault has occurred or a defect has occurred, but to be able to detect when a fault seems to occur or a defect is about to occur. Abnormalities such as the cause of these failures are clear at a glance. Only in this way can it be called the real "abnormal discovery capability".
2. The ability to deal with abnormalities correctly and quickly (handling recovery ability) For the abnormal phenomena that have been discovered, only by restoring them to the original correct state can the original function of the equipment be exerted, and it should also be able to respond according to the degree of abnormality. Decide whether to report to the superior and the maintenance department, and how to deal with it.
3. The ability to set conditions The ability to find abnormalities often depends on the level and experience of each person. Due to differences in level and experience, it may affect the discovery of abnormalities. In order to prevent this phenomenon, a certain amount should be determined to judge whether the equipment is normal. Judgment criteria should be quantitative, taking temperature as an example, the quantitative should be determined as "should be below XX degrees", rather than vaguely described as "no abnormal fever". What I want to emphasize here is that instead of delaying implementation by emphasizing the correctness of the judgment benchmark, it is better to set a temporary benchmark first, and then revise it several times to determine a more suitable benchmark. This method is more realistic. the
4. Maintaining management capabilities It is not as good as prevention if equipment fails to be repaired. For this reason, established standards must be strictly followed, such as "cleaning and refueling standards" and "self-inspection standards".
How ability is formed, it mainly depends on continuous learning and accumulation in work, so work itself is a kind of learning, and it can achieve more work results due to continuous improvement of ability, and the three are interdependent. , mutual promotion relationship.
In order to train operators who can control the equipment, it is necessary to form a self-maintenance system. On the one hand, it is necessary to pay attention to the cultivation of talents, and on the other hand, it is necessary to effectively improve the work according to their actual ability, so as to achieve the real effect, that is, this effect can be maintained. When carrying out self-maintenance, we should not hope to solve many problems at once. For this reason, we organize the goals and contents into seven steps, which is "step-by-step self-maintenance". The ideal way is to do each step thoroughly and wait until a certain level is reached before moving on to the next step.
Seven steps to complete self-maintenance
Step 1: Initial Cleaning The initial cleaning takes the equipment as the center and thoroughly cleans dust, garbage, etc. We need to change cleaning into inspection, inspection can find problems, discover potential defects of equipment, and deal with them in time. At the same time, cleaning can help the operator to take care of the equipment.
Step 2: Countermeasures for sources of occurrence and difficult parts In order to maintain and improve the results of the initial cleaning in the first stage, it is necessary to eliminate the root causes (sources) of dust, pollution, etc. For this purpose, countermeasures such as elimination, capping, and sealing can be taken. For parts that are difficult to maintain, such as refueling, cleaning, decontamination, etc., effective countermeasures should also be taken to improve the maintainability of the equipment.
Step 3: Write cleaning and refueling benchmarks Based on the experience gained in the first and second steps, write a temporary benchmark to maintain the equipment you are in charge of, such as cleaning, refueling, fastening and other basic conditions. the
Step 4: Comprehensive inspection In order to give full play to the inherent functions of the equipment, it is necessary to learn the structure, function and judgment criteria of the equipment, check the appearance of each main part of the equipment, find the defects of the equipment and restore them, and at the same time master the necessary inspection skills. Furthermore, continuous improvement of previously written benchmarks can be considered for inspection. the
Step 5: Self-inspection On the basis of the cleaning benchmarks, refueling benchmarks, and inspection benchmarks written in the third step, add the content learned in the fourth step, and fully follow the implementation. This is the self-checking benchmark. In the process of learning and execution, it is also necessary to continuously learn and be familiar with the operation and movement of equipment, the correlation between quality and equipment, etc., and have the ability to operate equipment correctly and detect abnormalities early.
Step 6: Arranging and rectifying Expand the scope of activities from the existing equipment-centered activities to peripheral equipment and the entire workshop. On the basis of mastering the capabilities of the above five steps, develop to realize and maintain the proper image of the entire workshop . The sorting mentioned in this step is to specify the fixtures, semi-finished products, defective products, etc. in the workshop, and to formulate management benchmarks. Management objects such as things and things should be completely reduced and simplified as much as possible. The so-called rectification is to observe (maintain) the established benchmark and gradually improve it so that the operators can easily abide by it. The workshop implements visual management and management implements standardization. the
The seventh step: the thoroughness of self-management Through the activities of the first six steps, a lot of results have been obtained, and the personnel have also been greatly trained. Therefore, the seventh step is to establish a sense of continuous improvement and carry out continuous improvement. The PDCA cycle, combined with the company's policies and goals, formulates new group activity goals suitable for oneself, so as to achieve thorough self-management.
