The use and maintenance of aluminum equipment
According to the wear pattern of aluminum equipment, the longer the normal wear period, the better the performance of the equipment. That is to say, in order to achieve the best performance of aluminum equipment during its service life, it is necessary to make the normal wear period equal to the natural life of the equipment. From this, it can be concluded that the basic concept is that after the equipment is put into production use, it is hoped that the more available time it has during its usage period, the better. The time availability of equipment usage effect is determined by the downtime and maintenance time of the equipment. The more downtime for equipment maintenance, the less time it can work and the lower the time utilization rate; On the contrary, the higher the time utilization rate. Our ideal is to require a 100% time availability rate for the equipment. To achieve this goal, various factors are involved. As far as the equipment itself is concerned, except that the quality in the composition period (including the reliability and durability of performance, the rationality of structure, the progressiveness and rationality of material selection, the quality assurance degree of processing and manufacturing, etc.) is the basic condition, the correct and reasonable use, careful maintenance and careful management of the service life are the objective requirements for extending the service life of the equipment, and the basic conditions for giving full play to the equipment efficiency and improving the time availability. Numerous examples in practical work have shown that equipment of the same model and manufactured by the same factory, which is put into production at the same time and operates under the same environmental conditions, can have vastly different effects due to the advantages and disadvantages of usage and maintenance conditions. This situation is not only between two devices, but even within the same device, the effectiveness of use may vary due to differences in usage and maintenance levels among different operators. For example, there is a steel barrel seam welding machine in a factory that has been in use for twenty years, but has not undergone major or medium repairs, has not undergone many minor repairs, and has had very few shutdowns due to malfunctions. The equipment still maintains the required accuracy and performance, and its appearance is still brand new. The operator of this equipment is an experienced worker with a high sense of responsibility and rich practical experience. His experience is to use it reasonably, maintain it carefully, and truly achieve the goal of "caring for equipment like soldiers caring for weapons". Such examples exist in many enterprises. This indicates that strengthening the use and maintenance of equipment can greatly reduce maintenance downtime and improve time utilization while saving costs. Therefore, the focus of equipment lifecycle management should be on the use and maintenance of the equipment.
一、Proper use of aluminum equipment
The basic conditions for achieving the rational use of equipment are: equipping equipment according to the production process characteristics and actual needs of the enterprise's products, making it well matched, with a reasonable and coordinated layout; Arrange production tasks for equipment based on its performance, load-bearing capacity, and technical characteristics; Select and equip qualified operators; Develop and implement regulations for the use and maintenance of equipment, including a series of rules and systems, to ensure that operators use and maintain the equipment in accordance with relevant technical information; An objective environment that ensures the full performance of the equipment, including necessary protective measures and measures against moisture, corrosion, dust, and shock; Establish and implement various responsibility systems for the use of equipment. The management of equipment usage is based on these basic conditions, from the signing of the contract with the supplier to the termination of production, through planning, organization, education, supervision, and a series of measures, to reduce wear and tear, maintain the accuracy, technical performance, and production efficiency of the equipment, extend its service life, keep the equipment in good technical condition, and achieve the best economic results.
（一）Reasonably equip aluminum equipment
Reasonable equipment allocation in the production department is a prerequisite for the correct and rational use of equipment, fully exerting efficiency, and improving usage effectiveness. Reasonable equipment allocation means that enterprises should equip and select equipment according to their production capacity, production nature, and development direction, as well as the actual needs of product process technology requirements. When equipping and selecting equipment, the following points should be noted:
?。?）Consider the completeness of the main production equipment and auxiliary production equipment. Otherwise, there will be a mismatch between devices, resulting in uncoordinated production arrangements and affecting normal production.
?。?）The equipment configuration should be coordinated in terms of performance and economic efficiency, and with changes in product structure, variety, quantity, and technical requirements, as well as the promotion and application of new processes and materials, the proportion of equipment configuration should also be adjusted accordingly to adapt.
?。?）In the process of equipping equipment, avoid pursuing "big and comprehensive" or "small and comprehensive". In a company, when comprehensively planning, balancing, and implementing the equipment capabilities of each unit, the starting point should be to maximize the role and utilization effect of the equipment, and to achieve concentration rather than dispersion as much as possible.
?。?）Some specialized equipment should not be purchased if it can be improved, modified, or solved through the innovation of a certain tooling fixture using existing equipment.
?。?）In equipping equipment, attention should be paid to improving the adaptability and flexibility of equipment processing technology. To meet the needs of products with multiple varieties, small batches, and short production periods.
（二）The use of new aluminum equipment
The use of new equipment should focus on the following key aspects:
1、Selection and training of operators
Technical workers with strong sense of responsibility, corresponding cultural level and professional knowledge, and the ability to study technical business diligently should be selected for training and learning based on the technical performance and structural complexity of aluminum profile equipment. Nowadays, there is an increasing number of electronic computer control equipment, multifunctional and efficient equipment, and programmable automation equipment. These devices have advanced technology, complex structures, and high requirements for operation and use. It is difficult for operators to master and operate without a certain cultural and professional technical foundation. Improper use not only fails to achieve the expected efficiency of the equipment, but may even damage it. When selecting operators, it is necessary to go through:
?。?）Cultural knowledge and intellectual choices.
?。?）Professional knowledge learning and assessment.
（3）Training on operational skills.
Only by learning and training in the above three aspects, passing all assessments and obtaining certificates of qualification, can one become a qualified equipment operator.
2、Develop operating procedures and maintenance guidelines
According to the technical requirements, performance, structural characteristics, operation and use specifications, adjustment measures, etc. specified in the equipment manual, safety operation procedures should be organized and formulated. At the same time, the specifications for operation and use requirements should be proposed to operators, and learning should be organized to enable them to master and be familiar with the specific requirements and relevant regulations for operating and using equipment. In the operating procedures and maintenance details, the scope of use, requirements, methods, operation and maintenance requirements, as well as other precautions of the equipment should be specifically specified.
At the same time as drafting safety operating procedures, maintenance details should be formulated. The content of the equipment maintenance rules includes external maintenance and transmission systems, safety devices, lubrication systems, control systems, hydraulic systems, electrical control measuring instruments, and other maintenance regulations and specific requirements, and specifies the maintenance time.
3、Clarify job responsibilities
For equipment used by a single person, after clarifying the operator, their responsibilities must be clearly defined; When two or more people use or operate equipment produced in two or three shifts, the team leader should be responsible for the maintenance and upkeep of the equipment.
（三）The normal use process of the equipment
The management of equipment during use should be closely integrated with production management, process management, and operational technology management in order to effectively manage and utilize it. During use, it is required to:
1、Reasonably arrange production tasks based on equipment technical performance
Producers should arrange production tasks reasonably based on the performance, technical conditions, processing range, load capacity, and other factors of the equipment. Do not use equipment beyond its load or range; We cannot blindly pursue production while competing for equipment, and do not repair what needs to be repaired or occupy equipment maintenance time. To avoid the waste of equipment and energy caused by "big horses pulling small cars".
2、Strengthen process management
The integrity of equipment is a prerequisite for excellent process management and operation. However, the rationality of the process directly affects the status of the equipment. According to the data accumulated by some enterprises in practical work, due to the unreasonable process, the wear rate increases and the amount of wear increases with the increase of dynamic load, which shortens the repair cycle of equipment by two-thirds.
3、Proper and reasonable use of aluminum equipment
During the use of the equipment, workers should use the equipment correctly and reasonably according to the operating procedures specified in the relevant technical documents and materials, as well as the characteristics, technical requirements, and performance of the equipment. In order to ensure the correct and reasonable use of equipment, it is necessary to regularly organize operators to learn theoretical knowledge of operating techniques and conduct basic skill training; Regularly organize theoretical knowledge and practical operation assessments. Through this series of measures, they have achieved the "four strengths": being proficient in equipment performance, structure, and principles, being able to maintain and repair equipment, and being able to inspect and troubleshoot general faults; Proficient and accurate in operation, with good coordination of movements; Strong in quality - understanding the process flow, processing products that meet the specified quality requirements; Strong in the face of complex situations - possessing certain knowledge of safety and prevention, able to judge, prevent and handle accidents, and prevent accidents from expanding and causing greater losses.
During the use of the equipment, the operator must adhere to the "three good" principles (management, proper use, and maintenance) and the "five don'ts" (i.e. do not leave the work post with the machine, stop and cut off the power when necessary; do not violate the operating procedures, strictly follow the usage requirements and specifications, do not step on the equipment or kick the electrical switch or handle with your feet; do not use the equipment beyond the load or processing range, and if necessary, report it in advance and obtain the consent of relevant parties before use; do not operate with "disease", and if any hidden faults are found, stop and check in a timely manner until the cause is identified and hidden dangers are eliminated before continuing to use; do not place workpieces, materials, tools, measuring tools, etc. on the machine, and strictly prohibit knocking on the equipment. Guide rails and other parts are used to keep the equipment tidy, clean, and lubricated regularly Safe.
4、Strictly implement the system of fixed personnel and fixed machines
In the analysis of the causes of equipment accidents, 'unskilled operation' is often due to the operator's unfamiliarity with the performance, operational requirements, and technical specifications of the equipment. Therefore, when the operator needs to switch to other models or categories of equipment for work, they should first familiarize themselves with the performance, structure, principles, operating specifications, and usage requirements of the equipment being operated in the new position. Only after passing the examination can they operate it. In order to adapt to the needs of "one specialization and multiple abilities" and organizational production, when assigning personnel and machines, operators are allowed to apply to operate several different types and models of equipment at the same time, but they must pass all assessments before operating and using these equipment.
5、Equip equipment inspectors and maintenance workers engaged in inspecting and supervising the use of equipment
In order to timely inspect and supervise the correct and reasonable use of equipment and the implementation of relevant rules and regulations on equipment maintenance, enterprises should establish a full-time "equipment inspector" responsible for formulating equipment operating procedures and maintenance rules, inspecting and supervising operators to strictly operate and maintain equipment in accordance with the operating procedures and maintenance rules; Responsible for solving technical problems in equipment maintenance and troubleshooting; Responsible for the statistics, analysis, and accumulation of relevant data on equipment failures, and researching solutions for common and frequent failures; Responsible for the storage, transmission, and feedback of information during the device's usage period. Equipment inspectors should regularly patrol various departments using equipment, timely understand and inspect the use, maintenance and upkeep of equipment, discover potential accidents, promptly notify shutdowns, and be responsible for supervising until they are eliminated.
The main responsibility of equipment maintenance workers is to inspect and supervise the correct use and maintenance of equipment in their respective areas; Assist equipment inspectors in conducting assessments on equipment usage, maintenance techniques, and helping operators master machine performance, structure, and principles; Eliminate equipment malfunctions during use to ensure normal operation. Maintenance workers should frequently patrol various equipment, ensuring diligent inquiry, listening, observation, and inspection.
6、Create necessary working environment and working conditions
Equipment has certain requirements for the working environment and working conditions. For example, general equipment requires a clean working environment that is not corroded by corrosive or harmful substances. Necessary protective, anti-corrosion, moisture-proof, warm, and cooling devices should be installed, and instruments and meters with necessary measurement, control, and safety alarm devices should be equipped. If the working environment and conditions of the equipment do not meet the requirements, or are even very harsh, it not only affects product quality, damages the equipment, but also harms the health of employees, thereby affecting the emotions of operators.
7、Establish and perfect necessary rules and regulations
Developing a scientific management system and methods based on the different characteristics and technical requirements of the equipment, organizing learning, and ensuring implementation are the basic conditions for the rational use of the equipment. The rules and regulations mainly include:
?。?）Equipment operation and use responsibility system.
?。?）Equipment operating procedures and maintenance guidelines.
?。?）Equipment maintenance system.
?。?）The patrol inspection system for equipment maintenance and repair professionals.
?。?）Equipment handover system.
Guangdong Yuanchen Machinery Equipment Co., Ltd（ http://qxyny.cn ）We are a specialized company that integrates research and development, design, production, installation, and service of high-tech aluminum equipment, electrophoresis oxidation line equipment, fully automatic oxidation electrophoresis equipment, three-dimensional automatic warehouse, aluminum profile three-dimensional automatic warehouse, and Foshan aluminum profile equipment. Welcome to inquire by phone