independent preservation is independent inspection. The first to fourth steps are mainly to restore the deterioration of the equipment, but it is still necessary to maintain improvements thereafter to further improve the reliability, maintainability, and quality of the equipment, and to check the cleaning standards, oiling standards, inspection standards, and We will sort out the efficiency of inspections and the negligence of inspections to achieve independent maintenance standards.
1． Inspection of cleaning standards and inspection standards
Operators need to check the cleaning standards and inspection standards from the following four perspectives.
(1) Inspection from the perspective of zero failures and zero defects
investigates past efforts to prevent recurrence of failures, defective products, and inspection errors, and checks whether there are any items that should be inspected in the independent maintenance standards.
(2) Inspection from the perspective of inspection efficiency
Is there any duplication of work when implementing cleaning standards, oiling standards, and general inspection standards? Consider whether inspections can be done during cleaning and refueling, whether operations can be combined with inspection items, and whether inspection items can be reduced.
(3) Check from the perspective of whether the inspection workload is balanced.
Inspection work is often concentrated at the start of work every Monday. Therefore, it is necessary to check whether the inspection cycle, inspection time, inspection route, etc., are balanced.
(4) Inspection from the perspective of visual management of and
① Can the location of the inspection items be immediately known?
② Is the inspection easy to perform?
③ Can abnormalities be detected immediately? The specific methods of visual management of
are shown in the table.
Specific practices of visual management
2. Key points for promoting self-inspection
One of the purposes of self-inspection is to improve the standards for self-inspection so that maintenance activities can be effectively implemented within the target time.
(1) The maintenance and operation standards of each equipment must be met.
The maintenance and repair department must complete various standards (standards for inspection, installation, disassembly and maintenance) before the end of the fourth step of independent maintenance, especially the formulation of inspection standards. The fifth step is to summarize and revise the maintenance and operation standards and clarify their respective responsibilities. The two together form a very complete inspection item.
(2) Operation and maintenance personnel agree on the inspection cycle
Daily inspections should go deep into the minimum items that directly affect safety and quality due to deterioration. Moreover, daily inspections should be considered as the minimum inspection items to prevent safety and quality problems, as part of the work, and ideally within the range that can be felt by the body.
The relationship between comprehensive inspection subjects and daily and regular inspection items is as shown in the figure.
The relationship between comprehensive inspection subjects and daily and regular inspection items
(3) Determining the time required for inspection
The time required for inspection depends on the inspection items, inspection cycle, inspection equipment and the specific conditions of the workshop, and also depends on the operator The work content, the number of units under management, and the method of shutdown inspection or inspection while running.
When determining this benchmark, the checklist should be compared with the actual inspection work, and then a feasible timetable should be determined. In actual operation, it may be time-consuming at first, but the inspection time will be shortened after a period of time when the autonomous maintenance equipment is used.
(4) Master the comprehensive knowledge of the equipment
In the fourth step, organize each department to learn the comprehensive knowledge of the equipment separately. Operators should have a full understanding of the functions, structural combinations and working principles of each part of their own equipment and the inherent parts of the equipment, and it is very important to clean, refuel, inspect and operate correctly. These practical operations are very important.
(5) Clarify the relationship between equipment and quality
To keep the equipment in good condition and achieve no faults in the workshop, it is necessary to clarify the 4M conditions for product quality, namely people (Man), equipment and tools (Machine), materials ( Material), method (Method), it is important to clarify the relationship between these accuracy and quality characteristics and include it in the inspection benchmark.
(6) Analysis of faults and defective products
After writing the above-mentioned benchmark book, it is also necessary to prepare an independent maintenance checklist, because faults and defective products often occur even if daily inspections are performed.At this time, you should consider the cause of the failure, whether there is any improvement in your work, and write the reflection content into the benchmark book. An example of the
autonomous preservation benchmark is shown in the table.
Autonomous maintenance (inspection, cleaning, refueling) benchmark
Autonomous maintenance inspection form
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