In recent years, with the continuous reform and development of the printing industry, the binding process of post-press processing has gradually formed a mechanized, linked, and automated operation process from a backward manual operation process, and the equipment has been continuously updated. However, due to inadequate equipment maintenance and repair techniques and inadequate management, the machine cannot operate normally, and delays in the delivery period of books and periodicals or affecting the quality of books and periodicals occur from time to time. Here I will talk about my personal views on how to perform binding equipment maintenance and repair management.
Economic significance of maintenance management of binding equipment
Although the maintenance and repair of the equipment does not produce direct economic benefits, it has a function that can not be ignored to extend the service life of the equipment and fully realize the potential of the equipment. For example, the ZYH670A folding machine of our factory has reached the end of its scrap period, but it can still be used normally through maintenance and repair. The measures are as follows:
(1) Dismantle all the folding rollers for processing and grinding to make them meet the requirements when adjusting the gap.
(2) Check and adjust the gear gap of the folding roller to check whether the bearing is damaged.
(3) Check the keys and pins of each connecting part for looseness and damage, and replace damaged parts.
(4) After repairing the system of the whole machine, clean the oil circuit and gas circuit, and replace the lubricating oil.
After repair, the life of the equipment can be extended by 3 to 5 years. At that time, it took about RMB 15,000 to replace the equipment with old ones, and the factory only restored more than 2,000 yuan to restore the accuracy and functions of the machine.
Another example is the BBY40 / 5 disc pack machine purchased by our factory in 1998. By 2002, all parts were seriously worn, and the package book could not meet the quality requirements. So all the loose keys and pins are reworked, the worn copper sleeves are replaced, and the loose gears are readjusted. From disassembly and processing of parts to re-installation and use, the total cost is less than 2,000 yuan, saving a lot of money.
Do technical personnel training
In recent years, the binding process has gradually been mechanized and automated. According to the author's understanding, the major schools and colleges across the country have not set up a specialty for binding machinery, and employees are learning while working and accumulating experience. Therefore, when introducing binding equipment, we must pay attention to the training of technical personnel and strengthen the technical training of on-the-job personnel. The training content can be divided into two aspects: on the one hand, related technical theories required for technical maintenance; on the other hand, technical training for the principle analysis of equipment control systems, specific device functions, and inspection and maintenance. In addition, special attention should also be paid to the on-site training of technicians on the actual installation and operation of the machine. It is best to require the equipment supplier to conduct two on-site trainings for the technical and maintenance personnel of the factory to do how to maintain the equipment and prone problems Explain in detail.
Value experience and exchange
When the machine breaks down, the maintenance personnel must determine the location and type of the failure (electrical failure or mechanical failure) in the shortest possible time, find the cause and source of the failure, and then replace the corresponding failed component to eliminate malfunction. Therefore, maintenance personnel must understand the mechanical structure, electrical control principles, control device module structure and working principle of each part of the equipment, and master the judgment and detection methods of various fault phenomena through actual maintenance work experience. At the same time, maintenance personnel should discuss and communicate more to improve their overall technical level.
Create device file
From the signing of the purchase contract, the equipment must start to establish the equipment file, and the purchase contract, technical data, machine instruction manual, acceptance slip and related drawings will be included in the file. And at any time during the use of the equipment, the fault phenomena, causes, troubleshooting methods and hidden troubles discovered during the maintenance process are all recorded in the equipment file in detail, so that the status of the equipment will be more comprehensive The understanding of it is helpful to determine the period and type of failure, and prepare spare parts as early as possible. A spare parts library should also be established, managed by a dedicated person, and supplemented in time to ensure that spare parts for repairs can be supplied in a timely manner.
Establish equipment maintenance system
The binding equipment should also establish a reasonable equipment maintenance system and a prevention-oriented equipment management system to keep the equipment in good operating condition.
(1) Establish equipment management system. Establish the factory department → equipment section → binding workshop → machine team and four-level management system to ensure the effective implementation of various systems and measures.
(2) Formulate equipment plan maintenance system.
(3) Develop a three-level maintenance system for equipment to make it operable.
(4) Strengthen equipment maintenance knowledge and safety production education to enable operators to truly understand and achieve "three good" and "four meetings" during specific maintenance.
(5) Formulate equipment safety operation rules, daily cleaning and maintenance rules, lubrication management system, etc., so that the cleaning and lubrication work can be fixed, fixed, quantitative, regular and fixed.
(6) Establish scientific and reasonable assessment methods of equipment intact rate and link them to rewards and punishments.
(7) Set up an on-site equipment management team to realize regular inspection and comparison of workshop equipment, and be responsible for the implementation of various equipment management systems.
Economic significance of maintenance management of binding equipment
Although the maintenance and repair of the equipment does not produce direct economic benefits, it has a function that can not be ignored to extend the service life of the equipment and fully realize the potential of the equipment. For example, the ZYH670A folding machine of our factory has reached the end of its scrap period, but it can still be used normally through maintenance and repair. The measures are as follows:
(1) Dismantle all the folding rollers for processing and grinding to make them meet the requirements when adjusting the gap.
(2) Check and adjust the gear gap of the folding roller to check whether the bearing is damaged.
(3) Check the keys and pins of each connecting part for looseness and damage, and replace damaged parts.
(4) After repairing the system of the whole machine, clean the oil circuit and gas circuit, and replace the lubricating oil.
After repair, the life of the equipment can be extended by 3 to 5 years. At that time, it took about RMB 15,000 to replace the equipment with old ones, and the factory only restored more than 2,000 yuan to restore the accuracy and functions of the machine.
Another example is the BBY40 / 5 disc pack machine purchased by our factory in 1998. By 2002, all parts were seriously worn, and the package book could not meet the quality requirements. So all the loose keys and pins are reworked, the worn copper sleeves are replaced, and the loose gears are readjusted. From disassembly and processing of parts to re-installation and use, the total cost is less than 2,000 yuan, saving a lot of money.
Do technical personnel training
In recent years, the binding process has gradually been mechanized and automated. According to the author's understanding, the major schools and colleges across the country have not set up a specialty for binding machinery, and employees are learning while working and accumulating experience. Therefore, when introducing binding equipment, we must pay attention to the training of technical personnel and strengthen the technical training of on-the-job personnel. The training content can be divided into two aspects: on the one hand, related technical theories required for technical maintenance; on the other hand, technical training for the principle analysis of equipment control systems, specific device functions, and inspection and maintenance. In addition, special attention should also be paid to the on-site training of technicians on the actual installation and operation of the machine. It is best to require the equipment supplier to conduct two on-site trainings for the technical and maintenance personnel of the factory to do how to maintain the equipment and prone problems Explain in detail.
Value experience and exchange
When the machine breaks down, the maintenance personnel must determine the location and type of the failure (electrical failure or mechanical failure) in the shortest possible time, find the cause and source of the failure, and then replace the corresponding failed component to eliminate malfunction. Therefore, maintenance personnel must understand the mechanical structure, electrical control principles, control device module structure and working principle of each part of the equipment, and master the judgment and detection methods of various fault phenomena through actual maintenance work experience. At the same time, maintenance personnel should discuss and communicate more to improve their overall technical level.
Create device file
From the signing of the purchase contract, the equipment must start to establish the equipment file, and the purchase contract, technical data, machine instruction manual, acceptance slip and related drawings will be included in the file. And at any time during the use of the equipment, the fault phenomena, causes, troubleshooting methods and hidden troubles discovered during the maintenance process are all recorded in the equipment file in detail, so that the status of the equipment will be more comprehensive The understanding of it is helpful to determine the period and type of failure, and prepare spare parts as early as possible. A spare parts library should also be established, managed by a dedicated person, and supplemented in time to ensure that spare parts for repairs can be supplied in a timely manner.
Establish equipment maintenance system
The binding equipment should also establish a reasonable equipment maintenance system and a prevention-oriented equipment management system to keep the equipment in good operating condition.
(1) Establish equipment management system. Establish the factory department → equipment section → binding workshop → machine team and four-level management system to ensure the effective implementation of various systems and measures.
(2) Formulate equipment plan maintenance system.
(3) Develop a three-level maintenance system for equipment to make it operable.
(4) Strengthen equipment maintenance knowledge and safety production education to enable operators to truly understand and achieve "three good" and "four meetings" during specific maintenance.
(5) Formulate equipment safety operation rules, daily cleaning and maintenance rules, lubrication management system, etc., so that the cleaning and lubrication work can be fixed, fixed, quantitative, regular and fixed.
(6) Establish scientific and reasonable assessment methods of equipment intact rate and link them to rewards and punishments.
(7) Set up an on-site equipment management team to realize regular inspection and comparison of workshop equipment, and be responsible for the implementation of various equipment management systems.
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