Although maintenance and repair of equipment do not generate direct economic benefits, they play a non-negligible role in extending the service life of equipment and fully utilizing its potential. For example, our ZYH670A folding machine, which had reached the end of its service life and was originally scheduled for disposal, is still functioning normally after maintenance and repair. The measures taken are as follows:
(1) Disassemble all the folding rollers and process them to round them, so that they can meet the requirements when adjusting the gap.
(2) Inspect and adjust the gap of the folding roller's driving gear, and check the bearings for any damage.
(3) Inspect the keys and pins of the connecting parts for any looseness or damage, and replace damaged parts.
(4) After systematic maintenance of the entire machine, clean the oil and air circuits, and replace the lubricating oil, etc.
After repair, the service life of the equipment can be extended by 3 to 5 years. At that time, if the equipment was traded in for a new one, it would have cost about RMB 15,000, but our factory only spent more than RMB 2,000 to fully restore the precision and various functions of the machine.
Another example is our BBY40/5 disc binding machine, which was purchased in 1998 and used until 2002. The components were severely worn, and the quality of the bound books did not meet the requirements. Therefore, all loose keys and pins were reprocessed, worn copper sleeves were replaced, and loose gears were readjusted. From dismantling and processing parts to reinstalling and using them, the total cost was less than RMB 2,000, saving a significant amount of money.
Do a good job in training technical talents
In recent years, the binding process has gradually become mechanized and automated. According to the author's understanding, there are no specialized binding machinery majors in major colleges and universities across the country, and employees learn while working and accumulate experience. Therefore, while introducing binding equipment, it is necessary to attach importance to the cultivation of technical talents and strengthen technical training for on-the-job personnel. The training content can be divided into two aspects: one is the relevant technical theory required for technical maintenance; On the other hand, technical training should focus on the principle analysis of equipment control systems, specific device functions, and inspection and maintenance techniques. Additionally, special emphasis should be placed on on-site training for technical personnel during the actual installation and operation of the machinery. Ideally, equipment suppliers should provide two rounds of on-site training for the factory's technical and maintenance personnel, providing detailed explanations on how to maintain the equipment and potential issues that may arise.Emphasis on Experience Accumulation and Mutual ExchangeWhen a machine malfunctions and shuts down, maintenance personnel must quickly identify the location and type of the fault (electrical or mechanical), pinpoint the cause and source of the fault, and then replace the corresponding faulty components to resolve the issue. Therefore, maintenance personnel must understand the mechanical structure of each part of the equipment, the principles of electrical control, and the structure and working principles of control device modules. Through practical maintenance work experience, they must proficiently master the methods of judging and detecting various fault phenomena. At the same time, maintenance personnel should engage in more discussions and exchanges to improve their overall technical skills.Establish Equipment ArchivesFrom the moment a purchase contract is signed, equipment archives should be established, including the purchase contract, technical documents, machine manuals, acceptance forms, and related drawings. During equipment use, detailed records of any fault phenomena, causes, troubleshooting methods, and potential faults discovered during routine maintenance should be recorded in the equipment archives. This will provide a comprehensive understanding of the equipment's status, facilitating the determination of the fault occurrence cycle and type, and enabling early preparation of spare parts. A spare parts warehouse should also be established, managed by a dedicated person, and promptly replenished to ensure timely supply of repair spare parts.Establish Equipment Maintenance SystemA reasonable equipment maintenance system and a prevention-oriented equipment management system should also be established for the binding equipment, ensuring the equipment is in good operating condition.(1) Establish a four-level equipment management system, from the factory department to the equipment department, binding workshop, and machine team, to ensure the effective implementation of various systems and measures.(2) Develop a scheduled equipment maintenance plan.(3) Establish a three-level equipment maintenance system to make it operable.(4) Strengthen equipment maintenance knowledge and safety production education, so that operators can truly understand and achieve the "three good" and "four abilities" during specific maintenance.(5) Develop equipment safety operation procedures, daily cleaning and maintenance rules, lubrication management system, etc., ensuring cleaning and lubrication work is carried out with fixed points, fixed quality, fixed quantity, fixed time, and fixed personnel.
(6) Establish a scientific and reasonable equipment availability assessment method, and link it with rewards and punishments.
(7) Establish an on-site equipment management team to conduct regular inspections and evaluations of workshop equipment, and be responsible for implementing various equipment management systems.
