Who didn't pick up the kill call at 2:00 in the morning? The key equipment in the workshop was suddenly shut down, the alarms were panicking and the production manager was on the scene with his black eyelids, and a single word of it would be a big one: the entire line has been lost tens of thousands of dollars for an hour and must be turned around as soon as possible。
The more urgent this is, the easier it is to panic. Either the new man is in disarray and makes the glitch a big problem; or the old man is experienced and extends the range of failures。
In fact, emergency repairs of equipment are not carried out on site at all, and a standardized process, even for short-term technicians, can be completed in 30 minutes. Today, the practical processes to sum up the roll-over are shared, all of which are dry items that can be replicated directly, and it is suggested that the collection be expedited。
One, take it easy. Three minutes to do the right thing
As soon as they saw the equipment shut down, many of the maintenance staff wanted the tools to be dismantled, which was the most taboo operation. The more hasty the preceding period, the easier it is to develop security problems and secondary failures。
The core logic of emergency repairs has always been to keep security before finding problems and finally repair them. The first three minutes of preparatory work directly determine the efficiency and security of the entire operation。
The first high-frequency error zone is mentioned here: a number of people cut the power and went directly to the machine, completely forgetting that some of the equipment was equipped with electrical storage capacity, operated without charge, sustained electrical damage and burned the circuit boards directly. Remember to wait 5 to 10 minutes after the break and follow up。
The first step would be to make a security loop, press the stop, cut the total power supply, and put up a warning sign at the switch that the gate would be closed and kept under guard if necessary. The maintenance area is then surrounded by warning belts, which do not allow any unconnected personnel to enter the area, while the secondary risks of oil spills and loose parts are detected。
The failure was quickly identified, the on-duty operator asked for details, what was being done at the time of the launch, whether it was pre-heated, and then checked against the equipment to indicate the light, the instrument data, and fast-tracked the general direction of the failure, so as not to go blind。
Two, 25 minutes of precision recovery
The objective of the temporary rehabilitation is clear: the restoration of basic production, rather than a one-time overhaul, will be completed until the subsequent shutdown. Ninety per cent of the workshop's sudden breakdowns could not escape the mechanical, electrical, hydraulic gas, and follow the steps。
Mechanical malfunctions are most common, such as the weight of the track card, gear acoustics and bolts, with the core being the cleaning of the alien, the tight parts and the temporary lubrication. Watch locking first, blow off the alien, tighten the bolts, then target the lubricant, and then the last low speed test。
There is also a high rate of electrical failure, and the failure of alarms and sensors is a headache. When fuses are melted, do not replace it with copper wire, which appears to be temporarily usable, which would trigger short circuits that would directly burn the entire electrical module。
Electrical failure begins with the failure code, rapid locator back-tracking against the manual, softening of the connection, a broken sensor to replace the spares directly, a full-time empty test, and then a load operation。
Hydraulic gas-type malfunctions include oil spills, insufficient pressure, re-stabilization of entanglement belts when oil spills occur, refuelling and valves when pressure is not enough, cleaning of pipeline filters at a slow pace, and ensuring that oil models are not mixed and damage to equipment is avoided。
Three, do not go straight after the repairs! Two minutes to finish and no follow-up
The equipment was temporarily transferred and a number of masters packed their tools, followed by recurring malfunctions, production overloads and more trouble. The completion of these two minutes seems to be crucial。
The emergency maintenance desk accounts were filled in hand, the breakdown time, location, interim repair methods were clarified, emphasis was placed on “interim repairs” and follow-up was given to subsequent colleagues。
Clear contact with the production manager to clarify the operational restrictions of the equipment, such as the inability to overload, the processing of conventional specifications, and not to allow the production end to run hard, leading to a recurrence of malfunctions。
These failure cases will be sorted out at regular intervals to identify high frequency problem points, pre-position spare parts, strengthen looser components and turn after-action repairs into pre-mission prevention, which will reduce the number of sudden breakdowns。
Iv. The old equipmenter's thought: this list is still a lot of time night
Dry equipment maintenance is never about who is bold, who is fast to break, who is prepared in advance and the process is steady. Instead of panic, the emergency response process should be streamlined in advance and commonly used spare parts prepared。
I organized the entire process into a directly editable word list template, which, with modifications, became the workshop-specific emergency manual, followed the process by failure, repaired it in 30 minutes and minimized the loss of capacity。
Ladies and gentlemen, what kind of troubles have you encountered in general? Any quick fixes at the bottom of the box? Welcome to the comment section
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