Equipment management system for food production enterprises

Machinery and equipment are important material and technical foundations for enterprises to carry out production, one of the three major elements of enterprise productivity, and an important indicator of enterprise production scale and technical level. The integrity of equipment will affect the quantity and quality of processed products, the consumption of raw materials and power energy, the safety of production, and thus the cost of products. Therefore, in order to do a good job in equipment management, improve the integrity and utilization rate of equipment, reduce product costs, and improve economic benefits, this system is formulated.

1.0 Purpose and Scope

To make provisions for the purchase, installation, commissioning, acceptance, maintenance, repair, scrapping, and technical data management of equipment throughout the company

2.0 Terminology

2.1 Fixed assets: All electromechanical equipment that can independently complete more than one production requirement, with an original purchase value (including equipment value, freight, installation fees, etc.) of more than 2,000 yuan, are listed as fixed assets

2.2 Equipment use costs: refers to the sum of equipment depreciation costs, spare parts costs consumed in operation, and maintenance and planned maintenance labor costs.

2.3 New equipment (including updated equipment): Equipment purchased to improve product performance, product quality and expand production capacity.

2.4 Equipment improvement: Technical measures to change the technical status of equipment to extend the service life of equipment, improve the degree of automation, change weak links, improve operating conditions, and promote the serialization of maintenance spare parts.

2.5 Equipment modification: Technical measures to change the technical status of equipment to meet production process requirements, expand the scope of process use, and improve product quality and processing accuracy.

2.6 Daily maintenance (also called routine maintenance): The main content is to clean and lubricate the equipment before and after the shift, tighten the loosened screws, and check the integrity of parts; carefully observe the operation of the equipment during the shift, eliminate minor faults in time, and improve operating conditions.

2.7 First-level maintenance: According to the use of the equipment, disassemble and clean some parts; make appropriate adjustments to certain matching clearances of the equipment; remove rust and oil on the surface of the equipment, dredge the oil circuit, and prevent leakage; clean electrical devices, clean accessories and cooling devices, and tighten safety protection devices.

2.8 Secondary maintenance: According to the use of the equipment, the equipment is partially disassembled to check and clean the transmission, lubrication, and cooling systems, and the transmission, lubrication, and cooling systems are cleaned and oiled; the electrical system is inspected and repaired; the accuracy and level of the equipment are inspected and repaired.

2.9 Small equipment maintenance: It is a partial repair of the equipment with a small workload. The equipment is not completely disassembled, only the parts of the equipment that wear faster are repaired or replaced, and the equipment operating mechanism is adjusted to ensure the normal operation of the equipment and meet the process requirements.

2.10 Medium-sized equipment maintenance: It is a planned repair with a large workload. Not only the main parts and more wear parts of the equipment need to be repaired or replaced, but also the entire mechanical system needs to be checked, all parts need to be tightened, various expanded matching clearances need to be eliminated, oil needs to be changed, and the equipment base needs to be corrected to ensure that the equipment can be restored and meet the required standards and technical requirements.

2.11 Large-scale equipment maintenance: It is a planned repair with the largest workload. Including dismantling all equipment, inspecting and repairing or replacing all worn parts, calibrating and adjusting the entire equipment to fully restore the original accuracy, performance and production efficiency of the equipment, equipping with safety devices and necessary accessories, and repainting the equipment surface.

3.0 Management Responsibilities

3.1 The company's equipment director is responsible for unified management of the company's equipment.

3.2 All major and key equipment of the company should be classified, numbered and established as ledgers and archives by the equipment director. The original equipment technical data shall be archived and kept by the Enterprise Management Department. In principle, the equipment user unit shall use photocopies.

3.3 The equipment user unit is responsible for establishing the ledgers and archives of all equipment of the unit and reporting them to the Enterprise Management Department for filing. Use, manage and maintain the equipment well. Cooperate with the financial department to do a good job in the statistics of equipment maintenance and other usage costs.

3.4 The financial department sets up a usage account and works with the user department to do a good job in the statistics of equipment dismantling, maintenance, and repair costs, so as to conduct economic evaluation of the equipment when necessary.

4.0 Workflow

4.1 Purchase, installation, commissioning, acceptance, decommissioning, relocation, transfer and scrapping of equipment

4.1.1 Purchase of equipment

• A. When the company has to carry out annual renovation and transformation plan projects, the equipment director shall organize relevant departments to select the equipment to be purchased, fill in the corresponding "Equipment Purchase Application", submit it to the Enterprise Management Department for review and then submit it to the General Manager for approval.

• B. When the company needs to update the equipment according to the process requirements, the company's equipment director is responsible for filling in the "Equipment Purchase Application", and the Enterprise Management Department shall review it and submit it to the General Manager for approval.

• C. The Logistics Department shall purchase according to the approved "Equipment Purchase Application". After the purchase is completed, the "Equipment Purchase Application" shall be returned to the Enterprise Management Department for filing and storage.

• D. After the new equipment is in place, the equipment department shall promptly check and accept it. If it is inconvenient to unpack and accept it, the packing list shall be recorded and the equipment department and logistics department shall be notified.

4.1.2 Installation, commissioning and acceptance of equipment

• A. When the contract stipulates that the equipment supplier shall send personnel to install, the equipment department shall send personnel to assist, and the supplier or its representative shall preside over the unpacking. When unpacking, all spare parts will be checked by the company's warehouse department, and technical data will be registered for retrieval and archiving.

• B. When the contract stipulates that the company shall install the equipment by itself, the equipment installation shall be organized by the equipment department personnel of the company.

• C. After the new equipment is installed, it will be tested by the user department. After the test run is completed, the company organizes acceptance and signs the opinion.

• D. After the equipment is accepted, the company will issue a triplicate "Equipment Commissioning and Transfer Form". The user workshop uses the new equipment with the transfer form. The financial department depreciates and commissions with the transfer form. The other copy is archived and kept with other relevant technical data, and the user department establishes an equipment ledger.

4.1.3 Deactivation and activation of equipment

A. When the equipment will be idle for a certain period of time due to insufficient production tasks or other reasons, the equipment user department shall apply, the general manager shall sign the opinion, report to the chairman for approval, and fill in the "Equipment Deactivation Form", one copy is transferred to the user department, and one copy is transferred to the financial department. The equipment director is responsible for keeping the equipment deactivation record and filing it with the corporate management department. B. The user department deactivates the equipment with the form. During the deactivation period, people should be sent to regularly perform equipment maintenance work. The general manager shall be responsible for or send someone to supervise and inspect the maintenance work. C. When the user department requests to activate the equipment that has been stopped and sealed, it should first submit an application, the general manager shall make an opinion, and after the chairman's approval, an "Equipment Activation Form" shall be issued, one copy shall be transferred to the financial department to restore the equipment depreciation, one copy shall be transferred to the equipment user department to notify the activation, and one copy shall be filed with the business management department.

4.1.4 Equipment relocation and transfer

A. The equipment user department needs to do internal relocation of certain equipment, which shall be approved by the general manager.

B. When equipment is transferred between companies, the transferee shall submit an application, and after consultation with the transferee, it shall be submitted to the business management department for approval.

C. After the business management department verifies the situation, it shall fill in the "Equipment Transfer Form, one copy shall be transferred to the transfer-out company, and one copy shall be filed. The equipment transfer-out company shall transfer the ledger of the equipment to the transfer-in company.

4.1.5 Equipment scrapping

A. If the production equipment meets one of the following conditions, it can be scrapped according to the regulations:

• ① The service life has exceeded, the main structure and components are seriously worn, the accuracy and efficiency are reduced and cannot meet the minimum process requirements, and it cannot be improved or modified.

• ② The equipment is seriously damaged due to force majeure and cannot be repaired and cannot be used further.

• ③ The corrosion and wear are too severe, there is no value in repair or continued use is prone to danger.

• ④ The technology is backward, the performance is poor, and there is no value in improvement.

B. For equipment that meets the scrapping conditions, the user unit shall apply for it, and after the general manager and chairman of the company sign their opinions, it shall be submitted to the Enterprise Management Department for approval. After agreeing to scrap, the equipment director shall fill out the "Equipment Scrapping Form" in triplicate, one copy shall be transferred to the using department, one copy shall be transferred to the financial department, and one copy shall be filed with the Enterprise Management Department. Each department shall cancel the scrapped equipment in the fixed asset account or equipment ledger

C. After the equipment is approved for scrapping, it shall be handled by the affiliated company. The usable parts shall be recycled, and the other parts shall be treated as scrap by the warehouse department. The scrapping of equipment shall be reported to the Enterprise Management Department for record

4.2 Equipment use, maintenance, care and repair

4.2.1 Equipment use

4.2.1.1 Before new equipment is put into use, the using department shall formulate equipment operating procedures according to the equipment manual and production process, and report to the general manager for approval.

4.2.1.2 The equipment director shall organize personnel to formulate corresponding equipment maintenance procedures according to the equipment maintenance manual and production conditions

4.2.1.3 In addition to one copy of the equipment operating procedures and maintenance procedures, they shall be sent to the corresponding positions of the equipment using department.

4.2.1.4 Equipment operating procedures shall include but not be limited to the following contents:

• ① Equipment technical performance and allowable limits, such as maximum speed, load, pressure, temperature, voltage, current, etc.

• ② Equipment handover regulations. Handover shall be carried out in response to abnormal equipment operation, changes in original defects, changes in operating parameters, failures and handling of equipment operation conditions

• ③ Emergency handling regulations

• ④ Safety precautions, including that non-operators of the machine are not allowed to operate the machine without permission, and no one is allowed to remove or relax the safety protection devices at will, etc.

4.2.1.5 Maintenance procedures should include but not be limited to the following:

• ① Relevant parts, requirements or charts for daily and routine maintenance of equipment,

• ② Regulations and parts for regular cleaning of equipment.

• ③ Various inspection requirements during the use of equipment, including routes, parts, contents, standard condition parameters, and cycles (time). The cycle is generally divided into days, months, seasons, years, etc.

• ④) Troubleshooting methods for common faults during operation.

• ⑤ Safety precautions during maintenance,

4.2.1.6 When preparing to adopt new processes and technologies, the user unit should modify the original procedures according to the new use and maintenance requirements of the equipment. If it has been used for many years and the content has been modified more, it should be revised.

4.2.1.7 Before the new equipment is put into use, the user department should organize the equipment operators to study the procedures carefully, and they can only operate the equipment after passing the examination and actual operation assessment.

4.2.1.8 When using the equipment, the operator must operate the equipment strictly in accordance with the operating procedures. When it is found that the content of the regulations is incomplete, it should be reported in time. The user department shall modify the regulations after verifying the situation and report it to the company for approval and filing.

4.2.1.9 When the equipment has defects and cannot be repaired immediately, the user department shall formulate reliable temporary regulations and implement them after approval by the general manager. After the equipment defects are repaired, the temporary regulations shall be invalidated.

4.2.1.10 The general manager shall be responsible for or send personnel to supervise and inspect the use of the equipment, and has the right to stop any operation that violates the operating procedures.

4.2.2 Maintenance, care and repair of equipment

4.2.2.1 The maintenance, care and repair of equipment shall follow the principle of "prevention first, maintenance and repair equally", and adopt the form of "two maintenance and three repairs", namely routine maintenance, first-level maintenance, minor repairs, medium repairs, major repairs, etc., and take preventive maintenance for key equipment and key parts of general equipment; for non-critical equipment and sudden failures, take post-event repairs.

4.2.2.2 Equipment operators should perform routine maintenance according to the corresponding maintenance procedures when changing shifts every day. The equipment manager is responsible for or sends personnel to supervise and inspect.

4.2.2.3 The equipment user department shall formulate a maintenance plan based on the production situation and equipment operation situation every month, report it to the general manager for approval, and arrange personnel to perform first-level maintenance on key equipment and key parts of general equipment. For equipment with frequent failures, the user department shall formulate a plan and arrange professional personnel or personnel from the user department to perform maintenance. Records should be made after maintenance is completed.

4.2.2.4 For major, medium and minor repairs of equipment and facilities, the general manager is responsible for organizing professional personnel and equipment user departments to formulate repair plans based on production conditions, technical conditions and operation conditions of equipment, and professional personnel shall perform repairs or professional personnel

and corresponding operators of the user department shall perform repairs together. If the company's technical strength is insufficient to carry out this repair work, the general manager is responsible for contacting the maintenance force. Keep records after the maintenance plan is completed.

4.2.2.5 For general equipment failures or sudden failures of key and important equipment, the user department shall report to the company to send people for repair or qualified personnel of the user department shall perform repairs by themselves.

4.2.2.6 During maintenance, if production is busy and the machine cannot be shut down for a long time, if there are spare parts of the same model as the faulty parts, they can be replaced first to resume production as soon as possible. The replaced parts should be repaired as soon as possible, marked and returned to the using department or warehouse.

If they cannot be repaired, keep records so that they can be included in the spare parts purchase plan.

4.2.2.7 When production is tight, the faulty parts cannot be repaired, and there are no spare parts, the using department can apply for replacement with the same model of equipment that is out of service, and the executive personnel should keep records and marks. The using department should submit a purchase plan as soon as possible. After the new parts are in place, the original executor will install them back to the original place in accordance with the principle of who disassembles and installs.

4.3 Dynamic management of equipment operation and equipment improvement and modification

4.3.1 Dynamic management of equipment operation

4.3.1.1 Equipment users and operators are responsible for daily maintenance and primary maintenance of the equipment used in this position according to the maintenance procedures. When it is found that the equipment cannot continue to operate normally, it should be reported to the person in charge on duty in a timely manner. He will contact the electromechanical maintenance personnel for repair. For general hidden dangers or defects that do not affect operation, records should be made after the maintenance is completed, so as to prepare for targeted solutions during the next maintenance.

4.3.1.2 The user department shall summarize the hidden dangers or defects that cannot be solved immediately every month, keep one copy for itself, and report one copy to the company, so that it can be included in the maintenance plan and further repairs can be made.

4.3.1.3 The user department shall summarize the operation time and integrity of the equipment or production line every month and report to the company.

4.3.2 Equipment Improvement

4.3.2.1 When the equipment has the following weak links, a project can be considered for improvement:

A. Parts where equipment often fails during operation and stops, and repeated repairs are ineffective,

B. Equipment or parts that often affect product quality and output during production line operation.

C. Equipment or parts that have safety hazards and may endanger personal or equipment safety, and cannot be solved by daily maintenance and repair.

4.3.2.2 The equipment improvement work shall be proposed by the user department based on the operating status data, and the relevant personnel of the company shall review and propose feasible improvement plans, which shall be included in the maintenance plan after approval.

4.3.2.3 Equipment improvement work shall be carried out by professionals or maintenance personnel of the user department. The user department shall assign the operator of the machine to assist. After the improvement work is completed, the user department shall inspect the operating effect, make evaluation opinions, and store them in the equipment file after approval by the general manager.

4.3.3 Equipment modification

4.3.3.1 When the equipment can no longer meet the process requirements, or in order to improve the product processing accuracy, the user department shall submit an application for equipment modification, fill in the "Equipment Modification Report Form", and the process technology department shall sign and submit it to the general manager for approval.

4.3.3.2 The equipment modification application should indicate the current technical conditions of the equipment, the technical conditions expected to be achieved after modification, the parts to be modified, the modification principle, the planned parts and components. Electrical components and cost budget, etc.

4.3.3.3 After the modification application is approved, the user department shall formulate the required material plan, which shall be reviewed by the company's person in charge and submitted to the enterprise management department for approval before arranging for purchase.

4.3.3.4 After the modification conditions are ripe, the general manager shall be responsible for organizing professionals or maintenance personnel of the user department to carry out the modification, and the modification application department shall assign the machine operator to assist.

4.3.3.5 After the equipment modification is completed, the company shall organize relevant professionals and relevant personnel of the user department to conduct acceptance, handle the handover and activation procedures, and the equipment can be put into trial operation. During the trial operation, the user department shall report the relevant situation to the company in a timely manner. The trial operation shall be based on six shifts. 4.3.3.6 After the trial run, the company will organize the confirmation of the operation effect, appraisal opinions, modify the corresponding technical drawings, and store them in the equipment files.

4.4 Handling of equipment accidents

4.4.1 Definition of equipment accidents: Equipment accidents are those that are damaged by abnormal wear (or reasons), resulting in suspension of production, reduced efficiency or loss of function.

4.4.2 Classification of the severity of accidents

• A. Major equipment accidents: losses and repair costs of more than 50,000 yuan

• B. Major equipment accidents: losses and repair costs between 50,000 and 50,000 yuan,

• General equipment accidents: damage and repair costs of less than 10,000 yuan.

4.4.3 Distinction of the nature of accidents

• A. Equipment damage, suspension of production, reduced efficiency or loss of some functions due to human factors, such as violation of operating procedures, improper maintenance, etc., are liability accidents.

• B. Equipment damage, suspension of production and reduced efficiency due to poor manufacturing of equipment and facilities or improper maintenance and installation are quality accidents.

• C. Equipment damage, suspension of production, reduced efficiency or loss of function due to force majeure are natural accidents.

4.4.4 After an equipment accident occurs, the operator should immediately report to the head of the department and keep the scene. The report should specify in detail: time, location, team, equipment name, number, damaged part, degree of damage, and reporter.

4.4.5 The company and the equipment user department are responsible for handling general equipment accidents, analyzing the causes, formulating preventive measures, and keeping records and storing them in the equipment files.

4.4.6 For major equipment accidents, the head of the accident department and maintenance personnel, and if necessary, the supervisor and other heads of the user departments will also participate in the investigation and analysis of the accident to find out the cause of the accident, clarify the responsibility, formulate preventive and corrective measures, make final handling opinions, report to the Enterprise Management Department for approval, and fill in the "Equipment Accident Handling Report" and store it in the equipment file.

4.4.7 Principles of accident handling

• A. Restore the original technical conditions of the equipment as soon as possible, resume production, and minimize losses.

• B. Analyze the causes, clarify the responsibilities, and deal with them seriously to achieve the purpose of educating the responsible persons and other employees.

4.5 Purchase, use and storage of equipment spare parts

4.5.1 The reserve quantity of equipment spare parts is estimated by the affiliated company according to the statistical data of spare parts consumption according to the empirical statistical method. The reserve quantity should be able to ensure that there will be no interruption and production will not be affected during the ordering cycle.

4.5.2 Equipment spare parts that can be processed in the factory are made in the factory, and the rest are purchased from outside. Under the same functional conditions, those that can be processed domestically should be processed domestically first to reduce the cost of spare parts and maintenance costs.

4.5.3 The user department shall formulate a spare parts purchase plan according to the warehouse's notification or maintenance plan needs, report to the company's person in charge for review, and purchase after approval by the corporate management department

4.5.4 After the purchased spare parts are in place, the warehouse shall notify the user department to inspect and accept them, and qualified products shall go through the warehousing procedures. Unqualified products shall be issued with corresponding written explanations and handed over to the warehouse department for processing; insufficient quantities shall be supplemented, and those that cannot be used due to incorrect models or poor materials shall be required to be replaced by suppliers.

4.5.5 All spare parts are uniformly classified and managed by the user unit. In principle, spare parts of various departments shall not be used interchangeably, but shall be used according to the planned purpose. In special circumstances, when it is necessary to use spare parts of the same model and interchangeable with other departments, it shall be approved by the company's supervisor, otherwise the warehouse shall not issue them.

4.5.6 When the warehouse settles the monthly settlement of spare parts used in various departments, it shall check with various departments and finance, make cost statistics, and the cost of spare parts shall be included in the equipment use cost of the user department.

4.6 Management of equipment use cost

4.6.1 The finance department shall set up equipment use cost accounts according to different user departments, and make sub-item statistics on the depreciation, spare parts, lubricants, maintenance labor costs, and modification and improvement costs of equipment (or production lines), so as to accumulate data for the economic evaluation of equipment.

4.6.2 Each user department and warehouse shall check with the financial accounting personnel the spare parts, lubricants, maintenance labor costs, etc. consumed by each user department every month, make sub-item summaries, and report to the finance department. The finance department lists the equipment usage fees of each using department quarterly or annually.

4.6.3 Maintenance labor costs refer to the costs incurred for primary maintenance, planned overhaul, and troubleshooting of each production equipment (or production line) and auxiliary equipment in principle. When each department conducts primary maintenance and planned overhaul, its costs should be reviewed and approved by the affiliated company. The costs incurred for troubleshooting are the costs incurred by each using department for repairs by using electromechanical maintenance personnel.

4.7 Management of equipment technical data and archives

4.7.1 Collection channels for equipment technical data: First, the equipment data of all production equipment and auxiliary equipment of the company; second, the reference books and public books that need to be added for easy maintenance; and third, the relevant data sent by external Manufacturers.

4.7.2 The establishment of equipment archives is mainly based on key equipment and important equipment, and separate archives are established. The archive content includes but is not limited to equipment factory quality inspection form, equipment accessory list, equipment installation and commissioning, acceptance records, equipment transfer records to the using department, equipment maintenance plan, equipment repair records, equipment modification and improvement, transfer and migration records, equipment accident records, equipment scrapping records, etc.

4.7.3 When new equipment is unpacked and installed, the archive management personnel should be present to register the random data. For those needed for installation, the using department shall go through the borrowing procedures for retention. After the equipment is installed, all of them will be handed over to the General Office. The staff will number, file, and establish ledgers according to the equipment number.

4.7.4 The relevant records generated during the operation of the equipment will be summarized monthly by the using department and sent to the General Office for safekeeping.

4.7.5 For the reference books and books that need to be purchased for the convenience of maintenance work, the user shall apply for approval from the company's supervisor and purchase after approval by the Enterprise Management Department. After the reference books or books are purchased, they shall be uniformly numbered and stamped by the General Office to distinguish them from private books for easy management.

4.7.6 All equipment data, reference books and public books shall be classified and catalogued, and a book title catalog and borrowing card shall be established. All employees of the company can borrow materials and books with their identification cards. In principle, reference books are not loaned out and are only for reference. Orphan copies and originals are strictly controlled, and photocopies should be used when necessary.

4.7.7 The loan period for equipment and materials is two months, and for public books it is half a month. If it cannot be returned on time due to work needs, you should bring the books to go through the renewal procedures, and the renewal period shall not exceed one month.

4.7.8 All borrowers of books and materials should keep them carefully to prevent the loss, damage, and stain of books and materials. Return them on time, especially the orphan materials or books, to improve the utilization rate. When employees leave, they must go through the procedures for returning books and materials, otherwise they will be punished according to relevant regulations.

4.7.9 When equipment is scrapped, its materials and files, except for those with reference value, should be destroyed. When destroying, the General Office will list the destruction list, and the company leaders will destroy it after approval and keep records. The destruction personnel should sign to confirm the destruction.

4.7.10 When the equipment and file managers are transferred to other jobs, they should go through the handover procedures