Equipment Inspection and Maintenance Integrated Management System (1)
Original: https://cli.im/article/detail/1935
Background
Based on the new development stage, implementing new development concepts, and achieving new development goals. The year 2021 marks a significant year for the Group Company's management enhancement. Centered around the Group Company's new development requirements, we liberate our thinking, seek truth from facts, start with micro-management, focus on details, measures, and specific matters. Adhering to the principle of facing and solving problems as they arise, we define management enhancement goals, quantify and refine management tasks, and promote the standardization and digitalization of management work.
We have reached out to learn equipment maintenance experiences from advanced domestic cogeneration enterprises, drawing on their advanced management concepts, digesting and absorbing their essence. Combining our actual situation, we have tailored an Equipment Inspection and Maintenance Integrated Management System suited to our needs.
System Overview
The Equipment Inspection and Maintenance Integrated Management System is based on equipment inspection and maintenance. Through daily inspections, professional inspections, and precision inspections, it collects and analyzes data from inspections and equipment lubrication maintenance, identifying equipment degradation trends and patterns. This system adopts an equipment management model involving all staff and full-process management, determining maintenance cycles and durations based on preventive maintenance principles and the actual condition of equipment. It strictly implements equipment maintenance and upkeep according to plan, while feeding back periodic maintenance results into equipment inspection and maintenance, optimizing inspection and maintenance content, and achieving closed-loop management in equipment management.
- Flowchart of the Equipment Inspection and Maintenance Integrated Management System
Specific Measures:
1. Implement One-Object-One-Code Management for All Equipment
Each equipment QR code contains its unique information, including basic equipment details, various professional inspection forms, equipment lubrication records, equipment maintenance logs, historical record summaries, standardized equipment oil quality, equipment manuals, and drawings. Users can scan the code to view all specific information.
2. On-site Personnel Scan Codes to Operate
After scanning the QR code with WeChat on a mobile phone, users enter the main interface. Inspection personnel, maintenance personnel, operational staff, and management personnel can select the services they need based on functional zones. Inspection forms, equipment lubrication records, and equipment maintenance logs come with pre-set fixed formats. Inspection and maintenance personnel only need to make on-site selections. Additionally, various records can include uploaded images, videos, documents, and other materials as needed, combining text and visuals.
3. Abnormal Inspection Handling
When inspection personnel submit abnormal inspection forms, the backend settings automatically push notifications. Management personnel, equipment owners, and other relevant managers can simultaneously receive abnormal information, enabling rapid response. After review, managers can directly assign personnel to handle the anomaly. This information is synchronized to maintenance personnel, who can directly view the abnormal status submitted by inspectors. After completing the handling, maintenance personnel provide feedback to the inspectors, achieving closed-loop management.
Example: Mechanical Daily Inspection Form
4. Plan Management:
Includes daily inspection plans, weekly inspection plans, monthly inspection plans, equipment scheduled maintenance plans, and equipment upkeep plans, etc.
Management personnel can check plan execution status in real-time via the mobile backend: which plans are assigned to whom, specific execution details, whether completed on schedule, or overdue. The system also sends reminders for impending deadlines, automatically alerting managers of the current work status at the designated time. Managers can then remind relevant personnel to complete various plans promptly, embodying service-oriented management through service during the management process.
5. Data Summary and Analysis
All daily inspection forms, maintenance records, and other materials can be downloaded from the backend in Excel or PDF formats. This enables the classification, processing, and analysis of monthly and annual equipment data, revealing equipment degradation patterns and optimal maintenance cycles, thereby scientifically guiding equipment management.
Summary
The Equipment Inspection and Maintenance Integrated Management System establishes a scientific analysis to identify equipment maintenance points—components prone to degradation—and defines inspection locations, items, and standards. Building on equipment inspections, it ensures proper maintenance. By analyzing equipment operation status and degradation trends to identify wear patterns, it enables planned maintenance before failures occur, shifting from reactive repairs to preventive maintenance.
This system continuously tracks, analyzes, modifies, and refines equipment management values. These values remain dynamic; after each PDCA (Plan, Do, Check, Act) cycle, equipment managers propose improvements, making the management values progressively more scientific, accurate, and reasonable. This extends equipment lifespan, reduces failure rates, reasonably lengthens maintenance cycles, shortens maintenance durations, lowers maintenance costs, improves maintenance quality, and optimizes the balance between daily and periodic maintenance loads.
Traditional inspection, maintenance, and check records were mostly paper-based, making data statistics, summarization, and analysis complex and cumbersome, consuming significant time with minimal results. Equipment management logs often remained at a superficial level of simple record-keeping. With numerous devices, achieving detailed one-machine-one-file management was difficult, fundamentally hindering deep-level analysis and application of recorded information.
The Equipment Inspection and Maintenance Integrated Management Platform standardizes and digitizes equipment maintenance work. Full-process "trace" recording effectively prevents "over-maintenance" and "under-maintenance," optimizing equipment management in safety, stability, and economy. Within this system, all equipment follows a one-machine-one-code principle. Scanning a QR code reveals basic information like model, manufacturer, and commissioning date. Operators can access electronic drawings anytime. Inspection personnel directly upload results after completing daily maintenance inspections and lubrication. Maintenance personnel upload inspection and repair records immediately after scheduled checks or defect elimination, saving time and resolving later archiving challenges.
All daily electronic record forms create a dynamic, full-process equipment archive. Equipment data becomes easier to find and standardize, with significantly improved confidentiality. This greatly simplifies daily equipment status statistics and analysis, substantially reducing statistical time and enhancing work efficiency. New employees can quickly gain comprehensive equipment understanding by learning this management system, completing maintenance tasks with guaranteed quality and quantity, and significantly reducing reliance on work experience.