As an important part of enterprise management, equipment management has changed from the past emphasis on serving production and the pursuit of higher equipment integrity indicators to focusing on the economic benefits of the enterprise. Equipment management work is required to pay attention to the management and control of maintenance costs, so as to achieve the highest equipment availability with the minimum maintenance costs. As the energy shortage becomes increasingly serious, energy conservation and consumption reduction have become one of the important tasks of various printing companies, with the purpose of improving economic benefits. Printing is a complex comprehensive operation process. If you want to achieve lean management, equipment management must not be ignored. Equipment maintenance cost management and control is also a big question!
1. Pay attention to equipment procurement management
The purchase of equipment is extremely important in model selection. If it has high reliability and good maintainability, the later maintenance costs of the equipment will be reduced a lot.
In addition, it is necessary to choose a unified model, which not only facilitates the storage of spare parts and universal interchange, but also facilitates the organization of maintenance and saves inventory costs. The quality of equipment selection determines the life cycle cost of the equipment.
2. Choose the appropriate maintenance method
How to straighten the relationship between production and market, and the relationship between production and maintenance is crucial. Failure to pay attention to maintenance, high randomness in production, and failure to guarantee the most basic conditions for equipment management and maintenance in terms of organization, funds, and time will inevitably lead to equipment disrepair and a decline in equipment integrity, thereby affecting the performance of the equipment and causing Increase in equipment maintenance costs. Improve the traditional methods of three-level equipment maintenance, major and medium repairs that have been used for a long time in the past. Maintenance should be carried out by dedicated personnel and organized at a reasonable time. For planned pre-repairs such as major and medium repairs, flexible item repairs and maintenance should be used instead.
3. Improve the effective operation rate of equipment
Poor equipment performance, low efficiency, and excessive idleness are also an invisible waste of equipment assets, resulting in increased costs. To this end, we attach great importance to improving the effective operation rate of equipment, implement management systems such as "Responsibility and Maintenance" and "Annual evaluation System for Maintenance Personnel", and strengthen the construction of equipment management incentive mechanisms and the construction of self-discipline mechanisms for maintenance personnel. Organize and manage equipment in good condition, rectify "five leaks", eliminate "seven harmful behaviors" in operation and maintenance, and many other activities. The increase in the effective operation rate of equipment significantly reduces unit maintenance costs.
4. Carefully repair and maintain equipment
Careful and meticulous maintenance, correct operation, reasonable use and careful maintenance of equipment can prevent abnormal wear and damage of equipment parts, extend the repair interval and reduce maintenance costs. Currently, there are two main forms of maintenance waste: First, equipment is in disrepair. This is a phenomenon of equipment disrepair caused by missing items in equipment inspections, inaccurate predictions, or due to insufficient funds, lack of attention to equipment, and overuse of equipment. The second is excess maintenance. This is due to excessive maintenance arrangements for the equipment, as well as excessive pursuit of the integrity of the equipment's performance, such as requiring the old equipment to be repaired as new, etc., and requiring excessive functions to cause maintenance waste.
5. Improve rules and regulations
Perfect, scientific and reasonable equipment management systems and rules and regulations have a great impact on costs. Cost management is the core of enterprise management and the focus of equipment management. In order to eliminate and reduce the management loopholes in equipment management and maintenance work, such as inconsistency in accounts, inadequate maintenance, equipment malfunction, illegal operation and poor lubrication, etc., we must improve the consciousness of all employees. based on the actual statistics of maintenance costs, the company's equipment management department has successively formulated maintenance cost management regulations, reporting and handling systems for abnormally damaged parts and equipment accidents, identification and reward regulations for the repair of old parts, and other management systems, safety operating procedures, maintenance Standardize, inspect and maintain records, and strengthen the system construction of equipment management.
6. Formulate scientific and advanced technical and economic indicators
1. Indicators are the basis for guiding, inspecting and evaluating various business, technology, economic activities and their economic effects. Indicators can be divided into single technical and economic indicators and comprehensive indicators, and can also be divided into quantitative indicators and quality indicators. The main functions of indicators are: to quantitatively evaluate the performance of management work; to play the role of supervision, regulation and guidance in the management process; to play the role of motivation and promotion .
2. The technical and economic indicators of equipment management are a set of indicators that are interrelated and restrictive, and can comprehensively evaluate the effectiveness and efficiency of equipment management. The technical indicators of equipment management are an important part of the equipment management work objectives. Equipment management involves various aspects such as funds, materials, labor organization, technology, economy, production and operation goals, etc. To test and measure the management level of each link and the effectiveness of equipment asset management, a technical and economic indicator system for equipment management must be established and improved.
Maintenance quotas are valuable for comprehensively measuring the labor organization, materials, technical equipment, and repair technology levels of maintenance, and should continue to be used, but the maintenance quota coefficients are formulated and revised and supplemented at any time.
As the main assessment indicator of the technical status of the equipment, the equipment integrity rate is still valid and can continue to be used. However, in specific operations, the qualitative terms of the intact standards should be studied and improved to try to reduce the influence of subjective factors; or the calculation of indicators should be improved to ensure the accuracy of the indicators.
7. Strengthen cost management education
1. In order to control maintenance expenses, a maintenance and replacement parts inspection team was set up with engineers participating, and special regulations were formulated on the spare parts requisition procedures and the identification and treatment of abnormally damaged parts.
2. In order to adapt to the market situation, maintenance personnel actively participate in and cooperate with the factory department to optimize the allocation of raw and auxiliary materials, and actively adjust the equipment to adapt to various raw and auxiliary materials without increasing costs, so that the optimization work can proceed smoothly.
3. Vigorously carry out cost education activities. In order to do a good job in cost management, we held special meetings on cost issues, conducted research and analysis, and agreed on various countermeasures. Special instructions and requirements were often given during holiday maintenance and daily production meetings, and special training was conducted in conjunction with the repairman evaluation to make the cost Management work has been deepened.
8. Promote repairing old materials and reusing waste, saving energy and reducing consumption
1. In order to reduce maintenance costs and fully mobilize the enthusiasm of maintenance personnel, special appraisal procedures and reward and punishment regulations have been formulated for the repair of old parts and damaged parts.
2. Reducing consumption and production costs are the main contents of equipment management. Most of the consumption of raw materials is realized on equipment. Poor equipment condition will increase raw material consumption; equipment accounts for a larger proportion in energy consumption. Strengthening equipment management, improving equipment operation efficiency, and reducing equipment energy consumption are important means of saving energy. During the operation of the equipment, a certain amount of material consumption is required to maintain the normal operation of the equipment. Equipment generally has standing parts and wearing parts. If parts are consumed a lot, equipment maintenance costs will be high.
9. Strengthen technical improvement work
Technical improvements are of particular importance for improving equipment performance and reducing maintenance costs. We vigorously carry out technical research activities and make small changes to eliminate inherent defects in the equipment, improve the stability and efficiency of the system, greatly reduce the workload of inspection and maintenance, and save a lot of maintenance costs every year.
10. Establish a monitoring system and highlight the economic management of equipment
In the past, maintenance cost analysis was mostly conducted at the end of the period, which was a post-hoc analysis and could no longer meet the requirements of the market economy. At present, enterprises should not simply engage in post-event analysis, but should strengthen the promotion of cost forecast analysis, that is, combine planning analysis, forecast analysis and post-event performance analysis to establish a complete analysis and budget system.
Establish an effective equipment monitoring system. Reduce unnecessary investment in new equipment by checking the establishment of equipment projects; ensure after-sales service of equipment through countersigning of technical agreements; strengthen equipment maintenance, equipment repair technology research, and external services by controlling and assessing maintenance costs during the service life of equipment. Control the purchase of spare parts, repair and reuse of spare parts, etc.; optimize equipment resource allocation and revitalize idle assets through equipment adjustment, allocation, scrapping and reuse; strengthen maintenance technology research through equipment maintenance technology supervision and assessment, and ensure that equipment is basically in good condition In good condition; do a good job of comprehensive balance and maintain the optimization of equipment management and equipment resource allocation.
